Workshop Manual

WORKSHOP
MANUAL
EURO 5
GB
WORKSHOP
MANUAL
EURO 5
GB
II
The Company ASTRA VEICOLI INDUSTRIALI reserves the right to make any modifications to vehicles for technical or commer-
cial reasons at any time; the information, descriptions and illustrations contained in this publication are therefore updated at the
time of approval for printing.
This Workshop Manual deals with optional equipment which cannot be present on your vehicle, and alternative equipment as
well (e.g. mechanical and automatic gearbox).
Moreover, the regulations in force in certain countries affect the standard equipment of the vehicle.
This publication could therefore contain information and illustrations not corresponding to the vehicle version provided on a
particular market.ii
IMPORTANT NOTICE
This publication contains the information necessary for carrying out the major special maintenance
and repair works on the vehicle/s described.
These jobs on the one hand require dismantling/reassembly operations following set procedures, and
on the other a variety of dimensional checks and/or adjustments.
The technical information for these operations (required play, adjuster shims, dimensions to respect,
tightening torque, etc.), and the operating procedures are continually verified - in order to eliminate
any errors - and updated - to account for any variations.
However, to be more certain of the correctness of the technical information, before starting the job
we recommend making a series of additional checks, as follows:
D Request the most recent version of the Repair Manual and Parts Catalogue for the vehicle in
question, contacting your nearest ASTRA V.I. Dealer or the Technical Assistance Service;
D Check whether there are any Technical Bulletins for the vehicle and/or group you are working
on;
D Carefully check the Type and Chassis Number of the vehicle and the Type and Serial Number
of the group involved, before looking it up in the Repair Manual and Parts Catalogue.
In all cases, if you have any doubts while working on the vehicle, always call the ASTRA V.I. Technical
Assistance Service to obtain all the technical information you require.
ASTRA Veicoli Industriali

Product Logistics
Via Caorsana, 79 - 29100 PIACENZA (Italy)
Tel. 0523/5431 - Fax 0523/543459
Publication A3502147
First edition - NOVEMBER 2011
Second edition - MAY 2012
Third edition - SEPTEMBER 2012
Fourth edition - DECEMBER 2012
Fifth edition - FEBRUARY 2013
Sixth edition - JULY 2013
Seventh edition --- JUNE 2014
Eighth edition - OCTOBER 2014
Reproduction, even partial, of this text and illustrations contained therein is prohibited.
HD9 Euro5 INDEX OF SECTIONS 1
INDEX OF SECTIONS
Section Pages
Introduction 1 from 1 to 14
General Specifications 2 from 1 to 14
Engine F3B 3 from 1 to 180
Clutch 4 from 1 to 26
Power take-off 5 from 1 to 24
Transmission ZF 16SXX20 6 from 1 to 74
Automatic transmission
Allison 4700 7.1 from 1 to 98
Automatized gearbox
ZF 16AS 2601 (Astronic 2) 7.2 from 1 to 86
Hydraulic retarder Intarder 3 8 from 1 to 44
Reduction gear unit VG 2700 9.1 from 1 to 66
Splitter-Transfer unit TC 2200 9.2 from 1 to 38
Reducer-transfer case
VG 2000-396 9.3 from 1 to 58
Propeller shafts 10 from 1 to 14
Axle 11 from 1 to 36
2 INDEX OF SECTIONS HD9 Euro5
Front drive axle 12.1 A from 1 to 50 Cab and chassis LHD 18 A from 1 to 118
Kessler drive axle 12.1 B from 1 to 54 Cab and chassis RHD 18 B from 1 to 118
Second front axle 12.2 from 1 to 44 Towing devices 21 A from 1 to 30
Single rear axle 12.3 from 1 to 44 Towing devices 21 B from 1 to 12
Intermediate axle in tandem 12.4 from 1 to 56
Rear axle tandem 12.5 from 1 to 46
Wheels and tyres 13.1 from 1 to 10
Brakes (Duplex) 13.2 B from 1 to 32
Brakes (10 ton. version) 13.2 C from 1 to 42
Front suspensions 14.1 from 1 to 20
2-axle vehicles rear suspensions 14.2 from 1 to 16
Rear tandem suspensions 14.3 from 1 to 24
Steering system LHD 15 A from 1 to 76
Steering system RHD 15 B from 1 to 76
Pneumatic system - Brakes 16 from 1 to 114
Electrical\electronic system 17 from 1 to 258

INTRODUCTION
SECTION I
HD9 Euro5 SECTION I INTRODUCTION 1
SECTION I
Introduction
Page
PREFACE 3
- Definitions adopted in the current Manual 3
- Introduction 3
GENERAL PRECAUTIONS 4
- Graphs and symbols 6
MEASURES (INTERNATIONAL SYSTEM) 7
- Conversion values for British units 7
STANDARD TIGHTENING TORQUES 8
- Screws and nuts with metric thread 8
GENERAL OPERATING INSTRUCTIONS 9
- Before dismantling 9
- During dismantling 9
- After dismantling 10
- During assembly 10
- Interchangeable components 12
- Welding on chassis 14
2 INTRODUCTION SECTION I HD9 Euro5
Page left intentionally blank

PREFACE
Definitions adopted in the current Manual
The Company ASTRA VEICOLI INDUSTRIALI, Via Caorsana, 79 - 29100 PIACENZA (Italy) is hereinafter called Manufacturer.
The current WORKSHOP MANUAL is hereinafter called Manual.
The equipment dealt with in the current Manual is hereinafter called vehicle.
The operator directly or indirectly involved in vehicle repair is hereinafter called operator.
Introduction
The current Manual applies essentially to authorised workshop technical staff.

This Manual provides technical information but cannot replace a thorough professional experience.
This Manual contains all data and information required to perform correct checking and setting up operations as well as repair
and overhaul operations.
Read this Manual right through before performing any operation on the vehicle.
Compliance with the provided information and the use of the recommended tools guarantee correct repair and avoid damages
to operators.
You will frequently see that parts of the text are highlighted as shown below:
Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause injury.
Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause damage
to the vehicle.
Procedures, technical information and precautions which must be highlighted.
Failure to heed and/or correctly carry out procedures, technical information and precautions given may cause environ-
mental damages.
This Manual has been divided into Sections, each of which has a number and its relevant contents are indicated in the Index of
Sections.
Each section features a main Unit (e.g.: engine, gears, etc.)
Where possible, the same sequence of procedures has been followed for easy reference.
Diagram and symbols have been widely used to give a clearer and more immediate illustration of the subject being dealt with (see
next page) instead of giving descriptions of some operations or procedures.
Example:
Ø 1 = Housing for connecting rod small end bush

Tighten to torque
α Tighten to torque + angular value
Ø 2 = Housing for connecting rod bearings
GENERAL PRECAUTIONS
The precautions listed cannot possibly foresee all of the potetially hazardous situations that may arise. Consult your
supervisor in the event of any hazardous situation not described here.
Use all specific and general tools as instructed in the corresponding use and mainteannce manuals. Check the wear
and suitability of tools not subject to periodic inspection.
Any manual movement of loads must be previously evaluated, in terms of size and course in addition to simple weight.
The movement of loads using mechanical means must be carried out with lifters suitable for both the weight and the
shape and volume to be lifted. Lifting gear, cables and hooks used must bear clear indications of the maximum admissible
load. This type of equipment may only be used by authorised personnel. Keep a safe distance from the load and never
stand under it.
When carrying out dismantiling operations always follow all instructions given, and take steps to prevent mechanical
parts from accidentally hitting workshop personnel.
Workshop activities in pairs must always be carried out paying maximum attention, avoid operations that may present
a hazard to partners due to poor visibility or incorrect posture.
Any personnel not directly involved in the operations must keep well clear.
Learn all vehicle functions and safety systems prior to working on them. All safety indications present on the vehicle
must be strictly observed. Attach suitable ‘vehicle under maintenance’ signs. When repairs are finished, before starting
the vehicle make all the checks listed in the paragraph “Checks by user” in the Use and Maintenance handbook.
If vehicle manoeuvre visibility is poor, ask someone to give directions from the ground. Never abandon the vehicle with
engine running during repair works.
Immobilise the vehicle with suitable chocks.
For repair works on the vehicle hoisted from the ground, check that it is well anchored to the supporting rig and that
the manal and automatic safety systems are enabled if a vehicle hoist is used.
When working on methane powered vehicles, also follow the instructions given in the documentation as well as all
specific safety standards.
Remove the radiator cap only with engine cold, unscrewing it gradually to discharge any residual pressure.
Flammable fuels and all fluids and liquids must be handled with care, as per the instructions given on sheet 12, hazardous
materials materials. Refuelling must take place in the open air and with engine stopped, with no smoking or naked lights
in the vicinity to avoid risk of explosion/fire. Store flammable, corrosive and pollutant liquids and fluids as required by
current laws in force. Absolutely avoid using foodstuffs containers to store toxic fluids. Avoid perforating or burning
pressurised containers, and deposit rags soiled with inflammable products in suitable containers.
Worn or damaged parts or consumables must be replaced with original Iveco replacements.
Always keep the workplace clean. Clean up any accidental fluid or oil spillages immediately. Electrical sockets and
electrical equipment necessary for repair works must comply with safety standards.
Strictly follow the instructions given in the related sections of the manual when carrying out works on hydraulic and
pneumatic systems, air-conditioning and AIR-BAG systems.
GENERAL PRECAUTIONS
If required by repair works, always use the protective clothing foreseen by accident prevention standards. Contact with
moving parts may lead to serious injury. Wear suitable clothing, choosing tight-fitting clothing rather than loose and
avoiding jewellery, scarves, etc.
Never leave the engine running in the workshop if it is not fitted with an exhaust gas extractor pipe.
Avoid breathing fumes generated when paintwork is heated or welded, as these may be harmful to health. Work in
the open-air or in a well-ventilated area. War a suitable filter mask when working with paint powders.
Avoid contact with hot water or steam from the engine, radiator or piping. Extremely hot, could cause serious scalding.
Avoid direct contact with the fluids present in vehicle systems. In case of accidental contact, refer to sheet 12 for the
steps to be taken.
Clean the groups or assemblies removed from the vehicle and check their condition before proceeding with overhaul.
Place all removed or dismatled parts, along with their fasteners (nuts, bolts, etc.), in an orderly manner in suitable
containers
Check the condition of parts designed to lock fasteners: spring washers, split-pinns, clips, etc. Self-locking nuts with nylon
inserts must always be replaced.
Prevent rubber parts from contact with petrol or other incompatible materials.
Before proceeding to pressure washer mechanical parts, protect electrical connections and electronic control units.
All nuts and bolts must be tightened to the specified torques. The IVECO sales and service network is available to
provide any additional information necessary for repair works not described in this publication.
Before welding
- Disconnect all electronic control units and detach the postive cable and connectors from the battery (connect it
to chassis ground).
- Remove paint using the appropriate solvents or paint strippers and clean the surfaces to weld with soap and water.
- Wait circa 15 minutes before starting to weld.
Fit adequate flame shields to protect flexible piping or other components containing fluids or other inflammable
materials when welding.
All liquids and fluids must be disposed of in full observance of specific and current standards.
Graphs and symbols
Removal
Disconnection Intake
Re-fitting in place
Exhaust
Connection
Removal
Operation
Dis-assembly
Fitting in place
Ã Compression ratio
Assembly
Tolerance
Driving torque
Weight difference
Driving torque + angular value Rolling torque

α
ASTRA Replacement
Press or Caulk
Original spare parts
Regulation
Rotation
Adjustment
Caution Angle
Note Angular value
Visual check
Preload
Fitting position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Face for machining

Pressure
Machine finish bar
Oversized
Interference
Greater than ..
Strained assembly
Maximum, peak
Undersized
Thickness
Less than...
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0o C
Sealant
Cold
Adhesive
Winter
Temperature >0o C
Air bleeding Hot
Summer
MEASURES (INTERNATIONAL SYSTEM)
Force in N (Newton) Pressure in kPa (kilopascal)
Other units in use:

Conversion:
kg/cm2 (kilograms per square centimeter)
IN = 0,1019 kg Atm (metric atmosphere)
1 kg = 9,81 N psi (pounds per square inch)
Conversion:
Power in kW (kilowatt)
I kg/cm2 = 1 Atm
Other units in use: I kg/cm2 = 98,1 kPa
HP (Horsepower) I kg/cm2 = 0,981 bar
Conversion: I kg/cm2 = 1 bar *

I kg/cm2 = 14,22 psi
1 kW = 1,36 CV I bar = 100 kPa
1 kW = 1,34 HP I bar = 1,02 kg/cm2
1 CV = 0,736 kW I bar = 14,51 psi
1 CV = 0,986 HP I psi = 6,9 kPa
1 HP = 0,746 kW I psi = 0,069 bar
1 HP = 1,014 CV I psi = 0,0703 kg/cm2
I kPa = 0,145 psi
Torque in Nm (Newton/metre) I kPa = 0,0102 kg/cm2
I kPa = 0,01 bar
Conversion:
Conversion values for British units
1 Nm = 0,1019 kgm
1 kgm = 9,81 Nm 0,1 mm = 3,937 mils
1 kgm = 10 Nm * I mm = 0,039 inch
Im = 3,281 ft.
Specific consumption in g/kWh (grams per kilo- I km = 0,621 miles
watthour) I cm3 = 0,06 I cu. in.
Il = I ,759 pts (0,88 imp.qts)
Other unit in use:
I bar = 14,5038 psi
g/CVh (grams per horsepower-hour)
Ig = 0,035 oz. (0,564 dr.)
Conversion: I kg = 2,205 Ibs.
It = 1,102 short ton (0,9842 long ton)
I g/kWh = 0,736 g/CVh
0 C = 32 F
1 g/CVh = 1,36 g/kWh
(in case of differences in temperature 1 C = 1.8 F)
(*) Nm and bar are converted according to the ratios 10:1

and 1:1.
STANDARD TIGHTENING TORQUES
Screws and nuts with metric thread
Diameter SCREW — CLASS 8.8 SCREW — CLASS 10.9 SCREW — CLASS 12.9
x
Pitch
dxp
UN- DACRO- PHOSPHA- UN- DACRO- PHOSPHA- UN- DACRO- PHOSPHA-
(mm) COATE MET GAL-
CADMIUM
TE COA- COATE MET GAL-
CADMIUM
TE COATE MET GAL-
CADMIUM
TE
PLATED PLATED PLATED
D VANISED TED D VANISED COATED D VANISED COATED
3 x 0,5 0,12 0,12 0,11 0,09 0,17 0,16 0,15 0,13 0,21 0,19 0,18 0,15
4 x 0,7 0,28 0,26 0,24 0,20 0,39 0,37 0,34 0,29 0,47 0,44 0,41 0,35
5 x 0,8 0,56 0,52 0,48 0,40 0,79 0,74 0,67 0,57 0,94 0,88 0,80 0,68
6x1 1,0 0,9 0,8 0,7 1,3 1,3 1,2 1,0 1,6 1,5 1,4 1,2
8 x 1,25 2,3 2,2 2,0 1,7 3,3 3,1 2,8 2,3 3,9 3,7 3,3 2,8
8x1 2,5 2,4 2,1 1,8 3,5 3,3 3,0 2,5 4,3 4,0 3,6 3,0
10 x 1,5 4,7 4,4 4,0 3,3 6,5 6,1 5,6 4,7 7,9 7,4 6,7 5,6
10 x 1,25 5,0 4,7 4,2 3,5 7,0 6,5 5,9 4,9 8,4 7,9 7,1 5,9
12 x 1,75 8,0 7,5 6,8 5,7 11,3 10,6 9,6 8,0 13,6 12,7 11,5 9,6
12 x 1,25 9,0 8,4 7,5 6,2 12,6 11,8 10,6 8,7 15,1 14,1 12,7 10,4
14 x 2 12,8 12,0 10,9 9,1 18,0 16,9 15,3 12,8 21,6 20,2 18,4 15,3
14 x 1,5 14,1 13,1 11,9 9,7 19,8 18,5 16,7 13,6 23,8 22,2 20,0 16,4
16 x 2 19,8 18,5 16,8 13,9 27,9 26,1 23,6 19,5 33,5 31,3 28,3 23,4
16 x 1,5 21,5 20,0 18,0 14,6 30,2 28,2 25,3 20,6 36,3 33,8 30,4 24,7
18 x 2,5 27,2 25,4 23,1 19,2 38,2 35,8 32,4 27,0 45,8 42,9 38,9 32,4
18 x 1,5 31,4 29,2 26,2 21,1 44,1 41,1 36,8 29,7 53,0 49,3 44,2 35,7
20 x 2,5 38,4 36,1 32,7 27,0 54,3 50,8 46,0 38,0 65,2 61,0 55,2 45,6
20 x 1,5 43,9 40,9 36,5 29,4 61,7 57,5 51,4 41,3 74,1 68,9 61,6 49,5
22 x 2,5 53,9 49,0 44,6 36,2 75,9 68,8 62,8 51,0 91,0 82,6 75,3 61,1
22 x 1,5 59,0 54,8 48,9 39,1 82,9 77,1 68,8 55,0 99,5 92,5 82,6 66,1
24 x 3 66,7 62,4 56,4 46,6 93,8 87,7 79,3 65,5 112,5 105,2 95,2 78,6
24 x 2 74,2 69,1 61,9 50,0 104,4 97,2 87,1 70,3 125,3 116,7 104,5 84,4
27 x 3 98,7 92,2 83,1 68,2 138,8 129,6 116,9 95,9 166,5 155,5 140,2 115,0
27 x 2 108,4 100,8 90,1 72,4 152,4 141,8 126,7 101,8 182,9 170,2 152,1 122,2
30 x 3,5 133,7 124,9 112,7 92,8 188,0 175,6 158,5 130,5 225,6 210,7 190,2 156,5
30 x 2 151,6 141,0 125,8 100,6 213,2 198,2 176,9 141,5 255,9 237,9 212,2 169,8
Maximum tightening torques for metric threads in daNm

GENERAL OPERATING INSTRUCTIONS - When dismantling, carefully examine any interference,

Before dismantling contact or seizure between moving parts to identify the
cause of the problem.
Cleaning the vehicle before bring it into the workshop
Before bringing the vehicle into the workshop, remove all mud - When dismantling, record the measurements of all values,
and dirt. Bringing mud and dirt into the workshop makes dis- like play or protrusion that are only significant if measured
mantling more difficult, and increases the possibility that parts during the dismantling operation.
will be soiled while reassembling. - Wherever possible the adjusted value of the rods must
Visual inspection prior to dismantling be maintained unaltered. If necessary remove adjusters,
Before proeeding to dismantle the vehicle, perform a thor- measure lengths prior to removal and note the values in
ough premilinary visual inspection, recording the results. This order to be able to restore them on reassembly.
saves hours of work and component costs, and is very useful - If parts that are tapered or fitted with intereference come
for giving users advice for the prevention of future problems. apart easily, examine the components involved to identify
In particular: the cause, in order to prevent the same problem arising
on reassembly.
- Check the type and number of the vehicle, and the
odometer reading. Figure 1
- Check the reason for the overhaul.
- Check the symptom, the point and cause of the problem,
carrying out a further visual inspection if necessary.
- Check the degree of air filter contamination and any air
leaks.
- Check the type of fuel used, the degree of fuel filter
contamination and for any water in the fuel, fuel leaks and
for any deformed fuel lines.
- Check the engine oil level, the condition of the oil
(viscosity, colour and impurities) and for any water in the
oil, oil leaks or oil filter clogging.
- Check tension of the V-belts; 1730101
- Check for any faulty components and loose connectors.

- Use suitable extractors to remove bearings, instead of
forcing them.
Preparation for dismantling
To save time, check that all equipment is available, and that
there is space available on shelves according to the specific
type of overhaul to be carried out, and clean the area before
setting up the vehicle.
During dismantling
Removal of components
- Before removing components, check their fitted
condition, front/rear left/right up/down relations and the
removal procedures.
- Check for any fitting marking showing the relative
mounting positions and, if necessary, mark them with
clear signs to prevent errors on reassembly.
- Use special tools wherever specified.
- If a component cannot be removed even after removing
its fasteners, do not use force, but check the component
to find out where the problem is.
- All units, in particular the ones that are similar, must be
shelved in order and, if necessary, marked for
identification.
- Standard components like nuts and bolts must be
conserved, paying attention to their original positions and
quantity.
- The shims and washers used for play adjustment must be
kept in order to be refitted in the same conditions.
Disconnecting hydraulic lines After dismantling
Operate all control levers several times to vent any When using detergents, make certain to have fully
pressure in the lines to be disconnected. understood the use instructions and pay attention
Open the hydraulic reservoir air bleed plug. not to bring detergents into contact with skin or
eyes. Correct disposal of exhausted detergents.
Cleaning
Figure 2
- Clean the removed components and store them in an
orderly manner. In particular, remove all grime and dust
from the oil holes of all components.
- For effective cleaning, split the detergent into two
containers, one for removing dirt and the other for final
cleaning. When cleaning the most significant component,
make a further subdivision to prevent the use of soiled
detergent.
- When cleaning large cast components, like the cylinder
head or engine block, immerse them in a contained for 5
to 10 minutes in detergent with pH between 50 C and
70 C (122  158 ˚F), then thoroughly rinse them.
1730102 Prevention of rust and dust penetration

- Cover the cleaned components to prevent dust
- To disconnect two rigid pipe or a rigid pipe from a flexible penetration.
pipe, grip the male part with a wrench and loosen the joint
from the side of the nut (female). - Use plugs at the ends of any flexible or rigid piping.
- Seal the end of the rigid or flexible pipe with a plug as well - If the components require storage for a certain time
as the oil feed hole of the component removed, to before being refitted, apply a rust prevention product.
prevent foreign matter entering.
- Removed rigid or flexible pipes usually contain oil that During assembly
must be drained into a suitable container. Installation of components
- Before carrying out the job, clean all components and
- Clean up any oil spills in the working area. repair and damage. Dirt and dust have a negative influence
- To facilitate installation, label each rigid or flexible pipe on moving parts and will shorten the working life of the
and the connection of each hydraulic component. vehicle. Dust penetration must be limited to the minimum
possible.
- Before assembling, remove any anti-rust products present
on new components.
- Components with coupling marking must be fitted with
markings correctly aligned.
- Use a press and suitable tools when fitting bearings,
bushes, oil seals and so on. Use the specified special
equipment when fitting special components.
- Apply a layer of molybdenum grease or other specific
lubricant to the surfaces of components coupled with
torque, where specified.
Tightening of screw and nuts Connecting hydraulic lines

- Clean all rigid pipes with a suitable detergent and dry with
Figure 3
compressed air.
- Do not use three component coupling fluids.
- When fitting high pressure flexible pipes, do not twist
them. Also prevent other components interfering with
flexible pipes, where unprotected.
- During assembly, install all components correctly,
checking the labels attached to each rigid or flexible pipe
or hydraulic component connector.
Figure 5
1730103
- Cross-tighten bolts and nuts, to apply torque in a uniform

manner. The numbers in the diagram indicate the
tightening order.
- If not otherwise specified, apply lubricant to the threaded
part of the bolts, to obtain uniform tightening torque.
Figure 4
1730105
- When connecting pipes, first hand-tighten from both

ends and then alternate when fully tightening.
- After completing connections, run the engine at low
speed and operate all hydraulic components from the
driver seat controls, then visually inspect and top-up the
oil in the hydraulic reservoir.
- Points where terminal play, protrusion, offset and normal
play, which cannot be checked if not during assembly,
must be checked and measured before proceeding with
the work.
- The shims and washers used for play adjustment must be
1730104 fitted in the same conditions as when removed, if not
worn or damaged.
a: correct fitting
b: incorrect fitting - After reassembly, check al play values.
- Reassemble all linkages with an adjustment value identical
- Nuts and bolts that cannot be visually inspected from the to before removing.
outside, or those of significant part, must be installed and - If the parts to assemble with preloading or interference
locked with a suitable and correctly applied self-locking refit too easily, check the dimensions again and correct
system (wire, split pin, bent washer). any faults before completing the assembly.
- Screws that have been fitted with thread locking products
(that have traces of the product when removed) must be
cleaned with light oil and dried before refitting. Apply 2
or 3 drops of thread lock to the threaded parts of bolts
and then tighten them.
Interchangeable components Figure 7

Gaskets
- As a general rule, replace all gaskets with new ones.
- Apply sealant to gaskets wherever required.
- Remove any dust, paint, oil or previously applied sealant.
- Apply a uniform layer of the specified sealant and allow
it to dry for a few minutes.
- When the sealant is touch dry, apply the gasket.
O-rings
- If the O-rings are hardened after prolonged storage,
throw them away even if they have not been used.
1730107
- Use only the O-rings specified in the replacement parts
list. In particular, for engines using O-rings in special
materials, like silicon rubber to resist heat and - When fitting oil seals, apply grease to prevent dry start.
deterioration, do not use alternative components. a. Single lip oil seals
Apply the grease uniformly to the entire outer edge
- Before installing, apply a layer of oil to the O-rings to
prevent cracking. Silicon rubber tears easily and must be from the opposite side to the sealing part of the lip
handled with care. (arrow), maing certain to prevent accumulations
Oil seals from forming.
b. Double lip oil seals
Figure 6 Apply 40-60% grease to the outer edge of the part
between the lips (arrow).
- Make certain that on the contact face (area of the shaft)
of the oil seal there is not dust, rust or cracks, and apply
lubricant to facilitate installation.
Figure 8
1730106
A: internal side (presence of pressure)

B: outer side
a: main lip (seal)
b. dust protection lip
1730108
- Pay attention to the orientation of the oil seal lips.
- When installing, use a guide or a specific fitting tool to
- Take care not to allow dust to deposit on oil seals, and
prevent damage to the oil seal lips.
make certain that there are no traces of rust or cracking
(especially on the lip surfaces). - After fitting the oil seal, push it into its seat. Seals must be
fitted perfectly true.
- When applying adhesive products to the outer part of a - Bearings that have to be installed with high pressure
seal, pay attention to prevent the product depositing on values must be force fitted only if heated. To prevent
the lip Since any adhesive deposited on fitting tools can deterioration to the case hardening, these temperatures
easily transfer to the lips, use guides and tools that are must be limited to within 120 C (248 F).
perfectly clean.
Figure 10
Bearings
- Since dust has any extremely negative effect on bearings,
always try to remove and refit in a dust free environment.
- Handle bearings with care, and do not allow them to
rotate when cleaning with compressed air.
- During installation, to not tap on the inner or outer race
of the bearing as this may cause damage to the rolling
surface.
Figure 9
1730110
- Bearings that are not separable that require pressure

fitting for both inner and outer race, must be fitted using
the appropriate fitting tool.
Snap rings and circlips

- Use special circlip pliers when removing circlips and snap
rings, taking care not to open them too much.
- After fitting, check that the snap rings are correctly seated
in the corresponding grooves.
1730109
- If the bearings have to be fitted with pressure on the inner

race, push them inwards using a suitable fitting tool.
Welding on chassis - weld the opposite side as described above. Allow the side
Before starting to weld disconnect the negative terminal of the member to cool slowly and uniformly. Do not use
battery and connect the welder ground directly to the part compressed air or other cooling method. Grind off any
being welded. excess material;
Welding must be carried out exclusively by trained personnel Figure 12

with suitable equipment and in a workmanlike fashion.
Figure 11
1730112
A = 0,3 H
1730111
B = H 175 mm (7 in)
S = (0,8 — 1) S1
It is forbidden to cut the side members at points
where profile changes or at points subject to particu- - internally apply steel corner reinforcement of the same
lar stress. The weld line must not intersect with any type as used on the chassis. The minimum indicative
holes already in the side member. dimensions are given in the figure);.
- They should only be fastened to the side member vertical
Remove paint and rust from the parts to weld. At the point rib using weld beads. The cross section and length of the
to weld, on the internal part of the side member and for the bead must be adequate for transferring the bending and
entire length of the weld, cut a “v” bevel of 60 shear moments of the particular section.
Operative instructions for correct welding procedure are - The welded part must be effectively protected from
given below: corrosion with primer.
- heat all around the zone to be welded. Perform the arc
weld in various passages using thoroughly dry basic
electrodes, or MIG-MAG procedure with suitable
material. Avoid current overload. The weld must be free
of residues marginal incisions;
GENERAL SPECIFICATIONS
SECTION 2
HD9 Euro5 SECTION 2 GENERAL SPECIFICATIONS 1
SECTION 2
General specifications
Page
POSITION OF VEHICLE IDENTIFICATION DATA
PLATES 3
- Model identification plate 3
- Imprinting of the vehicle chassis 3
- Vehicle identification plate 3
- Chassis punching 4
- Vehicle registration number 4
- Vehicle identification plate 4
ENGINE 5
MANUAL TRANSMISSION 6
- Clutch 6
- Gear shift 6
- Ratios 6
AUTOMATED TRANSMISSION 6
- Clutch 6
- Gear shift 6
- Ratios 6
AUTOMATIC TRANSMISSION 7
- Gear shift 7
- Ratios 7
TRANSFER DISTRIBUTOR 7
FRONT AXLE 8
- Front steering axle 8
- Second front steering axle 8
FRONT AXLE 8
- Front steering drive axle 9 ton 8
- Front steering drive axle 10 ton 8
REAR AXLE 8
- Single rear drive axle 8
- Tandem rear drive axles 8
DRUM BRAKES 9
- Simplex 9
2 GENERAL SPECIFICATIONS SECTION 2 HD9 Euro5
- Duplex 9
- Systems 9
- ABS 9
TYRES 10
SUSPENSION 11
- Front 11
- Rear 11
STEERING 11
- Vehicles without auxiliary cylinder 11
- Vehicles with auxiliary cylinder 11
ELECTRICAL SYSTEM 12
CHASSIS 12
- Standard fuel tank 12
- Oversize fuel tank 12
LUBRICANT AND HYDRAULIC FLUID TABLES 13
POSITION OF VEHICLE IDENTIFICATION Imprinting of the vehicle chassis

DATA PLATES
Figure 2
Model identification plate
Figure 1
1A
Punch marked at the front end of the right-hand side mem-

ber (Fig. 2, see arrow).
(see following page)
Vehicle identification plate
Figure 3
1B
Located on the side walls of the cab (Fig. 1A vers. LHD,

Fig. 1B vers. RHD, see arrow).
Applied below the front grille on the right side for vehicle
identification (Fig. 3A vers LHD, Fig. 3B vers RHD, see
arrow).
(see following page).
Chassis punching
Figure 4
b
a
a. right side member - b. rear axle front leaf spring
Vehicle registration number 1. Approved type number marking

2. Vehicle chassis punching
Figure 5 3. Code of country issuing type approval
4. Not used
5. Full load maximum weight legally admissible
6. Full load maximum weight technically admissible
7. Assembly maximum weight legally admissible
8. Assembly maximum weight technically admissible
1) World—wide identification of manufacturers (Astra Vei- 9. 1st axle maximum weight legally admissible
coli Industriali S.p.A.) 10. 1st axle maximum weight technically admissible
2) Type of vehicle 11. 2nd axle maximum weight legally admissible
3) Vehicle features 12. 2nd axle maximum weight technically admissible
4) Year of construction 13. 3rd axle maximum weight legally admissible
5) Production facility (P=Piacenza) 14. 3rd axle maximum weight technically admissible
6) Chassis number 15. 4th axle maximum weight legally admissible
16. 4th axle maximum weight technically admissible
17. 5th axle maximum weight legally admissible
18. 5th axle maximum weight technically admissible
19. Axles unit maximum weight legally admissible
Vehicle identification plate 20. Axles unit maximum weight technically admissible
21. Vehicle commercial name
Figure 6 22. Lights inclination percentage
23. Distance between axles
24. Number of axles
25. Type of engine
26. Engine power
27. Smokiness index
ENGINE Figure 8
Main assemblies mounted on vehicle are identified by a serial
number which can be found on the concerned assembly in
the positions shown on drawings.
Figure 7
IVECO F2B (Cursor 8) IVECO F3B WG (Cursor 13)

4-stroke Diesel, liquid cooled, variable geometry exhaust gas 4-stroke Diesel, liquid cooled, turbocharger with Wastegate
turbocharger. pressure limiter.
Exhaust brake integrated in the engine. Exhaust brake integrated in the engine.
Main specifications
IVECO F3B VGT (Cursor 13)
Number of cylinders 6 4-stroke Diesel, liquid cooled, variable geometry exhaust gas
Bore mm 115 turbocharger.
Exhaust brake integrated in the engine.
Stroke mm 125
Total displacement cm3 7790
Compression ratio 16.5
Injection order 1-4-2-6-3-5 Main specifications
Number of cylinders 6
Bore mm 135
Stroke mm 150
Total displacement cm3 12882
Compression ratio 16.5
Injection order 1-4-2-6-3-5
MANUAL TRANSMISSION AUTOMATED TRANSMISSION
Figure 9 Figure 10
Clutch
Dry single disk, Diameter 17”.
Electro-pneumatic control.
Clutch
Dry single disk.
Diameter 17”.
Hydraulic control.
Gear shift
Gear shift - ZF ASTRONIC2 16 AS 2601 OD
- ZF ECOSPLIT4 16 S 1620 TD Version V33 (TYPE I): Lever selector
16 S 1820 TO Version V35 (TYPE I): Pushbutton selector
16 S 1920 TD
16 S 2220 TO Manual with 16 forward and 2 reverse gears.
16 S 2220 TD Electro-pneumatic servoshift.
16 S 2320 TD Automatic or manual mode selection.
16 S 2520 TO Hydrodynamic intarder mounted on gearbox output (op-
16 S 2720 TO tional).
Syncromesh manual with 8 forward gears, split into a low
range group (1- 4) and a high range group (5 - 8), and 1 R.G,
normal and low.
Pneumatic servoshift device.
Neutral switch for preventing starting the motor with gear Ratios
engaged.
1st 14,12 9th 3,09
Hydrodynamic retarder (intarder) mounted on gearbox out-
put (optional). 2nd 11,67 10th 2,55
3rd 9,53 11th 2,08
4th 7,88 12th 1,72
5th 6,52 13th 1,42
Ratios 6th 5,39 14th 1,18
Direct Drive Over Drive 7th 4,56 15th 1,00
Normal Low Normal Low
8th 3,77 16th 0,82
1st 13,80 16,41 11,54 13,80
2nd 9,49 11,28 7,93 9,49 1˚ R.G. 13,07 2˚ R.G. 10,81
3rd 6,53 7,76 5,46 6,53
4th 4,57 5,43 3,82 4,57 R.M.= Retromarcia
5th 3,02 3,59 2,53 3,02
6th 2,08 2,47 1,74 2,08
7th 1,43 1,70 1,20 1,43
8th 1,00 1,19 0,84 1,00
R.G. 12,92 15,36 10,80 12,92
R.G. = Reverse Gear
AUTOMATIC TRANSMISSION TRANSFER DISTRIBUTOR
Figure 11 STEYR VG 2700/400

Figure 12
Transmission ratios:
Normal (on road): 0.913
Low (off road): 1.407
Gear shift Maximum torque at input: 30.000 Nm
- ALLISONHD 4700
Epicyclical automatic, 7 forward plus reverse. IVECO TC 2200
Hydrodynamic torque converter with free wheeldistributor Figure 13
.
Automatic engage converter lock-up clutch.
Ratios
1st 1:7,63
2nd 1:3,51
3rd 1:1,91
4th 1:1,43
5th 1:1,00 Normal (on road): 1.0
6th 1:0,74 Low (off road): 1.6
7th 1:0,64 Maximum torque at input: 22.000 Nm
R.G. 1:4,80
STEYR VG 2000
R.G. = Reverse Gear
Figure 14
Normal (on road): 0.89
Low (off road): 1.536
Maximum torque at input: 25.000 Nm
FRONT AXLE REAR AXLE
Figure 15
Figure 18
Front steering axle

High resistance pressed steel with double T section, of non--
drive steering type.
Second front steering axle
High resistance pressed steel with double T section, of non-- Single rear drive axle
drive steering type. With double reduction, central by pinion set and final in
wheel hubs with epycicloid gear.
Differential between wheels with pneumatic lock.
FRONT AXLE
Figure 16
Figure 19
Front steering drive axle 9 ton

With double reduction (central and final) in wheel hubs by
means of epicyclical gear set. Drive shafts controlling front
wheels equipped with Cardan joints.
Front steering drive axle 10 ton Tandem rear drive axles

With double reduction (central and final) in wheel hubs by Two drive axles in tandem with double reduction, central
means of epicyclical gear set. Drive shafts controlling front with bevel gear and final in wheel hubs with epicyclical gear
wheels equipped with Cardan joints. set.
The intermediate axle is equipped with a differential transfer
case (splitter) between the axles and is lockable by pneumatic
control.
Figure 17 Differential between wheels with pneumatic lock.
Second front steering engine axle

With central and final double reduction in the wheel hubs by
epicyclic train. The axle shafts that control the front wheels
are articulated with universal joints.
The axle is equipped with a differential transfer case (splitter)
between the axles and is lockable by pneumatic control.
DRUM BRAKES Systems
Service brake: pneumatically operated in two independent

Simplex sections for non-towing vehicles, and in three independent
sections for towing vehicles.
Figure 20
Parking and emergency brake : pneumatically operated and
acts on the rear wheel drums, through the use of a spring
cylinder.
Supplementary parking brake (optional): pneumatically ope-

rated: must be engaged with the engine running.
ABS
Anti-lock braking system (ABS) with a four channel electro-
Wedge-shaped type with simple effect braking parts.
nic control unit and four solenoid valves that apply the ABS
The adjustment of the brakes is automatic, therefore no
function during braking.
intervention is necessary before the total wear of the brake
Phonic wheels and sensors on 1st and 2nd axle (2-axle vehi-
linings.
cles)
Phonic wheels and sensors on 1st and 3rd axle (3-axle vehi-
cles)
Phonic wheels and sensors on 2nd and 4th axle (4-axle vehi-
cles)
Duplex
Figure 21
Wedge-shaped type with dual effect braking parts.

The adjustment of the brakes is automatic, therefore no
intervention is necessary before the total wear of the brake
linings.
TYRES
Front: single (*)
Rear: double (**) or single (*) for single track versions
(*) (**) (*) (**)

DIMENSION TYPE DIMENSION TYPE
bar bar bar bar
MICHELIN XZY2 8 8 MICHELIN XDY 8.5 8.5
MICHELIN XDY3 8 8 MICHELIN XZY2 8.5 8.5
MICHELIN XZH 8 8 MICHELIN XZL 8.5 8.5
PIRELLI AP05 9 - MICHELIN XZY 8.5 8.5
12.00R20
PIRELLI AT75 - 9 PIRELLI AP05 9 -
PIRELLI AT99 8.5 8.5 PIRELLI AT75 - 8.5
13R22.5 PIRELLI FG85 9 9 PIRELLI FG85 9 9
PIRELLI TG85 9 9 PIRELLI TG85 9 9
PIRELLI FG88 9 9 MICHELIN XZE2TL 9 9
315/70R22.5
PIRELLI TG88 9 9 MICHELIN XDE2TL 9 9
CONTINENTAL
- - PIRELLI FG88 9 9
HSC
325/95R24
CONTINENTAL
- - PIRELLI TG88 9 9
HDC
MICHELIN XZY2 8.5 8 20.00R20 CONTINENTAL - -
MICHELIN XDY3 8.5 8 MICHELIN XZY3 9 -
385/68R22.5
MICHELIN XZE2 8.5 8 MICHELIN XFA1+ 8.5 -
MICHELIN XDE2 8.5 8 365/85R20 MICHELIN XZL 7.5 -
MICHELIN XDE2+ 8.5 8 365/80R20 MICHELIN XZL 6 -
PIRELLI AP05 8 8 16.00R20 MICHELIN XZL 7.6 7.6
PIRELLI AT75 8 8 MICHELIN XZL 7.6 7.6
315/80R22.5 14.00R20
PIRELLI FG85 8 8 PIRELLI PS22 PISTA 7 7
PIRELLI TG85 8 8 24.00R20.5 MICHELIN XS 6 -
PIRELLI FG88 8.5 8.5 385/95R24 MICHELIN X 9 -
PIRELLI TG88 8.5 8.5 385/55R22.5 MICHELIN XFA2 9 9
CONTINENTAL
- - 525/65R20.5 MICHELIN XS 8 -
HSR1
CONTINENTAL
- - 395/85R20 MICHELIN XZL 8.5 .
HDR
495/45R22.5 MICHELIN XDA2 9 - 525/80R25 MICHELIN XL 7 .
445/65R22.5 MICHELIN XZL 8 - 24R21 MICHELIN XZL 6 .
SUSPENSION STEERING
Front Vehicles without auxiliary cylinder
Figure 22 Figure 25
Longitudinal single leaf springs. Telescopic duplex hydraulic

shock absorbers and roll bar.
ZF SERVOCOM 8098
Oil pump driven by engine.
Rear Emergency pump controlled by transmission (if present).
2-axle vehicles Front wheel steering with quadrilateral kinetic motion assem-
bly.
Figure 23
Vehicles with auxiliary cylinder
Figure 26
Longitudinal double leaf springs.

Telescopic duplex hydraulic shock absorbers and roll bar.
3 and 4 axle vehicles
Figure 24
ZF SERVOCOM 8099
Oil pump driven by engine.
Emergency pump driven by transmission.
Front wheel steering with quadrilateral kinematic motion
assembly.
Auxiliary cylinder.
Single leaf springs, individual for the two rocking axles with
rocker system.
The torque bars between axle and central support counter-
act the axial thrust on acceleration and braking.
Anti-roll bar on intermediate axle and on rear axle (upon
request).
Leaf spring: parabolic or semi-elliptic (upon request).
Leaf springs: parabolic (standard)
...... semi-elliptic (optional).
ELECTRICAL SYSTEM CHASSIS
Figure 28
Figure 27
Built with rectilinear side members in high strength “C” sec-

Nominal voltage: 24 V tion steel, connected by riveted or bolted cross-members.
Accumulators (Fig. 1) (n˚ 2):
12 V - 170 Ah or
12 V - 220 Ah
Alternator: 28 V - 90 A Standard fuel tank
Steel, capacity 300 liters with level and reserve indicator.
The characteristics of accumulators and alternator

may change according to the outfitting and the des- Oversize fuel tank
tination market. Steel, capacity 600 liters with level and reserve indicator.
Starter motor
24V - 4.5 kW (engine F2B)
24V - 5 kW (engine F3B)
Ground reference: negative pole.
LUBRICANT AND HYDRAULIC FLUID TABLES


ENGINE
F3B
SECTION 3
HD9 Euro5 SECTION 3 ENGINE F3B 1
SECTION 3
Engine F3B
Page
VIEWS OF THE ENGINE 7
- Front view 7
- Left side view 8
- Rear view 9
- Right side view 10
- Upper view 11
DESCRIPTION 12
- Cursor engine configuration 12
- Location of right side engine components 13
- Location of left side engine components 14
FEEDING 15
ENGINE FEEDING DIAGRAM 16
- Overpressure valve 17
- Feed pump 17
- Injector-pump 17
- Pressure damper 17
TURBOCHARGER 19
TURBOCHARGING 19
HOLSET HY55V (Variable geometry turbine) 20
- Actuator 21
- Operating principle 21
- Location of shut-off solenoid valve 22
HOLSET HX 50W (WASTEGATE TURBINE) 23
- Description 23
VGT SOLENOID VALVE 22
ENGINE BRAKE 24
- Functional principle 24
COOLING 26
- Water pump 26
ENGINE COOLING SYSTEM 27
- Engine cooling system diagram 27
- Vehicles with standard system 27
2 ENGINE F3B SECTION 3 HD9 Euro5
- Vehicles with front radiator and retarder with CONTROL DEVICE FOR EMISSIONS 81
separate heat exchanger 28
- Precautions 81
- Vehicles with front radiator and retarder with
integrated heat exchanger 29 CHANGING THE ENGINE OIL 82
- Engine cooling system components layout 30 GENERAL 82
- Engine cooling system thermostat function - Safety instructions 82
(version without heat exchanger) 31
- Vehicle preparation 82
- Engine cooling system thermostat function
(version with heat exchanger) 32 - Hazardous and/or polluting substances 82
LUBRICATION SYSTEM 34 - Specific safety instructions 82
- Oil pump 34 DESCRIPTION OF OPERATION 83
- Overpressure valve 34 - Preliminary operations 83
- Lubrication system outline 35 - Drainage 83
- Oil pressure regulator valve 37 - Filling 83
- Heat exchanger 37 - Final operations 83
- Thermostatic valve 38 CHANGING THE ENGINE OIL FILTERS 84
- By-pass valve 38 GENERAL 84
- Engine oil filters 38 - Safety instructions 84
- Valve integrated in piston cooling nozzle 39 - Vehicle preparation 84
NOX EMISSION CONTROL SYSTEM (SCR) 40 - Specific safety instructions 84
- Introduction 40 DESCRIPTION OF OPERATION 85
- Description 40 - Removal 85
- NOX emission control system - operating - Assembly 85
principle 41
- Final operations 85
- Location of the SCR system components on
the vehicle 42 RADIATOR FLUID REPLACEMENT 86
- ADBLUE 43 GENERAL 86
- Urea 43 - Safety instructions 86
- AdBlue solution features 44 - Vehicle preparation 86
- Special AdBlue features 44 - Hazardous and/or polluting substances 86
TECHNICAL DESCRIPTION 45 - Specific safety instructions 86
GENERAL CHARACTERISTICS 46 DESCRIPTION OF OPERATION 87
DATA - ASSEMBLY PLAY 51 - Preliminary operations 87
TIGHTENING TORQUES 58 - Drainage 87
ENGINE SUPPORTS TIGHTENING TORQUES 61 - Inspections and checks 87
- Front engine supports tightening torques 62 - Filling 87
TIGHTENING ORDER OF GEARBOX TO ENGINE - Final operations 87
BLOCK FASTENING SCREWS 64
FEEDING CIRCUIT BLEEDING 88
TOOLS 65
GENERAL 88
TROUBLESHOOTING BY SYMPTOMS 74
- Safety instructions 88 - Removal 96

- Hazardous and/or polluting substances 88 - Inspections and checks 104
DESCRIPTION OF OPERATION 89 - Final operations 104
- Preliminary operations 89 - Refitting 104
- Execution of operation 89 RADIATOR ASSEMBLY REMOVAL RADIATORS 105
- Final operations 89 GENERAL 105
CLIMATE CONTROL COMPRESSOR BELT - Safety instructions 105
REPLACEMENT 90
GENERAL 90
- Very heavy parts 105
- Safety instructions 90
- Hazardous and/or polluting substances 105
- Specific safety instructions 105
DESCRIPTION OF OPERATION 91
- Preliminary operations 91
- Removal 91
- Removal 106
- Inspections and checks 91
- Refitting 108
- Refitting 91
FAN REMOVAL-REFITTING 109
REPLACING THE ACCESSORIES DRIVE BELT 92
GENERAL 109
GENERAL 92
- Removal 93
- Removal 110
- Refitting 110
- Refitting 93
INJECTOR REMOVAL-REFITTING ADBLUE 111
ENGINE REMOVAL-REFITTING 94
GENERAL 111
GENERAL 94
- Removal 112
- Refitting 112
TANK REMOVAL-REFITTING ADBLUE 113
- Handling AdBlue additive 95
GENERAL 113 - Mounting the piston rings 143

- Safety instructions 113 - Fitting the big end bearing shells 143
- Vehicle preparation 113 - Fitting connecting rod - piston assemblies in the
cylinder liners 144
- Checking piston protrusion 144
- Checking crankpin assembly clearance 145
CYLINDER HEAD 145
- Removal 114
- Dismounting the valves 145
- Checking head bearing surface on cylinder block 145
- Refitting 114
- Valves 146
- Valve seats 146
ENGINE OVERHAUL 115
- Checking clearance between valve-stem and
DISMANTLING ENGINE ON THE BENCH 115 associated valve guide 147
REPAIR OPERATIONS 123 - Valve guides 147
- Cylinder block 123 - Replacing injector cases 147
- Checks and measurements 123 - Checking protrusion of injectors 149
CYLINDER LINERS 124 TIMING GEAR 150
- Replacing cylinder liners 125 - Camshaft drive 150
- Removal 125 - Idler gear pin 150
- Fitting and checking protrusion 125 - Idler gear 150
- Crankshaft 126 - Twin intermediate gear pin 150
- Measuring main journals and crank pins 127 - Twin idler gear 150
- Preliminary data for selecting the main and - Replacing the bushings 150
big-end journal half-shells 128
- Timing gear 151
- Choice of big end and main bearing half-shells 129
- Checking cam lift and pin alignment 151
- Replacing the timing control gear and the oil
pump 136 - Bushes 152
- Checking main journal installation clearance 136 - Removal 153
- Checking crankshaft end float 137 - Replacement 153
- Piston-connecting rod assembly 138 - Valve springs 155
- Removal 138 - Fitting valves and oil seal 155
- Measuring the diameter of the pistons 139 ROCKER SHAFT 156
- Conditions for correct gudgeon pin-piston - Shaft 156

coupling 139
ROCKERS 156
- Piston rings 140
ASSEMBLING THE ENGINE ON THE BENCH 157
- Connecting rod 141
- Fitting connecting rod - piston assemblies in
- Bushings 142 cylinder liners 160
- Checking connecting rods 142 - Fitting the cylinder head 161
- Mounting the connecting rod - piston assembly 143 - Replacing flywheel casing 162
- Replacing engine flywheel 163

- Fitting the camshaft 164
- Fitting the injector pump 165
- Fitting the rocker shaft 165
- Camshaft timing 166
- Timing the phonic wheel 168
- Adjusting the unload/intake rockers play and
pump injector control rockers preload 169
COMPLETING THE ENGINE 170
TURBO CHARGER REMOVAL-REFITTING 172
GENERAL 172
- Removal 173
- Refitting 173
OVERHAUL OF TURBOCHARGER WITH
VARIABLE PITCH 174
- Variable pitch movement check 175
- Actuator check 175
- Actuator stroke check 176
- Cleaning the turbine body 176
FIXED PITCH TURBOCHARGER OVERHAUL 179
PRESSURE LIMITER VALVE 179
- Pressure limiter valve replacement 180
HYDROCAR POWER TAKE-OFF ON TIMING
SYSTEM - (OPTIONAL P.T.O.) 181
- Description 181

VIEWS OF THE ENGINE

Front view
Figure 1
335B003001R
1. Air filter control valve VGT - 2. Alternator - 3. Oil level dip stick - 4. Automatic take-up device - 5. Not used -
6. Not used - 7. Viscostatic damper flywheel - 8. Fixed tightener pulley - 9. Water pump - 10. Fan pulley -
11. VGT actuator - 12. Thermostat
Left side view

Figure 2
335B003002R
1. Compressed air delivery to intercooler - 2. Oil filters - 3. Oil return pipes from turbocharger -
4. Water-oil heat exchanger - 5. Oil pressure adjustment valve - 6. Turbine discharge - 7. Distribution cover -
8. Exhaust manifold - 9. Turbocharger - 10. VGT actuator
Rear view
Figure 3
335B003003R
1. VGT actuator- 2. Turbocharger - 3. Oil filter - 4. Engine flywheel - 5. Blow-by filter - 6. Blow-by valve
Right side view

Figure 4
342B031001R
1. Distribution cover with blow-by filter and valve - 2. Air compressor - 3. Starter motor - 4. Power steering pump -
5. Not used - 6. Not used - 7. Oil level dip stick - 8. Not used - 9. Intake manifold - 10. VGT control valve air filter -
11. Fuel pump - 12. Fuel filter
Upper view
Figure 5
335B003005R
1. Exhaust manifold - 2. Engine oil filler cap - 3. Intake manifold - 4. Compressed air delivery to intercooler -
5. Turbocharger - 6. Turbine exhaust
DESCRIPTION
Cursor engine configuration
This engine has a high pressure type injection system with injector — pump operated by the overhead cam shaft.
The electronic control unit is mounted on the engine and contains specific software for each different power calibration.
In service it is not possible to intervene on the control unit software, except to enter, where necessary, certain configuration data
(for example, in the case of injector — pump replacement).
Figure 6
CURSOR ENGINE
ENGINE INJECTOR CONTROL UNIT
UIS N 31 MS 7.0
Liters
Engines have a multitude of components that must not be painted or that have to be partially protected. The simplest
solution is not to paint the engine.
The electrical and electronic components (sensors, control units, cables,...) do not require painting. Painting in most cases will result
in damage.
In particular, consider the following points for the EDC:

- paint negatively affects the heat exchange capacity of the unit
- paint damages connectors
- paint covers labels (that must be intact and legible)
- paint jeopardises the function of the ambient pressure sensor built-in to the control unit.
Failure to respect these points, in addition to cancelling the warranty, may cause serious problems and malfunctions.
Location of right side engine components
Figure 7
276A004004A
1. Timing sensor (engine timing) - 2. Fuel temperature sensor -

3. EDC engine control unit - 4. Pre-post heating element -
5. Supercharge air temperature and pressure sensor - 6. Injectors - pump
Location of left side engine components
Figure 8
276A004005A
1. VGT electrovalve actuator - 2. Not used - 3. Engine coolant fluid temperature sensor - 4. Engine brake pedal electrovalve -
5. Flywheel sensor (engine speed) - 6. Turbine revs sensor
FEEDING
Feeding is by means of fuel per-filter and filter, mechanical feed pump, 6 injectors - pump controlled by camshaft by rocker arms
and electronic control unit.
Fuel pressure inside the cylinder head is adjusted by a valve set at 3.5 bar located on the return to the feeding pump , whereas
a unidirectional valve set at 0.2 - 0.3 bar on return to tank prevents the cylinder head emptying when engine is not running
Key to figure on next page

1. Tank
2. Fuel filter
3. Feeding pump
4. Pressure damper
5. Fuel pre-filter with manual priming pump
6. Engine control unit
7. Overpressure valve for fuel return to tank
8. Pump injectors
ENGINE FEEDING DIAGRAM
Delivery circuit
Return circuit
342B031002R
Overpressure valve Injector-pump

Figure 9 Figure 11
92829
An overpressure valve is a single-acting valve, calibrated to 0.2

 0.3 bar, placed on the piping that returns fuel to tank. The
overpressure valve prevents fuel duct in cylinder head from
emptying with engine stopped.
Feed pump
Figure 10
102405
INJECTOR SECTION
The new pump injectors are capable, thanks to the higher in-
jection pressure, of atomizing the fuel in the combustion
chamber to a greater extent, thus improving combustion and
therefore reducing the polluting exhaust emissions.
92830 Pressure damper

Engine feed pump for vehicles 4x2 - 4x4 - 6x4 Figure 12
1. Overpressure valve - 2. Delivering fuel to injectors -
3. Sucking in fuel - 4. Pressure control valve
Pump performances
Pump rotation speed (rpm) 2600 600 170 100
Minimum flow rate (l/h) 310 45 12

Negative pressure
on aspiration (bar) 0.5 0.3 0.3 0.3
Pressure on delivery
Test (bar) 5 3 0.3 0.3
conditions
Test liquid
temperature (ºC) 30 30 30 30 102606
Test liquid ISO 4113

FUEL PRESSURE DAMPER
Field of use
Pump rotation speed (rpm) 2600
The function of the fuel pressure damper located on the deliv-
Overrunning rotation speed (max 5 min) (rpm) 4100 max ery pipe between the fuel filter and the cylinder head is to at-
Diesel oil temperature (ºC) -25/+80 tenuate the supply return back pressure due to the increase
Filtering rate on aspiration (micron) of the injection pressure.
Negative pressure on 30
aspiration (bar) 0.5 max
Pressure control valve

Taratura valvola (bar) 5  5.8
Injectors return valve

Valve calibration (bar) 3.2  3.8
Figure 13
104245
For each injector replaced, hook up to the diagnostic station

and, when asked by the program, enter the code punched on
the injector () to reprogram the control unit.
When checking the clearance of the rocker arms, it

is important to check the injector-pump pre-load.
TURBOCHARGING
The turbo-charging system mainly consists of:
- an air filter;
- a turbo-charger;
- an intercooler radiator.
Figure 14
Engine exhaust gas 1780325

Intake air
TURBOCHARGER AND EXHAUST SYSTEM OUTLINE
1. Air duct to intake manifold - 2. Intake manifold - 3. Catalyst silencer - 4. Exhaust pipe - 5. Intake piping -
6. Air filter - 7. Turbocompressor - 8. Air duct to intercooler - 9. Exhaust manifold - 10. Intercooler
TURBOCHARGER The movement of the device, choking the exhaust gas

Operating principle flowing section, is carried out by a mechanism, activated by
a pneumatic actuator.
The variable geometry turbocharger (VGT) consists of a
centrifugal compressor and a turbine, equipped with a This actuator is directly controlled by the electronic control
mobile device which adjusts the speed by changing the area unit by a proportional solenoid valve.
of the passing section of exhaust gases to the turbine. The device is in maximum closing condition at idle speed.
Thanks to this solution, gas velocity and turbine speed can At high engine operating speed, the electronic control
be high even when the engine is idling. system is activated and increases the passing section, in
If the gas is made to go through a narrow passage, in fact, order to allow the in-coming gases to flow without
it flows faster, so that the turbine rotates more quickly. increasing their speed.
A toroidal chamber is obtained during the casting process
in the central body for the passage of the coolant.
HOLSET HY55V (Variable geometry turbine)

Figure 15
71759
1. Air delivery to intake manifold - 2. Compressor - 3. Air intake - 4. Actuator - 5. Exhaust gas speed regulator -
6. Exhaust gas intake - 7. - Exhaust gas outlet - 8. Turbine
MINIMUM FLOW SECTION MAXIMUM FLOW SECTION

71733 71734
TURBOCOMPRESSOR CROSS-SECTION
1. Air delivery to intake manifold - 2. Compressor - 3. Air intake - 4. Actuator - 5. Exhaust gas flow rate regulator ring -
6. Exhaust gas intake - 7. - Exhaust gas outlet - 8. Turbine - 9. Exhaust gas flow-rate command fork
Actuator
Figure 16
Stroke
72421
a. Gradient characterised by effect of external spring

(4)
b. Gradient characterised by effect of external (4) and
internal (6) spring
71834
1. Air intake - 2. Gasket. - 3. Piston - 4. External spring. - 5. Internal spring command disk. - 6. Internal spring. - 7. O-ring. -
8. Spring holder. - 9. Stroke limit. - 10. Dust seal - 11 Command rod.
Operating principle
The actuator piston connected to the command rod is pi-
loted by compressed air entering through the air intake (1)
on the upper part of the actuator.
Modulating the air pressure varies the shift of the turbine
command piston and rod. During its excursion the piston
progressively compresses the external spring (4) until the
base of the piston reaches the internal spring (6) command
disk (5).
Further increasing the pressure the piston interferes with the
lower limit stop (10) through the disk (5).
The use of two springs permits variation in the ratio between
piston excursion and pressure. Approx. 85% of the rod stroke
is contrasted by the external spring, whereas only 15% by the
internal spring.
VGT SOLENOID VALVE

This is a proportional N.C. type solenoid valve located on the front of the engine.
The electronic control unit, by means of a PWM signal, drives this solenoid valve, adjusting the feeding pressure of the turbine
actuator that, changing its position, changes the exhaust flow section on the impeller blades and hence the speed of the same.
Figure 17
1. Service tank
2 Shut-off solenoid valve
3. Air filter
4. VGT solenoid valve
5. Not used
6. Turbine actuator 71765B
Location of shut-off solenoid valve Figure 18

The shut-off solenoid valve is located inside the chassis side
member on the engine right side .
342B031003R
HOLSET HX 50W (Wastegate Turbine)

Figure 19
71766
Description
The turbocompressor is fitted with pressure limiter valve.
It essentially consists of:
- a central body that houses a shaft supported on bushing.
At the opposite ends of this shaft are: The turbine im-
peller and the compressor impeller;
- a turbine body and a compressor body mounted at the
ends of the central body;
- an overpressure limiter valve applied to the turbine body.
This serves to regulate exhaust gas output, delivering
part directly to the exhaust pipe when supercharge pres-
sure downstream of the compressor reaches the cali-
brated value.
ENGINE BRAKE
Functional principle
Toward the end of the compression phase (Fig. A), a few degrees before TDC, a specific device slightly opens the exhaust valve,
evacuating the pressure formed in the cylinder (Fig. B).
In this case the braking torque of the compression phase is used, eliminating the subsequent return thrust of the piston.
Figure 20
A B
001413t
FUNCTIONAL PRINCIPLE (ITB)

Operating the engine brake, a hydraulically controlled mechanism cancels the play of the exhaust valve.
In this way, given the particular profile of the exhaust cam, the corresponding rocker is slightly raised, at the right moment in the
cycle, proportional to the engine brake command.
As a consequence, the exhaust valves open slightly in the vicinity of TDC at the end of the compression phase, discharging the
compressed air in the combustion chamber.
Figure 21
A Engine brake disengaged
B Engine brake engaged
C Exhaust cam
d Valve rise for engine brake
00592t
COOLING
Forced circulation type cooling by centrigual pump driven by Figure 24
crankshaft via Poly-V belt.
Water circulation is regulated by the thermostat.
The radiator is vertical type.
Check that the pump body is not cracked or leaking.

Otherwise replace the complete water pump.
Check thermostat function and if in doubt, replace
it
71731
Water pump WATER PUMP ON ENGINE
Figure 22
60631
SECTION ON WATER PUMP
Figure 23
45159
The water pump consists of the impeller, gasket bearing and

drive pulley.
ENGINE COOLING SYSTEM

Engine cooling system diagram
Vehicles with standard system
Figure 25
358A003100R
1. Radiator - 2. Thermostat - 3. Engine - 4. Cab heater - 5. Transmission -

6. Expansion reservoir
Vehicles with front radiator and retarder with separate heat exchanger
Figure 26
358A003101R

6. Expansion reservoir - 7. Transmission oil heat exchanger
Vehicles with front radiator and retarder with integrated heat exchanger
Figure 27
360F003003R

6. Expansion reservoir - 7. Transmission oil heat exchanger
Engine cooling system components layout

Figure 28
1780323
1. Radiator - 2. Fan - 3. Water pump - 4. Water-engine oil heat exchanger - 5. Turbocompressor - 6. Thermostat -
7. Air compressor - 8. Cab heater - 9. Front expansion reservoir - 10. Piping from engine to transmission heat exchanger
(if present) -11. Piping from transmission heat exchanger to thermostat (if present)
Engine cooling system thermostat function (version without heat exchanger)

Thermostat closed
Figure 29
1. Fluid to expansion chamber - 2 Fluid from engine - 3. Fluid to by-pass
Thermostat open
Figure 30
1. Fluid to expansion chamber - 2 Fluid from engine - 3. Fluid to radiator

Engine cooling system thermostat function (version with heat exchanger)

Thermostat closed
Figure 31
341B003001R
1. Pipe from radiator to engine (coolant fluid pump) - 2. Pipe from expansion chamber to engine (coolant fluid pump) -
3. Pipe from cab heater to engine - 4. Pipe from engine to cabin heater - 5. Engine intake - 6. Engine output -
7. Pipe from engine to exchanger (if present) - 8. Pipe from exchanger (if fitted) to thermostat - 9. Vent -
10. Pipe from thermostat to radiator
A. Engine - B. Exchanger (if fitted) - C. Thermostat

Thermostat open
Figure 32
341B003002R
1. Pipe from radiator to engine (coolant fluid pump) - 2. Pipe from expansion chamber to engine (coolant fluid pump) -
3. Pipe from cab heater to engine - 4. Pipe from engine to cabin heater - 5. Engine intake - 6. Engine output -
7. Pipe from engine to exchanger (if present) - 8. Pipe from exchanger (if fitted) to thermostat - 9 Vent - 10. Pipe from
thermostat to radiator
A. Engine - B. Exchanger (if fitted) - C. Thermostat

LUBRICATION SYSTEM
Oil pump Overpressure valve
Figure 33 Figure 34
73540
60560 MAIN DATA TO CHECK THE OVERPRESSURE

VALVE SPRING
The oil pump (1) cannot be overhauled. On finding any
damage, replace the oil pump assembly.
See under the relevant heading for replacing the gear (2) of
the crankshaft.
Figure 35
108846
OIL PUMP CROSS-SECTION

1. Overpressure valve - 2. Start of opening pressure 10  1 bars.
Lubrication system outline

Figure 36
gravity fed oil

oil under pressure
1780320
1. Oil sump. - 2. Crankshaft. - 3. Engine oil-water heat exchanger. - 4. Engine oil filter. - 5. Turbocompressor. - 6. Camshaft. -
7. Valve timing gears.
Lubrication system outline - Detail A

Figure 37
Gravity fed oil
Oil under pressure
B - to cylinders 1 -2 - 3
C - to cylinder 4
D - to cylinders 5 - 6
DETAIL A
1780321
8. Engine brake solenoid valve with 4th cylinder command piston.

Oil pressure regulator valve

Figure 38 Figure 39
73542 73543
The oil pressure regulator valve is located on the left side of MAIN INFORMATION FOR CHECKING THE OIL
the engine block. PRESSURE REGULATOR VALVE SPRING
Start aperture pressure 5 bar. Heat exchanger
Figure 40
HEAT EXCHANGER
The heat exchanger is fitted with: 1. Oil temperature transmitter — 2. Oil pressure transmitter —
3. Filter bypass valve — 4. Thermostat
Number of heat exchanger elements: 11.
Thermostatic valve
Figure 41 This is a new generation type filter that permits much better
filtering since able to retain a greater quantity of fine
particules than traditional filters with paper elements.
The use of these high level filters, up until now only used in
industrial processes, permits:
- reduced engine wear over time;
- maintain oil performance / specifications and extend oil
life.
Outer spiral winding
73546
The filter elements are spiral wound such that each fold is
Start aperture: solidly anchored to the spiral with respect to the others. This
- stroke 0.1 mm at temperature of 82 2ºC. means uniform use of the element even in the heaviest
End aperture: conditions, such as cold starting with high viscosity fluids and
- stroke 8 mm at temperature 97˚C. flow peaks. It also assures uniform distribution of the flow
over the entire length of the filter element, with consequent
By-pass valve optimisation of pressure drop and working life.
Upstream support
Figure 42
To optimise flow distribution and filter element rigidity, the
element is fitted with an exclusive support consisting of a
strong nylon mesh and high strength synthetic material.
Filter element
Filter element made up of inert inorganic fibre bound with an
exclusively made porous type structure. The elements are
made according to strict manufacturing procedures and
stringent quality control.
Downstream support
A filter element support and a strong nylon mesh give the
element extra strength, particularly useful during cold starting
and long periods of use. Filter performance thus remains
constant and reliable, element after element for its entire
73545
working life.
Structural parts
The by-pass valve on the oil filter opens rapidly at pressure
of : 3 bar The O-rings the filter element is fitted with assure perfect seal
between the element and the container, eliminating the risk
of by-pass and maintaining filter performance constant. A
Engine oil filters corrosion resistant base and strong metal internal cor
Figure 43 complete the structure of the filter element.
When fitting the filters, proceed as follows:
- oil and fit new seals;
- screw-in the filters until the seals come into contact with
the bases;
- tighten the filter to torque of 35  40 Nm.
47447
Valve integrated in piston cooling nozzle

Figure 44
109080
The valve allows oil to enter only above the threshold

pressure of 1.7  0.2 bar. This permits filling the circuit and
therefore lubricating the most stressed parts even when
working at lower pressures.
NOX EMISSION CONTROL SYSTEM (SCR)

Introduction
A nitrogen oxide (NOX) post-treatment system has been fitted to restrict the exhaust gases emissions of such substances within
the limits set forth by Euro 5 standards. The system essentially consists of an electronically controlled oxidizing catalyser.
Description
The system essentially consists of:
- a reacting solution tank (water - urea: AdBlue) with level indicator
- an engine coolant diverter valve with pipes for pre-heating the system
- a pump module
- an injection mixing module (metering module)
- a catalyser
- a NOX sensor
- two exhaust gas temperature sensors (pre-cat and post-cat)
- a humidity sensor mounted on the engine air intake pipe downstream of the air cleaner.
The system is electronically controlled by a DCU (Dosing Control Unit) built into the pump module, which adjusts the flow of
AdBlue to be introduced into the system according to engine rpm, delivered torque, exhaust gas temperature, amount of nitrogen
oxide and humidity of the intake air.
The pump module takes the reactant solution from the tank, and sends it under pressure to the metering module, which injects
it into the exhaust pipe upstream of the catalyser.
The first step of the process occurs in the first part of the catalyser: the reactant solution, by effect of the exhaust gases, vaporises
and is converted into ammonia (NH3) and carbon dioxide (CO2) by electrolysis. At the same time, the evaporation of the solution
lowers the exhaust gas temperature taking it closer to the optimal temperature required for the process.
The exhaust gases with added ammonia are introduced at the reaction temperature in the catalyser where the second step of
the process takes place: the ammonia reacts with the exhaust gas oxygen and is converted into free nitrogen (N2) and water
vapour (H2O).
NOX emission control system - operating principle

Location of the SCR system components on the vehicle

Location of the SCR system components on the vehicle (see previous page)
1. Water-urea (AdBlue) solution tank
2. AdBlue level indicator
3. Pump module
4. Water diverter valve
5. Metering module
6. Catalyser
7. Intake air humidity sensor
8. Pre-cat exhaust gas temperature sensor
9. Post-cat exhaust gas temperature sensor
10. NOx sensor
ADBLUE
AdBlue is the European trademark of a high-quality aqueous urea solution. It contains urea and demineralised water needed for
SCR operation.
Urea
Chemical formula of urea: N2 H 4
Discovered in urine in 1773, it was the first organic chemical compound to be synthetically reproduced using lead cyanate and
an aqueous ammonia solution.
Today, urea is used to make agricultural fertilisers. It is also used in the pharmaceutical and cosmetic industries.
AdBlue solution features

Classified as not dangerous (EC Directive 67/548/EC) for humans and for the environment.
It has the following features:
Liquid, transparent, odourless
Non flammable
Non explosive
Non oxidising
May be irritating
Crystallisation temperature = -11 ˚C
Sold by the litre
DIN V 70070 specifications
Composition specified in DIN V 70700 standard:
32.5% urea
67.5% water
A 32.5% concentration was chosen to obtain a freezing temperature of -11˚C.
Special AdBlue features

White urea crystals may be observed after all the water has evaporated. These crystals are harmless.
Toxic fumes (containing ammonia, carbon diode and nitrogen oxides) may be released in contact with fire.
The following widely used materials are compatible with AdBlue:

Carbon steel
Stainless steel
Aluminium
Polyethylene (PE)
Polyvinylchloride (PVC)
Polypropylene (PP)
Ethylene propylene diene M-class rubber (EPDM) used for seals and gaskets
Use of copper, zinc and alloys must be avoided.

TECHNICAL DESCRIPTION
ENGINE
TYPE SERIAL NUMBER
F 3 B E 3 6 8 1 B * P 0 0 1 -
Progressive production number

Version no. within D.B.
Level of Gas Emissions
Engine torque and power level S Euro 5
Use (1 truck, ...)
Supply + Injection (TCA, diesel direct injection)
Number of cylinders
Number of strokes and cylinder position (3 = 4 stroke, vertical with

post-treatment)
Engine
Development of family with/without same displacement
Engine family
GENERAL CHARACTERISTICS
Type F3B
Cycle Diesel 4 strokes

Feeding Turbocharged with aftercooler
Injection Direct
N. of cylinders 6 on-line
j
Diameter mm 135
Stroke mm 150
+ + +.. = Total displacement cm3 12882
ρ Compression ratio 16.5 : 1
WG VGT
Max. power kW
(HP)
306 328 358 388 418
(410) (440) (480) (520) (560)
rpm 1900 1900 1900 1900 1900
Max. power kW 1900 2200 2300 2400 2500

(HP) (193) (224) (234) (244) (254)
rpm 1000S1515 1000S1400 1000S1450 1000S1600 1000S1550
Engine idling speed,

no load
rpm 550  50
Maximum engine
speed, no load
rpm 2320  50
Type F3B
A VALVE TRAIN
Start before TDC A 19
End after BDC B 36
C Start before BDC D 50
End after TDC C 9
For timing check
mm _
X
mm _
X
Operating
mm 0.40 ± 0.05
X
mm 0.60 ± 0.05
FUEL SUPPLY By fuel pump - Filters

Injection With UIS N3.1 electronically regulated injectors.
Bosch type Injectors-pump driven by overhead camshaft
Nozzle type -
Injection order 1-4-2-6-3-5
bar
Injection pressure bar 2000
Injector calibration bar 296  6
F3B F3B
Type
WG VGT
Holset Variable geometry

SUPERCHARGING
Wastegate Holset
Turbocharger type HX50W HE551 V
By centrifugal pump, regulating thermostat, viscostatic fan,
COOLING radiator and heat exchanger
Water pump control By belt
Thermostat: N. 1
starts to open: 84 ± 2˚ C
fully open: 94 ± 2˚ C
LUBRICATION Forced by gear pump, pressure control valve, oil filter
Oil pressure, engine hot
(100 oC  5 oC):
bar
at idling speed bar 1.5
at maximum speed bar 5
OIL FILLING (*)
Total capacity at 1st filling
liters 35
kg 25.5
Capacity:
- engine sump min level
liters 20
kg 18
- engine sump max level
liters 28
kg 25.2
- quantity in circulation that
does not flow back to the
engine sump
liters 7
kg 6.3
- quantity contained in the
cartridge filter (which has to
be added to the cartridge filter
refill)
liters 3
kg 2.7
(*) For the correct type of fluid, see section 2 - HYDRAULIC FLUID AND LUBRICANTS TABLE
Figure 45
99112
LONGITUDINAL SECTION OF ENGINE

Figure 46
71699
CROSS-SECTION OF ENGINE
DATA - ASSEMBLY PLAY
Type F3B
CYLNDER GROUP AND CRANK GEAR mm

1
Cylinder barrel seats:
upper 153.500  153.525
1
lower 152.000  152.025
Cylinder barrels:
external diameter:
L upper 153.461 153.486
2
lower 151.890  151.915
2 length L _
Cylinder barrels -
engine block seats
upper 0.014  0.039
lower 0.085  0.135
ASTRA
External diameter 2 _
3
Cylinder barrels:
X
internal diameter 3A* 135.000  135.013
internal diameter 3B* 135.011  135.024
Protrusion X** 0.045  0.075
* Selection class
** Under load of 8000 kg
Pistons: FEDERAL MOGUL
1
measurement level X 18
X
external diameter 1AD 134.861  134.873
2 external diameter 1BDD 134.872  134.884
pin seat 2 54.010  54.018
Piston — cylinder barrel
A* 0.127  0.152
B* 0.127  0.152
* Selection class
ASTRA
Piston diameter 1 _
X
Piston protrusion X 0.12  0.42
3 Piston pin 3 53.994  54.000
Piston pin — pin seat 0.010  0.024

D Class A pistons supplied as replacement parts.
DD Class B pistons mounted only in production and not supplied as replacement parts.
F3B
Type
mm
FEDERAL MOGUL
X1 X1* 2.427
X2 Snap ring grooves X2 1.550  1.570
X3 5.020  5.040
X3
* measured at  of 130 mm
Snap rings:
- trapezoidal grip S1* 2.296  2.340
S1 - tab grip S2 1.470  1.500
S2 - milled scraper ring with
S3 slit and internal spring S3 4.970  4.990
* measured at 2.5 mm from
external
1 0.087  0.131
Snap rings - hollow 2 0.050  0.100
3 0.030  0.070
ASTRA
Snap rings _
X1 Snap ring aperture at ends

in cylinder barrels:
X2
X1 0.40  0.50
X3
X2 0.65  0.80
X3 0.40  0.75
Small end bush seat

1 Ø1 59.000  59.030
Con rod bearings seat
Ø2
2 1 94.000  94.010
Selection class Ø2 2 94.011  94.020
3 94.021  94.030
4 Small end bush diameter
external 4 59.085  59.110
3 54.019  54.035
internal 3
Con-rod half-shells S
S Red 1.965  1.975
Green 1.976  1.985
Yellow 1.986  1.995
Small end bush - seat 0.055  0.110
Piston pin - bush 0.019  0.041
ASTRA
Con-rod half-shells 0.127 - 0.254 - 0.508
Con-rod weight
Ag 4741  4780 g
Class Bg 4781  4820 g
Cg 4821  4860 g
F3B
Type
mm
X
Measurement level X 125
Maximum error
in parallel
of con-rod axes 0.08
Main journal pins 1

- nominal 99.970  100.000
- class 1 99.970  99.979
- class 2 99.980  99.989
- class 3 99.990  100.000
1 2
Con-rod pins 2
- nominal 89.970  90.000
- class 1 89.970  89.979
- class 2 89.980  89.989
- class 3 89.990  90.000
S1 S 2 Main journal half-shells S1
Red 3.110  3.120
Green 3.121  3.130
Yellow 3.131  3.140
Con-rod half-shells S2
Red 1.965  1.975
Green 1.976  1.985
Yellow 1.986  1.995
3 Main bearings 3 106.300  106.330
Half-shells-
main journal pins f 0.060  0.108 * - 0.061  0.119 ** - 0.060  0.130 ***
Half-shells — con-rod pinsf 0.050  0.108 * -0.051  0.109 ** -0.050  0.098 ***
ASTRA Main journal half-shells 0.127 - 0.254 - 0.508
Con-rod half-shells 0.127 - 0.254 - 0.508
Main journal pin

for shoulder X1 47.95  48.00
X1
Main journal
for shoulder X2 40.94  40.99
X2
X3
Shoulder half-rings X3 3.38  3.43
Crankshaft shoulder 0.10  0.30

1 2
Alignment 1-2  0.025
Ovalisation 1-2 0.010
Taper 1-2 0.010
* Fitted for production only and not supplied as replacement part.

f Supplied as replacement: * standard; ** = 0.127; *** = 0.254 — 0.508
Type F3B
CYLINDER HEAD — VALVE TRAIN mm

 1
Valve guide seats
in cylinder head
1 15.980  15.997
 2
2 10.015  10.030
Valve guides
3 16.012  16.025
 3
Valve guides and seats in head 0.015  0.045

ASTRA
Valve guides _
 4 Valves
4 9.960  9.975
 60 30  7 30
4 9.960  9.975
 45 30  7 30

Valve stem and corresponding
guide 0.040  0.070
Seat on head for valve

seat
49.185  49.220
1
46.985  47.020
 1 1
Valve seat external

diameter; valve seat
 2
inclination in cylinder head
49.260  49.275
2 60 - 30’

 47.060  47.075
2
45 - 30

ASTRA
Valve seat 0.2
X 0.45  0.75
Recess
X X 1.65  1.95
Between valve seat

and head 0.040  0.090
F3B
Type
mm
Valve spring height:
free spring H 76
H under load of:
H1
H2 775  39 N H1 59
1366  68 N H2 46
Injector protrusion X 0.52  1.34

X
Seats for camshaft bushes in

cylinder head
17 Ø 88.000  88.030
  
 2
Camshaft support
pins
17 Ø 82.950  82.968
 1  3
External diameter of
 camshaft bushes  88.153  88.183
 Bush internal diameter  83.018  83.085
Bushes and seats

in cylinder head 0.123  0.183
Bushes and support pins 0.050  0.135
Cam working height
9.231
H 9.5607
13.376
 1
Rocker shaft 1 41.984  42.000
F3B
Type
mm
Rocker bush seats
45.000  45.016
59.000  59.019

46.000  46.016
External diameter of
rocker bushes
45.090  45.130
 59.100  59.140
46.066  46.091
Rocker bush internal

diameter
42.025  42.041
 56.030  56.049
42.015  42.071
Bushes and seats

0.074  0.130
0.081  0.140
0.050  0.091
Rocker shaft and bushes

0.025  0.057
0.025  0.057
0.015  0.087
O1
Engine braking
control lever
Cam pin external
diameter 1 55.981 ÷ 56.000
O2
Rocker shaft seat 2 42.025 ÷ 42.041
Type F3B
mm
Engine brake control lever
rocker bushes and cam pin
0.030 ÷ 0.068
Rocker shaft and seat on

engine brake control lever
0.025 ÷ 0.057
TURBOCOMPRESSORE
Type 380 CV engine HOLSET HOLSET
480 CV engine HX 50W HE 551 V
Axial play 0.025  0.127 0.051  0.152
Radial play 0.381  0.610 0.381  0.533
Holset HX50W turbocompressor Waste Gate ope-
ning stroke at 1.75 bar pressure:
- control 0.43  1.95
- adjustment 0.86  1.40
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
Sump to engine block fasteners
External fasteners M12x1.75 First phase: pre-tightening 30 (3)
Internal fasteners M 18x2 Second phase: pre-tightening 120 (12)
Internal fasteners M 18x2 Third phase: closure to angle 60
Internal fasteners M 18x2 Fourth phase: closure to angle 55
External fasteners M 12x1.75 Fifth phase: closure to angle 60
Piston cooling nozzle filler 35 2 (3.5 0.2)
Heat exchanger to block fasteners
tightening 19 3 (1.9 0.3)
Scavenger pipe to engine block fasteners 24.5 2.5 (2.4 0.25)
Oil sump spacer fasteners
tightening 45 (4.5)
Gearbox to engine block fasteners M 12x1.75  63 7 (6.3 0.7)
Cylinder head bolts
First phase pre-tightening 60 (6)
Second phase pre-tightening 120 (12)
Third phase closure to angle 90
Fourth phase closure to angle 65
Rocker shaft fasteners
Second phase closure to angle 60
Rocker adjuster locknut 39 5 (3.9 0.5)
Injector bracket fasteners 26 (2.6)
Plastic cover fasteners 8.5 1.5 (0.85 0.15)
Head shoulder plate fasteners 19 3 (1.9 0.3)
Engine mounting bracket fasteners at cylinder head
Second phase closure to angle 45º
 Lubricate with UTDM oil before mounting

 Lubricate with graphite oil before mounting
TORQUE
DETAIL
Nm kgm
Engine mounting bracket fasteners at flywheel casing
Camshaft pinion fasteners
Phonic wheel fstener on camshaft pinion 8.51.5 (0.850.15)
Exhaust manifold fasteners
pre-tightening 405 (40.5)
tightening 705 (70.5)
Engine braking actuator cylinder fasteners 193 (1.90.3)
Big end bolts
Flywheel fasteners
Damper flywheel fasteners
Intermediate gear pin fasteners
Link rod fasteners for adjustment of drive gear 24.52.5 (2.45 0.25)
Oil pump fasteners 24.52.5 (2.45 0.25)
Front Crankshaft gasket cover fasteners 24.52.5 (2.45 0.25)
Fuel pump / filter support fasteners 193 (1.9 0.3)
Control unit fasteners 193 (1.9 0.3)
Turbocompressor nuts and bolts
pre-tightening 35 (3.5)
tightening 46 (4.6)
Thermostat group fasteners 303 (3.00.3)
Water pump fasteners 25 (2.5)
Fasteners for fan hub to spacer 30 (3)
Fan spacer to pulley fasteners 30 (3)
Fan support to engine block fasteners 100 (10)
Automatic belt tensioner to conditioner fasteners 263 (2.60.3)
Automatic belt tensioner to alternator support fasteners 505 (50.5)
Fixed auxiliaries drive pulley to engine block fasteners 1055 (10.50.5)
Starter motor fasteners 744 (7.40.4)
Air heater fasteners 303 (30.3)
Air compressor fasteners 744 (7.40.4)

TORQUE
DETAIL
Nm kgm
Compressor drive cog nut 170 10 (17 1)
Alternator fasteners M 10x1.5 44 4 (4.4 0.4)
Power steering pump fasteners 46.5 4.5 (4.65 0.45)
Air conditioner compressor to support fasteners 24.5 2.5 (2.5 0.25)
Cover fasteners 24.5 2.5 (2.5 0.25)
Filter block sensor fastener 55 5 (5.5 0.5)
Water / fuel temperature sensor fastener 35 (3.5)
Thermometric switch / transmitter fastener 25 (2.5)
Air temperature transmitter fastener 35 (3.5)
Pulse transmitter fastener 8 2 (0.8 0.2)
Engine brake electrovalve fastener 32 (3.2)

ENGINE SUPPORTS TIGHTENING TORQUES
AD RH front : see next page

AS LH front: see next page
Apply LOCTITE 243 thread lock
342B0310006R
Front engine supports tightening torques

4X2 VEHICLES
ENGINE OVERHAUL
342B0310007R
6X4 8X4 VEHICLES
6X6 8X6 8X8 VEHICLES
342B0310007R
TIGHTENING ORDER OF GEARBOX TO ENGINE BLOCK FASTENING SCREWS
Figure 47
stage 1:
FRONT SIDE pretightening,
outer screws
30 Nm
60592
stage 2:
FRONT SIDE pretightenig,
inner screws
120 Nm
60593
stage 3:
angle, inner
FRONT SIDE screws
60º
60593
stage 4:
angle, inner
FRONT SIDE screws
55º
60593
stage 5:
angle, outer
FRONT SIDE screws
60º
60594
TOOLS
TOOL N˚ NAME
Rotary telescopic stand

99322230 (load bearing capacity 200 dsN, torque 375 dsNm)
99340053 Crankshaft front seal extractor tool
99340054 Crankshaft rear seal extractor tool
99340205 Percussion extractor
99342149 Injector holder sheath extractor
99342155 Tool to extract injectors

TOOLS
TOOL N˚ NAME
99346250 Crankshaft front seal fitting tool
993462260 Crankshaft rear seal fitting tool
99348004 Universal 5 to 70 mm internal extractor
99350072 Socket wrench for engine block-sump union bolts
99360143 Beater for fitting — removing valve guides
99360180 Injector seat protection plugs (6)

TOOLS
TOOL N˚ NAME
Piston ring removal-replacement clamp

99360184 (105-106 mm)
99360192 Wedge for elastic belt
Engine valve removal-replacement tool

99360261 (use with specific plates)
Engine valve removal-replacement plate

99360263 (use with 99360261)
99360296 Tool to fit back valve guide (to be used with 99360143)
99360314 Tool to remove oil filter (engine)

TOOLS
TOOL N˚ NAME
99360321 Tool to rotate engine flywheel (to be used with 99360325)
99360325 Spacer (to be used with 99360321)
99360329 Tool to install gasket on valve guide
99360334 Attrezzo di compressione per rilievo sporgenza canne cilindri

(usare con 99370415-99395603 e piattelli specifici)
99360336 Distanziali (usare con 99360334)
99360338 Piattello per compressione canne cilindri (usare con 99360334-

99360336)
TOOLS
TOOL NO. DESCRIPTION
99360351 Tool to stop engine flywheel
99360499 Tool to take down and fit back camshaft bushes
99360500 Tool to lift crankshaft
99360551 Bracket to take down and fit engine flywheel
99360553 Tool for assembling and installing rocker arm shaft
99360585 Swing hoist for engine disassembly assembly

TOOLS
99360605 Belt to insert piston in cylinder liner (60 - 125 mm)
99360612 Tool for positioning engine P.M.S.
99360613 Tool for timing of phonic wheel on timing gear
99360703 Tool to stop cylinder liners
99360706 Tool to extract cylinder liners (to be used with specific rings)
99360728 Ring (125 mm) (to be used with 99360706)

TOOLS
99361036 Brackets fixing the engine to rotary stand 99322230
99365056 Tool for injector holder heading
99370415 Base supporting the dial gauge for checking cylinder liner
protrusion (to be used with 99395603)
99378100 Tool for printing engine identification plates (to be used with
special punches)
99378101
99378102
99378103 Punches (A,B,C,D,E,F) for printing engine identification plates (to
99378104 be used with 99378100)
99378105
99378106
99390330 Valve guide sleeker

TOOLS
99390772 Tool for removing injector holding case deposits
99390804 Tool for threading injector holding cases to be extracted (to be

used with 99390805)
99390805 Guide bush (to be used with 99390804)
99394015 Guide bush (to be used with 99394041 or 99394043)
99394041 Cutter to rectify injector holder housing (to be used with

99394015)
99394043 Reamer to rectify injector holder lower side (to be used with
99394015)
TOOLS
99395216 Measuring pair for angular tightening with 1/2” and 3/4” square
couplings
99395219 Gauge for defining the distance between the centres of camshaft
and transmission gear
99395603 Dial gauge (0 - 5 mm)
99395687 Reaming gauge (50 - 178 mm)
99396035 Centering ring of crankshaft front gasket cap

TROUBLESHOOTING BY SYMPTOMS
Main engine operating anomalies:
6- Poor engine braking efficiency;
1- The engine does not start; 7- The engine stops;
2- The engine is excessively heated; 8- Excessive fuel consumption;
3- The engine lacks efficiency; 9- Excessive or insufficient oil pressure.
4- The engine has grey smokes (tending to white);
5- The engine has blue smokes;
1 ENGINE DOES NOT START
Battery efficient Pre-heating element always on

NO Check alternator efficiency
Check battery terminal connections
YES
Starter motor efficient Carry out checks / replace

NO
YES
Air heater efficient Check power supply and earth connection

NO Check heater relay by active diagnosis
YES
Main relay efficient Check fuses

NO Check relay by active diagnosis
YES
Fuel pump efficient Check efficiency checking pressure at filter

NO
YES
Fuel prefilter - filter efficient Check for clogging / replace

NO
(continued)
0.8 bar valve on fuel return efficient Check efficiency, replace if blocked open
NO
YES
Fuel circuit efficient Check circuit seal and bleed

NO
2 ENGINE OVERHEATS
Coolant level correct Check for leaks and top-up

NO
YES
Water pump and fan belts efficient Check, adjust tension and if necessary replace
NO components
YES
Water pump efficient Overhaul or replace group

NO
YES
Thermostat efficient Check whether remains closed or partially open.

NO Replace
YES
Radiator efficient Thoroughly clean, check for leaks, replace if necessary

NO
YES
Air filter and circuit piping efficient Check that hoses and pipes are clear
NO Check filter clog indicator, replace filter.
(continued)
Cylinder head gasket efficient Check water pressure and replace head gasket
NO
YES
Fan efficient Replace

NO
3 ENGINE LACKS POWER
Fuel circuit efficient Check whether tank filter, prefilter and fuel filter are
NO clogged. Replace.
Check whether 0.8 bar valve on fuel return from head
is blocked open (low pressure) or closed (high
temperature). Replace
Check for circuit leaks and fuel pump efficiency
YES
Injectors efficient Injector pump may seize or fuel leak from O-ring.
NO Carry out engine test and proceed as per instructions
given
YES
Engine air intake circuit efficient Remove obstruction on circuit and replace air filter if
NO clogged.
Check clogged cartridge indicator
YES
Exhaust gas circuit efficient Eliminate leaks on exhaust manifold

NO
YES
Correct running temperature Check cooling system

NO
(continued)
VGT actuator efficient Carry out Engine Test following instructions displayed
NO by diagnosis tool
YES
Turbocompressor efficient Carry out Engine Test on turbine and check integrity of
NO following turbo components
- turbine blades
- bearings
- modulator valve
- Clogged VGT filter
- turbine actuator
YES Replace faulty components.
Engine Test with IT2000.
Mechanical injection system efficient Check injector rocker wear, check rollers, rocker
NO bushes and camshaft cams
YES
Valve play correct Adjust valve play

NO
4 ENGINE EMITS GREY/WHITE SMOKE
Head gasket efficient Grind head and replace gasket

NO
YES
Injector sheathes efficient Replace sheathes

NO
YES
Turbocompressor cooling circuit seal efficient Overhaul turbo

NO
YES
Good quality fuel Check for water in tank and eliminate

NO
5 ENGINE EMITS BLUE SMOKE
Piston rings efficient Overhaul pistons - cylinder

NO
YES
Turbo lubrication circuit efficient Overhaul turbo

NO
YES
Valve oil seals efficient Replace valve guide gaskets

NO
6 POOR ENGINE BRAKING EFFICIENCY
Engine braking components efficient Check correct function of engine brake actuator
NO cylinders and command solenoid
Check cylinder command oil piping seal
Check exhaust valve play
YES
Turbocompressor efficient VGT blocked open

NO Faulty VGT actuator (seepage from tie rod)
Faulty modulator valve
Incorrect air supply to modulator valve
Replace faulty components
7 ENGINE STOPS
Fuel in tank Bleed group after filling tank

NO
YES
Tank filter, pre-filter and engine fuel filter efficient Clean tank filter and replace filter and prefilter
NO
YES
Tank fuel lines correctly connected Inverting the pipes may cause vehicle to stop
NO after 200 - 300 km even if tank has fuel because piping
that feeds engine has less scavenge.
Invert pipes.
ENGINE
8 EXCESSIVE FUEL CONSUMPTION
Air filter efficient Replace

NO
YES
Tank and fuel lines efficient. Eliminate any leaks and replace worn parts
NO
9 OIL PRESSURE INSUFFICIENT OR

EXCESSIVE
Pressure regulator valve operates correctly Check and if necessary replace

NO
YES
Oil pump and delivery piping efficient Check and if necessary replace.
NO
YES
Main bearings and big ends efficient Replace bearings and if necessary grind crankshaft
NO
YES
Engine oil SAE viscosity correct Change engine oil with suitable viscosity oil
NO
CONTROL DEVICE FOR EMISSIONS

Precautions
Proceed as follows:
- S.C.R. technology requires the addition of an additive
named AdBlue to exhaust gas before it passes through the
catalyst converter, which converts the nitrogen oxides to
nitrogen and water vapour, substances that already exist
is nature.
- AdBlue is a make used at European level to name a high
quality urea solution composed of approx. 32%
concentrated urea and demineralised water necessary for
S.C.R. functioning.
Figure 48
318CNU011L
- AdBlue additive has the following chemical-physical

properties:
- Odourless
- Non-toxic
- Not flammable
- Colourless
- Non oxidant
- Non explosive
If AdBlue comes into contact with painted surfaces or

aluminium, immediately clean the parts involved with
plenty of water.
If there are AdBlue crystals on holes between engine
and silencer, these can be removed with clean water
In the case of prolonged overheating over 50˚C

inside the tank (direct sunlight), AdBlue may
decompose, producing ammonia fumes. When
unscrewing the cap, do not inhale the fumes coming
from the tank.
However, in this concentration ammonia vapours are
not harmful or a danger to health.
CHANGING THE ENGINE OIL

GENERAL Hazardous and/or polluting substances
Safety instructions
The operation described requires handling of
Before carrying out any operation make certain to hazardous and/or polluting substances
have taken all precautions and clarified all aspects Do not touch with the hands.
concerning safety of the personnel involved in the Avoid contact with painted parts.
operation. If in doubt, consult a more experienced Collect and dispose of used lubricants and fluids,
person. Read the instructions provided in the first according to the laws and local regulations.
part of this manual.
Always observe all the general recommendations to
carry out maintenance jobs correctly.
Specific safety instructions
Be very careful: drained oil and fluids, as well as filters

Vehicle preparation and surrounding parts, could be very hot .
Take the vehicle onto a suitable flat, solid surface,

switch off the engine, remove the ignition key, engage
the parking brake and apply the warning signboards.
Figure 49
2371801
- cut off the battery master switch or disconnect the

terminals from the battery (see arrow) to avoid the risk of
short circuits;
- restore vehicle operation at the end of the operations.
DESCRIPTION OF OPERATION
Preliminary operations Filling
Proceed as follows: Proceed as follows:
- tip the cab following the Maintenance Instructions in the Figure 51
USE AND MAINTENANCE HANDBOOK
Drainage
Proceed as follows:
Figure 50
178NM11
- clean the fill cap area and pour in the specific amount of
lubricant through the filler (see arrow);
- install the fill cap and return the dipstick into its housing;
- start the engine and warm it up. Stop the engine and wait
for a few minutes;
178NM10
Figure 52
- prepare an adequate container; then take out the dip stick;
- clean the cap area, loosen the drain cap and drain all the
oil, leaving it for sufficient time to pour out;
- clean the cap, check that the threading is in good condition,
replace the sealing ring with a new one and close the drain
cap.
156NM11
- remove the oil dipstick and check that the level is between
reference marks on the dipstick;
- if necessary top up the level.
Final operations
Proceed as follows:
- tip the cab following the Maintenance Instructions in the
CHANGING THE ENGINE OIL FILTERS

GENERAL
Safety instructions
Before carrying out any operation make certain to

have taken all precautions and clarified all aspects
concerning safety of the personnel involved in the
operation. If in doubt, consult a more experienced
person.
Read the instructions provided in the first part of this
manual. Observe all general recommendations for
the correct execution of maintenance work.
Vehicle preparation

Figure 53
2371801

short circuits;

and surrounding parts, could be very hot .
Assembly
This operation is usually carried out when changing Proceed as follows:
the relevant oil/fluid.
Figure 55
Removal
Proceed as follows:
Figure 54
178NM13
- hand-tighten the cartridge until the seal comes into contact

with the housing, then turn by another 3/4 of a turn;
178NM12
Do not overtighten the cartridge. This could damage

the seal. Observe the specifications provided by the
- loosen both filter cartridges ( see arrow) using the filter supplier.
tool and clean the housing;
- run the engine for a few minutes and check for leakage of
lubricant;
Final operations
Check the correct oil level. if necessary top up with specified
fluid.
RADIATOR FLUID REPLACEMENT

Safety instructions
hazardous and/or polluting substances
Do not touch with the hands.
Avoid contact with painted parts.
Collect and dispose of used lubricants and fluids,
according to the laws and local regulations.
person. Read the instructions provided in the first


Figure 56
2371801

short circuits;
Preliminary operations Inspections and checks
Proceed as follows: - check that the system pressure control valve functions
correctly: replace if necessary;
- bring the cab heater tap to maximum heat position;
- check sleeves and pipes are intact: otherwise replace any
- cut off the additional heater (if present)
damaged part.
Drainage Filling
Proceed as follows:
Proceed as follows:
Figure 57 - refit the sleeve;
- very slowly introduce the specified liquid into the
expansion reservoir to fill completely;
Appropriate signal restoration of electric power and

subsequent engine start-up
- start the engine and let it run just over minimum for about
5 minutes;
- stop the engine and top up the liquid in the expansion
reservoir;
- start the engine and warm up, then leave it running until
342BNM007L
there are no more air bubbles in the reservoir liquid;
- prepare an adequate container; then remove the fill cap
(1) of the expansion reservoir; Final operations
Check there are no leaks from pipes and sleeves: otherwise
replace any damaged part.
The system pressure control valve ( 2) is sealed and
must not be removed for any reason.
Figure 58
1780301
- disconnect the outlet sleeve from the radiator (see arrow);

then wait for the coolant to flow out completely;
FEEDING CIRCUIT BLEEDING

GENERAL
Safety instructions

Hazardous and/or polluting substances

Preliminary operations Filter
Proceed as follows:
Figure 60
1
Execution of operation
Proceed as follows:
- attach suitable hose to the bleed screws and allow them
to drain into a suitable container;
- loosen the bleed screw a few turns.
Never soil the alternator belts with fuel to prevent

damaging it.
206NM03
- repeat the operation for screw (1);

Pre-filter
Figure 59 Cylinder head bleed screw
Figure 61
272NM006MY
178NM119
- Operate the manual primer pump command (see arrow)
until fuel without air bubbles comes out of the screws, - remove the soundproofing cover;
then tighten the screw.
- repeat the operation for screw (1).
Final operations
Proceed as follows:
CLIMATE CONTROL COMPRESSOR

BELT REPLACEMENT
GENERAL
Safety instructions

Vehicle preparation

Figure 62
2371801

short circuits;
Preliminary operations Removal
Proceed as follows:
Figure 63
Figure 65
178NM14
HD9ST0035MR
The engine has two accessory drive belts:
- using a square wrench, turn (arrow) the take-up device in
1. alternator/fan/water pump drive belt the direction shown to loosen tension of the climate
2. climate control compressor drive belt. control compressor belt (2);
Each belt has an automatic take-up device and does Do not turn the take-up device in the opposite
not require adjustment. direction to prevent damaging the internal load
spring.
- insert a stop pin in the hole to lock the tensioner;

Proceed as follows: - remove the belt.
- wait until the engine cooling liquid temperature is below
60˚C; Inspections and checks
Carefully check the pulleys and eliminate all traces of dirt and
foreign bodies.
Figure 64 Refitting
Proceed as follows:
- fit the new climate control compressor drive belt;
Do not twist the belt on the pulley to fit it in the

groove. Do not use a tool (e.g. a screwdriver) as a
lever to prevent damaging and early breaking.
- withhold the take-up device, remove the stop pin and

release it;
Final operations
Proceed as follows:
- refit the fan;
- start the engine and let it turn for a few minutes; switch it
274A04026 off and wait until it is cold then, exerting manual pressure
on the longest branch, check that the tensioner is working
- unscrew the screws fastening the fan to the hub; properly;
- move the fan toward the radiator to obtain passage for the - tip the cab following the Maintenance Instructions in the
belts; USE AND MAINTENANCE HANDBOOK.
REPLACING THE ACCESSORIES

DRIVE BELT
GENERAL
Safety instructions

Vehicle preparation

Figure 66
2371801

short circuits;
Figure 67 Proceed as follows:
Figure 69
178NM14
342B031008R
The engine has two accessory drive belts: - using a square key, turn (arrow) the take-up device in the
sense shown to loosen tension of the alternator/coolant
1. alternator/fan/water pump drive belt
pump belt (1);
2. climate control compressor drive belt.
Do not turn the take-up device in the opposite

Each belt has an automatic take-up device and does direction to prevent damaging the internal load
not require adjustment. spring.
- remove the belt.

Proceed as follows:
Inspections and checks
- wait until the engine cooling liquid temperature is below Carefully check the pulleys and eliminate all traces of dirt and
60˚C; foreign bodies.
USE AND MAINTENANCE HANDBOOK. Refitting
Proceed as follows:
Figure 68
- fit the new alternator/coolant pump drive belt and release
the take-up device;
Do not twist the belt on the pulley to fit it in the

groove. Do not use a tool (e.g. a screwdriver) as a
lever to prevent damaging and early breaking.
Final operations
Proceed as follows:
- assemble theclimate control belt following the instructions
in the Chapter CLIMATE CONTROL BELT
REPLACEMENT in this Section
274A04026 - refit the fan;
- unscrew the screws fastening the fan to the hub; - run the engine for a few minutes, switch it off, wait for it
to cool down, then pressing with the hand on the longer
- move the fan toward the radiator to obtain passage for the branch, check both take-up devices are functioning
belts; properly.
- remove the climate control belt following the instructions - tip the cab following the Maintenance Instructions in the
in the Chapter CLIMATE CONTROL BELT USE AND MAINTENANCE HANDBOOK.
REPLACEMENT in this Section.
ENGINE REMOVAL-REFITTING
GENERAL Very heavy parts
Safety instructions
The following operation requires handling of heavy
Before carrying out any operation make certain to parts. To lift and transport, use appropriate
have taken all precautions and clarified all aspects equipment and accessories.
Always observe all the general recommendations to Hazardous and/or polluting substances

Vehicle preparation Avoid contact with painted parts.

Figure 70
2371801

short circuits;
DESCRIPTION OF OPERATION Handling AdBlue additive

Figure 72
For special vehicle outfittings, partly or completely
remove the outfitting to have access to the parts to
be disconnected and to remove the relevant
mechanical units.
Refer to the procedures provided by the outfitting
manufacturer for how to proceed.
The removal of the tear/snap clips is not described in

detail. These clips must be cut or released and then
restored while refitting to ensure the correct
fastening of the elements to be hold.
272CNU092
Preliminary operations
- drain off the AdBlue tank using a suitable aspirating pump
Proceed as follows: applied to the filler (1).
- empty the climate control system following the
instructions in the Chapter CLIMATE CONTROL
SYSTEM FLUID REPLACEMENT in SECTION 18; AdBlue additive has the following chemical-physical
properties:
- drain off the cooling system as described in the - Odourless
RADIATOR FLUID CHANGE chapter in this Section; - Non-toxic
- drain off lubricant oil as described in the ENGINE OIL - Not flammable
CHANGE chapter in this Section; - Colourless
- Non oxidant
- arrange a suitable container and drain off the power - Non explosive
steering hydraulic circuit as described in HYDRAULIC
FLUID CHANGE chapter in Section 15;
- disconnect the hydraulic and electric connections from the
PTO and respective device fitted on the gearbox, if
applicable; If AdBlue comes into contact with painted surfaces or
aluminium, immediately clean the parts involved with
plenty of water.
If there are AdBlue crystals on holes between engine
and silencer, these can be removed with clean water
Figure 71
In the case of prolonged overheating over 50˚ inside

the tank (direct sunlight), AdBlue may decompose,
producing ammonia fumes. When unscrewing the
cap, do not inhale the fumes coming from the tank.
However, in this concentration ammonia vapours are
not harmful or a danger to health.
357A003102R
- disconnect the propeller shaft at gearbox outlet (see

arrow) as described in the PROPELLER SHAFT REMO-
VAL-REFITTING chapter in Section 10.
Removal
Proceed as follows:
- tip the cab;
Figure 73
342B031011R
- from the turbo assembly, remove the exhaust pipes con- - disconnect electrical connection and piping on the
sisting of the following: AdBlue injection system:
— turbo assembly flexible connection hoses (18a ) — AdBlue injection electrical connector (51)
— intermediate tubes (18b) — AdBlue delivery tubes (52)
— connection piping to exhaust silencer (18c); — AdBlue return tubes (53);
- disconnect catalyst temperature sensors electrica con-
nection:
— exhaust gas temperature sensor upstream the cata-
lyst (54)
— exhaust gas temperature sensor downstream the
catalyst (55).
Figure 74 Figure 75
1780305
Versions with supplementary steering pump

- disconnect the following hydraulic tubes:
— from power steering tank (29)
— power steering intake on compressor (23)
— power steering delivery on compressor (24)
— power steering pump intake (25) and delivery (26)
on transmission.
All versions
- remove strut (40) and supporting frame (41) with
exhaust silencer;
- disconnect transmission unit electrical, pneumatic and
hydraulic connections and remove the transmission unit
following the indications :
— in SECTION 6 (manual transmission)
— in SECTION 7.1 (automatic transmission)
342B031012R — in SECTION 7.2 (automated transmission).
- disconnect/remove engine coolant liquid pipes:
- disconnect the control unit electrical connection from the
NOx control device — from thermostat to radiator (2)
— from thermostat to cab heater (3)
— NOx detection sensor (56) — from expansion reservoir to pump intake (5).
— NOx detection sensor control unit (57).
- bleeder from engine to expansion reservoir (8);
Versions without supplementary steering pump

- disconnect the following hydraulic tubes:
— from power steering tank (29) Dispose of coolant fluid correctly, and not into the
— power steering intake on compressor (23) public drainage system.
— power steering delivery on compressor (24).
- disconnect conditioner system cooling fluid piping (9)

from compressor;
- remove air pipes:
— from air filter to turbo assembly (10)
— from turbo assembly to intercooler (11);
— from intercooler to intake manifold (12);
— compressor intake (13);
— compressor delivery (14);
— compressor reservoir-disconnect connection (15);
— engine vent (16);
— waste-gate control (17) (only VGT version).
Figure 76
1780343
Figure 77
1780344
Figure 78
272D31004
disconnect the following electric connections:

— from starter motor (31);
— from alternator (32);
— from power steering oil level indicator (33);
— from A/C compressor (34);
— from diagnostics cable (35);
- remove the start/stop button support (36) by loosening

the fastening screws;
- disconnect connector (39) from the engine ECU (37) as
follows;
A Lift the stop lever turning it fully in direction to the
wiring inlet side .
B Extract the connector in direction perpendicular to
the control unit without turning it until it is fully
released.
Do not disconnect connectors (38a) and (38b)

unless operating on engine side wiring.
- remove the fastening clips and turn wiring on the vehicle

side so that it does not create an obstacle;
- disconnect the following pipes:
— fuel return (27)
— fuel inlet (28).
- remove transmission drive control (43) and related levers

tipping and fastening the rod to the cab;
- remove the engine oil dip stick (not shown) from the
radiator support;
Figure 79
- attach appropriate chains or cables to the engine brackets,

then with appropriate lifting equipment slightly tension
the chains;
- check with extreme care that all elements have been

disconnected and that all wiring clamps and pipes
connectors have been severed;
- tighten the support chains slightly;
- remove the fastening screws of the front [65] and rear
(66) flexible engine mounts from both sides;
- loosen the fastening screws to remove spacer (67)
connecting bracket and gearbox from both sides;
Figure 80
2370316
- raise and simultaneously move the engine assembly

forward carefully, extracting it from above until the vehicle
is fully released;
- lay the drive unit on the specific tool, taking care to centre
the reference markings in the respective seats:
A front rest corresponding with engine support
brackets: tighten fastening screws.
B. rear rest corresponding to engine flywheel cover:
make sure that the engine is correctly positioned.
Figure 81
2370320
Inspections and checks Final operations

Proceed as follows: Start the engine and warm it up until the thermostat opens for
the first time, then check that:
- check the flexible mounts of the engine and gear
assemblies: if these become damaged, replace them; - that there is no lubricant leakage between cover and
cylinder head, sump and crankcase, or from any of the
- check the parts of the exhaust pipe: if these become
pipes present;
damaged, replace them;
- that there is no fuel leakage in piping and injectors;
Refitting - there are no coolant leaks from the engine cooling system
Follow the removal instructions in reverse order. and cabin heating system hoses, correcting any leaks
Pay attention to correctly reconnect all previously found;
disconnected electrical connections;
- the braking system functions correctly;
connect the connectors to the engine control unit, following
the removal operations in reverse. - the warning lights and instruments disconnected during
the removal operation function correctly;
Carry out the following operations.
- the air conditioning system functions correctly;
- fill the cooling system as described in the RADIATOR
FLUID CHANGE chapter in this Section; - engine stop and start devices are functioning correctly.
- fill the engine oil sump as described in the ENGINE OIL
CHANGE chapter in this Section;
- bleed the feeding system as described in the FUEL
CIRCUIT BLEEDING chapter in this Section;
- fill the climate control system as described in CLIMATE
CONTROL SYSTEM FLUID CHANGE in Section 18;
- fill drained hydraulic systems with specified fluid, then start
the engine and carry out bleeding operations, if required;
- reconnect the propeller shaft from gearbox outlet as
described in the PROPELLER SHAFT REMOVAL-
REFITTING chapter in Section 10.
RADIATOR ASSEMBLY REMOVAL

RADIATORS Very heavy parts
GENERAL
Safety instructions The following operation requires handling of heavy
parts. To lift and transport, use appropriate
equipment and accessories.
part of this manual. Hazardous and/or polluting substances
carry out maintenance jobs correctly. The operation described requires handling of
Vehicle preparation according to the laws and local regulations.


Figure 82 and surrounding parts, could be very hot .
2371801

short circuits;
- empty the air conditioning system following the - Disconnect both air condition system fluid pipes (09) from
instructions in the Chapter AIR CONDITIONING the condenser;
SYSTEM FLUID REPLACEMENT in SECTION 18;
- empty the cooling system as described in the Maintenance Pay attention to recuperate the O-rings. Replace
Instructions of the USE AND MAINTENANCE them if they appear damaged.
HANDBOOK.
- unscrew the fasteners (arrow) then remove the

condenser (10) extracting it upwards and forwards;
- completely tip the cab.
Figure 83
2331821
Figure 84
2331822
- working from the left side of the vehicle, disconnect the - unscrew the radiator support fasteners (20);
engine breather pipes (2);
- disconnect the air pipes (11) between the turbo group and
the intercooler;
Figure 85
2331823
- working from the right side of the vehicle, disconnect the - remove oil dipstick (21);
pipe (03) from the radiator to the engine coolant
- unscrew the radiator support fasteners (20);
thermostat;
- disconnect the air pipe (12) from the intercooler to the
intake manifold;
Figure 86 Refitting
To refit, follow the removal instructions in reverse order.
Pay attention to correctly reconnect all previously
disconnected electrical connections;
- fill the cooling system as described in the Maintenance
Instructions of the USE AND MAINTENANCE
HANDBOOK;
- fill the air conditioning system following the instructions
in the Chapter AIR CONDITIONING SYSTEM FLUID
REPLACEMENT in SECTION 18.
Final operations
Start the engine and warm it up until the thermostat opens for
- there are no coolant leaks from the engine cooling system
and cabin heating system hoses, correcting any leaks
found.
- the air conditioning system functions correctly.
2331824
- using suitable lifting gear hook the radiator assembly and

move it forwards (in the direction of travel) until
completely disengaging the fan from the conveyor
(arrow);
Figure 87
2331825
- loosen the fastening screws (22) and remove engine

cooling fan (23); .
- shift the radiator assembly backward (opposite to
direction of travel) and remove the assembly upwards.
FAN REMOVAL-REFITTING
GENERAL
Safety instructions

Vehicle preparation

Figure 88
2371801

short circuits;

Preliminary operations Refitting
Proceed as follows: To refit, follow the removal instructions in reverse order.
- remove the radiators following the instructions in
RADIATORS ASSEMBLY REMOVAL-REFIT in this Final operations
Section. Proceed as follows:
- refit the radiators following the instructions in
Removal RADIATORS ASSEMBLY REMOVAL-REFIT in this
Proceed as follows: Section.
Figure 89
335B003021R
- loosen and remove all fastening screws (1);
Figure 90
335B003022R
- remove the fan (2) freeing it in the travel direction, them

extract it upwards.
INJECTOR REMOVAL-REFITTING
ADBLUE Hazardous and/or polluting substances
GENERAL
Safety instructions The operation described requires handling of
Before carrying out any operation make certain to Avoid contact with painted parts.
have taken all precautions and clarified all aspects Collect and dispose of used lubricants and fluids,
concerning safety of the personnel involved in the according to the laws and local regulations.
Vehicle preparation

Figure 91
2371801

short circuits;
Removal
Proceed as follows:
Figure 92
335B003024R
- disconnect ADBlue quick coupling pipes(1) and (2)from

the injector;
Fluid may be released from the pipes during these

operations.
- disconnect the injector electric connector (3);

- loosen the fastening screws and remove the injector (4).

Check that pipes are intact: otherwise replace any damaged
part.
Refitting
TANK REMOVAL-REFITTING ADBLUE

Safety instructions
Before carrying out any operation make certain to equipment and accessories.
Vehicle preparation Collect and dispose of used lubricants and fluids,

Figure 93
2371801

short circuits;
Removal Figure 96
Proceed as follows:
To facilitate the operations described, empty the tank.
Figure 94
335B003027R
- sling the tank and support it during removal;

- loosen and remove the screw (2);
- loosen screw (1);
- loosen and remove the screw (3);
- remove the fastening strap (4);
335B003025R
Figure 97
- loosen the fastening strap (1);
- remove the rubber protection (2);
Figure 95
335B003028R
- remove the tank from the vehicle withdrawing it sideways

(arrow).

- Check that hydraulic connections are intact: otherwise
335B003026R
replace any damaged part;
- check that electrical connections are intact: otherwise
- disconnect the Ad Blue intake pipe (1);
replace any damaged part.
- disconnect the Ad Blue return pipe (2);
Refitting
- disconnect engine coolant liquid inlet pipe (3); - to refit, follow the removal instructions in reverse order;
- disconnect level sensor electric connector (4); - fill the tank as described in the Maintenance Instructions
of the USE AND MAINTENANCE HANDBOOK.
- disconnect engine coolant liquid outlet pipe (5);
Final operations
Start the engine and warm it up until the thermostat opens for
Fluid may be released from the pipes during these - there are no leaks from the piping.
operations.
ENGINE OVERHAUL
DISMANTLING ENGINE ON THE BENCH Figure 100
Before fixing the engine on the rotary stand 99322230
remove the following components:
On the engine right-hand side

- diesel cartridge filter;
- electric connections;
Figure 98
60484
- remove the air conditioner control belt (1) using a fit tool
(3) and acting in the direction shown by the arrow;
- disassemble the air conditioner (2) fitted with the engine
support.
On the engine left-hand side
Figure 101
60482
- soundproofing shield (1);

- all the pipes connecting the compressor;
Figure 99
60485
- engine support (1);
Figure 102
60483
- compressor (1) fitted with power steering pump (2);
60486
- oil pressure controlling valve (1);

Figure 103
71700
Fix the engine to the rotary stand 99322230, by means of brackets 99361036 (1), remove the fan.
Removing the entire wiring harness from sensors and Figure 107
electrical actuators.
Figure 104
73584
71701 Using the correct tool (1), working in the direction of the
Remove the fan (1) from the flange (2). arrow, remove the auxiliaries drive belt (2).
If present, remove the air-conditioning compressor and
Figure 105 corresponding elastic drive belt.
The elastic belt must be replaced with a new one

after each removal.
71702
Lock the engine flywheel with tool 99360351 (1).
Figure 106 Figure 108
92840 73585
Remove the flywheel (1) by removing the 6 Alen screws. Remove: the alternator (1), the electric fan joint (2), the
automatic tensioners (3 nd 5), the pulley (4), the water pump
(6) and the pulley (7).

(Version without Intarder)
71707
Remove the following parts: water delivery pipe (5), water

98863 return pipe (1), actuator drive air pipe (2), oil delivery pipe
Disconnect the pipes (3 and 4) from the VGT command (3), oil return pipe (4), the turbocompressor group (6) and
electrovalve. exhaust manifold (7).
Remove the thermostat group (1) complete with the VGT
command electrovalve (2).
Figure 113
Figure 110
(Version with Intarder)
60492
Using tool 99360314 unscrew the oil filter (1).

98864
Disconnect the pipes (3 and 4) from the VGT command Figure 114
electrovalve. (Version without Intarder)
Remove the water pipes and output (1) complete with the
VGT command electrovalve (2).
Figure 111
60493
- Unscrew the screws (1) and remove the heat exchanger
60490
(4).
Apply the extractor 99340053 (2) and extract the crankshaft - Unscrew the screws (2) and remove the water pipes (3).
seal (1). Remove the flange (3).
Figure 115 (Version with Intarder) Figure 118
85480
72674
Remove the rocker cover (1) remove the screws (2) and
remove: the cover (3), the filter (5) with seals (4 and 6).
- Unscrew the screws (1) and remove the heat exchanger Remove the screws (8) and remove the blow-by box (7).
(4).
- Unscrew the screws (2) andremove the thermostat
group (3).
70708 60575
To remove the PTO (if present): - Unscrew the screws (2) and remove the gear cog (1)
- disconnect the oil pipe (1); complete with phonic wheel.
- unscrew the 4 screws (2) and (3).
Figure 117
Figure 120
60494
Remove the following parts: fuel filter suport (1), fuel pump
(2) and related piping, starter motor (3), engine starter 60497
button support (4), PWN valve air filter (5), intake manifold
(6) complete with engine pre-heater element, engine control - Unscrew the screws (1) and fasten one in a reaction
unit (7). hole to remove the shoulder plate (2), remove the sheet
metal gasket.
Figure 121 1
Figure 124
60498
60501
Unscrew the screws (2) and remove the drive gear cog (1).
Unscrew the screws (1) and remove the gear box (2).
Figure 125
Figure 122
106219
If present, remove the PTO drive gear (1)

Unscrew the screws (3) and remove the double gear (2).
60499
Remove the fasteners and remove the link rod (5).
With the flywheel locking tool 99360351 (1) fitted, unscrew Remove the oil pump (4).
the fastners (2), remove the tool (1) and remove the flywheel Figure 126
(3).
Figure 123
60511
- Unhook the engine brake lever retainer springs (3)

- Unscrew the screws (1) to remove the electrical
connections from the electroinjectors.
- Unscrew the screws (6) fastening the injector wiring in
60500
the head.
- Electrically disconnect the engine brake electrovalve (8).
Apply the extractor 99349954 (2) and extract the seal (1).
- Remove the pipes (5 and 7) feeding the engine brake
cylinders (4).
- Unscrew the screws (2) fastening the rocker shaft.
- Unscrew the screws (6) to remove injector wiring in the
head. The wiring must be extracted from the front side.
Figure 127 2
Figure 130
73533
60515
With tool 99360144 (3) fasten the plates (4) to the rockers
(2). Apply tool 99360553 (1) to the rocker shaft (5) and - Using metal cables lift the cylinder head (1).
remove the shaft (5) from the cylinder head. - Remove the o-ring (2).
Figure 128
Figure 131
108831
61516
- Unscrew the screws (2) fixing the brackets (3);
- hook tool 99342155 part (9) to pump injector (1); Unscrew the screws (2) and take out the engine oil sump (1)
- mount part (8) on part (9) resting part on cylinder head; together with the spacer (3) and gasket.
- screw nut (7) and extract pump injector (1) from cylin-
der head.
- unscrew the screws (4) and remove the exhaust brake
pins (5). Figure 132
- unscrew the screws and remove the slave cylinder (6).
Figure 129
60517
Unscrew the screws and take out the suction strainer (1).
60514
- In place of the injectors fit the plugs 99360180 (1).

- Extract the camshaft (2).
- Unscrew the cylinder head screws (3).
Figure 133 Note down the assembly position of the top and
bottom main bearing shells since, if reusing them,
they will need to be fitted in the position found
upon removal.
Figure 136
47574
Turn the engine block (1) into a vertical position.
Figure 134
47570
Using tool 99360500 (1), extract the crankshaft (2).
Figure 137
60518
Unscrew the big eng bolts (3) and remove the big end- From
above, extract the con-rod — piston assembly (1).
Repeat the same operations for the other pistons.
Figure 135
47571
Extract the main hournal half-shafts (1), unscrew the screws
and remove the oil sprayers (2).
Proceeed to dismantle the cylinder barrels as described at
pag. 96 in the corresponding paragraph.
Having dismantled the engine, thoroughly clean all

the removed parts and check their condition.
The following pages give instructions for carrying out
the main checks and measurements for determining
60519 the validity of parts destined for re-use.
Using the correct hexagonal wrench unscrew the screws (1)

and (2) and remove the oil sump.
REPAIR OPERATIONS
Cylinder block Figure 140
Checks and measurements
Figure 138 (Demonstration)
34994 60595
Internal diameter of the cylinder liners is checked for A = Selection class Ø 135.000 to 135.013 mm
ovalization, taper and wear, using a bore dial (1) centesimal B = Selection class Ø 135.011 to 135.024 mm
gauge 99395687 (2) previously reset to ring gauge (3),
diameter 135 mm. In case of maximum wear >0.150 mm or maximum
ovalization >0.100 mm compared to the values indicated in
the figure, the liners must be replaced as they cannot be
ground, lapped or trued.
If a 135 mm ring gauge is not available use a
micrometer caliper.
Cylinder liners are equipped with spare parts with
ASTRA “A“ selection class.
Figure 139
Figure 141
60596 60597
A = Ø 153.500 to 153.525 mm
B = Ø 152.000 to 152.025 mm
1 = 1st measuring C = Ø 153.461 to 153.486 mm
2 = 2nd measuring D = Ø 151.890 to 151.915 mm
3 = 3rd measuring
The figure shows the outer diameters of the cylinder liners
and the relative seat inner diameters.
Carry out measurings on each cylinder liner at three different
levels and on two (A-B) surfaces, to one another The cylinder liners can be extracted and installed several
perpendicular, as shown in Figure 139. times in different seats, if necessary.
CYLINDER LINERS
Figure 142
60598
BLOCK WITH CYLINDER LINERS
Figure 143
71710
Selection class A mm 135.000 to 135.013
B mm 135.011 to 135.024
CYLINDER LINERS MAIN DATA
Figure 144
108833
DETAIL “X”
“Y“ - Selection class marking area
Replacing cylinder liners

Removal
ASTRA
47577
Place details 99360706 (2) and plate 99360728 (4) as shown 60520
in the figure, by making sure that the plate (4) is properly Check the protrusion of the cylinder liners, using tool
placed on the cylinder liners. 99360334 (2) and tightening screw (1) to 225 Nm torque.
Tighten the screw nut (1) and remove the cylinder liner (3) Using comparator 99395603 provided with comparator base
from the block. 99370415 (3) that the cylinder lining protrusion from the
cylinder head surface is 0.045 - 0.075 mm (Figure 147). If not,
replace the adjuster shim (1) (Figure 146) supplied in various
thickness.
Fitting and checking protrusion
Figure 146
Figure 148 0,045  0,075
ASTRA
49017
CYLINDER LINER PROTRUSION
Figure 149
16798
Always replace water sealing rings (3, 4 and 5).

Install the adjustment ring (1) on the cylinder liner (2);
lubricate lower part of liner and install it in the cylinder unit
using the proper tool.
The adjustment ring (1) is supplied as spare parts in

the following thicknesses: 0.08 mm - 0.10 mm - 0.12
ASTRA
- 0.14 mm.
60521
When the installation is completed, block the cylinder liners
(1) to the block (2) with studs 99360703 (3).
Crankshaft
Figure 150
Upper main journal half bearing
Lower main journal half bearings 71712
MAIN DATA FOR THE CRANK SHAFT PINS AND THE HALF BEARINGS
Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or excessive wear.
The data given refer to the normal diameter of the pins.
108834 108835
X. Detail of the main journal unions Y. Detail of the crankpin unions

Measuring main journals and crank pins

Before grinding the crank pins using a micrometer (1), Figure 154
measure the main journals and the crank pins (2) and decide,
on the basis of the undersizing of the bearings, the final
diameter to which the pins are to be ground.
Figure 153
47536
MEASURING CRANK PINS

During grinding, pay attention to journal and crank pins values
47535
specified.
MEASURING THE MAIN JOURNALS
It is advisable to enter the values found in a table. All journals and crank pins must also be ground to
the same undersizing class, in order to avoid any
alteration to shaft balance.
Figure 155
Fill in this table with the measurements of the main journals and the crank pins.
MAIN JOURNALS
∅ MIN.
∅ MAX.
∅ MIN.
∅ MAX.
CRANK PINS 36061

Preliminary data for selecting the main and big-end journal half-shells
For each of the ain journals, carry out the following operations:
MAIN JOURNAL: BIG END JOURNAL:
- determine the diameter class of the seat in the engine - determine the diameter class of the seat in the big end;
block;
- determine the diameter class of the big end journal;
- determine the diameter class of the main journal;
- choice of class of half-shells to fit.
- choice of class of half-shells to fit.
DEFINITION OF DIAMETER CLASS OF SEAT FOR HALF-SHELLS IN BLOCK
There are two series of numbers punched onto the front of the block at the indicated position:
- the first series of numbers (four) represents the coupling number of the block with the respective crankcase;
- the second series of numbers (seven) represents the diameter class of each of the journal seats to which they refer;
- each of these numbers may be1, 2 or 3.
Figure 156
NOMINAL
CLASS DIAMETER
MAIN JOURNALS
106,300  106.309
106,310  106.319
106,320  106.330
47535
Choice of big end and main bearing half-shells
In order to obtain the clearance required, main half-bearings and big end half-bearings must be selected as specified
below.
This operation makes it possible to identify the most suitable half-bearings for each journal (half-bearings can belong to different
classes for the individual journals).
Depending on half-bearing thickness, tolerance classes are Figure 157 shows the characteristics of main half-bearings
selected by colors (red-green-red/black-green/black). and big end half-bearings supplied as spare parts in standard
measures (STD) and admissible oversizing (+0.127, +0.254,
+0.508).
Figure 157
STD +0.127 +0.254 +0.508

Big end half-bearings
red 1.965 to 1.975 2.092 to 2.102 2.219 to 2.229
red/black 2.028 to 2.038
green 1.976 to 1.985 2.103 to 2.112 2.230 to 2.239
green/black 2.039 to 2.048
Main half-bearings STD +0.127 +0.254 +0.508
red 3.110 to 3.120 3.237 to 3.247 3.364 to 3.374
red/black 3.173 to 3.183
green 3.121 to 3.130
green/black 3.184 to 3.193

Definition of main journal and big end diameter class (journals with nominal diameter)
Three series of numbers are specified on the driving shaft, in the position specified.
- a five-digit number, representing the shaft serial number;
- under this number, on the left, a six-digit number refers to big end pins and is preceded by a single digit, which indicates pin
status (I = STD =-0.127); each of the following six digits represents the diameter class of each big end pin it refers to (bottom);
- the seven-digit series, on the right, refers to the journals and is preceded by a single digit, which indicates journal status (I
= STD =-0.127); each of the following seven digits represents the diameter class of the journal it refers to (bottom);
Figure 158
BIG END PINS
JOURNAL PINS
Selection of main half-bearings

After detecting, for each journal, the necessary data on block and crankshaft, select the type of half-bearings to be used, in
compliance with the following table:
Figure 159
STD.
CLASS 1 2 3
green green green
1
green green green
red green green
2
red green green
red red green
3
red red green
Selection of main half-bearings (rectified)

If the journals have been rectified, the procedure described cannot be applied.
In this case, make sure that the new diameter of the journals is as specified on the table and install the only half-bearing type
required for this undersizing.
Figure 160
red/black = -0.127
mm 3.173 to 3.183
green/black =
mm 3.184 to 3.193
1 2 3
99.843 green/black green/black green/black
1
99.852 green/black green/black green/black
99.853 red/black green/black green/black

2
99.862 red/black green/black green/black
99.863 red/black red/black green/black

3
99.873 red/black red/black green/black
-0.254
red =
mm 3.237 to 3.247
1 2 3
red red red

99.726
99.746 red red red
-0.508
red =
mm 3.364 to 3.374
1 2 3
red red red

99.472
99.492 red red red
Choice of big-end half-shells (standard diameter)

Three indications are marked on the connecting rod, in position “A”
Figure 161
1 Letter indicating the weight class

A = 4741  4780 g.
B = 4781  4820 g. VIEW FROM “A”
C = 4821  4860 g.
2 Number indicating the diameter selected for the
housing of the big end bearing:
1 = 94.000 to 94.010 mm
2 = 94.011 to 94.020 mm
3 = 94.021 to 94.030 mm
3 Numbers identifying the cap-connecting road
coupling.
47557
The number specifying the diameter class of the half-bearing housing can be 1, 2 or 3.
Determine the type of big end half-bearings to be installed on each pin by following the indications given in the table (Figure 162).
Figure 162
STD.
CLASS 1 2 3
green green green
1
green green green
red green green
2
red green green
red red green
3
red red green
Choice of big-end half-shells (rectified)

If pins have been rectified, the procedure described must be applied.
In this case, (for each undersizing) determine the tolerance field the new big end pins belong to, and install the half-bearings
identified according to the relative table.
Figure 163
red/black =
mm 2.028 to 2.038 -0.127
green/black =
mm 2.039 to 2.048
1 2 3
89,843 green/black green/black green/black
1
89,852 green/black green/black green/black
89,853 red/black green/black green/black

2
89,862 red/black green/black green/black
89,863 red/black red/black green/black

3
89,873 red/black red/black green/black
-0.254
red
mm 2.092 to 2.102
green =
1 2 3
mm 2.103 to 2.112
89,726 red green green
89,736 red red green
-0.508
red =
mm 2.219 to 2.229
green =
1 2 3
mm 2.230 to 2.239
red green green

89,472

Replacing the timing control gear and the oil

pump
Check that the teeth of the gears are not damaged or worn, Figure 166
otherwise remove them using the appropriate extractor.
Figure 164
ASTRA 2
47578
Using pulley system and hook 99360500 (1), mount the

crankshaft (2).
49020
When fitting the new gears (1) on the crankshaft (2), heat
them for about 15 minutes in an oven at 180C.
Let them cool down after the installation.
Checking main journal installation clearance

Figure 167
Figure 165
49021
47579
Install the half-bearings (1) on the main bearings in the

Install the oil spray nozzles (2) and have the dowel coincide underblock (2).
with the block hole (3). Check the installation clearance between the main journals
Install the half-bearings (1) on the main bearings. and the relative bearings as follows:
60559 47578
Place a piece of calibrated wire on the journal of the - Lubricate inside screws (1) con UTDM oil, and tighten
crankshaft (2), parallel to the longitudinal axis; install the them by dynamometric wrench to 120 Nm torque, thus
underblock (1), by hoist and appropriate hooks. with 60º angle closing, following the diagram in
Figure 169.
Figure 169
FRONT SIDE
60593
DIAGRAM SHOWING THE TIGHTENING ORDER OF THE SCREWS FIXING THE LOWER UNDER-BLOCK TO THE
BLOCK
Figure 170 Checking crankshaft end float
Figure 172
ASTRA
ASTRA
47579 47588
- Remove the under-block
The clearance between the main bearings and the journals is End float is checked by placing a magnetic dial gauge (1)
obtained by comparing the calibrated wire length (2) at the (99395603) on the crankshaft (2), as shown in the figure. If
maximum deflection point, with the calibrated scale on the the value obtained is higher than specified, replace the rear
coating (1) containing the calibrated wire (1). thrust half-bearings and repeat this check.
Numbers shown on the scale specify the clearance in coupling
millimeters. If the clearance obtained is different from the
clearance required, replace the half-bearings and repeat this
check.
Piston-connecting rod assembly
Figure 173
60607
PISTON CONNECTING ROD ASSEMBLY

1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Split ring - 6. Scraper ring with
spiral spring - 7. Bevel cut sealing ring - 8. Trapezoidal sealing ring - 9. Piston pin - 10. Piston
Make sure the piston does show any trace of seizing, scoring, Pistons are equipped with three elastic rings: a sealing ring, a
cracking; replace as necessary. trapezoidal ring and a scraper ring.
Pistons are grouped into classes A and B for diameter.
Removal
60608 49024
Removal of the piston split rings (2) using the pliers 99360184 Remove the piston pin split rings (2) using the round tipped
(1). pliers (1).
49025 32618
Remove the piston pin (1). Measuring the gudgeon pin diameter (1) with a micrometer
If removal is difficult use the appropriate beater. (2).
Measuring the diameter of the pistons

Figure 177
Conditions for correct gudgeon pin-piston

coupling
71714
Using a micrometer (2), measure the diameter of the piston

Figure 179
(1) to determine the assembly clearance; the diameter should
be measured at the specified value.
49026
Lubricate the pin (1) and the relevant housing on the piston
hubs with engine oil; piston must be inserted with a slight
finger pressure and it should not come out by gravity.
Figure 180
108837
MAIN DATA OF THE PISTON, PISTON RINGS AND PIN

F Dimension detected on 130 mm . - J measured at 2.5 mm from outer  - X = 0,80,1
Piston rings Figure 183
Figure 181
3513
The sealing ring (2) of the 1st cavity is trapezoidal. Clearance

“X” between the sealing ring and its housing is measured by
placing the piston (1) with its ring in the cylinder barrel (3),
16552
so that the sealing ring is half-projected out of the cylinder
barrel.
Check the thickness of the piston ring (2) using a micrometer
(1). Figure 184
Figure 182
ASTRA
36134
Check the opening between the ends of the sealing rings (1),
using a thickness gauge (2), entered in the cylinder barrel (3).
60610
If the distance between ends is lower or higher than the value
Check the clearance between the sealing rings (2) and the required, replace split rings.
relative piston housings (1) using a thikness gauge (3).
Connecting rod
Figure 185
Data concerning the class section of connecting rod
housing and weight are stamped on the big end.
When installing connecting rods, make sure

they all belong to the same weight class. VIEW FROM “A”
DIAGRAM OF THE CONNECTING

ROD MARKS
1 Letter indicating the weight class:
A = 4741  4780 g.
B = 4781  4820 g.
C = 4821  4860 g.
2 Number indicating the selection of diameter for the
big end bearing housing:
1 = 94.000 to 94.010 mm
2 = 94.011 to 94.020 mm
3 = 94.021 to 94.030 mm
3 Numbers identifying cap-connecting rod coupling
47957
Figure 186
71716
MAIN DATA - BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS

* Values to be obtained after installing the bush
Bushings
Figure 187 Checking torsion
Figure 189
73535
Check the bushing in the small end has not come loose and
shows no sign of scoring or seizure; replace it if it does.
61694
The bushing (2) is removed and fitted with a suitable drift (1).
When driving it in, make absolutely sure that the holes for the
oil to pass through in the bushing and small end coincide. Check the torsion of the connecting rod (5) by comparing
Using a boring machine, rebore the bushing so as to obtain two points (A and B) of the pin (3) on the horizontal plane
a diameter of 54.019 — 54.035. of the axis of the connecting rod.
Position the mount (1) of the dial gauge (2) so that this
pre-loads by approx. 0.5 mm on the pin (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
Checking connecting rods opposite side B of the pin (3): the difference between A and
B must be no greater than 0.08 mm.
Figure 188
Checking bending
Figure 190
61696 61695
Check the bending of the connecting rod (5) by comparing

two points C and D of the pin (3) on the vertical plane of the
Checking axis alignment axis of the connecting rod.
Check the alignment of the axes of the connecting rods (1) Position the vertical mount (1) of the dial gauge (2) so that this
with device 99395363 (5), proceeding as follows: rests on the pin (3) at point C.
Fit the connecting rod (1) on the spindle of the tool 99395363 Swing the connecting rod backwards and forwards seeking the
(5) and lock it with the screw (4). highest position of the pin and in this condition zero the dial
gauge (2). Shift the spindle (4) with the connecting rod (5) and
Set the spindle (3) on the V-prisms, resting the connecting rod repeat the check on the highest point on the opposite side D
(1) on the stop bar (2). of the pin (3). The difference between point C and point D
must be no greater than 0.08 mm.
Mounting the connecting rod - piston assembly Mounting the piston rings
60614
To fit the piston rings (1) on the piston (2) use the pliers
99360184 (3).
73536
The rings need to be mounted with the word ”TOP” (4)
facing upwards. Direct the ring openings so they are
The piston (1) has to be fitted on the connecting rod (2) so staggered 120 apart.
that the graphic symbol (4), showing the assembly position
in the cylinder liner, and the punch marks (3) on the
connecting rod are observed as shown in the figure.
Fitting the big end bearing shells

Figure 194
Figure 192
1
2
49030
74052
Fit the bearing shells (1), selected as described under the
Fit the pin (2) and fasten it on the piston (1) with the split rings heading ”Selecting the main and big end bearing shells”, on
(3). both the connecting rod and the cap.
If reusing bearing shells that have been removed, fit them
back into their respective seats in the positions marked
during removal.
Fitting connecting rod - piston assemblies in Figure 195

the cylinder liners
With the aid of the clamp 99360605 (1, Figure 195), fit the
connecting rod — piston assembly (2) in the cylinder liners,
according to the diagram of Figure 196, checking that:
- The openings of the piston rings are staggered 120
apart.
- The pistons are all of the same class, A or B.
- The symbol punched on the top of the pistons faces the
engine flywheel, or the recess in the skirt of the pistons
tallies with the oil nozzles.
60616
Checking piston protrusion

The pistons are supplied as spares in class A and can On completing assembly, check the protrusion of the pistons
be fitted in class B cylinder liners. from the cylinder liners; it must be 0.12 — 0.42 mm.
Figure 196
60615
ASSEMBLY DIAGRAM OF CONNECTING ROD — PISTON ASSEMBLY IN CYLINDER LINER

1. Connecting rod — piston assembly — 2. Area of punch marking on the top of the piston,
symbol showing assembly position and selection class — 3. Connecting rod punch mark area
Checking crankpin assembly clearance Figure 198

To measure the clearance, carry out the following
operations.
Connect the connecting rods to the relevant journals of the
crankshaft, placing a length of calibrated wire on the journals.
Figure 197
47583
Mount and secure the tool 99360263 (2) with the bracket
(4). Screw down with the device 99360261 (1) to be able to
remove the cotters (3). Take out the tool (2) and extract the
top plate (5), spring (6) and bottom plate (7).
Repeat this process on all the valves.
47594 Turn over the cylinder head and take out the valves (8).
Mount the connecting rod caps (1) together with the bearing
shells. Tighten the screws (2) fixing the connecting rod caps
to a torque of 60 Nm (6 kgm). Using tool 99395216 (3),
further tighten the screws with an angle of 60.
The thread of the screws (2), before assembly, has
to be lubricated with engine oil.
Remove the caps and determine the clearance by comparing

the width of the calibrated wire with the graduated scale on Checking head bearing surface on cylinder
the case containing the calibrated wire. block
Upon final assembly: check the diameter of the thread of the
screws (2), it must be no less than 13.4 mm; if it is, change the Figure 199 (Demonstration)
screw. Lubricate the crankpins and connecting rod bearings.
Tighten the screws (2) as described above.
CYLINDER HEAD
Before dismounting cylinder head, check cylinder head for
hydraulic seal by proper tooling; in case of leaks not caused
by cup plugs or threaded plugs, replace cylinder head.
When replacing, the cylinder head is supplied as a

spare part with a threaded plug, which must be
removed during assembly.
In case of plugs dismounting/replacement, on

mounting, apply sealant Loctite 270 on plugs. 36159
Check the supporting surface (1) of the head on the cylinder

block with a rule (2) and a feeler gauge (3). If you find any
deformation, level the head on a surface grinder; maximum
Dismounting the valves amount of material that can be removed 0.2 mm.
Before dismounting cylinder head valves, number

them in view of their remounting in the position
observed on dismounting should they not have to
be overhauled or replaced.
After this process, you need to check the valve
Intake valves are different form exhaust valves in recessing and injector protrusion.
that they have a notch placed at valve head centre.
Valves Figure 201

Decarbonizing and checking valves
Figure 200
ASTRA
71718
48625 MAIN DATA OF VALVES AND VALVE GUIDES

Remove the carbon deposits on the valves with a wire brush. * Measurement to be made after driving in the valve guides
Check that the valves show no signs of seizure or cracking
and check with a micrometer that the valve stem diameter
comes within the required values (see Figure 201); replace Check with a micrometer that the diameter of the valve
the valves if it does not. stems is as indicated. If necessary, grind the valve seats with
a grinding machine, removing as little material as possible.
Valve seats
Regrinding — replacing valve seats
The valve seats are reground whenever the valves

or valve guides are ground and replaced.
Figure 202
1 2
73555
MAIN DATA OF VALVE SEATS

1. Intake valve seat — 2. Exhaust valve seat
Figure 203 Part 99360296 determines the exact position of assembly of

the valve guides in the cylinder head. If they are not available,
you need to drive the valve guides into the cylinder head so
they protrude by 30.831.2 mm.
After driving in the valve guides, rebore their holes with the
smoother 99390330.
Replacing injector cases

Removal
Figure 205
41032
Check the valve seats (2). If you find any slight scoring or
burns, regrind them with tool 99305019 (1) according to the
angles shown in Figure 202. If it is necessary to replace them,
using the same tool and taking care not to affect the cylinder
head, remove as much material as possible from the valve
seats so that, with a punch, it is possible to extract them from
the cylinder head.
Heat the cylinder head to 80  100C and, using a drift, fit
in the new valve seats (2), chilled beforehand in liquid
nitrogen. Using tool 99305019 (1), regrind the valve seats
according to the angles shown in Figure 202.
After regrinding the valve seats, using tool 99370415 and dial
gauge 99395603, check that the position of the valves in
relation to the plane of the cylinder head is:
- -0.45  -0.75 mm (recessing) intake valves
- -1.65  -1.95 mm (recessing) exhaust valves.
Checking clearance between valve-stem and

associated valve guide
Using a dial gauge with a magnetic base, check the clearance
between the valve stem and the associated guide. If the
clearance is too great, change the valve and, if necessary, the
valve guide.
Valve guides
Replacing valve guides
Figure 204
60619
ASTRA
To replace the injector case (2), proceed as follows:
- Thread the case (2) with tool 99390804 (1).
The steps described in Figs. 179 - 182 - 183 - 184 need to be
carried out by fixing the tools, with the bracket A, to the
cylinder head.
108838
The valve guides are removed with the drift 99360143.

They are fitted with the drift 99360143 equipped with part
99360296.
ASTRA
60622
- Lubricate sealing rings (3) and fit them to the case (4);
fix tool 99365056 (2) to the cylinder head by means of
bracket A, install the new case, tighten the screw (1),
60620
upsetting the case lower part.
- Fasten extractor 99342149 (2) to case (3), by tightening
the nut (1), and pull out the case from cylinder head. Figure 209
Figure 207
60621
- Remove any residue (1), with tool 99390772 (2), from

60623
the cylinder head groove.
- Ream the case hole (3) with reamer 99394041 (1).
108839
INJECTOR CASE ASSEMBLY DIAGRAM

60624
- Using grinder 99394043 (1-2), ream the injector seat in

the case (3).
Checking protrusion of injectors

Figure 211
47585
Using dial gauge (1), check the protrusion of the injector (2)
which must be 0.52 to 1.34 mm.
TIMING GEAR
Camshaft drive Twin intermediate gear pin
Twin idler gear
Figure 213
Figure 215
86925
86934
TIMING CONTROL COMPONENT PARTS
1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod -
5. Camshaft control gear - 6. Idler gear - 7. Twin idler gear -
8. Drive shaft driving gear.
Replacing the bushings

Bushings (2, Figure 214, and 2, Figure 215) can be replaced
when they are worn. Put up the bushing, then bore it to
Idler gear pin obtain the diameter shown on Figure 214 or Figure 215.
Idler gear
Figure 214
The bushing must be driven into the gear by following

the direction of the arrow and setting the latter to the
dimension shown on Figure 214 or Figure 215.
Rated assembling play between gear bushings and pins:

Figure 214 — 0.045  0.085 mm
Figure 215 — 0.045  0.085 mm.
86933
Timing gear
Checking cam lift and pin alignment
Figure 216
47506
Place the camshaft (4) on the tailstock (1) and check cam lift (3) using a centesimal gauge (2); values are shown in table on page
17.
Figure 217
ASTRA
47507
When the camshaft (4) is on the tailstock (1), check alignment of supporting pin (3) using a centesimal gauge (2); it must not exceed
0.030 mm. If misalignment exceeds this value, replace the shaft.
Figure 218
1
ASTRA
47505
In order to check installation clearance, measure bush inner diameter and camshaft pin (1) diameter; the real clearance is obtained
by their difference.
If clearance exceeds 0.135 mm, replace bushes and, if necessary, the camshaft.
Figure 219
108841
MAIN DATA OF THE CAMSHAFT AND TOLERANCES

The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth.
Whereas, if they show any signs of seizing or scoring, you should replace the shaft and the relevant bushings.
TOLERANCES TOLERANCE CHARACTERISTIC SYMBOL
ORIENTATION Perpendicularity ⊥
POSITION Concentricity or coaxial alignment

OSCILLATION Circular oscillation ↗
IMPORTANCE CLASS ASSIGNED TO PRODUCT CHARACTERISTICS SYMBOL
CRITICAL 
IMPORTANT ⊕
SECONDARY ⊝
Bushes
Figure 220
ASTRA
60627
MAIN DATA OF CAMSHAFT BUSHES AND RELEVANT HOUSINGS ON CYLINDER HEAD.

* Bush inner diameter after installation
The bush surfaces must not show any sign of seizing or Measure the bush inner diameters with a baremeter and replace
scoring; if they do replace them. them, if the value measured exceeds the tolerance value.
To take down and fit back the bushes, use the proper tool
99360499.
Replacing camshaft bushings with drift 99360499

Drift
Figure 221
107217
A = Drift with seat for bushings to insert/extract.

B = Grub screw for positioning bushings.
C = Reference mark to insert seventh bushing correctly.
D = Reference mark to insert bushings 1, 2, 3, 4, 5, 6 correctly (yellow marks).
E = Guide bushing.
F = Guide line.
G = Guide bushing to secure to the seventh bushing mount.
H = Plate fixing bushing G to cylinder head.
I = Grip.
L = Extension coupling.
Removal Replacement
Front Front
Rear
Rear 71722
Fit the beater complete with extension.

71725 To insert bushes 1, 2, 3, 4 and 5, proceed as follows:
The bush removal order is 7, 6, 5, 4, 3, 2, 1. The bushes are 1. Place the bush for insertion on the beater (A) lining up
slipped out from the front side of their individual seats. the pin (B) (Figure 221) with the seat on the bush.
Removal does not require the beater extension for bushes 2. Position the guide bush (E) and fasten the guide bush (G)
5, 6 and 7 and use of the guide bush is not necessary. (Figure 221) in the seat of the 7th bush by means of plate
The extension is instead required for bushes 1, 2, 3 and 4, as H).
well as the guide bush
Position the beater precisely during the removal operation. 3. When inserting the bush, line up notches F and M. Doing
so, when the bush is pushed in the lubrication hole on
it is aligned with the oil hole in the seat.
The bush is fully inserted when the 1st yellow reference
notch (D) is flush with the guide bush (G).
Figure 224
Front
Rear
71723
To insert bush 6, proceed as follows:

- remove the grip (I) and the extension (N);
- position the extension (N) and the guide bush (E) as
shown in the figure;
- repeat operations 1, 2 and 3.
Figure 225
Front
Rear
71724
To insert bush 7, proceed as follows:

- remove the grip (I) and the guide bush (G) fastened to
the head (Figure 225);
- replace the guide G from the inner side as shown in the
figure.
- Position the bush on the beater (A) and bring it toward
its seat making sure the hole in the bush aligns with the
lubrication hole in the head. Proceed to fit.
The 7th bush is fully inserted when the reference mark
( C ) is flush with the bush seat.
Valve springs Fitting valves and oil seal

70000
Before installation, check valve spring flexibility using tool

99305047 and compare the loading and elastic deformation
data with data referred to the new valves, shown in the
following figure.
87051
Lubricate the valve stem and insert the valves in the

respective valve guides; fit the lower caps (1). Use tool
99360329 to fit the oil seal (2) on the valve guides (3) of the
exhaust valves; then, to fit the valves, proceed as follows.
Should valves not have been overhauled or

replaced, remount them according to numbering
performed on dismounting.
Intake valves are different form exhaust valves in
that they have a notch placed at valve head centre.
Free spring
Valve closed
775  39 N
1366  68 N
76
Valve open
59
46
47583
108842
- Fit springs (6) and the upper plate (5);
- apply tool 99360263 (2) and block it with bracket (4);
MAIN DATA TO CHECK THE SPRING FOR INTAKE tighten the lever (1) until cotters are installed (3),
AND EXHAUST VALVES remove tool (2).
ROCKER SHAFT
Figure 230
44925
The camshaft cams directly control rockers: 6 for injectors and 12 for valves. Rockers slide directly on the cam profiles via rollers.
The other end acts on a bar directly supported by the two valves stems. A pad is placed between the rocker adjusting screw
and the bar. Two lubrication holes are obtained inside the rockers. The rocker shaft practically covers the whole cylinder head;
remove it to have access to all the underlying components. The length of the rocker shaft is practically the same as that of the
cylinder head. It must be removed in order to remove all the components located beneath it.
Shaft
Figure 231
ASTRA
73557
MAIN DATA OF THE ROCKER ARM SHAFT
Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.
ROCKERS
SECTION
SECTION
A-A SECTION A-A
B-B SECTION
ASTRA B-B
71728 71730
PUMP INJECTOR ROCKER ARMS EXHAUST VALVE ROCKER ARMS
SECTION
A-A SECTION
B-B
71729 92842
INTAKE VALVE ROCKER ARMS LEVER WITH ENGINE BRAKE CONTROL

ECCENTRIC PIN
Check the surfaces of the bushings, which must show no signs of scoring or excessive wear; if they do, replace the rocker arm
assembly.
ASSEMBLING THE ENGINE ON THE BENCH

Fix the engine block to the stand 99361036 by means of Figure 238
brackets 99322230.
Install the cylinder liners as described in the relevant
paragraph.
Figure 236
49021
Place the half-bearings (1) on the main bearings in the

underblock (2).
47586
Fit the oil spray nozzles (2), so that the dowel coincides with
the block hole (3).
Place the half bearings (1) on the main bearings.
Not finding it necessary to replace the main bearings,

you need to fit them back in exactly the same
sequence and position as in removal.
Choose main bearings, if they are to be replaced,
based on selection described in chapter “Selecting
main and big end bearings”.
47595
47570
Lubricate the half bearings, then install the crankshaft (2) by By means of suitable equipment (1) apply silicone LOCTITE
means of hoist and hook 99360500 (1). 5699 to the block, as shown in the figure.
60632
Sealant application diagram
Fit the underblock within 10’ of the application of the 47579
sealant.
Close the inner screws (1) to 120 Nm torque by means of
a dynamometric wrench (3), then with two further angular
phases 90 + 45, using tool 99395216 (4). Tighten again the
outer screws (1, Figure 242) with 60 angular closing, using
tool 99395216 (3, Figure 242).
Figure 241
60559
Fit the underblock by means of a suitable hoist and hooks (1).
Figure 242
47581
Fit the underblock and, using a dynamometric wrench (2),

close the splined outer screws (1) to 30 Nm torque,
according to the diagram shown in Figure 244.
Figure 244
stage 1:
FRONT SIDE
pretightening
outer screws
30 Nm
60592
stage 2: pre-
FRONT SIDE
tightenig
inner screws
120 Nm
60593
stage 3:
FRONT SIDE angle
inner
screws
60º
60593
stage 4:
FRONT SIDE
angle
inner
screws
55º
60593
stage 5:
FRONT SIDE angle
outer
screws
60º
60594
DIAGRAM SHOWING TIGHTENING ORDER OF UNDER-CRANKCASE SECURING SCREWS

Fitting connecting rod - piston assemblies in Figure 247

cylinder liners
Figure 245
60616
Turn the cylinder block, setting it upright.

49030 Lubricate the pistons, piston rings and inside the cylinder
liners. With the aid of the clamp 99360605 (1) mount the
Not finding it necessary to replace the connecting connecting rod — piston assemblies (2) in the cylinder liners
rod bearings, you need to fit them back in exactly the according to Figure 246. Check that:
same sequence and position as in removal. - The number of each connecting rod corresponds to the
Choose main bearings, if they are to be replaced, cap coupling number.
based on selection described in chapter “Selecting
main and big end bearings”. - The symbol (2, Figure 246) punched on the top of the
pistons faces the engine flywheel or the recess in the
Lubricate the bearing shells (1 and 3) and fit them on the piston skirt tallies with the position of the oil nozzles.
connecting rod (2) and on the cap (4).
The pistons are supplied as spares in class A and can
Do not make any adjustment on the bearing shells. also be fitted in class B cylinder liners.
Figure 246
1 Connecting rod — piston assembly
2 Area of punch marking on the top of the

piston with the symbol for the mounting
position and selection class.
3 Area of connecting rod punch marking
60615
Fitting the cylinder head

47594
Connect the connecting rods to the relative journals, fit the 60515
connection rod caps (1) with half bearings; tighten the fixing Make sure that pistons 1-6 are exactly at the TDC Place the
screws (2) of the connecting rod caps to 60 Nm torque (6 sealing gasket (2) on the block.
kgm). Using tool 99395216 (3), further tighten screws with Fit the cylinder head (1) and tighten screws as shown in
60 angle.
Figure 252, Figure 253 and Figure 254.
Before reusing the screws (2), measure the diameter
Lubricate the thread of the screws with engine oil
of the thread; it must be no less than 13.4 mm; if it
before assembly.
is, change the screw.
Lubricate the thread of the screws with engine oil
before assembly.
Figure 252
Figure 249
61270
Diagram showing the cylinder head fixing screws tightening

order
60563
By means of centering ring 99396035 (2), check the exact Figure 253
cover position (1), otherwise act as necessary and tighten the
screws (3).
Figure 250
60565
- Preliminary tightening by means of a dynamometric

60564 wrench (1):
Fit the sealing gasket (1), install the fitting tool 99346250 (2) 1st phase: 60 Nm (6 kgm)
and drive the sealing gasket (1) by screwing nut (3). 2nd phase: 120 Nm (12 kgm);
Figure 254
Install the gear box within 10’ of the application of
the sealant.
Figure 257
α
60566
- Angular tightening using tool 99395216 (1);

3rd phase: 90˚ angle
4th phase: 65˚ angle.
Figure 255
60633
Tighten the screws shown in the figure by means of a

dynamometric wrench, in compliance with the following
order and tightening torque:
no. 10 M12 x 1.75 x 100 56 to 70 Nm
no. 2 M12 x 1.75 x 70 56 to 70 Nm
71773
no. 4 M12 x 1.75 x 35 56 to 70 Nm
Fit the oil pump (5), intermediate cogs (2) complete with
P.T.O. tie-rod (1) and drive cog (3) no. 1 M12 x 1.75 x 120 56 to 70 Nm
Tighten the screws (4) to the specified torque.
: no. 2 M12 x 1.75 x 193 56 to 70 Nm
Replacing flywheel casing
Figure 258
Figure 256
60568
47592
Fit the sealing gasket (1), install the fitting tool 99346251 (2)
Apply (as shown in the figure) sealant LOCTITE 5970 to the and drive the sealing gasket by screwing the nut (3).
gear box using the proper equipment (1).
Replacing engine flywheel

Figure 259
HOLES VIEW: HOLE VIEW:

A-B-C D
60668
DETAIL OF PISTON POSITION MARKS ON ENGINE FLYWHEEL
A = Hole on the flywheel with 1 notch, corresponding to C = Hole on the flywheel with 1 notch, corresponding to
TDC of pistons 3-4. TDC of pistons 2-5
B = Hole on the flywheel with 1 notch, corresponding to D = Hole on the flywheel with 2 notches, corresponding
TDC of pistons 1-6. to 54.
Position the flywheel (1) on the crankshaft, lubricate the
If the teeth of the ring gear mounted on the engine thread of the screws (2) with engine oil and screw them
flywheel, for starting the engine, are very damaged, down. Lock rotation with tool 99360351 (3). Lock the
replace the ring gear. It must be fitted after heating screws (2) in three phases.
the ring gear to a temperature of approx. 200C. First phase: pre-tightening with torque wrench (4) to a
torque of 120 Nm (12 kgm).
Install the engine flywheel without blocking the fixing screws
and insert pin 99360612.
α α
49037
49036
Second phase: closing to angle of 90 with tool 99395216 (1).

The crankshaft has a locating peg that has to couple
with the relevant seat on the engine flywheel.
Fitting the camshaft

60570
- Apply the gauge 99395219 (1). Check and record the

position of the drive gear link rod (3). Fasten the screws
72436 (2) to the specified torque.
Position the crankshaft with pistons 1 and 6 at TDC.
This condition is achieved when:
1. the reference hole (5) with notch on the flywheel (4) is
visible in the spyhole;
2. tool 99360612 (1) fits in the hole (3) in the flywheel (4)
through the engine revs sensor seat (2).
Otherwise suitably turn the flywheel (4).
Remove tool 99360612 (1).
Figure 263
Figure 265
73843
Fit the camshaft (4) aligning it with the references ()

positioned as in the figure.
Lubrificate the O-ring (3) and fit it to the shoulder plate (2). 60571
Fit the shoulder plate (2) with the metal gasket (1) and - Fit the drive gear (1) and tighten the screws (2) to the
tighten the screws (5) to the specified torque. specified torque.
Figure 266 3
Figure 268
5
60572
71775
Position the gear (2) on the camshaft such that the 4 slotted Fit:
holes are centred with respect to the shaft fastening holes,
without fully tightening the screws (5). With the magnetic - the injectors (2) and with a torque wrench tighten the
base comparator (1) check the play between the gears (2 and bracket screws to a torque of 26 Nm;
3). This must be 0.073 ÷ 0.195 mm, otherwise adjust play - the engine braking cylinders (1) and (4) and with a
proceeding as follows: torque wrench tighten them to a torque of19 Nm;
- loosen the screws (4) fastening the drive gear (3); - the braces (3) on the valve stem all with the largest hole
- loosen the link rod fastening screw (2, Figure 264) move on the same side.
the link rod (3, Figure 264) to achieve the required play;
- tighten the link rod fastening screw (2, Figure 264) and
the drive gear fastening screws (4, Figure 266) to the
specified torque.
Fitting the rocker shaft

Figure 269
Fitting the injector pump
Before refitting the rocker shaft assembly, check that
Figure 267 all the adjuster screws have been fully unscrewed.
73533
108843
With tool 99360144 (3) fasten the plates (4) to the
rockers (2).
Apply tool 99360553 (1) to the rocker shaft (5) and fit the
shaft (5) to the cylinder head.
Fit the O-rings (1) (2) (3) to the injectors
Figure 270 4
Camshaft timing
Figure 273
70.567A
DIAGRAM OF ROCKER SHAFT

TIGHTENING ORDER
Tighten the screws (1-2-3) until bringing the rocker shaft into
contact with the corresponding seats on the cylinder head,
tighten the screws in the order indicated in the diagram in two
stages, as shown in the next diagram.
Figure 271
71776
Apply tool 99360321 (7) and spacer 99360325 (6) to the

gearbox (3).
α
The arrow shows the direction of engine rotation.
With the above tool, turn the flywheel (1) in the

direction of engine rotation, such as to
approximately bring the piston of cylinder 1 to firing
stroke TDC.
45261
This condition is achieved when the hole with one
Fasten the rocker shaft screws (2) as follows: notch (4) that follows the hole with two notches (5)
- Stage 1 tighten with a torque wrench (1) to torque of present on the flywheel (1) is visible in the spyhole
80 Nm (8 kgm); (2).
- Stage 2: closure, using tool 99395216 (3), with angle 60˚.
Figure 272
60574
- Fit the engine brake lever retainer springs (3).

- Connect the piping (2) to the engine brake cylinders (4)
and the engine brake cylinder with electrovalve (1).
71774
The exact position of piston 1 at TDC is achieved in the

previously described position, when tool 99360612 (1) fits
into the hole (3) on the flywheel (4) through the engine revs 72436
sensor seat (2).
The camshaft is timed if the following conditions are present
Otherwise turn and suitable orient the engine flywheel (4). when the cam lift values are 5.33 ± 0.05 mm:
Remove tool 99360612 (1).
1) the hole marked with a notch (5) can be seen through the
inspection window;
2) tool 99360612 (1) can be inserted into hole (3) on the
engine flywheel (4) through the seat (2) of the engine
rpm sensor.
60573 60575
Position the magnetic dial gauge (1) with the stem on the rol- If the conditions illustrated in Figure 276 and specified in
ler (2) of the rocker controlling the injector of cylinder 1, and points 1 and 2 above do not exist, proceed as follows:
pre-load it 6 mm. - Loosen the screws (2) securing gear (1) to the camshaft
Using tool 99350321 (7) Figure 273, turn the crankshaft and use the slots (1) on the gear.
clockwise until the pointer on the gauge reaches the mini-
mum value beyond which it cannot go. - Move the engine flywheel to obtain the conditions de-
Reset the dial gauge. scribed in points 1 and 2, Figure 276, while keeping the
Turn the flywheel anti-clockwise until the gauge reads a lift cam lift value the same.
value of 5.33 ± 0.05 mm for the camshaft cam. - Lock the screws (2) and repeat the check already descri-
bed.
- Tighten the screws (2) to the specified torque.
Figure 278 Fit the gear (2) Figure 278 with the 4 slotted holes centred
with respect to the camshaft fastening holes, tightening the
screws to the specified torque.
Check camshaft timing first by turning the flywheel clockwise
to fullydischarge the barrel and then turning the flywheel
anti-clockwise until reading a value of 5.33  0.05 on the
comparator.
Check the timing conditions described in Figure 276.
Timing the phonic wheel

Figure 280
71778
When adjustment by means of the slots (1) is no longer

sufficient to recover timing and the camshaft rotates because
fastened with the gear (2), proceed as follows to vary the cam
rise reference value:
check that the screws (2, Figure 277) are fastened.
Turn the flywheel by 1/2 turn.
Turn the flywheel anticlockwise until reading a cam rise value
of 5.33  0.05 mm on the comparator.
Remove the screws (2, Figure 277) and remove the gear cog
(2) from the camshaft.
Figure 279
77260
Turn the crankshaft to bring piston n. 1 to TDC. Turn the

flywheel the opposite way to normal by circa ¼ turn.
Turn the flywheel again in the normal direction until the hole
marked with a double notch (4) appears in the spyhole under
the flywheel casing. Insert tool 99360612 (5) into the
flywheel sensor seat (6).
Through the sensor seat, insert tool 99360613 (2) into the
tooth in the phonic wheel.
If it is difficult to insert the tool (2), loosen the screws (3) and
72436
turn the phonic wheel (1) until the tool (2) fits into the tooth
Turn the flywheel again until bringing it into the following correctly. Proceed to tighten the screws (3).
conditions:
- one notch (3) visible in the lower spyhole;
- too 99360612 (1) inserted flush in the engine revs
sensor seat (2) and (3).
Adjusting the unload/intake rockers play and pump injector control rockers preload
Figure 281
60577
ADJUSTMENT OF INTAKE, EXHAUST AND INJECTION ROCKERS
The adjustment of clearance between the rockers and rods - Using an appropriate wrench (4), loosen the adjust-
controlling the intake and exhaust valves, as well as the ad- ment screw until the pumping element is at the end-of--
justment of pre-loading of the rockers controlling pump in- stroke;
jectors, must be carried out carefully.
- Tighten the adjustment screw, with a dynamometric
Take the cylinder where clearance must be adjusted to the wrench, to 5 Nm tightening torque (0.5 kgm);
bursting phase; its valves are closed while balancing the sym-
- Untighten the adjustment screw by 1/2 to 3/4 rotation;
metric cylinder valves.
Symmetric cylinders are 1-6, 2-5 and 3-4. - Tighten the locking nut.
In order to properly operate, follow these instructions and
data specified on the table. FIRING ORDER 1 - 4 - 2 - 6 - 3 - 5
Adjustment of clearance between the rockers and rods
Departure Balance Adjust valve Adjust injector
controlling intake and exhaust valves:
and clockwise valves play on preload
- Using a polygonal wrench, loosen nut (1) locking the ad- rotation cylinder n. cylinder n. cylinder n.
justment screw; 1 and 6 at TDC 6 1 5
- Insert the thickness gauge blade (3); 120º 3 4 1
- Tighten or untighten the adjustment screw with the ap- 120º 5 2 4
propriate wrench; 120º 1 6 2
- Make sure that the gauge blade (3) can slide with a slight 120º 4 3 6
friction; 120º 2 5 3
- Lock the nut (1), by blocking the adjustment screw.
In order to properly carry out the above-mentioned
Pre-loading of rockers controlling pump injectors: adjustments, follow the sequence specified in the
table, checking the exact position in each rotation
- Using a polygonal wrench, loosen the nut locking the phase by means of pin 99360612, to be inserted in
rocker adjustment screw (5) controlling the pump injec- the 11th hole in each of the three sectors with 18
tor (6); holes each.
ASTRA
85480
Fit the valve train cover (1).

Fit the blow-by box (7) and gasket and tighten the screws (8)
to the specified torque.
Fit the filter (5) with the gskets (4 and 6).
The filter functions in a single direction, therefore it

has to be fitted with the two reinforcing barsvisible
as indicated in the diagram. 47573
Fit the cover (3) and tighten the screws (2) to the specified - Turn the engine and fit the oil scavenge pipe. Fit the
torque. gasket (4) to the oil sump (1) with the spacer (3) and fit
the sump to the crankcase tightening the screws (2) to
For engines equipped with PTO apply LOCTITE the specified torque;
5970 silicon - IVECO n. 2995644 to the blow-by box
fitting (7) as per the procedure described in the next COMPLETING THE ENGINE
diagram. Proceed to complete the engine fitting or connecting the
following parts:
- Power take off (PTO, if present) and corresponding
Figure 283 pipes;
- Air compressor complete with power steering pump;
- Fuel pump;
- Complete fuel filter and piping support;
- EDC control unit;
- Intake manifold;
- Pre-heater element;
- Heat exchanger;
- Oil filter, lubricating the O-ring;
- Exhaust manifold;
- Turbocompressor and corresponding water and oil
pipes;
- Pulley and damper flywheel;
- Thermostat group;
- Belt tensioner, water pump, alternator;
- Electromagnetic coupling;
- Drive belt;
- If present, air-conditioner compressor belt tensioner;
- Dipstick;
85481
- Electrical and sensor connections.
To the blow-by box (1), apply LOCTITE silicon 5970 - The turbocompressor cooling water and oil pipes
. the figure,
IVECO n. 2995644, to form a bead (2) as shown in must be tightened to a torque of:
of  1.5  0,5
0,2
- 35 5 Nm, water pipe connections;

Fit the blow-by box within 10 seconds of applying - 55 5 Nm, oil pipe female connector;
the sealant.
- 20-25 Nm, oil pipe male connector.

ASTRA
106223
- Drive belt (1).

106224
To fit the belt (1), use the correct tool (3) on the tensioner
(2) in the direction indicated by the arrow in Figure Apply tool 99360321 (2) and spacer 99360325 to the
gearbox (1).
Fit the belt (3) to the crankshaft pulley, fit the chuck
99360192 (4) to the air conditioner compressor pulley (5).
The tensioners are automatic an no adjustment is Position the belt (3) in the space on tool 99360192 marked
required after fitting. “cursor 10/13”.
With tool 99360321 (2) turn the crankshaft in the direction
of the arrow () until the belt (3) fits snugly in the
- fill the engine with the specified quantity of oil; compressor pulley (5).
- remove the engine from the rotary stand and remove
the engine anchor brackets (99361036).
During this operation, hold tool 99360192 (4) in
Fit:
contact with the pulley while guiding the belt (3) to
- oil pressure regulator valve; prevent twist.
- left engine mounting;
- Air compressor complete with power steering pump;
- Soundproof bulkhead; Figure 287
- piping.
- if present, air conditioned compressor and drive belt in
the same way as the belt (1, Figure 285).
For engines fitted with elastic air conditioner

compressor drive belt, to fit the belt always use tool
99360192 (4) proceeding as described. Any other
method may cause tension that could damage the
belt.
The elastic belt must be replaced with a new one

after each removal.
102650
Replacement of the belt with engine mounted in
vehicle can be carried out in the engine bay with the DIAGRAM OF AIR CONDITIONER COMPRESSOR
cabin tilted. ELASTIC DRIVE BELT
1. Alternator — 2. Air conditioner compressor -
3. Electromagnetic coupling — 4. Water pump -
5. Crankshaft — 6. Elastic belt
TURBO CHARGER REMOVAL-REFITTING

Safety instructions
Before carrying out any operation make certain to Do not touch with the hands.
concerning safety of the personnel involved in the Collect and dispose of used lubricants and fluids,
operation. If in doubt, consult a more experienced according to the laws and local regulations.
Observe all the general recommendations to carry
out maintenance jobs correctly.
Vehicle preparation Pay very careful attention because the parts involved
may be very hot.

switch off the engine, remove the ignition key,
engage the parking brake and apply the warning
signboards.
Figure 288
2371801

terminals from the battery (see arrow) to avoid the risk
of short circuits;
Preliminary operations - disconnect the VGT pneumatic control pipes (5);
Proceed as follows: - disconnect the turbine speed sensor electric connector
- tip the cab following the Maintenance Instructions in the (6);
USE AND MAINTENANCE HANDBOOK - support the turbo assembly and remove it, unscrewing
Removal the nuts that fasten it to the exhaust manifold.
Proceed as follows:
- loosen the fastening straps and remove the intake sleeve Refitting
(1); To refit, follow the removal instructions in reverse order.
- loosen the fastening straps and remove the ecxhaust
sleeve (2);
Final operations
Proceed as follows:
- disconnect the intercooler air delivery tube (3);
- disconnect the lubrication oil inlet (4) and outlet (5) USE AND MAINTENANCE HANDBOOK.
pipes;

operations.
Figure 289
335B003029R
OVERHAUL OF TURBOCHARGER WITH

VARIABLE PITCH
If an engine fault attributable to the turbocharger

system is found, firstly check the turbocharger itself,
checking the condition of seals and gaskets and the
manifold fasteners, to make certain there are no air
blockages in the manifolds or air filter. If the
turbocharger is damaged due to lack of lubrication,
check the oil lines for damage and replace them if
necessary.
After carrying out the above checks, check turbocharger

function by performing an Engine Test using the diagnosis
equipment, following the instructions given by the
equipment.
The test must be carried out in the following

conditions:
- Engine coolant temperature >50 ˚C;
- battery charge (voltage >22V for compression
test;
- charging system efficient.
If values outside tolerance are found, check efficiency.

- shut-off valve;
- pressure sensor;
- engine pressure sensor cable connection (if oxidised,
clean with specific product);
- absence of solenoid electrical faultsWGT (connection
with continuity);
- actuator operation by active diagnosis as described in
previous chapter, in case of seizure grease the bushing
with Kemite (high temperature grease) and if the fault
persists, replace the actuator;
- sliding hose must slide freely. If blocked and if the check
on the bushing is not sufficient, or no faults are indicated
or found at other points, after obtaining authorisation via
the technical “Help Desk”, replace the turbocharger
following the standard procedure.
Variable pitch movement check Actuator check

106226 106227
Remove the bolts (2) and detach the actuator (1) from the Check actuator 3) efficiency as follows:
turbocharger (7). Apply the compressed air feed line fitted with a pressure
Remove the bolts (6), the disk underneath (5), the ring (4) regulator (4) to the actuator (1) intake (2). Through the
and disconnect the actuator (1) tie rod (3) from the variable pressure regulator, introduce compressed air into the
pitch control lever pin (8). actuator gradually from 03.5 bar. The actuator (1) tie rod
Thoroughly clean the pin () of the lever (8) and the bush (3) should move without binding /sticking. If not, replace the
() for the tie rod (3) with a non-abrasive microfibre cloth. actuator (1).
Do not use any kind of abrasive paper.
Figure 292
Visually check the condition of the bushing () the tie rod
(3) and the pin () of the lever (8). If worn, replace the
actuator (1) or the turbocharger (7).
Check the movement of the control mechanism inside the
variable pitch system, operating the lever (8) which must not
bind. Otherwise clean the turbine body as instructed in the
related chapter.
106228
Check for any leaks in the actuator at the points indicated

() applying soap and water solution.
Operate the actuator (1) applying compressed air to the
points indicated (). Check for absence of air bubbles. If
present, replace the actuator (1).
Figure 293 Cleaning the turbine body

ASTRA Figure 295
106229
106231
Lubricate the bushing () of the tie rod (3) and the pin ()
of the lever (8) with Castrol LM lithium based GREASE and Mark the fitting position of the clamp (2) on the central body
reattach the actuator (1) to the turbocharger (7) proceeding (1).
as follows. Apply rust preventing spray lubricant to the thread and the
Connect the tie rod (3) to the lever (8). nut (4), and loosen the clamp (2) by unscrewing the nut (4).
Fit: a new ring (4), the disc (5) and tighten the bolt (6). Slightly rotate the clamp (2) using pliers (5).
Tighten the bolts (2) fastening the actuator (1) to the Mark the fitting position of the turbine body (3) on the
turbocharger (7). central body (1).
Tighten the bolts (2 and 6) to a torque of 25 Nm.
Actuator stroke check Figure 296

Figure 294
106230
106232
Check the stroke X of the actuator (1) tie rod (2) proceeding
as follows. Using a copper hammer, knock on the two opposite points
Measure the distance X1, between the actuator (1) and the (~180º) of the turbine body (2) to separate it from the
eye centre (4). central body (1).
Apply the compressed air feed line (3) fitted with a pressure
regulator to the actuator (1) intake. Using the pressure During this operation, take care not to damage the
regulator feed compressed air into the actuator (1) gradually turbine propeller.
from 03.5 bar, until the lever (5) reaches the end of the
stroke.
Measure the distance X2, between the actuator (1) and the After removing the turbine body, check the variable pitch
eye centre (4). movement as instructed in the corresponding chapter. If the
The stroke X of the actuator (1) tie rod (2) is given by movement has not improved after the check, replace the
subtracting X = X2-X1 and must be 11.50.5 mm. turbocharger.
106233 106236
Thoroughly clean any carbon deposits from the ring (1) and
the zone surrounding the turbine body and check that the Remove the external O-ring (1) from the central body (2).
ring rotates freely. Otherwise replace the turbocharger. Thoroughly clean the O-ring (1) and check that it is not
damaged. If damaged, replace it..
Any minor damage between the groove and the ring

may be tolerated since this does not affect Figure 301
turbocharger function.
Figure 298
106237
Check the turbine propeller (1). There must be no: carbon

deposits, deformation, damage or scored blades and it must
106234
rotate freely.
Using a suitable scraper and abrasive paper, thoroughly clean Using a comparator, check the play in the turbine propeller
any carbon deposits from the surfaces () of the turbine shaft (1). This must be:
body (1) , taking care not to damage them. - axial play 0.0510.152 mm
- radial movement 0.3810.533 mm.
If higher values are found, or any of the listed faults, replace
Figure 299
the turbocharger.
Before cleaning the central body, turbine side,

suitably protect the oil, air and water intakes and
outlets () to prevent dirt or foreign matter from
entering the turbocharger.
106235
Remove the clamp (1) from the central body (2) and check
it is not damaged. If damaged, replace it.
106238 106240
Using a suitable scraper and abrasive paper, thoroughly clean Fit the turbine body (1) to the central body (2) taking care
any carbon deposits from the surfaces () of the central not to damage the turbine propeller and align the turbine
body (1) , taking care not to damage them and the variable body grooved ring with the variable pitch. Do not force fit.
pitch ring. If it binds, this could damage the variable pitch and cause the
Clean any residues from the surfaces and the variable pitch regulation system to malfunction.
ring with compressed air. Once mounted, check that the turbine body is correctly
Check again, as instructed in the previous chapters: coupled to the central body.
- the variable pitch movement; Position the turbine body on the central body and fit the
- the actuator; clamp so that the marks made during removal are correctly
- the actuator stroke. aligned.
Tighten the clamp nut to a torque of 11.3 Nm.
Check again, as instructed in the previous chapters:
- the actuator;
- the actuator stroke.
Figure 303
ASTRA
106235
Position the clamp (1) on the central body (2).
If the clamp with built-in heat shield (1) has to be

replaced, a new actuator with built-in heat shield
must be installed in place of the old one.
Position the outer O-ring (thoroughly cleaned) on the

central body.
Apply a thin coat of anti-seize paste to the cleaned coupling
surfaces: central body / turbine body.
FIXED PITCH TURBOCHARGER OVERHAUL

Figure 305
71766
PRESSURE LIMITER VALVE

If an engine fault attributable to the turbocharger Pressure limiter valve checks and adjustments:
system is found, firstly check the turbocharger itself,
checking the condition of seals and gaskets and the - Cover the exhaust gas and lubricating oil intakes and
manifold fasteners, to make certain there are no air outlets.
blockages in the manifolds or air filter or in the
- Thoroughly clean the outside of the turbocharger using
radiators. If the turbocharger is damaged due to
non-corrosive liquid.
lack of lubrication, check the oil lines for damage
and replace them if necessary.
86939
Disconnect the pipe from the pressure limiter valve inlet (3) 71770
and apply the pipe from the 99367121 device (2) to it.
Rest the magnetic base comparator pointer (1) on the end Remove the cover (1) to inspect the turbine mechanism
of the tie rod (4), and zero it. piloted by the actuator.
Using the 99367121 device(2), feed compressed air into the
valve body (3) at the pressure of 1.75  0.01 bar and make
certain that thi value remains constant throughout the check,
otherwise replace the valve as instructed in the
corresponding chapter. Figure 309
In the above conditions, the tie rod must have travelled a
stroke of 0.43  1.95 mm.
If a different value is found, loosen the nut (6) and suitably
rotate the tie rod (5) such that at the indicated pressure the
rod stroke results as 0.861.40.
ASTRA
Figure 307
ASTRA
71771
From the inspection hole (2) check that the internal leverage
control (1) does not bind or seize. If so, lubricate it, and if the
fault persists replace the turbine.
86940 Pressure limiter valve replacement

If the pressure limiter valve (3, Figure 306) is seized, (see Figure 307)
disconnect the tie-rod (1) from the lever (2), and remove the Remove the pin (3) fastening the tie rod (4) to the lever (2)
snap ring (3). and remove the valve (4, Figure 306) from the turbocharger
Using the 99367121 device (2, Figure 306) feed low pressure by removing the nuts (4, Figure 306).
air into the valve body (3, Figure 306) to check whether the Fit the new valve following the removal operations in reverse
valve is seized. If it is, replace the valve (3, Figure 307) as order and adjust the tie rod stroke as instructed in the
instructed in the corresponding chapter. corresponding chapter.
Otherwise, check the efficiency of the mechanism as follows.
Before fitting the turbocharger to the engine, fill the
central body with engine oil.
HYDROCAR POWER TAKE-OFF ON TIMING SYSTEM - (OPTIONAL P.T.O.)

Description
This is a one-axle power take-off with gear movement and clutch engagement which takes power from the gears of the timing
system independently of the vehicle clutch. It can be used with the vehicle either stationary or running and for continuous use
it can be turned on/off with the engine running.
The PTO can be in the direct pump connection version or with a flange for a universal joint.
Figure 310
108621
Ratio of no. output rpm/engine rpm 1,14

Nominal output torque (Nm) 600
Foreseen duration of the nominal torque (hours) 500 (at 1500 rpm)
Rotation direction (compared to the engine Opposite
Assembly side (vehicle travel direction) Upper
Control system Pneumatic

CLUTCH
SECTION 4
HD9 Euro5 SECTION 4 CLUTCH 1
SECTION 4
Clutch
Page
DESCRIPTION 3
- Controls 4
- Master cylinder 5
SPECIFICATIONS AND DATA 7
TIGHTENING TORQUES 8
TOOLS 8
DIAGNOSTICS 9
CLUTCH CONTROL OIL REPLACEMENT 12
GENERAL 12
- Dumping 13
- Filling 13
BRAKE PEDAL ADJUSTMENT 14
GENERAL 14
- Execution of operation 15
CLUTCH ACTUATOR ADJUSTMENT 16
GENERAL 16
- Clutch wear indicator adjustment 18
2 CLUTCH SECTION 4 HD9 Euro5
ROBOTIC TRANSMISSION SERVO-CLUTCH - Removal 26

ACTUATOR ADJUSTMENT 19
- Refitting 26
GENERAL 19
CLUTCH ASSEMBLY REMOVAL-REFIT 22
GENERAL 22
- Removal 23
- Refitting 24
CLUTCH THRUST BEARING REMOVAL-REFIT 25
GENERAL 25
- Removal 25
- Refitting 25
CLUTCH SHAFT SUPPORT BEARING
REMOVAL-REFIT 26
GENERAL 26
DESCRIPTION
The clutch is the single plate dry type, with a pull type engagement mechanism and a diaphragm spring.
Figure 1
1. Thrust pad — 2. Clutch disc — 3. Collar bearing — 4. Servo-clutch — 5. Fork shaft — 6. Fork — 7. Spacer — 8. Ball joint —
9. Stud — 10. Nut — 11. Stud — 12. Nut — 13. Bolt — 14. Nut — 15. Rod — 16. Pin — 17. Plug
Controls
The control consists of:
1. a master pneumo-hydraulic cylinder incorporated in the pedal unit and equipped with integrated tank;
2. A hydraulic actuator located below the gearbox cover
3. connecting pipe.
Figure 2
342B041001R
Master cylinder
Master cylinder hydro-pneumatic diagram
Figure 3
342B041002R
1. Clutch pedal — 2. Hydraulic oil reservoir — 3. Pneumatic distributor — 4. Pneumohydraulic servo actuator —
5. Master cylinder — 6. Switches S1 and S2
Master cylinder wiring diagram
Figure 4
342B041004R
Master cylinder circuit diagram Switch S1 opens during the first part of the stroke: the signal to
The following proximity (read) switches are mounted on the disable Cruise Control during gear shift is transmitted to the en-
master cylinder: gine control system.
- S1 (N.C. type), to disable the Cruise Control; In the second part switch S2 closes to enable the servoshift con-
trol solenoid valve, to prevent gear shift with the clutch insuffi-
- S2 (N.O. type) for synchro protection. ciently depressed.
Switch S2 is also used to enable splitter engagement. The signal
coming from the switch is sent to a solenoid valve on the gear-
1. Push rod
box. When energised it pilots the splitter engagement actuator.
2. Piston
3. Magnetic ring
S1 Proximity switch for Cruise Control disable

S2 Gearbox synchro protection proximity switch Switch S2 closes with 21.5 mm stroke of the piston
(2), equal to 70% of the clutch pedal disengage stroke,
A Pneumatic pressure from distributor corresponding to the point of intervention of the ser-
O Clutch servo hydraulic pressure voshift.
SPECIFICATIONS AND DATA

* For the correct type of fluid, see section 2 - HYDRAULIC FLUID AND LUBRICANTS TABLE
17” CLUTCH VALEO BORG & BECK FICHTEL & SACHS
Type Dry, single-plate
Engagement mechanism “Pull” type with diaphragm spring
Driven plate With friction facings
Driven plate hub With damper springs
Ø External diameter of
430 430 430  1
friction Facings mm
Ø Internal diameter of
242 240 240
friction Facings mm
Plate thickness (new) mm 10  0,3
Max. permitted driven plate mm

~ 0,2
Withdrawal stroke mm 12 + 2
Wear stroke mm 15 + 2
Master cylinder with built-in oil reservoir-Slave cylinder with full

Hydraulic control
driven plate self-adjustment
Oil type * (*)
* For the correct type of fluid, see section 2 - HYDRAULIC FLUID AND LUBRICANTS TABLE
TIGHTENING TORQUES
TORQUE
DETAIL
Nm (kgm)
Disk pusher to flywheel M12 hex head flanged screw 65  7 (6.5  0.7)
M10 nut for clutch casing to crankcase fastening stud 46  5 (4.6  0.5)
M10x80 clutch casing to crankcase fastening stud 19  2 (2  0.2)
TOOLS
Air remover for bleeding air from clutch control circuit

99306010
99370264 Guide pin for clutch disk centring
99370280 Guide pin for clutch disk centring
Suport for clutch group removal and replacement

99370547 (to apply to hydraulic jack)
DIAGNOSTICS
Main operating faults in the clutch :
1 - Noise when the clutch pedal is depressed.

2 - Noise when the pedal is released
3 - The clutch snatches 4 - The clutch does not disengage
5 - The clutch slips
6 - Abnormal wear of driven plate linings.
1 NOISE WHEN CLUTCH PEDAL

IS DEPRESSED
Thrust bearing excessively worn, damaged or not Replace thrust bearing

properly lubricated YES
NO
Excessive play between the splines on the transmission Replace the shaft and also the driven plate If necessary
input shaft and the splined portion of the driven plate YES
2 NOISE WHEN THE PEDAL

IS RELEASED
Springs of driven plate broken or weak Replace driven plate.

YES
NO
Transmission input shaft worn Replace the shaft and also the driven plate if necessary
YES
NO
Thrust bearing has play in engagement sleeve Replace the thrust bearing
YES
3 THE CLUTCH SNATCHES
Oil or grease on engine flywheel or on driven plate Eliminate the problem causing the contamination; clean
linings YES flywheel thoroughly then replace driven plate
NO
Pressure plate distorted Replace the clutch.

YES
NO
Uneven wear of friction linings due to run-out of driven Replace the driven plate.
plate YES
NO
Diaphragm spring weak or fingers broken Replace the driven plate.

YES
4 THE CLUTCH DOES NOT DISENGAGE
Oil or grease on driven plate linings. Replace the driven plate.

YES
NO
Transmission input spline damaged thus preventing Replace the shaft and also the driven plate if necessary
driven plate from sliding YES
(continued)
5 THE CLUTCH SLIPS
Driven plate linings worn or burnt Replace the driven plate.

YES
NO
Diaphragm spring weak or fingers broken Replace the clutch.

YES
NO
Oil or grease on driven plate linings. Eliminate the problem causing the contamination and
YES replace driven plate
6 ABNORMAL WEAR OF
DRIVEN PLATE LININGS
Driver resting his foot on the clutch pedal Driver must avoid the harmful habit and rest his
while driving YES foot on the clutch pedal only when necessary
NO
Diaphragm spring with weakened or broken fingers Replace the clutch.

YES
CLUTCH CONTROL OIL REPLACEMENT

GENERAL
Safety instructions Hazardous and/or polluting substances
The operation described requires handling of hazard-

ous and/or polluting substances
have taken all precautions and clarified all aspects con- Avoid contact with painted parts.
cerning safety of the personnel involved in the oper- Collect and dispose of used lubricants and fluids,
ation. If in doubt, consult a more experienced person. according to the laws and local regulations.
manual.

Vehicle preparation and surrounding parts, could be very hot.

Figure 5
2371801
- cut off the battery master switch or disconnect the ter-

minals from the battery (see arrow) to avoid the risk of
short circuits;
Drainage
Proceed as follows: Final operations
Proceed as follows:
Figure 6
- check that fluid level in reservoir is at maximum;
Figure 8
342B041003R
272NM004X
- arrange a container of appropriate capacity and then
remove the cap (1);
- using a section of transparent pipe, fit one end to the bleed
valve (B) and the other end into a clean container;
Figure 7 - depress the clutch pedal and hold it down;
- loosen the upper bleed valve allowing oil and air bubbles
to flow out, and close it after a few seconds;
- fully release the clutch pedal;
- repeat the operation unitl oil flows from the bleed valve
without air bubbles;
- carefully close the valve fitting (B);
- top-up fluid level in the tank.
272NM004X
- unscrew the drain pipe (A) and fully drain off the oil;
- clean the drainage fitting and close again.
Filling
Proceed as follows:
- fill to tank maximum level with the specified fluid;
- close the cap.
BRAKE PEDAL ADJUSTMENT

GENERAL
Safety instructions

have taken all precautions and clarified all aspects con-
cerning safety of the personnel involved in the opera-
tion. If in doubt, consult a more experienced person.
manual.
Observe all general recommendations for the correct
execution of maintenance work.
- Bring the angle bracket (3) into contact with the spacer.
Proceed as follows:
- Loosen the angle bracket bolts (4) without removing
them. Fitting the spacer prevents the splitter control distrib-
- Place a spacer of predetermined thickness (A = 1 mm) in utor working as a stop for the clutch pedal.
front of the button (2) of the splitter control distributor.
- Bring the clutch pedal (5) into contact with the stop screw
(1) and hold it down. - Tighten the angle bracket bolts (4).
- Release the clutch pedal (5).
Figure 9
A
3
4
5
27204004
CLUTCH ACTUATOR ADJUSTMENT

GENERAL
Safety instructions

have taken all precautions and clarified all aspects con-
cerning safety of the personnel involved in the opera-
tion. If in doubt, consult a more experienced person.
manual.
Clutch actuator adjustment - press the spherical push-rod to its limit (arrow);
- loosen the lock nut and adjust push-rod position until ob-
taining the required distance B.
The procedure must be carried out with the actuator
fitted. B = A — C mm
C being the actuator excursion, according to clutch type:
C = 25 mm (VALEO, BORG & BECK)
Proceed as follows: C = 33 mm (FICHTEL & SACHS).
- measure the distance A between the bottom of the lever
cavity and the servoclutch mounting plane.
The clutch lever must be in contact with the thrust Disk wear (90% of the lining) is indicated by a signifi-
bearing. cant increase in load on the pedal during clutch disen-
gage.
Figure 10
”C”
”C” ”B”
”A”
27204005
Clutch wear indicator adjustment

Proceed as follows: - cut the part of the rod (19) protruding from the ring (4);
- push the rod (1) against the piston (2); - loosen the fastening screw and turn the check plate 85,
- push the red plastic indicator (3) against the clutch servo corresponding to the clutch disk wear limit) until obtaining
box; the clearance D required (corresponding to actuator ex-
cursion), depnding on the type of clutch.
- fasten the red ploastic indicator (39) on the rod (1) with D = 25 mm (VALEO, BORG & BECK)
the ring (4); D = 33 mm (FICHTEL & SACHS)
- tighten the check plate fastening screws.
Do not operator the clutch servo before fastening the

ring (4).
Figure 11
ROBOTIC TRANSMISSION SERVO-CLUTCH

ACTUATOR ADJUSTMENT
GENERAL
Safety instructions

person.
manual.
- Adjust the push-rod H as below:
Servoclutch adjustment
Proceed as follows: B = (A -13,9 mm) + C
- Measure the distance A between the bottom of the lever Where:
cavity and the servoclutch mounting plane. B = distance between the push rod H and the servoclutch
mounting plane
A = distance between the bottom of the lever cavity and the
servoclutch mounting plane.
The clutch lever must be in contact with the thrust
bearing. C = actuator stroke (33 mm)
- Tightent the lock nut F.
- Fit the actuator as shown below.
The clutch wear stroke at servoclutch (set in the

transmission control unit) is 25 mm, which corre-
sponds to disk wear of 2.5 mm (minimum guaranteed
wear on clutch disk).
Figure 12
H
F
C B
A
27204006
Mounting servoclutch in clutch housing
Proceed as follows: - Fit the push rod in the lever cavity

- Unscrew the plug (3) from the inspection hole, to release - Mount the servoclutch and secure it with the four nuts (1).
air from the chamber.
- Unscrew the cap (3) and move the piston forward
- Manually bring the servoclutch piston backwards against
- Retighten the cap (3).
the pressure of the internal spring
- Connect the electrical connector (2) and the air delivery
- Replace the cap (3) to lock the piston back.
pipe (4)
Before connecting the air line check that the servo-

clutch is correctly fastened to the clutch housing.
Figure 13
1 2
27204007
CLUTCH ASSEMBLY REMOVAL-REFIT

GENERAL
Very heavy parts
Safety instructions

person.
Read the instructions provided in the first part of this Hazardous and/or polluting substances
manual.
execution of maintenance work. The operation described requires handling of
according to the local laws and regulations.
Vehicle preparation

Figure 14
2371801

short circuits;
Preliminary operations Figure 17
Proceed as follows:
- Remove the gearbox following the indications in MAN-
UAL GEARBOX REMOVAL-REFIT in Section 6.1.
Removal
Proceed as follows:
Figure 15
40195
- Remove the clutch disk (2) at the same time withdrawing

the centring pin 99370280 (1).
38438
- Insert the clutch centring pin 99370264 or 99370280 (1)

in gearbox input shaft support bearing .
Figure 16
40194
- Fit support 99370547 (1) on a hydraulic jack and apply this

to the pressure plate (3) Unscrew screws (2) and remove
the pressure plate from the engine flywheel.
Inspections and checks Figure 19

The following chack are to be made:
- Check that the idle disk resting surface on the engine fly-
wheel, is not badly worn or scored;
- that the teeth of the engine flywheel crown wheel are not
deteriorated or badly worn.
Replace the engine flywheel if required.
Check there are no lubricant leaks, even slight, from the sealing
ring of the driving shaft rear cover.
If necessary, replace the sealing ring
Check that the bearing or bushing supporting the motion input
shaft of the gearbox mounted on the driving shaft is not work
or deteriorated.
Replace the bearing if required.
Check condition of pressure plate, that there are no deforma- - If the disc is out of line use a hook wrench (1) as in the
tions, signs of wear or signs of overheating on the idle disk rest- figure.
ing surface. Check that the diaphragm is intact.
Check condition of idle disk:
- check friction gaskets are not badly worn, and do not
show signs of overheating or fouling from oil or grease;
- the hub is not to have excessive play on the gearbox input Refitting
shaft; Follow the same procedures as for removal in reverse order
and:
- check that the hub flexible coupling springs do not rotate
in their seats or show signs of breakage. - carefully clean the faying surface of the flywheel disc using
methylated spirit or petrol;
If any anomaly is found, replace the faulty part.
- if any slight scratches are noted remove an abrasive cloth;
- Position the driven disc, using the guide pin to obtain per-
fect centring and to avoid straining the hub when the gears
are reconnected.
- using support 99370547 on the hydraulic jack, position
the thrust pad on the flywheel fit the fixing screws and
tighten them to the prescribed torque.
Figure 18
Final operations
Proceed as follows:
- refit the gearbox following the indications in MANUAL
GEARBOX REMOVAL-REFIT in Section 6.1.
Before fitting a new driven plate, it should be checked for

run-out as follows:
- Mount the driven plate (1) in a lathe, then using a dial
gauge with a magnetic base (2) check the surface of the
disc for run-out.
- Maximum run-out permitted for the driven plate is 0.20
mm.
CLUTCH THRUST BEARING REMOVAL-- DESCRIPTION OF OPERATION

REFIT Preliminary operations
GENERAL Proceed as follows:
Safety instructions - remove the clutch assembly as indicated in CLUTCH
ASSEMBLY REMOVAL-REFIT in this Section.
have taken all precautions and clarified all aspects Removal
Proceed as follows:
person.
manual. Figure 21
ASTRA
Vehicle preparation

Figure 20 36800
- Using appropriate pliers, open the safety split ring (1)

extract the thrust bearing (2) from the pressure plate (3).
Refitting
Final operations
Proceed as follows:
- refit the clutch assembly as indicated in CLUTCH ASSEM-
BLY REMOVAL-REFIT in this Section.
2371801

short circuits;
CLUTCH SHAFT SUPPORT BEARING

REMOVAL-REFIT DESCRIPTION OF OPERATION
GENERAL
Proceed as follows:
Safety instructions
- remove the clutch assembly as indicated in CLUTCH
ASSEMBLY REMOVAL-REFIT in this Section.
have taken all precautions and clarified all aspects Removal
Proceed as follows:
person.
manual. Figure 23
Vehicle preparation

Figure 22 40196
- Using the appropriate pliers remove the split ring (3).

- Using the universal extractor 99348004 (1) remove the
bearing (2).
Refitting
To refit, follow the removal instructions in reverse order using
an appropriate tool.
Final operations
Proceed as follows:
- refit the clutch assembly as indicated in CLUTCH ASSEM-
BLY REMOVAL-REFIT in this Section.
2371801

short circuits;
POWER TAKE-OFF
SECTION 5
HD9 Euro5 SECTION 5 POWER TAKE OFF 1
SECTION 5
Power take off

Page
DESCRIPTION 3
- Function (PTO on) 6
- Function (PTO off) 7
FEATURES AND DATA 8

TOOLS 10
EXPERIMENTAL TOOLS 12
SPECIAL MAINTENANCE 13
- Oil replacement 13
REMOVAL — REPLACEMENT OF TOTAL

POWER TAKE OFF ASSEMBLY 14
- Removal 14
- Replacement 15
OVERHAUL 16
- Main box dismantling 16
- Dismantling the power take off group 16
- Dismantling shaft bearing with toothed wheel 16
- Oil pump removal 17
- Oil pump assembly 18
- Cleaning and checking components 18
- Shaft bearing with toothed wheel assembly 19
- Power take off group assembly 19
- Drive output shaft tapered bearing adjustment 21
- Main box assembly 22
- Ball bearing adjustment 22

2 POWER TAKE OFF SECTION 5 HD9 Euro5

DESCRIPTION
The power take off is situated between the engine flywheel and the clutch assembly and is fitted with a non-synchronised pneumo--
mechanical positive clutch to transfer the movement from the engine drive shaft to the pick up flange. Lubrication is ensured by
an oil pump.
Figure 1
1780501 1780502
4
Figure 2
POWER TAKE OFF
SECTION 5
71565
POWER TAKE OFF COMPONENTS (DEMONSTRATIVE)

1. Bush - 2. Flange - 3. Laminar coupling - 4. Screw and washer - 5. Roller bearing - 6. O-ring - 7. Intermediate gear shaft - 7a. Intermediate gear - 8. Bracket with nut -
9. Connector with washer - 10. O-ring - 11. Reference screw - 12. Bearing - 13. Screw - 14. Flywheel - 15. Box - 16. Stud with nut - 17. Oil pump - 18. Bearing -
19. Screw, washer and bracket - 20. O-ring - 21. Oil filter - 22. Cap - 23. Cover - 24. Cap - 25. Screw - 26. Gear - 27. Screw with washer - 28. Pipe with washer -
29. Pipe with connector and washer - 30. Screw - 31. O-ring - 32. Pinion shaft - 33. Ball bearing - 34. Safety snap ring - 35. Adjuster ring - 36. Gasket- 37. Cover -
38. Screw - 39. Screw
HD9 Euro5
Figure 3
40776
POWER TAKE OFF COMPONENTS

1. Safety snap ring - 2. Connector - 3. O-rings - 4. Fork shaft - 5. Pin - 6. Screw - 7. Transmitter - 8. Washer - 9. Cap - 10. Box -
11. O-rings - 12. Connector - 13. Safety snap ring - 14. Cap - 15. Vent - 16. Screw - 17. Nut - 18. Flange - 19. Gasket -
20. Screw - 21. Cover - 22. Tapered roller bearing - 23. Toothed otput shaft - 24. Control fork - 25. Sliding sleeve - 26. Roller
bearing - 27. Screw - 28. Cover - 29. Adjuster ring - 30. Tapered roller bearing - 31. Shoulder ring - 32. Output shaft drive gear
Figure 4
Function (PTO on)

A = Electromagnetic valve N.C. (normally closed) with switch on.
B = Electromagnetic valve N.A. (normally open) with switch on.
With switch (F) (on) the electromagnets of valves A and B are exited and therefore close the valve A circuit and open that of valve
B.
Delivered air enters from the connector (7) into valve B, exits from connector (6) and through the pipe arrives in chamber C, moving
the drive shaft with fork D into PTO on position. At the same time the air in chamber E, through the pipe, enters into the connector
(3) in valve A and discharges into the atmosphere from connector (4).
Figure 5
Function (PTO off)

A = Electropneumatic valve N.A. (normally open) with switch off.
B = Electromagnetic valve N.C. (normally closed) with switch off.
With switch (F) off the electromagnets of valves A and B are not exited and therefore the valve A circuit remains open and valve
B circuit remains closed..
Delivered air enters from the connector (2) into valve B, exits from connector (3) and through the pipe arrives in chamber E, moving
the drive shaft with fork D into PTO off position. At the same time the air in chamber C, through the pipe, enters into the connector
(6) and discharges into the atmosphere from connector (5).
FEATURES AND DATA
Ratio revolutions - rpm 1 : 1,29
Torque 900 Nm
Direction of rotation Same as engine
Type of engagement/release control Electro - pneumatic
Bearings for output shaft 2 tapered roller bearings
Bearing settings Using setting rings
ASTRA 5,5 — 5,6 — 5,7 — 5,8 — 5,9

Distances setting rings
6 — 6,1 — 6,2 mm
Bearing for control shaft 1 ball bearing
Bearing settings Using setting rings
ASTRA 3,95 — 4 — 4,05 — 4,10 — 4,15 — 4,20

Thickness setting rings
4,25 — 4,30 mm
ASTRA 3,60 — 3,65 — 3,70 — 3,80

Thickness safety split ring
3,85 — 3,90 mm
Quantity (*) 2,5 litres (2 kg)
TIGHTENING TORQUES
307005001R
Figure 6
60240
TIGHTENING TORQUES
TORQUE
DESCRIPTION
Nm kgm
1 Cap 27.5 2.75
2 M10x140 screw 43 4.3
3 Screw 43 4.3
4 M8x60 screw 18 1.8
5 Connector 5.5 0.55
6 Cover screw 22 2.2
7 Screw 82 8.2
8 M10x1.5 screw 10 1
9 Nut with flange for stud 29 2.9
* Screws must be tightened in two stages: 1a pre-torque stage 95 9,5
10
2a closure to angle stage 60 60
11 M8x30 screw 18 1.8
12 M10x30 screw 43 4.3
13 M33x1.5 nut 465 46.5
14 M8x30 screw 18 1,8
NOTE — apply “LOCTITE 242” to caps and connectors in contact with oil
TOOLS
TOOL NO. DESIGNATION
99305121 Hot air apparatus
99322205 Rotary stand for group overhaul
99341003 Two-way stand
99341009 Bracket pair
99341015 Clamp
99341016 Bracket pair with hole

TOOLS
TOOL NO. DESIGNATION
99345049 Extractor reaction block
99360503 Rings for lifting cylinder groups
99363241 Plates (2) for measuring transmission primary or secondary shaft

bearing preload
99370317 Flange retainer reaction lever with extension
99395216 Measurement pair for angular tightening with 1/2” and 3/4” square
fitting
EXPERIMENTAL TOOLS
This chapter gives the technical drawing of the experimental tools (S.P.) used for overhauling the power take off described in this
section, which may be constructed in the repair shop itself.
SPECIAL MAINTENANCE Figure 7

Oil replacement
Proceed as follows:
- unscrew the cap (1) and drain off the oil completely
- pour in new oil through the cap (2)
- having finished this operation, move the vehicle for about
5 minutes. Stop it on level ground.
- check the oil level through the screw (arrow), waiting until
the oil has finished pouring out.
After the first 25 hours of use, it is necessary to clean

the filter on the intake pipe. To do so, proceed as fol-
lows:
D take out the filter unscrewing the retaining cap
(3), clean it with diesel oil and dry it with com-
pressed air. If it is not in good condition replace
it;
D check the gaskets and if necessary replace them. Figure 8
Figure 9
REMOVAL — REPLACEMENT OF TOTAL

POWER TAKE OFF ASSEMBLY
Figure 12
Removal
Operation including:
- transmission shafts removal — replacement. For more
information refer to the corresponding chapter;
- gearbox removal — replacement. For more information
refer to the corresponding chapter;
- Clutch removal — replacement. For more information
refer to the corresponding chapter;
Figure 10
87022
Loosen the clamps (2) fastening exhaust pipe (3) to the

silencer (1).
Figure 13
87020
Remove the plugs (4 and 7) and drain the oil into a suitable
container.
From the lower cover (3) disconnect the oil pipes (5 and 6).
Remove the screws (8) and detach the lower cover (3).
If present, loosen the clamp and disconnect the oil vapour pipe
(1) from the drain pipe (2).
Remove the exhaust pipe to frame fittings (2).
87023
Figure 11
Set up bracket 99360551 (1) on the hydraulic lifter and apply
it to the clutch attachment flywheel.
Remove the screws (3) and detach the flywheel (2) from the
power take off shaft.
Figure 14
87021
Remove the bolts and disconnect the transmission shaft from

the flange (7).
From the power take off (3):
- disconnect the electrical connection (5);
- disconnect the pneumatic pipes (1 and 6);
- remove the connector (2) and detach the oil piping. 87024
To overhaul the drive take off group (3). Remove the screws (1) and detach the inspection cover (2)
Loosen drive output flange (8) nut (7). from the gearbox (3).
Apply flywheel rotation tool 99360321 (4) to the gearbox (3).
On F3B engines this tool must be completed with spacer
Remove the screws (4) and detach drive output group (3). 99360325.
Figure 15 Figure 17
87027
87025
Position a hydraulic lifter with support 99370629 (2) under
Remove the screws (3) fastening the connector coupling (2) the power take off box (1) and harness the power take off box
to the engine flywheel (1). with the chain provided (1)
Remove the nuts and detach the power take off from the
engine.
To render the remaining screws (3) that are not
visible accessible, turn the flywheel with tool
99360321 (4)
Replacement
Refit the power take off assembly following the

removal operations in reverse order, with the
following additions:
- lubricate the connector shaft with MOLYCOTE
HSC grease;
Figure 16 - apply LOCTITE 510 to the power take off
attachment surfaces and lower cover;
α - apply LOCTITE 242E to the threads of screws
in contact with oil;
- tighten screws / nut to the specified torques;
Use tool 99395216 for tightening the clutch

attachment flywheel screws to angle.
- the drive output flange fastening nut must be

tightened (if not done during overhaul) to a
87026 torque of 465 Nm (46.5 kgm) after fitting the
power take off group;
From inside the power take off box remove the upper nuts
(1) and the lower nuts (2). - refill the assembly with oilapretar los
tornillos/tuercas al par prescrito;of the specified
type.
OVERHAUL Dismantling the power take off group

Main box dismantling
Figure 18 Figure 21
41022
41019
Using an appropriate driver remove the shaft (2) and extract
the intermediate gear (1). Remove the o-ring from the box.
Position the complete group on rotary stand 99322205.
Block rotation of the laminar coupling (2) using the reaction
lever 99370317 (1) and with a suitable wrench unscrew the
retainer screws (3), remove the laminar coupling and the Dismantling shaft bearing with toothed wheel
flange.
Figure 22
Figure 19
41023
41020
Using suitable pliers (1) remove the retainer snap ring (2).
Unscrew the screws (1), remove the cover (2) complete with
o-ring and recover the adjuster ring (3).
Figure 20 Figure 23
41024
41021
Using eye bolt 99360503 (1) and lifter remove the shaft with Extract the ball bearing (4) using extractor 99341003 (1), grips
toothed wheel (2). 99341009 (2) and reaction block 99345049 (3).
Figure 24 Figure 27
41025 41028
Position the group in the vice, unscrew the nut (3) extract the Remove the elastic plug (1), extract the shaft (2) and remove
flange (2), unscrew the screws and remove the cover (1). the control fork (3).
Figure 25 Figure 28
41026 41029
Unscrew the screws and remove the cover (2). Recover the Position the toothed output shaft in the vice and extract the
adjuster ring. tapered roller bearing (4) using extractor 993441002 (1),
Remove the safety ring and extract the connector (1), grips 99341009 (2) and clamp 99341015 (3).
unscrew the electric transmitter.
Oil pump removal
Figure 26
Figure 29
41027
60241
Apply extractor 99341002 (2) with grips 99341016 (1) and Extract the shaft complete with gear (3) from the oil pump (4).
extract the toothed output shaft (3). Unscrew the pump retainer screws (1) and remove it from the
Remove the gear cog (4). cover (2).
Oil pump assembly
Figure 30 Figure 31
71568
Fit the roller bearing (2) to the shaft of the driven gear (1).
With the press, push on the gear (1) to fit the roller bearing
(2) into the pump body (3).
71567
Figure 32
Remove the screws (4) and remove the cover (3) from the
pump body (1).
Extract the gear shafts (5 and 6) from the pump body (1).
With a suitable extractor remove the roller bearing (2) from
the pump body (1).
Cleaning and checking components

After dismantling, immerse all parts except for bearings into
a bath containing water and soda heated to 80  85C until
all traces of oil have dissolved.
Using a metal brush remove any deposits from the parts as
well as traces of Loctite and mastic sealant from coupling
surfaces, taking care not to cause damage.
Repeat the bath and then dry the components with
compressed air.
Using a metal brush power tool on the bench eliminate any
traces of Loctite and mastic sealant from screw threads.
To thoroughly clean the bearings they should be immersed in
71569
petrol and cleaned with a brush.
Dry the bearings with compressed air, taking care not to rotate
the bearings while doing so.
Fit in the pump body (3): the gear (6) such that the end of
Lubricate the bearings with oil of the same type used for the the shaft engages with the corresponding space in the shaft
gears. (2) of the driven gear (1) and the gear (7).
Holding the bearings tightly in the hand, rotate them slowly in
both directions. There should be no roughness or noise when
rotating. The gears must be lubricated previously.
Inspect the rollers and cages, and the inner and outer races for
wear.
Check all parts to decide whether they can be reused or have On the pump body (3), position the cover (4), fit the screws
to be replaced. (5) and tighten them to the specified torque.
When moving the oil pump, take care that the shaft
(2) of the driven gear does not disengage from the
shaft of the gear (6).
Figure 33 Figure 35
60241
41036
Position the oil pump (4) on the lower cover (2) and fasten
it to the same with the screws (1), tightening to the specified Using a thickness gauge (2) measure the clearance (1)
torque. between bearing and the seat of the elastic safety ring, then
choose the ring that assures the least play possible.
When moving the lower cover (2), take care that the Power take off group assembly
shaft of the driven gear (3) does not disengage from
the shaft of the oil pump gear. Figure 36
41028
Position the box in the vice.

Shaft bearing with toothed wheel assembly Fit the fork (3), fit the shaft (2) and fit the elastic plug (1).
Figure 34
Figure 37
41035
41037
Heat the inner race of the bearing (2) to ~ 80C and fit it to
the shaft (1). Heat the inner race of the bearing (2) to ~ 80C and fit it to
Allow to cool before proceeding to the next operation. the toothed shaft (1).
Figure 38 Figure 39
41038 41040
In the box, fir the gear (3) complete with sliding coupling (2), Fit the bearing outer race (1).
insert the toothed shaft (1).
Figure 40
41039
POWER TAKE OF GROUP SECTION

Drive output shaft tapered bearing adjustment
Figure 41 Figure 43
41041 41043
With a suitable driver fit the O-ring (1) into the cover (2), Apply the plates 99363241 (3) to the outer race of the
apply LOCTITE 510 to the surfaces, fit the cover (2) and fasten bearing, fasten the screws (2) to torque of 18 Nm (1.8 kgm)
the screws to a torque of 18 Nm. Fit the flange (3) and tighten corespnding to an axial load of∽ 250 Kg, turn the output shaft.
the nut by hand (4). Using the gauge (1) measure the distance between the resting
surface and the bearing outer race.
The value measured will correspond to the thickness of the
adjuster shim.
The nut (4) must be tightened to a torque of 380 Nm

(38 Kgm) on the vehicle, after having fitted the power
take off to the main box.
The choice of adjuster shim must be made by
rounding off.
Example: measured value mm 6  6.04, choose
the 6 mm shim;
value measured mm 6.05  6.09,
choose the 6.1 mm shim.
Figure 44
Figure 42
ASTRA
41044
Fit the adjuster shim (1), apply LOCTITE 510 to the surface
41042 (2), fit the cover (3) and fasten the screws to a torque of 18
Remove the box (4) from the vice and turn it over. Fit the Nm (1.8 kgm).
roller bearings (3), the shoulder ring (2) and tapered roller Replace the o-rings on the connectors (2-12, Figure 3) then
bearings (1) to the shaft. fit them and position the safety rings (1-13, Figure 3), fasten
the transmitter (7, Figure 3).
Main box assembly
Figure 45 Figure 48
41045
Slightly heat the seat (⇓) for the ball bearing on the box and
fit the shaft (1) with toothed wheel complete with bearing..
41048
PARTIAL SECTION OF BEARING AND SHAFT WITH

TOOTHED WHEEL
Ball bearing adjustment
The value “C” of the adjuster shim is given by the formula A
—B=C
Figure 46
If the measured value “C” is equal to the nominal

thickness of the adjuster shim (see table on page 4)
fit the corresponding shim.
If instead “C” is different, fit the adjuster shim of a
smaller value.
Example: ”C” = mm 4.14  4.11, fit the 4.1 mm shim.
41046
Using the gauge (1) measure the distance (A, Figure 48) on
the main box (2).
Figure 49
Figure 47
ASTRA
41049
Fit the intermediate gear (3) in the box after having replaced
41047
the o-rings (1).
Using the gauge (1) measure the distance (B, Figure 48) on the
bearing cover (2).
Figure 50
The screw (2) has a left-hand thread.
Remove the lower cover complete with oil pump.
Figure 52
41020
Fit the adjuster shim (3), apply LOCTITE 510 to the cover
contact surfaces, fit the cover (2) complete with o-rings and
fasten the screws (1) to a torque of 22 Nm (2.2 kgm).
Use tool SP 2481 shown on page 8 to fit the o-ring 41019

on the cover (2) and on the opposite side of the box.
Fit the coupling (2) with the flange, lock rotation with reaction
lever 99370317 (1) and tighten the screws (3) to a torque of
95 Nm (9.5 Kgm) 1st stage.
Figure 51
Figure 53
In the event the shoulder screw (2) of the oil pump (4) gear
has been removed from the box (1), determine the thickness
of the adjuster shim (3) proceeding as follows: 41050
Provisionally fit the lower cover complete with oil pump. Apply tool 99395216 (1) to the socket wrench and tighten the
Insert the screw (2) without washer (3) in contact with the screws by a further 60 2nd stage.
driven gear (4).
With a thickness gauge measure the distance between the
underside of the screw head (2) and the box (1), distanceA.
Remove the screw (2), apply LOCTITE 242E to the thread, fit
a shim (3) and retighten the screw.
S=A+B
where A is the measured distance
B = 0.3 ± 0.1
corresponding to the distance between the end of the screw (2)
and the driven gear (4).
Tighten the screw (2) to the specified torque.

TRANSMISSION
ZF 16Sxx20
SECTION 6
HD9 Euro5 SECTION 6 TRANSMISSION ZF 16Sxx20 1
SECTION 6
Transmission ZF 16Sxx20
Page
DESCRIPTION 3
- Standard version 4
- Version with Intarder 4
- Identification plate 5
- Gears layout diagram 6
- Manual transmission assembly drawing - longitudinal
section 7
PNEUMATIC CONTROLS DIAGRAM 8
- Operation (see figure on previous page) 9
- Servoshift 10
- Synchro protection 11
COOLING SYSTEM WITH RADIATOR 12
- Oil circulation diagram 13
DIAGNOSTICS 18
EQUIPMENT 23
TRANSMISSION OIL CHANGE 27
GENERAL 27
- Version without Intarder 28
- Drainage 28
- Filling 28
- Version with radiator 29
- Drainage 29
- Filling 29
2 TRANSMISSION ZF 16Sxx20 SECTION 6 HD9 Euro5
- Version with Intarder 30 GEARSHIFT OVERHAUL 41

- Drainage 30 - Servoshift gearbox control 41
- Filling 31 - Removal 41
- Final operations 31 - Disassembly 41
TRANSMISSION REMOVAL-REFITTING 32 - Assembly 43
GENERAL 32 - Refitting 45
- Safety instructions 32 - Epicyclic reducer (G.R.E.) rear box removal 47
- Vehicle preparation 32 - Epicyclic reducer (G.R.E.) removal 48
- Very heavy parts 32 - Epicyclic reducer disassembly 49
- Hazardous and/or polluting substances 32 - Epicyclic reducer unit (G.R.E.) assembly 51
- Specific safety instructions 32 - Epicyclic reducer box (G.R.E.) assembly 53
DESCRIPTION OF OPERATION 33 - Epicyclic reducer unit rear box refitting (G.R.E.) 54
- Preliminary operations 33 - Gear box disassembly 55
- Removal 33 - Drive input cover disassembly 55
- Versions with cooling radiator 34 - Oil pump 56
- Versions with intarder and separate heat - Clutch bell removal 56
exchanger 34
- Clutch bell disassembly 56
- Versions with intarder and integrated heat
exchanger 35 - Shafts disassembly 57
- Inspections and checks 37 - Main shaft disassembly 59
- Refitting 37 - Drive input shaft disassembly 62
- Final operations 38 - Driven shaft disassembly 63
REMOVING AND REFITTING THE TRANSMISSION - Inspections 63
OIL RADIATOR 39
- Synchronisers 64
GENERAL 39
- Driven shaft assembly 64
- Drive input shaft assembly 65
- Main shaft assembly 66
- Main shaft adjustment 68
- Gear box fitting 69
- Splitter control fork adjustment 70
- Clutch bell assembly 71
- Drive input cover assembly 71
- Removal 40
- Main shaft bearing end float adjustment 72
- Driven shaft bearing end float adjustment 73
- Refitting 40
- Splitter control unit assembly 74
DESCRIPTION The servoshift is a device consisting of a mechanical/pneumatic

The ZF 16 S xx20 gear shifts in the T.D. (direct drive) or T.O. module and a double action cylinder.
(Multiplied) versions consist of: This device has the following advantages:
- a central box containing the main shaft, the input shaft, the - faster gear selection and engagement with less effort;
transmission shaft and the gears of the four forward gears - abates the control linkage vibrations reducing the noise;
and one reverse gear;
- less synchroniser stress.
- a rear box containing Epicyclic reducer unit (G.R.E.). Its
function is to double the number of forward gears by using The device functions mechanically in the case of failure on the
epicycling helical gears;” in this way a gear selection range pneumatic system.
is obtained that, starting from the four input gears, offers The gear box is fitted with a synchro protection device.
eight different ratios in output (four normal gears and four
reduced gears); It allows the servoshift pneumatic supply to engage the gear
only after the clutch pedal has covered 70% of the
- a front box containing the multiplier unit (splitter) that disengagement stroke.
permits a further double selection for each of the eight
forward gears and for the reverse gear. It consists of a solenoid valve controlled by a proximity switch
on the clutch disengagement control master cylinder.
The ”splitter” therefore halves the scaling between two
successive ratios and each gear is divided into a slow ratio (L The gear box can be equipped with an electro-pneumatically
= slow ratio) and a fast ratio (S = fast ratio). controlled intarder.
Therefore these gearboxes have sixteen forward gears with The intarder is mounted at the gearbox output, and has an heat
finely tuned ratios that can be engaged in succession, and two exchanger.
reverse gears.
Lubrication is by means of a gear pump. For further information regarding the version with
intarder, see Section 8 - Retarder.
The double H type gear control has a pneumatically controlled
”servoshift” device for better selection and gear engagement.
Standard version
Figure 1
342B006001R
1. Gear selection actuator - 2. Servoshift actuator - 3. Servoclutch actuator - 4. Epicyclic reduction gear actuator
Version with Intarder
Figure 2
357A006002R
1. Gear selection actuator - 2. Servoshift actuator - 3. Servoclutch actuator - 4. Epicyclic reduction gear actuator - 5. Intarder -
6. Integrated heat exchanger
Identification plate
Figure 3
342B006002R
A. Type of transmission (ECOSPLIT 4 - 16 S xx20 TO or TD) - B. N. drawing ZF - C. N. progressive production -

D. N. IVECO drawing for spare parts - E. Gear transmission ratioo - F. Tachometer transmission ratio - G. Type of P.T.O. -
H. P.T.O transmission ratio. - I. Oil quantity with gear dry - L. Denomination of ZF lubricants list
Gears layout diagram

Figure 4
Direct drive (T.D.)
A 4-gear part with splitter Epicycloidal unit
342B006003R
Figure 5
Multiplied (T.O.)
A 4-gear part with splitter Epicycloidal unit
342B006004R
1. Wheel always gripped slow splitter - 2. Wheel always gripped fast splitter - 3. Gears torque 3rd - 7th gear -
4. Gears torque 2nd - 6th gear - 5. Gears torque 1st - 5th gear - 6. Reverse gears - 7. Epicycloidal unit
Manual transmission assembly drawing - longitudinal section

Figure 6
342B006005R
1. Clutch shaft - 2. Wheel always gripped slow splitter - 3. Wheel always gripped fast splitter -
4. Gears torque 3rd - 7th gear- 5. Gears torque 2nd - 6th gear - 6. Gears torque 1st - 5th gear - 7. Reverse gears -
8. GRE epicycloidal unit coupling sleeve - 9.GRE epicycloidal unit - 10. Countershaft - 11. Main shaft -
12. Splitter selection sleeve - 13. Lubrication pump
PNEUMATIC CONTROLS DIAGRAM

Figure 7
342B006006R
1. Splitter control selector - 2. Double Reed contact - 3. APU - 4. Dual control valve - 5. G.R.E control cylinder -
6. Reverse gear switch - 7. Neutral gear switch - 8. Pneumatic supply - 9. Servoshift control cylinder
Operation (see figure on previous page)

The vehicle pneumatic system feeds, through the A.P.U (3), the gear services socket (8).
The Splitter control selector (1) and the servoshift actuator cylinder (9) are supplied from the services socket through an integrated
solenoid valve.
The servoshift is piloted by an integrated solenoid valve only if this receives consent from proximity switch Reed 2 mounted on the
clutch master cylinder (2). The proximity switch gives consent to the integrated solenoid valve when the clutch pedal has covered
70% of the clutch disengagement stroke.
Splitter control (gears slow range- gears fast range) and the epicycloidal reduction unit are pneumatic and integrated in the gear con-
trol lever.
With the splitter engagement selector (1) , through the dual control valve (4), the range is pre-selected: L (slow) or V (fast).
The splitter is piloted by the integrated solenoid valve .only if this receives consent from proximity switch Reed 2 mounted on the
clutch master cylinder (2). The proximity switch gives consent to the integrated solenoid valve when the clutch pedal has covered
70% of the clutch disengagement stroke
The epicycloidal unit engages or disengages automatically upon passage from 1a H to 2a H and vice-versa.
A switch (6) on the gear control switches on the reverse gear light when this is engaged. On the gear control cover there is a switch
(7) to indicate gear in neutral. Another switch (not shown) on the epicycloidal reduction unit control cylinder (5) , switches on the
warning light in the cab ( with tortoise symbol) when the Epicycloidal reduction unit is engaged.
Servoshift
The servoshift is a device consisting of a mechanical/pneumatic module and a double-acting cylinder.
It operates during the engagement of the separate gears in the longitudinal movement of the gear control lever.
When the clutch is pressed to change gear, air under pressure is sent through the pneumatic servo clutch to the servoshift device
inlet union (6).
The piston (5), moved by the valve control lever (1), feeds compressed air to the cylinder (7) which turns the gear engagement
lever (2) in the same direction as the driver in the cab moves the tie-rod mounting lever (9) through the gear lever, making the axial
movement of the gear engagement rod easier.
At the end of the useful stroke the discharge gap (4) is opened and the manoeuvre finishes, whilst a thrust spring (8) brings the device
to neutral position.
Figure 8
61225
1. Control valve lever - 2. Gear engagement lever - 3. Driving roller - 4. Exhaust union - 5. Piston - 6. Feed union -
7. Cylinder - 8. Thrust spring - 9. Gear tie-rod mounting lever.
Synchro protection
The gear shifts on vehicles with F3B engine have a synchro protection device .
This allows servoshift pneumatic supply to engage gears , only after the clutch pedal has covered l 70% of the disengagement stroke.
It consists of a solenoid valve controlled by a proximity switch located on the master clutch disengagement master cylinder .
Figure 9
HD9ST0036MR
1. Push rod - 2. Piston - 3. Magnetic ring
S1 Proximity switch for deactivating the Cruise Control

S2 Proximity switch for protecting the gearbox synchronisers
A Pneumatic pressure from the distributor
O Hydraulic pressure to the servo clutch
Switch S2 closes when piston (2) stroke is 21.5 mm equal to 70% of the clutch pedal’s disengagement stroke, corresponding to when
the servoshift starts working.
SPECIFICATIONS S1 S2
Voltage V 48 max
Current:
min mA 5 5
max mA 400 700
Power W 10 max 20 max
Permanent current mA 250 max 700 max
COOLING SYSTEM WITH RADIATOR
Transmission can be equipped with an oil cooling system.

The radiator has a thermostatic switch to activate the electric fan.
Figure 10
HD9ST0037MR
1. Radiator-transmission oil delivery - 2. Check valve - 3. Transmission-radiator oil return - 4. Check valve -
5. Thermostatic sensor - 6. Electric fan - 7. Radiator
Oil circulation diagram
Figure 11
5. Transmission - 6. Radiator
The position of each check valve along the pipe depends on the type of system.

GEARBOX
Type Manual
Weight 300 kg
Gears 16 forward gears

2 reverse gears
Control of the four main

gears Mechanical
G.R.E. * control Pneumatic
”Splitter” control Pneumatic
Power take off On request
Gear engage:
Forward gears Free ring type synchroniser

Single cone Bk type 1st - IInd - IIIrd - IVth - Vth -
VIst gear
Reverse Rapid engage
Anti-disengage Sliding sleeve retaining by:

pawls and springs
Gears Helical teeth
* G.R.E. = Epicyclical Reducer Group

TD = Truck Direct Drive
TO = Truck Over Drive

GEARBOX TD TO
Gear ratio
1st 16.41 13.80
2nd 13.80 11.54
3rd 11.28 9.49
4th 9.49 7.93
5th 7.76 6.53
6th 6.53 5.46
7th 5.43 4.57
8th 4.57 3.82
9th 3.59 3.02
10th 3.02 2.53
11th 2.47 2.08
12th 2.08 1.74
13th 1.70 1.43
14th 1.43 1.20
15th 1.19 1.00
16th 1.00 0.84
1st reverse 15.36 12.92
2nd reverse 12.92 10.80
Type of oil
Quantity:
first filling
16 S 1630 1 13.4
16 S 2230/2530 1 15.4
periodical replacement
16 S 1630 1 12
16 S 2230/2530 1 14.4
Primary and secondary shaft bearings tapered rollers
Motion output flange assembly tempera-

70 C Max.
ture
Secondary shaft gears assembly tempe-

rature 160 - 180 C
TD = Truck Direct Drive

TO = Truck Over Drive

GEARBOX
Primary and secondary shaft fixed hub and

bearings assembly temperature 100
Axial play: with adjuster ring without adjuster ring

- G.R.E.* planet gear shaft bearing 0 - 0.1 mm 0 - 0.26 mm
- G.R.E.* fixed hub snap ring 0 - 0.1 mm
- secondary shaft bearing snap ring 0 - 0.1 mm
Axial play of drive input shaft, first, second

and third gear 0.2 mm minimum
Fourth gear axial play 0.05 mm minimum
Axial play between planet gear spider and

G.R.E.* planet gears 0,4 - 1.3 mm
Shaft bearings axial play: primary and se-

condary shafts, drive input side 0,0 - 0.1 mm
Primary shaft rear bearing snap ring axial

play -0,05 - 0,05 mm
Synchroniser rings wear limit check quota:

- first/second gear 1.5 mm at 50 Nm (5 kgm)
- third/fourth gear 0.8 mm
- G.R.E. * 1.2 mm
Reverse drive gear axial play 0,4 - 1.5 mm
Shafts half-rings axial play or preload: pri-

mary and drive input from -0.05 to +0.05
* G.R.E. = Epicyclical Reducer Group

Print 603.93.373

GEARBOX
Value for play adjustment of splitter control fork
runners on corresponding sliding coupling -
Play of fork runners in corresponding seats in sliding

couplings 0,6 - 1.2 mm
O-ring fitting value on double lip of rear cover 9 ± 0.1 mm
Quota di montaggio rotore pompa olio 23 mm

DIAGNOSTICS
Main operating troubles of the gearbox are the following:
1 - Noise
2 - Spontaneous speed disengagment and uneven engagement
3 - Difficult and rough speed engagement
4 - Faulty or inefficient Pneumatic system
1 NOISE
Too much backlash of gears Check the gearbox and replace the gears worn out
YES
NO
Gears, bearings, synchronizer rings and coupling el- Replace the shaft and the driven disc, if required.
ements worn out. YES
NO
Inadequate oil level in the box Top up with the specified oil to the required level.
YES
SPONTANEOUS DISENGAGEMENT
2 OR UNEVEN ENGAGEMENT OF
GEARS
Uncorrect engagement operation Engage the gears to bottom before releasing the clutch
YES pedal.
NO
Forks broken Remove the gearbox, check the elements and replace
YES where required.
NO
Synchronizer rings worn out. Check the engaging gears and sliding sleeves, replace
YES those worn out, replace the synchronizer rings.
(continue)
Faulty operation of the E.R.U. Check and replacer the parts worn out
YES
3 DIFFICULT AND ROUGH GEAR

ENGAGEMENT
Rod forks bound. Remove the gearbox and find cause of binding; carry
YES out the required repair operations.
NO
Move of sliding sleeves hindered. Check and repair

YES
NO
Not suitable type of oil in the box Drain the oil and fill in with specific oil.
YES
NO
Clutch engagement missing Adjust or replace the control device

YES
4 PNEUMATIC CONTROL SYSTEM

FAULTY OR INEFFICIENT *
Air pipe fittings faulty Check pipe fittings and replace where required.
YES
NO
Air pipe bent and/or squeezed. Replace the pipe.

YES
Air leaks from the pipe Check that there are no leaks from pipes and pipe fit-
YES tings; use an acoustic tester or suds. Replace or seal
where required.
NO
Air leaks from the pressure reducing valve. Replace the valve or the sealing rings.
YES
NO
Faulty adjustment of the pressure reducing valve. Check the valve pressure. Replace where required.
YES
NO
Air leaks from the inlet valve. Inlet valves not operating. Check the inlet valves. Replace the valves or the valve
YES sealing rings where required.
NO
Air leaks from the control cylinders. Replace the gaskets and the sealing rings in the control
YES cylinder.
* Checks are to be carried out with the engine off and air tanks filled up.
TIGHTENING TORQUES
Figure 12
357A006003R
357A006004R
TORQUE
PART
Nm kgm
1 Threaded M24 caps on gearbox 60 6.0
2 Oil vapour breather 10 1.0
3 M26 screw for interlock 70 7.0
4 Theaded M18 cap on clutch bell 35 3.5
5 Clutch bell M10 fastening screws 50 5.0
6 Motion input cover pipe M8 fastening screws 32 3.2
7 Motion input cover M10 fastening screws 46 4.6
8 M18 threaded caps on gear box 35 3.5
9a Gears control box M8 fastening screws 23 2.3
9b Gears control box M8 fastening screws 23 2.3
10 Screws to fasten valves block to gear control box 23 2.3
11 Neutral switch on valves block 45 4.5
12 Switch on valves block 45 4.5
13 Oil pump cover Torx M6 fastening screws 10 1.0
14 G.R.E.* box M10 fastening screws 50 5.0
15 Splitter control switch 45 4.5
16 Splitter control valve M6 fastening screws 9,5 0.9
17 Rod positioning push rod 50 5.0
18 M16 lock nut to fasten splitter control rod to plunger 150 15.0
19 Pulse transmitter 45 4.5
20 M24 threaded cap on G.R.E.* box 60 6.0
21 Motion output flange rear cover fastening M10 screws 46 4.6
22 Screws to fasten cover pre-set for PTO 79 7.9
23 M10 threaded cap on G.R.E.* box 15 1.5
24 Motion output flange M12 fastening screws 120 12.0
25 M24 screw pins for G.R.E.* control fork connection 250 25.0
26 M16 lock nut fastening G.R.E.*control rod to plunger 150 15.0
27 G.R.E* cylinder M10 fastening screws 46 4.6
28 Rod positioning push rod 50 5.0
29 Clutch disengagement bearing control fork support fastening screws 115 11.5
30 Gearbox switch 45 4.5
31 Control unit fastening screws 23 2.3
Gear box threaded caps 23 2.3
G.R.E.* Epicyclic reduction gear

 Apply LOCTITE 574
 Apply LOCTITE 241
EQUIPMENT
TOOL N˚ NAME
99305121 Hot air tool
99322225 Group support (applied to stand 99322205)
99341003 One-way bridge
99341015 Clamp
99341018 Pair of brackets with hole
99341019 Link rod pair with grips

EQUIPMENT
TOOL N˚ NAME
99341020
Link rod pair with grips
99341021
99341024
Grips
99341025
99345097 Reaction tool to extract sun gear and to fit main shaft oil pipe
99360502 Rings for removing and replacing reducer group
99370006 Grip for interchangable driver
99370007 Grip for interchangeable driver

EQUIPMENT
TOOL N˚ NAME
Driver for fitting gasket and/or bushes on gear selector box

99370113
99370154 Splitter control fork adjustment tool
Tool for fitting gasket to transmission front casing (use with

99370420 99370006)
99370449 Primary shaft extraction and insertion tool
99370565 M10 eyebolts (2) to lift different units
Support for sustaining transmission during removal and replacement

99370629 in vehicle
99371061 Brackets to secure gearbox on stand

EQUIPMENT
TOOL N˚ NAME
Driver for inserting bearing outer races (91-134)

99374093 (use with 99370007)
99374221 Tool for fitting gaskets on rear cover
99374370 Tool for fitting oil deflector to direct drive shaft (use 99370006)
99395604 Comparator (0 - 10 mm)

TRANSMISSION OIL CHANGE Hazardous and/or polluting substances
GENERAL The operation described requires handling of

Safety instructions Do not touch with the hands.
Before carrying out any operation make certain to Collect and dispose of used lubricants and fluids,
have taken all precautions and clarified all aspects according to the laws and local regulations.
Observe all the general recommendations to carry Specific safety instructions

and surrounding parts, could be very hot.
Vehicle preparation

Figure 13
2371801

short circuits;
DESCRIPTION OF OPERATION Filling

Proceed as follows:
Version without Intarder
Figure 16
Drainage
Proceed as follows:
Figure 14
342BNM009L
- fill with the required lubricant through the level/filler plug

342BNM009L (1) until it spills out;
- clean the level/filler plug zone (1) and then remove the - clean the level/filler plug, check that the thread is in good
plug; condition, replace the o-ring and close the plug.
Final operations
- carry out a trial run and then check the level again;
- if necessary top up with the lubricant prescribed until it
comes out through the hole; repeat the trial run and check
the level again.
342BNM011L
- arrange a container of suitable capacity, remove the drain

plug (1) and drain off the lubricant;
- clean the plug, check that the threading is in good condi-
tion, replace the sealing ring with a new one and close the
drain plug.
Version with radiator Figure 19

Drainage
Proceed as follows:
Figure 17
HD9ST0041MR
- have a suitably large container handy, disconnect the oil

delivery pipe to the radiator DOWNSTREAM of the
check valve (see arrow) and empty the radiator
completely;
- reconnect the pipe.
342BNM009L
Filling
- clean the level/filler plug zone (1) and then remove the Proceed as follows:
plug;
Figure 20
Figure 18
342BNM009L
342BNM011L
- fill with the required lubricant through the level/filler plug
(1) until it spills out;
plug (1) and drain off the lubricant; - clean the level/filler plug, check that the thread is in good
condition, replace the o-ring and close the plug.
- clean the plug, check that the threading is in good condi-
tion, replace the sealing ring with a new one and close the Final operations
drain plug.
Proceed as follows:
the level again.
It is necessary to check the level and topping up

several times until the radiator is completely full.
Version with Intarder Only the version with separate exchanger

Drainage
Figure 23
Proceed as follows:
Figure 21
HD9ST0042MR

delivery pipe from the retarder (see arrow) and empty
the exchanger completely;
342BNM009L
- clean the level plug zone (1) and then remove the plug;
Figure 24
Figure 22
357ANM102L

plugs (1) and (2) and drain off the lubricant;
357ANM104L
- clean the plugs, check that the threading is in good condi-
tion, replace the o-ring with a new one and close the drain
plugs; - arrange a container of adequate capacity;
- loosen the fastening screws (1) and remove the lid (2);
- remove the filter (3) from the lid;
Lubricate the o-rings of the filter (4) when refitting.
- refit the filter following the operations in reverse.

Filling Final operations

Figure 25 - carry out a trial run and then check the level again;
the level again.
In the case of a separate exchanger it will be necessary

to check the level and topping up several times until
the exchanger is completely full.
357A006100R
- fill with the specified lubricant through the filler plug (1)
until it flows out from the level plug (2);
The unit may be fitted through the level plug (2),

except for first filling after overhauling.
- clean the filler plug and the level plug, check that the thread
is in good condition, replace the o-ring and close the plugs.
TRANSMISSION REMOVAL-REFITTING Very heavy parts
GENERAL The following operation requires handling of heavy

Safety instructions equipment and accessories.

operation. If in doubt, consult a more experienced Hazardous and/or polluting substances
Observe all the general recommendations to carry The operation described requires handling of
out maintenance jobs correctly. hazardous and/or polluting substances
Vehicle preparation

the parking brake and apply the warning signboards. Specific safety instructions
Safety component.
Tighten the fastening bolts to the specified torque.
Figure 26
2371801

short circuits;
DESCRIPTION OF OPERATION - For versions with steering pump on transmission only:

disconnect the intake (1) and delivery (2) pipes from the
Preliminary operations emergency steering pump.
Proceed as follows:
Figure 28
- tip the cab;
- disconnect hydraulic and electrical connections of power
take-off and any facility mounted on the transmission;
- remove any outfitting compoents that prevent access to
the transmission;
- drain off the lubricant as described in the TRANSMISSION
OIL CHANGE chapter in this Section.
- For versions with steering pump on transmission only:
drain off the power steering fluid as described in
HYDRAULIC FLUID CHANGE chapter in Section 15.
- For versions with Intarder and integrated water-oil heat
exchanger: drain off the engine coolant as described in
COOLANT CHANGE chapter in Section 3.
220073
- Only for versions with 4-axle front wheel drive: remove
the second axle operating as described in Chapter - Unscrew the fixing screws (1) of the cradle (2).
REMOVAL-REFITTING of SECTION 12.2.
- disconnect the propeller shaft from gearbox outlet as Figure 29
described in the PROPELLER SHAFT REMOVAL-REFIT-
TING chapter in Section 10.
- For front-wheel drive versions only: disconnect the front
wheel-drive propeller shaft from gearbox outlet as descri-
bed in the PROPELLER SHAFT REMOVAL-REFITTING
chapter in Section 10.
Removal
The removal of the tear/snap clips is not described in

detail. These clips must be cut or released and then
restored while refitting to ensure the correct fasten-
ing of the elements to be hold.
342B006007R
Proceed as follows:
- unscrew the fastening screws (arrow) of the servo-clutch
Figure 27 and remove it from the transmission fastening it for the
moment to the chassis
220084
Versions with cooling radiator Figure 32
Figure 30
220085
- disconnect the lubricant delivery (1) and return (2) pipes

to/from the exchanger.
During this operation,you might find some oil leaks.
Versions with intarder and separate heat 220087
exchanger
- disconnect the electric sensor and actuator connector
Figure 31 from the intarder control unit (1);
The control unit is fitted on the heat exchanger and

located on the chassis near the air cleaner.
DO NOT disconnect the vehicle electric interface
connector from the control unit.
- release the wiring from the chassis and position it on the

retarder.
The wiring remains fitted on the retarder because the

sensors cannot be disconnected from the respective
wire.
220086
- Disconnect and remove the lubricant delivery (1) and

return (2) pipes from the heat exchanger;
Versions with intarder and integrated heat Figure 34

exchanger
Figure 33
220088
- Disconnect and remove the engine coolant delivery (1)

and return (2) pipes;
220089
- disconnect the vehicle electric interface connector from

the intarder control unit (1).
DO NOT disconnect the electric sensor and actuator

connector from the control unit.
The wiring remains fitted on the retarder because the
sensors cannot be disconnected from the respective
wire.
Figure 35
220090
- disconnect the control lever (11) for gears selection by - disconnect the electric connections:
undoing the nuts (9, 10); - servocontrol consent solenoid valve (4)
- splitter engaged indicator (5);
- disconnect the pneumatic connections:
- reverse gear switch (6);
- transmission services supply (1)
- low range engaged indicator (7);
- splitter control (from gear leverI (2):
- neutral position indicator (8);
- midiservo feed on clutch pedal (3)
Figure 36 Figure 38
342B006008R
220074
- disengage electrical wiring separating it from the strap; - unscrew engine connection screws (1), bring the assem-
bly back to free the main shaft from the clutch and take
out the assembly from below.
Figure 37

Proceed as follows:
- check integrity of connecting flanges;
- check intactness of brackets and fastening bolts, if
required replace any damaged parts
- check the flexible mounts: if necessary replace damaged
component.
220091 - check perfect intactness of electrical wiring and relevant
connections.
- appropriately support the unit to keep it horizontal while
it is being retracted.
Refitting
- For versions with upper rear mount only: loosen the faste- Refit by reversing the removal sequence.
ning screws (see arrow) of rear mounts to chassis;
Final operations
Proceed as follows:
- For four-axle drive versions only: refit the front interme-
diate axle as described in the REMOVAL-REFITTING
chapter in Section 12.2.
- For front-wheeldriveversions only:refitthefrontwheel--
drive propeller shaft as described in the PROPELLER
SHAFT REMOVAL-REFITTING chapter in Section 10;
- refit the propeller shaft to the gearbox outlet as descri-
bed in the PROPELLER SHAFT REMOVAL-REFITTING
exchanger: top up the engine coolant as described in
top up the power steering fluid as described in
HYDRAULIC FLUID CHANGE chapter in Section 15;
- top up the lubricant as described in the TRANSMISSION
OIL CHANGE chapter in this Section;
- start the motor and check there are no hydraulic fluid
leaks from the piping;
- check the level operating as described in the USE AND
MAINTENANCE HANDBOOK.
REMOVING AND REFITTING THE Very heavy parts

TRANSMISSION OIL RADIATOR Not applicable
GENERAL
Safety instructions
Before doing any work, make certain that all the pre-
cautions have been taken and all aspects concerning The job described below entails handling dangerous
the safety of the people involved in the work are com- and/or polluting substances.
pletely clear. If there are any doubts consult someone Do not touch with hands.
who has more experience. Do not let them come into contact with painted
Read the instructions given at the beginning of this parts.
Manual. Collection and disposal of spent lubricant oils and
Also comply with all the general recommendations fluids must comply with existing standards and laws.
for correct maintenance work.
Vehicle preparation Specific safety instructions

Not applicable
Take the vehicle to a suitably level and solid surface,
switch the engine off, take the ignition key out, engage
the parking brake and affix the indication signs.
Figure 64
2371801
Turn the battery isolator switch off or disconnect the

battery terminals (see arrow) to ensure against any
short circuit risks.
At the end of the operations, restore vehicle functio-
nality.
DESCRIPTION OF THE OPERATION - disconnect:

- the thermostatic sensor connection (3);
Preliminary operations - the electric fan connection (4);
Not applicable - remove the fixing bolts (see arrow) and remove the
radiator.
Removal
During this operation, you might find some oil leaks.
Removal of the tear/pressure fixing straps is not
detailed. This means that such straps have to be
cut/released and subsequently restored when
reassembling to ensure that the components that
have to be held in place are secured correctly.
Not applicable
Perform the following: Refitting

Start refitting proceeding in the opposite order to removal.
- place a suitably large container under the radiator,
disconnect the top coupling (1) from it and drain the fluid Final operations
from the pipe; Perform the following:
- disconnect the bottom coupling (2) from the radiator and - fill with lubricant as described in the CHANGING THE
drain the fluid from both pipe and radiator; TRANSMISSION OIL Chapter in this Section.
Figure 65
HD9ST0040MR
GEARSHIFT OVERHAUL Disassembly

Figure 67
Carefully wash the unit before starting the overhaul.
The specific and/or standard equipment is to be used
in the manner for which it is intended.
For easier assembly, place the removed parts in the
order of removal in the specific container.
When assembling always replace with new parts:
gaskets and seal rings, spring pins, safety plates and
springs.
Nuts and screws are to be tightened to the specified
torque with a dry and degreased thread.
For lubricant and detergents disposal observe the
specific standards.
147078
Unscrew the screws (1) and remove the servoshift (2) from
The ZF 16 S 2530 gearshift overhaul operations the gear control box.
follow, and unless otherwise indicated , they are also
valid for ZF 16 S 1630/2230 gearshifts. Figure 68
Drain the oil from the gearbox and the intarder (if present).
If present, remove the intarder from the gearbox as described
in the relevant chapter.
Servoshift gearbox control

Removal
Figure 66
147079
Remove the seal (2).

Remove the push rod (4) with the spring (5).
Figure 69
147077
Make a note of the piping assembly positions (3, 4 and 5) and

disconnect them from the gear control box (8) acting on the
fittings (2, 6 and 7) as indicated in Figure 93.
Unscrew the fastening screws (1) and remove the gear control
box (8) with the servoshift from the gear box. 147080
The servoshift device cannot be overhauled, if there Mark the fitting position of the lever (7) on the rod (6). Loosen
are faults, replace it. the nut (5) and take the lever (7) from the rod (6).
Withdraw the cup (8).
Remove:
- the valve (3) after removing the screws (4);
- the switches (l and 9) with the washers and push rods (2
and 10);
- the plug ( 13) with the washer, spring ( 12) and push rod
(11).
Figure 70 Figure 73
61229
61231
Unscrew the screws (l) and remove the upper cover (2).
Withdraw the pin (3). Remove the split ring (2)from the rod (1).
Act on the washer (4) to limit the action of the spring (5) and
Figure 71 remove the split ring (3), take out the washer (4), the spring (5)
and the washer (6).
Figure 74
61230
Remove the split ring (3) and remove the plunger (2) complete
with O-ring (1).
61232
Figure 72
Remove the split rings (1) and take out the gudgeons (2) that
clamp the actuator (4) to the rod (3).
Figure 75
61259
Unscrew the plugs (2) with the washers, withdraw the springs
(1) and remove the levers (6). 61233
If necessary take out the pins (3).
Loosen the screws (4) and remove the cover (5). Move the sleeve (1) in the direction of the arrow.
With a punch knock on the top of the lever (6) to remove it
from the bearing (3) and the gudgeon (2), releasing it from the
groove ( 4) of the rod (5).
Figure 76 Assembly
When assembling always replace the sealing elements

with new ones: rings, copper washers, flat gaskets,
split rings and needle bearings with relevant
gudgeons. Check that the springs are not broken or
slack.
Figure 79
61234
Make a note of the assembly position of the levers (2 and 3)

and remove the same from the box (4) withdrawing the rod
(1).
Figure 77
61236
In the box (4) place the clamping element (1) and the actuator
(2) as marked at removal and insert the sleeve (3) into them.
Figure 80
ASTRA
61235
With the internal puller 99348004 take out the bushing (2) and
the seal ring (1) from the box (3).
Figure 78
61235
With the appropriate tool 99370113 assemble the bushing (2)

in the box (3).
With an appropriate locking device fit the seal ring (1) in the
box (3). Lubricate inside the seal ring (1) with grease.
61236
Make a note of the assembly position of the clamping element

(1) and the actuator (2)and remove them from the box (4)
after withdrawing the sleeve (3).
Figure 81 Figure 84
ASTRA
61234
61231
Position the levers (2 and 3) in the box (4) as they were marked
at disassembly and insert the rod (1) into them. On the rod (1): position the washer (6), the spring (5),the
washer (4) and fit a new split ring (3).
Figure 82 Fit a new split ring (2).
Figure 85
ASTRA
ASTRA
61233
Move the sleeve (1) in the direction of the arrow. 61259

Fit a new needle bearing (3) and pin (2) on the lever (6). Posi-
tion the rod (5)so that the groove (4) corresponds to the Fit the cover (5) with a new seal, tighten the screws (4) and
needle (3) and the pin (2). lock to the specified torque.
Resting the lever (6) on a surface, carefully knock on the bear- Position the levers (6) on the pins (3).Tighten the plugs (2) with
ing (3) and pin (2) so they position flush with the top of the lever the new washers and the springs (1) and lock to the specified
( 6) and insert correctly into the groove (4) of the rod (5). torque.
Figure 83 Figure 86
ASTRA ASTRA
61230
61232
Fit a new seal ring (1) on the plunger (2), and fit this in the box
Clamp the actuator (4) to the rod (3) inserting the gudgeons and secure with the split ring (3).
(2) and fit new split rings (1) on them.
Figure 87 Figure 89
ASTRA
61229 147079
Insert the pin (3) in the box. Position the pushrod (4) with the spring (5) in the box (3). Refit
Mount the upper cover (2) with a new seal. Fasten the screws the servoshift (1) with a new seal (2).
(1) and lock to the specified torque.
Figure 90
Figure 88
ASTRA
147078
147080
Fasten the screws (1) and lock to the specified torque.
Complete the gear control box assembly mounting:
- the rod (11), the spring (12), the plug (13) with a new seal; Refitting
- the pushrods (2 and l0), the switches (1 and 9) with the Figure 91
new washers;
- the cup (8), the lever (7) on the rod (6) in the position
marked at removal and tighten the nut (5) to the specified
torque;
- the valve (3) and tighten the screws (4) to the specified
torque.
147077
Refit the gear control box (8), tighten the fastening screws (1)
and lock to the specified torque.
Connect the piping (3,4 and 5) to the box (8), in the same posi-
tion as before removal, acting on the fittings (2,6 and 7) as
shown in the figure.
Figure 92
61237
GEAR CONTROL BOX COMPONENTS

1. Cover - 2. Plugs - 3. Seals - 4. Gear control box - 5. Sleeve - 6. Rod - 7. Actuator - 8. Plunger - 9. Spring
Epicyclic reducer (G.R.E.) rear box removal

Figure 93
147023
Make a note of the mounting position of the piping (14) on the Loosen the fastening gudgeons (7 and 9) of the splitter control
G.R.E. control cylinder (15) and disconnect them acting on the fork without removing them.
fittings (16) as indicated in the figure.
Remove the plug (1).
Remove the push rod (2).
Remove the switch (12) with the gudgeon (11).
Remove the plastic insert (13).
Withdraw the oil piping (2).
Remove the reverse gear gudgeon (3).
Withdraw the spacer (4) on the main shaft.
Figure 94
147024
Remove the screws that fasten the G. R. E.rear box (1) to the
gearbox (2). With two screws, clamp the retaining plate (3)
to the shaft (4). With a rope and a hydraulic jack remove the
GRE box. (1) from the gearbox (2).
Remove the seal (5);
Epicyclic reducer (G.R.E.) removal

Figure 95
147025
Remove the previously loosened trunnions (2).

Loosen the screws (13) and remove the cylinder (12) with the The seal (4) is to be replaced at each assembly.
seal (10).
Loosen the nut (7) and take out the G.R.E control rod (3) and
the plunger (6) with the two seal rings (5 and 9) and the vibra-
tion damper ring (8).
Figure 96 Epicyclic reducer disassembly

Figure 98
147026
Using a puller consisting of: tie-rods 99341018 (2); axle

99341003 (1) and reaction block 99345058 (3), take the box
(5) from the GRE unit (4).
Figure 97
147028
147027 1. lntarder gear- 2. Fifth wheel bearing - 3. Synchroniser

ring - 4. Sliding sleeve- 5. Fork -
Remove the bearing (1) and the switch (2) from the box. 6. Shoes - 7. Split ring - 8. Blocks - 9. Springs -
10. Springs - 11. Synchroniser ring- 12. Coupling unit -
13. Plate - 14. Spider shaft - 15. Hub
Figure 99
147029
Extract the gear (2) from the shaft (1), using an appropriate
puller if necessary.
Remove the fork (3) with the blocks, from the sliding sleeve.
147030 147033
Remove the fifth wheel bearing (2) from the gear (1). Remove the synchroniser ring (1) and the coupling unit (2).
147031 147034
Remove the synchroniser ring (1) from the sliding sleeve hub. Remove the plate (1)
Taking care that the blocks (5) and springs (3 and 4) do not
come out from the hub , withdraw the sliding sleeve (2) from Figure 105
the hub and remove the split ring (6).
Figure 102
71117
147032
Remove the crown wheel (1) from the spider shaft (2).
Remove the hub (1)
Figure 106 Epicyclic reducer unit (G.R.E.) assembly

Lubricate the internal surfaces of the planet wheels (4,
Figure 107).
Position the gudgeons (10, Figure 107) so that the collars face
downwards.
Slide the rings (l, Figure 107) on the gudgeons (10, Figure 107).
Position the planet wheels (4, Figure 107)on the gudgeons.
Insert the needles (2, Figure 107) and press the ring (3,
Figure 107) on the gudgeons.
Lubricate the needles (5, Figure 107) and insert them into the
planet wheels.
147035 Fit the thrust ring (6).
Position the spider (9, Figure 107)so that it rests on the side of
Remove the spacer (2). the shaft.
Take out the split ring (5) and separate the crown wheel (4)
from the support (3). Carefully remove the planet wheels (4, Figure 107) with the
rings (1,3,6 Figure 107) from the gudgeons (10, Figure 107)
Figure 107 and insert them in the spider shaft (9, Figure 107).
Align the planet wheels with the holes on the speder shaft.
Fit the bearing gudgeons (10, Figure 107) in the spider (9,
Figure 107) matching the ”O” references stamped on the
gudgeons with the holes for the spring pins.
The ”O” references stamped on the gudgeons (10,

Figure 107) are to face upwards.
Figure 109
147036
Push all the spring pins (7 and 8) for the entire length inside the
gudgeons (10).
With an approptiate tool, remove the gudgeons (10) from the
spider shaft (9).
Withdraw the planet wheels (4) with the rings (1 ,3 and 6) and
needles (2 e 5) from the spider shaft (9).
Figure 108 147038
Fit the spring pins (7and 8, Figure 107) inside the gudgeons (1)
so that the apertures are rotated by 180 as shown in the figure.
147038
Withdraw the pins (7 and 8 Figure 107) from the gudgeons (1).
147035
Fit the spacer (2) on the spider shaft (1).

Fit the support (3) inside the crown wheel (4).
Insert the split ring (5) in its housing.
147039
Fit the crown wheel (4) in the spider shaft and check the gears
rotate correctly.
Before assembly lubricate the tapered surfaces of the
Figure 111 coupling units (1 and 12) with oil.
Fit the plate ( 13) taking care to mount correctly ().

Fit the coupling unit (12) and the synchroniser ring (11).
Fit the hub (15) so that the synchroniser ring projecting parts
(11) position correctly in the hub housing.
ASTRA Fit the split ring (7).
Check the clearance between split ring (7) and its housing.
The clearance is to be between 0.01 and 0.1 mm.
The split ring (7) is supplied as spare part in different

thicknesses.
13211 ASTRA
Before reassembling the synchronisers, check for wear on the

synchroniser rings (1) and the coupling units (3); with a thick-
ness gauge (2), measure the distance between the synchro- Fit the sleeve (4) observing the assembly direction and ensuring
niser ring (1) and the coupling unit (3) in two opposite points. that the projecting parts of the synchroniser ring (11) position
If the distance (X) measured is less than 1.2 mm, replace the correctly in the sleeve housings.
synchroniser ring (l) or the coupling unit (3). Insert the springs (9 and 10) and pins (8) in the hub housings
Do not confuse the checked parts (it is advised to mark them). fitting them under the sliding sleeve.
Fit the synchroniser ring (3) so that the projecting parts posi-
tion correctly in the hub housings (15).
Fit the fifth wheel bearing (2).
Assemble the gear (1), to facilitate the operation it may be Epicyclic reducer box (G.R.E.) assembly
necessary to warm the gear internal surface to ensure correct
coupling centred with the sliding sleeve (4). Figure 113
Arrange the fork (5) with the blocks (6) on the sliding sleeve
(4).
Grease the holes on the fork ().
147040
Heat the ball bearing housing (1) on the rear GRE box (2) to
~ 60 ˚C by means of hot air device 99305121 and fit the ball
bearing (1).
Figure 114
147041
Heat the bearing inner ring (16) and mount the box (17) on
the GRE unit (15) taking care to match the pins (18) with the The nut (7) is to be replaced at each assembly.
holes on the spider shaft plate ().
Insert the rod (3) in its housing in the box (17).
Apply LOCTITE 241 sealant to the threads of the gudgeons (2).
Clamp the fork (14) to the box with the 2 trunnions (2), with- Generously grease the seal rings (5 and 9) and the cylinder
out tightening to torque. internal surfaces (12).
Grease the seal (4) and fit it, using the appropriate tool. Fit the cylinder on the box and tighten the fastening screws to
Fit the seal rings (5 and 9) and the spacer ring (8) of the the specified torque.
plunger (9). If previously removed, tighten the fittings (11) to the specified
Fit the plunger (6) on the rod (3) and tighten the nut (7) to torque.
the specified torque.
Epicyclic reducer unit rear box refitting (G.R.E.)

Figure 115
147041
Install the seal (10) on the gear box.

Fit the spacer (4) on the main shaft with the collar facing down-
wards.
Insert the pipe (5) with the three oil holes facing downwards.
Fit the reverse gear gudgeon (3).
Make sure the insert (13) is in the housing.
Using eyebolts, ropes with hooks and mobile lifting unit,
arrange the rear box (9) on the gearbox (17).
Fasten the screws (8) to the specified torque.
Tighten the fork fastening gudgeons (7 and 9) to the specified
torque after applying Loctite 241 to the thread.
Assemble the push-rod (2) and the plug (1) with a new seal
ring.
Grease the gudgeon(11) and insert it in its housing.
Fit the switch (12) and tighten to the specified torque.
Connect the piping (14) on the GRE control cylinder (15) as
indicated in the figure.
Gear box disassembly Figure 118

Figure 116
147043
Loosen the screws (3) and remove the fork (4) and the hinge
pin (2). If present, remove the thrust bearing (1).
147042
Figure 119
From the gear box (1) remove:
- by hand the splitter control cylinder(5)with the seal rings
(6 and 8);
- the split ring (7);
- the nut (9);
- the plunger (11) with the double lip seal (10);
- the splitter control valve (2).
Do not dismantle the splitter control valve (2).

It cannot be overhauled, in the case of faults, replace
it.
Remove the stiffener gudgeon (3) if it has not already been

removed and replace it with an appropriate screw ro release
the control rods acting on the chain (4).
Drive input cover disassembly

Figure 117
147044
Loosen the screws (12) and remove the pipe (11).

Loosen the screws (9) and remove the drive input cover (8).
Remove the shoulder ring (4), the spring (5),the shoulder ring
(6), the adjustment ring (7) and the seal (3).
149243 Make a note of the assembly position of the seal rings

(4 and 6) because they have different dimensions.
Using ropes with hooks and mobile lifting equipment, place the
assembly on rotary stand 99322205 (1) complete with sustain-
ing support 99322225 (3) and specific brackets 99371060 (2).
Remove the adjustment ring (1) of the driven shaft. Figure 122
Remove the filter (2) and clean it with care.
Oil pump
Figure 120
147049
Apply appropriate hooks 99370565 (1) to the clutch bell (2),

with ropes and lifting equipment detach it from the gearbox (3).
147045
Clutch bell disassembly
To dismantle the oil pump : unscrew the Torx screws (5), Figure 123
remove the cover (4) from the drive input cover (l) and take
out the external (2) and internal rotor (3).
To reassemble, follow the operations in reverse.
Apply anti-corrosive lubricant on the surface of the

rotors (3 and 2).
Fasten the screws (5) to the specified torque.
Clutch bell removal

Figure 121
147050

Unscrew the switch (6) and withdraw the gudgeon (7).
If necessary remove the oil piping (2).
Remove the plug (1) complete with seal ring.
With an appropriate tool, remove the two outer rings (3) and
147046 (5) of the main and drive shafts support bearings.
Remove the cover (9) if necessary.
With the appropriate tool remove the pins (1) centring the Unscrew the plugs (8 and 10) with the seal rings.
clutch bell to the gearbox.
Unscrew the clutch bell fastening screws (2);
Shafts disassembly Figure 127

Figure 124
147051
If necessary, loosen the stiffener of the splitter rod (),

unscrew the two socket head screws (3), withdraw the splitter
control rod (2) and remove the fork (4) with the shoes from
the sliding sleeve.
Remove the drive input shaft (1).
Figure 125
148564
From the rear of the gearbox remove the oil pipe (4) from the
main shaft (3).
Insert tool 99370449 (2) in the main shaft (3)and clamp it with
the locking nut.
Appropriately clamp the rods (1) and related forks to the
main shaft.
Check that the rods have been released acting with

a suitable screw on the chain as already described.
147053
Hook tool 99370449 (2) to the lifting equipment, raise the
main shaft (3) and lock in a vice.
Move the reverse gear (1) toward the external wall of the gear- Remove tool 99370449 (2) and the rods (1).
box.
Figure 126
147054
Using eyebolt 99360502 (1), remove the driven shaft (2) from
the gearbox first making sure it is released from the main shaft
(3).
Figure 128
147055
1. Rod with R.M. fork -

2. Rod with 1st - 2nd speed fork -
3. Rod with 3rd - 4th speed fork
When removing rods and forks make a note of

correct assembly position.
Figure 129
147057
Remove the screw (1) used to block the rods.

Remove the gear shift chain (2) with spring from the gearbox.
With the appropriate tool, remove the two outer rings (4) and
(5) of the support bearings, G.R.E. side, of the main and driven
shafts.
Remove the reverse drive gear (3) with the two needle bear-
ings.
Main shaft disassembly

Figure 130
147069
1. Safety ring - 2. Half-rings - 3. Taper roller bearings - 4. Shoulder ring - 5. Ring - 6. Roller bearing cilindrici - 7. 4th gear shift -
8. Straight roller bearing - 9. Coupling unit - 10. Bushing - 11. Spacer ring - 12. Synchroniser ring - 13. Hub - 14. Spring -
15. Pin - 16. Sliding sleeve - 17. Synchroniser ring - 18. Coupling unit - 19. 3rd gear shift- 20. Needle bearing - 21. Main shaft -
22. Neeedle bearing - 23. 2nd gear shift - 24. Coupling unit - 25. Synchroniser ring - 26. Hub - 27. Pin - 28. Spring -
29. Sliding sleeve - 30. Synchroniser ring - 31. Coupling unit - 32. Bushing - 33. Needle bearing - 34. 1st gear shift -
35. Coupling unit - 36. Bushing - 37. Needle bearing - 38. Reverse gear - 39. Taper roller bearing - 40. Split ring
61190
102665
Raise the dent of the safety ring (1) and remove the half rings (2).
With an appropriate puller , remove the taper roller bearing inner
ring (3), withdraw the shoulder ring (4). Dismantle the synchroniser unit (1). Remove from the hub (3)
the sliding sleeve (2), taking care to recover the pins (5) and
Figure 132 springs (4).
Figure 135
102663
From the main shaft remove : the ring (1), bearing (2), 4th gear
shift(3), the bearing (4), coupling unit (5) and synchroniser ring 71120
(6).
Figure 133 Overturn the main shaft in a vice and remove the split ring (1).
Figure 136
102664
With a puller composed of: axle 99341003 (1), tie-rods 99341

020 (2), block 99345058 (3), grips 99341024 (6) and clamp
99341015 (5) remove from the main shaft(4): 71121
- 3 rd gear shift (12);
- coupling unit (11); Remove the reverse gear (4) and the inner ring (6) of the sup-
- synchroniser ring (10); port bearing G.RE. side, using a puller composed of : grips
- synchroniser unit (9); 99341024 (3), tie-rods 99341019 (2), axle 99341004 (1), reac-
- spacer ring (8); tion block 99345058 (7), clamp 99341015 (5).
- bushing (7).
Remove the needle bearing (13).
102666 71123
Remove the needle bearing (2) from the main shaft (1). From the main shaft (1) remove the synchroniser ring (2).
102786
71122
With the puller composed of axle 99341004 (1), reaction
block 99345058 (2), tie-rods 99341024 (3) grips 99341024
Remove the 1 st gear shift (5), the coupling unit (4) and the (5), clamp 99341015 (4) disassemble the 2nd gear shift (9), the
bushing (3) of the reverse gear bearing with a puller composed coupling unit (8), the synchroniser ring (7),the synchroniser unit
of: grips 99341024 (6), tie-rods 99341020 (8), axle 99341004 (6) and the bushing (10).
(1), reaction block 99345058 (2), clamp 99341015 (7). Remove the bearing (2, Figure 160).
102667
102665
From the main switch (1), remove the needle bearing (2), the Dismantle the synchroniser unit (1). From the hub (3) remove
coupling unit (3). the sliding sleeve (2), paying attention to the pins (5) and springs
(4): and recover them.
Drive input shaft disassembly

Figure 143
147062
1. Sliding sleeve - 2. Synchroniser ring 3. Coupling unit - 4. Pin - 5. Spring - 6. Oil seal cover - 7. Split ring - 8. Tube -
9. Gudgeon - 10. Drive input shaft - 11. Synchroniser ring - 12. Coupling unit - 13. Gear - 14. Bearing inner ring - 15. Safety ring
Unscrew the coupling unit (3) and the synchroniser ring (2). Figure 145
Figure 144
27168
147063
Remove the split ring (1) and remove the tube (2).
From the hub (1) remove the sliding sleeve (2)paying attention
to the pins (3)and springs (4), and recovering them. Remove
the oil seal cover (5).
27469 147064
Remove the safety ring (1). Remove the synchroniser ring (1).
Remove the gudgeon (2) if present.
Figure 147
Driven shaft disassembly
Figure 149
37326
27470
Remove the split ring (1) and with a puller take out the inner
Take out the coupling unit (5), the gear (6) and the inner ring ring (2) of the support bearing splitter side.
(3) of the drive input shaft support bearing using a puller com- In the same way, after overturning the driven shaft, remove the
posed of: inner ring of the support bearing G. R. E.side
- grips 99341025 (7);
The two roller bearings of the driven shaft cannot be
- tie-rods 99341021 (8): inter-changed. Take care to place them separately
- axle 99341003 (1); and mark them to avoid confusion when
reassembling.
- reaction block 99345058 (2);
- clamp 99341015 (4).
With a hydraulic press extract the gears (3, 4 e 5) from the
driven shaft.
Inspections
Gear box
The gear box and related covers are to be free of cracks.
The contact surfaces between cover and box are to be free of
damage and/or deformation. Remove any remaining sealant
from the threaded holes for the oil pump and input drive shaft
cover fastening screws.
The housings of the bearings, shafts and gear control rods are S Visually check that the friction surface is not wrinkled.
to be free of damage and not excessively worn.
Check that the holes, pipes and lubrication grooves are not Figure 151
obstructed by grease or foreign bodies.
Bearings
The roller bearings or the roller cages are to be in perfect
condition with no signs of wear or overheating.
Shafts - gears
The bearing housings on the shafts are not to be damaged or
worn. Gear teeth are not to be damaged or worn.
Hubs — sliding sleeves
Grooves on the hubs and on the sliding sleeves are to be free
of damage. The sliding sleeve is to slide freely on the hub. The
sliding sleeve positioning blocks or pins are not to be damaged
or worn. The sliding sleeve engagement teeth are to be free of
damage.
61194
Rods - forks
The forks are to be intact and the blocks are not to have an 1. Coupling unit - 2. Synchroniser ring -
end float , in the sleeve radial groove , that is more than 0.6 — 3. Compression spring - 4. Pin - 5. Hubsynchroniser -
1.2 mm. 6. Sliding sleeve
If it is necessary to remove the splitter control fork, at assembly
adjust the position on the rod as described in the relevant
chapter.
Driven shaft assembly
To assemble the driven shaft follow the disassembly operations
in reverse. The operations and assembly phases that require
Synchronisers specific fixtures, clearance checks, adjustments or special provi-
Wear conditions of the synchroniser rings and the coupling sions are described below.
unit are to be checked before assembly.
Proceed as follows: Figure 152
Figure 150
61193
147058
S Place the synchroniser ring (1) on the relevant coupling
unit (2). Heat the gears (3, 4 and 5) to approx. 170˚ C using hot air
Turn the synchroniser ring (1) to obtain correct coupling device 99305121 and with a press drive them onto the shaft
on the coupling unit (2). .
S With a thickness gauge, check on two opposite diametrical
points the distance A. At assembly, the taper roller bearing inner rings are
This is not to be less than : to be previously heated to approx. 130 ˚C with hot
- 0.8 mm for the gears and splitter; air device 99305121 for approx. 15 minutes.
- 1.2 mm for the epicyclic reducer
If distance A is less than the indicated reference values, the syn-
chronier ring (1) and/or the coupling unit (2) are to be Fit: the inner ring (6) of support bearing splitter side, the split
replaced. ring (7) and with a thickness gauge check the clearance
between split ring (7) and its housing; clearance is to range
between 0.01 and 0.1 mm.
Drive input shaft assembly Figure 154

Fit gudgeon (9, Figure 143) if present (7).
Figure 153
147066
147065 Heat the bearing inner ring (2) to approx. 100 ˚C using the hot
air device (1) 99305121.
Fit the synchroniser ring (3) and coupling unit (2).
Figure 155
Position the synchroniser ring (3) so that the
projecting parts position correctly in the coupling unit
housings (2).
Fit the gear (1)
Position the gear (1) so that the projecting parts

position correectly in the coupling unit housings (2).
147067
Insert the bearing (2) in the drive input shaft (1).
Make sure that the bearing (2) is up against the drive

input shaft shoulder (1).
27469 147063
Insert the safety ring (1). On the hub (1) fit the sliding sleeve (2).
In the hub housings (1): insert the springs (4) and pins (3)
Figure 157 arranging them under the sliding sleeve (2).
Insert the synchroniser ring (2, Figure 143) and coupling unit (3,
Figure 143).
Move the sliding sleeve (2) to central position keeping it
pressed against the coupling unit (3, Figure 143).
Main shaft assembly

Figure 160
27168
Insert the tube (2) and the split ring(1).
Figure 158
147070
Clamp the main shaft (1) in a vice and position on it:

- the lubricated needle bearing (2)
- 2nd gear shift(6)
- coupling unit (5)
- synchroniser ring (4)
Heat the hub (3) to 120 ˚C with hot air device 99305121 and
fit it on the main shaft (1), making sure that the projecting parts
of the synchroniser ring position correctly in the hub housings
147068
(3).
Check that the end float of the gear (6) is 0.2 mm.
Fit the oil seal cover (3) using the locking device 99374370 (2)
and grip 99370006 (1).
102780
102778
Heat the bushing (2) to 120˚ C with the hot air device
Fit the sliding sleeve (2) on the hub (1). In the hub housings (1) 99305121 and fit it on the main shaft (1).
insert: the springs (3) the pins (4) stopping them under the slid- Mount the following on the main shaft (1):
ing sleeve (2).
Heat the bushing (5) at 120˚ C using the hot air device - lubricated needle bearing (4) ,
99305121 and fit it on the main shaft. - R.M. gear (3).
ASTRA
102781
147071
Heat the taper roller bearing (3) to 120˚ C with the hot air
On the main shaft (1) device 99305121 and fit it on the main shaft (1).
- fit the synchroniser ring (7) so that the iprojecting parts Fit the split ring (2);
insert into the hub housings (2)
With a thickness gauge check the clearance between split pin
- the coupling ring (6) (2) and its housing. Clearance is to be between 0.01 and 0.1
- the lubricated needle bearing (5) mm.
- 1st gear. shift

The split ring (2) is supplied as spare part in different
Heat the toothed ring (3) to 120˚ C using the hot air device thicknesses.
99305121 and fit it on the main shaft (1).
Check that the end float of the 1st gear shift (4) is 0.2 mm.
Check that the end float of the R.M. gear (4) is 0.4 - 1.15 mm.
102782 102784
Overturn the main shaft (1). Heat the bushing (2) to 120˚ C with the hot air device
99305121 and fit it on the main shaft (1).
For this operation use tool 99370449. Fit:
- the synchroniser ring (10) so that the projecting parts posi-
tion in the hub housings (4);
Mount the following on the main shaft (1): - the coupling unit (9);
- lubricated needle bearing (2) - the 4th gear shift(7), with roller bearings (6 and 8);
- 3rd gear shift (6) - the spacer ring (5);
- coupling unit (5)
- synchroniser ring (4); Main shaft adjustment
Heat the hub (3) to 120˚ C with the hot air device 99305121
and fit it on the main shaft (1), taking care that the projecting Figure 168
parts of the synchroniser ring position correctly in the hub
housings (3).
Check that the end float of the gear (6) is 0.2 mm.
Figure 166
61203
Determine the thickness of the shoulder ring for the 4th gear
shift operating as follows:
Measure distance A between the end of the shaft (1) and the
support housing (2) of the taper roller bearing.
102783 Fit the shoulder ring (3) and measure distance B between this
and the end of the main shaft (1).
Fit the sliding sleeve (2) on the hub (1).
In the hub housings (1) fit the springs (3) and pins (4) arranging The difference between A-B is to be between + 0.07 ÷ 0.08
them under the sliding sleeve. mm.
If the value found is different, replace the shoulder ring (3) with
another of an appropriate thickness.
Figure 169 The flat seals are to be fitted dry, with no hermetic compound
or grease.
Before assembling the double lip seals, fill the space
between the two lips with TUTELA MR3.
ASTRA
Figure 171
61205
Fit the adjustment ring (1) having the thickness determined

in the previous measurements.
Figure 170
147057
Heat the bearing housings (4 and 5) to 80 ˚C with the hot air

ASTRA
device 99305121 and fit the outer rings with grip 99370007
and tool 99374093.
Fit the gears chain (2) with spring.
Fit the reverse gear drive (3) with the two needle bearings.
Figure 172
102785
Fit the bearing (3) previously heated to 80 ˚C with the hot air
device 99305121.
Fit the divided ring (2) that has a thickness to obtain an end float
in the housing equivalent to -0.05 ÷ 0.05 mm.
Fit the check ring (1) and dent it on several equidistant points
under the divided ring (2).
Check that the end float of the 4th gear shift (4) is 0.05 mm.
147056
Gear box fitting

Clamp the main shaft (3) in a vice and insert the tool 99370449
(2) clamping with the relevant lock nut. Hook tool 99370449
The rings and seal rings, ring nuts, spring pins, safety (2) to the lifting unit, raise the main shaft (3) and insert it into
plates and self-locking screws, found to be worn and the gear box, taking care to fit the rods (1) and forks in the same
all the parts that are inefficient, scratched, dented or position as noted during disassembly.
deformed are to be replaced during assembly.
The threading of the oil pump and drive input shaft From the rear of the gear, insert the oil pipe (4, Figure 127) on
ASTRA the main shaft (3).
cover, is originally lined with hermatic material,
therefore, they are to be replaced with new items at With a suitable screw (1, Figure 171) in the gear box hole, push
every assembly. the chain so that the rods can enter into their housings.
Figure 173 Splitter control fork adjustment
Adjustment is made only if new parts are added.
Figure 175 (Demonstrational)
147054
With eyebolt 99360502 (1) lift the driven shaft (2) and after
manipulating the main shaft (3), insert it in the gear box.
Figure 174
71126
On the gear box fit tool 99370154 (2) fitted with spacer (3)
for the gear version with long box (16 S 2530/2230) , without
specer for the version with short box ( 16 S 1630).
Insert the splitter control fork control rod in the tool and clamp
with the nut (1).
Figure 176
147059
Fit the drive input shaft (2) and the splitter control rod (1)taking
care to engage the fork in the relevant sleeve.
Remove the screw (1, Figure 171).
119426
Acting on the two socket head screws (2) position the splitter
control fork (1) so that the two shoes (4) are centred in the
groove of the sliding sleeve. Use two thickness gauges (3).
After adjustment fasten the two screws (2) to the specified
torque.
On the gearbox, tighten the splitter control rod stop screw,
tightening to the specified torque.
Remove the adjustment tool 99370154 (2, Figure 175) from
the gear box together with the spacer(3, Figure 175) after
looseneing the screw (1, Figure 175).
Clutch bell assembly Drive input cover assembly

147061
Fit the threaded plugs (10) with new seal rings tightening them
Fit the cover (11).
Fit the oil piping (2).
Fit the outer rings of the bearings (3 and 5).
Place a new seal (4) on the gear box (7).
Fit the clutch bell (12).
Tighten the screws (13) but not completely, insert the centring
pin (6) completely and tighten the screws (13) to the specified
torque.
Grease the gudgeon (8) and insert it in the housing.
Fit the switch (9) tightening to the specified torque.
Fit the threaded plug (1) with seal ring and tighten to torque.
147044
Assemble the filter (2).

If previously removed, fit the greased seal (10),in the drive input
shaft cover (8).
To assemble the seal ring (10) use locking device 99370420
and grip 99370006.
Place the adjustment ring (7) of thickness S 1 determined in
the measurement that follows
Main shaft bearing end float adjustment Figure 180

Figure 179
147073
Measure the protrusion of the housing on the pump body (1)

of bearing (2, Figure 179), dimension B.
The thickness S1 of the adjustment ring (7, Figure 178) is deter-
mined by the following equation:
S1= [ (A+C)-B] - D
147072 Where:
S A - B, measurements read;
Determinr the thickness S1 of the rings (7, Figure 178) to
adjust the end float of the main shaft bearing (2) operating as S C seal thickness ;
follows: S D, end float 0.01 ÷ 0.1 mm.
S rotate the shafts and check that the outer ring (2) of the Fit the shoulder rings (4 and 6, Figure 178)and the spring (5,
bearing rests on the bearing rollers without any clearance; Figure 178) in the correct position:
S measure on two diametrically opposite points the distance S Thickness(6) = 88 mm
between the surface of the clutch bell (1) and the outer
ring (2), dimension A. S Thickness (4) = 85 mm
Position the adjustment ring (1, Figure 178) of thickness S2
determined by the following measurement.
Driven shaft bearing end float adjustment Figure 182

Figure 181
147074
Measure the distance between pump housing (1) and the flat
resting surface of the drive input cover (2), dimension B.
The thickness S2 of the adjuster ring (1, Figure 178) is given by
147047 the following formula:
S2= [(A+C)-B] - D
Determine the thicknessS2 of the adjustment rings (1,
Figure 178) of the driven shaft bearing end float (2) operating Where:
as follows: S A - B, measurements read;
S rotate the shafts and check that the outer ring (2) of the S C, seal thickness;
bearing rests without clearance on the bearing rollers;
S D, end float of 0.01 ÷ 0.1 mm.
S measure on two diametrically opposite points the distance
between the clutch bell surface (l) and the outer ring (2), Fit a new seal (3, Figure 178).
dimension A. Fit the pipe (11, Figure 178) on the cover (8, Figure 178)
tightening the screws (12, Figure 178) to the specified torque.
Figure 183
147075
Fit the drive input cover on the clutch bell aligning (as in figure)
the pump shaft so that it inserts correctly in its housing.
147043
147076
Fit the thrust bearing (1).

Tighten the drive input cover fastening screws to the specified Insert the trunnion (2) in the lever (4) and tighten the fastening
torque in the order indicated in the figure. screws (3) on the front box, to the specified torque.
Figure 185
Splitter control unit assembly
Figure 187
ASTRA
147042
Overturn the gear box.

On the cylinder (5) fit the seal rings (6 and 8) and lubricate
them.
Fit the greased seal (10) on the plunger (11).
Position the split ring (7) in the splitter control cylinder housing.
Fit the cylinder (5) in the gear box.
Tighten the nut (9) to the specified torque.
Fit the splitter control valve (2) with two new O-rings.
On the gear box (2) position a suitable tool to keep the cylinder
124535 (5) in the housing.
Feed the splitter control valve (2) (max 6,8 bar) with com-
Grease the points (1) of the thrust bearing and the lever. pressed air and listen to check that the internal piston functions
Use IVECO 2996483 grease. and that there are no air leaks.
Remove tool ().
Fit the stifferner gudgeon (3).
Be very careful not to grease the points (2) indicated Refit the epicyclic reducer unit box as described in the relevant
in the figure. chapter.
Supply the gear box with lubrication oil of the specified quality
and quantity.
AUTOMATIC TRANSMISSION
ALLISON 4700
SECTION 7.1
HD9 Euro5 SECTION 7.1 AUTOMATIC TRANSMISSION ALLISON 4700 1
SECTION 7.1
Automatic transmission
Allison 4700
Page
DESCRIPTION 3
- Location of Manufacturer’s plate 3
- External views 4
- Automatic transmission assembly

(version without retarder) 5
- Lock-up clutch 6
- Torque converter 7
- Clutches 9
- Epicyclic gear 10
- Retarder 11
- Hydraulic assembly 12
COOLING SYSTEM 14
- Version without retarder 15
- Version with retarder 15
- Radiator oil circulation diagram (only the version

with retarder 16
TORQUES 17
TOOLS 18
DIAGNOSTICS 19
- Procedure to read diagnostic trouble codes
using the DIAGNOSTIC pushbutton 19
- Automatic Transmission Fault Codes List 21
- Location of control unit and Allison diagnostics

connector 25
HYDRAULIC DIAGNOSTICS 26
- Stalling test 26
- Clutch driving pressure check 27
HYDRAULIC CIRCUITS PRESSURES TABLE 28

- Hydraulic system_1 diagnostics flow-chart 29
- Hydraulic system_2 diagnostics flow-chart 30

GENERAL 31
2 AUTOMATIC TRANSMISSION ALLISON 4700 SECTION 7.1 HD9 Euro5
- Safety instructions 31 - Final operations 40
- Vehicle preparation 31 TRANSMISSION REMOVAL-REFITTING 41
- Hazardous and/or polluting substances 31 GENERAL 41
- Specific safety instructions 31 - Safety instructions 41
DESCRIPTION OF OPERATION 32 - Vehicle preparation 41
- Exhaust 32 - Very heavy parts 41
- Filling 32 - Hazardous and/or polluting substances 41
- Final operations 32 - Specific safety instructions 41
TRANSMISSION REMOVAL-REFITTING 34 DESCRIPTION OF OPERATION 42
GENERAL 34 - Preliminary operation 42
- Vehicle preparation 34 - Inspections and checks 42
- Very heavy parts 34 - Refitting 42
- Hazardous and/or polluting substances 34 - Final operations 42
- Specific safety instructions 34 AUTOMATIC TRANSMISSION OVERHAUL 44
DESCRIPTION OF OPERATION 35 - Disassembly 44
- Preliminary operation 35 - Cleaning 50
- Removal 35 - Checks and controls 50
- Inspections and checks 38 - Main checking and overhaul operations 51
- Refitting 38 - Reassembly 88
TRANSMISSION REMOVAL-REFITTING 39
GENERAL 39
- Preliminary operation 40
- Removal 40
- Refitting 40
DESCRIPTION
The ALLISON 4700 automatic transmission basically consists of the following components:
Torque converter: to transfer the drive torque from the engine to transmission with no rigid components interposed.
It consists of three parts: pump, turbine and stator. The pump is the input component and is controlled by the engine The turbine
is the output component and is hydraulically controlled by the pumps The stator is the feedback component (servo amplifier).
Lock-up clutch is between the pump and the turbine: when the turbine speed is close to that of the pump, the lock-up clutch
is coupled, so that the drive torque of the engine is sent directly to the transmission with a ratio of 1:1.
Epicycloidal gears and clutches. The forward and reverse gear ratios are defined by a series of modules, consisting of epicyclic
trains in cascade connection. The different ratios are obtained by the engagement of hydraulic multiple disk clutches.
Oil pressure pump: clamped on the input shaft, it is the lobe type and ensures the pressure required for lubrication and functioning
of the hydraulic assembly.
Retarder downstream of the gear modules, the purpose is to absorb the drag torque coming from the wheels during the release.
Hydraulic assembly a series of solenoid valves controlled by the transmission control unit and a series of channeling and pipelines
to transmit the oil pressures in the appropriate points.
Automatic transmission control unit (TCU) and wiring: the control unit receives the input signals and drives the output, to ensure
correct transmission functioning.
Location of Manufacturer’s plate
Figure 1
274A05002
1 Model
2 Groups
3 Year of manufacture
4 Part Number
External views
1. Filler cap
2. Electro-hydraulic assy connector
3. Retarder temperature connector
4. Turbine speed sensor
5. Main pressure fitting
6. Motion output flange
7. Output speed sensor
8. Pump speed sensor
9. Torque converter
Figure 2
306A071006R
Automatic transmission assembly (version without retarder)
Figure 3
1. Converter turbine 10. C5 clutch 19. P3 module

2. Converter pump 11. C6 clutch casing 20. P2 module
3. Converter stator 12. C6 clutch 21. P1 module
4. Lock-up clutch 13. P4 module 22. Turbine shaft
5. Oil pump 14. Rear lid 23. C1 clutch
6. Front casing 15. Output shaft 24. C2 clutch
7. Main casing 16. Primary shaft 25. Converter casing
8. C3 clutch 17. P3 sun gear
9. C4 clutch 18. P2 sun gear
306A071001R
Lock-up clutch
The lock-up clutch is a mechanical coupling device between pump P and turbine T of the converted when it is engaged.
With the lock-up clutch engaged the sliding between pump P and turbine T is eliminated, converting the automatic transmission
to a manual transmission, with related reduction of friction loss in the converter and consequent reduction in fuel consumption.
The lock-up clutch engages as from the second gear. The lock-up clutch is disengaged when there are control system faults.
A. Clutch disengaged (converter phase)

The oil circulating in the converter acts with the same pressure on the rear (a) and front (b) side of the piston (1) that engages
the clutch (2): turbine T is free to rotate in relation to pump P.
B. Clutch engaged (lock-up phase)

The control unit drives a solenoid valve that increases the pressure in the rear zone (a), as a consequence the piston (1) slides
and locks the clutch (2). In this way turbine T is integral with pump P and the related sliding is eliminated.
Figure 4
274A05003
274A05004
Torque converter
The torque converter hydraulically transmits the engine driving torque to the automatic transmission, according to a multiplication
ratio that ranges from maximum of approx. 2.5:1 to a minimum of 1:1 (direct drive).
The torque converter consists of three parts: pump P, turbine T and stator S. The pump is the input components and is controlled
by the engine. The turbine is the output component and is hydraulically controlled by the pumps The stator is the feedback (torque
multiplier) and is mounted on a free wheel that only allows rotation in the same direction as the pump.
The assembly is enclosed in a box full of specific oil.
The pump is connected to the engine and, rotating, transmits its energy to the oil. The centrifugal force projects the oil to the
peripheral area of the pump, where it flows at high speed to the turbine Here the oil kinetic energy imposes a rotary motion to
the turbine in the same direction as the pump.
Coming out from the turbine the oil passes through the stator where it is deviated according to an angle that allows it to return
to the pump with high output (direction as that of the pump vanes).
In this way the stator, prevented from rotation by the free wheel, forms a feedback torque that is added to that of the turbine.
The ratio between the resisting torque acting on the turbine and the drive torque is called converter multiplication ratio, and is
directly proportioned to the difference in speed between pump and turbine.
In detail:
- At wheels with vehicle stationary the ratio is approx. 1:2.5 (condition A, maximum sliding);
- When running in converter phase (sliding depends on conditions) this ratio reduces to intermediate values between 1:2.5
and 1:1 (condition B; reducing the speed difference between pump and turbine, the multiplication ratio decreases. The
converter automatically determines each time the balance between speed and torque required at output.
- When the turbine speed reaches a value of 80% of the pump speed, the ratio is almost 1:1 (sliding  0).
The sliding condition =0 is never reached completely, except by the clamping of the lock-up clutch (condition C).
When the speed of the pump and the turbine are almost the same, the stator receives a flow of oil in a direction that causes it
to rotate in the same direction as the turbine.
In fact, the free wheel allows the rotation only in the same direction as the turbine, and there is no stator feedback torque the
converter becomes just a hydraulic joint.
Figure 5
1730714
TT = TP + TS
Multiplication ratio: TT/TP or nP/nT
Condition A: n T = 0, ratio 2.5
Condition B: n T < n P ratio variable between 2.5 and 1; if n T ~ 0.8 n P, ratio ~ 1
Condition C: n T = n P, ratio = 1 (lock-up clutch engaged)
Clutches
The multiple disk type clutches prevent the rotation between hub and bell when they are engaged. They are controlled by the
drive hydraulic circuit to obtain the forward gear and reverse ratios.
Each clutch consists of a set of disks with external teeth (4) interposed to a set internal toothed disks (5). The externally toothed
disks engage in the bell (3) whereas the internally toothed disks engage in the hub (1).
It is locked hydraulically sending oil under pressure behind the control piston (2) by means of appropriate solenoid valves (arrow,
item A).
In this condition there is no sliding between the disks and the bell and the hub are made integral with each other.
When the oil pressure is no longer applied to the piston, the unlocking (arrow, item B) is assured by the mechanical action of a
spring (6) that acts on the piston in the opposite direction to the pressure of the oil A clearance is created between the disks
that allows the relevant sliding.
Figure 6
274A05005
Epicyclic gear
The different transmission ratios are obtained by a series of epicyclic gears.
The gear has three basic parts.
Internal sun gear (1) usually keyed on a shaft.
External crown ring (2) with internal teeth, into which the individual satellites mesh.
The satellites (3) that mesh in the sun gear and in the crown ring, are supported by the carrier (4) which is also able to rotate.
according to the ratio and the direction of rotation to be obtained, the three parts of the gear are made integral or left free by
the multiple disk clutch.
In detail:
- locking the carrier the sun gear and the crown ring rotate in opposite directions.
- locking the crown ring (or the sun gear) the sun gear (or the crown ring) and the carrier rotate in the same direction.
Furthermore, the different parts can be locked in relation to each other: in particular, locking two parts to each other, the whole
gear rotates in an integral manner.
Figure 7
274A05006
Retarder Figure 8
Downstream of the epicyclic gear assembly, the purpose is to
absorb the drag torque coming from the vehicle wheels during
the release.
2
This consists of the rotor (1), the stator (2, double) and the 2
control circuit.
The rotor, integral with the torque output shaft (3) and
therefore the propeller shaft, is driven by the wheels.
Each stator is composed of two parts: The actual stator,
integral with the automatic transmission external box, and the
stator ring, that is a ring with blades inserted between stator
and rotor.
Both parts have internal blades and are enclosed in a box
isolated from the automatic transmission. 1
The control device consists of a solenoid valve an a series of
appropriate channels.
When the retarder is disengaged, there is no oil in the box: as
a consequence the rotor rotation takes place without
resistance.
The retarder is engaged when oil under pressure is sent into
the box by the control device. The oil is sent by the rotor
against the stator blades that send it to the rotor with a
reversed direction, so as to create a strong resistance to rotor
rotation.
3
In this way the driving torque coming from the vehicle is partly
dissipated by the oil contained in the retarder box, thus causing
a vehicle braking effect.
This dissipation causes heating of the oil that is cooled by the
exchanger to the engine coolant.
274A05007
Hydraulic assembly Figure 10

A series of solenoid valves controlled by the transmission
control unit and a series of channeling and pipelines to transmit
the oil pressures in the appropriate points.
The group is located beneath the main box.
The group has the following circuits:
- main pressure circuit
- main pressure control circuit
- torque converter circuit
- lubrication / cooling circuit
- clutch driving circuit (one for each clutch)
- return circuit
The group has a pressure sensor on the driving circuit of clutch
C3 to monitor the clutch driving pressures.
Inside the group twp hydraulic fluid filters are installed.
In the lower part of the main box there are the points to
measure the hydraulic pressures.
Figure 9
306A071002R
1. Filters
2. Lock-up clutch pressure fitting
4. Hydraulic fluid drainage cap
5. C1-C2-C3-C4-C5 clutch pressure unions
6. C6 clutch pressure union
For further information regarding the pressure

control procedures, see the related Chapter.
274A05008
The solenoid valves that intercept the circuits to control the slide valves are of two types:
- NC= normally closed
- NO = normally open
Figure 11
274A05010
Both consist of an interception ball (1), an electric winding (2) that, when powered, moves the ball and a metal core (3).
NC valve
If not powered, the ball stops the fluid coming from (a) and the discharge (b) is open; if powered, the ball stops the discharge (c)
and the fluid coming from (a) can pass to (b).
NO valve
If not powered, the ball stops the discharge (c) and the fluid coming from (a) can pass to (b); if powered, the ball stops the fluid
coming from (a) and the discharge (c) is open.
COOLING SYSTEM
Version without retarder
Figure 12
HD9ST0043MR
1. Exchanger - 2. Exchanger-engine water delivery - 3. Engine-exchanger water return -

4. Exchanger-transmission oil delivery - 5. Transmission-exchanger oil return
Version with retarder
Figure 13
HD9ST0044MR
1. Exchanger - 2. Exchanger-engine water delivery - 3. Engine-exchanger water return -

4. Exchanger-transmission oil delivery - 5. Transmission-exchanger oil return - 6. Radiator -
7. Radiator-transmission oil delivery - 8. Check valve - 9. Transmission-radiator oil return -
10. Thermostatic sensor - 11. Electric fan
Radiator oil circulation diagram (only the version with retarder)
Figure 14
HD9ST0045MR
1. Radiator-transmission oil delivery - 2. Transmission-radiator oil return - 3. Check valve -

TORQUES
The tightening torques for the parts being overhauled are included in the text of the relevant Chapter.
Figure 15
306A071003R
TOOLS
The codes in the following list are the original ALLISON codes
Tool code Description

J8092 Grip
J35923-2 C1 springs disassembly tool
J37030-3 C1, C2, C5 springs disassembly base tool
J37031 O-ring assembly tool
J37034 Bearing assembly guide/block
J37038 Roller bearing assembly guide/block
J37041 Bearing assembly guide/block
J38548 Tool for checking torque converter axial clearance
J38564 Torque converter nut tightening tool
J41462 Spring disassembly tool
DIAGNOSTICS Figure 17
Procedure to read diagnostic trouble codes
using the DIAGNOSTIC pushbutton
Before reading the DTC (Diagnostic Trouble Codes) :

- shut off the engine;
- select Neutral position;
- engage the parking brake;
- switch on the electric power supply (if it is off) and bring
the ignition key to run position, to supply the system.
Figure 16
272007003AL
Example: code P0722 is displayed as:

d1/P_/07/22
where
d1 is the first error memory location
P_ 07 is the main assembly concerned by the fault
22 indicates the type of failure
One character at a time is displayed for approx. one second.
The viewing starts from the codes of faults that are still
present (active codes), then passes to any faults that have
been detected but that have not occurred again, and are still
in the memory (historic codes).
If the warning light (3) incorporated in the MODE
pushbutton is alight, the code is active, if the warning light (3)
is off, the code is deactivated. For a fault that has been found,
but then solved, after a certain number of start-ups without
357A007200R the fault, the TCU automatically deletes it from the memory.
To read the diagnostic codes from the display, enter the

related mode by pressing the DIAGNOSTIC pushbutton (1).
In this way the TCU displays the first memory location.
If there are other errors, after displaying the code of the first
fault, when the DIAGNOSTIC pushbutton is pressed again
the second code is displayed, and so forth for a maximum of
five stored faults. These codes are stored in the five locations
of the faults memory (from d1 to d5).
Asterisks are shown to indicate that all the codes have been
viewed.
Example:
Code List Active Historic Check Failure
location DTC * code code Trans Record Description
d1 P0880 Yes Yes Not Yes TCM Power Input Signal

Pressure Control Solenoid 1 Stuck
d2 P2723 Yes Yes Yes Yes Off
d3 P0727 Not Yes Not Yes Engine Speed Input Circuit No Signal
TCM Vehicle Options (TransID)
d4 P0610 Not Yes Not Yes Error
d5 - - - - - -
To delete the fault codes, keep the DIAGNOSTIC pushbutton pressed for at least ten seconds, until the acoustic signal
is heard.
If the fault occurs again when using the vehicle, it is necessary to repair the failure.
To exit from this mode:

- press the DIAGNOSTIC pushbutton, or
- cut out the electric power supply, or
- move the gear selector lever to another position, or
- wait about ten minutes after the last intervention.
Automatic Transmission Fault Codes List
CHECK
DTC Description TRANS Inhibited Operation Description
Light
May inhibit retarder operation if not using J1939
C1312 Retarder Request Sensor Failed Low No datalink
May inhibit retarder operation if not using J1939
C1313 Retarder Request Sensor Failed High No datalink
P0122 Pedal Position Sensor Low Voltage No Use default throttle values. Freezes shift adapts.
P0123 Pedal Position Sensor High Voltage No Use default throttle values. Freezes shift adapts.
Use hot mode shift schedule. Holds fourth range.
P0218 Transmission Fluid Over Temperature No TCC is inhibited. Freezes shift adapts.
P0602 TCM Not Programmed Yes Lock in Neutral
P0610 TCM Vehicle Options (TransID) Error Yes Use TID A calibration
P0613 TCM Processor No All solenoids off
Allows operation only in reverse and second ran-
P0614 Torque Control Data Mismatch-ECM/TCM Yes ge.
P0634 TCM Internal Temperature Too High Yes SOL OFF (hydraulic default)
P063E Auto Con?guration Throttle Input Not Present Yes Use default throttle values
Auto Con?guration Engine Coolant Temp Input
P063F Not Present No None
P0658 Actuator Supply Voltage 1 (HSD1) Low Yes DNS, SOL OFF (hydraulic default)
P0659 Actuator Supply Voltage 1 (HSD1) High Yes DNS, SOL OFF (hydraulic default)
P0702 Transmission Control System Electrical (TransID) Yes Uses TID A calibration
No Neutral to Drive shifts for refuse packer. TCM
P0703 Brake Switch Circuit Malfunction No inhibits retarder operation if a TPS code is also acti-
ve.
P0708 Transmission Range Sensor Circuit High Input Yes Ignore defective strip selector inputs
P070C Transmission Fluid Level Sensor Circuit-Low Input No None
P070D Transmission Fluid Level Sensor Circuit-High Input No None
Transmission Fluid Temperature Sensor Circuit
P0711 Performance Yes Use default sump temp

P0712 Low Input Yes Use default sump temp

P0713 High Input Yes Use default sump temp
P0716 Turbine Speed Sensor Circuit Performance Yes DNS, Lock in current range
P0717 Turbine Speed Sensor Circuit No Signal Yes DNS, Lock in current range
P0719 Brake Switch ABS Input Low No TCM assumes ABS is OFF
P071A RELS Input Failed On Yes Inhibit RELS operation
P071D General Purpose Input Fault Yes None
P0721 Output Speed Sensor Circuit Performance Yes DNS, Lock in current range
P0722 Output Speed Sensor Circuit No Signal Yes DNS, Lock in current range
P0726 Engine Speed Sensor Circuit Performance No Default to turbine speed
P0727 Engine Speed Sensor Circuit No Signal No Default to turbine speed
P0729 Incorrect 6th Gear Ratio Yes DNS, Attempt 5th, then 3rd
P0731 Incorrect 1st Gear Ratio Yes DNS, Attempt 2nd, then 5th
P0732 Incorrect 2nd Gear Ratio Yes DNS, Attempt 3rd, then 5th
P0733 Incorrect 3rd Gear Ratio Yes DNS, Attempt 4th, then 6th
P0734 Incorrect 4th Gear Ratio Yes DNS, Attempt 5th, then 3rd
CHECK
Light
P0735 Incorrect 5th Gear Ratio Yes DNS, Attempt 6th, then 3rd, then 2nd
P0736 Incorrect Reverse Gear Ratio Yes DNS, Lock in Neutral
P0741 Torque Converter Clutch System Stuck Off Yes None
P0776 Pressure Control Solenoid 2 Stuck Off Yes DNS, RPR
P0777 Pressure Control Solenoid 2 Stuck On Yes DNS, RPR
P0796 Pressure Control Solenoid 3 Stuck Off Yes DNS, RPR
P0797 Pressure Control Solenoid 3 Stuck On Yes DNS, RPR
P0842 Transmission Pressure Switch 1 Circuit Low Yes DNS, Lock in current range
P0843 Transmission Pressure Switch 1 Circuit High Yes DNS, Lock in current range
P0880 TCM Power Input Signal No None
P0881 TCM Power Input Signal Performance No None
P0882 TCM Power Input Signal Low Yes DNS, SOL OFF (hydraulic default)
P0883 TCM Power Input Signal High No None
P0894 Transmission Component Slipping Yes DNS, Lock in ?rst
Pressure Control Solenoid Main Mod Control Cir-
P0960 cuit Open Yes None

P0962 cuit Low Yes DNS, SOL OFF (hydraulic default)

P0963 cuit High Yes None
Pressure Control Solenoid 2 (PCS2) Control Cir-

P0964 cuit Open Yes DNS, SOL OFF (hydraulic default)


P0967 cuit High Yes DNS, SOL OFF (hydraulic default)



P0973 Shift Solenoid 1 (SS1) Control Circuit Low Yes DNS, SOL OFF (hydraulic default)
P0974 Shift Solenoid 1 (SS1) Control Circuit High Yes DNS, SOL OFF (hydraulic default)
P0975 Shift Solenoid 2 (SS2) Control Circuit Open Yes 7-speed: Allow 2 through 6, N, R
7-speed: Allow 2 through 6, N, R. Inhibit TCC ope-
P0976 Shift Solenoid 2 (SS2) Control Circuit Low Yes ration
P0977 Shift Solenoid 2 (SS2) Control Circuit High Yes 7-speed: Allow 2 through 6, N, R
P0989 Retarder Pressure Sensor Failed Low No None
P0990 Retarder Pressure Sensor Failed High No None
P1739 Incorrect Low Gear Ratio Yes Command 2nd and allow shifts 2 through 6, N, R
P1891 Throttle Position Sensor PWM Signal Low Input No Use default throttle values
P1892 Throttle Position Sensor PWM Signal High Input No Use default throttle values
Engine Coolant Temperature Sensor Circuit Low
P2184 Input No Use default engine coolant values
Engine Coolant Temperature Sensor Circuit High

P2185 Input No Use default engine coolant values
CHECK
Light
P2637 Torque Management Feedback Signal (SEM) Yes Inhibit SEM
P2641 Torque Management Feedback Signal (LRTP) Yes Inhibit LRTP
P2714 Pressure Control Solenoid 4 (PCS4) Stuck Off Yes DNS, RPR
P2715 Pressure Control Solenoid 4 (PCS4) Stuck On Yes DNS, SOL OFF (hydraulic default)


P2724 Pressure Control Solenoid 1 (PCS1) Stuck On Yes DNS, RPR



P2736 cuit Open Yes Inhibit retarder operation
Pressure Control Solenoid 5 (PCS5) Control Cir- Allow 2 through 6, N, R. Inhibit retarder and TCC
P2738 cuit Low Yes operation
P2739 cuit High Yes Inhibit retarder operation
P2740 Retarder Oil Temperature Hot No None

Retarder Oil Temperature Sensor Circuit-Low In-
P2742 put No Use default retarder temp values
Retarder Oil Temperature Sensor Circuit-High In-

P2743 put No Use default retarder temp values
P2761 TCC PCS Control Circuit Open Yes Inhibit TCC operation
P2763 TCC PCS Control Circuit High Yes Inhibit TCC operation
7-speed: allow 2 through 6, N, R. Inhibit TCC ope-
P2764 TCC PCS Control Circuit Low Yes ration
P278A Kickdown Input Failed ON No Inhibit kickdown operation
P2793 Gear Shift Direction Circuit Yes Ignores PWM input from shift selector
P2809 Pressure Control Solenoid 6 (PCS6) Stuck On Yes DNS, RPR


CHECK
Light
Hi Speed CAN Bus Reset Counter Overrun (IE-
U0001 SCAN) No Use default values, inhibit SEM
U0010 CAN BUS Reset Counter Overrun No Use default values, inhibit SEM
U0100 Lost Communications with ECM/PCM (J1587) Yes Use default values
Lost Communication With Gear Shift Module Maintain range selected, observe gear shift direc-
U0103 (Shift Selector) 1 Yes tion circuit
U0115 Lost Communication With ECM Yes Use default values
Lost Communication With Gear Shift Module Maintain range selected, observe gear shift direc-
Incompatible Gear Shift Module 1 (Shift Selector)
U0304 ID Yes Ignore shift selector inputs
Incompatible Gear Shift Module 2 (Shift Selector)

U0333 ID Yes Ignore shift selector inputs
Invalid Data Received From Gear Shift Module Maintain range selected, observe gear shift direc-
Invalid Data Received From Gear Shift Module Maintain range selected, observe gear shift direc-
Location of control unit and Allison diagnostics connector

1. Allison control unit
2. Allison diagnostics device socket
Figure 18
357A007201
HYDRAULIC DIAGNOSTICS Stalling test
Before carrying out any operation, make sure all the Before starting the test, send all the personnel away
precautions have been taken and all the safety from the work area.
aspects have been made clear to the persons Carry out the tests in the open, in a zone away from
involved in the job. the fixtures and other vehicles.
Read the relevant instructions in SECTION 1 of this
manual.
If in doubt consult a person who is more expert.
Observe all the general recommendations for the The stalling test is only to be carried out when
correct execution of the maintenance operations. necessary. It is not a normal procedure to check the
automatic transmission.
The stalling test is to be carried out after a cold and

a hot control of the hydraulic fluid level.
Proceed as follows:
- Check that the accelerator pedal can complete the full
stroke;
- Check that the engine intake filter is not clogged and that
the sleeves are intact;
- Provide a precision rev counter;
- Provide a thermometer to measure the hydraulic fluid
temperature;
- Start the engine and warm-up the vehicle to reach the
automatic transmission operating temperature (70-95
C);
The stalling testm causes a rapid increase in the

hydraulic fluid temperature. It is not to exceed a
time of 30 seconds Furthermore it is to be
interrupted if the hydraulic fluid temperature
reaches 150 ˚C.
- Insert the chocks on the drive wheels, engage the parking

brake and press the brake pedal;
- Select drive position on the transmission;
- Accelerate to maximum;
- When the engine speed has stabilised; make a note of
the value reached;
- Decelerate the engine and bring the gear to Neutral.
To analyse the results, proceed as follows:

- If the difference in relation to the engine maximum speed
is greater than 1 50 [rpm] it could be that the problem
concerns the automatic transmission;
- A big difference (more than 1/3) in relation to engine
maximum speed could be a sign of torque converter
problems;
- if the temperature of the hydraulic fluid is not within
normal limits after testing for two minutes, the internal
cooling system is not functioning correctly.
Clutch driving pressure check - prepare an appropriate container, then connect a fitting,
Proceed as follows: a tube and an appropriate gauge to each pressure tap
involved;
- take the vehicle to an appropriate flat. solid surface,
the parking brake and affix the warning notices. During these operations there could be an outflow
of oil.
Figure 19
For further information regarding the pressure

values to be measured see the following table.
- Provide a thermometer to measure the hydraulic fluid

temperature
- Start the engine and warm-up the vehicle to reach the
automatic transmission operating temperature (70-95
˚C);
- Record the pressure, temperature and engine speed for
each operating condition, with special attention to any
malfunctioning conditions;
For more information on test conditions, see next

table.
- To analyse the results, compare the values recorded with

those indicated in the following table.
306A071002R - In the case of nonconformity, carriy out the necessary
overhaul operations.
- After these operations, return the vehicle to normal
1. Filters operating conditions.
2. Lock-up clutch pressure fitting
4. Hydraulic fluid drainage cap
5. C1-C2-C3-C4-C5 clutch pressure unions
6. C6 clutch pressure union
HYDRAULIC CIRCUITS PRESSURES TABLE
Main Convert- Lubrica-

Test Pressure Pressure
engine rpm Gear Clutches pressure er output tion
condi- [kPa] clutches lock-up
[rpm] engaged engaged pressure pressure
tions [kPa] (*) [kPa] (*)
(main) [kPa] [kPa]
1500
Neutral C5 0-40 - - -
2200
1500
RM C5, C3 0-40 - > 3,5 -
Engine at 2200
580-620
minimum 1300 0-70 C1
1 conv C1, C5 - > 3,5 -
1800 0-40 C5
1300 0-70 C1
2 conv C1, C4 - > 3,5 -
1800 0-40 C4
1800
Neutral C5 0-40 75-300 50-190 -
2200
1800
RM C5, C3 0-40 170-300 120-190 -
2200
1550 0-70 C1
1 conv C1, C5 170-300 120-190 -
1800 0-40 C5
1550 0-70 C1
2 conv C1, C4 170-300 120-190 -
1800 0-40 C4
1050 0-70 C1
2 lock C1, C4, LU 200-350 140-190 0-60
1400 0-40 C4
1550 0-70 C1
3 conv C1, C3 170-300 120-190 -
1800 0-40 C3
Engine run- 1050 0-70 C1
1780-1820 3 lock C1, C3, LU 200-350 140-190 0-60
ning steady 1400 0-40 C3
1550 0-70 C1
4 conv C1, C2 132-250 90-150 -
1800 0-70 C2
1050 0-70 C1
4 lock C1, C2, LU 160-300 110-150 0-60
1400 0-70 C2
1270 0-70 C2
5 conv C2, C3 132-250 90-150 -
1305 0-40 C3
900 0-70 C2
5 lock C2, C3, LU 160-300 110-150 0-60
1250 0-40 C3
1270 0-70 C2
6 conv C2, C4 132-250 90-150 -
1305 0-40 C4
900 0-70 C2
6 lock C2, C4, LU 160-300 110-150 0-60
1250 0-40 C4
Conv = convertr phase (lock-up disengaged)

Lock = lock-up phase (lock-up engaged)
(*) difference between main pressure and clutch actuation pressure
HD9 Euro5
MAIN CIRCUIT LEAK FROM

PRESSURE MAIN CIR-
GEAR IN IDLE, EN- LOW AFTER CUIT AFTER
GINE AT MINI- WARM--- UP
WARM--- UP
MUM, ACTIVATE
CLUTCH TEST
MODE CLUTCH C3 SOLENOID C3
ACTIVATED NOT OPERATING
ALL OTHER CONDITIONS
SOLENOID C5 CLUTCH C5
NOT OPERATING ACTIVATED
SELECT FIFTH SOLENOID C1
CLUTCH C1
Hydraulic system_1 diagnostics flow-chart
GEAR, ENGINE NOT OPERATING

AT MINIMUM ACTIVATED
SOLENOID C4 CLUTCH C4
NOT OPERATING ACTIVATED

SECTION 7.1
VALVE C1 NOT CLUTCH FORWARD GEAR

OPERATING NO CLUTCH
C1 DEACTI- SOLENOID NOT
ACTIVATED
VATED OPERATING
LOW PRESSURE IN LOW SELECT FOURTH CLUTCH VALVE C2 OR

MAIN CIRCUIT PRESSURE GEAR, ENGINE C2 FORWARD GEAR
C1 & C2 ACCELERATED DEACTI- SOLENOID NOT
VATED OPERATING

SOLENOID C1 LOW C2
PRESSURE PRESSURE SOLENOID C2
NOT OPERATING
C1 LOW NOT OPERATING
AUTOMATIC TRANSMISSION ALLISON 4700
29
274A05001
30
SOLENOID C2 CLUTCH C2 SELECT SECOND CLUTCH C4 SOLENOID C4

NOT OPERATING ACTIVATED GEAR, ENGINE AT ACTIVATED NOT OPERATING
MINIMUM

AUTOMATIC TRANSMISSION ALLISON 4700
SELECT THIRD CLUTCH C3 SELECT THE

GEAR, ENGINE ACTIVATED REVERSE GEAR, CLUTCH C5
Hydraulic system_2 diagnostics flow-chart
SELECT FIRST
AT MINIMUM ENGINE AT ACTIVATED GEAR, ENGINE
MINIMUM
AT MINIMUM
SECTION 7.1

CLUTCH C3
ACTIVATED CLUTCH C5
ACTIVATED
CLUTCH C3 NO CLUTCH HYDRAULIC
ACTIVATED ACTIVATED SYSTEM OK CLUTCH C5
ACTIVATED
SOLENOID C3
NOT OPERATING SOLENOID C5
NOT OPERATING
VALVE C1 NOT
OPERATING FORWARD GEAR
SOLENOID NOT
OPERATING
VALVE C2 NOT
OPERATING
HD9 Euro5
274A05002

GENERAL

Vehicle preparation

signboards.
Figure 20
2371801

of short circuits;
DESCRIPTION OF OPERATION only versions with retarder
Exhaust Figure 23
Proceed as follows:
- prepare an appropriate container, clean the filler cap and
pluug area, uncrew the grip by two or three turns and
withdraw the dip stick;
Figure 21
HD9ST0047MR

return pipe from the radiator (see arrow) and empty the
radiator completely;
274NM1C1
- remove the drainage cap (arrow) and drain off the

lubricant completely;
- clean the drainage cap, check that the thread is in good
condition and close it.
Figure 22
HD9ST0046MR
- have a suitably large container handy, disconnect both

pipes from the transmission connecting to the exchanger
(see arrow) and empty the exchanger completely;
- reconnect both pipes.
The filters replacement can be carried out after

Filling
emptying the lubrication oil. Proceed as follows:
- pour in the specified amount of lubricant through the
filler, then return the dip stick to its position and tighten
Proceed as follows: the grip;
Figure 24
Final operations
Proceed as follows:
- carry out a brief trial run and then check the level when
cold as described in the Maintenance Standards of the
USE AND MAINTENANCE MANUAL;
- top up with the lubricant prescribed if necessary.
It is necessary to check the level and topping up

several times until the exchanger and radiator (if
installed) are completely full.
274NM1C2
- When finished, check the level when hot as described in

- arrange an appropriate container, clean the flanges area, the Maintenance Standards in the USE AND
then unscrew the fastening screws (1) and remove the MAINTENANCE MANUAL.
flange (2) and gaskets (3);
- remove the cartridge (4);
During these operations there could be an outflow

of oil.
- fir the new cartridge in its seat, fir the new gasket and the
flange, then tighten the fastening screws.

GENERAL

signboards. Specific safety instructions
Safety component.
Figure 25 Tighten the fastening bolts to the specified torque.
2371801

of short circuits;
DESCRIPTION OF OPERATION Removal

Preliminary operation
Proceed as follows: The removal of the pull/clasp securing straps is not
given in detail. It is intended that these straps are to
- tilt the cab; be cut/disengaged then refitted at reassembly to
- disconnect the electrical and hydraulic connections from ensure the correct attachment of the parts to be
the power take-off and any other related user assembled retained.
on the gearbox;
- remove any outfittings that interfere with access to the
transmission;
The operations described refer to the next figure.
- drain off the lubricant as described in the
TRANSMISSION OIL CHANGE chapter in this Section;
Figure 26
- disconnect these pipelines from the automatic
transmission:
- return (3) from heat exchanger;
- delivery (4) to heat exchanger;
During these operations there could be an oil

outflow.
- disengage the bracket that supports the hydraulic pipes

that pass at the side of the gearbox;
360F072005R
- disconnect the automatic transmission (10) electrical
connections.
- disconnect the propeller shaft from gearbox outlet (14)
as described in the PROPELLER SHAFT
REMOVAL-REFITTING chapter in Section 10.
wheel-drive propeller shaft from transmission outlet Versions with cooling radiator
(13) as described in the PROPELLER SHAFT Figure 27
REMOVAL-REFITTING chapter in section 10.
- For four-axle drive versions only: disconnect the front
intermediate axle as described in the
REMOVAL-REFITTING chapter in section 12.2.
HD9ST0048MR
- disconnect the lubricant delivery (15) and return (16)

pipes to/from the exchanger;
During this operation,you might find some oil leaks.

Figure 28
357A007202R
- from each side, unscrew the lower fastening bolt of the Figure 31
rear silent-block support;
Figure 29
274A04016
- remove the cap (1) arranged sidways to the engine block

to have access to the flexible disks fastening screws;
- remove the plate (2);
357S007203R
Figure 30
- rotating the engine with the mounted tool, through the
space left free by the cap, unscrew one at a time the
converter —flexible disks connecting screws (arrow);
Figure 32
274A04017
- fit the specific crankshaft rotation tool (1) instead of the

plate;
306A071005R
- unscrew the bolts (1) that fasten the rear silent-block

supports from each side,
Figure 33 Refitting
Proceed as follows:
1
Figure 34
274005013
- remove all the nuts (1) fastening the automatic

transmission to the engine;
- cautiously bring back the automatic transmission
withdrawing it from the engine;
- recover the spacer flange (2);
357A007203R
- fit the spacer ring (1), then align the flexible disk holes
Check that all the connections and tubes have been
(arrow) with the transmission interface ring holes (2);
disconnected and that all the fastening straps have
been unlatched. - continue the automatic transmission assembly to come
up against the spacer ring;
- cautiously lower the automatic transmission with the During assembly the group is to remain perfectly
slide, removing it from below. aligned with the engine axis.

Proceed as follows: - tighten the flexible disks-interface ring connecting screws.
- Check integrity of the connection flanges.
- Check integrity of the brackets and fastening buttons, if Final operations
needed, to replace the damaged component. Proceed as follows:
- Check the flexible mountings: if necessary replace - For four-axle drive versions only: refit the front
damaged component. intermediate axle as described in the
- Check perfect integrity of the electric wiring and REMOVAL-REFITTING chapter in section 12.2.
respective connections. - For front-wheel drive versions only: refit the front
wheel-drive propeller shaft as described in the
PROPELLER SHAFT REMOVAL-REFITTING chapter in
section 10.
- refit the propeller shaft to the gearbox outlet as
described in the PROPELLER SHAFT
REMOVAL-REFITTING chapter in Section 10;
OIL CHANGE chapter in this section;
- run the engine for a few minutes and check for hydraulic
fluid leakage from the pipes;
REMOVING AND REFITTING THE OIL Very heavy parts

RADIATOR Not applicable
GENERAL
Dangerous and/polluting substances
General safety standards
The job described below entails handling dangerous
Before doing any work, make certain that all the and/or polluting substances.
precautions have been taken and all aspects Do not touch with hands.
concerning the safety of the people involved in the Do not let them come into contact with painted
work are completely clear. If there are any doubts parts.
consult someone who has more experience. Collection and disposal of spent lubricant oils and
Read the instructions given at the beginning of this fluids must comply with existing standards and laws.
Manual.
Also comply with all the general recommendations
Specific safety standards
Not applicable
Preparing the vehicle

switch the engine off, take the ignition key out,
engage the parking brake and affix the indication
signs.
Figure 35
2371801

At the end of the operations, restore vehicle
functionality.
DESCRIPTION OF THE OPERATION Verifications and checks

Not applicable
Preliminary steps
Not applicable
Refitting
Removal
cut/released and subsequently restored when Final steps
reassembling to ensure that the components that Perform the following:
have to be held in place are secured correctly. - fill with lubricant as described in the CHANGING THE
TRANSMISSION OIL Chapter in this Section.
Perform the following:

- Place a suitably large container under the radiator,
disconnect the top coupling (1) from it and drain the fluid
from the pipe.
- Disconnect the bottom coupling (2) from the radiator
and drain the fluid from both pipe and radiator.
- Open the electrical connections box and disconnect:
- the electric fan connection (4).
- Remove the fixing bolts (see arrow) and remove the
radiator.
Figure 36
HD9ST0049MR

WATER-OIL EXCHANGER
The job described below entails handling parts that
GENERAL are very heavy. Use suitable tools and accessories for
General safety standards lifting and transporting.
Before doing any work, make certain that all the

precautions have been taken and all aspects Dangerous and/polluting substances
concerning the safety of the people involved in the
work are completely clear. If there are any doubts
consult someone who has more experience.
and/or polluting substances.
Read the instructions given at the beginning of this
Do not touch with hands.
Manual.
Do not let them come into contact with painted
parts.
Collection and disposal of spent lubricant oils and
fluids must comply with existing standards and laws.

Take the vehicle to a suitably level and solid surface, Not applicable
signs.
Figure 37
2371801
- Turn the battery isolator switch off or disconnect the

battery terminals (see arrow) to ensure against any short
circuit risks.
- At the end of the operations, restore vehicle functionality.

Preliminary steps Not applicable
- drain the cooling system as described in the
CHANGING THE RADIATOR FLUID Chapter in Refitting
SECTION 3 - F3B ENGINE Start refitting proceeding in the opposite order to removal.
Removal
Final steps
Removal of the tear/pressure fixing straps is not Perform the following:
cut/released and subsequently restored when - fill the cooling system as described in the CHANGING
THE RADIATOR FLUID Chapter in SECTION 3 - F3B
reassembling to ensure that the components that ENGINE
- fill with lubricant as described in the CHANGING THE
The steps described below refer to the following

figure.

- place a suitably large container under the exchanger,
disconnect the inlet coupling (1);
- disconnect the outlet coupling (2).
During this operation, you might find some coolant.
- place a suitably large container under the exchanger,

disconnect the oil inlet coupling (3) from the exchanger
and drain the fluid from the pipe;
- disconnect the outlet coupling (4) from the exchanger
and drain the fluid from the pipe;
- remove the coolant return pipe fixing bracket (5);
- remove the bracket fixing bolts (see arrow) and remove
the exchanger.

Figure 38
HD9ST0050MR
AUTOMATIC TRANSMISSION OVERHAUL Figure 40
The operations described in this chapter are

indicative.
Before starting it is most important to check
correctness (with special attention to dimension
values and tightening torques to be observed)
referring to the original documentation of the
transmission Supplier.
Before carrying out any operation, make sure all the

precautions have been taken and all the safety
aspects have been made clear to the persons
involved in the job.
manual. 274A05031
If in doubt consult a person who is more expert.
Observe all the general recommendations for the
correct execution of the maintenance operations.
- Unscrew the fastening screw, remove the retaining
bracket and remove the input speed sensor (1) the
turbine speed sensor (2) and the output speed sensor
(3) with the related O-rings;
Before starting to proceed:
 drain off the transmission lubricant;
operating as indicated in the relevant Chapter. Figure 41
Disassembly
External parts disassembly
Proceed as follows:
- Remove PTO from transmission, where applicable;
Figure 39
306A071006R
- Remove oil dipstick assembly (1).
306A071006R
- Remove motion output flange (1);

Hydraulic control group disassembly Torque converter disassembly.

Figure 42 Figure 43
274A05033 274A05034
- Remove the device that fastens the solenoids electric - Lock the converter rotation.
connector to the gearbox.
- Unscrews the screws (1) and (2) that fasten the group
to the gearbox. To lock the turbine shaft rotation, proceed as
follows:
- Release the group acting on the resting shelves or use
screws as puller.  if the hydraulic control assembly has already
been removed, insert a large screwdriver in the
- With appropriate lifting equipment remove the hydraulic teeth of clutch groups C3 and C4 (detail A).
assembly (3).
 if the hydraulic control assembly has not been
- Remove the gasket (4). removed, engage the lock-up clutch introducing
compressed air in the cap indicated (detail B)
then clamp the shaft as indicated.
Figure 44
274a050035
- Remove the cap (2) and its O-ring (3).

- Using tool J38564 remove the central nut (4).
- remove the adjustment ring (5).
- With appropriate lifting equipment remove the torque
converter (1).
Converter bell disassembly

Proceed as follows:
Figure 45
1 2
274a050036
- Unscrews the screws (3) that internally fasten the bell (1)
to the gearbox (4).
- Unscrews the screws (3) that externally fasten the bell
(1) to the gearbox (4).
- With appropriate lifting equipment remove the
converter bell(1).
- Remove the gasket (2).
Rear lid disassembly C6 clutch casing disassembly

Figure 46 Figure 47
306A071008R 306A071009R
- Loosen screws (4) and screws (5) fastening the rear lid Support the C6 clutch casing appropriately before
(6) to the C6 clutch casing. proceeding.
- Use appropriate lifting means to remove the rear lid (6).
- Remove the seal (3).
- Loosen the screws (3) fastening the C6 clutch casing (4)
to the main box (1).
- Use appropriate lifting means to remove the C6 clutch
casing (4).
- Remove the o-ring (5).
Internal gear disassembly

Proceed as follows:
Figure 48
306A071010R
- Remove the shim (5) and the spacer (4).

- Remove the flange (4) from the P4 module,
- Using tool J43020 remove the P3 module gear carrier (2)
from the main box (1).
Figure 49 Figure 52
274A05038 274A05041
- With appropriate lifting equipment remove the main - Unscrews the screws (1) and (2) that fasten the front
shaft module (1). cover (3) to the gearbox.
- Remove thrust ring (2) and thrust ring (3). - Remove the front cover (3).
Figure 50 Figure 53
274A05039 274A05042
- Remove module P2 (1).

- Remove clutch C5 consisting of externally toothed disks Before removing clutch assemblies C1 and C2
(2) and internally toothed disks (3). remove the turbine speed sensor to avoid damaging
it.
Figure 51
- Remove clutch assemblies C1 and C2 (1).
274A05040
- Remove module P1 (1).

Figure 54
3
1
274A05043
Before continuing, make sure that the gearbox is

perfectly horizontal.
- Unscrews the screws (3) that fasten the clutch

assemblies C3 and C4 (1) to the gearbox (2).
- Remove clutch assemblies C3 and C4 (1).
Cleaning Bearings and axial shims

- Check all the bearings looking for any notches, prick
Cleaning the components
markings, scoring or excessive wear, replacing those with
Clean all the dismantled components with care, bearing in defects or irregular functioning after cleaning and
mind the following: lubrication.
- carefully clean all the casings also externally, to be able - inspect bearings that could have notches, burrs, ovalising,
to check them and prevent dirt penetrating inside: sharp edges or signs of overheating replace damaged
components;
- for the bearing clutch disks, use solvent only All other
transmission metal components are to be perfectly - inspect end of stroke shims that could be deformed,
cleaned with solvent or steam. For steam cleaning, do scored, worn or with burrs replace faulty or worn parts.
not use solutions with caustic soda base;
Seal rings and other gaskets
- except for the bearings, all the components are to be
dried with compressed air The steam-cleaned - Check the piston rings and lip-seals, looking for any
components are to be oiled immediately after the drying; notches, cuts, tears, cracks and/or deformations if a
removed gasket is deteriorated, this could indicate faults
- clean the oil ducts passing a piece of soft wire in both
in the piston grooves or on the corresponding surface,
directions, then washing with solvent Dry the ducts with
that will also damage the new gasket;
compressed air;
- replace all the gaskets.
Never dry the bearings by rotating them with Gears, grooves and threaded parts
compressed air If it rotates very quickly, a bearing
that is not lubricated can easily deteriorate; - Check gears that could have localised wear, prick
markings, burrs or broken teeth: replace the gear if
defects are found;
- the bearings that have been used are to be thoroughly
washed with solvent if the bearings are very dirty or full - check that the grooves are not deformed, chipped or
with burrs, replace the gear if any defects are found;
of hardened grease, dip them in solvent before starting
to clean. - check there are no burrs or damaged threads, replace
damaged parts.
- to obtain the maximum life of the bearings correct
cleaning is important at disassembly/assembly.
Circlips and springs
Checks and controls - Check there are no signs of pricking, strain or excessive
wear on the circlips, if any one of these faults is found,
Casings and machined surfaces replace the circlip;
- Inspect the bores and mounting surfaces looking for any - look for signs of overheating, permanent set or wear
traces of wear, scoring, grooves remove scores and burrs caused by friction of adjacent parts on the springs: if any
with emery cloth replace badly scored or grooved parts; of these faults are found, replace the spring;
- check all the oil ducts: obstructions are to be removed
with a jet of compressed air or passing a smooth wire in Clutch disks
both directions of the duct and rinsing with a cleaning - Check the disks looking for any encrusted metal particles,
solvent strongly pricked surfaces, excessive wear, excessive
- check the thread, grind damaged threads with a tapping taper, cracking, deformation or damaged grooving;
device of the required dimensions; - replace damaged disks.
- replace boxes or other castings that are cracked or show
signs of grooving caused by excessive wear;
- check all the oil circuits in the control distributor and the
main body, looking for any porosity, broken seats, cracks,
dirt and/or surface flaws;
- check all the resting surfaces of the gaskets finding
deformations or surface flaws;
Main checking and overhaul operations

Torque converter end float check
Proceed as follows:
- place the converter in horizontal position (vertical axis) with the front side upward.
- With a depth gauge, measure dimension (A).
Figure 55
274A05055
- Install tool J38548 on the rear of the converter and place it in the same position, so that the converter hub rests on the tool.
Figure 56
274A05056
- With a depth gauge, measure dimension (B).

- Find dimension C as follows:

C = A — B (mm) (in)
where:
A = distance between converter front surface and thrust
ring rest under load
B = distance between converter front surface and thrust
ring rest without load
C= prescribed end float
- Check that dimension C is within the prescribed values.
C = 0.08 — 0.36 mm ( 0.003 — 0.014 in)
- If it is not so, determine the thickness of the thrust ring
acting as described below:
Find the thrust ring thickness

Proceed as follows:
The references for the operations described refer

to the figure on the next page.
- Place the converter in horizontal position (vertical axis)

with the front side upward.
- Unscrew the fastening screws (6).
- Carefully separate the cover (7) from the pump (35).
- Remove the turbine group (18) from the cover (7).
- Remove the stator (22).
- Remove the thrust ring (30).
- On the basis of value C find the thrust ring from the
following table:
Dimension C Allison p/n notches

0.08-0.36 mm ---
---
0.003-0.014 inch ---
0.36-0.58 mm 0.23-0.27mm
29503879
0.014-0.023 inch 0.009-0.011 in.
0.58-0.81 mm 0.46-0.50 mm
29503880
0.023-0.032 inch 0.018-0.020 in.
0.81-0.99 mm 0.69-0.73 mm
29503881
0.032-0.039 0.027-0.029 in.
- Install the selected thrust ring (30).

- Install the stator (22).
- Install the turbine group (18) on the cover (7).
- Tighten the four equidistant fastening nuts (6) to the
specified torque.
Tightening torque: 30-35 Nm (22-26 lb ft).
- Check the clearance as described in the relevant chapter.
- If it is not correct, repeat the procedure.
- If it is correct, tighten the remaining nuts to the specified
torque.
Tightening torque: 30-35 Nm (22-26 lb ft)
Torque converter assembly

1. Circlip
2. Plug
3. O-Ring
4. Not used
5. Torque converter module
6. Nut
7. Torque converter assembly(complete)
8. Converter cover assembly
9. Converter cover
10. Bushing
11. Lockup piston seal ring
12. Lockup piston assembly
13. Lockup piston seal ring
14. Flexible coupling assembly
15. Lockup clutch driven disk
16. Screw
17. Axial bearing assembly
18. Turbine assembly
19. Turbine hub seal ring
20. Axial bearing assembly
21. Toothed disk
22. Converter stator assembly (complete)
23. Circlip
24. Stator axial disk assembly
25. LH stator axial washer
26. Stator raceway
27. Stator spring
28. Stator roller
29. Cam and stator assembly
30. Spacer
31. Axial bearing ring
32. Pump axial bearing cage
33. O-Ring
34. Axial bearing ring
35. Converter pump assembly (complete)
36. Screw
Torque converter assembly
274A05060

Front support and oil pump module disassembly

Figure 59
The references of the operations and the table

described refer to the figure on the next page.
Proceed as follows:
- Remove the three seal rings (21) from the front support
hub (16).
- Unscrew the eight bolts (6) that join the oil pump body
(7) to the front support assembly.
- Remove the oil pump group (7) and the oil pump gear
assembly (8).
274A05063
Figure 57
- Measure the axial clearance between the oil pump body

and the oil pump gears.
Figure 60
274A05061
- Measure the depth of the gear housing in the oil pump

body.
Figure 58
274A05064
- Measure the clearance between the ends of the oil pump

gear teeth.
274A05062
- Measure the diameter of the gear housing in the oil

pump body.
- Insert the oil pump gear group (7) in the oil pump
assembly (8).
Front support and oil pump assembly

1 Screw
2 Screw
3 Front module assembly
4 O-ring
5 Seal ring
6 Screw
7 Oil pump body
8 Oil pump gear assembly
9 Bushing
10 Plate
11 Screw
12 Front support group (complete)
13 Sleeve
14 Front support group
15 Location pin
16 Front support body
17 Bushing
18 Spring
19 Ball
20 Location pin
21 Seal ring (three)
22 Needle bearing
Front support and oil pump assembly
274A05065
Figure 61 Figure 62
274A05066 274A05067
- Measure the clearance between oil pump driven gear - If worn or damaged, remove the sleeve (13).
and oil pump assembly.
- Using tool J41462 compress the spring (18) to free the
- Carefully check the bushing (9) inside the oil pump location pin (20).
driving gear.
- Remove the location pin (20).
- Unscrew the fourteen bolts that join the plate (10) to
- Carefully decompress the spring (18) turning tool J41462
the front support group (12).
grip anticlockwise.
- Remove the plate (10).
- When the spring (18) is completely extended, remove
- If worn or damaged, remove the needle bearing (22) tool J41462.
using a plug and a rubber hammer.
- Remove the spring (18) and the ball (19) from the front
- If worn or damaged, remove the bearing (17) from front support body.
support body (16).
- Carefully check the ball housing on the front support
body is not worn..
- Check the condition of the spring (18).
Wear limits
Ref. Description
mm In.
Oil pump body, maximum depth of gear
7 19,04 0.750
cavity
Oil pump body, maximum diameter of
7 150,25 5,915
gear cavity
Maximum clearance between driven
7,8 0.30 0,012
gear and pump body
Maximum axial clearance between
7,10 0,10 0,004
pump body and gear
Maximum clearance between gear teeth
8 0,15 0,006
ends
Front support bearing minimum outer
17,16 119,81 4,717
diameter
Front support reassembly Figure 64

Proceed as follows:
- Replace the front support body (16) if worn.
- Replace the spring (18) if the elastic constant is no longer
within the prescribed limits.
- Fit the ball (19) and the spring (18) on the front support
body.
- Using tool J41462 to compress the spring (18) and insert
the location pin (20).
- Remove tool J41462.
Figure 63 A
274A05069
- If removed, align the bearing lubrication hole (17) with

the pressure relief valve hole (A).
- Refit the bearing (17) using the press and tools J37041
and J37034.
- Refit the plate (10) tightening the fourteen bolts to the
specified torque.
Tightening torque: 50-60Nm (38-45 lb ft)
- Refit the needle bearing (22) using a press and tools
J37038 and J8092.
- Embed the 0.25 mm ( 0.009 inch) needle bearing (22)
under the surface.
Oil pump body reassembly

Proceed as follows:
- If removed, refit the bearing (9) of the oil pump gear
assembly driving gear (8).
- Align the groove with the gear location in the oil pump
gear assembly (8).
- Lubricate the oil pump gear assembly and refit it in the
oil pump body.
- Refit the oil pump body tightening the eight bolts (6) to
Tightening torque: 50-60Nm (38-45 lb ft)
274A05068 - Refit the three seal rings (21) on the front support hub
(16)
- If removed, refit the sleeve (13) with a press Pay

attention that the notch (A) on the sleeve is perfectly
aligned to the arrow (B) stamped on the front support
body.
- Insert the sleeve (13) in the central support body (16).

Rotating clutches moduledisassembly - Remove the O-ring (2) from the turbine shaft (5).
The references of the operations and the table Figure 65

Proceed as follows:
- Remove the internal circlip (41).
- Remove the complete sun gear.
- Carefully check the wear of the bushing (40) Replace if
very worn.
- Remove the internal circlip C2 (38).
- Remove the clutch C2 contrast disk (37).
- Remove the clutch C2 pack consisting of seven internal
tooth disks (36) and seven external tooth disks (35).
- Remove the clutch C2 hub (34) and the two thrust rings 274A05075
(33) Carefully check the state of wear of the clutch hub
grooved shaft. - Place the rotating clutches assembly (1) on tool
- Remove clutch C1 hub (32) Carefully check the state of J37030-3 so that the drum is sustained by the tool arms.
wear of the clutch hub grooved shaft. - Insert tool J35923-2.
- Remove the clutch C1 external circlip (31). - Using the tools, compress the clutch C1 balancing piston
- Remove clutch C1 consisting of: a contrast disk (30) (24) and the clutch springs (23) and remove the circlip
seven external tooth disks (28) and seven internal tooth (26).
disks (29) and a pressure plate (27).
- Remove thrust ring (12) from the rotating clutch hub (9). Release the springs contrast force very cautiously
The piston springs are strongly compressed Risk of
- Remove the circlip (13) and the turbine shaft (5). serious accidents if the force of the springs is not
- Carefully check the state of wear of the bearing (3) inside controlled.
the turbine shaft (5).
- Remove the three seal rings (6). - Stretch the springs rotating the grip of the tool
anticlockwise Remove tools J37030-3 and J35923-2.
- Remove the clutch balancing piston (24), the seal ring
(25) and the clutch C1 springs.
Figure 66
274A05076
- Install tools J37030-3, J37030-1, J35923-2.

- Using the tools, remove the internal circlip (20) Only
remove the tools after the springs contrast force has
been completely released.
Rotating clutches module assembly

1 Rotating clutches assembly
2 O-ring
3 Bushing
4 Turbine shaft assembly
5 Turbine shaft
6 Seal ring (three)
7 Rotating drum
8 Thrust ring
9 Rotating clutch hub (complete)
10 Bushing
11 Rotating clutch hub
12 Thrust ring
13 Circlip
14 Piston C2 seal ring
15 Piston C1 seal ring
16 External seal ring
17 Clutch C2 piston
18 Clutch C2 spring
19 Clutch C2 pressure plate
20 Internal circlip
21 Clutch C1 seal ring
22 Piston C1
23 Clutch C1 spring
24 Rotating clutch balancing piston
25 Rotating clutch balancing piston seal ring
26 Rotating clutch balancing piston circlip
27 Clutch C1 pressure plate
28 Clutch C1 external tooth disk (seven)
29 Clutch C1 internal tooth disk (six)
30 Clutch C1 contrast disk
31 External Circlip
32 Clutch C1 hub
33 Thrust ring (two)
34 Clutch C2 hub
35 Clutch C2 external tooth disk (seven)
36 Clutch C2 internal tooth disk (seven)
38 Internal circlip
39 Sun gear (complete)
40 Bushing
41 Internal circlip
Rotating clutches module assembly
274A05077
- Remove clutch C2 springs (18). Rotating clutches module reassembly.

- Raise the rotating drum (7) without the rotating clutch Proceed as follows:
hub assembly (11) and pistons C1/C2 (22) and (17)
Carefully check the state of wear of the rotating drum Figure 67
grooved shaft.
- Remove pistons C1/C2 (22) and (17) and seal rings (16)
and (21) from the rotating clutch hub (9).
- Remove the piston seal rings (14) and (15) from rotating
clutch hub (11).
- Separate the piston C1 (22) and seal ring (21) from
piston C2 (17) and from seal ring (16) knocking lightly
on piston C1 (22).
Wear limits
Ref. Description
mm In.
Turbine shaft bearing maximum inner di-
3 36,14 1,423
ameter 274A05078
7 Drum groove maximum wear 0,38 0,015
32,34 Clutch hub groove maximum wear 0,38 0,015
- Refit the piston seal ring (14) on the rotating clutch hub
and the seal ring (16) in piston C2 (17) Pay attention to
the direction of the ring assembly (16).
- Refit the piston seal ring (15) on the rotating clutch hub
and the piston seal ring (21) on piston C1 (22).
- With a rubber hammer, insert piston C2 (17) with the
seal ring (16) in the rotating clutch hub assembly (9).
- Align the notch on piston C1 to one of the lubrication
holes on the rotating clutch hub With a rubber hammer,
insert piston C1 (22) with the seal ring (21) in the centre
of piston C2 (17) and in rotating clutch hub assembly
(11).
- Refit the rotating drum (7)on the rotating clutch hub
assembly (9) and on pistons C1/C2 (22) and (17).
- Refit the C2 springs unit Fit the springs unit aligning it with
the shanks of the driver hub and the grooves on piston
C2.
- Make sure that the C2 springs unit is in contact with the
piston C2 flange If the C2 springs unit does not contact
the flange, remove the complete unit and refit until it
rests correctly on the flange.
- Refit the clutch pressure plate (19) Fit the clutch - Insert tool J35923-2, compress springs unit C1 and refit
pressure plate aligning it with the shanks of the driving the circlip (26) in the rotating clutch assembly hub.
hub and the grooves on piston C2.
- Only remove the tools after the springs contrast force
has been completely released.
Figure 68 - If removed, refit the bushing (3) in the turbine shaft (5)
using tools J37036 and J8092.
- Remove the O-ring (2) from the front of turbine shaft
(5).
- Refit the three seal rings in the seats on the sleeve.
- Refit the turbine shaft assembly (4) Clamp the turbine
shaft with the circlip (13).
Make sure that the thrust ring is assembled correctly

Make sure that the shim edge outside and inside the
guide does not interfere with the coupling of the
parts. Problem that would cause premature wear of
the shim and a wrong adjustment of the internal
clearances.
274A05079
- Refit thrust ring (12) on the rotating clutch hub (11).
- Fit the rotating clutches assembly on tool J37030-3 so - Refit the clutch unit C1 consisting of: pressure plate (27)
that the drum is supported by the tool arms. Insert tools seven external tooth disks (28) and seven internal tooth
J35923-2 and J37030-1. Using the tools, compress the disks (29) and a contrast disk (30) Assemble the clutch
C2 springs unit (18) and insert the internal circlip (20). disks alternating the disks with external teeth and those
with internal teeth, starting with external teeth (28) Refit
- Refit the seal ring (25) on the rotating clutch balancing the external circlip C1 (31).
piston (24).
- Refit clutch C1 hub Make sure that the hub does not
- Refit the C1 springs unit (23) Align the sign on the interfere with the external teeth of the seven clutch disks
balancing piston with the groove on clutch piston C1. (28).
Refit the balancing piston (24) and clutch piston C1.
- Refit the two thrust rings on both sides of clutch C2 hub
(34) and fit the group on the clutch C1 hub (32).
Figure 69
- Refit the clutch unit C2 consisting of: seven clutch disks
with internal teeth (36) seven clutch disks with external
teeth (35) Assemble the clutch disks alternating the disks
with external teeth and those with internal teeth, starting
with external teeth (35).
- Refit the clutch C2 contrast disk (37) Refit the internal
circlip (38).
- If removed, refit the bushing (40) on the complete sun
gear (39).
- Refit the sun gear hub (39) Refit the internal circlip (41).
274A05080

Clutches C3/C4 and main body module disassembly Clutches C3/C4 and main body module reassembly
Proceed as follows:
The references of the operations and the table - Replace clutch C4 piston (27) with a new one Refit
described refer to the figure on the next page. clutch C4 piston (27) in clutch C4 body (28) Refit the
return spring assembly ring (24).
- If removed, refit the four return springs (27) and secure
Proceed as follows: them correctly to the pressure plate (23).
- Remove the fourteen bolts (2) that join the clutch C3 - Refit the pressure plate (23) with the four return springs
contrast disk (3) to the clutch C3 body (16) Remove the (22)
clutch C3 contrast disk (3).
- Refit clutch C4 group Assemble the clutch disks
- Remove module P1 crown ring (7) Carefully check the alternating the disks with internal teeth (21) and those
state of wear of the module P1 crown teeth. with external teeth (20), starting with internal teeth (21).
- Remove clutch C3 group consisting of: five clutch disks - Replace the deformed clutch C3 piston (15) with a new
with internal teeth (8) and four clutch disks with external one Refit clutch C3 piston (15) in clutch C3 body (19).
teeth (9).
- Refit clutch C3 body (19) with clutch C3 piston (15) on
- Remove the pressure plate (11) with the four return clutch C4 body assembly Make sure that the notches on
springs (10) Carefully check the wear on the pressure the two clutch bodies are aligned Refit the return spring
plate. assembly ring (12).
- If damaged or very worn and it has to be replaced, - Refit the pressure plate (11) and the four return springs
remove the return springs (10) from the pressure plate (10) If removed, replace the return springs unit (10) with
(11) Remove the return springs assembly ring (12) and a new one, securing it correctly to the pressure plate
clutch C3 piston (15) Remove the seal rings (13) and (11).
(14) from clutch C3 piston (15).
- Refit module P1 crown ring (7).
- Remove the Clutch C3 body assembly (16).
- Refit clutch C3 group Assemble the clutch disks
- Remove the clutch C4 group consisting of five internal alternating the disks with internal teeth (8) and those
tooth disks (21) and four external tooth disks (20). with external teeth (9), starting with internal teeth (8).
- Remove the pressure plate (23) with the four return - Refit the clutch C3 contrast disk (3) Align the notch on
springs (22) Carefully check the wear on the pressure contrast disk C3 with the notches on the clutch C3 and
plate. C4 assemblies.
- Remove the return springs assembly ring (24) and clutch - Refit the fourteen bolts (2) of clutches C3 and C4
C4 piston (27) from the clutch C4 body (28). If present, tightening to the specified torque.
remove the seal rings (25) and (26) from clutch C4
piston (27) Carefully check the wear of the clutch C4 Tightening torque: 50-60Nm (38-45 lb ft)
body grooves (28).
Wear limits
Ref. Description
mm In.
7 Module P1 crown teeth maximum wear 0,38 0,015
11,23 Pressure plate minimum thickness 4,91 0,193
19,28 Clutch body groove maximum wear 1,15 0,045
Clutches C3/C4 and main body module assembly

1 Clutches C3/C4 assembly
2 Screw
3 Clutch C3 contrast disk (complete)
5 Module P1 thrust ring (four)
6 Rivet (twelve)
7 Module P1 crown ring
8 Clutch C3 internal tooth disk (five)
9 Clutch C3 external tooth disk (four)
10 Return springs (four)
11 Pressure plate
12 Return springs assembly ring
13 Seal ring
14 Seal ring
15 Clutch C3 piston
16 Clutch C3 body (complete)
17 Rivet (twelve)
18 Module P1 thrust ring (four)
19 Clutch C3 body
20 Clutch C4 external tooth disk (five)
21 Clutch C4 internal tooth disk (five)
22 Return springs (four)
23 Pressure plate
24 Return springs assembly ring
25 Seal ring
26 Seal ring
27 Clutch C4 piston
28 Clutch C4 body
29 Clutch C5 internal tooth disk (eight)
30 Clutch C5 external tooth disk (nine)
31 Screw
32 Automatic transmission box
Clutches C3/C4 and main body module assembly
274A05085

Planetary module P1 disassembly Planetary module P1 reassembly

Proceed as follows:
The references of the operations and the table - Refit the two needle bearings (12) inside the satellite
described refer to the figure on the next page. (11). Fit thrust rings (10) and (13) inside the module P1
carrier, align the tabs of the thrust rings with the planet
gear grooves Restrain the thrust rings with grease soluble
in oil Slide the satellite sideways with its needle bearings
Proceed as follows: in the module P1 carrier in the middle of the thrust rings
- Remove the internal circlip (2) from the P2 crown ring Repeat the same procedure with the other five satellites.
(15). - Refit the six satellite pins (6) positioning the chamfer to
- Remove module P 2 crown ring (15). guarantee correct assembly of the positioning ring (5).
- Remove the circlip (4) Remove the positioning ring (5). - Refit the positioning ring (5) and the circlip (4).
- Remove the six satellite pins (6) from module P1 carrier - Refit the module P2 crown ring (15) on the module P1
(8). carrier assembly (3).
- Slide a satellite (11), thrust rings (10) and (13) and two - Refit the internal circlip (2) on the module P2 crown ring
needle bearings (12) sideways from module P1 carrier. (15), thus joining the module P1 carrier assembly with
Repeat the same procedure with the other five satellites. module P2 crown ring (15).
- Remove thrust ring (14) from the module P1 carrier (8).
- Carefully check the state of wear of the bearing (9) inside Make sure that the thrust bearings are mounted
the module P1 carrier (8). correctly. Make sure that the bearing inner and
outer rings do not interfere with the coupling of the
parts Problem that would cause premature wear of
Wear limits
the bearing and a wrong adjustment of the internal
Ref. Description clearances.
mm In.
9 Bearing maximum inner diameter 89,32 3,516
- Refit thrust ring (14) on the module P1 carrier assembly
(3).
Planet gear module P1 assembly

1 Module P1
2 Internal circlip
3 Module P1 carrier assemblies
4 Circlip
5 Positioning ring
6 Satellite pin (six)
7 Module P1 carrier (complete)
8 P1 module carrier
9 Bushing
10 Thrust ring (six)
11 Satellite (six)
12 Needle bearing (twelve)
13 Thrust ring (six)
14 Thrust bearing
274A05086

Planet gear module P2 disassembly Planet gear module P2 reassembly

Proceed as follows:
described refer to the figure on the next page. - Refit the two needle bearings (10) inside the satellite
(11). Fit thrust rings (9) and (12) inside the module P2
carrier, align the tabs of the thrust rings with the planet
gear grooves. Restrain the thrust rings with grease
Proceed as follows: soluble in oil. Slide the satellite sideways with its needle
bearings in the module P2 carrier in the middle of the
- Remove the circlip (2). thrust rings. Repeat the same procedure with the other
- Remove module P 3 crown ring (15) Remove and three satellites.
carefully check the wear on the thrust ring (14). - Refit the four satellite pins (13) positioning the chamfer
- Remove the internal circlip (4) Remove the positioning to guarantee correct assembly of the positioning ring (5).
ring (5) Remove the four satellite pins (13) from module - Refit the positioning ring (5) and the circlip (4).
P2 carrier (7).
- Refit the module P3 crown ring (15) on the module P2
- Slide a satellite (11), thrust rings (9) and (12) and two carrier assembly (3).
needle bearings (10) sideways from module P2 carrier
(7). Repeat the same procedure with the other three - Refit the circlip (2) on the module P3 crown ring (15),
satellites. thus joining the module P2 carrier assembly with module
P3 crown ring.
- Carefully check the state of wear of the bearing (8) inside
the module P2 carrier (7).
Make sure that the thrust bearings are mounted
Wear limits
Ref. Description correctly. Make sure that the bearing inner and
mm In. outer rings do not interfere with the coupling of the
8 Bearing maximum inner diameter 53,23 2,096 parts Problem that would cause premature wear of
the bearing and a wrong adjustment of the internal
clearances.

1 Module P2
2 Circlip
3 Module P2 carrier assemblies
4 Internal circlip
5 Positioning ring
6 Module P2 carrier (complete)
7 P2 module carrier
8 Bushing
9 Thrust ring (four)
10 Needle bearing (eight)
11 Satellite (four)
12 Thrust ring (four)
13 Satellite pin (four)
14 Thrust bearing
274A05087

Planet gear module P3 disassembly Planet gear module P3 reassembly

Proceed as follows:
- Refit the two roller bearings (10) inside the satellite gear
(9). Fit the shims (8) inside the P3 planetary module (4),
align the tongues of the shims with the planetary
grooves. Stop the shims with oil soluble grease. Make
the satellite gear slide with the corresponding roller
Proceed as follows:
bearings by the side of the P3 planetary module in the
- Measure the clearance of a satellite of the P3 planetary middle of the shims. Repeat the same procedure on the
module (1). Clearance must be less than 0.94 mm (0.037 other three satellites.
inches). Repeat the measurement on the other three
- Refit the four satellite pins (7) orienting the chamfer so
satellites (9) of the module.
as to guarantee the correct assembly of the positioning
- Remove the inner safety circlip (2). Remove the ring (3).
positioning ring (3). Remove the four satellite pins (7).
- Refit the positioning ring (3) and the inner safety circlip
- Extract the planetary module P3, the satellite (9), the (2).
shim (8) and the two roller bearings (10) from the side.
- If parts have been replaced, check the clearance of a P3
Repeat the procedure on the other three satellites (9)
planetary module satellite gear (1). Clearance must be
of the module.
less than 0.94 mm (0.037 inches). Repeat the
- Measure the thickness and the degree of wear of the measurement on the other three satellites (9) of the
eight shims (8). The minimum allowed thickness is 1.40 module.
mm (0.055 inches). The maximum allowed wear is 0.12
mm (0.005 inches).
Do not fit the spacer (6) or the adjustment ring (12).
The measurements must be carried out at the end
of re-assembly.

1 P3 planetary module
2 Safety circlip
3 Positioning ring
4 P3 module carrier assembly
5 P4 module shaft flange
6 Spacer ring
7 Satellite pin (four)
8 Shims (eight)
9 Satellites (four)
10 Roller bearings (eight)
11 Bolt
12 Shim
13 Seal
14 C6 clutch casing
15 Piston assembly
16 Outer safety circlip
17 Return spring assembly
18 Piston
19 Piston o-ring
20 Piston o-ring
21 C6 clutch box assembly
22 C6 clutch box
23 Pressure test point assembly
24 Pressure test point
25 O-ring
26 Ball bearing
27 Driven clutch plate
28 Driven clutch plate
29 C6 clutch pressure plate
30 P4 module sun gear
31 Bronze bearing
32 P4 module carrier (complete)
33 Inner safety circlip
34 Inner safety circlip
35 Positioning ring
36 P4 module assembly and bushing
37 P4 module
38 Bushing
39 Satellite pin (six)
40 Shims (twelve)
41 Satellites (six)
42 Roller bearings (twelve)
43 C6 clutch drum hub
44 Bronze bearing
45 Ring gear and P4 module hub assembly
46 P4 ring gear
47 P4 module hub gear
48 Safety circlip
49 Ring
306A071011R
C6 clutch casing disassembly Final disassembly

Proceed as follows:
The references to the operations and table - Lift the C6 clutch pack consisting of eight drive plates
described below refer to the figure on the following (28) and nine driven plates (27) from the C6 clutch box.
page.
- Measure the thickness and taper ratio of each drive plate
(28). Minimum allowed thickness is 3.68 mm (0.145
Proceed as follows: inches). Maximum allowed taper ratio is 0.25 mm (0.010
- Remove the ring gear and P4 module hub assembly (45). inches).
- Remove the safety circlip (48) from the ring gear and P4 - Measure the thickness and taper ratio of each driven
module hub (45) and separate the P4 ring gear (46) from plate (27). Minimum allowed thickness is 3.24 mm (3.251
the P4 module hub gear (47). mm). Maximum allowed taper ratio is 0.25 mm (0.010
inches).
- Remove the bronze bearing (44).
- Remove the bronze bearing (31).
- Remove the C6 clutch pressure plate (29).
- Remove the P4 module sun gear.
- Fasten the three M8 eyebolts into the three blank holes
of the P4 module carrier assembly. - Fit tool J 43025 on the return spring assembly (17).
- Lift and remove the P4 module carrier assembly (32)
from the C6 clutch box (22).
Figure 70
P4 planetary module disassembly
Proceed as follows:
- Remove the inner safety circlip (33) from the C6 clutch
drum hub (43).
- Turn the P4 module carrier (complete) upside down and
remove the C6 clutch drum hub (43).
- Remove the inner safety circlip (34) and the positioning
ring (35) from the P4 module (complete) (32).
- Remove the six pins from the satellites (39) of the P4
module (37).
- Measure clearance with a satellite. Clearance must be
less than 0.94 mm (0.037 inches). Repeat the
measurement on the other five satellites of the module.
- Remove the six satellites (41) from the P4 module carrier 306A071012R
(complete) (32).
- Remove the twelve shims (40) and the twelve roller - Using tools J 35923-4 and J 43025 press the return spring
bearings (42) from the satellites. assembly (17).
- Measure the thickness and the degree of wear of the - Remove the outer safety circlip (16) and release the
twelve shims (40). The minimum allowed thickness is contrast force of the springs very carefully.
1.40 mm (0.055 inches). The maximum allowed wear is
0.12 mm (0.005 inches). - Remove the contrast spring assembly (17).
- Carefully check the wear of the bushing (38) of the P4 - Remove the C5 piston (18) from the C6 clutch casing
module (37). The maximum allowed inner diameter is (14).
113.33 mm (4.462 inches). Replace the bushing (38) if it - Remove the inner o-ring (20) from the C5 piston (18).
is worn or damaged. Remove the outer o-ring (19) from the C5 piston (18).
- Position the C6 clutch box assembly (21) on the press Re-assembly

base. Position tools J 43047 and J 37034 on the ball Proceed as follows:
bearing (26). Use a wooden block to secure the ball
bearing and prevent it from falling. - Position the C6 clutch box assembly (21) upside down
and position it on the press base.
- Position the ball bearing (26) on the C6 clutch box
Figure 71 assembly (21).
- Position tools J 43047 and J 37034 on the ball bearing
(26).
Figure 72
306A071013T
- Remove the ball bearing (26) using the press. 306A071014R
- Using the press, fit the ball bearing (26) into the
corresponding seat of the clutch box C6 assembly (21).
- Fit the lip seal (20) on the C5 piston (18). Fit the outer
o-ring (19) on the C5 piston (18).
- Align the notch on the back of the C5 piston with the
notch printed on the C6 clutch box (22) before fitting
the C5 piston (18). Using a rubber hammer, insert the
piston C5 (18) into the C6 clutch casing (14).
- Position the return spring assembly (17) in the C6 clutch
box assembly (21). Use the notch for correctly aligning
the two components.
Release the spring contrast force with great care.

The piston springs are very compressed. Risk of
severe accident if the force of the springs is not
controlled.
- Fit the outer safety circlip (16) in the C6 clutch box

assembly (21).
- Using tools J 35923-4 and J 43025 press the return spring P4 planetary module re-assembly
assembly (17). Remove the outer safety circlip (16) and Proceed as follows:
release the contrast force of the springs very carefully.
- Refit the two roller bearings (42) inside the satellite gear
(41). Fit the shims (40) inside the P4 planetary module
Figure 73 (4), align the tongues of the shims with the grooves of
the P4 module carrier (37). Stop the shims with oil
soluble grease. Make the satellite gear (41) slide with the
corresponding roller bearings (42) by the side of the P4
planetary module (37) in the middle of the shims (40).
Repeat the same procedure on the other five satellites.
- Refit the six satellite pins (39) orienting the chamfer so
as to guarantee the correct assembly of the positioning
ring (35).
- Refit the positioning ring (35) and the inner snap ring
(34).
- If parts have been replaced, check the clearance of a P4
planetary module satellite gear. Clearance must be less
than 0.94 mm (0.037 inches). Repeat the measurement
on the other six satellites of the module. Remove the
306A071012R bronze bearing (44).
- Refit the P4 module carrier assembly (32) in the C6
clutch drum hub (43).
- Appropriately position the C6 clutch drum hub (43) on
the work bench to prevent the P4 module carrier
Figure 74 assembly (32) from slipping inside. Fit the inner safety
circlip (33) on the C6 clutch drum hub (43).
- Fasten the three M10 eyebolts into the three blank holes
of the P4 module carrier assembly (32).
Figure 75
306A071015R
306A071016R
- If they need to be replaced, refit the bushing (38) on the

P4 module (37) using tools J 43023 and J 37034.
- Refit the bronze bearing (31) on the P4 module sun gear
(30).
- Position the P4 module sun gear (30), with the bronze C6 clutch casing re-assembly
bearing facing upwards, in the P4 module carrier Proceed as follows:
assembly (32). Using a specific lifting means refit the P4
module sun gear (30) and the P4 carrier assembly (32) - Fit the C6 clutch pack with eight drive plates (28) and
in the C6 clutch box (22). nine driven plates (27) in the C6 clutch casing starting
with a driven plate. Fit all the plates in the same sense.
The driven plates (27) mesh with the C6 clutch box (22)
Do not fit the ring gear and the P4 module hub (45) while the drive plates (28) mesh with the C6 clutch drum
in the C6 clutch box assembly (21). The hub (43).
measurements must be carried out at the end of - Fit the C6 clutch pressure plate (29).
re-assembly.
Reassembly
When reassembling, bear in mind the following:

 heat the bearings and rings for thrust assembly in
oven at 100 ˚C.
 exactly centre and assemble the seal rings and
bearings with appropriate keying device;
 lubricate ring nuts and bearings;
 lubricate driven and driving disks.
Clutches and gears assembly

Proceed as follows:
Figure 76
274A05090
Before continuing, make sure that the gearbox is

perfectly horizontal.
- Install clutch assemblies C3 and C4 (1) in the gearbox.

- Tighten the two screws (3) in symmetrical position to
secure the group.
- Bring the gearbox to vertical position and tighten the
other screws (3) to the specified torque.
Figure 77
Satellites P1 mesh with P1 external crown ring
inside clutches C3 and C4 assembly.
Figure 80
1
C5
2
3
274A05091
- Install clutch assemblies C1 and C2 (1) in the gearbox.
Figure 78
2 - Install module P2 (1).
274A05094
Satellites P2 mesh with external crown ring P2.
- Install clutch C5 consisting of externally toothed disks (2)

and internally toothed disks (3) starting with an
1 externally toothed disk.
- Fit all the disks in the same direction.
274A05092
The externally toothed disks mesh with the

- Fit the front cover (3) on the gearbox. gearbox, the internal teeth with external crown ring
- Tighten the screws (1) and (2) that fasten the front cover P3.
(3) to the gearbox locking to the specified torque.
Tightening torque: 50-60 Nm (38-45 lb ft) Figure 81
Figure 79
1
1
274A05095
274A05093
- With appropriate lifting equipment install the main shaft
- Install module P1 (1) module (1).
P3 planetary module assembly C6 clutch casing assembly
Figure 82 Figure 83
306A071010R
- Fit tool J 43020 on the P3 planetary module (2). Using

306A071017R
a suitable lifting tool, fit the P3 planetary module on the
automatic transmission assembly (1).
- Position a new seal (2) on the C6 clutch casing.
- Fit the P4 shaft flange (3).
Caution: either two operators or suitable lifting

Do not fit the adjustment shim. The measurements means are needed considering the weight of the C6
must be carried out at the end of re-assembly. clutch casing.
- Use appropriate lifting means to position the C6 clutch

casing (4) on the automatic transmission.
- Fasten the fourteen bolts (3) which join the C6 clutch
casing (4) to the automatic transmission assembly (1).
Determining the thickness of the P3 planetary module shim - Identify the P3 planetary module spacer according to
(arrow) dimension C in the following table:
Figure 84
Dimension C
Allison p/n Notches
[mm / in]
0.8830 - 1.1534
29530516 no notch
0.0347 - 0.0454
1.1535 - 1.4234
29530517 1 notch
0.0455 - 0.0560
1.4235 - 1.6934
29530518 2 notches
0.0561 - 0.0666
1.6935 - 1.9634
29530519 3 notches
0.0667 - 0.0772
1.9635 - 2.2334
29530520 4 notches
0.0773 - 0.0879
2.2335 - 2.5034
Proceed as follows: 29530521 5 notches
0.0880 - 0.0985
- Fit the seal on the C6 clutch casing. 2.5035 - 2.7734
29530522 6 notches
- Using a calibrated ruler J43922, measure dimension (A) 0.0986 - 0.1091
on the C6 clutch casing. 2.7735 - 3.0434
29530523 7 notches
- Arrange the rear lid so that the output shaft does not rest 0.1092 - 0.1198
on the bench. 3.0435 - 3.3134
29530524 7 notches
Figure 85 0.1199 - 0.1304
- Install the chosen P3 planetary module spacer (2) and

the thrust bearing ring (3) in the C6 clutch casing.
- Fit the outer ring gear of the P4 module locking it with
safety circlip.
Proceed as follows:
- Fit the hub of the outer ring gear of the P4 module
(arrow).
- Using the calibrated ruler and the shims J43922, measure
the dimension (B) on the rear lid.
- Determine dimension C as follows:
C = A — B (mm) (in)
where:
A = distance between C6 clutch casing assembly surface
(with seal) and P3 module shim resting surface;
B = distance between rear lid assembly surface and resting
surface of the P4 module outer ring gear hub spacer;
274A05096
Rear cover assembly Figure 88

Proceed as follows:
Figure 86
- Fasten the bearing ring nut at the specified torque using

tools J 37035 and J 43278.
- Fit the centring bolts to maintain the seal (3) in position Tightening torque: 74-88 Nm (55-64 lb ft)
and facilitate the assembly of the rear lid (6).
- Use a new seal and position it on the C6 clutch casing
Always use a new ring nut.
(2).
- Use appropriate lifting means to position the rear lid (6)
on the C6 clutch box (2). Fit the rear supporting
brackets, if used.
Figure 89
Figure 87
- Fit the shaft o-ring (29) using tools J 43024 and J 37034
and a rubber hammer.
- Fasten the fourteen bolts (4) and the five bolts (5).
Tighten all bolts at the specified torque.
Converter assembly Figure 91

Proceed as follows:
Figure 90
1 2
274A05036
- Fit two centring pins of an appropriate length.

- Fit the gasket (2).
- With appropriate lifting equipment install the converter
bell(1) on the gearbox (4).
- Tighten the screws (3) that internally fasten the bell (1)
to the gearbox (4).
- Remove the location pins.
- Tighten the screws (3) that externally fasten the bell (1)
to the gearbox (4) locking to the specified torque
Figure 92
274A05034
- Install tool J38548 on the converter shaft.

- Tighten tool J38548 to a torque of 27-34 Nm (20-25
lbft).
The correct torque of tool J38548 clamping screw

is important for the choice of the adjustment ring.
274A05099
To lock the turbine shaft rotation, proceed as
- With appropriate lifting equipment install the torque follows:
converter (1).  if the hydraulic control assembly has already
been removed, insert a large screwdriver in the
teeth of the clutch groups C3 and C4 (detail A).
The stator shaft groove meshes with the converter  if the hydraulic control assembly has not been
stator, the turbine shaft groove meshes with the removed, engage the lock-up clutch introducing
converter turbine. compressed air in the cap indicated (detail B)
The converter pump hub groove meshes with the then clamp the shaft as indicated.
pump.
Find the adjustment ring thickness where:

Proceed as follows: A = height of tool J38548;
- Find dimension C as follows: B = distance between tool J38548 and turbine shaft surface
C = A — B (mm) (in) for adjustment ring resting;
C = adjustment ring thickness + prescribed end float.
Figure 93
274A05100
- On the basis of value C find the adjustment ring from the

following table:
Dimension C thickness Allison p/n n ID
0.4129-0.6598 mm 4.000 mm
29505688 0
0.0163-0.0259 inch 0.157 inch
0.6599-0.8378 mm 4,203 mm
29505689 1
0.0260-0.0329 inch 0.165 inch
0.8379-1.0158 mm 4.381 mm
29505690 2
0.0330-0.0399 inch 0.172 inch
1.0159-1.1938 mm 4.559 mm
29505691 3
0.0400-0.0469 inch 0.179 inch
1.1939-1.3708 mm 4.736 mm
29505692 4
0.0470-0.0539 inch 0.186 inch
1.3709-1.5488 mm 4.914 mm
29505693 5
0.0540-0.0609 inch 0.193 inch
1.5489-1.7268 mm 5.092 mm
29505694 6
0.0610-0.0679 inch 0.200 inch
1.7269-1.9048 mm 5.270 mm
29505695 7
0.0680-0.0749 inch 0.207 inch
1.9049-1.9733 mm 5.448 mm
29505696 8
0.0750-0.0776 inch 0.214 inch
- Remove tool J38548.

Figure 94 Hydraulic control group assembly

Proceed as follows:
Figure 95
274A05101
- Install the selected adjustment ring (5).

- Using tool J38564 tighten the central nut (4) to the
specified torque. 3
Tightening torque: 100-120 Nm (74-89 lb ft) 1
- Fit the cap (2) and its O-ring (3).
2
274A05102
- Fit two location pins of an appropriate length.

- Fit the gasket (1).
- With appropriate lifting equipment install the hydraulic
assembly (2).
- Insert solenoid valves electric connector (3) in the
gearbox cable clamp.
- Remove the location pins.
- Tighten the screws (4) and (5) that fasten the group to
the gearbox locking to the specified torque.
- Fasten the connector with the related device.
External parts assembly Figure 97

Proceed as follows:
Figure 96
1 2
274A05106
- Install the input speed sensor (1), the turbine speed

sensor (2) and the output speed sensor (3) with the
O-rings.
306A071007R - Lock the sensors with the retaining bracket and tighten
the fastening nut.
- Fit the oil level rod assembly (4). Figure 98
306A071006R
- Fit the output flange (1).


AUTOMATIZED GEARBOX
ZF 16AS 2601 (Astronic 2)
SECTION 7.2
HD9 Euro5 SECTION 7.2 AUTOMATIZED GEARBOX 1
SECTION 7.2
Automatized gearbox ZF 16AS 2601
(Astronic 2)
Page
DESCRIPTION 3
- Version with Intarder (retarder) 4
- Standard version 4
- Main components location 7
- EuroTronic transmission display - Version V33
(lever selector) 8
- EuroTronic transmission display - Version V35
(push button selector) 9
COOLING SYSTEM WITH RADIATOR 10
- Oil circulation diagram 11
- List of failure codes 12
TOOLS 36
GENERAL 41
- Version without Intarder 42
- Exhaust 42
- Filling 42
- Version with radiator 43
- Exhaust 43
- Filling 43
- Version with intarder 44
2 AUTOMATIZED GEARBOX SECTION 7.2 HD9 Euro5
- Exhaust 44 - Checks 53
- Filling 45 - Gearbox actuator 53
- Final operations 45 - Removal 53
TRANSMISSION REMOVAL-REFITTING 46 - Refitting 54
GENERAL 46 - Removing the rear box 54
- Safety instructions 46 - Removing the rear box 55
- Vehicle preparation 46 - Removing the epicyclic reduction gear train
(E.R.G.) 56
- Hazardous and/or polluting substances 46 - Fitting the epicyclic reduction gear train (E.R.G.) 58
- Very heavy parts 46 - Adjusting epicyclic reduction gear train bearing
end float 59
- Adjusting main shaft end float 60
- Synchronizing device assembly for engaging
- Preliminary operation 47 normal or reduced gears 62
- Removal 47 - Removal 62
- Versions with cooling radiator 48 - Removing the middle box 65
- Versions with intarder and separate heat - Removing the main shaft 67
exchanger 48
- Removing the drive input shaft 69
- Versions with intarder and integrated heat
exchanger 49 - Removing the splitter synchronizing device 70
- Inspections and checks 50 - Fitting the splitter synchronizing device 71
- Refitting 50 - Fitting the main shaft 72
- Final operations 50 - Fitting the drive input shaft 72
REMOVING AND REFITTING THE TRANSMISSION - Splitter control fork 75
OIL RADIATOR 51
- Removal - Fitting 75
GENERAL 51
- Gear control forks 75
- Removal 75
- Fitting 76
- Transmission shafts 77
- Removal - Fitting 77
- Fitting the middle box 77
- Fitting the front box 80
- Front cover 82
- Removal 52
- Removal 82
- Fitting the front cover 82
- Refitting 52
- Adjusting drive input shaft bearing end float 82
- Adjusting transmission shaft bearing end float 83
OVERHAULING THE GEARBOX 53
- Clutch release lever 85
DESCRIPTION
The AsTronic 16 AS 2601 is a dual-shaft, electro-pneumatically controlled mechanical transmission.
The driver may choose to program manual or automatic gear selection/engagement. For this purpose, the following components
are provided:
S an electronic control system
S a gear engagement/disengagement actuator
S a dry clutch engagement/disengagement actuator.
The shafts and gears have a helical toothing to ensure quiet operating noise.
The primary shaft gears are engage by means of front toothing sleeves. Engagement of the splitter and planetary reducer unit
is synchronised.
Gears are selected with finely graded ratios and may be engaged in sequence using the planetary gear reducer and the low or
high gears using the splitter.
The primary shaft gears are doubled by engaging the planetary gear reducer. The ratios thus obtained are further doubled by
engaging the splitter. Each ratio is therefore split into a low range and a high range.
The transmission may be equipped with a supplementary electro-pneumatically controlled retarder brake (intarder) equipped
with independent or integrated heat exchanger.
See SECTION 8 of this manual for more information on the retarder.

Standard version
Figure 1
357A072100R
1. Clutch actuator - 2. Transmission outlet speed sensor for tachograph - 3. Transmission outlet speed sensor for ECU -
4. Neutral position sensor - 5. ECU connector chassis side - 6. ECU - 7. ECU connector on transmission side
Version with Intarder (retarder)

Figure 2
360F072001R
1. Dry single plate clutch - 2. Clutch electro-pneumatic actuator - 3. ECU - Electro-hydraulic gear engagement/disengagement
actuator - 4. Intarder - 5. Integrated heat exchanger
Figure 3
360F0072002R
1. Transmission type - 2. ZF part number - 3. Serial number - 4. IVECO part number for spare parts - 5. Transmission
transmission ratio - 6. Tachometer transmission ratio - 7. PTO type - 8. PTO transmission ratio -
9. Dry oil change amount - 10. ZF lubricant list name
Figure 4
360F0072016R
K1 = splitter low gears (GV)

K2 = splitter high gears (GV)
1 = 1st gear
2 = 2nd gear
3 = 3rd gear
4 = 4th gear
R = Reverse
GP = planetary gear reducer (H/L)
Main components location

Figure 5
357A072200R
1. Clutch actuator - 2. Nor used - 3. Transmission outlet speed sensor for control unit - 4. Neutral position sensor -
5. Control unit connector chassis side - 6. VDB (Vehicle Data Bus) CAN line - 7. System internal CAN line -
8. Transmission electronic control unit - 9. Control unit connector transmission side
EuroTronic transmission display - Version V33 (lever selector)
The display shows information regarding transmission condition.

A Indication of gear engaged (e.g. 1./.16 or N, RL and RH).
Other information displayed:
CH = system self-diagnosis; shown with ignition key on.
AL = no air; shown in alternation with normal indication.
FP = bring the accelerator pedal to idle position : if the indication on the display remains, there is a system fault and it is
not possible to continue driving.
CL = alternates with the current indication and signifies a clutch overload.
CW = worn clutch; the clutch requires replacement.
__= gear change; shown during a gear shift.
EE = shown when there is a dialogue error between display and electronic control unit.
HT = electronic control unit temperature too high.
nn = alphanumeric code that identifies a fault found by the control unit : for example.
68 = fault 68 found in system.
B Up/down arrow: along with the number of the bars displayed it indicates possible gear shifts.
C Bars: along with the arrows, they indicate the number of gears that can be changed or down shifted (max 4).
D Wrench for bolts: system error. Displayed when running is only possible with some limitations.
Go to a specialised workshop as soon as possible.
E STOP: together with the previous indication: indicates an immediate stop is necessary due to a serious system failure.
EuroTronic transmission display - Version V35 (push button selector) (fig. 1)
2 3
Indications on the instrument display
Fig. 2, ref- 1
01 - 16 = Indicates the forward gear engaged
00 = idle
R1 = fast reverse gear
R2 = slow reverse gear
In addition, the display shows any information regarding faults:
AL = no air supply
AP = accelerator depressed at engine start
CH = system troubleshooting: at ignition.
CL = indicated clutch overloaded.
CW = indicates clutch wear; clutch must be replaced as soon as possible.
HT = excessive electronic control unit temperature.
Fig. 2, ref. 2
Mode symbol
The following cases may occur for the modes below (Fig. 3)
a. automatic mode
b. manual mode
The number of horizontal lines stands for the gears that can be shifted in the current condition: e.g: three lines = 3 speeds
c. manoeuvre mode at low speed
COOLING SYSTEM WITH RADIATOR

Transmission can be equipped with an oil cooling system.
The radiator has a thermostatic switch to activate the electric fan.
Figure 6
HD9ST0037MR
5. Thermostatic sensor - 6. Electric fan - 7. Radiator
Oil circulation diagram
Figure 7
HD9ST0038MR
The position of each check valve along the pipe depends on the type of system.
List of failure codes
Buzzer
Code
Failure description System reaction
Short circuit to ground If the error occurs while shifting is in process, depending on the driving
at output stage to conditions either the current gear will be kept active or the TCU will
splitter (GV) Valve Y2. try to engage a gear which is engageable with the current error.
For direct drive design: The driver is able to initiate shiftings both in driving and stationary
002 shifting into high splitter X X situations. The type of error will influence the shifting-process.
group not possible.
For overdrive design: If no allowed gear is correct engageble, the TCU shifts to „Neutral“
shifting into low splitter or the clutch remains open.
group not possible. Output stages with short circuit will be switched off.
Short circuit to ground If the error occurs while shifting is in process, depending on the driving
at output stage to conditions either the current gear will be kept active or the TCU will
splitter (GV) Valve Y3. try to engage a gear which is engageable with the current error.
003 shifting into low splitter X X situations. The type of error will influence the shifting-process.
group not possible.
For overdrive design: If no allowed gear is correct engageble, the TCU shifts to „Neutral“
shifting into high splitter or the clutch remains open.
If the error occurs while shifting is in process, depending on the driving
conditions either the current gear will be kept active or the TCU will
try to engage a gear which is engageable with the current error.
Short circuit to ground The driver is able to initiate shiftings both in driving and stationary
004 at output stage to Y4 X X situations. The type of error will influence the shifting-process.
(Valve Select).
If no allowed gear is correct engageble, the TCU shifts to „Neutral“
or the clutch remains open.
Output stages with short circuit will be switched off.
(Valve Select).
006 at output stage to Y6 X X X situations. The type of error will influence the shifting-process.
(Valve Select).
Buzzer
Code

007 at output stage to Y7 X X X situations. The type of error will influence the shifting-process.
(Valve Select).
Short circuit to ground try to engage a gear which is engageable with the current error.
at output stage to Y8
The driver is able to initiate shiftings both in driving and stationary
008 (Valve Range). X X situations. The type of error will influence the shifting-process.
Shifting into Range
”Low“ not possible.
Short circuit to ground try to engage a gear which is engageable with the current error.
009 (Valve Range). X X situations. The type of error will influence the shifting-process.
Shifting into Range
”High“ not possible.
Short circuit to ground No gearshifting possible! No neutral shifting possible!
010 (Main valve). Air supply X X X Selected gear remains engaged; Vehicle start permitted in engaged
not available. gear. After ignition on, system not available
Short circuit to ground

011 at output stage to X Warning-Buzzer permanently active
warning buzzer.
Vehicle without Mux:
at output stage to
reverse light relay.
Reverse light respectively „add. manoeuvering mode lamp“
012 Vehicle with Mux: X permanently switched on. No other functional restrictions.
at output stage to ”add.
Manoeuvering mode
lamp“.
Driving: Gearshifting blocked. Stationary: TCU tries to open the
Short circuit to ground clutch, when coming to standstill. Neutral automatically engaged at
013 at output stage to PTO X X X standstill. Gearshifting blocked, continued driving not possible. System
1.
not available.
Buzzer
Code

Short circuit to ground clutch, when coming to standstill. Neutral automatically engaged at
014 at output stage to PTO X X X standstill. Gearshifting blocked, continued driving not possible. System
2.
not available.
TCU output switches off. Driving: Upshifts during driving are
controlled like downshifts. Input speed will be synchronized by engine
speed. Upshifts blocked, when input target speed is below engine idle
Short circuit to ground speed. Increased shifting time. Stationary: Increased self adjustment
017 at output stage to Y1 X X time.
(inertia brake valve).
Increased shifting time when shifting out of neutral.
Increased PTO engagement time.
at output stage to Y17 TCU output switches off. Function taken on by valve Y16 (clutch
018 (valve clutch disengage X X disengage fast). Decreased comfort for clutch functions.
slow).
at output stage to Y15 TCU output switches off. Function taken on by valve Y14 (clutch
019 (valve clutch disengage X X disengage fast). Decreased comfort for clutch functions.
slow).
at output stage to Y16 TCU valve output switches off. Function taken on by valve Y17
020 X X (clutch disengage, slow). Increased shifting time. Decreased comfort
(valve clutch disengage
for clutch functions.
fast).
at output stage to Y14 TCU valve output switches off. Function taken on by valve Y15
021 X X (clutch disengage, slow). Increased shifting time. Decreased comfort
(valve clutch disengage
for clutch functions.
fast).
at output ADVP or
ADVP1 (wakeup Driving: Gearshifting blocked. Stationary: TCU tries to open the
control signal for shift clutch, when coming to standstill. Neutral automatically engaged at
022 X X X standstill. Gearshifting blocked, continued driving not possible. System
lever ECU, voltage
supply to ZF-display, not available.
warning buzzer, output
speed sensor 1).
at transmission actuator
025 (TCU) output SD to X If ZF-display existing, display is flashing ”EE”. No system restrictions.
ZF-display.
Applied substitute parameters (P1 to P7) from data application field
will be taken. Reduced functionality for automatic mode and start gear
CAN engine
026 X X calculation, if deviation of substitute parameters and real values is high.
configuration timeout.
Target speed for downshifting can be reduced. Quality of clutch
disengagement for stopping can be reduced.
Applied substitute parameters (P1 to P7) from data application field
Error on ”engine will be taken. Reduced functionality for automatic mode and start gear
027 configuration message” X X calculation, if deviation of substitute parameters and real values is high.
(engine configuration). Target speed for downshifting can be reduced. Quality of clutch
disengagement for stopping can be reduced.
Buzzer
Code
Error on ”Actual
driveline retarder - No calculation of driving resistance possible. No automatic
028 X X calculation of start off gear. When coming to standstill, medium start
percent torque” signal
off gear will be shifted. No other functional restrictions.
(ERC1_DR).
Error on ”Engine
There are no downshift requests coming from retarder to increase
029 coolant load increase” X X engine speed to improve cooling power.
signal (ERC1_DR).
Error on ”Driveline
retarder configuration No calculation of driving resistance possible. No automatic
030 X X calculation of start off gear. When coming to standstill medium start
message” (Driveline
off gear will be shifted. No other functional restrctions.
retarder configuration).
No calculation of driving resistance possible. No automatic
Error on ”Actual engine calculation of start off gear. When coming to standstill medium start
retarder - percent off gear will be shifted. No other
031 torque” signal functional restrictions. No information about engine brake torque. If
(ERC1_ER). exhaust brake is active, shifting quality at start of shifting may be poor.
Engine brake is considered not active.
Error on ”Engine
retarder configuration No calculation of driving resistance possible. No automatic
message” (Engine
retarder configuration).
CAN ”Engine retarder
configuration” timeout.
Interruption at output If the error occurs while shifting is in process, depending on the driving
stage to splitter (GV) conditions either the current gear will be kept active or the TCU will
Valve Y2 try to engage a gear which is engageable with the current error.
034 shifting into high splitter X X situations. The type of error will influence the shifting-process.
group not possible.
For overdrive design: or the clutch remains open.
shifting into low splitter
Interruption at output If the error occurs while shifting is in process, depending on the driving
stage to splitter (GV) conditions either the current gear will be kept active or the TCU will
Valve Y3. try to engage a gear which is engageable with the current error.
group not possible.
For overdrive design: or the clutch remains open.
shifting into high splitter
Buzzer
Code

Interruption at output
036 stage to Y4 (Valve X X situations. The type of error will influence the shifting-process.
Select). If no allowed gear is correct engageble, the TCU shifts to „Neutral“
037 stage to Y5 (Valve X X situations. The type of error will influence the shifting-process.
Select). If no allowed gear is correct engageble, the TCU shifts to „Neutral“
Interruption at output The driver is able to initiate shiftings both in driving and stationary
038 stage to Y6 (Valve X X X situations. The type of error will influence the shifting-process.
Shift).
Interruption at output The driver is able to initiate shiftings both in driving and stationary
039 stage to Y7 (Valve X X X situations. The type of error will influence the shifting-process.
Shift).
Interruption at output try to engage a gear which is engageable with the current error.
stage to Y8 (Valve The driver is able to initiate shiftings both in driving and stationary
040 Range). Shifting into X X situations. The type of error will influence the shifting-process.
Range „Low“ not
possible. If no allowed gear is correct engageble, the TCU shifts to „Neutral“
Buzzer
Code

Interruption at output try to engage a gear which is engageable with the current error.
041 Range). Shifting into X X situations. The type of error will influence the shifting-process.
Range „Low“ not
Interruption at output No gearshifting possible! No neutral shifting possible!
stage to Y10 (Main
042 valve). Air supply not X X X Selected gear remains engaged; Vehicle start permitted in engaged
available. gear. After ignition on, system not available
043 to warning buzzer. X Warning -Buzzer can not be activated

stage to reverse light
relay
No reverse light respectively „add. manoeuvering mode lamp“
044 Vehicle with Mux: X activation possible. No further system restrictions.
stage to “add.
manoeuvering mode
lamp“.
Interruption at output PTO1 not available. PTO1-engagement-Error will be surpressed.
045 X X PTO1-request is not accepted. No further restrictions.
stage to PTO 1.
Interruption at output PTO2 not available. PTO2-engagement-Error will be surpressed.
046 X X PTO2-request is not accepted. No further restrictions.
stage to PTO 2
Driving: Upshifts during driving are controlled like downshifts. Input
Interruption at output speed will be synchronized by engine speed. Upshifts blocked, when
049 X X input target speed is below engine idle speed. Increased shifting time.
stage to Y1 (inertia
brake valve). Stationary: Increased self adjustment time. Increased shifting time
when shifting out of neutral.
Function taken on by valve Y16 (clutch disengage fast)
050 stage valve Y17 (clutch X X
Decreased comfort.
disengage slow).
Function taken on by valve Y14 (clutch engagement fast) Decreased
051 stage valve Y15 X X comfort.
(clutch engage slow).
Function taken on by valve Y17 (clutch engagement slow) Decreased
(clutch engage fast).
Buzzer
Code
Function taken on by valve Y15 (clutch engagement slow) Decreased
(clutch engage fast).
ADVP or ADVP1
(wakeup control signal clutch, when coming to standstill. Neutral automatically engaged at
054 X X X
for shift lever ECU, standstill. Gearshifting blocked, continued driving not possible. System
voltage supply to ZF- not available.
display, warning buzzer,
output speed sensor 1).
If PTO1 acknowledge signal is active before PTO1 request is active,
Acknowledge fault of
059 X X output stage PTO1 will be activeted after PTO1 request is activeted.
PTO 1.
No further system restrictions.
If PTO2 acknowledge signal is active before PTO2 request is active,
Acknowledge fault of
060 X X output stage PTO2 will be activeted after PTO2 request is activeted.
PTO 2.
No further system restrictions.
clutch, when coming to standstill. Neutral automatically engaged at
Disengagement fault
of PTO 1. not available.

Disengagement fault
of PTO 2. not available.
Engagement fault of PTO activation is switched off. No PTO 1 available. No further system
063 PTO 1. X X restrictions.
Engagement fault of PTO activation is switched off. No PTO 2 available. No further system
064 PTO 2. X X restrictions.
Short circuit to positive
at output stage to
splitter (GV) Valve Y2
For direct drive design:
group not possible.
For overdrive design:
group not possible.
Buzzer
Code

at output stage to
splitter (GV) Valve Y3
For direct drive design:
group not possible.
For overdrive design:
group not possible.
Short circuit to positive The driver is able to initiate shiftings both in driving and stationary
(Valve Select).
(Valve Select).
(Valve Select).
(Valve Select).
Buzzer
Code

Short circuit to conditions either the current gear will be kept active or the TCU will
positive at output try to engage a gear which is engageable with the current error.
072 X X situations. The type of error will influence the shifting-process.
range). Shifting into
Range „High“ not or the clutch remains open.
possible.
Short circuit to positive try to engage a gear which is engageable with the current error.
at output stage to Y9 The driver is able to initiate shiftings both in driving and stationary
073 (Valve range). Shifting X X situations. The type of error will influence the shifting-process.
into Range “High“ not
Driving: Gearshifting of all gears possible. Stationary: All starting gears
074 at output stage to Y10 X X can be engaged.
(Main valve).
075 at output stage to X Warning-Buzzer not available
warning buzzer.
at output stage to
reverse light relay
No reverse light respectively „add. manoeuvering mode lamp“
076 Vehicle with Mux: X activation possible. No further system restrictions.
at output stage to “add.
manoeuvering mode
lamp“.
PTO1 not available. PTO1-engagement-Error will be surpressed.
077 at output stage to PTO X X PTO1-request is not accepted. No further restrictions.
1.
PTO2 not available. PTO2-engagement-Error will be surpressed.
078 at output stage to PTO X X PTO2-request is not accepted. No further restrictions.
2.
Short circuit to positive Driving: Gearshifting blocked. Stationary: Shift of start off gears
081 at output stage to Y1 X X possible. Main valve will be only activated during shifting, if clutch is
(inertia brake valve). opened. Start off possible.
Gearshifting generally blocked, system not available.
Driving and gear engaged: Attempt to keep clutch engaged
at output stage to valve
082 X X X (prevention with engagement valves).
Y17 (clutch disengage
slow). Stationary: Engagement valves are switched off, automatic neutral
shifting when clutch is disengaged.
Buzzer
Code

Y15 (clutch engage
slow). Stationary: Engagement valves are switched off, automatic neutral
Y16 (clutch disengage
fast). Stationary: Engagement valves are switched off, automatic neutral
Y14 (clutch engage
fast). Stationary: Engagement valves are switched off, automatic neutral
at output ADVP or 1. After ignition off/on failure will be detected during initialization. Shift
ADVP1 (wakeup lever ECU does not switch off. If ZFdisplay
control signal for shift
086 X X existing, display can not be switched off; after ignition off, ZF-display
lever ECU, voltage
supply to ZF- display, is flashing „EE“.No restrictions on system availability. 2. During
warning buzzer, output operation no restrictions on system availability.
speed sensor 1).
089 at output SD to X If ZF-display existing, display is flashing „EE“. No system restrictions.
ZF-display.
Communication error clutch, when coming to standstill. Neutral automatically engaged at
between controller 1 standstill. Gearshifting blocked, continued driving not possible. System
090 and controller 2 (TCU X X X
not available.
failure).

CAN EBC1 timeout
(brake messages).
Error on „ABS active calculation of start off gear. When coming to standstill medium start
092 signal“ (EBC1). X X off gear will be shifted. No other functional restrictions.

Error on ”ASR engine calculation of start off gear. When coming to standstill medium start
093 control active” signal X X off gear will be shifted. No other functional restrictions.
(EBC1).
Error on ”ASR brake No calculation of driving resistance possible. No automatic

094 control active” signal X X calculation of start off gear. When coming to standstill medium start
(EBC1). off gear will be shifted. No other functional restrictions.
Buzzer
Code
Error on ”Cruise
095 control active” signal X X No other functional restrictions.
(CCVS).
Error on ”Cruise
No other functional restrictions, gear hunting in cruise control
096 control set speed”
possible
(CCVS).
Driving: Time based control of clutch during shifting.
Decreased clutch comfort after shifting. Clutch does open below
fixed value (No clutch opening according coasting condition) Engine
Error on ”Engine speed governor during upshift does not work. Stationary: No
097 speed” signal (EEC1). X X
manoeuvering operation possible.
Time based control of clutch during starting off.
Decreased clutch comfort of manoeuvering and starting.
Driving: Increased shifting time. During upshifting and downshifting
clutch will be partially closed when t/m in neutral to substitute input
Error on ZF speed by engine speed. If gear is engaged, input speed is substituted
098 transmission input X X by output speed.
speed signal “n_sek“.
Stationary: Increased shifting time. Decreased clutch comfort in
manoeuvering and starting.
Output speed signal will be calculated depending on system
application from redundant output speed information. Redundant
Error on ZF-output speed information will be taken depending on application from
099 speed signal 1 X X vehicle speed signal via CAN OR output speed signal from CAN
“n_ab_1“. tachograph.
Manual shifting of all gears possible.
Error on CAN output
100 speed signal 2 X X If outspeed signal 1 is available, no functional restrictions of system.
“n_Ab_2“.
Error on both output
speed signals: Driving: Gearshifting blocked. Stationary: TCU tries to open the
ZF-output speed signal clutch, when coming to standstill. Neutral automatically engaged at
1 “n_ab_1“ and CAN
output speed signal 2 not available.
“n_Ab_2“.
Plausibility error
between transmission Driving: Gearshifting blocked during driving including neutral shift
102 input speed „n_sek“ X X attempt. Stationary: Start off gears can be engaged. Driving with start
and output speed off gear possible.
„n_ab_1“.
CAN CCVS Error on
In automatic mode the down shifting could be initiated relayed or
103 wheel based vehicle X X prematured.
speed.
High voltage (Vehicle No system restrictions while driving.

104 electrical system X If fault occurs before ’Ignition ON’ (key 15) the transmission does not
voltage too high). get out of the check phase.
Buzzer
Code
At all: Subsequent failure detection of all failures during low voltage

will be supressed.If PTO is engaged and relay cannot be kept active,
PTO will be disengaged.
Low voltage (Vehicle Driving: Gearshifting blocked. Clutch valves will be controlled
105 electrical system X X X independent on voltage level.
voltage too low).
Stationary: Gearshifting blocked. If gear is engaged and driver switches
off ignition, attempt to shift to neutral is allowed independent on
voltage level. TCU will be switched off independent on successful
neutral shifting after time out.
Driving: Clutch is disengaged and engaged by time control. Stationary:
Stabilised voltage
Manoeuvering not possible. If start does not occur within certain time,
supply at output AU
107 X X transmission is automatically shifted to neutral. New start off gear
(clutch sensor supply)
must be engaged by selector lever. Decreased clutch comfort during
out of valid range.
start off.
Control lever (joy stick):
No shifting during driving. At standstill in MANUAL (semiautomatic)
the last starting gear will be engaged, in AUTOMATIC the
AUTOMATIC starting gear. If at standstill NEUTRAL is activated or
NEUTRAL already available, no starting gear is shifted.
Error in selector lever NEUTRAL switch:
108 or tip lever. X X
No shifting during driving possible. At standstill starting gear
engagement possible and driving in starting gear.
REVERSE switches:
If at standstill one of the two REVERSE switches fails (no signal) and
REVERSE (-/--) actuated at selector lever, slow reverse gear (RL) will
be engaged.
1. After ignition off/on: Failure will be detected during
initialization. No shift lever information. System not available. 2.
During operation: No gearchange possible.
110 ZF CAN timeout. X X
When coming to standstill, last selected startoff gear will be
automatically engaged. Continuous driving only with startoff gear
possible. If reverse gear has been engaged, transmission will
automatically shifted to neutral. No shift lever information.
Error on ”Driveline No calculation of driving resistance possible. No automatic
113 retarder configuration” X X calculation of start off gear. When coming to standstill medium start
timeout. off gear will be shifted. No other functional restrictions.
Clutch engaged Standstill: shift to neutral. If ”Neutral” is reached, no further system
114 unintentionally in X X X restrictions. Driving after a Neutral confirmation (shift lever to pos.
standstill, gear engaged. “N“) possible.
Error in clutch
117 selfadjustment process. X X X System not available.
Driving: Gearshifting blocked. Stationary: TCU tries to

Clutch does not open the clutch, when coming to standstill. Neutral automatically
118 disengage. X X X
engaged at standstill. Gearshifting blocked,
continued driving not possible. System not available.
Buzzer
Code
Driving: Gearshifting blocked. Stationary: TCU tries to

Clutch does not engage
open the clutch, when coming to standstill. Neutral automatically
119 / does not transmit X X X
engaged at standstill. Gearshifting blocked,
engine torque.
continued driving not possible. System not available.
Mechanical failure of
120 small disengagement X X Function taken on by redundant valve.Decreased clutch comfort.
clutch valve.
121 large disengagement X X Function taken on by redundant valve.Decreased clutch comfort.
clutch valve.
122 small engagement X X Function taken on by redundant valve.Decreased clutch comfort.
clutch valve.
123 large engagement X X Function taken on by redundant valve.Decreased clutch comfort.
clutch valve.
Driving: Clutch is disengaged and engaged by time control. Stationary:
Error on clutch travel Manoeuvering not possible. If start does not occur within certain time,
124 X X transmission is automatically shifted to neutral. New start off gear
signal. must be engaged by selector lever. Decreased clutch comfort during
start off.
No system restrictions on availability, íf external air supply is sufficient.
Error on pressure No air pressure indication AL on display in case, air pressure is not
126 X X sufficient. Self adjustment of transmission and clutch is done time
sensor signal. based and not related to the sensor signal. Time for adjustment could
be longer.
Error on TCU
127 temperature sensor X X No system restrictions on availability.
signal.
Error on oil No system restrictions on availability. Shift monitoring
128 temperature sensor
signal. time will be depending on TCU temperature signal.
Driving: When failure occurs during shifting, gear engaged signal is

transmitted based on time control.
No shift sensor signal Further gearshifting blocked. Only shifting out of neutral possible
129 (Short circuit to X X Stationary: Neutralshifting will be verified by select test procedure.
positive). Engagement of starting gears possible. Change of starting gears
possible. Main valve and gear valves remain active until clutch
engagement exceeds defined threshold or driving condition is
detected (to overcome tooth-to-tooth).
Buzzer
Code

No shift sensor signal Further gearshifting blocked. Only shifting out of neutral possible
130 (Short circuit to X X Stationary: Neutralshifting will be verified by select test procedure.
ground). Engagement of starting gears possible. Change of starting gears
Further gearshifting blocked. Only shifting out of neutral possible
No shift sensor signal Stationary: Neutralshifting will be verified by select test procedure.
131 (Interruption). X X
Engagement of starting gears possible. Change of starting gears
With ignition off, t/m will be automatically switched to neutral. With
ignition on, valve Y6 and Y7 (neutral) will be switched on together
with main air valve Y10. If sensor value is outside of neutral self
adjustment range and air pressure is sufficient, TCU tries three times
to adjust neutral position. If neutral position could not be adjusted,
self adjustment failure will be set. If air pressure is not sufficient and
neutral could not be adjusted, no adjustment failure will be set. If air
pressure sensor is faulty, N will be adjusted one time. If neutral could
not be reached, a waiting time will be started. After waiting time has
Self adjustment error of past, neutral adjustment will be tried again.
132 shift sensor. X X
The adjustment procedure will be repeated until a defined number
of attempts. If the maximum number of attempts will be exceeded,
then self adjustment failure will be set.
Stationary: Engagement of starting gears out of neutral possible, if air
pressure is sufficient. (Gear engaged signal created via time control)
Neutral position will be verified by select procedure. If air pressure is
not sufficient, shifting is blocked.
Driving: Gearshifting blocked.
Driving: Only forward gears can be selected, which are allocated in
opposite shift-position of the reverse gear. If failure occurs during
No gate select sensor
shifting, the target gate will be engaged by time control. Stationary: All
133 signal (Short circuit to X X
allowed starting gears can be switched, whose positions are allocated
positive).
in opposite shift-position of the reverse gear. No reverse gear
shiftable.
No gate select sensor
shifting, the target gate will be engaged by time control. Stationary: All
134 signal (Short circuit to X X
ground).
shiftable.
No gate select sensor shifting, the target gate will be engaged by time control. Stationary: All
135 signal (Interruption). X X
shiftable.
Buzzer
Code
With ignition off, splitter remains in last engaged position.

Engine stationary: With ignition on TCU checks the splitter sensor
value. If sensor value is within defined end position range high or low,
the appropriate splitter valve combination will be activated and
together with main valve Y10 splitter end position will be adjusted.
If splitter position is not within defined end position range and air
supply is sufficient, TCU tries to shift once into high position. If splitter
position is not within defined end position range and air supply is not
sufficient or air pressure sensor is faulty, no splitter position will be
shifted.
Engine running: With ignition on TCU checks the splittersensor value.
If sensor value is within defined end position range high or low, the
appropriate splitter valve combination will be activated and together
with main valve Y10 splitter end position will be adjusted. If splitter
position is not within defined end position range , clutch remains
closed and TCU tries to shift into high position. If high position could
not be engaged, splitter shifts into low position. If low position could
not be engaged, TCU tries three times to engage high or low position.
Gate select sensor self If air supply is sufficient and all attempts failed to engage splitter, a self
136 adjustment error. X X
adjustment failure will be set. If air supply is not sufficient or air
pressure sensor is faulty and splitter sensor is not within defined end
position range ,clutch remains closed and TCU tries to shift into high
position. If high position could not be engaged, splitter shifts into low
position. If low position could not be engaged, TCU tries three times
to engage high or low position. If splitter could not be engaged, TCU
waits a defined time and retry splitter adjustment in high or low
position. The adjustment procedure will be repeated until a defined
number of attempts. If the maximum number of attempts will be
exceeded, then self adjustment failure will be set.
For cases: If no splitter position could be adjusted, no gear shifting is
possible. System is not available. If only low splitter could be adjusted,
gear shifting in low splitter group is possible. If only high splitter
couldbe adjusted, gear shifting in high splitter group is possible.
Attempt shift gear into not adjusted positionduring driving and
standstill is allowed. If splitter cylinder reaches adjustment range,
adjustment failure will be reset. If splitter cylinder does not reach
adjustment range, last gear will be reengaged. Subsequent splitter
shifting failures will be supressed.
Driving: When shifting from low range group to high group, the
highest gear in low range group will be shifted.
When shifting from high range group to low group, the lowest gear
Range change group
in high range group will be shifted.
145 (GP) disengagement X X
error. Stationary: If it is not possible to select low range group, the lowest
gear in high range group is selected as starting gear. New attempt to
shift range group is allowed under all driving conditions. No reverse
gear in high range group possible.
Buzzer
Code
Driving and stationary: If selected range group could not be engaged,

range cylinder tries to repeat engagement three times. If selected
range group could not be engaged, following gear will be shifted:
Changeover error When shifting from low range group to high group, the highest gear
146 during range change X X in low range group will be shifted. When shifting from high range
group (GP) shifting. group to low group, the lowest gear in high range group will be shifted.
Stationary: If it is not possible to select low range group, the lowest
gear in high range group is selected as starting gear. New attempt to
shift range group is allowed under all driving conditions.
Driving and stationary: If selected range group could not be engaged,
range cylinder tries to repeat engagement three times. If selected gear
Range change group could not be engaged, old range position will be selected.If
147 (GP) does not engage. X X X
engagement into old range position failed, failure will be set.T/m shifts
to neutral. New attempt to shift range group is allowed under all
driving conditions.
If failure occurs, t/m shifts into next upper gear. Following gear
restrictions are valid:
Driving: The highest gear which can be selected, is the highest gear
Splitter (GV) does not in last engaged splitterposition.The lowest gear which can be selected
148 disengage. X X
is the lowest gear in last engaged splitter position.
Stationary:The highest gear which can be selected, is the highest start
off gear in last engaged splitterposition.The lowest gear which can be
selected is the lowest start off gear in last engaged splitter position.
If failure occurs, t/m shifts into next upper gear. Following gear
restrictions are valid:
Driving: The highest gear which can be selected, is the highest gear
Change over error in last engaged splitterposition.The lowest gear which can be selected
149 during splitter shifting. X X
is the lowest gear in last engaged splitter position.
Stationary:The highest gear which can be selected, is the highest start
off gear in last engaged splitterposition.The lowest gear which can be
selected is the lowest start off gear in last engaged splitter position.
Splitter (GV) does not System not available. New attempt to shift splitter group is allowed
150 engage. X X X under all driving conditions.
Driving: When failure occurs during shifting, t/m shifts back into the
last gear. If last gear is not shiftable because of overspeed condition,
the next possible target gear, which is next to last gear will be shifted.
Selector cylinder does When highest shiftable gear could not be shifted because of
151 not disengage. X X overspeed condition, then t/m shifts to neutral.
Stationary: If target select position could not be engaged,t/m shifts
into neutral. New shifting of start off gear must be initiated by selector
switch.
Driving: When failure occurs during shifting, t/m shifts back into the
last gear. If last gear is not shiftable because of overspeed condition,
the next possible target gear, which is next to last gear will be shifted.
Change over error When highest shiftable gear could not be shifted because of
152 during gate selection X X overspeed condition, then t/m shifts to neutral.
procedure.
Stationary: If target select position could not be engaged,t/m shifts
into neutral. New shifting of start off gear must be initiated by selector
switch.
Buzzer
Code
Driving and stationary: T/m shifts into neutral position.

Selector cylinder does
153 not engage. X X X New shifting of gear must be initiated by selector switch.no gate could
be engaged, system not available.
Driving: Clutch engages in previous gear. Next attempt to shift must
be initiated by selector switch. Stationary:
Main transmission gear
154 does not disengage. X X X Gearshifting only permitted after neutral signal has been reached.
Start off and driving can be tried with engaged gear, if gear is equal or
lower than lowest gear in range high position.
Transmission tries automaticly shift to Neutral. During
Main transmission gear Neutral-shifting the clutch remains open. For solving the shifting
155 does not engage. X X X failure, the driver can after a Neutral-confirmation (shift lever to pos.
„N“) in all driving conditions induce a new shifting by the shift lever.
Transmission tries automaticly shift to Neutral. During
Neutral-shifting the clutch remains open. For solving the shifting
156 Wrong gear shifting. X X X failure, the driver can after a Neutral-confirmation (shift lever to pos.
„N“) in all driving conditions induce a new shifting by the shift lever.
Selector sensor signal
Main valve will be activated automatically together with selector
157 leaves engaged
valves to shift into end position (in cycles).
position.
Main valve will be activated automatically together with gear valves
Shift sensor signal to shift into end position. If gear has been disengaged completely, a
158 leaves engaged position X X suitable gear depending on speed condition will be shifted
during driving.
automatically.
Range-change group Main valve will be activated automatically together with gear valves
sensor signal leaves to shift into end position. If gear has been disengaged completely, a
159 engaged position during X X suitable gear depending on speed condition will be shifted
driving. automatically.
Splitter sensor signal Main valve will be activated automatically together with gear valves
to shift into end position. If gear has been disengaged completely, a
160 leaves engaged position X X suitable gear depending on speed condition will be shifted
during driving. automatically.
Engine does not react
Driving: Gearshifting blocked. Stationary: Starting allowed. Decreased
163 on ASTRONIC engine X X clutch functionality and comfort.
torque control.
Driving: No calculation of vehicle weight and driving resistance
possible. No calculation of startoff gear possible. Drivers demand will
be substituted by accelerator pedal position information. After
shifting finished, fuel quantity will be released up to accelerator pedal
Error on ”Drivers
value. Clutch engagement quality could be reduced. During cruise
164 demand engine percent X X
contol operation no fuel quantity release is possible, because
torque” (EEC1).
accelerator pedal value is 0. After clutch is engaged, fuel quantity will
be released by EDC. => Bad shift quality after shifing. Stationary: Start
off possible. When coming to standstill, medium start off gear will be
shifted. No other functional restrictions.
possible. No calculation of startoff gear possible. Accelerator pedal
Error on ”Accelerator position will be substituted by drivers demand information. Shift
165 pedal position” (EEC2). X X
quality could be reduced. Stationary: Start off possible. When coming
to standstill, medium start off gear will be shifted. Manoeuvering and
startoff quality could be reduced.
Buzzer
Code
Driving: Shifting during driving allowed. Stationary: No manoeuvering

166 Permanent idle signal. X X and startoff possible. System not available.
Driving: No functional restrictions during driving.
Stationary: After RESET AP or FP is shown on display as long as
No idle signal or error accelerator pedal value is in coast condition and idle signal is off. If idle
on ”idle signal switch” signal does not appear within defined time, failure will be set and
168 signal (EEC2) or never X X display indication AC or FP disappears. TCU checks point P1 from
active ”idle signal”. engine configuration (low idle speed).Start off will be allowed, if TCU
detects accelerator pedal value > threshold and engine speed
exceeds idle speed + defined speed threshold (-> verification of start
off intention)
Cut-off relay in TCU clutch, when coming to standstill. Neutral automatically engaged at
169 does not switch off. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
No voltage supply at pin Driving and Standstill: block shifting and clutchfunction.
30 or cut-off relay in
170 TCU does not switch X X X System not available. State of clutch and transmission remains
on. unchanged.

possible. No calculation of startoff gear possible. Actual engine
percent torque will be substituted by drivers demand information.
Error on ”Actual engine Shift quality (fuel load reduction and fuel load release) could be
171 percent torque” signal X X reduced.
(EEC1).
Stationary: Start off possible. When coming to standstill, medium start
off gear will be shifted. Warning for clutch overload detection and
reaction on overload detection could appear earlier.
Error on ”Kickdown No Kickdown operation mode possible. No other functional
174 switch” signal (EEC2). X X restrictions.
Driving: Gearshifting in general blocked, as soon as no ignition on
signal is detected (failure detection might be delayed). Standstill: If
engine is running , TCU does not switch off. Start off gear shiftable
(forward and reverse).
Error on ”Ignition lock”
175 signal (Key 15). X X
Driving with start off gear possible. If engine is not running, t/m will
be automatically shifted to neutral and TCU switches off. No
initialization of system possible.
System not available.
IVECO: Failure Additional Manoeuvring Mode not active: Additional Manoeuvring
176 manoeuvring tip switch X X Mode not available Additional Manoeuvring Mode: Additional
signal. Manoeuvring Mode is switched off
System-CAN Busoff clutch, when coming to standstill. Neutral automatically engaged at
177 error. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
178 CAN Error warning. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
Buzzer
Code

179 CAN queue overrun. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
180 CAN EEC1 timeout. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
181 CAN EEC2 timeout. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
Wheel based vehicle speed missing (redundant output speed
information 2, if output speed will not be taken from 2nd output
speed sensor or CAN tachograph).
Service brake signal missing. In coast condition service brake signal is
182 CAN CCVS timeout. X X considered as active. Cruise control active information missing. No
calculation of vehicle weight and driving resistance possible. No
calculation of start off gear possible. Subsequent single failure of
message variables are suppressed. Clutch disengages always at foot
brake related engine speed (higher engine revolution).
No calculation of vehicle weight and driving resistance possible. No
calculation of startoff gear possible. No information about engine
CAN ERC1_ER brake torque. If exhaust brake is active, shifting quality at start of
183 timeout. X X shifting may be poor.
Engine brake is considered as not active. No further functional
restrictions.
No calculation of vehicle weight and driving resistance possible. No
CAN ERC1_DR
184 X X calculation of startoff gear possible. Medium start off gear will be
timeout.
shifted. No further functional restrictions.
TCU fault — wrong Driving: Gearshifting blocked. Stationary: TCU tries to open the
interrupt OR TCU and clutch, when coming to standstill. Neutral automatically engaged at
188 software not X X X standstill. Gearshifting blocked, continued driving not possible. System
compatible. not available.
TCU fault — stack clutch, when coming to standstill. Neutral automatically engaged at
189 watch. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
EOL EEPROM clutch, when coming to standstill. Neutral automatically engaged at
190 parameter out of valid X X X standstill. Gearshifting blocked, continued driving not possible. System
range.
not available.
EOL EEPROM clutch, when coming to standstill. Neutral automatically engaged at
191 parameter checksum X X X standstill. Gearshifting blocked, continued driving not possible. System
error.
not available.
Buzzer
Code
TCU fault — EEPROM

access failure
192 OR X X calculation of start off gear. When coming to standstill, medium start
checksum Error (only
processor 2).
Driving: Gearshifting blocked. Stationary: Clutch opens, when coming
to standstill. Neutral automatically engaged at standstill. Gearshifting
TCU temperature too
193 X X X blocked, continued driving not possible. Special display indication for
high.
TCU temperature too high alternating with gear information. System
not available.
Both sources for front
194 axle speed not available. X X ISMA is turned off. No other functional restrictions.

Error on ”Front axle
197 X X calculation of start off gear. When coming to standstill, medium start
speed” (WSI).
199 CAN WSI timeout. X calculation of start off gear. When coming to standstill, medium start
IVECO:CAN message clutch, when coming to standstill. Neutral automatically engaged at
226 BC_TC timeout. X X X standstill. Gearshifting blocked, continued driving not possible. System
not available.
Application-Error clutch, when coming to standstill. Neutral automatically engaged at
227 database for X X X standstill. Gearshifting blocked, continued driving not possible. System
CANcommunication.
not available.

GEARBOXES AsTronic
16 AS 2601 O.D.
Type Mechanical
Torque activated Nm 2200 Nm
Forward gears 16
Reverse gears 2
Type of running control electronically-operated semi-automatic
Side rear power takeoff optional
Gear engagement: by front engagement sleeves

E.R.U.* and splitter engagement free ring synchroniser
Gears constantly engaged straight toothed
Gear ratios
1st 14.12
2nd 11.68
3rd 9.54
4th 7.89
5th 6.52
6th 5.39
7th 4.57
8th 3.78
9th 3.09
10th 2.56
11th 2.09
12th 1.73
13th 1.43
14th 1.8
15th 1.00
16th 0.83
1st RM 13.07
2nd RM 10.81
ERG* = Epicyclic Reduction Gearing

O.D. = Geared up
GEARBOXES AsTronic 16 AS 2601 .OD
Bearings
- drive input shaft with balls
- ERG* shaft with cylindrical rollers
- transmission shafts with tapered rollers
Bearing end float:
- drive input shaft 0  0.1 mm
- ERG* planet shaft 0  0.1 mm
- transmission shafts - 0.05  + 0.05 mm
End float:
- main shaft 0.2 mm
- drive input shaft split ring 0  0.1 mm
Temperature for fitting bearings or

bearing seats on the boxes 120 C
Forced lubrication with positive

displacement pump flow rate (with 12th
speed engaged and oil at a temperature
of 80ºC) 50 dm3/min
pressure with 12th speed engaged at
2400 rpm and oil at a temperature of:
40ºC 1.7 bar
80ºC 1.2 bar
Oil
liters 12
kg 11
ERG* = Epicyclic Reduction Gearing

O.D. = Geared up
TIGHTENING TORQUES
See SECTION 8 of this manual for more information on tightening torques of retarder.
Figure 8
307072001R
TIGHTENING TORQUES
Figure 9
70824
TORQUE
DESCRIPTION
Nm kgm
1 Screws fixing gearbox actuator 23 2.3
2 Screw fixing oil pump 10 1
3 Screws fixing drive input shaft cover 23 2.3
Screw fixing clutch uncoupling lever control pin
4 M 12 8.8 79 7.9
M 12 10.9 115 11.5
5 Screws fixing cover (spread LOCTITE 241 on the thread) 79 7.9
6 Screws fixing clutch actuator 23 2.3
7 Screw cap to discharge air from clutch actuator 22 2.2
8 Screws fixing rear box to middle box 46 4.6
9 Screws fixing flange retaining plate 120 12
10 Screws fixing rear cover 5 4.6
11 Speed sensor 45 4.5
12 Screws fixing middle box to front box 50 5
Pin on rod (spread LOCTITE 262 on the thread) 23 2.3
Oil vapour vent 10 1
Screw plug M 10x1 on rear box 15 1.5
Screw plug M 24x1 on rear box 60 6
Screw M12 fixing power take-off bay cover 79 7.9
Screw plug M 24x1.5 on middle box 60 6
Screw fixing plates retaining fork joint pins on rear box 23 2.3
TOOLS
99305121 Hot air device
99322205 Rotary stand for overhauling assemblies
99322225 Mount to support assemblies (to fit onto stand 99322205)
99341003 Single-acting bridge
99341013 Reaction block
99341015 Clamp
TOOLS
99341018 Pair of brackets with hole
99345078 Extractor to remove drive input shaft bearing (use with 99345105)
993450998 Inserter to fit bearing on main shaft, rear side and to insert rear
flange of gearbox
99345105 Extractor for gearbox drive input shaft bearing (use with
99345078)
99347100 Small extractor (use with specific rings with 99347132)

TOOLS
99347132 Ring grips to extract gearbox transmission shaft bearings (use with
99345057 - 99347100)
99360323 Tool to turn drive input shaft when refitting the gearbox to the
engine
99360526 Tool to extract and insert main shaft (use with 99360527) and to
drive in gearbox drive input shaft bearing (use with 99345098)
99360527 Tool retaining gearbox main shaft forks (use with 99360526)
99366811 Set of M10 eyebolts (3) to remove and refit gearboxes
99370006 Grip for interchangeable drifts

TOOLS
99370007 Grip for interchangeable drifts
99370153 Tool for positioning main shaft when removing the transmission
shafts and for retaining gearbox reverse gear pins
99370172 Tools (6) to mount gearbox epicyclic reduction gear train

synchronizer rings
99370317 Reaction lever with extension to fasten drive output flange
99370415 Dial gauge base to adjust transmission shaft bearings (use with
99395604)
99370499 Guides (no. 3) to mount Splitter synchronizing device assembly

TOOLS
99370629 Mount to support gearbox when removing and fitting it back on

the vehicle
99374092 Drift to mount outer races of bearings (69 - 91) (use with
99370007)
99374221 Driver to mount seals on back cover
99374336 Driver to fit seals on the front cover of the gearbox (use with
99370006)
99395604 Dial gauge (0 - 10 mm)


GENERAL

Vehicle preparation

signboards.
Figure 10
2371801

of short circuits;

Version without Intarder Proceed as follows:
Exhaust Figure 13
Proceed as follows:
Figure 11
357ANM105L
- fill with required lubricant through the level/filler plug (1)

until it spills out;
357ANM105L
- clean the level/filler plug, check that the thread is in good
- clean the level/filler plug zone (1) and then remove the condition, replace the o-ring and close the plug.
plug;
Final operations
comes out through the hole; repeat the trial run and
check the level again.
357A072101R

- clean the plugs, check that the threading is in good
condition, replace the o-ring with a new one and close
the drain plugs.
Version with radiator Figure 16
Preliminary steps
Not applicable
Exhaust
Proceed as follows:
Figure 14
HD9ST0041MR

delivery pipe to the radiator DOWNSTREAM of the
check valve (see arrow) and empty the radiator
completely;
Verifications and checks

357ANM105L
Not applicable
- clean the level/filler plug zone (1) and then remove the Filling
plug; Proceed as follows:
Figure 15 Figure 17
357ANM105L
- fill with required lubricant through the level/filler plug (1)

until it spills out;
- clean the level/filler plug, check that the thread is in good
condition, replace the o-ring and close the plug.
Final operations
Proceed as follows:
357A072101R check the level again.
- clean the plugs, check that the threading is in good It is necessary to check the level and topping up
condition, replace the o-ring with a new one and close several times until the radiator is completely full.
the drain plugs.
Version with Intarder Only the version with separate exchanger

Exhaust
Figure 20
Proceed as follows:
Figure 18
HD9ST0042MR

delivery pipe from the retarder (see arrow) and empty
the exchanger completely;
357ANM105L
- clean the level plug zone (1) and then remove the plug;
Figure 21
Figure 19
357ANM104L
- arrange a container of adequate capacity;

- loosen the fastening screws (1) and remove the lid (2);
- remove the filter (3) from the lid;
360F072003R

plugs (1) and (2) and drain off the lubricant; Lubricate the o-rings of the filter (4) when refitting.
- clean the drain caps, check that the threading is in good

condition, replace the o-ring with a new one and close
the drain caps;
- refit the filter following the operations in reverse.
Filling Final operations

Figure 22 - carry out a trial run and then check the level again;
check the level again.
In the case of a separate exchanger it will be

necessary to check the level and topping up several
times until the exchanger is completely full.
360F072004R
- fill with the specified lubricant through the filler plug (1)
until it flows out from the level plug (2);
The unit may be fitted through the level plug (2),

except for first filling after overhauling.
- clean the filler plug and the level plug, check that the
thread is in good condition, replace the o-ring and close
the plugs.

GENERAL

part of this manual. The operation described requires handling of
Observe all the general recommendations to carry hazardous and/or polluting substances
out maintenance jobs correctly. Do not touch with the hands.
Vehicle preparation

switch off the engine, remove the ignition key, Specific safety instructions
signboards. Be very careful: drained oil and fluids, as well as filters
Figure 23
2371801

of short circuits;

The removal of the tear/snap clips is not described
Proceed as follows:
in detail. These clips must be cut or released and then
- tip the cab; restored while refitting to ensure the correct
fastening of the elements to be held.
- disconnect the hydraulic and electric connections from
the PTO and respective device fitted on the gearbox, if
applicable;
- remove any parts of the outfit with prevent access to the
transmission. Proceed as follows:
TRANSMISSION OIL CHANGE chapter in this Section. Figure 25
drain off the power steering fluid as described in
HYDRAULIC FLUID CHANGE chapter in section 15.
exchanger: drain off the engine coolant as described in
COOLANT CHANGE chapter in section 3.
Figure 24
357A006101R

disconnect the intake (11) and delivery (12) pipes from
the emergency steering pump;
Figure 26
360F072005R
- disconnect the propeller shaft from transmission outlet

(14) as described in the PROPELLER SHAFT
wheel-drive propeller shaft from transmission outlet (13)
as described in the PROPELLER SHAFT
- For four-axle drive versions only: disconnect the front
intermediate axle as described in the 360F072007R
REMOVAL-REFITTING chapter in section 12.2.
- disconnect the pneumatic connection (1) from the brake
booster.
Versions with cooling radiator Figure 29

Figure 27
- disconnect the lubricant delivery (15) and return (16)

pipes to/from the exchanger.
357A006103R
Versions with intarder and separate heat exchanger
Figure 28 - disconnect the electric sensor and actuator connector
from the intarder ECU (10).
The ECU is fitted on the heat exchanger and located

on the chassis near the air cleaner.
connector from the ECU.

retarder.
The wiring remains fitted on the retarder because

the sensors cannot be disconnected from the
respective wire.
357A006102R
- disconnect and remove the lubricant delivery (15) and

Versions with intarder and integrated heat exchanger Figure 31

Figure 30
360F072008R
- disconnect and remove the engine coolant delivery (17)

360F072009R

the intarder ECU (10).
DO NOT disconnect the electric sensor and

actuator connector from the ECU.
respective wire.
Figure 32 Inspections and checks

Proceed as follows:
- Check integrity of the brackets and fastening buttons, if
needed, to replace the damaged component.
- Check the flexible mountings: if necessary replace
damaged component .
- Check perfect integrity of the electric wiring and
respective connections.
Refitting
Refit by reversing the removal sequence.
Final operations
HD9ST0052MR
Proceed as follows:
- disconnect the pneumatic connection (2) supplying the - For four-axle drive versions only: refit the front
transmission services and the vehicle interface electric intermediate axle as described in the
connection (3) from the ECU; REMOVAL-REFITTING chapter in section 12.2.
- if installed, disconnect the gearbox sensor in Neutral (4). - For front-wheel drive versions only: refit the front
wheel-drive propeller shaft as described in the
PROPELLER SHAFT REMOVAL-REFITTING chapter in
Be careful not to damage the pneumatic pipe and the section 10.
wirings which remain on the unit during the
following operations. - refit the propeller shaft to the gearbox outlet as described
in the PROPELLER SHAFT REMOVAL-REFITTING
Figure 33 exchanger: top up the engine coolant as described in
- For versions with steering pump on transmission only: top
up the power steering fluid as described in HYDRAULIC
FLUID CHANGE chapter in Section 15;
OIL CHANGE chapter in this section;
- run the engine for a few minutes and check for hydraulic
fluid leakage from the pipes;
360F072011R

it is being retracted.
- For versions with upper rear mount only: loosen the
fastening screws (see arrow) of rear mounts to chassis;
- retract the unit to free the primary shaft of the clutch and
remove the unit by extracting it from the bottom.

TRANSMISSION OIL RADIATOR Not applicable
GENERAL
Safety instructions
Before doing any work, make certain that all the
precautions have been taken and all aspects The job described below entails handling dangerous
concerning the safety of the people involved in the and/or polluting substances.
work are completely clear. If there are any doubts Do not touch with hands.
consult someone who has more experience. Do not let them come into contact with painted
Vehicle preparation Specific safety instructions

Not applicable
signs.
Figure 34
2371801

functionality.
DESCRIPTION OF OPERATION - disconnect:

Preliminary operation - the electric fan connection (4);
Not applicable
- remove the fixing bolts (see arrow) and remove the
radiator.
Removal
have to be held in place are secured correctly. Inspections and checks
Not applicable
Refitting
Perform the following: Start refitting proceeding in the opposite order to removal.
- place a suitably large container under the radiator,
disconnect the top coupling (1) from it and drain the fluid Final operations
from the pipe; Perform the following:
- disconnect the bottom coupling (2) from the radiator - fill with lubricant as described in the CHANGING THE
and drain the fluid from both pipe and radiator; TRANSMISSION OIL Chapter in this Section.
Figure 35
HD9ST0040MR
OVERHAULING THE GEARBOX Gearbox actuator

Removal
Figure 36
Wash the assembly thoroughly before overhauling.
The specific and/or general tools must be used in the
way for which they were designed.
To facilitate assembly, put the removed parts away on
the specific tray in their order of removal.
Upon assembly, the following must always be
replaced with new parts: the gaskets and seals, spring
pins, safety plates and springs. Nuts and screws must
be tightened to the prescribed torque with their
thread dry and degreased.
Keep to the specific regulations when disposing of
lubricant and detergents.
78649
Unscrew the ring nut (1 and 5) and disconnect the electric

wiring (2) from the speed sensor (6 and 7).
Checks Detach the wiring (2) from the clips () securing it to the
The gears, synchronizer rings, coupling bodies and sliding middle box.
couplings must show no sign of failure or excessive toothing
wear. Remove the nuts (4) and detach the actuator (3) from the
front box.
The main shaft must have no indentation, especially on the
sliding surfaces of the gear rotation and coupling sleeves.
The reverse idle gear shafts must have a polished surface free
from scoring.
The gearboxes must show no sign of cracking and the bearing
seats must be neither damaged nor worn, so as to prevent the
outer rings of the bearings from turning in their seats.
Check the shoulder spacers are neither worn nor damaged.
The gear coupling forks must show no sign of cracking and the
relevant control rods must slide freely, but without any
appreciable play, in their guide seats. Figure 37
Check that the shoes of the drive forks are fully efficient.
Check that the holes, grooves and lubrication pipes are not
obstructed by grease or foreign bodies.
Check the bearings are not worn, damaged or overheated.
The following described and illustrated overhaul

operations regard transmission 16 A6 2601 and, save
78650
different indications, are valid also for transmission 12
AS 2301. Fasten the gearbox (1) to brackets 99322225 (3) on the
rotating stand 99322205 (2).
Remove the plug and bleed the lubrication oil.
Figure 38 Removing the rear box

Figure 40
78651
Take out the screws (2) and detach the actuator (1) with its
gasket. 70863
The electronic control unit is integrated in the

actuator and these cannot be overhauled. See under Extract the springs (6-7-8) and the pawls (6).
the diagnosis heading for the check.
The springs (7 and 8) are of equal length, the spring
Check that the oil vapour vent (3) is not clogged; if it is, clean (6) is larger.
it.
Refitting Remove the pin (4) from the rod (5).

Remove the switch (1) together with the gasket (2) and
Figure 39 extract the cap (3).
ASTRA
Figure 41
70828
Put a fresh seal (6) on the front box (7).

Lubricate the stems of the solenoid valves (3-4-5) with silicone
grease and put them into a neutral position. Put the rods
(8-9-10) into a neutral position. Fit the actuator (1) on the
front box (7) verifying that the end of the stems of the solenoid
valves is correctly positioned in the seats of the rods (8-9-10).
Tighten the fixing screws (2) to the prescribed torque. After
removing the gearbox from the stand used for overhaul, refit 70830
the clutch actuator (3, Figure 38) and make sure the wiring (2)
is not damaged. Block rotation of the sleeve (1) by applying the lever
99370317 (3) and slightly loosen the screws (2).
Figure 42 Figure 44
70833
70831
Remove the adjustment ring (3) and the plate (1) together
Remove the screws (1) fixing the plates (2) fastening the pins with the coupling body (2).
(4) and extract these together with the seal (3) from the rear
box (7).
Removing the rear box
Extract the two centring pins (5). Remove the screws (6).
Figure 45
Fit the eyebolt 99366811 to the sleeve (8) and, using special
ropes and lifter, detach the rear box (7) from the middle one
(9).
70834
Remove the screws (3), disc (4) and seal (5) and extract the
sleeve (2) from the spider shaft. Should extraction prove
difficult, use an extractor (1) applied as illustrated in the figure.
Figure 43 Figure 46
70832 70835
Remove the oil pipe (1). Note down the assembly position of Remove the screws (2) and take off the cover (1). Remove the
the fork (3) and plugs (6) and remove them. Remove: the rod spider shaft bearing end float adjustment ring (3).
(2), synchronizing device assembly (4) and connecting sleeve
(5).
Figure 47 Figure 50
45946 70838
Using a press, extract the spider shaft (1) from the supporting Using pliers (2), tighten the ends of the circlip (3) and remove
roller bearing (2). Turn the rear box (3) upside-down and the coupling body (4) from the E.R.G. shaft (1).
extract the roller bearing (2).
Removing the epicyclic reduction gear train Figure 51

(E.R.G.)
Figure 48
70839
Using a punch, extract the pins (5) from the spider shaft (6).
70836 Remove the planetary gears (3) from the spider shaft (6),
Using a screwdriver, remove the circlip (3) fastening the ring together with the rollers (2) and shim adjustment rings (1 and
gear with internal toothing (4) to the ring gear with external 4).
toothing (2) and remove them from the E.R.G. (1). Figure 52
Figure 49
70837 70840
Extract the toothed ring (2) from the ring gear with internal Extract the toothed shaft (3) from the spider shaft (1) together
toothing (1). with the rings (2).
Figure 53 Figure 54
70842
Using a suitable extractor, remove the roller bearing ring (1)

from the spider shaft (2).
70841
Extract one of the pins (1) from the toothed shaft (2) and Using a punch, extract the disc (3) from the inside of the spider
extract the rings (3) from this. shaft (2).
Figure 55
70843
PARTS COMPRISING THE E.R.G.

1. Circlip - 2. Ring gear with external toothing - 3. Toothed ring - 4. Ring gear with internal toothing - 5. Bearing - 6. Circlip - 7.
Circlip - 8. Coupling body - 9. Pins - 10. Ring - 11. Toothed spindle - 12. Disc - 13. Spider shaft - 14. Pin - 15. Shim adjustment
ring - 16. Rollers - 17. Shim adjustment ring - 18. Planetary gear.
Fitting the epicyclic reduction gear train (E.R.G.)

Figure 56 Figure 59
ASTRA
70982
70844
Smear grease into the hole of the planetary gear (5) and insert
Heat the inside ring (2) of the roller bearing to 120C and fit the rollers (3) with the associated shim adjustment rings (2 and
it on the spider shaft (3). 4). Fit the planetary gears (5) onto the spider shaft (6),
Fit on the circlip (1). Fit on the disc (4). fastening them to it with the pins (1).
Figure 57 Figure 60
ASTRA ASTRA
70838
Using pliers (2), tighten the ends of the circlip (3) and fit the
coupling body (3) onto the E.R.G. shaft (1).
70845 Figure 61
Drive the rings (1 and 3) onto the toothed spindle (2) and fit
on the pin (4).
ASTRA
Figure 58
ASTRA
70983
Fit the ring gear with internal toothing (5) onto the spider shaft
70840 (3) together with the toothed ring (4), and the ring gear with
Insert the spindle (3) together with the rings (2) onto the external toothing (2) and fasten the two ring gears with the
spider shaft (1). circlip (1).
Adjusting epicyclic reduction gear train

Figure 62 bearing end float
Figure 64
45951
70847
Heat the seat of the bearing (1) of the rear box (2) to 120C
and mount the bearing (1). Determine the ball bearing end float adjustment thickness (3)
by proceeding as follows:
- measure the depth of the seat on the cover (1) of the
bearing (3), distance A;
- measure the protrusion of the bearing (3) from the
surface of the rear box (2), distance B.
The thickness S of the adjustment ring is determined by the

following equation:
S = (A - B) - C
Where:
A and B = measurements
C = end float 00.1 mm
For example:
A = 5.4 mm
B = 5 mm
C = 00.1 mm
Figure 63 S = (5.4 - 5) - (00.1 mm) = 0.3  0.4 mm
45943
Rest the spider shaft (1) on an appropriate spacer.

Heat the inside ring of the bearing (2) to 120C and drive it
together with the rear box (3) onto the spider shaft (1).
Figure 65 Figure 67
ASTRA
45954 70849
Using the driver 99374221 (1), fit the seal (2) in the cover (3). Heat the sleeve (1) to 90C and fit it onto the spider shaft (1).
Fit on a new seal (4), the disc (3) and screws (2) and tighten
them to the prescribed torque.
Adjusting main shaft end float

Figure 66 Figure 68
70848 70850
Mount the adjustment ring (1), of the thickness determined in

the preceding measurement, on the bearing (2, Figure 63) of
the spider shaft (3).
Position two calibrated blocks (2) on the rear box (4). Place
Spread IVECO sealant 1905685 on the mating surface of the a calibrated rule (1) on them and, using a depth gauge (3),
cover (4) with the box (5) and fit it onto the box, tightening measure the distance between the top side of the rule and the
the screws (2) to the prescribed torque. end of the spider shaft (5), distance A.
Figure 69 Using a depth gauge (3), measure the distance between the
top end of the circlip (5) and the top side of the calibrated rule,
distance B.
The thickness S of the main shaft end float adjustment ring is
determined by the following equation:
S = (A - B) - 2
For your information (see Figure 71), subtracting the thickness
of the calibrated blocks and rule:
- from the distance A gives the distance X corresponding
to the distance between the end of the spider shaft (2)
from the mating surface of the rear box (1).
- from the distance B gives the distance Y corresponding
to the distance between the circlip (4) and the mating
surface of the middle box (3).
70851
Fit the connecting sleeve (7) together with the circlip (5) on
the main shaft (6).
Position two calibrated blocks (2) on the middle box (4) and
place a calibrated rule (1) on them.
The calibrated blocks and rule must be the same ones

used in the preceding measurement.
Figure 70
70852
Figure 71 Figure 73
ASTRA
70855
70853
Put the springs (2) and pawls (3) into the seats of the
synchronizing device rings (1) and fasten them with the tools
Position the adjustment ring (2) (of the thickness determined
99370172 (4).
in the preceding measurements) on the main shaft (5). Mount
the connecting sleeve (1) and the tube (4). Figure 74
Mount the plate (6) together with the coupling body (3).
Synchronizing device assembly for engaging

normal or reduced gears
Removal
Figure 72 70856
Position the synchronizing device ring (2) on the synchronizing

device ring (3) so that it is possible to fit the sliding sleeve (1)
onto them. On completing assembly, remove the tools
99370172 (4).
Figure 75
70854
1. Synchronizing device assembly - 2. Synchronizing device

ring - 3. Sliding sleeve - 4. Pawl - 5. Spring -
6. Synchronizing device ring.
70857
Put a cloth on the synchronizing device assembly (1) so that,
when dismantling it, the springs (5) and pawls (4) are held back Fit the synchronizing device assembly (1) on the coupling body
as they come out of their seats. (3, Figure 71) with the ring groove () facing downwards.
Figure 76 Insert the rod (3) of appropriate diameter in the hole for the
screw (4, Figure 77) and in the oil pipe (5) to guide this into
its seat, while lowering the rear box (4). Lower the rear box
(4), paying attention that the spider shaft, oil pipe (5) and rod
(7) go into their seat correctly.
Figure 79
ASTRA
70858
Position the fork (1) with the plugs (3) and the reliefs (') facing
as illustrated in the figure.
Fit on the rod (4) and connect it to the fork (1). Fit on the oil
pipe (2).
Figure 77 70831
Screw down the screws (6) without tightening them; insert the
centring pins (5) and tighten the screws (6) to the prescribed
torque.
Fit the fork joint pins (4) with fresh seals (3) and tighten the
screws (1) fixing the fastening plates (2) to the prescribed
torque.
70859 Figure 80
Take out the screws (1) and remove the cover (2) with its seal
(3). Remove the screw (4) with the washer (5).
Figure 78
ASTRA
70862
Fit: the screw (4) with a new washer (5) and tighten it to the
prescribed torque.
70860 Fit the cover (2) with a fresh seal (3) and tighten the fixing
Spread IVECO sealant 1905685 onto the mating surface of screws (1) to the prescribed torque.
the middle box (6). Fit the eyebolts 99368811 (1) to the Block rotation of the sleeve (7) by applying the lever
sleeve (2). Using ropes and a lifter, position the rear box (4) 99370317 (8) and tighten the fixing screws (6) to the
coaxially to the middle one (6). prescribed torque.
Figure 81 Figure 82
ASTRA
70863
Fit the cap (3) and the switch (1) with a new gasket (2). Spread 78299
LOCTITE 262 onto the thread of the pin (4), screw it onto the
rod (5) and tighten them to the prescribed torque. Refit the gear actuator (1) as described under the relevant
heading. Detach transmission from turning stand.
Fit the pawls (9) and the springs (6-7-8). Refit the clutch actuator (3) and tighten the nuts (4) to the
prescribed torque.
The springs (7 - 8) are of equal length, the spring (6) Connect the electric wiring (2) to the speed sensor (6), tighten
is larger. the fixing ring nut (5) and secure the wiring (2) to the box by
inserting it in the clips ().
Figure 83
70864
COMPONENT PARTS OF THE REAR BOX OF THE EPICYCLIC REDUCTION GEAR TRAIN
Removing the middle box

Figure 84 Figure 86
78302
70865
Take out the screws (2) and remove the pin (3) in the joint
Detach the gear actuator and the rear box as described under
of the clutch uncoupling lever (1) with this lever.
the relevant headings. Remove the E.R.G. drive rod (4),
connecting sleeve (5), adjustment ring (3) and the plate (1) Remove the screws (4) fixing the front cover (5) to the front
together with the coupling body (2). box.
Figure 85 Figure 87
78300
Screw down two screws (1) into the front cover (2) and
detach this from the front box (3).
78301
Fit the plate 99370153 (1) to the middle box (2) so that the Figure 88
groove inside the plate coincides with the key (5) of the main
shaft (6).
Fasten the pins (4) by fitting the brackets (3) of the plate
99370153 to the middle box (2).
Turn the gearbox through 180.
70870
Remove the cap (3), the spring (4) from the transmission shaft
(5) and the adjustment rings (1-2-6 -).
Figure 89 Figure 92
78306
70871 Fit the eyebolt 99366811 (1) onto the front box (2). Using
special ropes and a hoist, detach the front box (2) from the
Remove the circlip (4) fastening the bearing (1) to the drive middle one (1).
input shaft (3). Remove the circlip (2) from the bearing (1).
Figure 93
Figure 90
78305
To perform the following operations, the gearbox

78303
must be positioned as shown in Figure 94 in order to
avoid any chance of the transmission shafts falling.
Using the extractors 99345078 (1) and 99345105 (2), extract
the ball bearing (4) from the drive input shaft (3). Take out the screws (1) and remove the brackets (2) of the
plate 99370153. Extract the reverse gear pins (3) from the
Figure 91 middle box (4).
Figure 94
78304
70875
Remove the speed sensor (5) and the cap (4) beneath.
Remove the phonic wheel (2) from the drive input shaft (1).
Take out the four centring pins (1). Extract the oil pipes (4-6) from the middle box (7).
Remove the screws (2) fixing the middle box (6) to the front Spread apart the transmission shafts (3-5) and remove them
box (3). from the middle box (7).
Figure 95 Figure 97
70876 78307
Fit tool 99360527 (1) onto the drive input shaft (9) and the Turn the middle box (1) upside-down, remove the circlip (2)
rods (2 and 3); fit parts (6-7 and 8) of tool 99360526 (4) onto and, working from inside the box, remove the roller bearing
the drive input shaft (9). (4).
Hook tool 899360526 (4) onto the lifter and extract the main Using a punch, and operating through the openings () of the
shaft (5) together with the drive input shaft (9) and rods (2 and middle box (1), remove the external rings (3) of the tapered
3) from the supporting bearing. roller bearings for transmission shafts.
Removing the main shaft

Figure 96 Figure 98
70877 78308
Remove the reverse gears (3) together with the roller Clamp the main shaft (5) in a vice and remove tool 99360526
bearings (2). (1) and 99360527 (2).
Remove the plate 99370153 (4). Remove the rods (3 and 4) with the relevant forks.
If replacement is necessary, remove the centring pins (1).
Before removing the pins (1) heat the seats of the box To remove the fork (5), the ring of the synchronizing
to ~ 90C. device has to be in the middle position.
*
*
70881
*
Through the bay of the coupling sleeve (1), using suitable
pliers, tighten the ends of the circlip (2) and remove the drive
input shaft (3) from the main shaft (4), see Figure 100.
Remove the coupling sleeve (1) and the tube (2) from the
main shaft (3).
Turn the main shaft (3) upside-down and remove the coupling
sleeve (4) from it; remove the key (5) from the hole () in
the shaft (3) and extract it.
To extract the shoulder spacers (6 - 8 * - 9 * - 11 -

13 - 15 - 16 - 18) it is necessary to turn them so that
their toothing is with the grooves of the shaft (3).
Extract:
- spacer (6);
- reverse gear (7);
- spacers (8 and 9) *;
- gear (10) *;
- spacer (11);
- coupling sleeve (12);
- spacer (13);
- 2nd gear (14);
- spacers (15 and 16);
- gear (17);
- spacer (18);
- tube (19).
70882
* 16 AS 2601 only
70883
If necessary, remove the circlips (1) from the gears (7 - 10 -

14 - 17, Figure 100) and extract the toothed ring (2).
Removing the drive input shaft 70886
Remove the half rings (2) from the drive input shaft (1) and
Figure 102 extract from it:
- thrust washer (3);
- thrust bearing (4);
- bushing (6) together with circlip (5);
- gear (9);
- synchronizing device assembly (12).
70884
Extract the ring (2), key (3) and gear (4) from the drive input
shaft (1).
Figure 103
70885
Turn the drive input shaft (1) upside-down, lift the notches
() of the safety cover (2) and take it off.
Removing the splitter synchronizing device

70887 70889
If necessary, remove the circlips (1-3) from the gear (4) and Put the synchronizing device assembly (1) on the workbench,
extract the toothed ring (2). cover it with a cloth to prevent the pins (8) and springs (7)
getting lost during subsequent dismantling.
Holding back the synchronizing device ring (6), lift the
synchronizing device ring (2); these will get freed: toothed ring
(5), three clips (7) and three pins (8).
Remove the key (4) and extract the toothed sleeve (3) from
the toothed ring (5).
Figure 106
70888
COMPONENT PARTS OF THE DRIVE INPUT SHAFT

Fitting the splitter synchronizing device Figure 108

Insert the three springs (7) and three pins (8) in the
synchronizing device ring (1) and keep them in their seat with
the centring pins 99370499 (2).
Position the toothed ring (4) on the synchronizing device ring
(6). Fit the synchronizing device ring (1) in the toothed ring (4)
and on the synchronizing device ring (6) so that the centring ASTRA
pins 99370499 (2) drive onto the pins (5) of the synchronizing
device ring (6). Press on the synchronizing device ring (2)
uniformly so that the components of the assembly fit together
correctly. Take out the centring pins (2).
70891
Figure 109
70759
Insert the toothed sleeve (1) in the toothed ring (2) so that the race between the two toothings corresponds to the inside toothing
of the ring (2) and allows it to rotate.
Turn the sleeve (1) so that the hole in it coincides with one of the three bays () of the toothed ring (1).
Then insert the key (3) as shown in the figure.
Fitting the main shaft

70884
On the drive input shaft (1), fit: gear (4), key (3) and thrust
washer (2).
70892
On the drive input shaft (1), fit:
- synchronizing device assembly (15);
- gear (10) together with circlips (9 and 12) and toothed
ring (11);
- bushing (6) with circlip (5); Fitting the drive input shaft
- thrust bearing (4); Figure 113
- thrust washer (3).
Figure 111
ASTRA
70885 70893
Fit on a new safety cover (2) and notch it () at three/four In the gears (4), fit: Reverse — 1st — 2nd — 3rd gears and toothed
equidistant points. Turn over the drive input shaft (1). rings (2) and fasten them to the gears with the circlips (1 and
3).
78309 78311
Clamp the main shaft (2) in a vice. Fit on the tube (1). Put the Put the spacer (3) in the ring groove (). Turn the spacer (3)
shoulder spacer (3) in the ring groove (). Turn the spacer so that its internal toothing rests on that of the main shaft (1).
(3) so that its internal toothing rests on that of the main shaft Insert the key (2) in the spacer and keep it in position.
(2).
Insert the key (4) in the spacer (3) so as to prevent rotation
and keep it in position.
78310 78312
Mount the 3rdspeed gear (2), put the spacer (4) in the ring Mount the 2ndspeed gear (2), put the spacer (4) in the ring
groove (). Turn the spacer (4) so that its internal toothing groove (). Turn the spacer (4) so that its internal toothing
rests on that of the main shaft (1). Insert the key (3) in the rests on that of the main shaft (1). Insert the key (3) in the
spacer (4) and keep it in position. spacer (4) and keep it in position.
78314 78316
Fit on the 1st/2nd

gear coupling sleeve (1) with the larger For 16 AS 2601 gearboxes only, fit on the gear (2). Put the
internal groove () turned to the side of the key (2). spacer (5) in the ring groove () so that its internal toothing
rests on that of the main shaft (1). Put the spacer (4) in the ring
groove () so that its internal toothing rests on that of the
main shaft (1).
Insert the key (3) in the spacers (4 and 5) and keep it in
position.
78317
78315
For all gearboxes, fit on the reverse gear (2). Put the spacer
Put the spacer (3) in the ring groove (). Turn the spacer (3) (4) in the ring groove () so that its internal toothing rests on
so that its internal toothing rests on that of the main shaft (1). that of the main shaft (1).
Insert the key (2) in the spacer (3) and keep it in position.
Extract the key (3) and insert it from the top side of the shaft
(1) in the groove on this and in all the spacers, so that its bent
portion goes into the hole () of the shaft (1).
Figure 122
Make sure that the circlip (2) gets correctly positioned
in the seat of the main shaft (3).
Splitter control fork

Removal - Fitting
Figure 125
ASTRA
70902
Fit on the reverse gear coupling sleeve (3) with the bay (2)
coinciding with the key (1).
Figure 123
70879
Extract the plugs (2) from the splitter synchronizing device

coupling fork (1) and fit on the new plugs.
70903
Turn over the main shaft (2) and fit on the sleeve (1) with the Gear control forks
bay (4) coinciding with the key (5). Removal
Fit on the tube (3). Figure 126
Figure 124
*
*
70905
Dismantle the gear control fork assembly (1), suitably adjusting

the ring (3) to prevent the gears simultaneously coupling and
70904
extracting from the rod (7): the coupling fork (6)*, pin (7),
coupling fork (5), fork (2) and ring (3).
Using suitable pliers, tighten the ends of the circlip (2) and fit
the drive input shaft (1) onto the main shaft (3). * For 16 AS 2601 gear boxes only.
Fitting
70760 70762
Insert the pin (1) in the seat on the rod (3). Drive the reverse For 16 AS 2601 gear boxes only
gear coupling fork (2) onto the rod (3), adjusting it so that the Drive the 3rd/4th gear coupling fork (1) onto the rod (2).
pin (1) gets positioned in the bay () of the fork (2).
Position the fork (1) in the ring (3) so that on turning it the bay
() of the fork (1) is inserted in the ring (3).
Figure 130
Figure 128
70761 70763
Drive the ring (1) and the 1st/2nd gear coupling fork (3) onto Position the fork assembly (2*-3) and the ring (1) assembled
the rod (2). Position the fork (3) in the ring (1) so that on in this way so that the bay () of the reverse gear coupling
turning it the bay () of the fork (3) is inserted in the ring (1). fork (4) is inserted in the ring (1).
* For 16 AS 2601 gear boxes only.
Transmission shafts
Removal - Fitting Figure 133
Figure 131
78319
Fit the plate 99370153 (2) onto the middle box (1).
70906
Remove the inside rings (1-3) of the roller bearings from the
transmission shaft (2), using the extractor 99347100 (4), grips Figure 134
993471132 (6) and plug 99345057 (5).
To fit the rings (1 - 3) on the shaft (2) it is necessary to first
heat them to 120C.
70909
From inside the box (1), heat the seats of the rings (4) to ~
90C, transmission shaft bearings. Fit on the rings (4) with
Fitting the middle box driver 99370092 (3) and grip 99370007 (2).
Figure 132
Figure 135
78318
Heat the seat (3) of the cylindrical roller bearing (5) to ~ 90C,
fit this and fasten it to the middle box with the circlip (2).
70910
If removed, refit the centring pins (4) after heating the seats
of the box to ~ 90C. Place the reverse gears (1) together with the roller bearings
(2) in the middle box.
70911
Fit the fork assembly (1) onto the main shaft (2), verifying that
the forks are correctly positioned on their respective coupling
sleeves.
Figure 137
78320
Hook the tool 99360526 (1) onto the lifter and fit the main
shaft assembly (5) in the gearbox, verifying that the shaft (5)
and the rods (3 and 4) get correctly inserted in their seats.
Remove the tools 99360526 (1) and 99360527 (2).
70912
Mount the splitter coupling fork (1) positioning the plugs (2)
on the toothed coupling ring (3).
Figure 138
Figure 140
70915
70913
Mount the transmission shafts (1 and 3) so that on joining
Fit tool 99360527 (1) onto the drive input shaft (8) and the
them to the main shaft (2) the marks stamped on them are
rods (2 and 3). Fit parts (5-6-7) of tool 99360526 (4) onto the
aligned. Use the slots () of the phonic wheel (4) to check
drive input shaft (8).
this.
78305 70917
To perform the following operations, the gearbox With no gears engaged, the shafts must turn freely,
must be positioned as shown in Figure 142 in order otherwise the alignment of the marks (see
to avoid any chance of the reverse gears falling. Figure 140) will not be correct.
Fit on the oil pipes (1 and 2).

Insert the pins (3) in the middle box (4) and in the reverse
gears (1, Figure 136), fastening them to the box (4) with the
brackets (2) of plate 99370153 and the screws (1).
Figure 142
*
*
70916
COMPONENT PARTS OF THE MIDDLE BOX

* For the 16 AS 2601 gearbox only
Fitting the front box

Figure 144
70918
COMPONENT PARTS OF THE FRONT BOX
ASTRA
70921
Spread IVECO sealant 1905685 onto the mating surface of

the middle box (5).
Fit the eyebolt 99368811 (1) onto the front box (2).
Using ropes and a hoist, lift the box (2) and position it coaxially
to the middle box (5).
Insert the rods (6), of suitable diameter, into the seats in the
front box (2) of the oil pipes (7 and 8) and into these too.
Lower the box (2) checking that the rods (3 and 4) and the
oil pipes (7 and 8) are correctly inserted in their seat.
70819
Remove the eyebolt (1) and the guide rods (6).
Remove the screw (1), lift the cover (2), remove the vents (3)
and clean them or replace them.
Then reassemble the parts.
Carefully clean the oil filter (6) and fit it back in its seat.
If the plugs (4) have been removed, it is necessary to fit them
back on with new seals (5).
70920 78304
Screw down the screws (2) fixing the front box to the middle
box (4). Insert the centring pins (1) and tighten the screws (2)
to the prescribed torque.
Heat the front box (1) to 90C in correspondence with the
seats for the external rings (2) of the tapered roller bearings Mount the cap (4) and the speed sensor (5), tightening it to
and fit these on. the prescribed torque.
ASTRA
70922 78322
Using the tools 99345098 (1) comprising parts (3-4 and 5) and Take out the screws (1) and, through the front cover (5), take
99360526 comprising parts (6 and 7), fit the ball bearing (11) out the oil pump comprising: cover (2), rotor (3) and stator
on the drive input shaft (9) and in the front box (10). (4).
Introduce compressed air through the hole () and expel
Figure 150 through the front cover (5): the overrun brake piston (8)
comprehensive of gasket (9), clutch plates with external
toothing (6), clutch plates with internal toothing (7) and
supporting ring (10).
ASTRA
Fitting the front cover

Recompose the front cover (5) by reversing the operations
described for removal, without parts (6 - 7 - 8).
The gasket (9) must always be replaced.
70871
Adjusting drive input shaft bearing end float
Fit the circlip (4) fastening the bearing (1) to the drive input
shaft (3).
Figure 153
Fit the circlip (2) onto the bearing (1).
Front cover
Removal
Figure 151
70924
Determine the thickness S of the drive input shaft bearing

adjustment ring by proceeding in the following way:
70985
- check that the circlip (1) of the bearing (2) rests in its seat;
Remove the screws (3) and take off the drive input shaft cover - measure the protrusion of the bearing (2) from the
(1) from the front cover (2). surface of the front box (3), distance A.
70986 70926
- measure the depth of the seat on the front cover (1) of - measure the distance between the surface of the front
the bearing (2, Figure 153), distance B. cover (2) and the oil pump (1), distance C;
The thickness S of the adjustment ring is determined by the - mount the overrun brake disc supporting ring (3) in the
following equation: seat on the front cover (2) and measure the distance
between this and the surface of the cover (2), distance D.
S = (A -B) - C
The thickness S of the adjustment rings is determined by the
Where: following equation:
A-B = measurements D oil pump side S=A+C+F
A-C = measurements
C = end float 0  0.1 mm
F = end float  0.05
For example:
For example:
A = 5.50 mm S = 2 + 0.05 ( 0.05) = 2 — 2.1
B = 3.90 mm D overrun brake side S = B + D + F
C = 0  0.1 mm B-C = measurements
F = end float  0.05
S = (5.50 -3.90) - 0  0.1=1.59 — 1.60 mm
For example:
S = 1.95 + 0.15 ( 0.05) = 2.05 — 2.15
Adjusting transmission shaft bearing end float
70925
70870
Determine the thickness S of the transmission shaft bearing On the external rings of the bearings supporting the drive
end float adjustment rings by proceeding in the following way: input and transmission shafts, mount the end float adjustment
- turn the shafts and check that the external rings (1 -3) of rings (1 - 2 and 6) of the thickness determined in the preceding
the bearings rest with no play on the rollers of the measurements. Insert the spring (4) and the cap (3) in the
bearings; transmission shaft (5).
- measure the distance between the surface of the front
box (2) and the external rings (1 - 3);
D external ring (1) pump side, distance A.
D external ring (3) overrun brake side, distance B
ASTRA
46007
Using the driver 99374336 (2) and grip 99370007 (1), fit the
seal (3) in the drive input shaft cover (4).
70869
In the sequence shown in the figure, position: the supporting

ring (3), clutch plates with internal toothing (2) and clutch
plates with external toothing (1).
70927 70928
Lubricate the sealing surface of the seal with Unisilikon.

Spread IVECO sealant 1905685 onto the surface of the front Spread IVECO sealant 1905285 onto the surface of the front
box (1) mating with the cover (2). Adjust the key of the oil box (1) mating with the cover (2). Mount the cover (2).
pump shaft so that it coincides with the coupling milling of the Spread LOCTITE 241 onto the thread of the screws and
transmission shaft. Fit on the cover (2) and tighten the screws tighten them to the prescribed torque.
(3) to the prescribed torque.
Clutch release lever

ASTRA
70929 78301
The bushings (2 and 4) and seals (1 and 5) of the lever (3) are Turn over the gearbox.
changed by using a suitable drift for removing — fitting new
Remove the plate 99370153 (1) and the brackets (3) fastening
parts.
the pins (4) from the middle box (2).
70930 70865
Insert the joint pin (4) into the lever (2) and tighten the screws Fit: the plate (1) together with the coupling body (2),
(3), fixing it to the front box (1), to the prescribed torque. adjustment ring (3), connecting sleeve (5) and rod (4).
Complete assembly of the gearbox by refitting the rear box
and the speed actuator as described under the relevant
headings.
On completing assembly, replenish the gearbox with the
prescribed grade and quantity of lubricating oil.

HYDRAULIC RETARDER
INTARDER 3
SECTION 8
HD9 Euro5 SECTION 8 HYDRAULIC RETARDER INTARDER 3 1
SECTION 8
Hydraulic retarder Intarder 3
Page
DESCRIPTION 3
- Intarder assembly - components 5
- Intarder assembly - electric component location 6
- Cooling system 7
- Integrated exchanger 7
- Vehicles with integrated heat exchanger - block
diagram 8
- Vehicles with integrated heat exchanger - water
circulation diagram 9
- Separate exchanger 10
- Vehicles with separate heat exchanger - block
diagram 11
- Vehicles with separate heat exchanger - water
- Vehicles with separate heat exchanger - oil
- Intarder 3 box screw tightening diagram 16
TOOLS 17
TROUBLESHOOTING 19
- Main mechanical faults 19
TRANSMISSION REMOVAL-REFITTING 23
GENERAL 23
- General instructions 23
- Removal 24
- Versions with separate heat exchanger 24
2 HYDRAULIC RETARDER INTARDER 3 SECTION 8 HD9 Euro5
- Versions with integrated heat exchanger 25 - Stator/rotor unit assembly 39
- Inspections and checks 26 - Bearing assembly and safety ring 40
- Refitting 26 - Solenoid valve assembly 40
- Final operations 26 - Pump assembly 40
REMOVING AND REFITTING THE SEPARATE - Intarder box and control box assembly 42
WATER-OIL EXCHANGER 27
- Intarder 3 control box screw tightening diagram 42
GENERAL 27
- Wiring assembly 43
- General instructions 27
- Heat exchanger assembly 43
- EST 52 ECU assembly with support 43
INTARDER REFITTING 44
- Flange assembly 44
- Oil level check 44
- Removal 28
- Refitting 29
INTARDER 3 OVERHAUL PROCEDURE 30
- Flange removal 30
- Heat exchanger removal 30
- EST 52 ECU removal with support 31
INTARDER REMOVAL 31
INTARDER DISASSEMBLY 32
- Wiring disassembly 32
- Control box disassembly 32
- Pump disassembly 33
- Control box disassembly 34
- Front box disassembly 35
- Stator/rotor unit removal 36
- Stator/rotor unit disassembly 37
- Stator disassembly 37
- Hydraulic retarder component inspection 37
INTARDER ASSEMBLY 37
- Stator/rotor unit assembly 37
- Front box assembly 38
DESCRIPTION The amount and pressure of the oil contained in the box is
The intarder is an auxiliary hydrodynamic brake (retarder) adjusted by means of a number of solenoid valves to obtain
built into the transmission. the required braking torque.
It consists of a rotor and a stator facing each other and enclo- Reduced oil flow speed between rotor and stator transforms
sed in a box. The rotor is connected to the propeller shaft. The kinetic energy into thermal energy. This causes an increase of
stator is connected to the chassis via the retarder box. oil temperature.
The braking effect is obtained by means of the oil contained The oil crosses an oil-to-water heat exchanger to dissipate
in the retarder. The oil in the compartments between the heat. In the heat exchanger, the heat of the oil is exchanged
rotor and the stator is turned by the rotor vanes creating a clo- with the coolant and dissipated through the vehicle cooling
sed circuit oil flow between the mobile part and the fixed part system.
of the retarder. The oil strikes the stator vanes and is slowed
down. This brakes the rotor, and supplies braking torque as For more information on the transmission, see
a consequence. This torque is applied to the driveline of the Section 6 MANUAL TRANSMISSION or Section
vehicle, slowing it down. 7.2 AUTOMATED TRANSMISSION in this manual.
1. PTO connection
2. Output flange
3. EST52 ECU
4. Oil-water heat exchanger
5. Rotor
6. Stator
7. Idling reduction device
8. Gear transmission
Figure 1
146327
1. Intarder type
2. ZF part number
3. Serial number
4. Transmission ratio
Figure 2
46326
Intarder assembly - components

1. Rotor/stator
2. Reduction device
3. Switching valve
4. Variable displacement pump
5. Control solenoid valve
6. Switching solenoid valve
7. Partition
8. Pump bushing
9. Filling valve
10. Oil filter
Figure 3
148525
Intarder assembly - electric component location

1. Coolant temperature sensor
2. Oil temperature sensor
3. Oil pressure sensor
4. Intarder wire connector
5. Control solenoid valve
6. Switching solenoid valve
7. ECU
8. Vehicle interface wiring connector
Figure 4
357A008100R
COOLING SYSTEM
The transmission in the versions with retarder has an oil cooling system by means of a water-oil exchanger, fed by the engine’s
coolant.
The exchanger can be:
- integrated with the retarder
- separate
Integrated exchanger
Figure 5
HD9ST0053MR
1. Exchanger - 2. Retarder control unit - 3. Connector on vehicle side - 4. Connector on transmission side -
5. Exchanger-engine water delivery - 6. Engine-exchanger water return
Vehicles with integrated heat exchanger - block diagram
Figure 6
360F003003R
1. Radiator - 2. Thermostat - 3. Engine - 4. Interior compartment heater - 5. Transmission -

6. Expansion tank - 7. Transmission oil exchanger
Vehicles with integrated heat exchanger - water circulation diagram
Figure 7
357A008101R
1. Radiator - 2. Thermostat - 3. Engine - 4. Water delivery to the exchanger - 5. Water return from the exchanger -
6. Not used - 7. Transmission oil exchanger
Separate exchanger
Figure 8
HD9ST0054MR
1. Exchanger - 2. Retarder control unit - 3. Connector on vehicle side - 4. Connector on transmission side -
5. Exchanger-engine water delivery - 6. Engine-exchanger water return - 7. Exchanger-transmission oil delivery -
8. Transmission-exchanger oil return
Vehicles with separate heat exchanger - block diagram
Figure 9
358A003101R
1. Radiator - 2. Thermostat - 3. Engine - 4. Interior compartment heater - 5. Transmission -

6. Expansion tank - 7. Separate transmission oil
Vehicles with separate heat exchanger - water circulation diagram
Figure 10
357A008102R
1. Radiator - 2. Thermostat - 3. Engine - 4. Water delivery to the exchanger - 5. Water return from the exchanger -
6. Expansion tank - 7. Transmission oil exchanger
Vehicles with separate heat exchanger - oil circulation diagram
Figure 11
HD9ST0063MR
1. Retarder - 2. Exchanger - 3. Exchanger-transmission oil delivery - 5. Transmission-exchanger oil return

INTARDER
Maximum braking torque Nm 3200
Braking power kW 500
Weight (without oil and water) kg 64
Control Electro-hydraulic
Nominal voltage V 24
Transmission ratio 2.035
Oil quantity (transmission + intarder)

First filling
- 16S 1631 litres 23.6
- 16S 2231/2531 litres 25.6
TIGHTENING TORQUES
Figure 12
146332
TORQUE
PART
Nm kgm
1 Rotor control gear fastening screw (M12x80) 95 9.5
2/3 Oil filter fastening screw 23 2.3
4 Closing screw 130 13
5/7 Closing screws 110 11
6 Oil drain plug 60 6
8 Switching valve fastening screw 150 15
9 Motion outlet flange fastening screws 120 12
I0 Pressure port closing screws 23 2.3
11/15/16 Temperature and oil pressure/water temperature transmitter fastening screws 9.5 0.9
12 Closing screw 20 2
13 Safety valve fastening screw 30 2.5
14 Control box fastening screws (H) pre-tightenin 5 0.5
g tightening 23 2.3
17 Solenoid valve screws 9.5 0.9
18/20 Heat exchanger fastening screws 50 5
19 Screws fastening EST52 ECU to support 9.5 0.9
21 Screws fastening ECU support to heat exchanger 9.5 0.9
Transmission - intarder fastening screws 50 5
(H) Follow the fastening order shown on the following page.

Intarder 3 box screw tightening diagram

Figure 13
146333
- Insert 24 hex head screws from the top and three hex
head screws (*) from the bottom.
- Tighten the screws in the order shown in the figure:
- Step 1: pre-torque 5 Nm
- Step 2: torque 23 Nm
- Check correct tightening of the screws. No screw must
turn during the check. Repeat the tightening operation if
they do.
TOOLS
TOOL NO. NAME
99305121 Hot air blower
M 28x2
99341003 Dual effect beam
Pair of brackets with hole

99341018
99370007 Interchangeable ram grip
99370629 Transmission stand for removal-refitting support
Rams for fitting outer bearing races (69 ÷ 91 mm) (for use with
99374092 99370007)
TOOL NO. NAME
Ram for fitting outer bearing racings (91 ÷ 134)

99374093 (for use with 99370007)
Fitter for fitting seals on rear lid

99374221 rear
TROUBLESHOOTING
Main mechanical faults
1 NO BRAKING EFFECT
Faulty control lever operation. Replace the control lever.

YES
NO
Faulty ECU operation. Check and replace the ECU if needed.

YES
NO
Faulty electric system operation. Locate the fault and repair the system.
YES
2 POOR BRAKING EFFECT
Incorrect retarder use. Use the retarder correctly as shown in the use and
YES maintenance manual.
NO
Low oil level. Top up oil level.

YES
(continued)
Leakage or breakage of the pneumatic system pipes. Close the loose fittings. Replace the broken or
YES damaged pipes.
NO
Faulty operation of the hydraulic accumulator control Replace the electro-pneumatic valve.
electro-pneumatic valve. YES
NO
Faulty operation of the proportioning valve with Replace worn or faulty parts.
control valve. YES
NO
Fault operation of temperature sensor. Replace the temperature sensor.

YES
NO
Fault inside retarder. Overhaul the retarder.

YES
3 IRREGULAR BRAKING EFFECT
Presence of water in retarder from heat exchanger. Check tightness of heat exchanger and replace it, if
YES required.
NO
Faulty operation of the proportioning solenoid valve Replace worn or faulty parts.
with control valve. YES
NO

YES
DELAYED OPERATION OR NO
4 OPERATION OF RETARDER
Faulty operation of the hydraulic accumulator control Replace the electro-pneumatic valve.
electro-pneumatic valve. YES
NO

YES
THE LIGHT INDICATOR BLINKS

5
(control lever in position 1-6)
Heat adjuster operation caused by low engine rpm. Run the engine at higher rpm to increase coolant flow
YES as a consequence.
NO
Fault operation of temperature sensor. Replace the temperature sensor.

YES
NO
Low coolant level. Top of the coolant fluid level.

YES
NO

YES
NO
Faulty electric system operation. Locate the fault and repair the system.
YES
6 EARLY HEAT ADJUSTMENT OPERATION
Faulty coolant system operation. Repair correct coolant system operation.

YES
NO

YES

GENERAL
General instructions The following intervention requires handling of
heavy parts. Suitable tools and accessories must be
used for lifting and handling.
Before starting any operation make sure all the
necessary safety precautions have been taken and
fully explained to those involved in the operations.
If in doubt, consult a more experienced person. Read
the instructions provided in the initial section of this Hazardous and/or polluting substances
manual.
carry out maintenance jobs correctly. The operation described below requires handling of
dangerous and/or polluting substances.
Vehicle preparation

engage the parking brake and apply the warning Specific safety instructions
signboards.
Safety component.
Figure 14
2371801

of short circuits;
DESCRIPTION OF OPERATION Figure 16

Proceed as follows:
- tip the cab;
- disconnect the hydraulic and electric connections from
the PTO and respective device fitted on the gearbox, if
applicable;
- remove any parts of the outfit with prevent access to the
transmission.
TRANSMISSION OIL CHANGE chapter in section 6 or
section 7.2.
- For versions integrated water-oil heat exchanger: drain
off the engine coolant as described in COOLANT
CHANGE chapter in section 3.
Removal

in detail. These clips must be cut or released and then
restored while refitting to ensure the correct
fastening of the elements to be held.
Versions with separate heat exchanger 357A006103R
Figure 15 - disconnect the electric sensor and actuator connector

from the intarder ECU (10).
The ECU is fitted on the heat exchanger and located

on the chassis near the air cleaner.
connector from the ECU.

retarder.

respective wire.
357A006102R
- disconnect and remove the lubricant delivery (15) and

Versions with integrated heat exchanger Figure 18

Figure 17
360F072008R
- disconnect and remove the engine coolant delivery (17)

360F072009R

the intarder ECU (10).
DO NOT disconnect the electric sensor and

actuator connector from the ECU.
respective wire.
Figure 19
357A008103R

it is being retracted;
- loosen the fastening screws to the transmission (detail)
and remove the retarder.
Recover shim rings from the stator and from the

planetary gear set shaft bearing seat.

Proceed as follows:
- Check integrity of the fastening buttons, if needed, to
replace the damaged component.
- Check perfect integrity of the electric wiring and respec-
tive connections.

SEPARATE WATER-OIL EXCHANGER
The job described below entails handling parts that
GENERAL are very heavy. Use suitable tools and accessories for
lifting and transporting.
cautions have been taken and all aspects concerning Dangerous and/polluting substances
the safety of the people involved in the work are
completely clear. If there are any doubts consult
someone who has more experience.
and/or polluting substances.
Read the instructions given at the beginning of this
Do not touch with hands.
Manual.
Do not let them come into contact with painted
parts.
fluids must comply with existing standards and laws.

Take the vehicle to a suitably level and solid surface, Not applicable
signs.
Figure 20
2371801

functionality.
DESCRIPTION OF THE OPERATION - place a suitably large container under the exchanger,
disconnect the oil inlet coupling (3) from the exchanger
Preliminary steps and drain the fluid from the pipe;
Not applicable
- disconnect the outlet coupling (4) from the exchanger
Removal and drain the fluid from the pipe;

detailed. This means that such straps have to be Figure 23

figure.

- drain the coolant into an appropriate container;
Figure 21
220076
- remove the coolant return pipe fixing bracket (1);
Figure 24
220078
- remove the water temperature sensor from the pipes

(1);
Figure 22
220077
- disconnect from the retarder control unit:

- the vehicle interface’s electrical connector (1);
- the sensors’ and actuators’ electrical connector (2);
220075
- disconnect the inlet fitting from the exchanger (1);

- disconnect the outlet fitting from the exchanger (2);
Figure 25 Inspections and checks

Not applicable
Refitting
Final steps
- fill the cooling system as described in the CHANGING
THE RADIATOR FLUID Chapter in SECTION 3 - F3B
ENGINE
- ill with lubricant as described in the CHANGING THE
220079
- remove the bracket fixing bolts (1) and the exchanger.

INTARDER 3 OVERHAUL PROCEDURE Figure 29
To avoid damage, do NOT hang the transmission by

the inlet shaft, the outlet flange or other external
components.
Figure 26
146821
Remove the cylindrical pin (1).

146818
Figure 30
Remove the plug (1) and drain off the transmission oil.
Remove the plug (2) and drain off the intarder oil.
Figure 27
146822
Disconnect the coolant temperature sensor (1).

146819
Disconnect the electric wiring from the EST52 ECU (2).
Place two pieces of square wood on a flat, firm support. Heat exchanger removal
Place the transmission on suitable supports so that the inlet Figure 31
shaft can turn freely.
Flange removal
Figure 28
146823
146820
Remove the screws (4) from the flange (1). Remove the disc Remove the six hex head screws (2).
(3) and the o-ring (2). Carefully remove the heat exchanger (1).
Remove the flange (1) using the extractor made by beam Remove the o-rings from the coolant inlet/outlet pipes.
99341003, brackets 99341018 and reaction block.
EST 52 ECU removal with support

Figure 32
146824
Remove the screws (5) and remove the EST 52 ECU (4).
Remove the screws (3) and remove the cover (2) from the
heat exchanger (1).
INTARDER REMOVAL
Figure 33
146825
Remove the screws (1) fastening the intarder to the planetary

gear reducer box.
Figure 34 INTARDER DISASSEMBLY

Wiring disassembly
Figure 36
146826 146828
Remove the intarder (1) from the rear box (2) using specific Disconnect the electric connections from the two solenoid
ropes and lift. valves (2). Loosen the screws and remove the oil temperature
sensor (6). Loosen the screws and remove the oil pressure
Figure 35 sensor (4). Disconnect the fastener (3). Remove the screw (1)
and detach the wiring.
The coolant temperature sensor (5) was previously

disconnected.
Control box disassembly

Figure 37
146827
Remove the seal (1) and clean the resting surface of the box
on the intarder.
For Ecosplit transmissions, make sure that the plastic

insert (2) is in the indicated position () during
removal and refitting.
146829
Remove the 24 hex head screws (1).
Remove the three remaining screws from the other

side (2).
Figure 38 Figure 41
146830 146833
Carefully strike with a block and plastic mallet on the three ribs Press the pusher (1) with a suitable tool against the spring pack
of the control box. to compress the spring (2) and insert the pin (3).
Remove the spring pack.
Figure 39 Pump disassembly
Figure 42
146831
Remove the box (1) and lift it slowly and carefully without
146834
inclining it.
Remove the shaft (1) from the cage (3).
Figure 40 Remove the blades (2).
Remove the cage (3).
Remove the pusher (4).
146832
Carefully remove the flat seal (2) complete with pump (1).
Control box disassembly

Figure 43
146835
1. Intarder box - 2. Closing screw with o-ring - 3. Pressure spring - 4. Control solenoid valve piston -
5. Control solenoid valve - 6. Control solenoid valve fastening screws - 7. Switching solenoid valve fastening screws -
8. Switching solenoid valve - 9. Switching solenoid valve piston - 10. Ball - 11. Pressure spring -
12. Closing screw with o-ring - 13. Closing screw with o-ring - 14. Cylindrical pins - 15. Safety ring - 16. Bearing
Remove the safety ring (15). Remove the closing screw complete with o-ring (12).
Remove the bearing (16) with an extractor from inside the Remove the ball (10) and the pressure spring (11) from the
box (1). hole in the box.
Remove the screws (6) and the control solenoid valve (5) Remove the closing screw (13) complete with o-ring.
complete with o-ring. Remove the closing screw (2) complete with o-ring.
Remove the piston (4). Remove the cylindrical pins (14) from the box (1).
Remove the pressure spring (3). Remove the screws (7) and Replace the pins during assembly if they are damaged.
the control solenoid valve (8) complete with o-ring.
Remove the piston (9).
Front box disassembly

Figure 44
146835
1. Closing screw with o-ring - 2. Pressure spring - 3. Switching valve - 4. Pressure spring -
5. Closing screw with o-ring - 6. Plug - 7. Piston with spring - 8. Pressure spring -
9. Closing screw with o-ring - 10. Closing screw with o-ring - 11. Filter fastening screws - 12. Intake filter
Loosen the hex head screws (11) and remove the intake filter Remove the closing screw (5).
(12). Remove the pressure spring (4) and the piston (3).
Remove the closing screw (1) complete with o-ring. Remove Remove the plug (6).
the pressure spring of the unit (2). Remove the closing screw (10).
Remove the piston (7) complete with spring.
Remove the closing screw (9) complete with o-ring.
The piston of the unit (2) cannot yet be removed.
Remove the pressure spring of the unit (8).
The piston of the unit (8) cannot yet be removed.

Stator/rotor unit removal Figure 47

Figure 45
146839
146837 Push the pistons (1) inwards and remove the oil collection pla-
tes (2).
Remove the pistons (1) until resistance is felt. Remove the pistons (1).
The oil collection plates (2) must be removed with Figure 48

the pistons from the stator/rotor unit groove.
Follow the instructions above to remove the
stator/rotor in order to prevent damage.
Figure 46
146840
Remove the roller bearing (1) with an extractor from inside

the box (2).
Figure 49
146838
Place suitable supports (1) on the box to prevent

damaging the box when levers for disassembly are
rested on it.
Rest the two levers on the supports and insert them from
underneath at the stator ribs.
Remove the stator/rotor unit (3) from the box operating on
the levers with care.
Remove the cylindrical pins (2).
146841
Remove the seal (1) without damaging the box.

Stator/rotor unit disassembly Hydraulic retarder component inspection

Carefully clean the single parts of the retarder and
Figure 50
check wear to determine whether they can be reu-
sed.
Clean the closing plugs threading and the respec-
tive seats removing sealant residues.
Check that the coupling surfaces are not deformed
ASTRA and lubricate sliding surfaces.
Replace the seals, safety elements and valve springs
with new parts.
INTARDER ASSEMBLY
Stator/rotor unit assembly
Figure 52
146842
Carry the rotor/stator unit to the bench and clamp it in

a vice.
Remove the safety ring (7).
Remove the cross plate (5).
Remove the screw (4).
Remove the drive plate (3).
Detach the rotor (2) from the stator (1).
Stator disassembly
Figure 51
146843
Fit new conical roller bearings.
Heat the inner ring of the conical roller bearing (2) using the
hot air blower (99305 121) at max. 120 ˚C and fit it on the
pinion (1).
Lubricate the conical roller bearing (2).
Fit the hole of the stator (4) to max. 120˚C by means of the
hot air blower (99305121). Using the fitter 99374093 and grip
99370007, fit the outer race (3) of the conical roller bearing
(2).
146843
Using the fitter 99374092 and grip 99370007, fit the outer
race (7) of the conical roller bearing (8).
Remove the o-ring (5). Insert the o-ring (5) into the annular groove of the stator and
Put the stator (4) on wooden supports and remove the pinion apply a thin layer of grease to it.
under pressure (1). Remove the bearing (8). Fit the stator (4) on the pinion (1).
Extract the outer race (7) of the bearing (8) using a punch. Heat the inner race of the conical roller bearing (8) by means
Remove the ring (6). of the hot air blower (99305121) to max. 120 ˚C and fit it in
Remove the bearing (2). a manual press using a suitable block.
Extract the inner race (3) from the conical roller bearing using Lubricate the conical roller bearing (8).
a suitable tool.
Figure 53
146842
Apply a little grease onto the inner ring of the rotor (2).
Fit the rotor (2) onto the stator (1).
Fit the drive ring (3) and tighten the fastening screw (4) to a
torque of 95 Nm.
Fit the cross plate (5) on the pinion.
Fit the snap ring (6) and the safety ring (7).
Front box assembly
Figure 54
146836
Insert the pressure spring with the piston (7) into the box. Lubricate the o-rings of the new oil filter (12).
Tighten the closing screw (10) complete with new o-ring to Fit the oil filter (12) into the box tighten the screws (11) to
a torque of 130 Nm. a torque of 23 Nm.
Insert the piston (3) with pressure spring (4) into the box. Tighten the plug (6) with new O-ring to a torque of 60 Nm.
Tighten the closing screw (5) complete with new o-ring to a Insert the pistons (1) and (9) in the box.
torque of 150 Nm.
Stator/rotor unit assembly Figure 57

Figure 55
146846
146844
Fit the cylindrical pins (1) only after having inserted
Couple the oil collection plates (1) and the pistons (2) and the stator/rotor unit to prevent damaging the box or
then push the oil collection plates completely outwards. the rotor.
Figure 56
Introduce the cylindrical pins (1).
It must be possible to turn the gear (2) without

excessive effort after assembly.
Figure 58
146845
Fit the stator/rotor unit in the correct position in the box ()
observing the position of the stator recess.
Slowly push the stator/rotor unit downwards using a manual
press as far as it will go.
146847
Tighten the closing screws (1, 2) complete with new o-rings

to a torque of 110 Nm.
Bearing assembly and safety ring Pump assembly

Figure 59 Figure 61
146850
Fit the pump pusher (1) on the cylindrical pin (2) and intro-
146848 duce it into the box (3).
Heat the bearing seat in the box (3) using the hot air device
(99305121) to max. 120 ˚C. The pusher (1) has a direction of assembly. The
Carefully introduce the bearing (2) with a suitable ram in cor- notches () must be facing upwards as shown in the
rect position as fare as it will go. figure.
Insert the safety ring (1) into the groove in the box.
Solenoid valve assembly Figure 62

Figure 60
146851
146849 Apply a little grease on the outer surface of the cage (1) and
fit it in the box.
Insert the piston (7) into the hole in the box.
Fit the switching solenoid valve (6) complete with The notches () must be facing upwards as shown
new o-ring and fasten the screws (5) to a torque of 9.5 Nm. in the figure.
Insert the spring (1) on the piston (2).
Fit the spring/piston unit into the hole in the box.
Fit the control solenoid valve (3) complete with
new o-ring and fasten the screws (4) to a torque of 9.5 Nm.
Introduce the ball (10) and the spring (9) in the hole in the
box.
Tighten the closing screw (8) complete with new o-ring to a
torque of 30 Nm.
Tighten the closing screw (11) complete with new o-ring to
a torque of 20 Nm.
Fasten the closing screw (13) complete with o-ring to
a torque of 25 Nm.
Introduce the cylindrical pins (12) into the box.
Figure 63 Figure 66
146852 146855
Insert the pump shaft (1). Fit the flat seat (1) onto the three cylindrical pins and position
The notch () must be visible. Fit the blades (2). it on the box.
During blade assembly, make sure that the smaller Check that the pump shaft can be turned by 360˚
groove (3) is facing sideways towards the lobe (4). anticlockwise. If this is not possible, it means that one
or more blades were not fitted correctly.
After having fitted all the blades, check that the shaft (1) turns
freely in both directions. Figure 67
Figure 64
146840
Fit the bearing (1) with suitable tool in correct position until
146853 it abuts in the box (2).
Figure 68
The spring pack (2) is loaded and is supplied as a
complete unit. Do extract the pin (1).
Fit the spring pack (2) in the box.

Figure 65
146841
Using the fitter 99374221 fit a new seal (1) in the Intarder box.
146854
Push the pusher (4) with a lever against the spring pack (3) to
compress the spring and extract the pin (2).
Intarder box and control box assembly Figure 70

Figure 69
146856
146857
The pump shaft must be fitted towards the hole of Place the control box (1) carefully on the box (2).
the cylindrical pin as shown in the figure to ensure
correct assembly.
Intarder 3 control box screw tightening

diagram
Figure 71
146833
Fit the 24 hex screws from the top and the three remaining Check correct tightening of the screws.
screws No screw must turn during the check. Repeat the tightening
(*) from the bottom. operation if they do.
Tighten in the order shown.
- Pre-tightening: 5 Nm
- Tightening: 23 Nm
Wiring assembly Figure 74

Figure 72
146859
Fit the coolant temperature sensor (1) with a new o-ring faste-
ning the screws to a torque of 9.5 Nm.
146828
EST 52 ECU assembly with support

Connect the solenoid valve connectors (2).
Figure 75
The connectors have different colours (black/red)
and must be connected as shown on the control
box.
Fit the oil temperature sensor (6) with a new o-ring. Tighten
the fastening screws to a torque of 9.5 Nm.
Fit the oil pressure sensor (4). Tighten the fastening screws to
a torque of 9.5 Nm.
Fix the wiring with the fastener (3) and tighten to a torque of
9.5 Nm.
Heat exchanger assembly

Figure 73
146824
Fix the support (2) to the EST 52 ECU by tightening the

screws (3) to a torque of 9.5 Nm.
Carefully clean the resting surfaces of the ECU and

the support.
Fix the ECU (4) tightening the screws (3) to

a torque of 9.5 Nm.
Connect the wiring connector to the ECU.
146858
Fit new o-ring (1) in the seats on the box.

Fit the heat exchanger (2) tightening the screws (3) to a tor-
que of 50 Nm.
INTARDER REFITTING Figure 79

Figure 76
146827
Fit a new seal (1) on the transmission.
For Ecosplit transmissions, make sure that the plastic

insert (2) is in the indicated position during removal
and refitting. 146860
Figure 77 For Ecosplit transmissions, the indicated screws are

micro-encapsulated.
Fasten the screws (1) and tighten to a torque of 50 Nm.

Flange assembly
Figure 80
148529
Using suitable ropes and lift, couple the heat exchanger (1)
and position the intarder (2) slowly and carefully on the rear
box of the transmission (3).
Figure 78
146820
Fit the flange (1) as far as it will go (heating it if needed to max.

80 ˚C by means of the hot air device (99305121).
Fit a new o-ring (2).
Fit the plate (3) in correct position and tighten the screws (4)
to a torque of 120 Nm.
Oil level check

Fill and check the oil level as shown in the respective chapter.
146821
Insert the centring pin (1).

REDUCTION GEAR UNIT
VG 2700
SECTION 9.1
HD9 Euro 5 SECTION 9.1 REDUCTION GEAR UNIT VG 2700 1
SECTION 9.1
Reduction gear unit VG 2700
Page
DESCRIPTION 3
- Longitudinal shaft section 4
- Drive transmission scheme: normal gear engaged 5
- Drive transmission scheme: low gear engaged 6
- Neutral position 6
- Drive transmission scheme: transfer 7
- Bevel gear pair (first step-down) 9
EQUIPMENT 10
CHANGING THE OIL 16
GENERAL 16
- General safety standards 16
- Preparing the vehicle 16
- Dangerous and/polluting substances 16
- Specific safety standards 16
DESCRIPTION OF THE OPERATION 17
- Preliminary steps 17
- Draining 17
- Verifications and checks 17
- Refuelling 17
- Final steps 17
REMOVING AND REFITTING THE REDUCER--
TRANSFER BOX 18
GENERAL 18
- General safety standards 18
- Preparing the vehicle 18
- Dangerous and/polluting substances 18
2 REDUCTION GEAR UNIT VG 2700 SECTION 9.1 HD9 Euro 5
- Specific safety standards 18

DESCRIPTION OF THE OPERATION 19
- Preliminary steps 19
- Removal 19
- Verifications and checks 20
- Refitting 20
- Final steps 20
OVERHAUL 22
- Removal procedure 22
- Checks on dismantled parts 36
- Bearings and shims diagram 36
- Refitting 37
DESCRIPTION
The transfer group is located between the transmission and The transfer group is located on the output shaft and consists
the front and tandem axles. of a cylindrical wheel epicyclical differential.
The two step-down ratios are obtained through two pairs of The differential can be locked by means of a fork operated
constant mesh gears mounted on the primary shaft and grooved coupling, to obtain fixed torque transfer.
secondary shaft.
Shift between on ratio and the other is achieved by means of
a grooved sliding coupling operated by a fork.
Figure 1
HD9ST0056MR
Plate:
1. Variation number
2. Serial number/Date of manufacture
3. Assembly number
4. Type/transmission ratios
Longitudinal shaft section
Figure 2
28309001
1. Main shaft - 2. Reducer control device - 3. Secondary shaft - 4. Oil gear pump - 5. Rear output shaft flange -
6. Transfer box differential - 7. Front output shaft flange - 8. Transfer box locking control device - 9. Speed sensor
Drive transmission scheme: normal gear This way the engagement coupling meshes the larger
engaged diameter gear with the primary shaft: this engages the longest
transmission ratio.
The control fork is shifted to the right by the movement of the
command cylinder.
Figure 3
28309002
Drive transmission scheme: low gear engaged Neutral position

The control fork is shifted to the left by the movement of the Figure 5
command cylinder.
This way the engagement coupling meshes the smaller
diameter gear with the primary shaft: this engages the shortest
transmission ratio.
Figure 4
28309013
The control fork is maintained in the middle by the control

cylinder displacement.
In this way, the engagement sleeve remains in home position
and both the gears turn idly on the primary shaft.
28309003
Drive transmission scheme: transfer This layout permits a different speed for the two shafts,
When the transfer lock is disengaged, the drive from the compensated by the rotation of the satellites about their axis.
constant mesh gear on the secondary shaft drives the gear set
which, through the satellites, drives both the outer sun gear
(connected to the rear output shaft) and the inner one
(connected to the front output shaft).
Figure 6
28309004
When the transfer lock is engagedm the coupling meshes the

gear set wth the front output shaft through the gear set front
teeth. This prevents any relative rotation between these two
elements, and thus between the two shafts as well.
Figure 7
28309005
Transfer STEYR
Type VG 2700/400
Maximum input torque 30,000 Nm (22,214lbft)
Maximum input speed 2,800 rpm
Normal: 0,913
Transmission ratio
Stepped down: 1,407
Torque distribution (front/rear) 1 : 2,600
Weight (without oil) 451 kg
Lubrication system pressure 0,5 bar
Exchanger delivery pressure 2.0 bar
Shift actuation air pressure 6.5 - 10 bar
Primary shaft bearings axial play 0.14 — 0.20 mm
Secondary shaft bearings axial play 0.14 — 0.20 mm
Transfer shaft bearings axial play 0.14 — 0.20 mm
Adjustments
Figure 8
Primary shaft bearings

axial play:
Secondary shaft bearings

axial play:
Transfer shaft bearings

axial play:
28309006
EQUIPMENT
The codes given in the following list refer to the original ZF coding.
TOOL N˚ NAME
5873.002.030 Extractor for transfer
5873.002.001 Extractor for transfer (disk)
5870.100.051 Extractor for transfer
5870.051.059 Buffer for fitting bearings
5870.260.011 Guide for fitting bearings
5870.052.004 Buffer for fitting oil baffle

TOOL N˚ NAME
Buffer for fitting bush containing O-rings into front output shaft
5870.053.003 flange
5870.050.023 Buffer for fitting O-rings into the rear output shaft flange bush
5870.053.007 Buffer for fitting bush containing O-rings into the drive input flange
TIGHTENING TORQUES
Figure 9
LOCTITE 518 64 Nm 30 Nm
LOCTITE 243
50 Nm
125 Nm LOCTITE 243
LOCTITE 518
LOCTITE 243
15 Nm
LOCTITE 518
80 Nm
LOCTITE 243
46 Nm
615 Nm
LOCTITE 243
1080 Nm
80 Nm
LOCTITE 243
LOCTITE 518
9,5 Nm
80 Nm
50 Nm LOCTITE 518
46 Nm
28309007
TIGHTENING TORQUES
Figure 10
30 Nm
80 Nm
LOCTITE 243
105 Nm
23 Nm
80 Nm
LOCTITE 243
LOCTITE 243
LOCTITE 518
LOCTITE 243 LOCTITE 243
1080 Nm 1080 Nm
120 Nm
LOCTITE 518
125 Nm LOCTITE 518
28309008
TIGHTENING TORQUES
Figure 11
307091001R
TIGHTENING TORQUES
Figure 12
28309010
CHANGING THE OIL Very heavy parts

GENERAL Not applicable
Dangerous and/polluting substances
cautions have been taken and all aspects concerning The job described below entails handling dangerous
the safety of the people involved in the work are and/or polluting substances.
completely clear. If there are any doubts consult Do not touch with hands.
someone who has more experience. Do not let them come into contact with painted
Preparing the vehicle Specific safety standards
Take the vehicle to a suitably level and solid surface, Pay maximum attention due to the possibility of
switch the engine off, take the ignition key out, high temperatures of the oil/fluid to change and
engage the parking brake and affix the indication adjacent parts.
signs.
Figure 13
2371801

nality.

Not applicable
Preliminary steps Refuelling
Not applicable
Draining - fill with the lubricant prescribed through the plug hole
(1) until it spills out;
Figure 14 - clean the fill-up/level plug, check that the thread is in
good condition, replace the sealing ring and reclose.
Final steps
- carry out a trial run and then check the level again via
the plug (1);
- if needed, top up the level with the lubricant prescribed,
repeat the trial run and check the level again.
HD9ST0057MR

- have a suitably large container handy, clean the plug area
and then remove the fill-up/level plug (1);
- remove the drain plug (2), draining off all the lubricant;
- clean the drain plug, check that the thread is in good
condition, replace the sealing ring and reclose.

REDUCER-TRANSFER BOX
GENERAL The job described below entails handling parts that
are very heavy. Use suitable tools and accessories
General safety standards for lifting and transporting.
cautions have been taken and all aspects concerning
the safety of the people involved in the work are
completely clear. If there are any doubts consult Dangerous and/polluting substances
someone who has more experience.
Read the instructions given at the beginning of this The job described below entails handling dangerous
Manual. and/or polluting substances.
Also comply with all the general recommendations Do not touch with hands.
for correct maintenance work. Do not let them come into contact with painted
parts.
Preparing the vehicle fluids must comply with existing standards and laws.

engage the parking brake and affix the indication Specific safety standards
signs.
Safety component.
Tighten the fixing bolts to the prescribed torque.
Figure 15
2371801

nality.
DESCRIPTION OF THE OPERATION Removal
Preliminary steps Removal of the tear/pressure fixing straps is not

Perform the following: detailed. This means that such straps have to be
- bring the vehicle onto a level surface; cut/released and subsequently restored when
- drain the lubricant as described in the CHANGING THE
OIL Chapter in this Section.
Figure 16 Only vehicles with heat exchanger for the transfer unit
Figure 17
HD9ST0058MR
- remove the following flanges:

A. input shaft flange;
B. front output shaft flange;
C. rear output shaft flange, proceeding as
described in the REMOVAL AND REFITTING OF THE
PROPELLER SHAFT Chapter in SECTION 10. HD9ST0059MR
- disconnect the delivery (1) and return (2) pipes to/from

the transfer unit and heat exchanger.
The return pipe coupling (2) is fitted with a check

valve (3). Consequently, when removing the pipes,
more hydraulic fluid could spill out.
All vehicles Verifications and checks

- check the integrity of connecting flanges;
figure. - check the integrity of the brackets and fixing bolts - if
necessary replace any damaged components;
- check the elastic supports: if necessary replace any
damaged components;
Perform the following: - check the state of the wiring and relative connections.
- disconnect the electrical connections:
4. transfer box locking control;
5. reducer engage control; Refitting
6. speed sensor; Start refitting proceeding in the opposite order to removal.
7. transfer box locking control; Final steps
8. reducer engage control; Not applicable
- temporarily fix the shafts to the chassis so as not to
hinder the next operations;
- position a hydraulic lift under the transfer unit, remove
the connecting screws on the support pads (arrow);
- lower the lift, extracting the transfer unit from
underneath.
Figure 18
4 8
28309015
OVERHAUL Figure 20
Before carrying out any operation, check that all

precautions have been taken and all aspects
regarding safety of the personnel involved have been
clarified.
manual.
If in doubt, contact someone with more experience.
28309022
Removal procedure
- Using a suitable extractor remove the flange;
Before proceeding, remove the transfer box as
instruction in the “removal-replacement” section. Figure 21
Rear drive output flange removal

Figure 19
28309023
- Loosen the bearing cover screws.

- Using suitable levers remove the bearing cover complete
with O-ring.
Figure 22
28309021
Proceed as follows:
- Unscrew and remove the rear axle drive output flange
ring nut.
The ring nut is locked with thread locker.

Heat the threading to about 120 ˚C before
unscrewing to avoid damage.
28309024
- Using a suitable buffer remove both O-rings from the

bearing cover.
Oil pump removal Figure 25

Figure 23
28309025
- Loosen the fastening screws and remove the oil pump

housing cover.
Figure 24
28309027
- Unscrew the pump body screws.

- Using suitable levers remove the pump body Servendosi
di adatte leve rimuovere il corpo pompa mantenendo in
posizione la sfera di trascinamento (freccia).
28309026
Figure 26
Bring the reference notches on the secondary shaft 1
and on the oil pump body to the indicated position
(arrow)
This operation is to be carried out before removing
the pump.
4 2
28309028
1. Oil pump body

2. Oil pump cover
3. External tooth gear
4. Internal tooth ring
- Unscrew the union screws between pump and pump
body and dismantle the oil pump.
Figure 27 Figure 30
1
2
28309029
- Unscrfew the safety valve fasteners (1) and (2).

1
Figure 28 3
4
2
28309032
1. Circlip
2. Ball
3. Shim
4. O-ring
28309030 - Unscrfew the safety valve fasteners (1) and (2).
- Remove the circlip and dismantle both safety valves. - Remove the circlip and dismantle both safety valves.
Figure 29
28309031
- Remove the adjuster shim from the secondary shaft

bearing (F).
Primary shaft cover removal Figure 34

Figure 31
28309033 1
Proceed as follows: 2
- Unscrew the primary shaft cover screws. 3
- Remove the primary shaft cover. 4
5
The cover cannot be further dismantled.
6
7
8
Figure 32
28309036
- Remove the circlip.

Remove the pressure limiter valve components from the
valve block.
1. Valve block
2. Cone
3. Seal disk (Viton)
4. Washer
5. Counter-pressure spring (0.2 bar)
6. Oil passage disk with guide
7. Cover
28309034 8. O-ring
Remove the adjuster shim from the primary shaft bearing (F). Figure 35
Oil cooler circuit valve removal

Figure 33
28309037
- Remove the fasteners on the rear side of the transfer box.
The fasteners on the transfer box have to be

removed in order to separate the two halves of the
28309035
box.
Proceed as follows: Once removed, these screws cannot be used again
- Unscrew the valve block fasteners and dismantle the
valve.
Figure 36 Figure 39
28309038 28309041
- Unscrew the ring nut from the primary shaft. - Using a suitable extractor remove the sleeve containing
the O-rings.
Primary shaft removal
The sleeve is locked with thread locker.
Figure 37
Front drive output flange removal

Figure 40
28309039
Proceed as follows:
- Turn the transfer by 180˚.
- Unscew the drive input shaft nut.
28309042
The nut is locked with thread-lock.
Heat the threading to about 120 ˚C before - Remove the front drive output flange nut.
unscrewing to avoid damage.
Figure 38 unscrewing to avoid damage.
- Remove the sleeve containing the O-rings
Once removed, the sleeve cannot be used again.
28309040
- Using a suitable extractor remove the flange;

Pneumatic step-down control removal - Remove the complete cylinder.

Figure 41 - Remove the components from the cylinder.
Figure 44
28309043
28309046
Mark the cover, the actuator cylinder and the box
(arrow) with suitable reference notches - Remove the shim from the shaft.
This operation is to be carried out before removing
the pneumatic step-down control. Speed sensor removal
Figure 45
- Remove the fasteners.
Figure 42
28309047
28309044 Proceed as follows:

- Remove the recessed hex head screw. - Remove the sensor.
The screw is locked with thread locker.
Figure 43
28309045
Transfer box removal Transfer dismantling

Figure 46 Figure 48
28309048 5
Proceed as follows:
- Unscrew and remove the transfer box fasteners.
Figure 47 1
4
2
28309050
1. Pessure switch
2. O-ring
3. Pin with lock ring
4. Adjuster screw
5. Hex head screw
- Remove the complete pressure switch.
Figure 49
28309049
- Using suitable lifting gear, raise the front cover.
A certain difficulty when dismantling is due to the 28309051

centring pins.
- Unscrew the lock nut.
Figure 50 Figure 53
28309052 28309055
- Reduce spring pre-compression by means of the nut. - Remove the transfer lock control from its housing.
Figure 51 Figure 54
1
28309053
- Position the front cover vertically.

- Remove the circlip..
4
Pay attention to the spring, that is pre-compressed.
3
7
2
- Remove the ring (1) and the spring (2) from their housing. 6
1
Figure 52 5
28309056
1. Nut
2. Cover
3. O-ring
4. O-ring
5. O-ring
6. Command piston
7. Rod
- Unscrew the lock nut and dismantle the control rod.

28309054
- Turn the front cover horizontal.

- Loosen the transfer lock control fasteners.
Front drive output flange removal Figure 58

Figure 55
28309054
- Insert a Ø 150 mm metal disk (arrow) of adequate

28309054 thickness.
Proceed as follows: - Using suitable levers remove the bearing outer race (C)
- Using a buffer and a press separate the shaft from the and extract the shim.
front cover.
Complete transfer removal
Suitably support the shaft, coupling and fork. Figure 59
1
Figure 56 3
2
28309054
Proceed as follows:
- Position the lifting gear (1).
28309054
- Apply an extractor (2) to the lower part of the box to
disengage the drive output shaft from the barrel roller
- Remove the coupling and fork from the cover. bearing.
Figure 57 - Lift the transfer assembly (3) with box.
Retain the barrel roller bearing.
28309054
- Remove the circip and extract the bearing from its

housing.
Figure 60 Figure 62
28309064
- Using suitable extractor screws, separate the gear set

from the gear cog.
A certain difficulty in separating is due to the centring

pins.
Figure 63
28309062
- Fit the ring nut upside-down (arrow) to offer a larger

contact surface. 5
- Using a suitable extractor remove the bearing inner race
(C).
Figure 61 3
2
4
3
7 6
28309065
28309063
- Press the cylindrical pin (6), under pressure from the
spring (7), through the hole in the satellite holder pin (5).
Apply reference notches to the gear set and gears - Push on the pin (5) to free the satellite gear (2) and permit
(arrow). dismantling of the other components.
- Repeat the procedure for all satellite gears.
- Push axially on the group on a suitable suport to prevent
its rotation.
- Loosen the gear set fasteners.
Rear drive output shaft dismantling Figure 66

Figure 64
28309066
Proceed as follows:
- Extract the rear drive output shaft from the gear.
Figure 65
28309068
- Remove the bearing inner race (d) using two extractor

screws.
28309067
- Remove the bearing outer race (D) and extract the oil
baffle (arrow).
Take care not to damage the oil baffle.
.
Primary shaft dismantling Figure 69

Figure 67 II
28309071
- Unscrew and remove the oil pipe (1).

28309069
Proceed as follows: The screws are locked with thread-locker.

- Unscrew the screw between the fork and control rod. unscrewing to avoid damage.
The screws are locked with thread locker.

unscrewing to avoid damage. Retain the O-rings.
- Extract the control rod (arrow).
Figure 68
Figure 70
28309070
- Remove the fork complete with sliders (arrow) from the

coupling sleeve.
Retain the fork sliders.
28309072
- Using suitable lifting gear, remove the primary shaft from

the box.
Slightly tilting the secondary shaft (arrow) will

facilitate this operation.
Figure 71 Figure 73
28309075
28309073
- Using a suitable extractor remove the gear complete with
- Using a suitable extractor, remove the gear complete bearing inner race (B).
with bearing inner race (A) from the primary shaft.
Figure 74
Figure 72
28309076
- Remove the bearing outer race (B) from the box.
Figure 75
28309074
- Using suitable levers remove the selector sleeve.
Suitably retain the balls and corresponding springs.
28309077
- Remove the bearing outer race (A) from the front cover.
Secondary shaft dismantling Figure 78

Figure 76
28309080
- Remove the bearing outer race (F) from the box.
Figure 79
28309078
Proceed as follows:
- Using suitable lifting gear, remove the secondary shaft
from the box.
Figure 77
28309081
- Remove the bearing outer race (E) from the front cover.
- Remove the oil pipe (arrow) from the front cover.
Figure 80
5873.002.030 III
5870.100.051
5873.002.001
28309082
28309079
- Remove the oil pipes (I) and (II) from the box.
- Using tools 5873.002.030, 5873.002.001 and
5870.100.051 remove the bearing inner races (E) and (F)
from the secondary shaft..
Checks on dismantled parts Outer box

Bearings - check the condition of bearing seats: these must not be
- check the condition of the bearings: replace them if deformed and/or ovalised;
marked with bluish stains, cracked and/or worn; - check that the seal surfaces and threads are intact and free
- check the condition of bearing seats: these must not be of dents or damage.
deformed and/or ovalised.
Gears
- check the condition of gear teeth: replace then if pitted,
cracked and/or worn;
- check the coupling surfaces with the pins.
Bearings and shims diagram

Figure 81
28309083
Refitting Figure 83
Respect the following general assembly instructions:

 heat the bearings and thrust washers in the oven
to 100˚C;
 carefully centre and fit bearings and seals with a
suitable fitting tool;
 lubrificate ring nuts, seals and bearings.
Fitting oil pipes

Proceed as follows:
The procedure described below is valid for all oil pipe

retainers.
28309101
- Fit the oil pipe to the front cover.

Figure 82
Figure 84
III
I
28309102
- Fit the oil pipes (I) and (III) in the box.

- Fit the oil pipe (II) in the box.
Fit the oil pipe (II) only after inserting the primary
shaft.
28309100
1. Oil pipe
2. O-ring
3. Perforated screw
- Insert the rings (2).
- Insert the screw (3) into the pipe retainer (1).
- Position the pipe.
- Tighten the screw to the specified torque.
Figure 85
5870.260.011
5870.051.059
X X
3 2
1
28309103
1. Transfer box
2. Secondary shaft bearing outer race (F)
3. Primary shaft bearing outer race (B)
- Using tools 5870.051.059 and 5870.260.011 insert the
secondary shaft bearing outer race (F) into the housing
in the box.
primary shaft bearing outer race (B) into the housing in
the box.
Respect the X=7.5 mm position indicated on the

diagram.
Secondary shaft Figure 88

Figure 86
5870.260.011
5870.051.059
28309106
Injury hazard.
Wear protective gloves.
- Heat the bearing inner races (E) and (F) and insert them
flush onto the secondary shaft.
Figure 89
28309104
Proceed as follows:
ring flush into the front cover.
Figure 87
5870.260.011
28309107
- Fit the pre-assembled secondary shaft into the box.

5870.051.059
28309105

ring flush into the front cover.
Primary shaft - Heat the bearing inner race (B) and insert it flush onto the
drive input shaft.
Figure 90
Figure 92
28309110
- Remove the ring nut

- Turn the primary shaft over.
- Insert the three balls and springs into the housings in the
shaft.
28309108
Figure 93
Proceed as follows:
Lubricate the components with the specified

lubricant before refitting them.
- Fasten the drive input shaft flange ring nut upside-down.

- Rotate the drive input shaft by 180˚ resting it stably on the
ring nut (arrow)
- Fit the larger diameter gear.
The part of the sleeve with teeth for engagement

must be pointing downward.
Figure 91
28309111
- Position the selector sleeve with the bevelled teeth

(arrow) corresponding to the three balls (3 x 120˚).
- Simultaneously compress the three balls and springs into
their respective seats.
28309109 - Insert the selector sleeve from above.
Check that the selector sleeve is in neutral position.

Injury hazard.
Figure 94 - Heat the bearing inner race (A) and insert it flush onto the
drive input shaft.
Figure 96
28309112
- Fit the smaller diameter gear. 28309114
Before refitting, lubricate the components with the - Fit the pre-assembled drive input shaft into the box.
specified lubricant.
Figure 97
II
The part of the sleeve with teeth for engagement

must be pointing downward.
Figure 95
28309115
- Fit the oil pipe (II).
28309113
Injury hazard.
Figure 98 Transfer
Figure 100
28309116
- Fit the sliders on the fork (arrow).

Use EP-1 bearing grease to hold the sliders in place and
facilitate the procedure.
- Position the fork in the selector sleeve.
Figure 99
28309117
28309118
- Insert the control rod aligning the fork. Proceed as follows:

- Fit the fork on the control rod and tighten the fastener - Insert the cylindrical pin (6) and spring (7) into the hole
to the specified torque. in the gearset (1).
- Insert the roller cage (4) into the satellite (2).
- Fit both the shims (3).
- Position the pre-assembled satellite inside the gearset.
28309119 28309121
- Press the cylindrical pin against the spring into the gearset. - Fit the bearing outer race (D) flush.
- Insert the satellite pin until the pin is locked by the Figure 104
cylindrical pin.
Indicate the position of the seat for the pin on the

flat part of the pins to facilitate assembly.
- Repeat the procedure for all satellite gears.
Figure 102
5870.260.011
28309122
- Insert the rear drive output shaft into the gear.
Figure 105
5870.052.004
28309120
- Using tools 5870.052.004 and 5870.260.011 insert the oil

baffle flush into the gear
28309123
- Insert the centring pin.

28309124 28309126
- Fasten the pre-assembled gearset in a press and tighten

the fasteners to the specified torque. Injury hazard.
Observe the reference markings made when
dismantling (arrow).
Lubricate all screws before fitting. - Heat the bearing inner race (C) and insert it flush into the
gearset.
Figure 107
Figure 109
28309125 28309127
- Seal centring pins with suitable punching.

Injury hazard.
- Heat the bearing inner race (D) and insert it flush into the
box.
Transfer support axial play adjustment Figure 112

Figure 110
28309130
- Insert the same S2 shim as removed into its housing on

the front cover.
Figure 113
28309128
Proceed as follows:
- Using suitable lifting gear, lower the pre-assembled
transfer into the housing in the transfer box.
Figure 111
28309131
- Fit the bearing outer race (C) flush.
Figure 114
28309129
- Insert the two centring pins into the box (arrow).
28309132
- Fit the front cover, without the front drive output shaft,
on the box and tighten the screws to the specified torque.
Figure 115 Front drive output shaft

Figure 117
28309133
- Tap the bearings with a plastic mallet to fully insert them. 28309135

- Insert the ball bearing into the housing on the front cover.
- Secure the bearing with the corresponding circlip.
- Heat the bearing inner race.
Figure 118
28309134
- Using suitable equipment check that the axial play of the

transfer bearings is within the required range.
Bearing axial play: 0.14 — 0.20 mm
28309136
- If not, correct the play by inserting an S2 shim of different
thickness. - Insert the fork and transfer locking sleeve into the front
cover.
- In particular:
 increase thickness to reduce play. The front teeth (arrow) of the transfer locking sleeve
 decrease thickness to increase play. must be facing upwards.
- Remove the screws.
- Using suitable lifting gear, remove the front cover from
the box.
28309137 28309136
- Fi the fron drive output shaft flush with the ball bearing. - Insert both O-rings into the corresponding seats on the
actuator piston.
Transfer lock control assembly
Lubricate the O-rings with EP-1 bearing grease.
Figure 120
28309138
Proceed as follows:
- Insert the O-ring (arrow) into the cover.
Lubricate the O-rings with EP-1 bearing grease.
Figure 121
28309136
- Partially tighten the adjuster nut (arrow) in the cover.

28309144
28309141
- Fit the control rod using a suitable support. - Tighten the transfer lock control to the specified torque.
- Fit the pre-assembled piston onto the control rod. The pneumatic connections in the transfer lock must
be facing upwards.
lubricant before fitting.
Figure 127
Figure 124 2
28309145
28309142 - Position the box horizontal.

- Fit the cover complete with adjuster nut onto the control - Insert the spring (1) and the ring (2).
rod.
- Tighten the nut to the specified torque. Figure 128
Figure 125
28309146
28309143
- Press the ring and fit the circlip.
- Insert the pre-assembled transfer lock control aligning the
control rod.
Figure 129 - Loosen the adjuster nut by 1/3 to ½ a turn.
Figure 131
28309147
- Apply the specified sealant to the contact surfaces of the

box.
- Align the front drive output shaft with the transfer and
position the front cover above the box.
- Tighten all screws to the specified torque.
Transfer lock control adjustment

Figure 130
28309149
- Check that, with the locking control cylinder without

pressure, the teeth in the sleeve do not come into contact
with those of the selector gear.
- Check that positioning the transfer such that the drive
input shaft is facing upwards, the front and rear output
shafts rotate freely.
After refitting or adjusting the transfer lock control,

bring it under pressure and check that there are no
leaks for at least 10 seconds.
28309148
- Connect the transfer lock control to a compressed air line

(6.5 — 10 bar).
- Turn the front drive output shaft until the gear with
frontal teeth engages.
- Turn the front drive output shaft again by hand.
- Slowly tighten the adjuster nut with the locking control
cylinder under pressure until noting increased roll
resistance of the shaft (the fork is pressing onto the sleeve
and braking it).
28309150
28309152
- Fasten the adjuster nut with the lock nut.
- Fit the sensor up to contact without forcing.
Take care not to change the previously made - Tighten the lock nut to the specified torque.
adjustment.
Do not rotate the sensor whle tightening the lock
nut.
Figure 133
Figure 135
28309151
- Bring the front teeth of the sleeve into contact with the
selector gear teeth, without meshing.
- Bring the lock control cylinder into pressure to hold the
sleeve front teeth and gear teeth pressed together.
28309153
- Connect a multimeter to pin (1) and pin (2) (detail).

- Check the following engage situations.
- Control not pressurised: contact open.
- Control pressurised but not engaged (front teeth in
contact with each other): contact open.
- Command pressurised and engaged: contact closed.
Front drive output flange Figure 137

Figure 136
2
3
5870.053.003
28309155
Injury hazard.
28309154
1. Bush - Heat the front drive output flange.

2. O-ring with dust boot - Insert the fasteners into the front drive output flange
3. O-ring holding them in position using adhesive tape.
The bush containing the O-rings must be replaced - Align the front drive output flange and insert it into the
with a new one. corresponding housing on the front cover until fully
inserted.
Figure 138
Fill the O-rings with EP-1 bearing grease.

Respect the orientation of the bush.
- Using tool 5870.053.003 insert the bush complete with

O-rings.
28309156
- Position the transfer vertically.

- Tighten the ring nut to the specified torque;
Figure 139 - Using tools 5870.050.023 and 5870.260.011 insert the

O-rings respecting their orientation.
Figure 141
28309157
Injury hazard. 28309159

- Fit the pre-assembled cover with the fasteners.
- Tighten the screws to the specified torque.
- Heat the barrel roller bearing inner race.
- Position the transfer horizontally. Apply the specified sealant to the two
through-screws (Arrow).
- Fit the barrel roller bearing and fully insert it.
Rear drive output flange Figure 142

Figure 140
2
1
5870.260.011
28309160
5870.050.023
Injury hazard.
- Heat the rear drive output flange.

- Insert the fasteners into the rear drive output flange
holding them in position using adhesive tape.
- Align the rear drive output flange and insert it into the
corresponding housing on the box until fully inserted.
28309158
1. cover
2. O-ring with dust boot
3. O-ring

Respect the orientation of the rings.
5870.053.007
28309163
28309161
- Position the transfer horizontally.
- Using tool 5870.053.007 insert the bush complete with
- Tighten the ring nut to the specified torque; O-rings, respecting the orientation.
Drive input flange Figure 146
Figure 144
3
2
5870.260.011
5870.050.023 28309164
Injury hazard.
- Heat the drive input flange.

- Insert the hex head screws into the drive input flange
holding them in position using adhesive tape.
- Align the drive input flange and insert it into the
corresponding housing on the box until fully inserted.
28309162
1. Bush
2. O-ring with dust boot
3. O-ring

Lubricate the outer circumference of the O-rings
with EP1 bearing grease.

O-rings respecting their orientation.
Figure 147 Primary shaft bearing axial play adjustment

Figure 149
28309167
Proceed as follows:
- Tighten the ring nut to the specified torque.
Figure 150
28309165

- Tighten the ring nut to the specified torque.
Figure 148
28309168
- Lock the primary shaft ring nut with a suitable punch mark.
Figure 151
28309166

- Tighten the screw on the box to the specified torque.
The screw must be replaced with a new one. 28309169
- Settle the bearings (A) and (B) to cancel out play without
pre-loading them.
Rotate the primary shaft back and forth, tapping with

a plastic mallet to settle in the bearings.
28309172
28309170
- Position A determination. - Fit the chosen shim (S1).
Figure 155
Determine position “A” precisely, measuring at
several points.
Figure 153
28309173
The cover may only be replaced with a complete

unit.
B Check the integrity of all cover components.
28309171 Check the oil passages in the piping and baffle by
bowing in compressed air.
- Position B determination.
- Determine the thickness of shim S1 as follows:
Figure 156
S1 = A - (B + 0.14 — 0.20) mm
where:
A = distance between box contact surface and bearing outer
race (B).
B = distance between box contact surface and bearing
shoulder (B).
0.14 — 0.20 = bearing axial play
Example
A = 7.90 mm
B = 4.70 mm
Bearing play (mean)= 0.17 mm
S1 = 3.03 mm
28309174
- Fit the cover and tighten the screws to the specified

torque.
Figure 157 Oil pump assembly

Figure 159
28309175
- Turn the transfer by 180˚. 28309177
Proceed as follows:
Rotate the drive input shaft back and forth, tapping
with a plastic mallet to settle in the bearings.
Figure 158
- Fit the external toothed gear and the internal toothed ring
into the pump body.
Figure 160
28309176
- Using a suitable tool check that the axial play of the

primary shaft bearings is within the specified range.
Bearings axial play: 0.14 - 0.20 mm 28309178
- Otherwise correct play by fitting a shim S1 of a different - Fit the oil pump cover and tighten the screws to the
thickness. specified torque.
- In particular:
 increase thickness to reduce play.
 reduce thickness to increase play.
- Turn the transfer by 180˚ again.
- Remove the primary shaft cover and apply sealant to the
contact surfaces between box and cover.
- Fit the cover and tighten the hex head screws to the
specified torque.
Fitting the safety valve in the pump body Figure 162

Figure 161
9
1
8
7
6
5
4
3
2 28309180
28309179 - Tighten both screws to specified torque.

1. Pump body
2. Cone
3. Sel disk (Viton)
4. Washer
5. Reaction spring
7. Fitting disk (14x20x1.5)
8. Stopper circlip
9. Fasteners
- Align the seal disk (3) and the washer (4) with the cone
(2) and insert them into the housing in the pump body
(1).
28309181
Pay attention to positioning the seal disk correctly.
- Tighten the screw (central hole) to the specified torque.
Axial play adjustment of secondary shaft support

- Insert the reaction spring (5) and the oil passage disk with Figure 164
guide (6).
- Insert the fitting plate (7).
- Fit the stopper clip in the corresponding seat in the pump
body.
- Repeat the procedure for the second safety valve.
28309182
- Settle in the bearings (E) and (F) to cancel out play

without pre-loading them.
Rotate the primary shaft back and forth, tapping with

a plastic mallet to settle in the bearings.
28309183 28309185
- Position A determination. - Fit the chosen shim (S3).
Determine position “A” precisely, measuring at Figure 168

several points.
Figure 166
28309186
- Fit the pre-assembled pump body.

- Tighten the hex head screws to the specified torque.
28309184 Figure 169
- Position B determination.
- Determine the thickness of shim S3 as follows:
S3 = A - (B + 0.14 — 0.20) mm
where:
A = from the cover contact surface to the bearing outer race
(F)
B = height of cover edge
0.14 — 0.20 = bearing axial play
Example
A = 9.70 mm
B = 6.55 mm
Bearing play (mean)= 0.17 mm 28309187
S3 = 2.98 mm
- Using a suitable tool check that the axial play of the
secondary shaft bearings is within the specified range.
Bearings axial play: 0.14 - 0.20 mm
- Otherwise correct play by fitting a shim S3 of a different
thickness.
- In particular:
 increase thickness to reduce play.
 reduce thickness to increase play.
28309190
28309188
- Assemble the pump body.
- Dismantle the oil pump again.
- Insert the ball into the hole in the intermediate shaft,
holding in position with EP1 bearing grease. Figure 173
Turn the intermediate shaft such that the position of

the ball coincides with the cavity on the pump body.
Figure 171
28309191
- Apply the specified sealant to the contact surfaces

between pump body and cover.
- Fit the cover.
28309189
- Align the cavity in the oil pump gear (arrow) with the one
in the pump cover and the reference notch on the pump
body.
Fitting the safety valve to the delivery line Figure 175

Proceed as follows:
Figure 174
4
1
28309193
- Fit the two screws with O-rings.
Figure 176
28309192
1. Ball
2. Disk 28309194
3. O-ring
4. Stopper circlip - Tighten the screw to the specified torque.
Grease the O-ring with EP1 bearing grease before

fitting.
- Insert the ball (1), the disk (2) with O-ring (3) and position
the circlip (4).
- Follow the same procedure for the second valve.
Pressure limiter valve and exchanger by-pass valve - Align the seal disk (4) and the washer (5) with the cone
(3) and insert them into the housing in the valve block (1).
The two valves are similar. This part describes the
pressure limiter valve. Pay attention to positioning the seal disk correctly.
Figure 177
- Insert the reaction spring (6) and the oil passage disk with
guide (7).
- Insert the adjuster shim (8).
12 13 - Fit the circlip (9) into its housing.
- Repeat the same procedure for the exchanger by-pass
valve.
10 11
3 Figure 178
2
4
5
6 1
7
8
9
13
11
16
21 28309196
15 22 - Fit the pre-assembled valve block.

14 - Tighten the screws to the specified torque.
20 - Fit the exchanger connectors with the corresponding
17 19 O-rings and tighten to the specified torque.
1 18
Figure 179
28309195
1. Valve block
2. Plug
3. Cone
4. Seal disk (Viton)
5. Washer
6. Reaction spring
8. Adjuster shim
9. Stopper circlip
10. O-ring
11. Fasteners
12. Split ring 28309197
13. Nut
14. Cone - Fit the by-pass valve plug with O-ring and tighten to the
15. Seal disk (Viton) specified torque.
16. Washer
17. Reaction spring
19. Adjuster shim
20. Stopper circlip
21. O-ring
22. Fasteners
Step-down command control and adjustment Figure 182

Figure 180
”A”
28309198

- Fit the cylinder aligning the control rod.
Pay attention to positioning the air passages

correctly (arrow).
28309200
- Position the step-down selector in neutral.

Respect the references marked on dismantling.
The selector sleeve is locked in position on the
Figure 181 primary shaft by the balls and springs.
The fork sliders must be in contact with the groove
in the selector sleeve.
- Determine distance A between cylinder surface and

adjuster shim contact surface on the conrol rod.
- Determine the thickness of the adjuster shim S as follows:
S = A — 63.285 mm
Example 1:
A = 65.09 mm
Specified value= 63.285 mm
S = 1.805 mm
28309199
- Temporarily fir the cylinder, without cover, using two

screws and spacers.
2
28309203
28309201
- remove the cylinder again. Lubricate the components with EP1 bearing grease
- Apply sealant to the contact surfaces between front before fitting.
cover and cylinder.
- Insert the O-ring into the housing in the cylinder. - Insert the piston (1) with correspon ding O-ring (2).
- Fit the pre-assembled cylinder. Figure 186

Lubricate the components with EP1 bearing grease
before fitting.
Figure 184
28309204
1 - Insert the O-ring 1), the piston (2) and corresponding
O-ring (3).

before fitting.
2
28309202
Figure 187
before fitting.
- Align and fit the adjuster shim (1) of the predetermined

thickness to the control rod (2).
28309205
- Tighten the recessed hex head screw to the specified

torque.
Figure 188 Step-down control function and seal

Figure 190
28309206
- Apply sealant to the contact surfaces between the 28309208

cylinder and corresponding cover.
- Fit the pneumatic connection with the correspoding
Do not block air passages with sealant. O-ring.
Figure 191
- Fit the cover and tighten the screws to the specified

torque.

The pneumatic connections (arrows) must be
correctly aligned.
Figure 189
28309207
- Fit the pneumatic connections with the corresponding

O-rings.
- Tighten the pneumatic connections to the specified 28309209
torque.
1. Normal gear pneumatic connection.
2. Step-down gear pneumatic connection.

- Blow compressed air )6.5 — max 10 bar) into the
connector.
- Check that the seal is within the specified limits.
No pressure drop over 10 seconds.
- Repeat the test for each step-dwn position.
Figure 192
28309210
- Fit the breather valve (1).

- Fit the step-down position indicator switch (2).
- Tighten the various components to the specified torque.
Figure 193
28309211
- Fit the speed sensor (1) and tighten it to the specified

torque.

SPLITTER — TRANSFER UNIT
TC 2200
SECTION 9.2
HD9 Euro5 SECTION 9.2 SPLITTER — TRANSFER UNIT TC 2200 1
SECTION 9.2
Splitter — Transfer unit TC 2200

Page
DESCRIPTION 3
OPERATION 4
- Drive transmission scheme: on-road gears 4
- Drive transmission scheme: off-road gears 5
TORQUE TRANSFER 6
- Splitter ratios calculation 6
- Transfer and differentials locking control 7
LUBRICATION 8
TOOLS 14
HYDRAULIC FLUID CHANGE 18
GENERAL 18
- Removal 19
- Filling 19
TRANSFER UNIT REMOVAL-REFITTING 20
GENERAL 20
2 SPLITTER — TRANSFER UNIT TC 2200 SECTION 9.2 HD9 Euro5
DESCRIPTION OF OPERATION 21 PRELOAD ADJUSTMENT OF BEARINGS 34

- Preliminary operations 21 - Input shaft 34
- Removal 21 - Countershaft 34
- Inspections and checks 21 - Output shaft 34
- Refitting 21 ASSEMBLY COMPLETION 35
- Final operations 21 - Adjustment of splitter lock and PTO engaged
indicator switch (if present) 37
FLANGE REMOVAL-REFITTING TRANSFER 22
- Pulse transmitter adjustment 37
GENERAL 22
- Refilling oil 37
- Removal 23
- Refitting 23
SPLITTER — TRANSFER UNIT OVERHAUL 24
DISASSEMBLY 24
PARTS CLEANING AND CHECKING 27
REPLACEMENT OF O-RINGS IN THE OUTPUT
SHAFT COVERS 28
REPLACING THE O-RING IN THE INPUT SHAFT
COVER 28
INPUT SHAFT 28
- Disassembly 28
- Assembly 29
EPICYCLIC TRANSFER GROUP 29
- Disassembly 29
- Assembly 30
COUNTERSHAFT 31
- Disassembly 31
- Assembly 31
REDUCTION UNIT-SPLITTER ASSEMBLY
ON BENCH 31
DESCRIPTION
The splitter-transfer group is located between the The input shaft is fitted with the toothed sleeve for selecting
transmission and the intermediate axle. normal or low gear ratios.
It consists of a series of constantly meshed cylindrical helical The output shaft is connected to the torque transfer
gears. differential for the front and rear axles and the transfer box
These gears are mounted on three shafts: input, countershaft differential locking system.
and secondary output shaft.
Figura 1
SECT. A---B
SPLITTER-TRANSFER BOX LONGITUDINAL CROSS-SECTION

OPERATION
Drive transmission scheme: on-road gears
Figura 2
In these conditions the sleeve (1) shifts in the direction of the The driving torque is transferred via the countershaft (3).
arrows engaging gear (2) with the input shaft (4).
Drive transmission scheme: off-road gears

Figura 3
In these conditions the sleeve (1) shifts in the direction of the The driving torque is transferred via the countershaft (3).
arrows engaging gear (2) with the input shaft (4).
TORQUE TRANSFER
The drive transmitted from the input shaft via the countershaft (4) turns the planetary gear carrier train (1) which via the crown gear
Z2 and sun gear Z1 transmits drive to the front (2) and rear (3) output shafts.
Splitter ratios calculation

Figura 4
62133
Input torque
Torque at front wheels
Torque at rear wheels
Z1
Ponte anterioreT 1 = = 18 = 0, 2
Z1 + Z2 18 + 72
Z2
Ponte posterioreT 2 = = 72 = 0, 8
Z1 + Z2 18 + 72
T2 0, 8
Ripartizione totale = = = 4, 0
T1 0, 2
Transfer and differentials locking control If the lock does not disengage immediately change the driving
The lock must only be used for travelling over muddy and direction to remove any tensions.
slippery terrain.
To operate the system correctly proceed as follows:
- Shift to the lock position with the vehicle stationary or at
low speed. - On muddy and slippery ground do not free
wheel without the differential lock because this
- Proceed with caution would cause serious damage to the gears (a few
When the poor road conditions have been passed, proceed seconds are sufficient).
as follows: - Do not engage the differential lock when a wheel
- Shift to the unlock position while maintaining vehicle is free-wheeling; this would cause serious
speed. damage to the gears.
- Momentarily lift the accelerator.
- Resume normal driving.
LUBRICATION
Figura 5
62140
Oil level checking and refilling procedure

Make sure the vehicle is parked horizontal
- Remove the plug (4). A small quantity of oil may spill out.
- Check that the oil is at the level of the plug (4) If necessary,
top-up through the filler (1) after removing the plug.
- Close the two plugs and tighten them to the specified
torque.
TC 2200
Gears Constant mesh helical gears
Transmission ratios
1:1
normal (on road)
1 : 1,6
low (off road)
Nm
Maximum input torque Nm 22000 Nm
Torque transfer 1:4
Shaft bearings pre-load: mm

input
0,05  0.10 mm
countershaft
output
Bearing preload adjustment by adjuster rings
Adjuster ring thickness mm

ASTRA input 1—1.1—1.2—1.3—1.4—1.5—1.6—1.7—1.8—1.9 mm
countershaft 1—1.6—1.7—1.8—1.9—2.0—2.1—2.2—2.3—2.4—2.5 mm
output 1—1.1—1.2—1.3—1.4—1.5—1.6—1.7—1.8-1.9-2 mm
ASTRA Adjuster rings thickness 1—1.5 mm

for pulse transmitter mm 1 -1.5 mm
1 - 1,5
Quantity (*) Kg (litres) 5,6 (6,2)
* See section 2 — LUBRICATING AND HYDRAULIC OILS TABLE for the required type of lubricant.
TIGHTENING TORQUES
Figura 6
SEC. A - A
62138
TORQUE
PART
Nm kgm
1 M 14 screw (TC 2200) 120  12 12,2  1,2
2 M 22 x 1.5 pin 500  50 50,9  5,1
3 M 12 screw (TC 2200) 78  8 7,9  0,8
4 M 6 screw 9,5  0,5 1  0,05
5 M 6 screw 9,5  0,5 1  0,05
6 M 18 x 1.5 pulse transmitter 45  5 4,6  0,5
7 Push rod switch nut M 18 x 1.5 45  5 4,6  0,5
8 M 8 screw (TC 2200) 22,5  2,5 2,3  0,25
9 M 10 screw 45  5 4,6  0,5
10 M 12 screw (TC 2200) 78  8 7,9  0,8
11 M 6 screw* 71 0,7  0,1
12 M 27 x 2 (TC2200) screw plug 55  5 5,6  0,5
13 M 14 x 1.5 (TC2200) screw plug 78  8 7,9  0,8
14 M 5 screw 4,5  0,5 0,46  0,05
15 M 5* screw (TC 2200) 5  0,5 0,5  0,05
16 M 10 dowel* 33  3 3,4  0,3
17 M 12 screw (TC 2200) 78  8 7,9  0,8
18 M 10 screw 65 6,6
19 M 5 screw 5  0,5 0,5  0,05
20 M 12 screw (TC 2200) 78  8 7,9  0,8
* Apply LOCTITE AVX.
J Apply LOCTITE 510
Figura 7
307092001R
Figura 8
62139
TORQUE
PART
Nm kgm
21 M 8 screw (TC 2200) 22,5  2,5 2,3  0,25
22 Oil vapour breather 100  10 10,2  1,02
23 M 22 x 1.5 (TC2200) screw plug 110  10 11,2  1,02
24 M 6 screw 71 0,7  0,1
25 M 14 threaded filler 45  5 4,6  0,5
26 ¼ filler terminal 45  5 4,6  0,5
27 M 22 x 1,5 (TC 2200) filler terminal 78  8 7,9  0,8
28 M 28 x 1.5 plug 110  10 11,2  1,02
29 Push rod switch M 14 x 1.5 45  5 4,6  0,5
30 M 8 screw (TC 2200) 22,5  2,5 2,3  0,25
31 M 12 x 80 special screw 78  8 7,9  0,8
32 M 10 screw (TC 2200) 47  3 4,8  0,3
33 M 12 screw 78  8 7,9  0,8
34 M 12 screw (TC 2200) 78  8 7,9  0,8
35 Push rod switch nut M 18 x 1.5 (TC 2200) 50  5 5,1  0,5
36 M 10 screw (TC 2200) 50  5 5,1  0,5
37 M 12 screw (TC 2200) 78  8 7,9  0,8
* Apply LOCTITE 242
J Apply LOCTITE 510
Figura 9
307092001R
TOOLS
For removal and refitting operations, always use the specified tools.
TOOL NO. NAME
99305121 Hot air tool
Rotating stand for group overhaul (capacity 1000 daN, torque 120
99322205 daN).
99340205 Percussion ram
99341003 One way extractor bridge
99341009 Bracket pair
99341015 Clamp
TOOL NO. NAME
Pin for extracting epicyclic group planet gear pins (use

99342143 with 99340205).
99345049 Reaction block for pullers
99360502 Pair of rings for removing-refitting splitter-transfer half case.
99366067 M8 eyebolts for countershaft removal-refitting.
99370006 Handgrip for interchangeable batons
99370317 Reaction lever with flange retainer extension

TOOL NO. NAME
Fitting tool for fitting seals to front drive shaft cover (use with
99370362 99370006).
Comparator base for secondary shaft bearings adjustment (use with

99370415 99395604).
99370565 Eyebolts for epicyclic group removal-refitting.
99370631 Support for splitter-transfer removal-refitting
Bracket for supporting splitter-transfer during overhaul (use with

99371051 99322205).
99374253 Fitting tool for fitting seal to rear drive input/output shaft cover.
TOOL NO. NAME
99395604 Dial gauge (0-10 mm)

HYDRAULIC FLUID CHANGE Hazardous and/or polluting substances

GENERAL

Vehicle preparation

Figura 10
2371801

short circuits;

Proceed as follows:
Removal
Proceed as follows: Figura 13
To facilitate the operations described, empty the tank.
Figura 11
238NM10
- fill through plug (2) with the specified oil until it flows from
the cap hole ( 1);
- clean the level and filler caps, check that the thread is in
good condition, replace the o-ring and replace the cap
238NM10 without tightening it;
- arrange a container of appropriate capacity, clean the area Final operations

around the caps and then remove the level cap (1); and - start the vehicle in motion for a few minutes so that the
filler cap (2); oil reaches all the transfer unit internal components; stop
the vehicle and wait about ten minutes so that the oil can
Figura 12 settle;
- unscrew the level cap(1); lubricant should flow out from
the hole; if it does not, top up through the cap only ( 2)
until it overflows from the cap ( 1);
- close the level cap and the filler cap.
238NM11
- remove drain caps (1) and fully drain the oil;

- clean the caps, check that the threading is in good
condition, replace the o-ring with a new one and close the
drain caps;
TRANSFER UNIT REMOVAL- Very heavy parts

REFITTING
Safety instructions parts. To lift and transport, use appropriate

person. Read the instructions provided in the first Hazardous and/or polluting substances
Always observe all the general recommendations to The operation described requires handling of
carry out maintenance jobs correctly. hazardous and/or polluting substances

Safety component.
Figura 14 Tighten the fastening bolts to the specified torque.
2371801

short circuits;
DESCRIPTION OF OPERATION Inspections and checks

Preliminary operations Proceed as follows:
Proceed as follows: - check integrity of connecting flange;
- drain off the fluid as described in HYDRAULIC FLUID - check intactness of brackets and fastening bolts, if
CHANGE in this Section required replace any damaged parts
Removal Refitting
- disconnect the transfer lock control electrical and
pneumatic connections (1); Final operations
Proceed as follows:
- disconnect the splitter lock control electrical and
pneumatic connections (2); - fill with the fluid as described in HYDRAULIC FLUID
CHANGE in this Section
- disconnect the odometer wire (7) after removing the seal;
- unscrew the input shaft flange (3), front output shaft
flange (4) and rear output shaft flange (5) bolts and
temporarily fasten the shafts to the chassis so that they do
not interfere with subsequent operations.
- place a hydraulic jack under the transfer unit;
- remove the screws connecting the four support pads (6);
- insert a screw into each block as indicted (arrow) to
compress the block to permit removal of the group;
- lower the jack and remove the transfer from below.
Figura 15
FLANGE REMOVAL-REFITTING Very heavy parts

TRANSFER

Always observe all the general recommendations to Safety component.
carry out maintenance jobs correctly. Tighten the fastening bolts to the specified torque.
Vehicle preparation

Figura 16
2371801

short circuits;

Preliminary operations Check conditions of flange front grooves if necessary replace
damaged component .
Proceed as follows:
- remove the transmission shaft as described in Refitting
TRANSMISSION SHAFT REMOVAL-REFIT.(..) in Section
10
Final operations
Removal
Proceed as follows:
Proceed as follows:
- refit the transmission shaft as described in
Figura 17 TRANSMISSION SHAFT REMOVAL-REFIT.(..) in Section
10
62143
Drive input flange (3) and front output drive (4)
Figura 18
62141
Rear drive output flange (3)

- block flange (3) rotation using tool 99370317 (2) or
equivalent ;
- remove the central screw using an appropriate socket
wrench (1);
- remove the flange with an appropriate puller.
SPLITTER — TRANSFER UNIT OVERHAUL Version with P.T.O.

DISASSEMBLY Figura 21
Position the splitter-transfer on rotary stand

99322205 with brackets 99371051, position it
vertically, unscrew the plugs and drain the oil.
Figura 19
62143
Unscrew the two clamp screws (1), the two connectors (2)
and remove the oil lines (3).
Figura 22
62141
Lock rotation of the flange (3) using reaction lever 99370317

(2), unscrew the retainers with the correct socket wrench (1)
and remove the flange.
Version without P.T.O.

Figura 20
62144
Unscrew the P.T.O enable push rod switch (1) and the normal
gears engage push rod switch (2).
Figura 23
62142
Turn the group by 90 with the rear side facing upwards.
Unscrew the normal gears engage push rod switch (1) (if
present).
Unscrew the 3 screws and remove the cover (2) with piston, 62145
unscrew the 14 screws and remove the cover (3).
Unscrew the 9 screws and remove the PTO (1) complete
Remove the drive input shaft and counter shaft bearings with flange (2) and control fork.
preload adjuster rings.
Figura 24 Figura 27
62146
Unscrew the 3 screws and remove the cover (1) with piston,
unscrew the 5 screws and remove the cover (3). 62148
Remove the drive input shaft and counter shaft bearings Lock rotation of the flange (3) using reaction lever 99370317
preload adjuster rings. (2), unscrew the retainers with the correct socket wrench (1)
Both versions and remove the flange. Repeat the same operation to remove
flange (4).
Figura 25
Figura 28
39875
Unscrew the 9 screws, then using 3 reaction screws inserted 62149
in the holes indicated by the arrows, remove the cover (1) and Unscrew the 6 screws and remove the cover (1) with the
remove the output shaft bearings preload adjuster rings. O-ring. Unscrew the 3 screws and remove the cover (2) with
transfer lock piston.
Figura 26
Figura 29
62147 39872
Turn the group by 180
Unscrew the vehicle speed pulse transmitter (1), the transfer Unscrew the 11 screws and remove the cover (2) complete
lock indicator push rod switch (2) and the low gears engaged with transfer lock control shaft (1) and fork (3). Unscrew the
push rod switch (3) (if present). 9 screws and remove the cover (4) complete with O-ring.
Figura 30 Figura 32
62150
Unscrew the 3 screws, remove the cover (2) with control

piston and extract the spring inside. With an Allen key unscrew
the screws and remove the locking plate (1).
Figura 31
62152
Position two rings 99360502 (1) as shown in the diagram to

balance the half case (2).
Using cables and hook lift the half case moving it in the
direction of the arrow to disengage the leaf spring (3) from
under the intermediate shaft.
Figura 33
62151
Unscrew the 3 Allen screws (1) fastening the internal leaf 62153
spring. Using the eyebolts 99370565 (1), cables and lifting gear,
Unscrew the half case screws (4). remove the epicyclic transfer unit (2) from the case.
Using a suitable punch, extract the 2 half case (3) centring pins
(2).
Figura 34 Figura 37
62154 62157
Straighten the locking plate (3), unscrew the screws (1) then Fasten the screw and washer (1) to the input shaft (2) and
remove the phonic wheel (2). using cables and lifter remove the input shaft (2) from the case
complete with control fork (3).
Figura 35
Figura 38
62155
Using the eyebolts 99366067 (1), cables and lifting gear,

remove the counter shaft (2) from the case. 39881
Using a suitable baton remove the outer rings (1 — 2 — 3) of

Figura 36 the bearings from the case.
PARTS CLEANING AND CHECKING

After removing the splitter-transfer unit, proceed to
disassemble the unit, the shafts and the epicyclic transfer and
to thoroughly clean all parts.
Check that the parts show no signs of excessive wear, binding
or cracks.
Always replace the O-rings and seals with new ones.
62156
Unscrew the 3 screws (1) on the opposite side of the case and
remove the leaf spring (2) that prevents removal of the input
shaft.
To do this, work from below without rotating the

group, because removal of the spring causes the input
shaft to drop.
REPLACEMENT OF O-RINGS IN THE INPUT SHAFT

OUTPUT SHAFT COVERS Disassembly
Figura 42
Figura 39
ASTRA
62159
39892
To replace the O-rings (3) in the rear output shaft cover (4) INPUT SHAFT COMPONENTS
remove the locking ring (1) and remove the bearing (2). Fit the 1. Bearing — 2. Leaf spring — 3. Spacer ring —
new O-ring (3) with fitting tool 99374253. 4. Gear — 5. Roller bearings — 6. Spacer ring — 7. Shaft —
8. Sliding sleeve — 9. Gear — 10. Bearing.
Figura 40 The bearings (1, Figura 43 e Figura 44) must be

removed under a hydraulic press.
Figura 43
ASTRA
39893
Fit the O-ring (1) in the front output shaft cover (2) using fitting
62160
tool 99370362 and handgrip 99370006.
After removing the bearing (1) manually remove the gear (9,
Figura 42) the roller bearings (5, Figura 42), the spacer ring (6,
Figura 42) and the sliding sleeve (8, Figura 42).
REPLACING THE O-RING IN THE INPUT
SHAFT COVER
Figura 44
Figura 41
ASTRA
62158
62161
Fit the O-ring (1) in the input shaft cover (2) using fitting tool Also remove the bearing (1) and extract the leaf spring (2,
99374253. Figura 42) the spacer ring (3, Figura 42), the gear (4, Figura 42),
the roller bearings (5, Figura 42), and the spacer ring (6,
Figura 42).
EPICYCLIC TRANSFER GROUP

Assembly Disassembly
Figura 45 Figura 47
39886
Sunscrew the screws (1) and remove the oil seal (2). Using
bridge 99341003, brackets 99341009 and clamp 99341015
and reaction block 99345049, remove the bearing (3), then
unscrew the screws (4).
Figura 48
39894
Fasten the shaft (3) in a vice with the grooved part upwards.
Fit the roller bearings (5, Figura 42) with the spacer (6,
Figura 42), fit the gear (2, Figura 45) with the teeth facing
downwards. Fit the spacer (1) and the leaf spring (2,
Figura 42).
Heat the inner roller bearing ring (1, Figura 42) to 80  90C
and fit it to the shaft.
39887
Figura 46 Using 2 screws (1) fastened in the holes indicated by the

arrows, remove the planetary gear carrier (2) from the crown
wheel (3).
Figura 49
62162
Turn the shaft over and fasten it in the vice. 39888
Fit the sliding sleeve (2) with the flare (arrow) facing upwards. Remove the sun gear (2) and remove the rear drive output
Fit the roller bearings (1) and the spacer (3). shaft (1).
Fit the gear (9, Figura 42) with the teeth facing the sliding
sleeve. On versions with transfer ratio 1 : 4, used on 6x6
Heat the inner bearing ring (10, Figura 42) to 80  90 C and models, the sun gear is not present since the teeth are
fit it to the shaft. cut directly into the front output shaft.
Figura 50 Assembly
Figura 53
39896
39889 Fit the gears (3) in the planetary carrier, fit the pin (1) so that
Using a suitable baton through the holes (arrows), remove the the indent (2) coincides with the hole for the grub screw (4).
bearing (1). Apply LOCTITE AVX to the grub screw (4) and tighten it to
the specified torque, and repeat the same operation for the
other pins. Turn the planetary gear carrier over and fit the
inner ring of the bearing after heating it to 80  90 C.
Figura 51
Figura 54
39890 39888
With an Allen key unscrew the 3 grub screws (1). MFit the rear output shaft (1) and sun gear (2) (if present) on
the crown gear and fasten the group in a vice.
Figura 52 Figura 55
39897
62163
Using the percussion ram 99340205 (1) with pin 99342143 MFit the complete planetary gear carrier (1), lining up the
(2) remove the shafts (3) of the gears (4). centring pins, fasten the screws (2) and tighten them to the
specified torque with the torque wrench (3).
REDUCTION UNIT-SPLITTER ASSEMBLY

Figura 56 ON BENCH
Figura 58
39898
Fit the oil seal (1), apply LOCTITE AVX to the screws (2) and 62366
tighten them to the specified torque.

Turn the group over and fit the bearing, after heating the Position the case (5) on stand 99322205 with brackets
intermediate ring to 80  90 C. 99371051 (4); fit the outer rings (1 — 2 — 3) of the bearings
with a suitable baton.
Figura 59
COUNTERSHAFT
Disassembly
Figura 57
62157
Fasten the screw and washer (1) to the input shaft (2) and
39885 using cables and lifter fit the shaft (2) in the case complete with
control fork (3).
Since it is a destructive operation, the removal of the

countershaft (2) bearings (1) does not present particular Figura 60
problems.
Assembly
Fit the new bearings (1) to the countershaft (2) after
heating the inner rings to 80  90 C.
ASTRA
62156
Insert the leaf spring (2) and lock it tightening the 3 screws (1)
on the opposite side of the case to the specified torque,
working from beneath without rotating the group.
Figura 61 Figura 64
62155
Using the eyebolts 99366067 (1) fit the countershaft (2).
Figura 62
62165
Using the rings 99360502 (1), hooks and cables insert the half
case (2) following the direction of the arrow to insert the leaf
spring pin (4) and the leaf spring (3) under the intermediate
shaft bearing.
62154
Fit the phonic wheel (1), the locking plate (3) and tighten the
screws (2) to the specified torque, then bend the plate.
Figura 63 Figura 65
62164 62166
Using the eyebolts 99370565 (1) fit the epicyclic reducer (2) Using a suitable punch, insert the two centring pins (1).
into the case. Apply LOCTITE 510 to the contact surfaces (3).
Position the leaf spring pin (4) in the respective hole on the
case.
Figura 66 Figura 68
62167 39903
Fasten the 3 internal leaf spring Allen screws (1) . Tighten the cover screws (2) with the torque wrench (1) to
Using the torque wrench (2) tighten the half case screws (3) the specified torque. Position the locking plate (3), apply
to the specified torque. LOCTITE AVX to the screw threads and tighten them to the
specified torque.
Figura 67 Figura 69
62168 39904
Apply LOCTITE 510 sealant. Fit the cover (3) complete with control piston and internal
Position the cover (1) complete with O-ring. spring. Spread OCTITE 510 on the seat (2) then fit the cover
(1) complete with splitter shaft and control fork.
Figura 70
The oil passage (2) must be positioned in line with the

corresponding hole (3).
39905
Tighten the screws (2) with the torque wrench (1) to the
specified torque.
Figura 71 PRELOAD ADJUSTMENT

OF BEARINGS
The input shaft, countershaft and output shaft preload is
adjusted as follows:
Input shaft
- Check that the outer race of the bearing fitted to the front
housing is perfectly flush.
- Settle the shaft into its seat applying an axial load of 50 kg
to the outer race of the rear bearing while turning the
shaft itself.
Figura 73
62149
Fit the cover (2) complete with control piston. Apply

LOCTITE 510, fit the cover (1) and tighten the screws to the
specified torque.
Figura 72
62170
- Using a depth micrometer (1) measure the protrusion of

the outer race (2) of the bearing relative to the plane of
the case (3) in at least two opposing points, while
maintaining the axial load.
The measured dimension A must be between:
TC 2200 10.5  11.5 mm.
39906
Fit the two flanges (1) apply the washers and using reaction
lever 99370317 (3) and the torque wrench (4) fasten the Figura 74
screws (2) to the specified torque.
62171
- Using the depth micrometer (1) measure the depth of the

seat (2) of the rear cover relative to the plane (3).
The measured dimension B must be between:
TC 2200 12.5  12.6 mm.
From the difference between the two measured dimensions, Output shaft
obtain the value of the spacer Se of the adjuster rings. Add the
specified preloading to this value. TC 2200
Se = (A — B) + 0.05 mm Figura 76
The choice of spacers must be made in excess in order to
achieve a total preload of 0.05 to 0.10 mm.
Countershaft
- Check that the outer race of the bearing fitted to the front
housing is perfectly flush.
- Settle the shaft into its seat applying an axial load of 50 kg
to the outer race of the rear bearing while turning the
shaft itself.
62175
- Using a depth micrometer (1) measure the protrusion of

the outer race (2) of the bearing relative to the plane of
Figura 75 the case (3) in at least two opposing points, while
maintaining the axial load.
The measured dimension D must be between:
5.2 and 7.0 mm
Figura 77 5,2 y 7,0 mm
62172
- Using a depth micrometer (1) measure the depth of the

outer race (2) of the bearing relative to the plane of the
case (3) in at least two opposing points, while maintaining
the axial load. 62176
The measured dimension C must be between:

- Using the depth micrometer (1) measure the depth of the
2.5 and 3.4 mm seat (2) of the rear cover relative to the plane (3).
2.5 y 3.4 mm The measured dimension E must be between:
Add the specified preload to the measured value to obtain the 8.0 and 8.1 mm
value of the spacerSr:
From the difference between the two measured dimensions,
Sr = C + 0.05 mm obtain the value of the spacer Su of the adjuster rings. Add the
specified preloading to this value.
achieve a total preload of 0.05 to 0.10 mm. Su = (E — D) + 0.05 mm
achieve a total preload of 0.05 to 0.10 mm.
ASSEMBLY COMPLETION Version with P.T.O.

Figura 78
Figura 80
62177
62179
Fit the adjuster rings of the previously calculated value then fit
the cover complete with bearing after heating to 80  90C,
and tighten the screws to the specified torque. Fit the adjuster rings of the previously calculated value then fit
the cover (1) complete with spring (2).
Version without P.T.O.

Figura 79 Fit the cover paying attention to align the indent (3)
with the grub screw (4) on the shaft.
Figura 81
62178
Fit the adjuster rings of the previously calculated value then fit
the cover (1) and tighten the screws to the specified torque.
Fit the splitter normal and low gear push rod switches and the
vehicle speed pulse transmitter and adjust them as described 62145
on the following page.
Fit the power take off (1) complete with flange (2) and control
fork, then tighten the screws to the specified torque.
Fit the splitter normal and low gear push rod switches (if
present), splitter lock and PTO control and the vehicle speed
pulse transmitter, and adjust them as described on the
following page.
Both versions Refilling oil

Figura 82 Replace the oil drain plug
Refill the group with the specified type of oil
39913
Fit the flange (1) and the washer (2) Using reaction lever
99370317 and the torque wrench tighten the screw (3) to a
torque of 500  50 Nm.
Adjustment of splitter lock and PTO engaged

indicator switch (if present)
Screw down the switch until it makes electrical

contact, unscrew by one turn then fasten the lock
nut to the specified torque.
Pulse transmitter adjustment
Figura 83
42447
Select and adjuster shim (2) to obtain a clearance A of 2  2.8

mm once the pulse transmitter is fitted.

REDUCER-TRANSFER CASE
VG 2000-396
SECTION 9.3
HD9 Euro5 SECTION 9.3 REDUCER-TRANSFER CASE VG 2000-396 1
SECTION 9.3
Reducer-transfer case VG 2000-396
Page
DESCRIPTION 3
- Longitudinal shaft section 4
- Differential lock device section 5
- Range selector device section 5
- Motion transmission diagram: fast gear engaged 6
- Motion transmission diagram: low gear engaged 7
- Neutral position 7
- Motion transmission diagram: splitter 8
- Adjustments 10
TOOLS 11
OIL CHANGE 16
GENERAL 16
- Exhaust 17
- Filling 17
SPLITTER-TRANSFER UNIT REMOVAL-REFITTING 18
GENERAL 18
2 REDUCER-TRANSFER CASE VG 2000-396 SECTION 9.3 HD9 Euro5
- Removal 19
- Refitting 19
OVERHAUL ALL NEW 21
- Disassembly 21
- Checking assembled parts 38
- Bearing and shim thickness diagram 39
- Sealant and thread lock diagram 40
- Re-assembly 41
DESCRIPTION
The reducer-transfer case unit is arranged between the trans- The splitter unit is arranged on the output shaft and consists
mission and the front and tandem axles. of an epicyclical cylindrical gear differential.
The two reduction ratios are obtained by means of two pairs A grooved sleeve actuated by a fork is used to lock the differ-
of permanently meshed gears mounted on the primary and on ential, thus fixing torque distribution.
the secondary shaft.
A grooved sleeve actuated by a fork engaged either one ratio
or the other.
Figure 1
1. Variant number
2. Serial number/date of manufacture
3. Assembly number
4. Transmission type/ratios
307A093001R
Longitudinal shaft section

Figure 2
307A093002R
1. Primary shaft
2. Not used
3. Secondary shaft
4. Gear oil pump
5. Rear output shaft flange
6. Differential splitter
7. Front output shaft flange
Range selector device section

Figure 3
1. Engagement sleeve
2. Sleeve actuating fork
3. Guide rods
4. Actuating piston
5. Contrast ball 307A093003R
6. Sensor
A. Fast ratio control

B. Slow ratio control
C. Idle control
Differential lock device section

Figure 4
1. Front output shaft

2. Engagement sleeve
3. Sleeve actuating fork
4. Actuating piston
5. Contrast spring
6. Sensor
307A093004R
Motion transmission diagram: fast gear en- In this manner, the engagement sleeve makes the larger diam-
gaged eter gear integral with the primary shaft: the longest transmis-
sion ratio results.
The control fork is moved rightwards by the control cylinder
displacement.
Figure 5
307A093005R
Motion transmission diagram: low gear enga- Neutral position

ged
Figure 7
The control fork is moved leftwards by the control cylinder
displacement.
In this manner, the engagement sleeve makes the smaller di-
ameter gear integral with the primary shaft: the shortest trans-
mission ratio results.
Figure 6
307A093007R
The control fork is maintained in the middle by the control cyl-

inder displacement.
In this way, the engagement sleeve remains in home position
and both the gears turn idly on the primary shaft.
307A093006R
Motion transmission diagram: splitter This allows the two shafts to turn at different speeds compen-
When the splitter lock is off, the torque from the permanently sated by the rotation of the satellite gears about their axis.
meshed gear on the secondary drives the carrier which by
means of the satellites drives the outer sun gear (connected
to the rear output shaft) and the inner sun gear (connected
to the front output shaft).
Figure 8
307A093008R
When the splitter lock is engaged, the sleeve makes the carrier
integral with the front output shaft by means of the front
teeth. All relative rotation between these two elements and
therefore also between the two shafts, is thus prevented.
Figure 9
307A093009R
Transfer STEYR
Type VG 2000/396
Maximum input torque 25.000 Nm (18.51lbft)
Maximum input speed 2.800 giri/min
high: 0.890
Transmission ratio
low: 1.536
Torque distribution (front/rear) 1 : 2.696
Weight (dry) 350 kg
Shift actuation air pressure 6.5 ÷ 8.5 bar
Primary shaft bearings axial play 0.06 ÷ 0.12 mm
Secondary shaft bearings axial play 0.40 ÷ 0.60 mm
Transfer shaft bearings axial play 0.02 ÷ 0.08 mm
Output shaft bearing pre-load 0.00 ÷ 0.05 mm
Adjustments
307A093156R
TOOLS
The codes in the following list are the original STEYR codes.
CODE ILLUSTRATION NAME
TS 220 W Mounting Device
TS 220 W/3 Clamping Device
TS 215 W Holding Device
TS 211 W Lifting and Measuring Device
TS 212 W Lifting Device
TS 213 W
Supporting Disk
TS 214 W
TS 222 W Lifter
TS 223 W Setting Tool
SK 17828/A Striking Weight
SKO-026506 Setting Tool
A-VG 2000-01 Setting Tool
SK 18 390 R Universal Handle

SKO-026530
Base
A-VG 2000-02 Centering Tool
Extractor
V-TS 86 W/1
for Oilpump
A-VG 2000-05 Flange Puller
Wrench
1 SKO-100720
for Drive Shaft
A-VG 2000-06 Release Device
A-VG 1600-03 Blocking Device

TIGHTENING TORQUES
Figure 10
307A093011R
TIGHTENING TORQUES
Figure 11
307A093012R
Figure 12
307A093013R
OIL CHANGE Hazardous and/or polluting substances

GENERAL

Vehicle preparation

signboards.
Figure 13
2371801

of short circuits;

Proceed as follows:
Exhaust
- fill with lubricant of the specified type through the hole
Figure 14 in the cap (1) until the fluid flows out of the hole in the
cap (3);
- clean the filling and level caps; check that the threading is
in good condition, replace the o-rings and close them.
Final operations
Proceed as follows:
- check the level proceeding as described in the USE AND
307A093014R
Proceed as follows:
- arrange a suitably sized container, clean the cap area and
remove the filler cap (1) and the level cap (3);
- remove both drain caps (2) and fully drain the oil;
- clean the drain caps; check that the threading is in good
condition, replace the o-rings and close them.
SPLITTER-TRANSFER UNIT REMOVAL- Very heavy parts

REFITTING

Always observe all the general recommendations to The operation described requires handling of
carry out maintenance jobs correctly. hazardous and/or polluting substances

signboards. Specific safety instructions
Safety component.
2371801

of short circuits;

Proceed as follows: in detail. These clips must be cut or released and then
- take the vehicle to level ground; restored while refitting to ensure the correct faste-
ning of the elements to be hold.
- drain off the lubricant as described in the OIL CHANGE
chapter in this Section;
Figure 16 The described operations refer to the following figu-

res.
- disconnect the electric connections:

1. splitter lock warning light
2. reducer on warning light
3. speed sensor
4. differential lock control
5. reducer on command (three fittings)
- temporarily fix the shafts to the chassis so as not to hinder
the next operations;
307A093016R - arrange a hydraulic jack under the transfer case and then
remove the connection screws to the mounts (arrow);
- remove the following flanges:
A. input shaft flange; - lower the jack and extract the transfer case from below.
B. front output shaft flange;
C. rear output shaft flange Inspections and checks
operating as described in the PROPELLER SHAFT
REMOVAL-REFITTING chapter in Section 10. Proceed as follows:
- Check integrity of connection flanges.
- Check integrity of the brackets and fastening bolts, if nec-
essary, replace the damaged component.
- Check the flexible mounts: if necessary. replace the dam-
aged component.
- Check perfect integrity of the electric wiring and respec-
tive connections.
Refitting
Refit by reversing the removal sequence.
Figure 17
307A093015R
OVERHAUL ALL NEW Figure 20
Before carrying out any operation, check that all pre-

cautions have been taken and all aspects regarding
safety of the personnel involved have been clarified.
Read the related instructions given in SECTION 1 of
this manual.
If in doubt, speak to a more experienced person.
Respect all general recommendations for correct ex-
ecution of maintenance works.
Disassembly
Before proceeding, remove the transfer case as 307A093020R

shown in the corresponding chapter.
- Remove the flange (1) using an appropriate extractor.
The ring nut is locked with thread locker.

Outer part disassembly Heat the threading to about 120 ˚C before unscre-
Figure 18 wing to avoid damage.
- Proceed in similar manner for all transfer case flanges.
Figure 21
307A093018R
Proceed as follows:
- Loosen the fitting and remove the oil pipe (1).
307A093021R
Figure 19
- Loosen the fastening bearing lid screws G (see bearing
diagram).
- Using appropriate levers, remove the bearing lid with
seals.
- Retrieve the shims S4.
- Remove the seals from the lid.
307A093019R
- Loosen and remove the motion input flange fastening nut

(1).
- Use tool TS 215W, if required (2).
Figure 22 Figure 25
307A093022R
- Remove the bearing support bushing G using an appropri-

ate extractor (2).
Figure 23
307A093025R
- Remove the snap ring (1) and the phonic wheel (2).
- Retrieve the centring ball (see detail).
Figure 26
307A093023R
- Loosen the speed sensor fastening screw (1).

- Remove the sensor using tool SK 17828/A (2).
Figure 24
307A093026R
- Using a plastic hammer, remove the speed sensor bushing

(1).
307A093024R
- Loosen the fastening screws and remove the speed sen-

sor phonic wheel lid (1).
Oil pump disassembly Figure 30

Figure 27
307A093030R
307A093027R - Loosen the pump body fastening screws M6x35 (1) and
M6x30 (2).
Proceed as follows:
- Loosen the fastening screws and remove the PTO hous- Figure 31
ing lid (1).
Figure 28
307A093031R
- Remove the oil pump body (1) with screws M6x60 (2).
307A093028R
Proceed as follows:
- Loosen the fastening screws and remove the oil pump lid
(1).
Figure 29
307A093029R
- Remove the lid (1), the washer (2) and the ball (3).
Figure 32 Figure 34
28309026
- Remove the outer race (1) and the inner race (2) of the
oil pump.
Figure 33 307A093033R
- Remove the seat (1) of the oil pump and the correspond-
ing resting flange (2).
- Remove the rear pump body (3) from the seat retrieving
the stop pin (4).
307A093032R
- Using a magnet, remove the driving ball (1).

Lid disassembly Figure 37

Figure 35
307A093036R
307A093034R - Remove the lid (1) and the range selection control cylin-
der.
Proceed as follows:
- Loosen the fastening screws and remove the lid (1) of Figure 38
bearing E (see bearing diagram).
- Retrieve the shims S3 (2).
Figure 36
307A093037R
- Loosen the rear fastening screws (1).
Figure 39
307A093035R
- Lock the intermediate shaft using tool A-VG 1600-03 307A093038R

(see detail).
- Loosen the fastening nuts (1) and remove the front mo-
- Remove the stop ring (1) of bearing B (see bearing dia- tion output lid with two screws M8x40 (2).
gram) using tool 1-SKO 100-20.
- Retrieve the adjustment shims S2 (see detail).
- Remove tool A-VG 1600-03.
Figure 40 Figure 42
307A093039R
307A093041R
- Loosen the fastening screw (1) of the differential lock
control retainer ball. - Loosen the fastening screws and remove bearing lid A
(see bearing diagram).
Pay attention to the spring. - Retrieve the adjustment shims S1 (see detail).
Retrieve the stop ball (see detail). - Remove the seals from the lid.
Figure 43
Figure 41
307A093042R
307A093040R - Loosen the front fastening screws (1).

- Remove the differential lock control device (1).
Figure 44
307A093043R
- Using appropriate lifting means, remove the splitter lid (1).

Shaft and bearing disassembly Figure 48

Figure 45
307A093047R
307A093044R - Lift by approximately 45 mm the intermediate shaft and

Proceed as follows: hole in position with a suitable spacer (1).
- Using appropriate lifting means, remove the differential Figure 49
from the splitter (1).
Figure 46
307A093045R
Pay attention to the spring. 307A093048R
- Using suitable lifting means, remove the input shaft (1)

with pin, fork and engagement sleeve (2).
- Turn by ¼ a turn and remove the washer (1) and the - Disassemble the input shaft if required.
spring (2) of the differential lock engagement fork.
Figure 50
Figure 47
307A093049R
- Remove the intermediate shaft (1) using suitable lifting

means.
307A093046R
- Remove the guard (1) and (2).

Figure 51
307A093051R
- Remove the spring bar from the box (1).
Figure 52
307A093052R
- Remove the guard (1).

Figure 53
307A093093R
- Remove the outer races of the bearings (A, B, C) .

- Remove the outer races of the bearings (E, F).
Front output shaft and different lock device removal-refit- - Remove the piston (1) and the spring (2).
ting
- Remove the seals (3 and 4).
Figure 54 - Remove the inner snap ring (5).
Figure 57
307A093054R
Proceed as follows:
307A093057R
- Loosen the fastening screws and remove the lid (1), the
nut (2), and the lock nut (3) of the differential lock device. - Remove the output shaft using a press.
- Remove the inner lid (4). - Remove the snap ring (1).
- Remove the ball bearing H using a press (2).
Figure 55
Figure 58
307A093055R
The piston is pushed against the snap ring by a spring. 307A093058R

Pay attention to the spring.
- Using a press, remove the bushing and rear plate from the
differential lock device.
- Remove the snap ring (1).
Figure 56
307A093056R
Front output shaft and different lock device refitting Figure 62

Figure 59
307A093063R
- Fit the fork (1) and the sleeve (2) of the differential lock
307A093060R
device with the teeth facing upwards.

- Fit the rear plate (1) of the differential lock device with the
sea of the spring facing upwards (see detail).
Figure 60
307A093064R
- Fit the output shaft using a press.

- Support the ball bearing H with tool SKO-026530 (2).
307A093061R
- Using a press, fit the bushing (1) with the rough edge to-
wards the rear plate (see detail).
Figure 61
307A093062R
- Assemble the ball bearing H using a press (2).

- Fit the snap ring (1).
Figure 64 Intermediate shaft disassembly
Risk of injury.
Figure 66
307A093067R
Proceed as follows:
307A093065R - Using a suitable extractor, remove the inner race of bear-
ing E (1) and the inner race of bearing F (2).
- Using a press and tool SKO-026526 (2) fit the bushing
with seals (1).
Input shaft re-assembly
Respect ring orientation (see detail). Lubricate components with the specified lubricant
Fill seals with bearing grease. before reassembly.
Figure 65
Risk of injury.
Figure 67
307A093066R
Lubricate o-rings with bearing grease.
- Fit the inner snap ring (1) and the o-ring (3) on the pin
307A093068R
(2).
Proceed as follows:
Seal (4) must have the open side facing outwards. - Fit the inner race of bearing E (1) and the inner race of
bearing F (2).
- Fit the seal (4) on the piston (5).

- Fit the spring (6) and the piston (5): press the spring and
fit the snap ring (7).
Input shaft disassembly Input shaft re-assembly
Risk of injury. Lubricate components with the specified lubricant

Wear protective gloves. before reassembly.
Figure 68 Risk of injury.

Figure 70
307A093070R
Proceed as follows:
- Using a suitable extractor, remove the inner race of bear-
ing B (1) and the smaller gear (2).
- Remove the engagement sleeve (3). 307A093068R
Proceed as follows:
Figure 69
- Fit the larger gear (1).
- Fit the inner race of bearing B (2).
Figure 71
307A093071R
- Using a suitable extractor, remove the inner race of bear-

ing A (1) and the larger gear (2).
307A093073R
- Fit the engagement sleeve (1).

- Fit the smaller gear (2).
- Fit the inner race of bearing A (2).
Differential disassembly Figure 74

Figure 72
307A093066R
307A093074R - Using an appropriate extractor, remove the inner race of

the tapered roller bearing C (1).
Proceed as follows:
- Mark the fastening screws (1) with a punch. Figure 75
- Loosen the screws.
Previously punched screws must be replaced.
Figure 73
307A093077R
- Using an appropriate extractor, remove the inner race of

the tapered roller bearing D (1).
Figure 76
307A093075R
- Mark the reciprocal position of the carrier and the gear

(see arrow).
- Using three operating screws M10x55 (2) remove the
carrier (1) from the gear (3).
307A093078R
The plug (1) is pushed by a spring.

Pay attention to the spring.
- Using a suitable pun, press the plug (1) and remove the
pin (2).
- Remove the spring with a magnet.
Figure 77 Figure 80
307A093080R 307A093083R
- Remove the gear from the carrier. - Using an appropriate extractor, remove the outer race of
the tapered roller bearing (1).
- Repeat the operation on all pins.
Figure 78 This operation will damage the bearing.

Use a new bearing.
Figure 81
307A093081R

- Remove the output shaft (2) from the outer sun gear (3).
Figure 79
307A093084R
- Using a press, remove the oil baffle (2) and the outer race
of tapered roller bearing D (3) of the gear (1).
307A093082R
- Remove the chalking from the outer roller bearing ring

(1).
Different re-assembly Figure 84
Lubricate components with the specified lubricant

before reassembly.
Risk of injury.
Support both the carrier and the gear if needed.
307A093088R
- Insert the rollers (1) in the bearing and hold them in posi-
Figure 82 tion with a little bearing grease.
Figure 85
307A093086R
Proceed as follows: 307A093090R
- Insert the spring (1) and the warning light (2). - Using a suitable punch, insert the plug and partially inset
the pin (1).
Figure 83
Figure 86
307A093087R
- Insert the washers (1) and hold it in position with a little 307A093091R
bearing grease. - Position the gear (1) and complete insertion of the pin (2).
Figure 87 Figure 90
307A093092R 307A093094R
- Fit the inner race of roller bearing (1). - Insert the output shaft (1) from the outer sun gear (2).
Figure 88 - Fit the snap ring (3).
Figure 91
307A093093R
- Using a press and tool TS 214W fit the outer race of the
roller bearing (1) on the output shaft (2).
Figure 89
307A093095R
- Fit the output shaft in the gear (2).

- Fit the carrier (3) on the gear (2).
307A093082R
- Using a punch chalk the outer race of the roller bearing

(1) in three points.
Figure 92 Figure 94
307A093098R
- Fit the outer race of the tapered roller bearing C (1) on

the carrier (2).
307A093096R
- Tighten the fastening screws (1) to the specified torque.

Differential box screw: 30 Nm
- Tighten by further 90˚ in a crisscross pattern (see detail).
Figure 93
307A093097R
- Insert the oil baffle (1) in gear (2) and refit it using tool
SKO-026506 (see detail).
- Using a press and tool SKO-026506, fit the outer race of
the taper roller bearing D (3).
Checking assembled parts

Bearings
- Check the state of the bearings: replace them if they have
blue contours, cracks and/or signs of wear;
- Check the bearing seats: to ensure there are no signs of
strain and/or ovalising.
Gears
- Check the state of the teeth: replace if there are signs of
pitting, cracks and/or sinking.
- Check the mating surfaces with the pins.
External box
- Check the bearing seats: to ensure there are no signs of
strain and/or ovalising.
Figure 95
307A09399R
- Check diameter of bearing seats.

A = 139.975 ÷ 140.000 [mm]
B = 139.975 ÷ 140.000 [mm]
C = 179.975 ÷ 180.000 [mm]
D = 154.975 ÷ 155.000 [mm]
E = 119.975 ÷ 120.000 [mm]
F = 119.975 ÷ 120.000 [mm]
- Check that the sealing surfaces and threads are intact and
are not dented or damaged.
Bearing and shim thickness diagram

Figure 96
307A093101R
Sealant and thread lock diagram

REF. DESIGNATION PRODUCT
Figure 97
F1 std. grease -
G1 additivised grease MOLYCOTE M55
D1 sealant DIRKO
LOCTITE 243
B1 thread sealant
blue
LOCTITE 638
B2 thread sealant
green
307A093102R
Re-assembly Figure 100
When reassembling, bear in mind the following ge-

neral rules:
 Heat the bearings and rings that are pressure-fit
in an oven at 100 ˚C;
 Carefully centre and fit the o-rings and bearings
with an appropriate fitter.
 Lubricate the ring nuts, o-rings and bearings.
Proceed as follows:
Figure 98
307A093104R
307A093106R
- Fit the guard (1) and fix it with the spring bar.
- Fit ball bearing G (1) oriented with stop slot facing inwards
Figure 99 on the bushing at the pin (2).
- Insert the pin making the flared part correspond to the
bearing slot (see detail).
Figure 101
307A093053R
- Install the outer races of bearings (A, B, C).

- Install the outer races of bearings (E, F).
307A093107R
- Using tool TS 213W (1) fit the outer race of roller bearing
G.
Output shaft bearing G pre-load adjustment Figure 104

Figure 102
307A093111R
307A093108R - Fit the bushing (1) and using three operating screws
M12x90 (2) and corresponding lock nuts (3) and washers
Proceed as follows:
(4).
- Measure value A.
Remove sealant in excess from the lubrication hole
Figure 103 (see arrow).
- Remove the operating screws.
Figure 105
307A093110R
- Measure value B.
- Determine the thickness of the shim S4 as follows:
S4 = A - B + (0.00 ÷ 0.05) mm
307A093112R
where:
A = distance between bushing-lid and roller bearing outer
race G contact surface Respect ring orientation.
B = distance between bushing-lid and roller bearing shoulder Fill seals with bearing grease.
G contact surface
0.00 ÷ 0.05 = pre-load [mm]
- Using tool SKO-026494 insert the seals in the lid.
307A093113R 307A093049R
- Refit the intermediate shaft (1) using suitable lifting means.

Do not introduce sealant in the lubrication holes (1).
Check correct insertion of the shaft on the cylindrical
roller bearing F.
Figure 107
Figure 110
307A093114R
- Fit the cover (1) with shim S4 (2). 307A093047R
Figure 108 - Lift by approximately 45 mm the intermediate shaft and

hole in position with a suitable spacer (1).
Figure 111
307A093115R
- Fit the inner race of the tapered roller bearing D (1) in the
bushing seat (2). 307A093048R
- Using suitable lifting means, fit the input shaft (1) with pin,
fork and engagement sleeve (2).
307A093116R 307A093117R
- Remove the thickness and the intermediate shaft (1). - Fit the differential complete with guard (1) using suitable
lifting means.
Figure 113
Figure 116
307A093118R
- Using appropriate lifting means, fit the splitter lid (1).
Figure 117
307A093046R
- Fit the guard (1) and (2).
Figure 114
307A093120R
- Tighten the front fastening screws M16x130 (1, n. 12) to

Splitter lid fastening screws: 195 Nm
- Remove the studs (2) if removed.
307A093045R
- Load the spring (2) of the differential lock engagement

fork and lock it by turning the washer by ¼ turn (1).
307A093121R
- Using tool A-VG-1600-01 and tool A-VG-1600-01 (1) fit

the outer race of roller bearing E.
Figure 119
307A093035R
- Lock the intermediate shaft using tool A-VG 1600-03

(see detail).
- Using tool 1-SKO 400720 tighten the stop ring (1) of
bearing B (see bearing diagram) to specified torque.
307A093122R
Input shaft bearing B ring: 600 Nm
- Tighten the rear fastening screws M16x100 (1, n. 10) to
the specified torque. - Remove tool A-VG 1600-03.
Splitter lid fastening screws: 195 Nm Figure 121
307A093123R
- Install the rear pump body in the seat (1).

- Fit the stop pin (2).
307A093124R 307A093030R
- Fit the seat (1) of the oil pump and the corresponding - Tighten the pump body fastening screws M6x35 (1) and
resting flange. M6x30 (2).
- Install the drive ball (see arrow) withholding it with a little Figure 126
bearing grease.
Figure 123
307A093068R
- Fit the oil pump housing lid (1) and tighten the fastening
28309026 screws.
- Fit the outer race (1) and the inner race (2) of the oil - Fit the PTO housing lid (2).
pump.
Figure 127
Figure 124
307A093028R
307A093031R
- Fit the oil pump housing lid (1) and tighten the fastening
- Fit the oil pump body (1) with screws M6x60 (2). screws.
307A093027R 307A093126
- Fit the PTO housing lid (1) and tighten the fastening - Fit the phonic wheel (1) at the drive ball.
screws.
- Fit the snap ring (2).
Figure 129
Figure 132
307A093029R
307A093024R
- Fit the cap (1), the washer (2) and the ball (3).
- Fit the speed sensor phonic wheel lid (1) and tighten the
Figure 130 fastening screws.
Figure 133
307A093125R
- Fit the speed sensor bushing (1) using two operating 307A093128R
screws.
- Fit the speed sensor and tighten the fastening screw (1).
- Install the drive ball (see arrow) withholding it with a little
grease.
Figure 134
307A093130
- Using an appropriate tool, fit the inner race of roller bear-

ing G (1).
Figure 135
307A093131R
- Settle the input shaft (1), intermediate (2) and output (3)
bearings.
Strike with care using a suitable tool and turn the

shafts at the same time.
Input shaft axial clearance adjustment (bearings A and B) Figure 138

Figure 136
307A093134R
307A093132R - Fit the cover (2) with shim S1 (1).

Proceed as follows: - Settle the bearings.
- Measure value A.
Figure 137 shafts at the same time.
Figure 139
307A093133R
- Measure value B.
307A093135R
S1 = A - B - (0.06 ÷ 0.12) mm
- Temporarily fit the lock nut (1).
where:
- Using a suitable comparator (2) check that the clearance
A = distance between seat-lid and roller bearing outer race is within the specific range.
A contact surface
B = distance between seat-lid and roller bearing shoulder A - Otherwise:
contact surface More clearance  Increase shim
0.06 ÷ 0.12 = axial clearance [mm] Less clearance  Reduce the shim
- Remove the lock nut and the lid.
Figure 140
307A093143R
- Using tool SKO-026494 (2) fit the bushing with seals (1).
Respect ring orientation (see detail).

Fill seals with bearing grease.
Figure 141
307A093134R
- Fit the cover (2) with shim S1.

Input shaft axial clearance adjustment (bearings E and F) Figure 144

Figure 142
307A093144R
307A093141R - Fit the lid with shim S3.

Proceed as follows:
Do not introduce sealant in the lubrication holes (1
- Measure value A. and 2).
Figure 143
307A093142R
- Measure value B.
S3 = B - A - (0.40 ÷ 0.60) mm
where:
A = distance between seat-lid and roller bearing outer race
A contact surface
B = distance between seat-lid and roller bearing shoulder A
contact surface
0.40 ÷ 0.60 = axial clearance [mm]
Differential axial clearance adjustment (bearings C and D) Figure 147
Arrange the lid without components for these ope-

rations.
See the following pages for more information on the
disassembly and reassembly procedure.
Figure 145
307A093138R
- Fit the lid with shim S2.

- Settle the bearings.

shafts at the same time.
307A093136R

- Measure value A.
Figure 146
307A093137R
- Measure value B.
S2 = B - A - (0.02 ÷ 0.08) mm
dove:
307A093140R
A = distance between seat-lid and roller bearing outer race
A contact surface - Temporarily fit tool TS 211W or a suitable threaded tie--
B = distance between seat-lid and roller bearing shoulder A rod (1) in the carrier hole of the differential (see detail)
contact surface and fasten a plate (2).
0.02 ÷ 0.08 = axial clearance [mm]
- Using a suitable comparator (3) check that the clearance
is within the specific range.
- Otherwise:
More clearance  Increase shim
Less clearance  Reduce the shim
- Remove the tool and the lid.
Refit the lid components.

See the following pages for more information on the
disassembly and reassembly procedure.
Figure 149
307A093105R
- Fit the complete lid with shim S2.

Range selector actuator assembly
Lubricate components with the specified lubricant

before reassembly.
Figure 150
307A093145R
Proceed as follows:
- Fit the o-ring (1) in the seat and in the grooves of the rod
(2).
- Fit the o-ring (3) in the piston seats (5).
- Fit the outer body of the actuator (4).
- Fit the piston (5) on the rod (2) and block is with the snap
ring (6).
- Fit the lid (7) and fasten the screws.
- Fit the fittings (8) with the seal (9).
Figure 151
307A093146R
- Fit the rear lid (1) and fasten the screws.

- Fit the contrast ball with spring and cap (2).
Range selector actuator adjustment - Tighten the screw by ½ a turn and then lock the lock nut
(2).
Figure 152
Figure 155
307A093147R
Proceed as follows:
- Loosen the adjustment screw and front and rear lock nut
and electric switch (see arrow) and remove all residues
of sealant.
Figure 153
307A093151R
- Connect the fitting B to a pneumatic line (6.5 - 8.5 bar).

- Turn the input shaft until the sleeve is engaged (slow
speed).
- Fasten the adjustment screw (1) until it comes into con-
tact with the rod (5).
- Tighten the screw by ½ a turn and then lock the lock nut
307A093148R
(2).
- Apply sealant and remove the adjustment screw and front - Fit the pin (7) and the switch (3).
and rear lock nut (see arrow).
Figure 154
307A093150R
- Connect the fitting A to a pneumatic line (6.5 - 8.5 bar).

- Turn the input shaft until the sleeve is engaged (fast
speed).
- Fasten the adjustment screw (1) until it comes into con-
tact with the rod (4).
Range selector actuator adjustment Figure 158

Figure 156
307A093154R
307A093152R - Loosen the lock nut (3) to take it into contact with the
lid (4).
Proceed as follows:
- Tighten the lock nut by ½ a turn and then lock nut (2).
- Loosen the electric switch (see arrow) and remove all
sealant residues. - Remove the operating screws.
- Remove all sealant residues from the adjustment nut, the - Fit the outer body (1) and fasten the screws.
lock nut and the lid (see arrow).
- Fit the switch (6) with the seal (7).
Figure 157
307A093153R
- Temporarily screw the lid using three operating screws

M8x25 (1).
- Apply sealant and remove the adjustment nut and the
lock nut.
- Push the rod inwards and turn the front motion output
shaft until the front tooth gear is engaged.
Completion Figure 161
Heat the flanges in oven to 120 ˚C for refitting.
Figure 159
307A093018R
- Fit the oil pipe (1) and tighten the fittings.
Figure 162
307A093019R
Proceed as follows:
- Fit the input flange and tighten the nut (1) to the specified
tightening torque.
- Use tool TS 215W, if required (2).
Figure 160
307A093014R
307A093155R
- Fit the breather valve, if removed (see arrow).
When refitting, make the groove on the flange coin- - Fit the filler, drain and level caps, if removed (1, 2 and 3).
cide with the lubrication hole (see arrow).
- Fill with lubricant as shown in the corresponding chapter.
- Proceed in similar manner for all transfer case flanges.

Input flange nut: 1080 Nm
Front output flange nut: 1080 Nm
Rear output flange nut: 1080 Nm
Figure 163
28309210
- Fit the breather valve (1).

- Fit the reducer position indicating switch (2).
- Then tighten various components at the specified torque.
Figure 164
28309211
- Fit the speed sensor (1) and tighten to the specified tor-
que.
PROPELLER SHAFTS
SECTION 10
HD9 Euro5 SECTION 10 PROPELLER SHAFTS 1
SECTION 10
Propeller shafts
Page
DESCRIPTION 3
- 4x2 vehicles 3
- 4x4 vehicles 3
- 6x4 vehicles 4
- 6x6 vehicles 4
- 8x4 vehicles 4
- 8x6 vehicles 5
- 8x8 vehicles 5
DIAGNOSTIC 6
EQUIPMENT 9
PROPELLER SHAFT REMOVAL-REFITTING 10
GENERAL 10
- Removal 11
- Refitting 11
UNIVERSAL JOINT 12
- Removing 12
- Cleaning 12
- Checks 12
- Assembling 13
CHECKING THE PROPELLER SHAFTS ON THE
VEHICLE 13
2 PROPELLER SHAFTS SECTION 10 HD9 Euro5

DESCRIPTION
The transmission of motion from the engine-gear unit to the The front end of the propeller shaft, besides the universal joint,
reduction gear unit (if any) and to axle/s is done through the features a splined sliding sleeve that enables the shaft to vary
propeller shaft (which may be a single section, or two or three its length to absorb any drive axial displacement, due to rear
sections with floating support). This is connected to the ends axle rocking.
through universal joints.
Figure 1
PROPELLER SHAFT
4x2 vehicles
Figure 2
M power unit
A front axle
P rear axle
4x4 vehicles
Figure 3
M power unit
T transfer unit
PA front axle
P rear axle
6x4 vehicles
Figure 4
M power unit
A front axle
I intermediate tandem axle
P rear tandem axle
6x6 vehicles
Figure 5
M power unit
T transfer unit
PA front axle
P rear tandem axle
8x4 vehicles
Figure 6
M power unit
A front axle
P rear tandem axle
8x6 vehicles
Figure 7
M power unit
T transfer unit
PA front axle
A front axle
P rear tandem axle
8x8 vehicles
Figure 8
M power unit
T transfer unit
PA front axle
PAI front intermediate axle
P rear tandem axle
DIAGNOSTIC
Propeller shaft operation faults:
1 - Driving noise and vibrations
1 DRIVING NOISE AND VIBRATION
Shaft strain Replace the shaft

YES
NO
Shaft is out of balance Check balancing and determine the points where bal-
YES ancing counterweights are to be welded
NO
Spline excessive slack Replace the shaft

YES
NO
Screws and nuts to fasten the shaft to the sleeves on Check accurately, then tighten loose screws and nuts;
the gearbox or the rear axle are loose YES if necessary replace any damaged parts.
NO
Propeller shaft universal joints are seized or badly Overhaul or replace the universal joints.
worn YES
NO
Insufficient lubrication Lubricate through the specific greasers.

YES
Central flexible mounting fastening screws are loose Tighten the screws to prescribed driving torque
YES
NO
Flexible small block of central mounting is worn Replace mounting

YES
NO
Bearing of the central flexible mounting is worn or has Replace mounting

too much slack YES
NO
Nut or screw to fasten sleeve to propeller shaft shank Tighten nut or screw to prescribed driving torque.
is loose. YES
TIGHTENING TORQUES
The figure shows the most complex version and is valid for all types.
Figure 9
27210001X
Figure 10
27210002x
EQUIPMENT
The codes given in the following list refer to the original ZF coding.
Support for transmission shaft removal-replacement

99370618
PROPELLER SHAFT REMOVAL-REFITTING Very heavy parts


operation. If in doubt, consult a more experienced Specific safety instructions
Observe all the general recommendations to carry Be very careful: drained oil and fluids, as well as filters
out maintenance jobs correctly. and surrounding parts, could be very hot.
Vehicle preparation

signboards.
Figure 11
2371801

short circuits;

Proceed as follows:
The procedure described is valid for all propeller - check integrity of connecting flange;
shafts.
- check intactness of fastening screws and bolts, if required
replace any damaged parts.
Removal Refitting
Figure 12
342B010001R
- support the propeller shaft (2) with a hydraulic jack (4)

fitted with tool 99370618 (3) before starting the removal
procedure;
- unscrew and remove the front flange (1) fasteners and
rear flange (5) fasteners of the propeller shaft;
- remove the shaft working from the lower part of the
vehicle.
UNIVERSAL JOINT Cleaning

Removing Wash removed parts with oil or petrol keeping parts im-
mersed for the time necessary to remove any particles of har-
Figure 13 dened grease.
Clean accurately every part by hard bristle brush and dry with
compressed air jet.
Checks
Propeller shafts are supplied ready for use.
They are balanced statically and dynamically; it is however
possible to check correct static balancing and eccentricity dur-
ing complete overhaul.
Perform the following operations:
- position the propeller shaft on a centering tester;
- turn the shaft around its own axis and with a dial gauge
previously set to zero, check that eccentricity of the pro-
38029
peller shaft on the central tubular part is not over 0.5 mm;
UNIVERSAL JOINT COMPONENTS - move the dial gauge towards the ends of the propeller
1. Fork — 2. Spider — 3. Circlips — 4. Bearings — 5. Sliding shaft;
sleeve - eccentricity must not exceed 0.3 mm;
Figure 14 - should higher values than the specified one be found,
straighten and balance the shaft by means of suitable press
and equipment, these operations shall be carried out by
skilled workers.
The plates welded to the propeller shafts are balancing plates.
Should these plates be missing, the shaft must be balanced
again.
Inspect the splines for wear and check whether the tubular
part of the shaft shows weld defects or cracks; replace the pro-
peller shaft if it has any crack, wear or distortion.
Check whether forks show cracks, wear or distortions.
Slight notches or burrs can be removed by an abrasive stone.
Check spiders, these must not show cracks.
38030 Needle bearing pins must not show scratches or wear signs.
Clamp the universal joint (1) in a vice.
Punch the sliding sleeve and the main components to obtain Using a propeller shaft not balanced correctly or in
reference marks to be followed for correct alignment during defective conditions, causes vibrations which can be-
assembling. come unacceptable in certain cases, and can be ex-
Using suitable pliers remove the circlips (3, Figure 13). tremely dangerous for the units but also for the
driver since breaking of the propeller shaft can result
Use a hammer to beat the fork (3, Figure 14) until the bearing in disastrous effects.
(2) starts to come out from its housing, i.e. when the spider
interferes with the fork.
Turn the part over and repeat the above operations.
Manually remove one of the two bearings (2).
Remove the fork (3) and use a punch to remove the other
bearing.
Repeat this procedure to remove the bearings from the other
fork and free the spider.
To disassemble the opposite joint, repeat the operations de-
scribed previously.
Assembling CHECKING THE PROPELLER SHAFTS ON

THE VEHICLE
To dis-assemble the opposite joint, repeat the operations de-
scribed above. Figure 15
Insert the spider into the joint fork and in the fork-sleeve.
Fit in place the bearings with the rollers on the spider pins, then
fit the circlips.
When assembling the spiders, take special care to

the correct fitting of circlips in their housings.
When fitting the shaft, check also that alignment reference

marks, performed before disassembling, coincide perfectly. 23808
Operating on the propeller shaft and at the same time, in the

A wrong connection can result in noisy propeller opposite direction, on the sliding sleeve (arrows) check that
shaft and can cause wear or damages to the whole there is not too much slack between the splines.
drive line. Operating on the sleeve forks (arrow) check that the spiders
are not worn; if they are, replace them as described above.

AXLE
SECTION 11
HD9 Euro5 SECTION 11 AXLE 1
SECTION 11
Axle
Page
DESCRIPTION 3
CHARACTERISTICS AND DATA 4
TIGHTENING TORQUE 6
TOOLS 7
DIAGNOSTIC 9
AXLE REMOVAL-REFIT 12
GENERAL 12
- Removal 13
- Refitting 13
SECOND AXLE REMOVAL-REFIT 15
GENERAL 15
- Removal 16
- Refitting 16
HUB OVERHAUL 18
- Disassembly 18
2 AXLE SECTION 11 HD9 Euro5
- Disassembled part inspection 20

- Reassembly 20
- Bearings and thread lock application and sealant
diagram - hub 21
STUB AXLE OVERHAUL 26
- Disassembly 26
- Leaf spring contact surfaces check using gauge
99305111 29
- Checking inclination of kingpin boss bores with
gauge 99305111 30
- Disassembled part inspection 31
- Assembly 31
DESCRIPTION
The front axle is constructed in high tensile pressed steel, with The wheel hubs are supported by two taper roller bearings,
double ”T” end section where the stub axles are joined. The fitted on the stub axle shank. Adjustment is performed
stub axle articulation takes place through taper pins built in the through threaded ring nuts.
axle body, and through four bronze driven roller bearings in
the overhang holes of the stub axle.
Figure 1
1. Brake drum — 2. Brake shoe — 3. Hub — 4. Hub cover fixing screw — 5. Bearing ring — 6. Bearing ring locking screw —
7. Hub cover — 8. Front taper roller bearing — 9. Brake drum fixing screw — 10. Rear taper roller bearing — 11. Bearing ring —
12. Kingpin axial taper roller bearing — 13. Ball joint — 14. Steering arm — 15. Axle — 16. Kingpin — 17. Stub axle —
18. ABS sensor (if any) — 19. ABS phonic wheel (if any)
CHARACTERISTICS AND DATA
Type of axle ASTRA 9820
SWIVEL AXLE PINS

Inclination of swivel pin housings 7o
1
Diameter of roller bearing housings

on the swivel axle
- upper housing 1 mm 52,5  52,53
- lower housing 2 mm 52,5  52,53
2
3
Outside diameter of roller
bearings for swivel axle
- upper bearings 3
mm 52,67  52,75
- lower bearings 4
mm 52,67  52,75
4
Swivel axle bearings mm 0,14  0,25
X1 Play between axle and upper
facing of swivel axle X1
mm 0,10
Clearance between axle and
X2
lower facing of swivel axle X2
mm 0
Shims to adjust X1, X2

S
ASTRA
0,25 mm S mm 0,8 - 1,0 - 1,2

Type of axle ASTRA 9820
WHEEL HUBS
Wheel hub bearings 2, taper rollers
Wheel hub bearing end play mm max 0,16
Wheel hub play adjustment using adjustment ring nut
Rolling torque
da Nm 0,50 max.
Bearing preloading
WHEEL GEOMETRY
Camber angle (vehicle with static

1o
load)
Castor angle (vehicle with static

+ 3
load)
TIGHTENING TORQUE
Figure 2
Assemble applying LOCTITE 510
341B011001R
TOOLS
TOOL N. DESCRIPTION
99321024 Hydraulic trolley for wheel removal and replacement
99322215 Stand for overhaul
99347068 Steering rod head pin extractor
99389819 Torque wrench (0  10 Nm) with ¼” square fitting
Hub rolling torque test tool (use with torque wrench)

99395026
99305111 Hole inclination gauge

TOOLS
TOOL N. DESCRIPTION
99370593 Stand
0/72068 Tool for dismantling/assembling stub axle bushes

DIAGNOSTIC
Main possible faults:
1 - Wheels hard to steer;

2 - wheel shimmy;
3 - wheel rolling noise.
1 WHEEL HARD TO STEER
Front axle not perfectly aligned Re-align correctly and tighten leaf spring U-bolt nuts
YES to the specified torque.
NO
Incorrect wheel toe-in Re-adjust front wheel toe-in.

YES
NO
Incorrect tyre pressure Inflate tyres to specified pressure.

YES
NO
Insufficient lubrication of kingpin Lubricate accurately.

YES
NO
Incorrect steering knuckle to axle mating Re-adjust accurately to specified limits.

YES
NO
Parts concerned with steering knuckle rotation on Check all parts and replace as required.
kingpin inefficient YES
2 WHEEL SHIMMY
Wheel caster incorrect Check axle assembly, repair and change distorted
YES parts as required.
NO
Front axle not perfectly aligned Re-align correctly and tighten leaf spring U-bolt nuts
YES
NO
Incorrect wheel toe-in Re-adjust correctly.

YES
NO
Inefficient steering linkage ball joint Change defective parts.

YES
NO
Incorrect wheel hub bearing play Re-adjust end play after changing parts as required.
YES
NO
Wheels incorrectly centered: Change the faulty rim..

rim not centered, distorted YES Deflate and centre tyre on rim.
tyre fitted to wrong rim
NO
Wheels incorrectly balanced Carry out wheel balancing.

YES
3 WHEEL ROLLING NOISE
Inadequate wheel hub bearing lubrication Restore a sufficient packing of grease in hubs.
YES
NO
Inefficient wheel hub bearings Change damaged bearing and re-adjust end play.
YES
NO
Incorrect mating between kingpin and needle Check and change deteriorated parts as required.
bearings YES
AXLE REMOVAL-REFIT Very heavy parts


Tighten the fastening bolts of steering ball joint to the
specified torque.
Vehicle preparation

Figure 3
2371801

short circuits;
Check support pads are intact, if necessary replace the
See figure on next page
damaged component
Check that electrical components and connectors are intact: if
necessary replace damaged component .
Check pneumatic fittings and tubes are intact: if necessary
replace damaged component .
Proceed as follows: Refitting
- park the vehicle on a flat surface and lock the rear wheels To refit, follow the removal instructions in reverse order.
appropriately;
- raise the front of the vehicle using a hydraulic jack and rest Final operations
it on the two support stands so that the wheels no longer To refit, follow the removal instructions in reverse order.
touch the ground;
- refit both axle wheels operating as described in the Rules
- remove both axle wheels operating as described in the for Use of the USE AND MAINTENANCE MANUAL
Rules for Use of the USE AND MAINTENANCE
- check limit switch stops as described in the Chapter
MANUAL
STEERING ANGLE ADJUSTMENT of Section 15
Removal - check and adjust toe-in as described in the FRONT
WHEELS TOE-IN ADJUSTMENT chapter of Section 15
Reverse the removal operation sequence to refit.
- disconnect the following electrical connectors:
(1) ABS transmitter from both sides (only 2 and 3 axle
vehicles);
(4) wear on breaking seals warning light on both sides ;
- disconnect the following pneumatic connections:
(5) brake air delivery lines from both sides;
- unscrew the ball joint nut (11) and disconnect the steering
rod (12);
- from both sides, loosen the bolts (17) fastening the
stabilizer bar bushing to the chassis;
- from both sides, remove the bolts (18) fastening the
stabilizer bar to the axle and rotate it downwards;
- position a hydraulic lift fitted with tool 99370617
underneath the axle;
- from both sides, unscrew the nuts (9), and lift the U-bolts
(10) fastening the leaf springs, then lower the axle and
relieve the leaf springs;
- remove the axle from under the vehicle.
Figure 4
SECOND AXLE REMOVAL-REFIT Very heavy parts


specified torque.
Vehicle preparation

Figure 5
2371801

short circuits;
DESCRIPTION OF OPERATION Final operations

Preliminary operations - refit both axle wheels operating as described in the Rules
Proceed as follows: for Use of the USE AND MAINTENANCE MANUAL
- park the vehicle on a flat surface and lock the rear wheels - check limit switch stops as described in the Chapter
appropriately; STEERING ANGLE ADJUSTMENT of Section 15
- raise the front of the vehicle using a hydraulic jack and rest - check and adjust toe-in as described in the FRONT
it on the two support stands so that the wheels no longer WHEELS TOE-IN ADJUSTMENT chapter of Section 15
touch the ground;
- remove both axle wheels operating as described in the
MANUAL
Removal
vehicles);
rod (5);

damaged component
Check that electrical components and connectors are intact:
if necessary replace damaged component .
Refitting
Figure 6
220083
HUB OVERHAUL
Figure 9
operation.
Read the applicable instructions in SECTION 1 of this
manual. If in doubt, consult a more experienced
person. Observe all general recommendations for the
correct execution of maintenance work.
Support and lock the knuckle joint pin to avoid

movement during the operations .
Disassembly
Proceed as follows:
Figure 7
342B11003R
- disconnect both pneumatic fittings (1) from the

pneumatic cylinder;
- loosen the pneumatic cylinder fastening ring nut (2);
- remove the pneumatic cylinder (3) unscrewing it from its
seat.
Figure 10
342B11001R
- unscrew the two fastening screws (1);
- remove the brake drum (2);
Figure 8
342B11004R
The screw(1) is blocked with sealant.

To avoid damaging it, heat to approx: 120˚C before
removing.
- loosen the ring nut lock screw (1);
WARNING
Ring-nut right side: left-hand thread
342B11002R
Ring-nut left side: right-hand thread.
- unscrew the two fastening screws (1);
- remove the brake drum (2); - remove the hub fastening ring nut (2)
Figure 11 Figure 13
342B11007R
- using an appropriate puller, remove the spacer (1) and

recover the stop pin (2);
342B11005R
- cautiously remove the hub (1) and inner ring (2) of outer Figure 14
bearing [A] from steering knuckle pin;
Figure 12
342B11008R
- loosen the two lock screws (1) of the ABS sensor bracket;
- remove the bracket (2) with the sensor, passing the
connector through the hole of the shoe carrier plate
342B11006R
- with an appropriate puller remove the inner ring (2) of the If necessary remove the sealant before removing the
inner brearing [B] from the knuckle joint pin sensor.
Figure 15 Disassembled part inspection

- check the bearing seats: to ensure there are no signs of
strain and/or ovalising;
- check the state of the bearings: replace them if they have
blue contours, cracks and/or signs of wear;
- check the thread on the bearing lock ring: there must be
no denting, strain and/or seizure.
Reassembly
When reassembling, bear in mind the following

general rules:
 heat the bearing inner rings in the over at a
temperature of 240˚C.
 carefully centre and fit the seals and bearings with
an appropriate fitter;
342B11009R  lubricate the ring nuts, seals and bearings;
 always replace seals and O-rings.
- loosen the shoe-holder plate fastening screws (1).
- remove the shoe-holder plate (2) with shoe and control
cylinder;
Figure 16
342B11043R
- with an appropriate puller, remove the outer ring (1) of

the outer bearing [A] and outer ring (2) of the inner
bearing [B] from the hub.
Bearings and thread lock application and sealant diagram - hub

Figure 17
342B11044R

Figure 18
342B11012R
- seal the shoe-carrier plate hole (1).
342B11010R
Figure 21
- fit the shoe-holder plate (1) with shoe and control

cylinder;
- screw the shoe-holder plate fastening screws (2) without
tightening
Figure 19
342B11011R
- install the ABS sensor bracket (1) with the sensor, passing
the connector through the hole of the shoe carrier plate
- fasten the fastening screws (2); 342B11045R
- tighten the screws to the specified torque.

- with an appropriate fitting too and a press, fit the outer
ring (1) of the outer bearing [A] and outer ring (2) of the
inner bearing [B] on the hub.
Figure 22 Figure 24
342B11013R 342B11015R
- fit the stop pin (1); - fill hub cavity with specified grease.
- install the spacer (2) with the pin seat side facing inward; - spread specified grease on pin between the two bearings.
If necessary, settle with a few light knocks inserting an Figure 25

appropriate tubular spacer to bring the ring to
correct position.
Figure 23
342B11016R
- use an appropriate lifting means to support the hub

assembly so as to ensure correct centring;
- Insert the hub assembly (1) onto the end of the steering
knuckle pin bringing the outer ring of the inner side of the
bearing [B] in contact with the related taper bearings.
342B11014R
During this operation, hold the hub perfectly parallel
to the steering knuckle axis.
Operate with caution to avoid damage to the spacer.
- with an appropriate tool insert the inner ring (2) of the Support the hub assembly until assembly is complete.
inner bearing [B] on the knuckle joint pin so that it remains
in contact.
Warning! scalding hazard

Wear appropriate protective gloves.
Figure 26
While applying torque, turn the hub forwards and
backwards while hitting it with a plastic mallet to bed
in the bearings.
Specified axial clearance permits a slight resistance to
hub rolling (approx. 5 Nm)
Figure 28
342B11017R
Warning! scalding hazard

Wear appropriate protective gloves.
342B11018R
- fit the inner ring (1) of outer bearing [A] on steering - After adjusting the bearings clearance, lock the ring nut
knuckle pin. tightening the lock screw (1) to the specified torque.
If necessary, settle with a few light knocks inserting an

appropriate tubular spacer to bring the ring to Figure 29
correct position.
Figure 27
342B11018R
WARNING
Ring-nut right side: left-hand thread 342B11020R
Ring-nut left side: right-hand thread.

- unscrew the pneumatic cylinder fastening ring nut (1)
completely;
- manually tighten the ring nut (1) to fasten the hub; - fit the pneumatic cylinder (2)screwing it into its seat.
- Progressively tighten the ring nut to obtain the specified - tighten the ring nut (1) to the specified torque;
axial clearance. - connect both pneumatic fittings (3) to the pneumatic
Bearings axial clearance: 0,044 0,220 mm cylinder;
Figure 30 Figure 32
342B11021R
- Fill the cover (1) with specified grease. 342B11023R
- Position the seal (2).

- fit the brake drum (1) to have contact;
Figure 31 - tighten the two fastening screws (2).
342B11022R
- fit the cover (1);

- tighten the cover fastening screws (2);
STUB AXLE OVERHAUL

operation.
Read the applicable instructions in SECTION 1 of this
manual. If in doubt, consult a more experienced
person. Observe all general recommendations for the
correct execution of maintenance work.
Before proceeding:
 remove the hub;
 remove the complete shoe-carrier plate
Proceed as shown in the corresponding Chapter.
Disassembly
Proceed as follows:
Figure 33
342B11024R
- remove the stop cotter pins (1)

- unscrew fastening nuts (2);
- free both sides of the knuckle joint (3);
- remove the coupling bar (4);
Figure 34 Figure 36
342B11027R
- with a punch remove caulking from the coupling bar

lever fastening nuts.
- unscrew the fastening nuts (1);
342B11025R
- remove the lever (2) and its plate (3);
- unscrew the fastening nuts (1) and remove the upper

plate (2) and seal; Figure 37
- remove the flat washer (3);
Figure 35
342B11028R
- overturn the axle;

342B11026R - unscrew the fastening nut (1);
- with a baton expel the lock pin.
- if necessary unscrew the fastening nuts (1) of the steering
lever;
- remove the steering lever (2); Usually the pin has to be replaced.
Otherwise do not damage the thread
during extraction .
Figure 38 Figure 39
342B11030R
- with an appropriate tool remove the stub axle pin (1)

from the axle;
- recover the bearing (2) and clearance take-up spacers (3)
Figure 40
342B11029R
Support the knuckle pin to avoid it falling.
- remove the stop ring (1)

- Remove the cover (2).
- with a punch, expel the pin (3).
342B11031R
- remove the O-rings (1) from the seat of the knuckle pin
- if necessary recover the bushings (2) from the knuckle pin
seat with an appropriate punch.
Leaf spring contact surfaces check using gauge Figure 42

99305111
Set the two rods (1) with the cones (3) in the kingpin holes;
press down the cones and lock them in position with the
screws on the rod.
Insert the two set screws (2) in the seats on the leaf spring con-
tact surface.
Figure 41
Set the sliding bar (2) on the goniometer rods (4), adjusting the
length so that the shaped ends remain inserted in the rods (1)
Lock the clamp screw (7) and the screws (3) that fasten the go-
niometer to the rods (4)
Set the bases (5, Figure 42) with goniometers on the surfaces
(6) and insert the set screws (2, Figure 41).
Before placing the bases with the goniometers, make

sure that there is no paint or roughness on the con-
tact surfaces.
Figure 43
Check for deviation angles on the goniometer scaled sec- surface with reference to the stub axle pin holes is correct.
tions indicated by the arrows. Remove the sliding bar and the bases with goniometer.
The goniometer indicators do not indicate any angular dis-
placement when the planarity of the leaf spring contact
Checking inclination of kingpin boss bores with

gauge 99305111
Figure 44
Set the supports (3) with goniometers on the rods (1) and
slightly turn the screws (2) without locking them.
Insert the coupling track rod (4) and tighten the screws (2) that
fasten the supports in the rods (1)
Figure 45
Read the kingpin holes camber angle value in the relevant scaled sectors (2) according to the indicators (1).
Disassembled part inspection Assembly

- check the bearing seats: to ensure there are no signs of Proceed as follows:
Figure 46
- check that the sealing surfaces and threads are intact and
are not dented or damaged;
- check bushings: to ensure there are no signs of strain
and/or ovalising;
- check pin: to ensure there are no signs of scoring or
seizing.
When reassembling, bear in mind the following

general rules:
 lubricate the ring nuts, seals and bearings;
 always replace seals and O-rings.
342B11032R
- if necessary fit the bushings (1) in the knuckle pin seat

with an appropriate fitting tool;
- fit the O-rings (2) in the seat of the knuckle pin (see
detail).
Figure 47 Figure 49
342B11046R
- measure value A;
- measure value B; 342B11034R
- measure value C;
- with an appropriate tool support the knuckle pin (1) and
- measure the thickness of the spacer as follows: fit it on the axle;
S = A (B + C) - 0,10 (mm) - fit the previously measured clearance adjustment spacers
where (2) in their seats.
A= distance between the knuckle pin two internal
surfaces
B= thickness of axle eye Tale care not to damage the bearing sealing gasket
C= thickness of thrust bearing (3).
S= thickness of spacer
0,10 = clearance in mm
Figure 48
Figure 50
342B11033R
342B11027R
- overturn the axle;

- fit the bearing (1) and seal (2)on the eye seat; - position the pin so that the seat of the clamping pin faces
downward and toward the axle.
Figure 51 Figure 52
342B11037R
- fit the cover (1).

- fit the stop ring (2);
Figure 53
342B11036R
- align all the parts for easy insertion of the pin;

- insert the pin without forcing;
Take care not to damage the O-rings (2) 342B11038R
- with a baton insert the lock pin.(1)
Figure 54
342B11039R
- tighten the fastening nut (1);

- tighten the bolt to the specified torque;
Figure 55 Figure 57
342B11027R
- tighten the fastening nuts (1);

- install the lever (2) and its plate (3);
342B11026R
Use a new plate.
- install the flat washer (1);
- install the upper plate (2) and seal;
- tighten the fastening nuts (3);
- tighten the nuts to the specified torque;
- with a punch, dent the plate;
Figure 56
342B11025R
- if necessary, fit the steering lever (1) and tighten the

fastening nuts (2);
- tighten the nuts to the specified torque;
Figure 58
342B11042R
- install the coupling bar (1);

- insert the ball joints (2) on both sides in the seat and
tighten the fastening slotted nuts (3)
- tighten the nuts to the specified torque.
- fit the stop cotter pins (4)
After these operations proceed as follows:

 assemble the complete shoe-carrier plate
 assemble the hub
Proceed as shown in the corresponding Chapter.
FRONT DRIVE AXLE
SECTION 12.1 A
HD9 Euro5 SECTION 12.1 A FRONT DRIVE AXLE 1
SECTION 12.1 A
Front drive axle

Page
DESCRIPTION 3
TOOLS 10
DIAGNOSTICS 16
AXLE OIL REPLACEMENT FRONT 18
GENERAL 18
- Axle 19
- Drainage 19
- Filling 19
- Hub 19
- Drainage 19
- Filling 19
FRONT AXLE REMOVAL-REFIT 20
GENERAL 20
- Removal 21
2 FRONT DRIVE AXLE SECTION 12.1 A HD9 Euro5

- Refitting 21
AXLE AND WHEEL HUB OVERHAUL 23
- Fork supports dismantling 27
- Stub axle dismantling 27
- Epicyclical reducer dismantling 28
CLEAN-OUT AND CHECKS 29
CHECKING THE AXLE CASING CAMBER ANGLE
AND CASTER ANGLE 29
- Fork support mounting 32
- Transfer shaft mounting 33
- Stub axle assembly 33
- Fitting in place the epicyclic reduction gear support 38
GREASING THE STUB AXLE PINS 39
EPICYCLIC UNITS LUBRICATION 39
REMOVING THE DIFFERENTIAL
(with axle on stand 99322215) 40
- Axle casing check 40
RE-FITTING IN PLACE THE DIFFERENTIAL
REPAIRING THE DIFFERENTIAL 42
- Removal 42
- Removing the gear housing 43
- Removing the bevel pinion support 44
- Checking the differential components 44
- Fitting in place the gear housing 45
- Fitting in place the bevel pinion support 46
- Procedure to determine the adjustment ring shim
for the bevel gear rolling torque 46
- Differential box mounting 48
- Adjusting the gear housing bearings rolling torque 49
- Adjusting the end play between pinion and bevel
gear pair 50
DESCRIPTION
The axle is double reduction bearing type. The pinion is supported by two taper roller bearings and
The first reduction is obtained from the pinion-ring bevel gear adjustment is through adjustment rings.
unit, the second through an epicyclic unit in the wheel hubs. The half shafts coming from the differential transmit the
The differential housing, with ring bevel gear, is supported by rotation to the epicyclic gears by means of constant velocity
two taper roller bearings that can be adjusted through two joints.
threaded ring nuts. Two flanges fitted to the end of the axle casing permit the stub
axles movement.
Figure 1
39386
DIFFERENTIAL LONGITUDINAL PICTORIAL SECTION

Figure 2
39387
LONGITUDINAL PICTORIAL SECTION OF WHEEL HUB AND EPICYCLIC REDUCTION GEAR


Figure 3
A Value engraved on pinion

B Shim
1 Pinion rolling torque without o-rings
2 Total rolling torque
a 7,5 ÷ 9,5 Nm (pinion rolling torque + o-rings)

Type of axle: 1
5985 / 2D (D1385)
Dual reduction carrier
Bevelled pinion bearings 2 with tapered rollers
Bevelled pair reduction 27/32 (1,185) - 28/37 (1,321) - 23/36 (1,565) - 19/33 (1,737) -
ratio 21/40 (1,905) - 17/35 (2,059)
Epicyclical reducer ratio at wheels 3.2
Bevelled pinion bearing rolling

with adjuster shims
torque adjustment
ASTRA Thickness of adjuster shims

for positioning bevelled pinion
with respect to crown mm 0.2 - 0.3 - 0.5 - 1
Play adjustment between pinion

and crown mm using ring nuts
WHEEL HUBS
Wheel hub bearings Two with tapered rollers
Wheel hub bearing rolling torque:

new bearings with surface protec-
tion Nm 6  7 + (7.5  9)
Wheel hub bearings rolling torque:
run in bearings and new,
lubricated seals Nm 6  7 + (4  5)
Wheel hub bearings rolling torque:
run in bearings and seals
Nm 6  7 + (3  4)
Drive shaft end float mm 0.5  1
Oil for differential

(*) 5 (4,5)
Quantity per hub Litres (kg)
Bevel drive pinion bearings

(*) 0,75 (0,68)
Quantity per hub Litres (kg)
WHEEL GEOMETRY
Wheel camber angle (vehicle with

–
static load)
Wheel caster angle (vehicle with

1 30’
static load)
B Wheel toe-in
B = A - (0  3 mm)
(vehicle with static load)
A
KING PINS
King pin camber 5
Thickness of adjustment rings

between axle and stub axle upper 1,75 — 2,00 — 2,25 — 2,50 — 2,75 — 3,00 3,25 — 3,50
shim X1 mm
ASTRA
Figure 4
39388
98972
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
1 Differential box to axle box fastening screw 180  10 18  1
2 Bevelled pinion fastening nut 700  50 70  5
3 Bevelled pinion support screw at differential box 180  10 18  1
4 Bevelled crown wheel to gearing box fastening screw 180  10 18  1
5 Bearing support fastening screw  180  10 18  1
6 Safety plate self-locking screw 51  4 5.1  0.4
7 Toothed flange screw 180  10 18  1
8 Differential locking cover screw 19  2 1.9  0.2
9 Differential locked signal transmitter 35 3.5
 Lock with LOCTITE AVX

* Apply sealantLOCTITE 573
Figure 5
98971
WHEEL HUB AND EPICYCLICAL REDUCER LONGITUDINAL SECTION
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
1 Wheel nut 615  35 61.5  3.5
2 Brake support fasteners 324  396 32.4  39.6
3 Steering lever pin fastening screw 207  253 20.7  25.3
4 Stub axle support screw 324  396 32.4  39.6
5 Notched nut for fastening stub axle 250 ** 2.5 **
6 Screw 207  233 20.7  23.3
7 Support screw 22  28 2.2  2.8
8 Cover screw z 44  54 4.4  5.4
* Apply LOCTITE 510
** Minimum torque — Maximum torque, tighten until first notch coincides with hole for split pin
z Apply LOCTITE 573 to coupling surfaces
j Before fitting apply MOLYCOTE lubricant to the contact faces
Z Lock with LOCTITE AVX
TOOLS
99322215 Axle overhaul trolley
Group support (applied to trolley 99322205)

99322225
Extractor reaction block

99345053
TOOLS
Steering rod head pin extractor

99347068
99348001 Extractor with locking device
99354207 Wrench (94.5 mm) for wheel hub bearing adjuster nut
99355025 Wrench for differential box bearing adjuster ring nut
99355081 Wrench (60 mm) for differential bevelled pinion nut

(use with 99370317)
TOOLS
Interchangeable grip for drivers

99370006
99370007 Interchangeable grip for drivers
99370133 Differential caps divergence locking tool
99370509 Differential gear half-box extractor hook
99370616 Support for differential removal-replacement

TOOLS
Universal axle support for removal and replacement

99370617
99372211 Tool for removing/replacing brake shoe retainer springs
Driver for inserting bearing outer races (91-134 mm)

99374093 (use with 99370007)

99374094 (use with 99370007)
99374233 Bevelled pinion seal fitting tool
99374369 Driver for fitting roller bearings in stub axle

(use with 99370006)
TOOLS
99374371 Driver for fitting roller bearings and o-rings to axle fork
(use with 99370006)
99374377 Wheel hub internal seal fitting tool
99374382 Driver for fitting roller bearings in stub axle fork

(use with 99370006)
99374390 Tool for fitting o-ring in stub axle (use with 99370006)
99389819 Torque wrench (0-10 Nm) with 1/4” square fitting

TOOLS
99395026 Tool for checking wheel hub rolling torque (use with torque
wrench)
99395027 Tool for determining thickness of differential bevelled pinion

adjuster shims (use with 99395603)
99395603 Dial gauge (0 - 5 mm)

DIAGNOSTICS
Main axle faults:

1 - Wheel hubs noisy
2 - Noise
3 - Noise at release
4 - Noise during acceleration
5 - Cornering noise
1 WHEEL HUBS NOISY
Insufficient lubrication Check there are no leaks from gaskets or the axle casing
YES and top up oil to correct level.
NO
Wheel hub bearings inefficient Remove the hub and replace inefficient parts.
YES
NO
Bad adjustment of wheel hub bearings Adjust bearings

YES
NO
Half-shaft splines to fit planetary gears of epicyclic gears Overhaul and replace worn or damaged parts
are worn YES
2 NOISE
Lubricating oil level low Check there are no leaks from gaskets or axle casing
YES and top up to correct level
NO
Half shaft splines to fit the differential crown wheels Overhaul the axle and replace worn or damaged parts.
damaged YES
Bad adjustment of hub bearings Adjust the bearings backlash.

YES
NO
Bad adjustment or wear on differential gears or Locate the trouble and overhaul the unit.
bearings YES
3 NOISE AT RELEASE
Improper fitting backlash between pinion and ring bevel Remove the gear housing inspection cover and adjust
gear YES backlash between pinion and ring bevel gear.
4 NOISE DURING ACCELERATION
Insufficient lubrication Check that there are no leaks from the gaskets or the
YES casing and top up to the correct level.
NO
Gear housing bearings badly set or deteriorated Overhaul the unit.

YES
NO
Bad tooth contact between pinion and ring bevel gear Adjust the contact.
YES
5 CORNERING NOISE
Improper backlash between planetary gears and crown Overhaul or replace the unit.
wheels. YES
AXLE OIL REPLACEMENT FRONT

GENERAL
Safety instructions
have taken all precautions and clarified all aspects Avoid contact with painted parts.


Figure 6
2371801

short circuits;
Axle Hub
Drainage
Proceed as follows: The operations described are valid for both hubs.
Figure 7
Drainage
Proceed as follows:
Figure 8
335BNM001L
- arrange a container of appropriate capacity, clean the area

around the caps and then remove the level cap (1);
- remove drain cap (2) and fully drain the oil;
cap.
Filling
Proceed as follows:
- fill until oil spills out the of the cap (1); 178NM50
- clean the level cap, check that the thread is in good condi-
tion, replace the sealing ring and replace the cap. - bring one of the screws (2) to the lowest position, so that
the cap (1) is in high position;
Final operations - clean the cap area and open the cap (1):
Proceed as follows: - prepare an adequate container, clean the screw area (2);
- run a road test, check the cap level (1); then remove it completely discharging all the lubricant;
- if required, top up with oil of the specified type until it spills - tighten the screw.
out of the hole. Repeat the road test and check the level
again. Filling
Proceed as follows:
- adjust the cap (1) so that the reference marking is in hori-
zontal position;
- fill until oil spills out the of the cap (1);
replace the sealing ring and close the cap;
Final operations
Proceed as follows:
- run a road test, check the cap level (1);
- if required, top up with oil of the specified type until it spills
again.
FRONT AXLE REMOVAL-REFIT
Very heavy parts

GENERAL

Figure 9 Safety component.

specified torque.
2371801

short circuits;
Check support pads are intact, if necessary replace the dam-
See figure on next page. aged component
appropriately;
Final operations
- raise the front of the vehicle using a hydraulic jack and rest
it on the two support stands so that the wheels no longer Proceed as follows:
touch the ground; - refit both axle wheels operating as described in the Rules
- remove both axle wheels operating as described in the for Use of the USE AND MAINTENANCE MANUAL;
Rules for Use of the USE AND MAINTENANCE MAN- - check limit switch stops as described in the Chapter
UAL. STEERING ANGLE ADJUSTMENT of Section 15;
- check and adjust toe-in as described in the FRONT
Removal WHEELS TOE-IN ADJUSTMENT chapter of Section 15.
Proceed as follows:
vehicles);
(2) differential lock engaged warning light (if present);
(4) wear on breaking seals warning light on both sides;
(7) differential lock (if present);
rod (12);
- unscrew the propeller shaft flange fasteners (13) and tem-
porarily fasten the shaft to the chassis so that it does not
interfere with the subsequent operations;
- from both sides, loosen the bolts (17) fastening the stabi-
lizer bar bushing to the chassis;
- from both sides, remove the bolts (18) fastening the stabi-
lizer bar to the axle and rotate it downwards;
- position a hydraulic lift fitted with tool 99370617 under-
neath the axle;
Figure 10
AXLE AND WHEEL HUB OVERHAUL Figure 13
Figure 11
39481 39483
- Set the axle on overhaul stand 99322205. - Loosen the three hexagonal screws (1) and remove
them.
Figure 12 Figure 14
39482 39484
- Turn the wheel hub (I) such that the oil drain plug (2) is Using a suitable tool detach the gear set holder (1) from the
facing downwards. hub (2) and remove it, taking care not to accidentally detach
the crown wheel engaged with the gear set.
- Remove the plug and drain the oil from the group into a
container.
- To facilitate draining, also remove a screw (3) from the
cover (4).
- Remove the plug on the axle box to drain the oil from the
differential group into a suitable container.
- Once the oil is drained, replace the plugs in the drain holes.
Figure 15 Figure 18
39485 39488
Shift the transfer-shaft outwards. Remove the wheel hub (I) with the bearing (2) from the stub
Remove the snap ring (2) and the shim and remove the gear axle (3).
(3).
Figure 16 Figure 19
39486 39489
Extract the shim (1). Unhook the brake shoe retainer springs (2) with the specific
Using a suitable tool remove the steeling from the nut (2). pliers.
Always unhook the spring where the show (1) rests on the ad-
juster unit first.
Extract both shoes from the retainer brackets (3) moving
Figure 17
them upwards and downwards.
Figure 20
39487
With wrench 99354207 (1) remove the nut (2, Figure 16). 39490
Then remove the gear set holder (56, Figure 27) along with the
bearing inner race behind it. Unscrew the screws (2) from the brake holder (1) and re-
move it along with the guards. Extract the ABS sensor (3).
Figure 21 Figure 24
39493
39525
Remove the intermediate ring (2) from the stub axle (1). Unscrew the pin (2) and articulation lever (3) screws. Remove
the pin (2) and the lever (3) from the corresponding seats on
the stub axle (5).
Figure 22 Figure 25
39491 39494
Remove the split pin (1) and unscrew the nut (2) by a few Remove the stub axle (1) and recover the shims (3) and (2).
turns without removing it completely.
Figure 26
Figure 23
39495
39492
Remove the transfer shaft (1).
Apply extractor 99347068 (2) and remove the stub axle head.
Remove the track rod (3).
26
Figure 27
FRONT DRIVE AXLE
SECTION 12.1 A
39540
FRONT DRIVE AXLE AND LATERAL REDUCTION UNIT COMPONENTS

1. Split rings - 2. Fork support - 3. Roller bearing - 4. Seal ring - 5. Adjustment ring - 6. Steering drop arm - 7. Bracket - 8. Arm fastening screw - 9. Washer - 10. Arm fastening screw - 11. Greasing nipple - 12. Washer - 13. Fo
support fastening screw - 14. Oil drain plug - 15. Sealing washer - 16. Oil inlet plug - 17. Sealing washer - 18. Axle casing - 19. Seal ring - 20. Sliding ring - 21. Brake support fastening screw - 22. Shim - 23. Baffle ring -
24. Adjustment nut - 25. Steering stop screw - 26. Stub axle - 27. Needle bearing - 28. Seal ring - 29. Half-axle with constant velocity joint - 30. Seal ring - 31. Crown wheel - 32. Shim washer - 33. Crown wheels - 34. Shim r
35. Bearing needles - 36. Planetary gear carrier - 37. Bearing pin - 38. Dowel pin - 39. Gasket - 40. Crown wheels carrier cover - 41. Washer - 42. Cover fastening screw - 43. Sealing washer - 44. Oil inlet plug - 45. Brake dru
46. Crown wheelscarrier fastening screw - 47. Sealing washer - 48. Spacer screw - 49. Sealing washer - 50. Lock nut - 51. Oil level plug - 52. Taper roller bearing - 53. Wheel fastening screw - 54. Wheel hub - 55. Taper roller
bearing - 56. Ring bevel bearing carrier greasing nipple - 59. Wheel hub fastening nut - 60. Support ring - 61. Planetary gears - 62. Circlip - 64. Arm fastening screw - 65. Greasing nipple - 66. Arm fastening screw - 67. Connec
arm - 68. Supporting ring - 69. Spacer ring - 70. Stop pin71. - Safety ring - 72. Track rod - 73. Seal ring - 74. Needle bearing - 75. Support ring - 76. Circlip -77. Seal ring - 78. Seal ring - 79. Needle bearing
HD9 Euro5
Fork supports dismantling Figure 31

Figure 28
39501
39498 Remove the roller bearing (1) with a specific driver (2).
Unscrew the screws (2) then remove the fork (1) from the
axle box (3).
Repeat the same operations on the opposite hub.
Figure 29 Figure 32
39499 71526
With pliers (1) remove the o-ring (2) and washer (4) under Using a suitable driver (3) on the roller bearings (2), expel the
the fork support (3). bearings with the o-rings (1) from the fork support (4).
Remove the O-ring.
Stub axle dismantling

Figure 30 Figure 33
39500 39502
With a driver (1) expel the O-ring (2) from the fork support Remove the O-ring (3) from the stub axle (1) with a suitable
(3). driver (2).
Figure 34 Epicyclical reducer dismantling

Figure 37
39506
71527 Unscrew the screws (3) then using a suitable driver separate
the cover (1) from the gear set support (2)
Remove the snap ring (3) and remove the oil breaker ring (4).
Using extractor 99348004 (1) extract the roller bearing (5) Figure 38
from the stub axle (2).
Figure 35
39507
Turn the support (1) holding the pins (2) in seat.
Figure 39
39504
Remove the o-ring (1). Remove the bearing outer race (2)
with a suitable driver.
Figure 36
39508
Extract the pins (2) from the support (1) along with the gears
(3) and scraper shims.
Figure 40
39505
Rest the wheel hub (1) on two supports (2) with a driver (3) 39510
remove the bearing outer race and corresponding gasket.
Remove the support bearing (2) from the gear set holder (1)
with extractor 99348001 and reaction block (3) 99345049.
CLEAN-OUT AND CHECKS CHECKING THE AXLE CASING CAMBER

After the unit has been dis-assembled, dip all the parts, except ANGLE AND CASTER ANGLE
the bearings, in a washing tank containing a soda and water To find the camber angle, device 99305111 is used, following
solution heated to a temperature of 80 - 85 C to dissolve all this procedure:
the lubricant residue.
Use a metal brush and scraper to remove any deposits, residue — Set the two supports (1, figure 37), together with the
from gaskets, Loctite or sealant that has remained between centering cones (5), in the stub axle housings and lock the
the connecting plates, taking care not to damage them. cones on their supports;
Wash again and dry the parts with compressed air. — Set up the gauge and read the camber values on the rel-
At the bench, with an electric metal brush, remove any Loctite evant goniometers (2).
or sealant remaining in the screw threads. The camber angle of the holes must be 5
To clean the bearings properly, place them in a petrolium bath
and use a brush to remove any lubricant residue. Check the flatness of the contact surfaces for the leaf springs.
Dry the bearings with compressed air making sure that the air Device 99305111 is used to find the caster angle, following the
jet does not cause the bearings to rotate. procedure described below:
Lubricate the bearings with the same type of oil as for the — Insert the two centering pins (4, figure 38) on the leaf
epicyclic unit. spring contact surfaces;
Keeping the bearings pressed with one hand and at the same
time turning them slightly in both directions, check that there — Using the centering pins, set up the two goniometers (2)
is no roughness or noise as they slide. on the leaf spring contact surfaces;
Carefully check that the rollers and their cages, the outer tracks — Set up the cross bar (1) on the supports (3) and gonio-
and raceways are not worn. meters (2) then read the relevant caster values on the go-
Check all the parts to decide whether they can be re-used or niometers.
must be replaced. Special attention must be given to the axle
casing, the fork supports and the stub axles; make sure there The axle caster angle must be 1 30’
are no signs of cracking or other faults.
Any parts that show signs of wear must be replaced.
Check the wheel fastening bolts; if any strain or damage to the
threads is seen, replace, using the press to remove them and
fit in place the new parts. After fitting, check that the
orthogonality tolerance does not exceed 0.3 mm.
Figure 41
39593
CAMBER ANGLE CHECK

1. Support - 2. Goniometer - 3. Cross bar - 4. Centering cones - 5. Spacer
Figure 42
39594
CASTER ANGLE CHECK

1. Cross bar - 2. Goniometer - 3. Support - 4. Centering pin - 5. Spacer
Fork support mounting

Figure 43 Figure 46
39511 39514
With driver 99374370 (1) and grip 99370006 (2) fit the roller Turn over the support (1) and fit the o-ring (2).
bearing (3) into its seat in the fork support.
Figure 44 Figure 47
39515
39512
Using fitting tool 99374371 (2) and grip 99370006 (3), fit the
Fit the shim (1) in the seat (2) in the fork support.
seal in the seat on the fork support (1).
Figure 45 Figure 48
71529
39513
With pliers (1) fit the retainer ring (3) in the fork support seat Using driver 99374382 (4) and grip 99370006 (3), fir the roller
(2). bearing (2) into the fork support (5), then fit the o-ring (1).
Repeat this operation on the opposite side. Apply the o-ring
(6) in fork support seat (5).
Figure 49 Figure 52
3
4
39517
Apply Loctite AVX to the fork support (1) and axle box union
faces then fit the support taking care to position the steering 72457
mechanical limit stud in the foreseen position.
Align the holes for the fastening screws. With driver 99374369 (1) and grip 99370006 (2) fit the roller
Spread Loctite AVX on the threads of the screws (3) and bearing (5). Fit the oil baffle (4) and fasten it to the stub axle
gradually tighten them flush. with the snap ring (3).
Tighten to specified torque with the torque wrench.
Transfer shaft mounting Figure 53

Figure 50
39518
39519
With driver 99374390 and grip (2) fit the o-ring (1) in the seat
Lubricate the inner race of the bearing (2) then insert the on the stub axle.
transfer shaft (1) paying attention not to damage the O-ring.
Stub axle assembly Figure 54

Figure 51
71530
Check that the surface of the shim (1) on which the hub o-ring
39520
runs is not damaged or worn. If so, replace the shim (1).
When fitting the shim (1) apply LOCTITE 573 to the contact Fit the stub axle (2) and provisionally insert the upper pin (1)
() face with the stub axle pin (2). and the scraper shim (3).
Figure 55 Figure 58
39521 39524
Grease the collar (2) and fit it in place on the steering (1) in Partially withdraw the upper pin (1) and insert the adjusting
the position indicated by the arrow (3). ring (2).
Figure 56 Figure 59
39522 39525
Fit in place the spacer (3) positioning the pins (4) as shown; Insert the upper pin (1).
fit in place the seal ring in the safety ring and insert it between Fit in place the brake air hoses coupling bracket (3) and lock
the fork support and the stub axle. it withscrews (2).
Figure 57
39523
Fit in place the arm (3) in the stub axle.

Spread Loctite AVX on the screw threads (2) then tighten
them with a dynamometric wrench (1) to the specified
torque.
Figure 60 Figure 62
39526 39528
Fit a vice (3) to lift the stub axle (2); check there is no backlash Fit in place the brake housing (3) and its guard (2) on the stub
using a feeler gauge (1). axle; use Loctite AVX on the screws (4) and tighten them to
If backlash is found, replace the ring with another of an a torque of 360 Nm. Fit in place the ABS sensor (1).
adequate thickness to eliminate the backlash.
Remove the upper pin fastening screws, apply Loctite to them
and re-fit them in place, tightening to the specified torque. Figure 63
Figure 61
39529
Fit in place the shoes (1) so that the embossed arrow is in the
forward driving direction; latch the return springs (2).
39527
Using two screws (1), fit the flange (2) on the stub axle (3) with Figure 64
the oil drainage notch downwards.
39530
Slightly heat the phonic wheel (1) and fit it in place on the
wheel hub (2)
Figure 65 Figure 68
39531 39488
Use beater 99374094 to fit in place the bearing outer rings (2 Fit in place the wheel hub (3) on the stub axle shank (2)
and 3) on the wheel hub (1).
Figure 69
Figure 66
39534
Fit in place the ring bevel gear-carrier (2) on the hub (1) together
39532
with the relevant bearing, screw it to contact the nut (3).
Insert the outer bearing inner ring (2) on the wheel hub (1) The oil passage milling on the ring bevel gear carrier
(2) must be set in a perpendicular position in the
lower part.
Figure 67
Figure 70
39533 39535
Using element 99374377 (2) fit in place the sealing gasket (1) Using wrench 99345207 (1) lock the wheel hub nut until the
on the wheel hub (3). assembly rotates with difficulty.
Use a teflon hammer on the hub to settle the bearings in
position.
Figure 71 Figure 73
39536 39538
Apply tool 99389819 (3) to the wheel hub (1) and use a Fit in place the shoulder ring (1), then the planetary gear (2)
dynamometric wrench (2) to rotate it.
Set the dynamometric wrench indicator (2) to zero then make
one wheel hub turn at about 25  30 r.p.m.
Find the rolling torque on the instrument scale indicator.
This value should correspond to that given in the Figure 74
SPECIFICATIONS AND DATA.
If the values do not coincide, loosen or tighten the nut to
obtain the required value.
Figure 72
39539
Fit the shoulder ring (1) and the circlip (2) on the half shaft,
using the appropriate pliers.
39537
Fit the shoulder ring (1) and the circlip (2) on the half shaft,
using the appropriate pliers.
Fitting in place the epicyclic reduction gear sup-

port
Figure 78
Figure 75
39544
39541
Spread sealant on the two coupling surfaces of the support
Fit the shim rings (2) on the pin (1) cover (1), fit in place the seal gasket and place the cover so that
the spaces indicated by the arrows coincide with the pins.
Figure 76 To make this operation easier, before fitting the gasket,
position the pins according to the seats on the cover, then fit
in place the gasket.
Tighten the fastening screws to a torque of 25 Nm (2.5 kgm).
Loosen nut (2) and unscrew some threads of the screw (3)
Figure 79
39542
Grease and fit in place the rollers (2) on the pin (1)
Figure 77
39545
Fit in place the ring bevel gear (2) with the outer chamfer
toward the operator. Grease the split ring (1) and fit it in its
housing.
39543
Insert the gears (2), the spacer washers (4) and pins (3) into
the support (1)
Figure 80 Figure 83
39546
39491
Fit in place the planetary gear carrier (2) on the wheel hub (1). Fit in place the track rod, tighten the nut (1) to the prescribed
Using a socket wrench (3) screw down the three hexagonal torque, fit the split pin (2) and bend it.
socket head screws and tighten them to a torque of 25 Nm
(2.5 kgm).
Figure 81
GREASING THE STUB AXLE PINS
Using a suitable grease pump, fill the grease nipples.
Continue with the grease pump until the pressure of the
grease, after the needle bearing housings are filled, overcomes
the sealing edges of the rings and seeps out through the spaces
between the stub axle post and the fork support.
Remove the excess grease.
EPICYCLIC UNITS LUBRICATION

Through the inlet hole on the cover, fill the epicyclic unit with
approx 0.75 lt (0.68 kg) of prescribed oil.
39705
Tighten the screw (1) to bring it into contact with the half axle
(3), then unscrew by 1/3  1/2 a turn to obtain the assembly
clearance (0.5  1 mm).
Lock the nut (2)
The washer must be replaced whenever the half-axles end
play is adjusted.
Figure 82
39547
Fit in place the brake drum (1) on the wheel hub and lock it
with the two screws.
REMOVING THE DIFFERENTIAL Axle casing check

(with axle on stand 99322215) The axle casing alignment must be checked since any
Figure 84 deformation will cause straining and noise (see page 18).
RE-FITTING IN PLACE THE DIFFERENTIAL

(with axle on stand 99322215)
To keep in place the seal ring between the axle casing and the
differential housing, moisten it with a little grease. Spread
Loctite 573 on the coupling surfaces of the axle casing (2) and
the differential housing (1).
Figure 86
39548
Set the axle casing (1) as shown in the figure and withdraw
the half shafts.
Unscrew the differential housing fastening screws (2).
Figure 85
39550
Using mobile hydraulic lifting equipment and ropes with

hooks (3-4) place the differential housing (1) in the axle casing
(2).
Figure 87
39549
Fasten two eye-bolts (1) to the differential output flange.

Using suitable lifting equipment and ropes remove the
differential (3) from the axle casing (2).
39551
Insert the screws (1) and tighten them with a dynamometric

wrench to the prescribed torque.
HD9 Euro5
Figure 88
SECTION 12.1 A
39613
DIFFERENTIAL COMPONENTS
1. Ring nut - 2. Bearing - 3. Gear housing cover - 4. Shoulder washer - 5. Crown wheel - 6. Washer - 7. Spider - 8. Short pin - 9. Planetary gear - 10. Differential housing
11. Adjusting shim - 12. Pinion - 13. Pinion support - 14. Flange - 15. Nut - 16. Seal ring - 17. Bearing - 18. Adjusting ring - 19. Spacer - 20. Bearing - 21. Ring nut -
FRONT DRIVE AXLE
22. Bearing - 23. Crown wheel - 24. Gear housing - 25. Plate and screw - 26. Long pin - 27. Caps
41
REPAIRING THE DIFFERENTIAL

Removal
Figure 92
Figure 89
39552 39555
Remove screw (1) and take away the safety plate (2). Using the appropriate beater, remove the dents (1) and
Remove screws (3) and take away the caps (4). Remove the unscrew the nut (2) as described below.
ring nuts.
Figure 93
Figure 90
39556
39553
Lock the coupling flange rotation with lever 99370317 (2) and
By means of the hook (1) lift the gear housing (2) with the using socket wrench 99355081 (1) loosen the flange fastening
relevant bearings (3). nut.
Figure 94
Figure 91
39557
39554
Remove the screws that fasten the bevel gear carrier to the
View of pinion (1) from inside the differential housing (2) differential housing.
Withdraw the carrier (1) with the bevel gear from the
differential housing (3); remove the pinion-crown wheel shims
(2)
Removing the gear housing

Figure 98
Figure 95
39558 39561
Set the gear housing (1) in a vice (2) Remove the gear housing cover (1).
Take out the crown wheel (3) with its shoulder washer (2)
Figure 96
Figure 99
39559
Using puller 9934801 (1) extract the bearing(2) on toothed 39562

side from the gear housing (3).
Use a beater to draw out the long pin (1), then the two short
pins (2)
Figure 97
The exact position of the pins is indicated on the
spider by a long stripe for the long pin and two short
stripes for the short pins.
Remove the spider and the four planetary gear wheels with
the shoulder washers.
Remove the crown wheel and shoulder washer
39560
Remove the screws (1)

Use the suitable beater to release the bevel gear (2)
Removing the bevel pinion support Checking the differential components

Carefully clean all the differential components.
Figure 100 Lubricate the bearings and rotate the roller cage freely, this
rotation should be regular with no stiffening. Check the
contact surfaces of the bevel gear and the stop plate of the half
box to ensure that the crown wheel adheres properly. Any
deformation of these surfaces will cause the vibration of the
fastening screws jeopardizing the unit functioning.
Carefully clean all the threads to ensure accurate

adjustments and exact driving torques.
39563
Using the suitable puller set up as shown in the figure, remove

the bevel pinion, bearing and adjustment ring from the support Check that the splined section for the flange connection onto
(1) the pinion is not worn. If it is, replace it.
Draw out the seal ring (2)
Figure 101
If it is necessary to replace the crown or the pinion,
both elements must be changed as they are supplied
in pairs.
Check the planetary gears and their shoulder washers, the

spider and the crown wheels with their shoulder washers.
All sealing elements and lock washers must be replaced with
new ones.
39564
Using puller 99348001 (1) remove the bearing (2) from the
bevel gear.
Figure 102
39565
Using a beater, release the front and intermediate bearing

outer rings (1 and 2) from the support.
Remove the oil baffle.
Fitting in place the gear housing Figure 106

Figure 103
39569
39566
Heat the bevel gear (1) to approx 80C, fit it into its seat on
Set the gear housing (3) on a suitable support, fit the crown the gear housing (2) and lock it immediately by means of two
wheel (1) in its seat with its shoulder ring (2) fastening screws.
39567
Fit in place the 4 planetary gears (2) and shoulder rings, then
39570
fit in place the spider (4). Insert the long pin (1) and two short
pins (3). Fit in place the other screws (1) and tighten them with a
The correct positions for the pins are marked on the spider dynamometric wrench (2) to a torque of 300 Nm.
(4) by a long stripe for the long pin and two short stripes for Heat the support bearings and fit them in place on the gear
the short pins. housing.
Figure 105
39568
Set the crown wheel (2) with its shoulder ring on the planetary
gears.
Fit in place the cover (1) on the gear housing (3) making sure
that the fastening screw holes coincide.
Fitting in place the bevel pinion support Figure 111

Figure 108
39571 39574
Fit a new oil baffle in the pinion support. Using beater Onto tool 99395027, fit in place:
99374093 (1) drive completely into their seats the outer ring
- pinion side bearing (6)
(2) for the front bearing and with beater 99374094 the outer
ring for the rear bearing. - spacer ring (5), the previously measured adjustment ring
(4) and bearing (3).
Screw on the ring nut (2) and lock it tight.
Procedure to determine the adjustment ring On the bearing (3), set element (1) of tool 99395027 (1)
shim for the bevel gear rolling torque equipped with a dial gauge and set the gauge to zero on the
end of the tool (7).
Figure 109 Now remove from the tool (7):
- element (1),
- ring nut (2),
- bearing (3),
- adjustment ring (4) .
Figure 112
39572
Measure the thickness of the adjustment ring (1) that has been
removed and make a note of the value (value A).
Figure 110
39575
Set the support (4, figure 105) on the bearing (6, figure 104)
then fit in place the bearing (3).
Tighten the ring nut (2) by hand. Check the rolling torque as
indicated in figure 108.
39573
Tighten tool 99395027 (1) and its extension bar (2) in a vice
39576 39577
Set the complete support (3) on two parallel bars; using the Heat the bearing (3) and connect it to the bevel pinion (4).
dynamometric wrench (1) mounted on the equipment (2) Fit in place the spacer (2).
find the rolling torque that should result: Fit in place an adjustment ring (1) that has the same thickness
as previously noted and set it on the bevel gear.
- 6  8 Nm; if it is not so, operate on the ring nut (2, figure 106)
Fit in place the support with the bearing outer rings on the
Once again place the part (1, fig. 107), with the dial gauge set bevel gear.
to zero, on the bearing (3, fig. 107) to find any deviation (value
B).
The adjusting ring thickness S is obtained from the following
formula: Figure 115
S = A - ( B) + C
where:
A = thickness of adjusting ring fitted to reset the dial gauge
B = deviation found
C = 0.05 mm coefficient that takes into account the

bearings dilatation caused by the assembly interference
on the bevel gear
39578
First example:
Heat the bearing (1) and using the beater, fit it into its seat on
A = 13.12 mm the bevel gear (2).
B = + 0.13 mm
C = 0.05 mm
S = 13,12 - (+ 0.13) + 0.05 =

S = 13,12 - 0.13 + 0,05 = 13.04 mm.
Second example
A = 13.12 mm
B = - 0.13 mm
C = 0.05 mm
S = 13.12 - (- 0,13) + 0,05 =

S = 13.12 + 0.13 + 0.05 = 13.30 mm.
Remove the parts from tool 99395027.

Figure 116 Differential box mounting

Figure 118
39579
39581
Using tool 99374233 (1), fit the new seal (3) in the support
(2). The replacement seals are supplied pre-lubricated and
with grease between the lips. Before fitting the complete bevel pinion mount on the differ-
ential box, check the value (1) punched on the bevel pinion
and to determine the thickness of the shim to be arranged
between mount and box (see TECHNICAL DATA).
Figure 117
Figure 119
39580
Position the transmission flange (1), complete with baffle (2)

71850
in the grooved part of the pinion (3) and with a suitable driver,
press it home.
Provisionally tighten the retaining nut (4). Carefully apply LOCTITE 573 to the contactfaces of the
differential box (1) and add LOCTITE 510 around the holes
indicated by the arrows. Fit the adjuster shim (2) to the
differential box (1) such that the hole (4) is facing toward the
upper part A of the differential box. Using eye bolts and cables
mount the complete bevelled pinion support (3) on the
differential box.
Tighten all screws to specified torque.
Apply LOCTITE 573 to the threads of the screws in

the holes passing through the differential box (1).
Figure 120 Adjusting the gear housing bearings rolling

torque
Figure 123
39583
Using the specific hook (1) lift the previously assembled

gearcase (2) and set it on the differential housing (3).
39587
Figure 121 The rolling torque adjustment for the gear housing bearings is
obtained measuring the total rolling torque.
Using torque wrench 99389819 (1) and appropriate socket
wrench, find the prescribed rolling torque, operating on the
bearing adjustmentring nuts with wrench 99355025 (2).
39584
Fit in place the bearing outer rings. Fit the caps (2) and tighten,
but not completely, the screws (1), Fit in place the adjusting
ring nuts checking that they can be screwed easily; with a
dynamometric wrench (3) lock the screws to the prescribed
torque.
Figure 122
39585
Set tool 99370133 (1) as shown in the figure to prevent

excessive angle variation of the caps during adjustment.
Adjusting the end play between pinion and Figure 126

bevel gear pair
Figure 124
19452
The pinion is too deeply set, therefore it requires further

adjustment.
To adjust the exact pinion position, shims must be added
under the pinion support to obtain an exact contact.
A slight internal crown wheel movement may be necessary
to maintain the exact nominal value.
39586
Adjust the end play between the pinion-crown wheel teeth;

the procedure is as follows:
Figure 127
- Set the dial gauge (1) with magnetic base as shown in the
figure;
- using wrench 99355205 (2) tighten the bearing
adjustment ring nuts (3) and loosen by the same amount
the ring nut on the opposite side. Taking this precaution
the rolling torque that has been previously adjusted is
maintained.
19453
The pinion is too far out, therefore it requires further

Figure 125 adjustment.
To adjust the exact pinion position, shims must be removed
from under the pinion support to obtain an exact contact.
A slight external crown wheel movement may be necessary
to maintain the exact nominal value.
Figure 128
39588
Using a brush (1) apply a thin coating of lead oxide on the

crown wheel teeth.
Turn the pinion and find the contact mark between the pinion
teeth and the crown wheel teeth.
The figures that follow show the possible contact points and
39552
how to correct any errors.
Fit the plate (2) and tighten the fastening screws to the
prescribed torque.
If the plate (2) does not fit into the ring nut groove (3) slightly
rotate the ring nut until the two parts match. Carry out the
same procedure on the other side.
KESSLER DRIVE AXLE
SECTION 12.1 B
HD9 Euro5 SECTION 12.1 B KESSLER DRIVE AXLE 1
SECTION 12.1 B
Kessler drive axle

Page
DESCRIPTION 3
- First reduction: bevel gear pair 4
- First reduction: cross section 5
- First reduction: functional diagram 6
- Second reduction: twin universal joint, hub and epicyclic
gear set 7
- Second reduction: cross section 8
- Second reduction: functional diagram 9
- First reduction: double bevel gear 11
- Second reduction: hud and epicyclic gear set 12
TOOLS 13
TROUBLESHOOTING 16
- Axle 16
AXLE OIL REPLACEMENT FRONT 19
GENERAL 19
- Axle 20
- Drainage 20
- Filling 20
- Hub 21
- Drainage 21
- Filling 21
2 KESSLER DRIVE AXLE SECTION 12.1 B HD9 Euro5
FRONT AXLE REMOVAL-REFIT 22

GENERAL 22
- Removal 23
- Refitting 23
EPICYCLIC REDUCER OVERHAUL 25
- Disassembly 25
- Checking assembled parts 29
- Re-assembly 29
- Bearing and thread lock and sealant diagram -
epicyclic reduction unit 30
KINGPIN AND AXLE SHAFT OVERHAUL 37
- Disassembly 37
- Assembly 40
DIFFERENTIAL OVERHAUL 42
- Disassembly 42
- Bearing and thread lock and sealant diagram -
epicyclic reduction unit 47
DESCRIPTION
The axle is a dual reduction bearing type.
It consists of a box-like structure containing bevel gear with dif-
ferential (first reduction), drive axles, twin universal joints, king-
pin and hubs with epicyclic reducer (second reduction).
It is connected to the chassis by means of two longitudinal leaf
springs which also form the suspension.
Figure 1
341B121H001R
1. Brake drum
2. Kingpin
3. Differential casing
4. Inlet flange
5. Steering linkage
6. Coupling bar
First reduction: bevel gear pair Key

The first reduction is obtained by the pinion-ring bevel gear
assembly (bevel gear pair) inside the differential.
The key is in common to both the following figures.
The pinion is supported by two taper roller bearings mounted
in O arrangement with a pre-load that can be adjusted by a
spacer. The pinion axial position can also be adjusted by means
of shims.
1. Differential lock actuator
The differential gear casing with ring bevel gear is supported 2. Tapered roller bearing ring gear side (C)
by two taper roller bearings mounted in X arrangement with 3. Differential casing
the pre-load and axial position that can be adjusted by two 4. Ring bevel gear
opposed ring nuts. 5. Pinion axial position adjustment spacer S1
6. Pinion axial position adjustment spacer S2
Operation 7. External taper roller pinion bearing (B)
8. Internal taper roller pinion bearing (A)
The differential is a wheelwork in which the casing is the gear
9. Bevel pinion
carrier, which carries the planet gear carrier shafts and receives 10. RH adjustment ring nut
the driving torque, whereas the two gear carriers are the sun 11. Tapered roller bearing planet gear side (D)
gears, both of which rotate, receive the driving torque and
12. Sun gear
transmit it to the axle shafts. 13. Planet gear carrier shaft
14. Planet gear
When both wheels are subject to the same stall torque or 15. LH adjustment ring nut
have the same speed (vehicle being driven on a straight road), 16. Differential lock collar
the ring bevel gear and the differential gear casing rotate as
one, transmitting the torque in equal parts to the two carriers,
and from here to the two axle shafts, that rotate at the same
speed: the wheels transmit the same driving torque.
Under these conditions there is no relative motion between
the two carriers and therefore the planet gears do not turn
around their shaft which is integral to the differential gear
casing.
When the resistance of one wheel is greater than that of the

other, or when the speed of the two wheels is not the same
(vehicle on a road with bends) the carriers have a different
rotation speed: the relative motion is permitted by the planet
gears, that now turn around their shafts in directions opposite
to each other.
Obviously, at a lower carrier rotation speed the transmitted
driving torque is greater, and vice versa.
Therefore when the differential is operating, the wheel with
a lower speed can transmit a greater torque, whereas the
wheel with a higher speed can transmit a lower torque.
An engageable lock is provided to avoid the possibility that

with a loss of grip one of the two axles freewheels, cancelling
the traction of both axles.
With this device engaged, the casing is integral with a carrier:
in this way the entire casing - planet gears - carrier assembly
rotates as a single unit and the torque is by force divided
equally between the wheels.
First reduction: cross section
Figure 2
341B121H002R
First reduction: functional diagram
Figure 3
341B121H003R
Second reduction: twin universal joint, hub Key

and epicyclic gear set
The twin universal joint has the function of ensuring speed
uniformity between the wheel and the drive axle exiting from The key is in common to both the following figures.
the differential.
The joint is contained inside the axle. The steering axis passing
through its geometric centre.
1. Planetary gear set carrier (planetary gear carrier plate)
Steering is obtained by means of the kingpin on the end of the 2. Planet gear
axle by means of two pins the axes of which form the steering 3. Planet gear pin
axis. 4. Sun gear
5. Spare ring.
The second reduction is obtained by a cylindrical gear epicyclic 6. Axle shaft
reduction unit contained in the wheel hub. 7. Snap ring
8. Spacer
The hub is supported by two taper roller bearings mounted 9. Adjustment ring nut
in O arrangement with a pre-load that can be adjusted by a 10. Planetary gear set ring gear
ring nut. 11. Wheel mounting bolt
12. Hub
The planet gears rotate on pivoting roller bearings. 13. Drum bell
14. Shoe
Operation 15. Steering linkage
The drive torque from the double universal joint is transmitted 16. Shoe holder plate
to the sun gear by means of a double spline. 17. Axle
18. O-rings
The four planet gears rotate in the opposite direction to the 19. Cup needle bearing
sun gear, whereas the ring gear is integral to the hub support 20. Axle shaft
and therefore does not turn. This makes the carrier turn in the 21. Twin universal joint
opposite direction to the planet gears, therefore in the same 22. Kingpin
direction as the axle shafts. 23. O-rings
24. Cup needle bearing
Since the carrier is integral to the wheel hub, the wheel turns 25. O-ring
in the same direction as the axle shaft. 26. Internal taper roller bearing
27. O-ring
28. External taper roller bearing
A: Section
B: Functional diagram
Second reduction: cross section
Figure 4
307B121H004R
Second reduction: functional diagram
Figure 5
307B121H005R

1
Code KESSLER LT 61PL478
Type Rigid, dual reduction
Differential Gleason double bevel gear
Pinion shaft bearings 2 taper rollers mounted in O arrangement
Differential bearings 2 taper rollers mounted in X arrangement
Hub bearings 2 taper rollers mounted in O arrangement on each side
Twin universal joint bearings 1 x 2 cup needle bearings on each side
Hub satellite bearings 3 x 4 needle bearings on each side
Bevel gear pair 1 : 1,149-1,235-1,345-1,44
Reduction ratio Wheel reducer 1 : 4,361
Total 1 : 5,010-5.384-5,866-6,280
Pinion shaft bearing pre-load 0,8 1,0 Nm
Differential bearing preload 2,0 - 3,0 Nm
Bevel pair backlash See value engraved on ring gear
Axle shaft - reducer carrier axial backlash 0.30 — 0.70 mm
Hub bearing pre-load Determined by ring nut tightening torque
1er serrage : 600-800 Nm, puis desserrer

Ring nut tightening torque
2ème serrage : 400 Nm
First reduction: double bevel gear
Figure 6
341B121H008R
Second reduction: hud and epicyclic gear set
Figure 7
307B121H054R
TOOLS
The tools shown in the list must be ordered from the supplier (KESSLER + CO GmbH & Co. KG).
Spanner for wheel safety nut
Assembly cone for O-ring (differential lock)
Seal ring sleeve driver
Spanner for thread rings (differential bearing)
Spanner for counter nut (planetary drive gear)

Assembly sleeve for piston (differential lock)
Assembly sleeve for piston (differential lock)
Sleeve driver for universal joint bearing (needle bearing - bearing

bushing)
Sleeve driver for bearing bushing (steering knuckle bearing )
Puller for universal joint bearing (needle bearing - bearing bushing)
Device to press in king pins

Hydraulic device to press in king pins
Hydraulic puller for king pins
Mechanical puller for king pins
Screw spindle for king pin puller

TROUBLESHOOTING
Axle
1. Continuous noise
2. Noise on bends
3. Alternating noise
4. Harsh knocks when accelerating or decelerating
5. Oil leakage
1 CONTINUOUS NOISE
Worn bearings. Replace.

YES
NO
Damaged or worn teeth. Replace.

YES
NO
No lubrication. Top up oil level.

YES
NO
Incorrect backlash. Adjust again.

YES
2 NOISE ON BENDS
Worn planet gears or carriers. Replace.

YES
3 ALTERNATING NOISE
Excessive wheel bearing backlash. Adjust bearings.

YES
NO
Wheels not fitted correctly. Remove and refit correctly.

YES
NO
Too little bevel gear backlash. Adjust again.

YES
NO
Too much bevel gear backlash. Adjust again.

YES
HARSH KNOCKS WHEN

4 ACCELERATING OR
DECELERATING
Imperfect gear adjustment. Adjust again.

YES
NO
Loose chassis structure anchoring. Fasten the screws at the specified torque.
YES
5 OIL LEAKAGE
Worn oil seals. Replace.

YES
NO
Loose screws. Fasten the screws at the specified torque.

YES
AXLE OIL REPLACEMENT FRONT

Safety instructions

Vehicle preparation

Figure 8
2371801

short circuits;
Axle Filling
Drainage Proceed as follows:
Proceed as follows:
Figure 11
Figure 9
HD9ST0213L
HD9ST0213L - fill until oil spills out the of the cap (1);
Proceed to supply very slowly. The operation is to be
cosidered ended if the level does not drop after at
least five minutes.
Figure 10
- clean the cap, check that the threading is in good

condition, replace the sealing ring and close the cap.
Final operations
Proceed as follows:
again.
342B121K002R

cap.
Hub
The operations described are valid for both hubs.
Drainage
Proceed as follows:
Figure 12
178NM50
- bring screw (2) to lowest position;

- clean the cap area and open the cap (1):
- prepare an adequate container, clean the screw area (2);
then remove it completely discharging all the lubricant;
- tighten the screw.
Filling
Proceed as follows:
- adjust the cap (1) so that the reference marking is in
horizontal position;
condition, replace the sealing ring and close the cap.
Final operations
Proceed as follows:
again.
FRONT AXLE REMOVAL-REFIT

Safety instructions

specified torque.
2371801

short circuits;
See figure on next page Check support pads are intact, if necessary replace the dam-
aged component
Preliminary operations replace damaged component.
appropriately;
Final operations
Proceed as follows:
it on the two support stands so that the wheels no longer
for Use of the USE AND MAINTENANCE MANUAL;
UAL STEERING ANGLE ADJUSTMENT of Section 15;
WHEELS TOE-IN ADJUSTMENT chapter of Section 15.
Proceed as follows:
(1) ABS transmitter from both sides ;
(4) wear on breaking seals warning light on both sides;
(7) differential lock (if present);
rod (12);
- place a hydraulic jack with an appropriate support fixture
under the axle;
Figure 14
307B121H008R
EPICYCLIC REDUCER OVERHAUL Figure 16
Before carrying out any operation, check that all pre-

cautions have been taken and all aspects regarding
this manual.
Respect all general recommendations for correct ex-
ecution of maintenance works.
Before proceeding:
 drain lubricant from the wheel hub
Proceed as shown in the corresponding Chapters. 307B121H010R
- Mark the matching positions of the planet gear carrier

Appropriately support and lock the kingpin so pre- plate and the hub.
vent movements during operations. - Loosen and remove all fastening screws (1).
- Remove the planet gear carrier plate (2) and the o-ring
(3).
Disassembly - Remove the snap ring (4) and remove the spacer (5), the
sun gear (6) and the spacer (7).
Proceed as follows:
- Remove the spacer (8) from the planet gear carrier plate
Figure 15 assembly.
307B121H009R
- Loosen the fastening screws (1) and remove the brake

drum (2).
Figure 17 Figure 19
307B121H011R
- loosen the ring nut lock screw (1).

307B121H013R
- remove the ring gear fastening ring nut (2).
- Remove the fasten screws (1) and the corresponding
stop plates (2).
- Separate the ring gear (3) of the corresponding flange (4).
Figure 18
- Using an appropriate extractor, remove the inner race
gear (5) of the bearing (E) wheel side from the ring gear
flange.
Figure 20
307B121H012R
- Remove the ring gear (1) carefully from the hub.
307B121H014R
- Using an appropriate supporting tool, carefully remove

the hub (1) from the hub support.
- Position the hub in vertical position.
- If removed, fit the wheel fastening screws on the hub.
Figure 21 Figure 23
307B121H015R 307B121H017R
- Remove the oil seal (1). - Remove the inner race (1) of the bearing axle side (A) and
the spacer (2) from the hub.
- Using an appropriate extractor, remove the outer race
(2) of the bearing on axle side (A) and the outer race (3)
of the bearing on wheel side (B).
The spacer is blocked with sealant.
- Remove the oil seal (4). Heat the threading to about 120 ˚C before unscrew-
ing to avoid damage.
Figure 22
307B121H016R
- Loosen the fastening screws (1) and remove the com-

plete shoe holder plate (2).
Figure 24 Figure 25
307B121H019R
- Remove the satellite (1) and the corresponding shims.
307B121H018R Figure 26
- Position the planet gear carrier plate onto an appropriate

working top.
- Using a punch, fully push in the fastening pin (1) and re-
lease the pin (2).
- Exract the pin (2) by pressing towards the inside of the
planet carrier plate (arrow).
Do not push the pin towards the outside of the planet

gear carrier plate to prevent damage to the seat due
to the different diameters between the internal and
external part of the pin itself.
- Remove the o-ring (3). 274A062039
- Extract the pin.

- Remove the needle bearings (arrow) of the planet gear.
- Repeat the procedure for all planet gears.
Checking assembled parts Re-assembly

Wheel hub
strain and/or ovalising; When reassembling, bear in mind the following gen-
eral rules:
- check the state of the bearings: replace them if they have  heat the bearings and rings that are pressure-as-
blue contours, cracks and/or signs of wear. sembled in an oven at 100˚C;
Axle shafts  carefully centre and fit the o-rings and bearings
with an appropriate fitter;
- check the condition of the axle shafts, replace them if
 lubricate ring nuts and bearings.
there are signs of strain on the end grooves and/or over
the whole length.
Transfer cases
- check the condition of the gear teeth: replace if there are
signs of pitting, cracks and/or sinking;
- check that the planet gears and needle bushings function
correctly;
- check the thread on the bearing lock nut: there must be
no denting, strain and/or seizure.
Bearing and thread lock and sealant diagram - epicyclic reduction unit
Figure 27
307B121H020R

Planet gear carrier plate
- Arrange the planet gear carrier plate in horizontal posi-
tion.
Figure 28
307B121H019R
- Fit the planet gear (1) with shims in its seat on the planet
gear carrier plate.
Figure 30
274A062032
- Fit the needle bearing in the planet gear.
307B121H021R
- Fit the o-ring (1) in the planet gear carrier plate seat.
- Insert the pin (2) of the planet gear carrier making the pin
holes coincide.
Fit the pin from the inside of the planet gear carrier
plate to avoid damaging the seat due to the diameter
differences of the pin itself.
- Fit the stop pin (3).

- Repeat the procedure for all planet gears.
Figure 31 Figure 32
307B121H022R 307B121H024R
- Install the complete shoe holder plate (1) and fasten the
- Using an appropriate fitter, insert the oil ring (1) into the
screws (2).
inner seat on the hub respecting the correct orientation
(detail) then fill it completely with lubricant grease for
bearings (arrows).
Figure 33
307B121H023R
- Arrange the hub in vertical position.

- Using an appropriate fitter, insert the oil rings (1) into the
inner seat on the hub respecting the correct orientation
(detail) then fill it completely with lubricant grease for
bearings (arrows).
- Use an appropriate fitter to mount the outer race (2) of
the bearing wheel side (B) and the outer race (3) of the
bearing axle side (A).
- Fit the inner race (4) of the bearing on wheel side (A).
Figure 34
307B121H025R
- Arrange the kingpin in horizontal position.

- Use an appropriate lifting means to support the hub as-
sembly so as to ensure correct centring.
- Introduce the hub assembly (2) onto hub support end (3)
making the inner race of the bearing (A) abut on the hub
support.
During this operation, hold the hub perfectly parallel

to the kingpin axis.
Proceed with care to prevent damage to the o-rings.
Support the hub assembly until assembly is complete.
- If removed, fit the wheel fastening screws on the hub.

Figure 35 To determine the hub bearing pre-load

Proceed as follows:
Figure 36
307B121H026R
307B121H028R
- Heat the inner race (1) of the bearing on wheel side (B)
and introduce it fully onto the gear flange. - Apply MOLYKOTE to the thread of the hub support and
- Insert the gear flange (2) on the ring gear (3). the thread and contact area of the lock ring nut.
- Fit the retainer plates (4) and fix with stop screws (5). - Manually fit the ring nut (1) without tightening.
- Tighten the lock ring nut at the specified torque.
Bearing lock ring nut tightening torque
Step 1: 700 - 900 Nm
Figure 37

backwards while hitting it with a plastic hammer to
bed in the bearings.
- Loosen the lock nut by half a turn.

- Tighten the lock ring nut at the specified torque.
Bearing lock ring nut tightening torque
Step 2: 450 Nm

307B121H027R backwards while hitting it with a plastic hammer to
- Fit the flange assembly and ring gear (1) on the hub to - After adjusting the bearing pre-load, lock the ring nut with
make the two parts of the bearing on wheel side (B) come the corresponding lock screw (2).
into contact.
The passage hole for lubricant oil on the gear flange If this is not possible, loosen the ring nut as much as
must be facing downwards. needed to fit the lock screw.
Figure 38 To determine the crown wheel gear-differential gear

carrier plate axial backlash
Proceed as follows:
Figure 39
307B121H029R
- Fit the spacer ring (1), the sun gear (2), the spacer ring (3)
and the snap ring (4).
307B121H030R
- Measure value A.
Measure value B.
Determine the thickness of the thrust spacer as follows:
S = A - B - (0.30 - 0.70) (mm)
where:
A =distance between planet gear holder plate assembly sur-
face and thrust spacer seat on the plate itself
B = distance between hub assembly surface and thrust spacer
seat on the axle shaft
S = thrust spacer thickness
0.30 - 0.70 = target backlash in mm
- Fit chosen the thrust spacer in the differential gear carrier
plate.
Completion
Proceed as follows:
Figure 40
307B121H031E
- Fit the o-ring (1) in the planet gear carrier plate seat.
- Fit the planet carrier plate assembly (2) into the hub.
Comply to the references marked at disassembly.
- Fit the screws (3) and tighten to the specified torque.
Figure 41
307B121H032R
- Fit the brake drum (1) and fasten all screws (2).
If no further operations on the differential are re-

quired, proceed as follows:
 fill the wheel hub.
Proceed as shown in the corresponding Chapters.
KINGPIN AND AXLE SHAFT OVERHAUL Figure 43

precautions have been taken and all aspects regarding
this manual.
Respect all general recommendations for correct
execution of maintenance works.
Before proceeding:
 drain lubricant from the wheel hub
 drain lubricant from the central differential 307B121H034R
 remove the hub
 remove the complete shoe holder plate - When proceeding on the left-hand side: loosen the secur-
Proceed as shown in the corresponding Chapters. ing screws and remove the steering lever (1);
- Loosen the fastening screws and remove the coupling
lever (2).
Apply differential lock manually. Support the kingpin appropriately to prevent dropp-
This will ensure that the procedure is carried out ing it.
properly.
Disassembly Figure 44
Proceed as follows:
- Release the ball joints and remove the coupling bar;
Figure 42
307B121H035R
307B121H033R
- Using an extractor remove the upper (1) and lower (2)
pins.
- When proceeding on the right-hand side: loosen the
fastening screws and remove the cover (1);
- Loosen the fastening screws and remove the coupling
lever (2);
Support the kingpin appropriately to prevent dropp-

ing it.
Figure 45 Figure 48
307B121H036R
Be careful not to drop the axle shaft when removing

the kingpin. 307B121H039R
- Remove the o-rings (1) and (2) and the snap ring (3) from
- Remove the kingpin. the axle.
Figure 46 - Using a ram, remove the cup needle bearing (4).

Figure 49
307B121H037R
- Remove the axle shaft with twin universal joint.
Figure 47
307B121H040R
- Remove the o-rings (1) and (2) and the snap ring (3) from
the kingpin.
- Using a punch, remove the cup needle bearing (4).
307B121H038R
- Remove the bushings (1) and (2), the o-rings (3), the
thrust rings (4) and (5) and the o-ring (6) from the kingpin.
Checking assembled parts

Cup needle bearings
- Always replace.
Thrust rings and bushings
- Always replace.
Axle shafts
- check the thread on the bearing lock nut: there must be
no denting, strain and/or seizure;
- check knurled grooves: they must be in perfect conditions,
without dents or rust;
- check the twin universal joint: must be free from backlash
(either axial or radial); all elements must be intact and well
lubricated.
Kingpin
- check that the sealing surfaces and threads are intact and
are not dented or damaged.
When reassembling, bear in mind the following gen-

eral rules:
 heat the bearings and rings that are pressure-as-
sembled in an oven at 100˚C;
 carefully centre and fit the o-rings and bearings
with an appropriate fitter;
 lubricate the ring nuts, o-rings and bearings.
Assembly Figure 52
Proceed as follows:
Figure 50
307B121H043R
- Insert the complete axle shaft with twin universal joint.
307B121H041R
The axle shaft must be engaged in the groove of the
differential.
Be careful not to damage the o-rings and the cup
- Using an appropriate tool, introduce the cup needle bear- needle bearing.
ing (1) into the kingpin.
- Fit the snap ring (2), then using an appropriate tool intro-
duce the o-rings (3) and (4). Figure 53
Figure 51
307B121H044R
307B121H042R
- Insert the o-rings (1), the thrust rings (2) and (3), the o--
ring (4) and the bushings (5) and (6) in the kingpin.
- Fit the snap ring (1) onto the axle.
- Using an appropriate tool, introduce the cup needle bear-
ing (2).
- Fit the snap ring (3), then using an appropriate tool intro-
duce the o-rings (4) and (5).
Figure 54 Figure 56
307B121H045R
307B121H034R
- Fit the kingpin onto the axle inserting the axle shaft into
the pin itself. - When proceeding on the left-hand side: fit the steering
lever (1) and fasten the screws.
- Fit the coupling lever (2) and fasten the screws.
Be careful not to damage the o-rings and the cup
needle bearing.
Be careful not to damage the thrust rings and the o--
ring. Figure 57
Figure 55
307B121H033R
- When proceeding on the right-hand side: fit the lid (1) and
fasten with screws.
307B121H035R - Fit the coupling lever (2) and fasten the screws.
- Refit the coupling bar and fasten the joint lock nuts.
- Insert the upper pin (1) and lower pin (2).
Proceed as follows:
 refit shoe carrier plate and wheel hub
 fill the wheel hub
 remove the hub
 fill the central differential
Proceed as shown in the corresponding Chapters.
DIFFERENTIAL OVERHAUL Figure 59

precautions have been taken and all aspects regarding
this manual.
Respect all general recommendations for correct
Disassembly
Before proceeding, remove the axle shafts as shown 307B121H048R

in the corresponding chapter.
- Remove the external cap (1) of the differential lock.

Proceed as follows:
The cap is locked with thread locker.

Figure 58 Heat the threading to about 120 ˚C before unscrew-
ing to avoid damage.
- Loosen the piston (2) holding the fork (3) still.
IMPORTANT: If you need to disassemble the piston

remember that it is left-handed.
- Remove the spring (4) and the o-rings.

- Remove the fork (3) and the locking collar (5).
341B121H005R
- Straighten the staking and remove the inlet flange lock nut.
- Remove the flange (1) using an appropriate extractor.
- Mark the relative position between casing and axle.
- Loosen and remove the screws fastening differential
casing to axle.
- Use appropriate lifting means to remove the differential
casing assembly (2) from the axle.
- Position the assembly on the stand, using suitable
adapters.
Figure 60 Differential disassembly

Proceed as follows:
Figure 62
276C063081
- Loosen the fastening screws and remove the locking plate

274A062048
(1) from both preload bearing adjustment rings.
- Loosen both bearing pre-load adjustment ring nuts (2). - Remove the external race (1) of the bearing ring gear side
- Mark each support cap and corresponding external box. (C) and the external race (2) of the bearing on planet gear
side (D).
- Loosen the mounting screws (3) and remove both sup-
port caps (4). - Using appropriate extractors, extract the inner race (3)
of the bearing ring gear side (C) and the inner ring (4) of
- Remove both adjustment ring nuts. the bearing planet gear side (D) of the differential half cas-
ings.
- Mark both differential half casings.
- Loosen the fastening screws and remove the differential
half casing.
Figure 61
Figure 63
274A062047 274A062049
- Using appropriate lifting means, extract the differential as- - Disassemble the planetary gear set into its various com-
sembly (1) from the corresponding casing. ponents.
- Remove the slip limiter plates and respective thrust rings.
- Loosen the fastening screws to remove the tapered ring
gear from the differential half casing loosening the fasten-
ing screws.
Pinion disassembly Figure 66

Proceed as follows:
Figure 64
314A063002R
- Remove the inner ring (1) from the pinion casing of the
314A063005R
bearing (B), and the bearing pre-load spacer S2 (2).
Figure 65
276C063084
- With a plug and a press, extract the pinion (1) from the
pinion casing.
Figure 67
314A063003R
- Using an appropriate extractor, remove the outer race

(1) from bearing (A) and the outer race (2) from the bear-
ing (B) of the pinion casing.
- Retrieve the pinion position adjustment spacer S1 (3).
Figure 68
274A062055
- Using an appropriate extractor (1), remove the inner race

(2) of the bearing (A).
Inspection of the disassembled parts

Bearings
- check the condition of the bearings: replace them if they
have bluish halos, cracks and/or signs of wear.
Crown wheels
- check the condition of the toothing: replace it if it has pits,
cracks and/or cavities.
Planet-gears
- check the condition of the toothing: replace it if it has pits,
cracks and/or cavities;
- check the coupling surfaces with the pins.
Damage to a single element entails the replacement

of the entire gear unit.
Cross pins
- check the coupling surfaces with the planet-gears.
Shoulder rings
- check the condition of the rings: replace them if they have
bluish halos, cracks and/or signs of wear.
Bevel gear
- check that the toothing of the crown wheel and the pinion
show uniform wear on the entire working zone of the
teeth: replace the bevel gear if it has pits, cracks and/or ca-
vities;
An anomalous wear may indicate an incorrect

adjustment of the bearings: check their integrity
before proceeding to the reassembly.
Damage to a single element entails the replacement
of the entire gear unit.
- check the bearing seats: they must not have deformations

or ovalling.
Bushes
- check the threading for the bearing locking bush: it must
not have dents, deformations and/or jams.
During reassembly consider the following general

observations:
 heat, to 100˚ C in the oven, the bearings and rings
to be mounted by pushing;
 carefully center and mount the sealing rings and
bearings with a suitable adjuster;
 lubricate the bushes, sealing rings and bearings.
Perform all the indicated measurements with

maximum precision.
Imprecise measurements lead to bad contact of the
bevel gear and thus make it necessary to repeat the
procedure.
Bearing and thread lock and sealant diagram - epicyclic reduction unit
Figure 69
341B121H006R
Complete differential assembly Ring gear and bearing assembly

Figure 70 Figure 71
274A062049 274A062060
- Fit the bushing (2) and the thrust ring (3). Proceed as follows:
- Fit the gear carrier. - Check that the contact area between gear wheel and dif-
ferential half casing is clean and free of grease.
- Repeat the assembly operation on the other half casing.
- Fit the ring gear on the half casing and tighten the fastening
- Assemble the shafts and planet gears and fit them on the
bolts (3) at the specified torque.
gear carrier.
- oin the two half casings and tighten the fastening screws
at the specified torque.
Figure 72
The two half casings area symmetric, except for the

ring gear assembly flange.
274A062062
- Heat the inner ring (1) of the taper needle bearing on the
rear side and fit it so that it touches the differential half cas-
ing.
- Heat the inner ring (2) of the taper needle bearing on ring
gear side (C) and fit it so that it touches the differential half
casing.
Finding the thickness of spacer S1 for pinion axial position Spacer S2 thickness, bearing pre-load and bearing assembly
determination
- Find thickness beff of the internal taper roller bearing (A). - Position the pinion casing in vertical position.
- Calculate the difference d in thickness between the actual - Arrange the chosen pinion position spacer S1 in the seat.
thickness and the theoretical thickness bteor = 38.0 mm
- Fit both outer races of inner bearings (A) and outer bear-
of the inner tapered roller bearing (A).
ings (B) in the seat.
d = breal btheor (mm)
- Provisionally fit both outer races of inner bearings (A) and
- Determine dimension a;
outer bearings (B) in the seat.
- Determine the thickness of the pinion position spacer S1
- Determine dimension d1.
as follows:
S1real = S1theor (d + a) (mm) - Determine dimension d2 on the pinion.
where: - Determine bearing pre-load spacer S2 thickness as fol-
S1theor = theoretical thickness of the pinion position spacer lows:
(S1) = 3 mm S2 = d1 d2 (mm)
d= previously calculated difference between real thick- where:
ness and theoretical thickness of the inner tapered d1 = distance between bearing inner race shoulder (A) and
roller bearing (A) outer bearing inner race edge (B)
a= dimension printed on pinion head
d2 = distance between inner bearing inner ring rest and
S1real = real thickness of the pinion position spacer S1 bearing S2 preload spacer rest
S2 = bearing pre-load spacer S2 thickness.
Example 1:
breal= 37.95 mm - Remove both outer races of inner bearings (A) and outer
difference d = 37.95 38.0 = 0.05 mm bearings (B).
a = +0.10
thickness S1 real= 3 ( 0.05 + 0.10) = 2.95 mm
Example 2:
breal= 38.05 mm
difference d = 38.05 38.0 = 0.05 mm
a = 0.10
thickness S1 real= 3 (0.05 0.10) = 3.05 mm
Figure 73
274A062057
Figure 74 Figure 76
1731281
- Using suitable tools, check that the rolling torque is within

the specified values.
Pinion bearing rolling torque
274A062058 0.8 - 1.0 Nm
- Otherwise, correct the rolling resistance by using a spacer
- Heat the inner ring of bearing (A) and fit it on the pinion. S2 of different thickness.
- Introduce the pinion in the casing. - Specifically:
- Fit the chosen bearing pre-load spacer S2 (2). - increase the thickness to reduce the torque
- reduce the thickness to increase the torque
- Heat the inner ring (3) of outer bearing (B) and fit it on
the pinion.
Take note of the real rolling torque value for the next
operations.
Figure 75
274A062059
- Fit the flange (1) on the pinion groove.

- Apply MOLYKOTE to the pinion thread and on the
thread and contact area of the lock ring nut.
- Fit the lock nut (2) and tighten to the specified torque.

backwards while hitting it with a plastic hammer to
Differential bearing pre-load determination Pinion-ring gear backlash check

Figure 77 Figure 79
17312101
17312104
- position the bearing outer races on both ends of the dif-
ferential;
- using suitable lifting equipment, assemble the ring gear in - assemble a dial gauge at a right angle to the outer diam-
the differential casing; eter of the crown wheel flank and sway the crown for-
- apply MOLYKOTE to the threading of the adjustment wards and backwards taking care not to move the pinion;
ring nuts; - Check that the backlash between crown and pinion is
- tighten both ring nuts by hand; within the specified values.
Figure 78 Pinion-ring gear backlash
see value engraved on ring gear
- if this is not the case, adjust by means of the adjustment
ring nuts;
- the backlash can be adjusted without altering the bearings
pre-load, by unscrewing one adjustment ring nut by a cer-
tain number of notches and then screwing the opposite
adjustment ring nut by the same number of notches.
Figure 80
17312102
- align the markings and fit the bearing support caps;

- fit the cap fastening screws and tighten them;
- using suitable tools, check that the rolling torque is within
the specified values.
The rolling torque should be measured at the crown

wheel output. When working from the pinion, the
transmission ratio has to be taken into account.
Bevel pair bearing rolling torque: 17312105
2,0 to 3,0 Nm
- Specifically:
- the rolling torque can be corrected by varying the two - loosen ring nut (D) and fasten ring nut (C) to reduce
adjustment ring nuts by the same number of notches; backlash (white arrow);
- Specifically: - loosen ring nut (C) and fasten ring nut (D) to increase
- loosen the ring nuts to decrease torque; backlash (black arrow).
- fasten the ring nuts to increase torque.
Checking the contact pattern area of the crown-pinion - cover about a dozen crown teeth with Prussian blue,
Proceed as follows: lubricated red lead or other paint or marking that can eas-
ily be removed;
- turn the ring gear by one complete turn;
Figure 82
- when the teeth mesh, the paint is sent out by the contact
of the teeth, leaving an exposed zone with the exact
dimension, shape and location of the contact area.
17312106
Figure 81
274A062063
Shape and position of contact area

1. Correct bevel pair position;
2. Pinion positioned too far back: reduce the distance
between pinion and ring gear axis by adopting a thinner
spacer S1; then adjust the clearance by moving the ring
gear from the pinion ring gear.
3. Pinion positioned too far forward: increase the distance
between pinion and ring gear axis by adopting a thicker
spacer S1; then adjust the clearance by moving the ring
gear towards the pinion ring gear.
Differential lock assembly

Proceed as follows:
- Fit the lock collar (1) and the fork (2).
- Apply plenty of grease onto the seats and fit the o-ring (3)
and the ring (4) on the piston (5).
- Fit the sleeve (6) onto the piston.
IMPORTANT: the threading is left-handed.
- Introduce the spring (7) to the piston.

- Using the specific tool, fasten the sleeve onto the fork (2)
at the specified torque.
Sleeve tightening torque: 150 Nm
- Apply plenty of grease onto the external cap (8) and then
insert the cap on the piston and fasten the screws at the
specified torque.
Screw tightening torque: 50 Nm
- Fit the electric contact, if removed.
- Check correct operation of the device.
Apply differential lock manually.

This will ensure that the procedure is carried out
properly.
Figure 83
307B121H053R
Completion Figure 86
Figure 84
274A062066
274A062064
- stake the nut as shown in the figure;
- when all adjustments and configurations are correct, fix

the lock plates (1) of both ring nuts with the help of
screws; If this is not possible, loosen the nut as much as
- remove the lock nut from the pinion and the correspon- needed for staking.
ding flange;
- support the complete outer casing with suitable lifting

equipment;
Figure 85
Figure 87
341B121H007R
- fit the complete external casing (1) onto the axle (2)
according to the reference marks made when
disassembling.
- fasten the mounting screws and lock to the specified
torque.
314A063010R Proceed as follows:

 refit the drive axles;
- insert the o-ring (1) in the differential casing respecting the  fill the wheel hubs;
assembly direction (detail) and fill it completely with bear-  fill the central differential.
ing lubricant grease; Proceed as shown in the corresponding Chapters.
- insert the flange (2) and tighten the lock nut (3) at the
specified torque;
SECOND
FRONT AXLE
SECTION 12.2
HD9 Euro5 SECTION 12.2 SECOND FRONT AXLE 1
SECTION 12.2
Second front axle

Page
DESCRIPTION 3
TOOLS 10
DIAGNOSTICS 16
SECOND AXLE OIL REPLACEMENT FRONT 18
GENERAL 18
- Axle 19
- Drainage 19
- Filling 19
- Final operation 19
- Hub 20
- Drainage 20
- Filling 20
SECOND FRONT AXLE REMOVAL-REFIT 21
GENERAL 21
- Removal 22
2 SECOND FRONT AXLE SECTION 12.2 HD9 Euro5
- Refitting 22
REPAIR OPERATIONS 24
- Overhauling axle, wheel hubs and epicycloidal
reduction units 24
TRANSFER-DIFFERENTIAL REPAIR 25
DISMANTLING 25
- Bevelled pinion and bearing dismantling 28
- Gearing box dismantling 29
- Transfer-differential dismantling 30
CHECKS ON DIFFERENTIAL-TRANSFER
COMPONENTS 33
ASSEMBLY 33
- Transfer-differential assembly 33
- Gearing box assembly 35
- Bevelled pinion bearing assembly 37
- Procedure for determining thickness of bevelled
pinion rolling play adjuster shim thickness 37
- Differential box assembly 39
- Gearing box bearing rolling torque adjustment 41
DESCRIPTION
The axle has dual reduction. The axle is fitted with distributor that distributes torque
between the axles.
The first by bevelled pair, the second by an epicyclical group
in the wheel hubs The transfer shafts transmitting drive to the epicyclical
reducers in the hubs are connected to the differential.
The differential box, with bevelled crown wheel, is supported
by two tapered roller bearings, adjustable by means of two The axle has one pneumatic system for locking the distributor
threaded ring nuts. and one for the transfer box.
The bevelled pinion is supported by two tapered roller
bearings, adjustable by means of adjuster shims.
Figure 1
41295
LONGITUDINAL SECTION OF DIFFERENTIAL DISTRIBUTOR

Figure 2
39387
LONGITUDINAL PICTORIAL SECTION OF WHEEL HUB AND EPICYCLIC REDUCTION GEAR

Figure 3

B Shim
1 Pinion rolling torque
a 6 - 8 Nm (pinion rolling torque)

Type of axle:
Dead axle with dual reduction and
pneumatic command differential 452146/2D (R 9174)
locking
Bevelled pinion bearings 2 with tapered bearings
Bevelled pair reduction 27/32 (1,185) - 28/37 (1,321) - 23/36 (1,565) - 21/34 (1,619) -
ratio 19/33 (1,737) - 21/40 (1,905) - 17/35 (2,059)
Epicyclical reducer ratio at wheels 3,2
Tapered pinion bearing rolling

with adjuster shims
torque adjustment
ASTRA Thickness of adjuster shims for

positioning pionion with respect to 0,2 - 0,3 - 0,5 - 1
crown mm
Play between pinion and crown

0,15 ÷ 0,35
wheel mm

using ring nuts
and crown
WHEEL HUBS

new bearings with surface protec-
tion Nm
6 ÷7 + (12 ÷16)
bearings run-in and new lubricated
o-rings Nm
6 ÷7 + (5 ÷7)
bearings and o-rings
run-in Nm
6 ÷7 + (2,5 ÷4,5)
Transfer shaft axial play mm 0,5 ÷ 1
Axle oil
(*)
Quantity Litres
13
kg
* See Section 2 TABLE OF LUBRICANT AND HYDRAULIC FLUIDS for the required type of fluid.
Oil for wheel hub bearings (*)

Quantity per hub Litres (kg) 27 (24.6)
Bevel drive pinion bearings (*)
Quantity per hub Litres (kg) 0.75 (0.68
WHEEL GEOMETRY
Wheel camber angle (vehicle with

–
static load)
Wheel caster angle (vehicle with

1 30’
static load)
B
Wheel toe-in
B = A - (0  3 mm)
(vehicle with static load)
A
KING PINS
King pin camber 5
Thickness of adjustment rings

between axle and stub axle 1,75 — 2,00 — 2,25 — 2,50 — 2,75 — 3,00 3,25 — 3,50
upper shim X1 mm
ASTRA
Figure 4
98974
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
1 Input shaft cap screw 33  3 3,3  0,3
2 Transfer cross ring nut 220  20 22  2
3 Oil pump plug 21,5  1,5 2,2  0,2
4 Output shaft flange nut 700  50 70  5
5 Output shaft cap screwH 33  3 3,3  0,3
6 Transmitter 35 3,5
7 Differential lock command cap screwH 19  2 1,9  0,2
8 Tapered crown wheel self-locking screw 170  10 17  1
9 Transfer half box screwH 110  10 11  1
10 Bevelled pinion support screw 170  10 17  1
11 Oil collector screw 91 0,9  0,1
12 Oil plug 80  8 8  0,8
13 Safety plate screw 51  4 5,1  0,4
14 Gearing box cap screwsH 180  10 18  1
15 Bevelled pinion shaft gear nut 690  60 69  6
16 Bearing retainer plate screw 120  10 12  10
17 Input shaft flange nut 700  50 70  5
18 Box fastening screw 170  10 17  1
19 Transmitter 35 3,5
20 Distributor lock command cap screwH 19  2 1,9  0,2
H Lock with LOCTITE AVX
○ Apply LOCTITE 573
Figure 5
98971
WHEEL HUB AND EPICYCLICAL REDUCER LONGITUDINAL SECTION
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
1 Wheel nut 615  35 61,5  3,5
2 Brake support screw 324  396 32,4  39,6
3 Steering lever pin fastening screw 207  253 20,7  25,3
4 Stub axle support screw 324  396 32,4  39,6
5 Notched nut for stub axle pin 250 ** 2,5 **
6 Screw 207  233 20,7  23,3
7 Support screw 22  28 2,2  2,8
8 Cover fastening screw z 44  54 4,4  5,4
* Apply LOCTITE 510
** Minimum torque — Maximum torque, tighten until first notch aligns with hole for split pin.
z Apply LOCTITE 573 to coupling surfaces
j Before mounting aply MOLYCOTE lubricant to the contact faces
Z Lock with LOCTITE AVX
TOOLS
99305121 Hot air device
99322205 Rotating stand for assembly overhaul
99322215 Stand for axles overhaul
99322225 Support for assemblies (to be fitted on stand 99322205)
99341003 Single-acting bridge
99341012 Pair of brackets

TOOLS
99341015 Press
99345053 Reaction block for extractors
99354207 Wrench (94.5 mm) for wheel hub bearings adjusting nut
99355025 Wrench for differential gear housing bearing adjustment ring nuts
99355086 Wrench for flow divider main shaft ring nut

TOOLS
99355131 Wrench (55 mm) for drive infeed flange nut
99363310 Tool for retaining spur gear on flow divider bevel pinion
99370005 Grip for interchangeable punches
99370006 Interchangeable grip for punches
99370007 Interchangeable grip for punches
99370121 Punch for fitting crown wheel bushings (use with 99370006)
TOOLS
99370133 Tool for locking differential caps spread
99370317 Reaction lever with extension for flange retaining
99370509 Hook to extract differential gear half-housing
99370617 Universal mounting to support axles during removal and refitting
99370630 Mounting for removal and refitting of flow divider
99371022 Pair of differential support brackets for use during overhaul (use
with 99322205-99322225)
TOOLS
99374013 Key to fit differential bevel pinion seal (use with 99370006)
99374093 Punch to fit external races of bearings (use with 99370007)
99374094 Punch to fit external races of bearings (134 - 215) (use with
99370007)
99374161 Key for assembly of wheel hub internal seals
99374233 Key to fit flow divider drive shaft seal
99374451 Tool for axle shaft disassembly-assembly

TOOLS
99389816 x 4 torque multiplier with 3/4 ” infeed and 1” square connection

(max. 2745 Nm)
99389819 Torque wrench from 0 to 10 Nm with 1/4” square connection
99389821 Torque wrench from 0 to 70 Nm with 3/8” square connection
99395026 Tool to check rolling torque of hubs (use with torque wrench)
99395027 Tool to determine thickness of differential bevel pinion adjustment

shims (use with 99395603)
99395603 Dial gauge (0 - 5 mm)

DIAGNOSTICS
Main axle faults:

2 - Noise
5 - Cornering noise
1 WHEEL HUBS NOISY
NO
YES
NO

YES
NO
are worn YES
2 NOISE
NO
damaged YES

YES
NO
bearings YES
3 NOISE AT RELEASE
NO

YES
NO
YES
5 CORNERING NOISE
wheels. YES
SECOND AXLE OIL REPLACEMENT

FRONT
Safety instructions

Vehicle preparation
and surrounding parts, could be very hot

Figure 6
2371801

short circuits;
Axle Filling
Drainage Proceed as follows:
Proceed as follows:
Figure 9
Figure 7
228NM230
335BNM001L
- arrange a container of appropriate capacity, clean the area - clean the level cap, check that the thread is in good
around the caps and then remove the level cap (1); condition, replace the sealing ring and replace the cap.
Final operations
Figure 8
Proceed as follows:
again.
228NM231

- clean both drain caps, check that the threading is in good
condition, replace the sealing ring with a new one and
close the drain cap;
Hub
The operations described are valid for both hubs.
Drainage
Proceed as follows:
Figure 10
178NM50
- bring screw (2) to lowest position;

- clean the cap area and open the cap (1):
- prepare an adequate container, clean the screw area (2);
then remove it completely discharging all the lubricant;
- tighten the screw.
Filling
Proceed as follows:
- adjust the cap (1) so that the reference marking is in
horizontal position;
condition, replace the sealing ring and close the cap;
Final operations
Proceed as follows:
again.
SECOND FRONT AXLE REMOVAL-REFIT

Safety instructions

specified torque.
2371801

short circuits;
See figure on next page Check support pads are intact, if necessary replace the dam-
aged component
Preliminary operations replace damaged component .
appropriately;
Final operations
Proceed as follows:
for Use of the USE AND MAINTENANCE MANUAL
UAL STEERING ANGLE ADJUSTMENT of Section 15
Proceed as follows:
(1) ABS transmitter from both sides (only 2 and 3
axle vehicles);
(7) differential lock (if present)
rod (12);
neath the axle;
Figure 12
REPAIR OPERATIONS
Overhauling axle, wheel hubs and epicycloidal reduction units
Proceed as described in Section 12.1 FIRST FRONT DRIVE AXLE for the repair operations on the axle, wheel hub units
and epicycloidal reduction units.
TRANSFER-DIFFERENTIAL REPAIR
DISMANTLING
Figure 13 Figure 16
43536
42533
Position the transfer-differential group (2) on support Unscrew the screws and remove the complete transfer com-
99322205 with brackets 99371022 (1). mand (1); unscrew the cover screws and remove the cover
(2).
Figure 14
Figure 17
42534
42537
Using a suitable punch (1) remove the steeling from the nut
(2). Unscrew the cover screws (2) and with ring bolts (I) remove
the cover (2).
Figure 15
Figure 18
42535
Apply torque bar 99379317 (2) with socket wrench

99355131 (I), unscrew the retaining screw and remove the
42538
transmission attachment flange (3).
Extract the sliding coupling (I), unscrew the screw and remove
the oil feeder (2).
Figure 19 Figure 22
42542
42539
With a suitable punch (I) remove the steeling from the nut (2). Using cables, lift and remove the transfer-differential group (I).
Figure 20 Figure 23
42540 42543
Apply tool 99363310 (4) to lock rotation of the gear (3); using Unscrew the screw fastening the bevelled pinion bearing (I)
socket wrench 99355131 (2) and torque multiplier 993898 I to the box (2) and with cables remove the complete bevelled
6 (I) unscrew the bevelled pinion lock nut. pinion.
Figure 21 Figure 24
42541
42544
Extract the driven gear (I) and the underlying shim.

Remove the adjuster shims (I).
Figure 25 Figure 28
71544
42548
Remove the guard plate(1). Remove the cap (3) complete
with washer (4), extract the spring (5) and the piston (6).
Remove the cam (2). Slightly loosen the adjuster ring nut (3). Heat at the points indi-
cated by the arrow with hot air blower 99305121 and un-
Figure 26 screw the screws (1) fastened with LOCTITE. After marking
them, remove the caps (2).
Figure 29
45546
Rotate the group by 180˚.

Unscrew the two screws and remove th cover (I), the piston 42549
(2), the fork (3) and the spring (4). Unscrew the screws and
remove the safety plates (5). With hook 99370509 (I) remove the gearing box (2) com-
plete with bearings (3) and ring nut (4).
Figure 27
42547
Using pliers remove the retainer circlip (2) in the direction

indicated by the arrow then extract the differential locking
fixed sleeve.
Bevelled pinion and bearing dismantling

Figure 30 Figure 33
42550
40077
The bevelled pinion (2) is removed from the bearing (I) under
With extractor 99348001 (1) extract the bearing (2) from the
a press.
pinion.
Figure 31
42551
Using a suitable driver, extract the outer races

(I - 2) of the bearings.
Figure 32
42552
Using a suitable driver (1) extract the roller bearings (2).

Gearing box dismantling

Figure 34 Figure 37
40089
40086 Remove the planet gear (1) complete with thrust washer (3)
from the gearing box (1).
With extractor 99348001 (1–2) and block 99345055 (3) ex-
tract the bevelled roller bearing from the gearing box. Repeat Figure 38
this operation on the opposite side.
Figure 35
40090
Using a suitable driver (1), extract first the long pin (2) then
the two short pins (3).
40087
Unscrew and remove the screws (I) fastening the bevelled The exact position of the pins is marked on the cross
crown (3) and cover (2) to the box (4). (2, Figure 39) by a long dash for the long pin and two
short dahses for the short pins.
Figure 36
Figure 39
40088
Mark the cover and the gearing box.

Remove the box cover (I) and disengage the crown (2) using
a suitable driver (3). 40091
Transfer-differential dismantling
Remove the cross (2), the satellites (3) complete with fifth Figure 43
wheels and the Planet gear (4).
Figure 40
42472
42553
I. Input shaft - 2. Driver gear - 3. Cross - 4. Ring nut -
5. Differential half-box - 6. O-ring
Mount the transfer differential group (1) in a vice. With an 8
mm Allen key (2) unscrew the screws (3).
Figure 44
Figure 41
42556
42554
Remove the drive gear (I).

Remove the half-box (1) complete with planet gear.
Figure 45
Figure 42
42555 42557
Using a suitable punch remove the steeling from the ring nut Extract the thrust washer (1). Remove the bush (2) [destruc-
(2). With wrench 99355086 (I) unscrew the ring nut (2) and tive operation]
remove the cross (3) complete with satellites and fifth wheels
Remove the half-box (4).
Figure 46
HD9 Euro5
SECTION 12.2
42449
I. Sliding coupling - 2. Fixed coupling - 3. Circlip - 4. Ring nut - 5. Bearing - 6. Cover 7. Crown - 8. Thrust washer - 9. Fifth wheel - 10. Satellite - 11. Cross - I 2. Short pin -
SECOND FRONT AXLE
I 3. Cap - I 4. Pin - I 5. Plug - I 6. Screw - I 7. Transfer shaft - I 8. Axle box - I 9. Shaft - 20. O-ring- 2 I. O-ring - 22. Nut - 23. Flange - 24. Screw - 25. Dust boot - 26. O-ring -
27. Cover - 28. Bearing - 29. Screw - 30. Plates - 31 . Ring nut - 32. Oil baffle - 33. Bearing - 34. Gearing box - 35. Planet gear - 36. Pinion - 37. Support -
31
38. Shim - 39. Screw - 40. Spring - 4I. Fork - 42. Piston - 43. Ring - 44. Cover - 45. Screw - 46. Switch - 47. Screw - 48 Long pin.
Figure 47 32
SECOND FRONT AXLE
SECTION 12.2
42448
PARTS COMPRISING THE TRANSFER-DIFFERENTIAL

1. Nut - 2. Flange - 3. Dust cover - 4. Screw - 5. O-ring - 6. Cover - 7. O-ring - 8. O-ring - 9. Box - 10. Plug - 11. Bearing - 12. Sliding coupling - 13. Shaft - 14. Washer - I 5. Bush -
16. Gear - I 7. Oil seal - I 8. Spring - I 9. Fork - 20. Piston - 21 . Cover - 22. Screw - 23. Switch - 24. O-ring - 25. Washer - 26. Screw - 27. Half-box - 28. Fifth wheel - 29. Satellite -
30. Cross - 31. Ring nut - 32. Bush - 33. Planet gear - 34. Washer - 35. Oil seal - 36. O-ring - 37. Snap ring - 38. Plug - 39. Box - 40. Bearing - 4I. Ring - 42. Washer -
43. Eccentric ring - 44. Screw - 45. Piston - 46. Spring - 47. Washer - 48. Cap - 49. Pin - 50. Box - 51. Crown - 52. Pinion - 53. Bearing 54. Shim - 55. Adjuster -
HD9 Euro5
56. Bearing - 57. Ring - 58. Oil feeder - 59. Screw - 60. Gear - 6I. Nut.
CHECKS ON DIFFERENTIAL-TRANSFER
COMPONENTS
Figure 48 Thoroughly clean the individual differential-transfer compo-
nents replacing any parts that are damaged and all seals.
Thoroughly clean all threads in order to obtain exact

adjustment and precise tightening torque.
If the crown or pinion have to be replaced, then both

must be replace since they are supplied as a coupled
pair.
Replace all damaged o-rings and bushes.
42558
ASSEMBLY
Working on the planet gear (I) in the direction indicated by
the arrow, remove the inner race (2) of the roller bearing and
remove the planet gear from the half-box (3). Transfer-differential assembly
Figure 49 Figure 50
42560
42559
Position the input shaft (3) in a vice, heat the bush (I) and fit
With a suitable driver remove the bush (2) from the planet it to the shaft. Fit the thrust washer (2).
gear (I).
Figure 51
42561
Fit the driven gear (I) onto the input shaft (2).
Figure 52 Figure 55
42562
42565
Position the driven gear (3) on the half-box (2) complete with
o-ring. Fit the cross (I) complete with satellites and fifth wheels. With a suitable punch (I) steel the ring nut (2) as shown in the
detail.
Figure 53
Figure 56
42563
Using torque wrench (I) and wrench 99355086 (2) tighten the 42566
ring nut (3) to the spcified torque.

Using driver 99370121 (1) with grip 99370006, fit the bush (2)
Figure 54 to the planet gear (3).
Figure 57
42564
After tightening the ring nut (I) check with a gauge (3) that
there is 0.1 mm play betwen the ring nut (I) and the cross (2), 42567
otherwise replace the parts concerned.

Fit the o-ring (I) to the half-box (2).
Gearing box assembly

Figure 58 Figure 61
40091
42568
Position the gearing box (1) on a suitable support, position the

I. Half-box - 2. Thrust washer - 3. O-ring - 4. Washer - planet (4) complete with thrust washer. Fit the 4 satellites (3)
5. Roller baring race - 6. Planet gear complete with fifth wheels and insert the cross (2).
Figure 59 Figure 62
42569
40092
Position the planet gear (1, Figure 59) on a support, fit the
thrust washer (2, Figure 58) the half-box (4, Figure 59), the Insert the long pin (1) and the two short pins.
washer (3), heat the roller bearing inner race (2) and fit it to
the planet gear. The long (through) pin must be fitted first. The exact
position of the pins is marked on the cross body by
Figure 60 a long dash for the long pin and two short dashes for
the short pins.
Figure 63
42570
Fit the previously assembled half-box assembly (2) on the half--

box (3) then, with a torque wrench (5) and socket (4) tighten 40093
the screws (1) to the specified torque. The screws must be
smeared with LOCTITE AVX. Fit the planet gear (1).
Figure 64 Figure 67
40097
40094 Insert the remaining screws (1). Lock gear rotation with the
press and torque wrench (2), tighten the screws (1) to speci-
Fit the thrust washer (1). fied torque.
Figure 65 Figure 68
40098
40095
With the hot air blower warm the cupport bearing (1) for 15’
Fit the gearing box cover (1). at temperature 100C and fit it to the box (2). Repeat this
operation on the opposite side.
Figure 66
40096
Warm the crown wheel (1) to  80 C with a hot air
blower, fit it in its seat in the box (2) and fasten it immediately
with two screws.
Procedure for determining thickness of

Bevelled pinion bearing assembly bevelled pinion rolling play adjuster shim
Figure 69 thickness
Figure 71
39572
42571 With a micrometer (2), measure the thickness of the adjuster

shim (1) found on dismantling and note the value (dimension
With driver 99374093 (2) and grip 99370007 (1), insert the A).
outer bearing race (3) into the support. Repeat the same
Figure 72
operation for the outer race (4) from the opposite side using
driver 99374094 (5).
Figure 70
42573
Tighten tool 99395027 in a vice and position on it:

- the pinion side bearing (6);
- the previously measured spacer (4) the shim (5) and the
42572
bearing.
Fit the ring nut (2) and fully tighten it.
On the bearing (3) position part (1) of tool 99395027 with
Using a suitable driver (1) fit the roller bearing (2). gauge and zero the gauge relative to the end of the tool. Re-
move from the tool:
- the part (1), the ring nut (2), the bearing (3), the adjuster
ring (4) and the shim (5).
Figure 73
42574
Position on the support (3) tool 99395027 complete with

bearing (6, Figure 72), arrange the bearing (2, Figure 73).
Hand-tighten the ring nut (1) and check rolling torque with
the torque wrench (4), which must be 6  8 Nm, if not, adjust
the ring nut (1).
Figure 74 Figure 75
42576
42575
Again position the part (1) with the previously zeroed gauge With the hot air blower heat the bearing (1) to~ 100C and
on the bearing (2) and measure any difference (dimension B). fit it to the bevelled pinion (2).
Remove the part from tool 99395027.
Figure 76
The thickness S of the shim is given by the following formula:
S = A - ( B) + C
where:
A = Thickness of shim fitted to zero gauge;
B = Measured difference;
C = 0.05 mm co-efficient that takes account of bearing
dilation due to assembly interference on bevelled pinion.
Example one:
A = 13.12 mm
B = +0,13 mm
C = 0.05 mm
42577
S = 13.12 - (+ 0.13) + 0.05 =
S = 13.12 -0,13 + 0.05 = 13,04 mm.
Fit the shim (2) and the adjuster ring (1) with the previously
Example two: measured thickness.
A = 13.12 mm
B = -0.13 mm Figure 77
C = 0.05 mm
S = 13.12 - (-0,13) + 0.05 =
S = 13.12 +0,13 + 0.05 = 13,30 mm.
42578
Position the support (1) on the bevelled pinion (2).

Figure 78 Figure 81
42579
42581
With the hot air blower heat the bearing (1) to~ 100C and
fit it to the bevelled pinion (2). Fit the caps (2), temporarily tighten the screws (1) and check
that the ring nut (3) tightens easily. Remove the screws one
Differential box assembly at a time, spread LOCTITE AVX on the threads and tighten
them with the torque wrench (4) to the specified torque.
Figure 79
Figure 82
42580
71740
Arrange the box (2) on the stand with brackets 99371022 (1).
Rotate the group, fit: the eccentric ring (1), the piston (2), the
spring (3), the cap (5) with new washer (4) and tighten to the
Figure 80
specified torque.
Figure 83
42549
42583
With hook 99370509 (I) lift the gearing box (2) complete with
bearings (3) and ring nut (4). Position it on the differential box.
Position the cover disk (1), apply a bead (⇒) of LOCTITE 573
Carefully arrange the ring nut on the differential box thread.
on the contact surface.
Figure 84 Figure 87
4
1
2 3
42587
42584
Fit the complete bevelled pinionb support (1), apply the bear-
Fit the bevelled pinion-crown positioning shim (1)on the box ing retaininer plate (2). Tighten the screws (4) to specified
(2). The thickness of the adjuster is determined by the refer- torque with the torque wrench (3).
ence mark (1, Figure 85) punched on the bevelled pinion.
Figure 88
Figure 85
16 + 0,20
42588
42585
Fit the gear (2) and tighten the retaining nut (1) to specified
torque.
Figure 86
42586
Apply a bead (⇒) of LOCTITE 573 to the adjuster shim.

Figure 89 Figure 91
42591
42589
Position tool 99370133 (1) on the caps (2) to prevent splaying Adjust the axial play between the teeth of the bevelled pinion--
during the adjustment. crown pair as follows:
- Poaition the magnetic base gauge (1) as shown in
Figure 91.
Gearing box bearing rolling torque adjustment - Lock pinion rotation and alternately rotate the crown and
with the gauge (1) check that the play between the two
sets of teeth, is as specified.
Figure 90 If not, adjust the ring nut (2) with the wrench (3).
To avoid altering the previously set rolling torque, when ad-
justing play between the pinion and crown teeth the ring nut
can be tightened, with wrench (3) to the same degree to
which the opposite adjuster nut was tightened.
When adjusted, check that the two adjuster nuts are posi-
tioned such as to allow the safety plate to be fitted.
Remove tool 99370133.
Figure 92
42590
Adjustment of gearing box bearing rolling torque is achieved

by measuring the total rolling torque.
Using torque wrench 99389819 (1) and the correct socket,
measure the specified rolling torque. If the indicated value
does not correspond, adjust the bearing adjuster ring nuts (3)
using wrench (4).
42592
With a brush apply a thin coat of lead oxide (primer) to the

crown wheel teeth.
Rotate the crown in both directions.
Figure 93 Figure 96
40160
42594
The imprint must be on both the drive face (1) and on the
thrust face (2), more or less at the centre of the tooth width. Remove the gear (3), apply tool 99363310 (4) locking gear
In loadless conditions, both facing engagement zones are rotation (2). With socket wrench 99355131 (2), torque mul-
slightly offset with respect to the crown external diameter. tiplier 99389816 (1) and the torque wrench (5), tighten the
gear nut to the specified torque.
Figure 94
Figure 97
42593
Fit the safety plate (1) and tighten the screws to the specified 42595
torque.
Fit the safety ring and fit the differential locking sleeve (2). With a suitable punch (1) steel the nut (2) as shown in the de-
tail.
Figure 95
Figure 98
42542
42596
Again remove the gear (2, Figure 88) then fit the differential--
transfer group (1). Fit the oil feeder (2), tightening the screws to the specified
torque. Fit the sliding sleeve (1).
Figure 99
To fit the internal o-ring (3) use fitting tool 9937013
(4) and handle 99370006.
Figure 102
42597
Fit the command (1) complete with differential locking fork.

Apply a bead (⇒) of LOCTITE 573 to the cover contact sur-
faces.
Figure 100
42600
Rotate the group.

Fit the flange (1) to the input shaft.
Tighten the nut and using the torque wrench (5), multiplier
(3), torque bar (4) and socket, tighten the nut to the specified
torque.
Figure 103
42598
Fit the cover (2) and tighten the screws to the specified
torque.
Heat the bearing inner race (1) and fit it to the input shaft.
Figure 101
42601
With a suitable punch (1) steel the nut (2) as shown in the de-
tail.
71547
Fit the cover (1) complete with internal (3) and external (2)
o-rings and tighten the screws (4) to the specified torque. Fit
the transfer lockng cover (5).

SINGLE REAR AXLE
SECTION 12.3
HD9 Euro5 SECTION 12.3 SINGLE REAR AXLE 1
SECTION 12.3
Single rear axle

Page
DESCRIPTION 3
TOOLS 9
DIAGNOSTIC 14
AXLE OIL REPLACEMENT REAR 16
GENERAL 16
- Drainage 17
- Filling 17
AXLE REMOVAL-REFIT REAR 18
GENERAL 18
- Drainage 19
- Removal 19
- Refitting 19
2 SINGLE REAR AXLE SECTION 12.3 HD9 Euro5
REAR AXLE ASSEMBLY OVERHAUL

OPERATIONS 21
REMOVING THE EPICYCLIC REDUCTION GEAR 21
- Wheel hub removal 24
WHEEL HUBS AND EPICYCLIC REDUCTION
GEAR COMPONENTS CHECK 25
WHEEL HUB MOUNTING 26
- Epicyclical reducer mounting 28
REMOVAL AND RE-FITTING IN PLACE
THE DIFFERENTIAL 31
- Removal 31
- Replacement 32
DIFFERENTIAL BOX DISMANTLING 33
REMOVING THE GEAR HOUSING 34
REMOVING THE BEVEL PINION SUPPORT 35
DIFFERENTIAL COMPONENTS CHECK 37
GEARING BOX MOUNTING 38
FITTING IN PLACE THE BEVEL PINION SUPPORT 39
- Procedure to determine the thickness of the
bevel pinion rolling torque adjusting ring 39
FITTING IN PLACE THE DIFFERENTIAL HOUSING 41
- Adjustment of bevelled pair — pinion axial play 43
DESCRIPTION
The rear axle is a double reduction type: the first reduction is The bevel pinion unit is adjusted through adjusting rings that
by means of the pinion - ring bevel gear unit and the second are fitted between the the two taper roller bearings.
is obtained through an epicyclic unit in the wheel hubs. The axle is equipped with a pneumatically controlled device
The differential housing, with the ring bevel gear , is supported to lock the differential.
by two taper roller bearings that can be adjusted through two The half shafts coming from the differential transmit the mo-
threaded ring nuts. tion to the epicyclic gears.
The pinion is supported by two taper roller bearings and a
third straight roller bearing.
Figure 1
39381
CROSS SECTION OF THE DIFFERENTIAL

1. Coupling flange - 2.Oil seal - 3. Outer seal ring - 4. Front bearing - 5. Adjusting ring - 6. Screw - 7. Bevel pinion support -
8. Intermediate bearing - 9. Adjusting ring - 10. Rear bearing - 11. Adjusting ring nut - 12. Differential housing bearing -
13. Short pin - 14. Spider - 15. Planetary gear - 16. Crown wheel - 17. Cover - 18. Gear housing - 19. Cover - 20. Screw -
21. Screw - 22. Long pin - 23. Safety plate - 24. Engaging sleeve - 25. Sliding sleeve - 26. Shoulder washer - 27. Split ring -
28. Engaging fork - 29. Transmitter - 30. Spring - 31. Plug - 32. Differential housing - 33. Taper pinion - 34. Oil baffle -
35. Lock nut
Figure 2
39382
CROSS SECTION OF EPICYCLIC REDUCTION GEAR AND WHEEL HUB

1. - Brake drum - 2. Oil manifold - 3. Seal ring - 4. Intermediate ring for sealing rings - 5. Bearing shaft - 6. Half shaft -
7. Seal ring - 8. Screw - 9. Bearing - 10. Phonic wheel - 11. Wheel hub - 12. Screw - 13. Seal ring - 14. Planetary gear support -
15. Crown wheel - 16. Cover - 17. Screw - 18. Crown wheel carrier - 19. Plug - 20. Collar nut - 21. Planetary gear -
22. Circlip - 23. Spacer screw - 24. Spacer ring - 25. Planetary gear needles - 26. Spacer rings - 27. Pin - 28. Planetary gear -
29. Gasket - 30. Spacer washer - 31. Bearing
Figure 3

B Shim
1 Pinion rolling torque without O-rings
a 4 - 6 Nm (pinion rolling torque + O-rings)
Type of axle:
Dead axle with dual reduction and ASTRA 451391/2D
pneumatic command differential (IVECO R 8284 D005)
locking
Bevelled pinion bearings 2 with tapered rollers and 1 with cylindrical rollers
27/32 (1.185) - 28/37 (1.321) - 19/33 (1.737) - 21/40 (1.905) -

Bevelled pair reduction ratio
17/35 (2.059)

with adjuster shims
torque adjustment
3.3 - 3.4 - 3.5 - 3.6 - 3.7 - 3.8 - 3.9 - 4.0 - 4.1 - 4.2 - 4.3 - 4.4 -
for bevelled pinion bearing
4.5 - 4.6 - 4.7
rolling torque mm
Play between pinion and crown

wheel mm 0.20 ÷ 0.33

using ring nuts
and crown
WHEEL HUBS
Wheel hub bearings two with tapered rollers

new bearings with surface
protection Nm 6  7 + (12  16)
O-rings Nm 6  7 + (5  7)
bearings and O-rings
Nm 6  7 Nm + (2.5  4.5 Nm)
Transfer shaft axial play mm 0.5  1
Axle oil (*)
Quantity Litres 16
kg 14.5
Figure 4
98975
TIGHTENING TORQUES
TORQUE
DESCRIPTION
Nm kgm
2 Bevelled pinion support screw at differential box 165  15 16.5  1.5
4 Differential box to axle box fastening screw D 160  10 16  1
5 Bevelled pinion support screw at differential box D 280  15 28  1.5
7 Safety plate to gearing box cover fastening screw 60  6 6  0.6
8 Switch 35 3.5
9 Command cylinder cheese-headed fastening screw 25  2 2.5  0.2
10 Oil filler cap 40  4 4  0.5
11 Self-locking screw 120  10 12  1
D Lock with LOCTITE AVX

 Spread with LOCTITE 573 sealant
Figure 5
98970
TIGHTENING TORQUES
TORQUE
DESCRIPTION
Nm kgm
1 Drum fastening flathead screw 25  3 2.5  0.3
2A Wheel nut 615  35 61.5  3.5
2B Wheel nut 415  35 41.5  3.5
3 Plant gear support cover screw h 50  5 5  0.5
4 Flathead screw 50  5 5  0.5
5 Carrier sleeve screw 295  30 29.5  3
d Spread LOCTITE 510 on attachment surface

h Apply LOCTITE 573 to threads
H Apply LOCTITE 573 to coupling surfaces
: Apply MOLYKOTE to the nut contact surfaces
TOOLS

99322225
Clamp
99341015
TOOLS
Link rod pair for grips

99341020
Grips
99341023
Extractor reaction block

99345055
Wrench for differential box bearing adjuster ring nut

99354001
Wrench (94.5 mm) for wheel hub bearing adjuster nut

99354207
Wrench (60 mm) for differential bevelled pinion nut

99355081 (use with 99370317)
TOOLS
Wheel brake shoe adjustment wrench

99356001

99370005

99370006

TOOLS
99370616 Differential removal-replacement support
Universal support for axles during removal and replacement

99370617
Bracket pair for supporting differential during overhaul (use with

99371022 99322205 and 99322225)
Tool for removing and refitting brake shoe retainer springs

99372211
Differential bevelled pinion seal fitting tool (use with 99370006)

99374013
Driver for inserting bearing outer races (99370007)

99374093
TOOLS
Driver for inserting bearing outer races (134-215) (use with

99374094 99370007)
99374451 Transfer shaft removal-replacement tool
Tool for checking hub rolling torque (use with torque wrench)
99395026
DIAGNOSTICS
Main axle faults:

2 - Noise
5 - Cornering noise
1 WHEEL HUBS NOISY
NO
YES
NO

YES
NO
are worn YES
2 NOISE
NO
damaged YES

YES
NO
bearings YES
3 NOISE AT RELEASE
NO

YES
NO
YES
5 CORNERING NOISE
wheels. YES
AXLE OIL REPLACEMENT REAR

GENERAL
Safety instructions hazardous and/or polluting substances
carry out maintenance jobs correctly. Specific safety instructions

Vehicle preparation

Figure 6
2371801

short circuits;
Drainage Filling
Figure 7 Figure 9
178NM51 228NMR09
- working on both hubs, bring one of the screws (1) to the - fill until oil spills out the of the cap (1);
lowest position;
- arrange a suitably sized container, clean the screw area and
remove both screws (1) and drain the lubricant com- Pour in the lubricant in several steps, so as to allow
pletely. time for the lubricant to reach the hub final
- tighten the screws. reductions. The operation terminates when the level
does not lower after at least five minutes.
Figure 8 - clean the level cap, check that the thread is in good condi-
tion, replace the sealing ring and replace the cap.
Final operations
Proceed as follows:
again.
228NMR09

cap.
AXLE REMOVAL-REFIT REAR

Very heavy parts
GENERAL
Vehicle preparation

Safety component.
specified torque.
2371801

short circuits;
Drainage Inspections and checks
Proceed as follows: Check support pads are intact, if necessary replace the dam-
aged component
See figure on next page Check that electrical components and connectors are intact: if
Refitting
Preliminary operations To refit, follow the removal instructions in reverse order.
Proceed as follows:
- park the vehicle on a flat surface and lock the front wheels Final operations
appropriately; To refit, follow the removal instructions in reverse order.
- raise the rear of the vehicle using a hydraulic jack and rest - refit both axle wheels operating as described in the Rules
it on the two support stands so that the wheels no longer for Use of the USE AND MAINTENANCE MANUAL.
touch the ground;
Rules for Use of the USE AND MAINTENANCE MAN-
UAL
Removal
Proceed as follows:
(2) differential lock warning light;
(5) brakes air delivery ;
(6) parking brake;
(7) differential lock;
- from both sides remove the nut(16) that fastens the shock
absorber to the axle;
neath the axle;
Figure 11
REAR AXLE ASSEMBLY OVERHAUL Figure 13

OPERATIONS
The removal and re-fitting into place operations for

the half-shafts, drums and brake shoes, air bleeder,
wheel hubs differential and epicyclic gears can all be
carried out with the units fitted on the vehicle.
Before setting the axle assembly on the stand to overhaul, un-

screw the axle casing lower plug todrain the oil.
Figure 12 Lock the sliding sleeve of the differential locking device with
a screw.
To do this, remove the threaded coupling from the control
39628 cylinder and in its place (1) fit a screw (M14 x 1.5).
At the same time, turn the axle mechanism so that the sliding
sleeve and enagagement sleeve are engaged. This will prevent
accidental movement of the sleeve while removing the half--
shaft.
Place a vessel under the wheel hub to collect the oil.
39627
Set the whole axle assembly on stand 99322215.
REMOVING THE EPICYCLIC REDUCTION

GEAR
Figure 14
40053
Remove the screws (2); remove the cover (3) and collect the
oil.
22
Figure 15
SINGLE REAR AXLE
SECTION 12.3
40430
WHEEL HUB COMPONENTS
1. Brake drum - 2. Adjusting screw and nut - 3. Cover - 4. Gasket - 5. Planetary gear pin and rollers - 6. Planetary gear carrier - 7. Adjusting nut - 8. Crown wheel carrier - 9. Planetary wheel- 10. Crown wheel - 11. Crown wheel gear -
12. Half-shaft - 13. Bleeder - 14. Bracket - 15. Shoulder pin - 16. Axle casing - 17. Bearing shaft - 18. Braking unit - 19. Phonic wheel - 20. Oil cup - 21. Supporting ring - 22. Seal ring - 23. Seal ring - 24. Bearing - 25. Wheel hub -
26. Bearing - 27. Bolt
HD9 Euro5
Figure 16 Figure 19
40338 39635
Using a socket wrench (2) unscrew the two drum retaining Use appropriate pliers to remove the circlip (2) withdraw the
screws (1); replace them with counteracting screws (5), planetary gear (3) from the half-shaft (1).
tighten to remove the drum (4) from the hub, then take it
away with a rope (3) and lifting equipment.
Figure 17 Figure 20
40054 39636
Remove the 3 retaining screws from the planetary gear sup- Screw tool 99374451 (1) into the shoulder pin seat and re-
port (3); insert the counteracting screws (1) and using a rope move the half shaft (2) from the bearing shaft.
(2) remove the support (3) Remove the spacer ring (3)
Figure 18
40055
Withdraw the crown wheel (1) from the crown wheel carrier.
Take out the shoulder pin (2)
Figure 21 Figure 24
39639
40056 Slip out the carrier sleeve (1), the crown holder (2) with bear-
ing and the complete wheel hub (3).
Expel the support pins (2) from the satellite support (1). Re-
move the satellites (3) from the support (1) and recover the Figure 25
rollers and shims.
Wheel hub removal
Figure 22
71535
Check that the surface of the shim (1) on which the hub O-ring
runs is not damaged or worn. If so replace the shim (1).
With the extractor consisting of: bridge 99341003 (8), grips
99341023 (3), tie rods 99341020 (6), clamp 99341015 (4)
and reaction block 99345053 (7), extract the race (1, if
39637 necessary, replace) and/or the inner race (2) of the tapered
roller bearing from the sleeve (5).
Using the appropriate punch straighten the steeling (1) on the
adjuster nut.
Figure 26
Figure 23
39641
Check the carrier sleeve (2) and if damaged, replace it. Release
39638
the brake shoes (3) with tool 99372217 and after unscrewing
Using socket wrench 99354207 (1) unscrew the adjuster nut. the hexagonal screws (1) fastened with “LOCTITE”, detach
the brake plate with the carrier sleeve.
Figure 27 Figure 29
39642 39644
With a suitable beater fitted in the holes on the crown wheel Check the oil manifold (1) and if it is damaged, replace it. To
carrier, remove the outer taper roller bearing (2) from the do this, extract it with a suitable beater inserted through the
crown wheel carrier (1). hub slots (3). Remove the shaped seal ring (2).
Figure 28
WHEEL HUBS AND EPICYCLIC REDUC-
TION GEAR COMPONENTS CHECK
Carefully clean the wheel hub components. Check
the half shafts to ensure they are not strained. If
necessary straighten the half shafts under a hydraulic
press. If the results obtained are not satisfactory, re-
place the half-shafts. Check the wheel bolts, if the
threads are strained or damaged, replace them
under the press. After fitting in place check that the
orthogonality error does not exceed 0.3 mm.
Lubricate the bearings and turn the roller cage freely;
the rotation must be even with no signs of stiffness.
Check the threads on the bearing adjustment nut
and the bearing shafts; if necessary replace the nuts.
Check the oil manifold, if it is damaged replace it.
39643 All seal elements must be replaced with new ones.
Use a bronze beater (1) to drive out the inner bearing outer Carefully clean all the epicyclic gear components.
ring (2). Visually check the teeth of the crown wheel carrier,
The seal ring will come away with it. the crown wheel, the planetary wheels and planetary
In the same way extract the outer bearing outer ring. If necess- gear.
ary remove the phonic wheel. Check the spacer rings, bearing needles and support
pins.
Replace any worn or damaged parts.
WHEEL HUB MOUNTING
Figure 30 Figure 32
39645 40410
After replacing the wheel studs (3), check, before fitting the Finish fitting manually using grip 99370007. Rotate and repeat
new ones, that the contact faces of the stud heads are free of the same operation for the inner and outer bearing race.
burring and residues.
Once fitted check that the studs are perfectly flush on the hub Figure 33
and that any orthogonality error does not exceed 0.3 mm.
If the oil collector (2) has to be replaced, before fitting a new

one spread the contact face with the collector hub and seat
on the hub with sealant: LOCTITE 573.
Refit the phonic wheel (1) checking, once fitted, that it rests
perfectly on the hub seat.
Check with the centesimal comparator that the orthogonality
of the phonic wheel is no greater than 0.2 mm.
71537
With the hydraulic press and fitting tool 99374161 (1) and
complete with O-ring (2) positioned as shown, fit the brown
inner ring (3) in the wheel hub (4).
Figure 31
Figure 34
39646
Using driver 99374093 (2) fit (under the press) the outer race 71538
of the outer bearing (3) stopping the operation at circa 5 mm Using a hydraulic press and key 99374161 (1), with the ring
from flush. Finish fitting manually using grip 99370007 (1). (2) positioned as shown in the drawing, fit the blue seal ring
(3) on the wheel hub (4).
Figure 35 Figure 38
39648
71540
Place the O-ring on the carrier sleeve, spread LOCTITE AVX
on the contact faces between axle box and carrier sleeve. Fit Lubricate the O-ring lip and the sleeve.
the carrier sleeve (3) complete with brake plate (4) and dust Fit the complete hub (1) on the carrier sleeve (2).
boot. Fasten the screws (2) previously spread with LOCTITE Lubricate the O-ring (3) and fit it to the wheel hub (2).
AVX and tighten with the torque wrench (1) to torque of 280
 15 Nm.
Figure 36 Figure 39
40375 40377
Spread SQ321M sealant on the seat () of the O-rings (2) With the blower heat the tapered roller bearing (1) to circa
on the carrier sleeve (3). With the blower, hear the ring (2) 100C and fit it, using a suitable driver, into its seat in the crown
and fit it to the carrier sleeve (3). Heat the inner race (1) of wheel holder (2).
the tapered roller bearing to 100C and fit it to the carrier
sleeve.
Figure 40
Figure 37
40067 39650
Refit the brake shoes (1) using tool 99372217. Fit the crown holder (3) with tapered roller bearing (2) to the
carrier sleeve (4).
Figure 41 Figure 44
40069
40070
Apply a thin layer of “Molycote” to the contact surfaces of the Fit the shim (2) in the carrier sleeve.
adjuster nut, tighten it with wrench 99354207 (1) until almost
locking the hub. Free the hub with a few taps of a hammer Epicyclical reducer mounting
given axially in both directions.
Figure 45
Figure 42
40071 39636
Position tool (1) 99395026 and, with a torque meter wrench With tool 99374451 (1) introduce the transfer shaft (2) into
(2) measure the rolling torque of the wheel hub. the carrier sleeve (3).
Fit the double splined short shaft in the differential lock

side carrier sleeve.
When measuring hub rolling torque hub rotation
must not exceed 40 revs per minute.
Figure 46
Figure 43
40072
39653
Obtain the specified rolling torque, and using an appropriate
punch, steel the adjuster nut (1) in the two grooves provided Position the sun gear (3) on the grooved part of the transfer
on the coupling sleeve (1). shaft and the snap ring (1) in its seat. Force the thrust pin (2)
into the transfer shaft seat.
Figure 47 Push the planetary gear support (2) onto the hub, for easier
tooth meshing, move the coupling flange alternately in the two
directions. Take care that the holes to fasten the planetary
gear support to the hub coincide.
Insert the three flathead screws(4) and tighten them with a
dynamometric wrench (3) to the prescribed torque.
Figure 50
39654
Position the crown wheel (1) with the chamfer directed out-
wards, then place it on the crown wheel carrier.
Figure 48
39656
Fit the brake drum (1) onto the planetary gear support. Fasten
the brake drum with the two flathead screws (2) tightening
them with dynamometric wrench (3) to the prescribed tor-
que.
Figure 51
26916
Grease the needles (1) arrange them with three spacer rings
(2) in the planetary gear (4) as shown in the figure.
Insert the planetary gear (4) and spacer washer (5) in the
planetary gear carrier support.
Insert the pin (3) from the cover side pushing it down to the
bottom of its seat.
Repeat the same operation for the other two planetary gears.
Figure 49
40073
Spread a thin coating of Hylomar SQ 321 M sealant on the

contact surfaces of the cover (3) and the planetary gear sup-
port (4).
Position the cover so that the pin chamfers coincide with the
notches in the cover.
Spread sealant paste on the threads of the screws (1) and with
dynamometric wrench (2) tighten to the prescribed torque.
39655
Spread a thin coating of Hylomar SQ 321 M or Reinzoplast

sealant on the contact surfaces of the planetary gear support
(2) and the wheel hub (1)
30
Figure 52
SINGLE REAR AXLE
SECTION 12.3
40431
DIFFERENTIAL UNIT COMPONENTS

1. Electric transmitter - 2. Seal and union ring - 3. Cover - 4. Seal ring - 5. Piston - 6. Fork - 7. Spring - 8. Bearing - 9. Cover - 10. Plate - 11. Screw - 12. Cover - 13. Washer - 15. Shoulder washer - 16. Half-box - 17. Bearing - 18. Ring - 19. Ring nut -
20. Oil baffle - 21. Crown wheel - 22. Seal ring - 23. Differential unit - 24. Flange - 25. Dust guard - 26. Seal ring - 27. 28. Bearing - 29. Pinion support - 30. 45. Bearing - 31. Adjusting ring - 32. Pinion - 33. Bearing - 34. Box - 35. Screw - 36. Crown
Wheel - 37. Pins and spider - 38. Screw - 39. Ring nut - 40. Sleeve - 41. Sliding sleeve - 42. Screw - 43. Screw - 44. Screw - 46. Rin - 47. Nut
HD9 Euro5
Figure 53 Figure 56
26924
The half shaft (1) end play is to be between 0.5 and 1 mm. To
obtain this, tighten the adjusting screw (2) to its stop, then
come back by half a turn and lock it with the hexagonal nut (3). 39659
Fit tool 9937445 (1) into the shoulder pin seat threads and
withdraw the half-shaft (2) from the bearing shaft
The flat surface of the hexagonal nut should be di-
rected towards the seal ring (4).
REMOVAL AND RE-FITTING IN PLACE THE Figure 57

DIFFERENTIAL
Removal
Figure 54
39660
Using the specific eye hooks and a rope, lift the pinion support
39658 (1) and remove the four differential housing screws (2).
Remove the screws (1) fastening the differential housing to the
axle casing. Remove the cap screws and hexagonal socket screws.
Figure 55
Figure 58
40053
Screw on the oil intake cap (1). Move one of the cover (3) hex 39661
screws (2) to a low position and unscrew it. Drain the oil from Using the specific eye hooks (1) and a rope, lift the differential
the epicyclic gears on the wheels. housing (2).
Replacement
Figure 59 Figure 62
39665
Spread LOCTITE 573 (1) on contact surfaces.

39662
Form a bead of LOCTITE 510 around oil passage ho-
Fit the sliding coupling (1) to the double toothed transfer shaft les.
(2).
Figure 60 Figure 63
39666
Arrange the bevelled pinion support (1) on the differential

box (2).
39663 Tighten the screws to the specified torque using the torque
Spread LOCTITE AVX (1) on contact surfaces. wrench (3).
When fitting the differential box it is important to make sure
that the differential lock engagement fork is correctly inserted The threads of the screws (3) inserted in the open
into the seat in the sliding coupling. holes must be apread with LOCTITE 573.
Figure 64
Figure 61
40073
Spread a thin layer of “Hylomar SQ 321 M” sealant paste on

the contact surfaces of the cover (3) and the planet gear sup-
39664
port (4). Arrange the cover such that the bevels of the pins co-
Position the O-ring and fit the differential box (1). Using the incide with the hollows cut into the cover.
torque wrench tighten the external screws (2) and internal Spread sealant paste on the threads of the screws (1) and
screws (3) to the specified torque. tighten them to the specified torque using the torque wrench
(2).
DIFFERENTIAL BOX DISMANTLING
Figure 65 Figure 68
39667 39670
Position he complete differential box, with the gearing box Lift the gearing box cover (1).
cover (1) facing upwards, on rotary stand 99322205 (2) com-
plete with support 99322228 and bracket pair 99371022 (3).
Figure 69
Figure 66
39671
Using hook 99370509 lift the gearing box (2) complete with
39668 tapered roller bearings and external bearing rings.
Unscrew the screws (1) and remove the safety plate (2).
Repeat this operation on the opposite side.
Figure 70
Figure 67
39672
39669
Turn the differential box by 90.
Heat at the points indicated by the arrow with hot air blower Remove the retainer nut steeling.
99305121 and unscrew the cover fastening screws (2) (fas- Apply to the transmission attachment flange reaction lever
tened with LOCTITE). 993701317 (2), loosen the retainer nut using socket wrench
99355081 (1).
Figure 71 Figure 74
39673 39676
Remove the screws and washers fastening the bevel pinion Withdraw the control piston (2) with the seal ring (3), engage-
support (1) to the differential housing (3). Insert the counter- ment fork (1) and compression spring (4).
acting screws (2) and take out the complete differential hous-
ing support.
REMOVING THE GEAR HOUSING
Figure 72
Figure 75
39674
39677
Use a beater to expel the bevel pinion straight roller bearing
(1) from its seat in the differential housing. Remove the split ring (1) and take away the differential locking
device engagement sleeve (3) from the gear housing cover (2).
Figure 73 Figure 76
39678
39675
Using puller 99347101 (1) equipped with a pair of gripping
Remove the two hexagonal socket head screws (1) and re- rings 99347182 (2), extension bar 99347361 (3) and counter
move the differential locking device control cylinder (2). block 99345055 (4), take out the taper roller bearing from the
gear housing.
Repeat the same operation on the other side.
Figure 77 Figure 80
39679 39682
Unscrew and remove the screws (1) that fasten the ring bevel Use a beater to remove the long pin (4) then the two short
gear (3) and cover (2) to the half-box (4). pins (3).
The exact position of the pins is marked on the spider

Figure 78 (2) by a long stripe for the long pin and two short
Remove the spider (2) and 4 planetary gears (1) with the
shoulder washers.
Remove the crown wheel and shoulder washer.
REMOVING THE BEVEL PINION SUPPORT
Figure 81
39680
Mark the cover and gear housing ( ).

Remove the gear housing cover (1) and release the ring bevel
gear (2)
Figure 79
39683
Remove the previously loosened lock nut and the coupling

flange (1).
If the flange removal is difficult, use a universal puller.
39681
Remove the crown wheel (2) with the relevant shoulder

washer (3) from the gear housing (1).
Figure 82 Figure 85
39684 39687
Take out the bevel pinion (1) with intermediate bearing and Withdraw the pinion location adjusting ring (2) from the bevel
adjusting ring from the support. It is suggested to use a press pinion (1)
for this operation, but if this is not possible, use a puller (2)
Figure 83 Figure 86
39685 39688
Remove the bearing adjusting nut (2) from the bevel pinion Remove the rear straight roller bearing inner ring (2) from the
(1). bevel pinion (1). This is a destructive operation.
Figure 84 Figure 87
39686 39689
With a universal puller 99348001 (1) remove the intermedi- Use a beater to take out the front and intermediate bearings
ate taper roller bearing (3) from the bevel pinion (2). outer rings (3 and 2) from the support (1).
DIFFERENTIAL COMPONENTS CHECK

Lubricate the bearings and rotate the roller cage freely. The
rotation must be even and without signs of stiffness.
Carefully clean all the threads in order to obtain exact

adjustments and accurate driving torques.
Check that the splined section for flange-pinion connection is

not badly worn, if it is, replace the pinion.
When replacing the crown wheel or pinion it is

necessary to replace both parts since they are sup-
plied in pairs.
GEARING BOX MOUNTING
Figure 88 Figure 91
39690
Fasten the gearing box (1) in the vice and position the planet
39693
gear (2) compete with thrust washer (3) in its seat.
Position the planet gear (2) with thrust washer (3) on the sat-
ellite gears.
Figure 89 Fit the cover (1) on the box aligning the marks made when dis-
mantling.
Figure 92
39691
Fit the 4 satellite gears (1) with thrust washers and correctly
insert the cross (2).
39694
Warm the crown wheel (1) with the hot air blower to circa
Figure 90 80 C, fit it in its seat in the box (1) and secure it with two
screws.
Figure 93
39692
Insert the long pin (1) and the two short pins.
The long (through) pin must be fitted first.

The exact position of the pins is marked on the cross 39695
body by a long dash for the long pin and two short Insert the remaining screws (2) and tighten with torque
dashes for the short pins. wrench (1) to specified torque.
Figure 94 Figure 97
39696
Heat the bearing (2) to a temperature of 100C for approx.

15 minutes then drive it in the gear housing cover using a suit- 39698
able beater (1). Repeat this operation on the other side. Fit tool 99395027 (6) in a vice and place on it:
- the pinion side bearing (5)
FITTING IN PLACE THE BEVEL PINION - adjusting ring (4), already measured, and bearing (3)
SUPPORT
Screw the ring nut (2) and lock it tightly.
Figure 95 Position the dial gauge fitted to element (1) of tool 99395027
(6) on the bearing (3) and set the gauge to zero on the end
of the tool (6).
Remove from the tool (6):
- element (1)
- ring nut (2)
- bearing (3)
- adjusting ring (4)
Figure 98
39697
Connect a new oil baffle to the pinion support (1).

Use beater 99374093 (2) to drive the intermediate bearing
outer ring and the front bearing outer ring right down into
their seats.
Procedure to determine the thickness of the

bevel pinion rolling torque adjusting ring
Figure 96
39699
Set the support (4, Figure 98) on the bearing (5, Figure 97);
set bearing (3) on the support.
Manually tighten the ring nut (2) and check the rolling torque
as indicated in Figure 99.
39572
Measure the thickness of the removed adjusting ring (1) and

make a note of the value (value A).
39701
39700
On the bevel pinion (1) fit in place the adjusting ring (2) to set
Set the complete support on 2 parallel bars and with a dyna- the pinion with reference to the crown wheel and the
mometric wrench (1) applied on tool 99395027 find the roll- chamfer directed downwards. The thickness of the adjusting
ing torque which should be 1.5 to 3.5 Nm. If this is not so oper- ring depends on the reference value (3) engraved on the bevel
ate on the ring nut (2, Figure 98). Place element (1, Figure 98) pinion.
with the dial gauage set to zero, on the bearing (3) and find
the deviation, if any (value B) Determination of bevel pinion positioning shim ring with
respect to ring gear according to the specific table (see TECH-
Adjusting ring thickness “S” is obtained through the following NICAL DATA).
formula:
S = A - ( B) + C
where: Figure 101
A = Thickness of adjusting ring fitted to set the dial gauage to

zero;
B = Deviation value found;
C = 0.05 mm coefficient that takes into account the bearings
dilation cause by assembling interference on the bevel pinion;
First example
A = 13.12 mm
B = + 0.13 mm
C = 0.05 mm
S = 13.12 - (+ 0.13) + 0.05 = 39702
S = 13.12 - 0.13 + 0.05 = 13.04 mm.
Heat the rear straight roller bearing (2) inner ring (1) to a tem-
Second example perature of 100C and fit in place on the bevel pinion.
A = 13.12 mm
B = - 0.13 mm
C = 0.05 mm
S = 13.12 - (- 0.13) + 0.05 =
S = 13.12 + 0.13 + 0.05 = 13.35 mm.
Remove the elements from tool 9939507.
FITTING IN PLACE THE DIFFERENTIAL

HOUSING
39706
39703
Use a beater to drive the rear straight roller bearing (1) into
its seat in the differential housing.
Heat the intermediate bearing (1) to approx. 100C and fit in
place on the bevel pinion (2).
Fit in place the adjusting ring (3) with the proper thickness. Figure 106
Figure 103
39707
Fit in place on the differential housing (3) the already as-

sembled bevel pinion support (2), insert 2 screws (4) with
39704
spring washers in diametrically opposite positions. With a dy-
namometric wrench (1) tighten them to the prescribed
Fit in place the support (1), already assembled, on the bevel torque.
pinion (2). Fit in place the front bearing. With a connection de-
vice (3) fit in place the oil seal ring (4) Figure 107
Figure 104
39708
Lock the coupling flange rotation with counter lever

99370317 (1) and using socket wrench 99355081, multiplier
39705
(3) and dynamometric wrench (4) tighten the lock nut to the
Fit in place the coupling flange (1) using a suitable beater, then prescribed torque
manually tighten the lock nut.
39671
39712
Using hook (1) 99370509 position the gearing box (2) com-
plete with roller bearings on the differential box. Using torque wrench 99389819 (1) and a suitable socket
wrench, check that the total rolling torque corresponds to the
specified value according to the bevelled pair ratio.
Figure 109
Figure 111
39709
Correctly fit the cover (3) aligning the marks made during dis- 2
mantling. Provisionally tighten the screws (2) and check that
the adjuster rings (4) fasten without difficulty.
Remove the screws again (2), spread LOCTITE AVX on the
threads and tighten them with the torque wrench (1) to the 39711
specified torque.
If a different value is found, using wrench 99354001 (1) adjust
the ring nuts (2) until obtaining the specified value.
Gearing box bearing rolling torque adjustment
Rolling torque is measured making certain that there is play

between the teeth of the bevelled pair. Total rolling torque
varies according to the ratio of the bevelled pair.
Adjustment of bevelled pair — pinion axial play Figure 114

Adjust the axial play between the teeth of the bevelled pair
as follows:
Figure 112
39704

crown wheel teeth.
Rotate the pinion and measure the contact imprint of the pin-
ion teeth on the crown wheel teeth.
The possible imprint types and methods for correcting any
error are shown in the following figures.
39710
- Position the magnetic base gauge (1) as shown; Figure 115

- Lock rotation of the bevelled pinion with reaction lever
99370317, invert rotation of the crown and measure play
between the teeth of the two gears with the gauge.
Otherwise, adjust the ring nut (2) with the wrench
(99354001) (1, Figure 113).
Figure 113
40160
thrust face (2), more or less at the centre of the tooth width.
In loadless conditions, both facing engagement zones are
slightly offset with respect to the crown external diameter.
Figure 116
39711

can be tightened, with wrench (99354001) to the same de-
gree to which the opposite adjuster nut was tightened.
40161A
If the imprint on the drive face (toward the outer diameter)

and on the thrust face (toward the inner diameter) is shift, this
means the pinion is too close to the crown.
Remedy: Increase the thickness of the adjuster shim between
the intermediate bearing and the bevelled pinion.
40161B
If the imprint on the drive face is shifted toward the internal 26609
diameter and the imprint on the thrust face is shifted toward Insert the compression spring (1) into the differential box. Fit
the outer diameter of the crown, it means that the pinion is the engage fork (2) such that the fork excursion stop (a) corre-
too far from the crown axis. sponds to the limit stop (b) on the differential box.
Remedy: Decrease the thickness of the adjuster shim between
Figure 121
Figure 118
39715
39713
Fit a new O-ring (1) on the command cylinder (2) and grease
Fit the engage coupling (1) to the splines of the gearing box it.
and position the snap ring (2) in its groove using a screwdriver. Insert the command piston (2) into the engage fork (3) in the
compression spring and then into the specific hole made in the
differential box.
Remove the bevelled pinion support again.
Figure 119 Fitting differential into axle box.
1 Fit the sliding coupling to the transfer shaft
2 Fit the gearing box making certain that the command fork
engages with the grooves in the sliding coupling.
3 Tighten the screw and at the same time push the transfer
shaft such that the sliding coupling engages with the engage
coupling on the differential.
4 Apply LOCTITE 573 to the thread and under the head
of the screws and fasten to specified torque using the torque
wrench.
5 Apply LOCTITE 573 to the contact surface and refit the
pinion support, tightening the screws to the specified torque.
39714
Fit in place the differential locking device assembly composed

of the control cylinder, piston (2), enagaging fork (1) and com-
pression spring (3).
INTERMEDIATE AXLE
IN TANDEM
SECTION 12.4
HD9 Euro5 SECTION 12.4 INTERMEDIATE AXLE IN TANDEM 1
SECTION 12.4
Intermediate axle in tandem

Page
DESCRIPTION 3
TOOLS 9
DIAGNOSTIC 16
AXLE OIL REPLACEMENT INTERMEDIATE TANDEM
AXLE 18
GENERAL 18
- Drainage 19
- Filling 19
AXLE REMOVAL-REFIT INTERMEDIATE TANDEM
AXLE 20
GENERAL 20
- Removal 22
- Refitting 23
2 INTERMEDIATE AXLE IN TANDEM SECTION 12.4 HD9 Euro5
SPLITTER REMOVAL-REFIT - Differential box mounting 50

(WITH AXLE ON VEHICLE) 24
GENERAL 24
- Adjustment of bevelled pair-pinion axial play 52
DRIVE OUTPUT SHIFT 56
- Dismantling 56
- Checks on parts 56
- Assembly 56
- Removal 25
- Refitting 26
INTERMEDIATE AXLE ASSEMBLY REPAIR
OPERATIONS 28
- Removal 28
- Removing the epicyclic reduction unit 28
- Removing the wheel hubs 29
- Checks on the wheel hubs and epicyclic reduction
gear components 31
- Wheel hub mounting 32
REMOVAL-REFITTING IN PLACE OF THE
DIFFERENTIAL-REDUCTION GEAR UNIT
- Removal 36
- Re-fitting in place 36
DIFFERENTIAL-REDUCTION GEAR UNIT OVERHAUL 37
- Removal 37
- Gearing box dismantling 41
- Removing the differential-reduction gear unit 44
- Checks on differential-reduction gear unit
components 45
- Refitting the differential-reduction gear unit 45
- Fitting in place the gear housing 47
- Fitting in place the bevel pinion housing 48
- Procedure to determine the adjusting ring thickness
for the bevel pinion rolling torque 48
DESCRIPTION
The intermediate axle is a double reduction type. The first A reduction gear unit on the intermediate axle transmits the
reduction is obtained through the pinion -ring bevel gear, the driving torque between the two axles.
second through an epicyclic unit in the wheel hubs. The axle has a pneumatic device to lock the differential and
another to lock the reduction gear unit.
Figure 1
39385A
LONGITUDINAL PICTORIAL SECTION OF DIFFERENTIAL REDUCTION GEAR UNIT

Figure 2
40379
CROSS SECTION OF EPICYCLIC REDUCTION GEAR AND WHEEL HUB (45139)

1. Brake drum - 2. Oil manifold - 3. Seal rings - 4. Intermediate ring for sealing gasket - 5. Bearing shaft - 6. Half-shaft -
7. Seal ring - 8. Screw - 9. Bearing - 11. Wheel hub - 12. Screw - 13. Seal ring - 14. Planetary gear carrier - 15. Crown wheel -
16. Cover - 17. Screw - 18. Crown wheel carrier - 19. Plug - 20. Collar nut - 21. Planetary gear - 22. Circlip - 23. Spacer screw -
24. Spacer ring - 25. Needles for planetary gear - 26. Spacer rings - 27. Support pin - 28. Planetary gear - 29. Gasket -
30. Spacer - 31. Bearing

Figure 3

B Shim

Type of axle:
Dead axle with dual reduction and ASTRA 453291/2D
pneumatic command differential lock- (IVECO R 9189 D001)
ing and distributor group
Bevelled pinion bearings 2 with tapered rollers and 1 with cylindrical rollers
Bevelled pair reduction 27/32 (1,185) - 28/37 (1,321) - 23/36 (1,565) -

ratio 19/33 (1,737) - 21/40 (1,905) - 17/35 (2,059)
Epicyclical reducer ratio

3,2
at wheels
Bevelled pinion rolling
with adjuster shims
torque adjustment

for bevelled pinion bearing 3,3-3.4-3,5-3,6-3,7-3,8-3,9-4,0-4,1-4,2-4,3-4,4-4,5-4,6-4,7
rolling torque mm
Play between pinion and crown wheel

0,20  0,33
mm

using ring nuts
and crown
Total bearing rolling torque S using ring nuts
WHEEL HUBS

new bearings with surface 6  7 + (12  16)
protection Nm
bearings run-in and o-rings 6  7 + (5  7)
new and lubricated Nm
bearings and o-rings 6  7 + (2,5  4,5)
run-in Nm
Transfer shaft axial play mm 0,5  1
Axle oil (*)
Quantity Litres 27
kg 24,3
Figure 4
107118
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
1 Hex head cover screw 62  6 6,2  0,6
2 Ring nut 230  20 23  2
3 Hex head screw 67  8 6,7  ,0,8
4 Self-locking screw 260  25 26  2,5
5 M12 x 1.5 threaded cap 21,5  1,5 2,1  0,1
6 Hex head cover screw 33  3 3,3  0,3
7 Self-locking screw { Stage 1

Stage 2:
100
300  10
10
30  1
8 Safety plate self-locking screw 51  5 5,1  0,5
11 Oil feed self-locking screw 16  2 1,6  0,2
12 Threaded cap 110  10 11  1
13 Transmitter 61  6 6,1  0,6
14 Cheese-headed screw 25  2 2,5  0,2
15 Self-locking nut 825  25 82,5  2,5
(1250  50) (125  5)
16 Cover fastening screw 182,5  17,5 18,2  1,7
17 Nut for oil feed fastening screw 16  2 1,6  0,2
18 Self-locking nut 700  50 70  5
19* M16 gearing box cap screws 270  25 27  2,5
20 Self-locking nut 825  25 82,5  2,5
z Apply LOCTITE 573to coupling surfaces
* Apply LOCTITE AVX to threads
( ) The values in brackets refer to the current production reinforced differential (H) with ring nut tightening torque
(15) increased.
Print 603.93.373
Figure 5
98970
SECTION ON EPICYCLICAL REDUCER AND WHEEL HUB
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
1 Drum fastening flathead screw 25  3 2,5  0,3
2A Wheel nut 615  35 61,5  3,5
2B Wheel nut 415  35 41,5  3,5
3 Satellite gear support cover screwV 50  5 5  0,5
4 Screw 50  5 5  0,5
5 Carrier sleeve screw 295  30 29,5  0,3
V Apply LOCTITE 573 to threads
* Before mounting spread MOLYCOT on the nut contact face
TOOLS
TOOL N˚ DESCRIPTION

(load capacity 1000 N, torque 120 daN/m)
99322215 Stand for axle overhaul

99322225
Clamp
99341015
TOOLS
Bracket pair with hole

99341017
99341020 Link rod pair for grips
99341023 Grips

TOOLS
99355081 Wrench (60 mm) for drive input flange retainer nut and cylindrical
gear retainer nut on transfer
99355121 Wrench for transfer primary shaft ring nut
99363310 Transfer bevelled pinion cylindrical gear retaining tool
Grip for interchangeable drivers

99370006
TOOLS
99370122 Driver for fitting transfer primary shaft planet gear bush
99370133 Differential caps divergence locking tool
Universal support for axles during removal and

99370617 replacement
TOOLS
99370630 Support for removal and refitting transfer between axles
99374013 Tool for fitting transfer drive output shaft seal (use with 99370006)

99374094 (use with 99370007)
99374233 Tool for fitting transfer drive output shaft seal
99374235 Tool for fitting planet gear shaft front seal

TOOLS
99374372 Tool for fitting planet gear primary shaft rear seal
(use with 99370006)
99389816 Torque multiplier (x4) with ¾” input and 1” output attachment

(max 2745 Nm)
99389819 Torque wrench (0-10 Nm) with ¼” square fitting
99395026 Tool for checking hub rolling torque

(use with torque wrench)

TOOLS
99395027 Tool for determining differential bevelled pinion adjuster shim

thickness (use with 99395603)
99395603 Comparator (0-5 mm)

DIAGNOSTICS
Main axle functional problems:

1 — Wheel hub noise;
2 — Axle noise;
3 — Noise on engagement;
4 — Noise on acceleration;
5 — Noise when turning.
1 WHEEL HUB NOISE
Insufficient oil Check for leaks from seals or axle box and restore level.
YES
NO
Wheel hub bearings inefficient. Proceed to dismantle hub and make necessary
YES replacements.
NO
Wheel hub bearings out of true. Make adjustments to bearings.

YES
NO
Wear to splines on transfer shafts coupling to sun gears Overhaul and replace worn or damaged parts.
in epicyclical gearing. YES
2 NOISE
Oil level insufficient Check for leaks from seals or axle box and restore level.
YES
NO
Damage to splines coupling transfer shafts to planet Overhaul the axle and replace worn or damaged parts.
gears in differential. YES
Wheel hub bearings out of true. Make adjustments to bearing play.

YES
NO
Imprecise adjustment or deterioration of differential Locate the problem and overhaul the assembly.
group gears or bearings. YES
3 NOISE ON ENGAGEMENT
Imprecise coupling play between bevelled crown and Remove gearing inspection cover and make
pinion YES adjustments for pinion and crown play.
4 NOISE ON ACCELERATION
Insufficient oil Check for leaks from seals or box and restore level.
YES
NO
Gearing box bearings maladjusted or worn. Overhaul the group.

YES
NO
Imprecise contact between crown and pinion teeth. Adjust teeth contact.
YES
5 NOISE WHEN TURNING
Imprecise planet gear set play Overhaul or replace the group.

YES
AXLE OIL REPLACEMENT

INTERMEDIATE TANDEM AXLE
GENERAL


Figure 6
2371801

short circuits;
Drainage Figure 9
Proceed as follows:
Figure 7
1
228NM233

178NM51
- clean both drain caps, check that the threading is in good
condition, replace sealing ring with a new one and close
- operating on both hubs, bring a screw (ref. 1) to lowest the drain cap;
position;
Filling
Proceed as follows:
remove both screws (1) and drain the lubricant
completely.
- tighten the screws. Figure 10
Figure 8
228NM232
Pour in the lubricant in several steps, so as to allow

228NM232 time for the lubricant to reach the hub final
reductions. The operation terminates when the level
- arrange a container of appropriate capacity, clean the area does not lower after at least five minutes.
- remove drain cap (2) and fully drain the oil; - clean the level cap, check that the thread is in good
condition, replace the sealing ring and replace the cap.
Final operations
Proceed as follows:
again.
AXLE REMOVAL-REFIT
INTERMEDIATE TANDEM AXLE
Safety instructions

2371801

short circuits;
Proceed as follows:
- park the vehicle on a flat surface and lock the front wheels
appropriately;
- raise the rear of the vehicle using a hydraulic jack and rest
touch the ground;
MANUAL
Removal
Figure 12
220097

- disconnect the following electric connectors:
(1) differential lock engagement warning light;
(2) differential lock between axles engagement warning
light;
- disconnect the following pneumatic lines:
(3) brakes air delivery on both sides;
(4) parking brake on right side only;
(6) differential lock between axles;
- unscrew the fastening screws of input (7) and output
propeller shaft flanges and momentarily fasten both shafts
to the chassis to avoid interference during the next
operations;
Figure 13
220100
- place a hydraulic jack fitted with tool 99370617 under the

axle;
- to facilitate the operation loosen the screws (1) that fasten
the bracket (2) on both sides, then lower the axle,
releasing both leaf springs;

damaged component
220098
- remove bolts (1) fastening upper reaction rod to axle; replace damaged component .
Figure 14
Refitting
Final operations
220099
- remove bolts (1) fastening lower reaction rod to axle;
SPLITTER REMOVAL-REFIT
(WITH AXLE ON VEHICLE)
Safety instructions

2371801

short circuits;
Figure 18
Proceed as follows:
appropriately;
touch the ground;
Rules for Use of the USE AND SERVICE HANDBOOK;
- remove the input propeller shaft operating as described in
REMOVAL-REFIT PROPELLER SHAFT Chapter in Sec-
tion 10;
- completely drain off the oil from the axle and hubs, operat-
40157
ing as described in OIL REPLACEMENT chapter of this
Section;
- in the two threaded holes (1) and (2) tighten appropriate
- remove both axle shafts as described in AXLE REPAIR screws to act as extractor for the differential.splitter.
chapter of this Section.
Removal
Proceed as follows:
Figure 17 Figure 19
342B123001R 40158
- disconnect the following electrical connectors: - using a hydraulic lift (1) arrange bracket 99370630 (2)
(2) differential lock warning light; with tilting unit 99370329 (4) under the differential
(3) differential lock between axles warning light; —splitter (3)
- disconnect the following pneumatic connections: - unscrew the fastening screws, tighten the two reaction
(7) differential lock; screws to remove the unit from the box.
(8) differential lock between axles;

Overhaul the group, operating as described in DIFFERENTIAL
OVERHAUL chapter in this Section.
Refitting
- carefully clean and spread sealant (LOCTITE 573) on the
resting surface of the differential box and axle shaft covers
- Always replace all seals.
- check that the differential lock control fork is engaged on
the sleeve
Final operations
Proceed as follows:
- refit both axle shafts as described in AXLE REPAIR chapter
of this Section.
- fill with oil operating as described in OIL REPLACEMENT
chapter of this Section.
- refit the input propeller shaft operating as described in
REMOVAL-REFIT PROPELLER SHAFT Chapter in
Section 10
Figure 17
40409

1. Brake drum — 2. Adjusting nut and screw — 3. Cover — 4. Gasket — 5. Planetary gear pin and rollers — 6. Planetary gear carrier
— 7. Adjusting nut — 8. Crown wheel carrier — 9. Shoulder pin — 10. Planetary gear — 11. Crown wheel — 12. Crown wheel gear
— 13. Half-shaft — 14. Bearing — 15. Wheel hub — 16. Bolt — 17. Bearing — 18. Seal ring — 19. Support ring — 20. Oil cup —
22. Brake assembly — 23. Bearing shaft — 24. Axle casing — 25. Differential-reduction gear unit assembly — 26. Bleeder
INTERMEDIATE AXLE ASSEMBLY REPAIR Removing the epicyclic reduction unit

OPERATIONS Figure 20
Removal
The removal/re-fitting in place operations on the

half-shafts - brake drums and shoes - air bleeder -
differential reduction gear unit - wheel hubs and
epicyclic reduction gears can all be carried out with the
unit fitted on the vehicle.
Before setting the axle assembly on the stand to overhaul,

unscrew the bottom plug on the axle casing and drain the oil.
Figure 18
40053
Place a container under the wheel hub. Remove the screws

(2): remove the cover (3) and collect the oil.
Figure 21
40052
Set up the axle assembly on stand 99322215.
Figure 19
40338
Using a socket wrench (2) remove the 2 drum stop screws (1);
fit the counteracting screws (5) in their place, tighten them,
releasing the drum (4) from the hub, then with a rope (3) and
lifting device, remove it.
Figure 22
40337
Lock the sliding sleeve of the differential locking device with
a screw.
cylinder (2) and in its place (1) fit a screw (M14x1.5).
At the same time, turn the axle mechanism to obtain the
engagement between the sliding sleeve and the engaging 40054
sleeve; this will prevent accidental movement of the sleeve Remove the 3 planetary gear carrier stop screws (3); tighten
while removing the half-shaft. the counteracting screws (1) and use a rope (2) to remove the
carrier (3).
Figure 23 Figure 26
40056
40055
Extract the support pins (2) from the planetary carrier (1).
Remove the planetary gears (3) from the support (1) and
Draw out the crown wheel (1) from the crown carrier. recover the needles and spacer rings.
Remove the shoulder pin (2)
Removing the wheel hubs
Figure 24
Figure 27
39635
39637
Using suitable pliers remove the circlip (2), withdraw the
Using a suitable punch straighten the dents (1) on the adjusting
planetary gear (3) from the half-shaft (1).
nuts.
Figure 25 Figure 28
39636 39638
Screw tool 99374451 (1) into the shoulder pin seat and Using socket wrench 99354207 (1) unscrew the adjusting nut.
withdraw the half-shaft (2) from the bearing shaft.
Remove the spacer ring (3)
Figure 29 Figure 31
40060
39639
Check the carrier sleeve (2) and if damaged, replace it.
Slip out the carrier sleeve (1), the crown holder (2) complete Release the brake shoes (3) and after unscrewing the
with bearing and wheel hub (3). hexagonal screws (1) fastened with “LOCTITE”, detach the
brake plate with the carrier sleeve.
Figure 30
71535
Check that the surface of the shim (1) on which the hub o-ring
runs is not damaged or worn.
If so, replace the shim (1).
With the extractor consisting of: bridge 99341003 (8), grips
99341023 (3), tie rods 99341003 (6), clamp 99341015 (4)
and reaction block 99345053 (7), extract the race (1, if
requiring replacement) and/or the inner race (2) of the
tapered roller bearing from the sleeve (5).
Figure 32 Figure 34
40061 40063
Using the appropriate beater fitted through the 3 holes on the Check the oil manifold (1) and if it is damaged, replace it. Use
crown carrier, eject the outer taper roller bearing (2) from the a beater inserted through the hub slots (2) to eject it.
crown wheel carrier (1).
Figure 33
Checks on the wheel hubs and epicyclic reduc-
tion gear components

the half-shafts to ensure they are not strained. If
necessary straighten the half-shafts on a hydraulic
press; if this operation does not give satisfactory
results, replace them. Check the wheel fastening
bolts; if they are strained or the threads are
damaged, replace them. After fitting in place
check under the press that the orthogonality error
does not exceed 0.3 mm.
Lubricate the bearings and rotate the roller cage
freely, the rotation must be even with no stiffness.
40062
Using the appropriate tools, eject the outer and inner seal rings
from the wheel hub. Use a bronze beater to release the cups
(2 and 1) for the inner and outer bearings from the wheel hub. Check the hub bearing adjustment nuts and the threads on the
bearing shafts; if necessary replace the nuts. Check the oil
manifold, if it is damaged, replace it.
All sealing elements must be replaced with new ones.
Carefully clean all the epicyclic reduction gear components.
Make a visual check on the crown wheel teeth, the crown, the
planetary wheels and planetary gears.
Check the spacer rings, shims, bearing rollers and support pins.
If any of these components are damaged or worn, replace
them.
Wheel hub mounting Figure 37
Figure 35
40410
Finish fitting manually using grip 99370007. Rotate and repeat

39645 the same operation for the inner and outer bearing race.
After replacing the wheel studs (3), check, before fitting the
new ones, that the contact faces of the stud heads are free of
burring and residues. Figure 38
Once fitted check that the studs are perfectly flush on the hub
on the hub with LOCTITE 573 sealant.
Figure 36
71537
With the hydraulic press and fitting tool 99374161 (1)

complete with o-ring (2) positioned as shown, fit the brown
inner seal (3) in the wheel hub (4).
Figure 39
40064
With driver 99374094 (2), under the press fit the outer race
of the outer bearing (3) stopping the operation at circa 5 mm
from flush.
71538
With the hydraulic press and fitting tool 99374161 (1)

complete with o-ring (2) positioned as shown, fit the blue
outer seal (3) in the wheel hub (4).
Figure 40 Figure 43
39648
Place the o-ring on the carrier sleeve, spread LOCTITE AVX

71540
on the contact faces between axle box and carrier sleeve. Fit
the carrier sleeve (3) complete with brake plate (4) and dust Lubricate the o-ring lip and the sleeve.
boot. Fasten the screws (2) previously spread with LOCTITE Fit the complete hub (1) on the carrier sleeve (2).
AVX and tighten with the torque wrench (1) to torque of 280 Lubricate the O-ring (3) and fit it to the wheel hub (2).
 15 Nm.
Figure 44
Figure 41
40375
40377
Spread Hylomar SQ321M sealant on the seat ()of the
o-rings (2) on the carrier sleeve (3). With the blower, hear the
ring (2) and fit it to the carrier sleeve (3). Heat the inner race With the blower heat the tapered roller bearing (1) to circa
(1) of the tapered roller bearing to 100C and fit it to the 100C and fit it, using a suitable driver, into its seat in the crown
carrier sleeve. wheel holder (2).
Figure 42 Figure 45
40067 39650
carrier sleeve (4).
Figure 46 Figure 49
40069
40070
Figure 50
Figure 47
39636
40071 With tool 99374451 (1) introduce the transfer shaft (2) into
Position tool (1) 99395026 and, with a torque meter wrench the carrier sleeve (3).
(2) measure the rolling torque of the wheel hub.
Fit the double toothed short shaft in the differential
lock side carrier sleeve.
Figure 51
Figure 48
40072
39653
Figure 52 Push the planetary gear support (2) onto the hub; to mesh the
teeth more easily, move the coupling flange alternately in
both directions. Take care that the holes to fasten the
planetary supports to the hub coincide.
Insert the three flathead screws (4) and tighten with a
dynamometric wrench (3) to the specified torque.
Figure 55
39654
Position the crown wheel (1) with the chamfer outwards then
set it on the crown wheel carrier.
Figure 53
39656
Fit in place the brake drum (1) on the planetary gear support.
Clamp down the brake drum with the two flathead screws (2)
and use a dynamometric wrench (3) to the specified torque.
26916
Figure 56
Grease the needles (1) set them with three spacer rings (2)
in the planetary gear (4) as shown in the figure.
Insert the planetary wheel (4) and the spacer washer (5) in the
planetary carrier support.
Insert the support pin (3) from the cover side, pushing it fully
into its seat.
Repeat the same operation for the other two planetary gear
units.
Figure 54
40073
Spread a thin coating of Hylomar SQ 321 M sealant paste on

the contact surfaces of the cover (3) and the planetary gear
support (4).
Position the cover so that the support pin chamfers coincide
with the cover grooves.
Apply sealant paste to the screw (1) threads and tighten the
screws with a dynamometric wrench (2) to the specified
torque.
39655
Spread a thin coating of Hylomar SQ 321 M or Reinzoplast

sealant paste on the planetary gear support (2) and wheel hub
(1) contact surfaces.
Figure 57 Figure 59
26924 40378
The half-shaft (1) end play should be within the range of 0.5 Remove the shoulder pin and fit tool 99374451 (2) in its place,
- 1 mm. partially withdraw the half-shaft (1). Repeat the operation on
To adjust, tighten the adjusting screw (2) to the stop then the other side.
return half a turn and lock it with the hexagonal nut (3)
Figure 60
The flat surface of the hexagonal nut must be directed

toward the seal ring (4).
REMOVAL-RE-FITTING IN PLACE OF THE

DIFFERENTIAL-REDUCTION GEAR UNIT
(with axle on stand 99322215)
40074
Removal
Remove the screws that fasten the differential-reduction gear
Place the axle assembly on stand 99322215 unit (2) to the axle casing (3), tighten the counteracting screws
(1). With lifting device, eye bolts and steel ropes withdraw the
unit from the axle casing.
Figure 58
Re-fitting in place
To re-fit in place, follow the removal steps in the reverse order
taking the following precautions:
Figure 61
40053
Place a container under the wheel hub; remove the screws (2)
and the cover (3), collect the oil.
40075
- to engage the differential locking, the sliding sleeve (1)

must be placed on the twin-tooth half-shaft.
Figure 62 Place the differential-reduction gear unit assembly on stand

99322205 with appropriate brackets.
Figure 65
40076
- clean carefully, spread LOCTITE 573 on the contact surface

(), position the differential-reduction gear unit taking care
that the fork engages the sleeve (1, Figure 61) and that the
centering pins enter into the holes (1, Figure 62); 40116
Using a suitable punch (1) remove the dent from the nut (2).
Figure 63
Figure 66
40052
- spread LOCTITE 573 on the thread and the contact

surfaceof the screws, tighten them with a dynamometric
wrench to the specified torque; 40117
- re-fit in place the half shafts and shoulder pins; fit in place With counteracting lever 99370317 (2) and socket wrench
the cover using LOCTITE 573 and tighten the screws to 99355081 (1) unscrew the locking nuts and withdraw the
the prescribed torques. Adjust the half-shafts backlash as coupling flange (3).
described in Figure 57.
Figure 67
DIFFERENTIAL-REDUCTION GEAR
UNIT OVERHAUL
Removal
Figure 64
71543
Unscrew the screws (4) and remove the cover (3), complete
with seal ring.
Remove the flow divider cover.
Remove the screws (1) and the differential lock cover (2),
40099 together with the switch (5).
38
Figure 68
INTERMEDIATE AXLE IN TANDEM
SECTION 12.4
39973
1. sleeve - 2. ring - 3. Ring nut - 4. Ring nut - 5. Bearing - 6. cover - 7. Crown wheel - 8. Washer - 9. Collar - 10. Planetary wheel - 11. Pin - 12. Pin - 13. Spider - 14. Planetary wheel - 15. Gear housing - 16. Bearing - 17. Oil seal -
18. Ring nut - Oil baffle - 20. Screw - 21. Plate - 22. Bearing - 23. Pinion - 24. Screw - 25. Spring - 26. Fork - 27. Piston - 28. Ring - 29. Cover - 30. Screw - 31. Switch - 32. Pin - 33. Screw - 34. Pin - 35. Caps - 36. Half shaft - 37. Shaft -
38. Seal ring - 39. Seal ring - 40. Bearing - 41. Cover - 42. Screw - 43. Seal ring - 44. Splashguar -45. Control side flange - 46. Nut
HD9 Euro5
HD9 Euro5
Figure 69
SECTION 12.4
39974
DIFFERENTIAL-REDUCTION GEAR UNIT COMPONENTS

. Nut - 2; Control side flange - 3. Hex. screw - 4. Splash guard - 5. Screw - 6. Sealing gasket - 7. Cover - 8. Seal ring - 9. Seal ring - 10. Switch - 11. Pin - 12. Cover - 13. Ring - 14. Plug - 15. Ring - 16. Screw - 17. Bearing - 18. Sleeve - 19. Shaft -
0. Washer - 21. Bush - 22. Pin - 23. Gear - 24. Seal ring + 25. Spring - 26. Fork - 27. Piston - 28. Half-box - 29. Washer - 30. Planetary wheels - 31. Spider - 32. Ring nut - 33. Bush - 34. Crown wheel gear - 35. Washer - 36. Oil seal - 37. Seal ring -
INTERMEDIATE AXLE IN TANDEM
8. Pin - 39. Half-box - 40. Screw - 41. Bearing - 42. Washer - 43. Eccentric ring - 44. Adjusting piston - 45. Compressed spring - 46. Ring - 47. Threaded plug - 48. Pin - 49. Self-locking screw - 50. Crown wheel - 51. Pinion - 52. Pin -
3. Self-lock ring screw - 54. Shim - 55. Bearing - 56. Shim - 57. Shim - 58. Bearing - 59. Oil drain - 60. Gear - 61 Oil drain cover - 62. Nut
39
Figure 70 Figure 73
40119 40122
Remove the cover screws (1), using puller (2) lift the cover (3) Remove the dents on the gear nut (2).
to withdraw the bearing from the shaft. Apply tool 99363310 (1) to lock the gear rotation (2); with
multiplier 99389816 (3) and socket wrench 99355081 (4)
unscrew the securing nut.
Figure 71
Figure 74
40120
Using eye bolts (2) and hooks with ropes (1) remove the 40114
cover. Move the reduction gear unit locking engagement fork Using two levers, withdraw the idle gear (1) from the bevel
to avoid damaging it. pinion (2).
Figure 72 Figure 75
40121 40115
Remove the screws (1) and take away the upper part of the Remove the three screws (1) and then the oil drain (2).
oil drain (2).
Figure 76 Gearing box dismantling

Figure 79
40116
Fit the flange (1) again and fasten it with the nut. Lift the 40113
differential transfer group (2) with hooks and cables. Turn the stand by 180.
Unscrew the two screws and remove the cover (4), the piston
(2), the fork (1) and the spring (3). Unscrew the screws and
remove the safety plate (5).
Figure 77
Figure 80
40.117A 40.111A
Unscrew the 14 screws (1) fastening the halves of the Remove the safety clip and extract the differential lock fixed
differential box. sleeve (1).
Mark the fitting position of the caps with respect to the
differential box.
Figure 78 Figure 81
40.119A 40102
With eye bolts hooks and cables lift and remove the half box Slightly loosen the adjuster ring, heat at the points indicated by
(2) complete with bevelled pinion from the differential box the arrow with hot air blower 99305121 and unscrew the
(1). screws (1) fastened with LOCTITE.
Remove the caps (2).
Figure 82 Figure 85
40108 71544
With a suitable hook lift the gearing box (1) complete with Remove the guard plate (1).
bearings (2) and adjuster ring nut (3). Remove the cap (3) complete with washer (4), extract the
spring (5) and the piston (6).
Remove the eccentric (2).
Figure 83
Figure 86
40104
Using a general driver expel the bevelled pinion tapered roller

bearing (1) in the differential box from its seat. 40105
Using a suitable tool remove the o-ring (1).
Figure 84
Figure 87
40086
40376
With extractor 99348001 (1–-2) and reaction block
99345053 (3) extract the bevelled roller bearing from the Rest the half-box (1) on two parallel supports and remove the
gearing box. Repeat this operation on the opposite side. bevelled pinion (2) with a suitable driver. Remove the tapered
roller bearings (3).
Figure 88 Figure 91
40087
Unscrew and remove the screws (I) fastening the bevelled

crown (3) and cover (2) to the half-box (4).
40079
Figure 92
Using a suitable driver (1) remove the outer races (2-3 of the
tapered roller bearings from the half-box.
Figure 89
40088
Mark the cover and the gearing box.

Remove the box cover (I) and disengage the crown (2) using
a suitable driver (3).
Figure 93
470077
With extractor 99348001 (1) extract the intermediate

bearing (2) from the bevelled pinion.
40089
Figure 90
Remove the planet gear (1) complete with thrust washer (3)
from the gearing box (1).
Figure 94
40078
Using suitable tools, extract the inner race (1) of the rear 400910
bearing from the bevelled pinion (2) Destructive operation. Using a suitable driver (1), extract first the long pin (2) then
the two short pins (3).
Figure 98
(2, Figure 95) by a long stripe for the long pin and two
short stripes for the short pins.
Figure 95
40138
Using a suitable punch remove the dent from the ring nut (2).
40091 Using wrench 99355121 (1) unscrew the ring nut (2), remove
the spider (3), planetary wheels and shoulder washers.
Remove the spider (2), the planetary gears (3) together with
the shoulder washer and crown wheel (4) from the gear
housing. Figure 99
Removing the differential-reduction gear unit
Figure 96
40139
1. Input shaft - 2. Driving gear - 3. Spider - 4. Ring nut -

5. Differential half box - 6. Seal ring
40135
Set the differential- reduction gear unit in a vice, remove the

screws (1) Figure 100
Figure 97
40140
40136
Withdraw the driving gear (1) from the input shaft (2),,
remove the shoulder ring.
Remove the half-boxes (1) and relevant bearing (2).
40137 40411
With a hydraulic press withdraw the bearing (1) from the If the bush has been removed, fit it in place in the idle gear (2)
half-box (2) operating on the crown wheel gear using the appropriate tool (1).
Checks on differential-reduction gear unit
components
Figure 104
Clean and carefully check the individual components, replacing
any that are strained. Replace all the seal rings.
If it should be necessary to replace the crown or the

pinion, both parts have to be replaced since they are
supplied as a pair.
If it should be necessary to replace the crown or the

pinion, both parts have to be replaced since they are
supplied as a pair.
40140
Check the bushes on the driven gear and in the crown
wheel. If they are strained, replace them using a press. Fit in place the idle gear (1) on the input shaft (2).
Refitting the differential-reduction gear unit Figure 105
Figure 102
40138
Fit in place the half box (4) and its seal ring
40141 Fit in place the spider (5) and its planetary wheels. With
Place the input shaft in a vice, fit in place the shoulder ring (1) wrench 99355121 (2) and dynamometric wrench (1) tighten
the ring nut (3) to the specified torque.
40142
40413
After locking the ring nut (1) use a feeler gauge (3) to check Fit in place the shoulder ring on the crown wheel gear (3),
that there is a clearance of 0.1 mm between the ring nut (1) then using the appropriate tool (1) fit in place the seal ring (2)
and spider (2). If this is not so, replace the relevant parts.

X
40143
40414
Using a suitable punch (1) dent the ring nut (2) as shown in
the detail
Fit the crown wheel gear unit (5) and parts (2 and 3) in the
half-housing (1).
Heat the ball bearings (4) to 100º - 110ºC and fit on the
Figure 108 crown wheel gear unit (5). Check that the half-housing (3) and
the bearing (4) are at a distance of X = 1.05 to 1.60 mm.
Figure 111
40412
With the suitable connection element (1) and press, fit in place
the bush in the crown wheel gear (2) 40136
On the lower half-box fit in place the half-box assembly (1)

with its relevantbearing (2) and crown wheel
40144
Tighten the fastening screws (2) and with the dynamometric 40093
wrench (1) lock them to the specified torque. Fit in place the crown wheel (1)
Fitting in place the gear housing
Figure 113
Figure 116
40091
Place the gear housing (1) on a suitable stand, fit the crown wheel 40094
(4) in its seat with its shoulder ring. Fit in place the 4 planetary Fit in place the shoulder washer (1)
wheels (3) and shoulder rings then insert the spider (2).
Figure 114
Figure 117
40092
Insert the long pin (1) and the two short pins
40095
The long pin (through pin) must be inserted first. The
exact position of the pins is marked on the spider by Fit in place the gear housing cover (1).
a long stripe for the long pin and two short stripes for
the short pins.
Figure 118 Fitting in place the bevel pinion housing

Figure 121
40080
Drive fully into their seats the intermediate and external
bearing outer rings (3) using beater 99374094 (1) and handle
40096
99370007 (2).
Heat the crown wheel (1) to 80 C, fit it in place in its seat
in the gear housing (2) and lock it immediately with two
Procedure to determine the adjusting ring
screws. thickness for the bevel pinion rolling torque
Figure 122
Figure 119
39572
With a micrometer (2) measure the adjusting ring (1)

thickness found when removed and make a note of the value
40097 (value A).
Insert the other screws (1); lock the gear housing rotation Figure 123
through the press and with a dynamometric wrench (2)
tighten the screws (1) to the specified torque.
Figure 120
40083
Fit tool 99395027 in a vice and place on it:

- Adjusting ring (4), already measured, the spacer and
bearing (3)
Screw the ring nut (2) and lock it tightly. Position the dial gauge
40098
fitted to element (1) of tool 99395027 on the bearing and set
the gauge to zero on the end of the tool. Remove from the
Heat the bearing (1) for about 15 minutes at a temperature tool:
of approx 100 C and fit it in place on the gear housing (2).
Repeat the same operation on the other side. - element (1), ring nut (2), bearing (3) adjusting ring (4) and
the spacer.
Figure 124 Example two:

A = 10,12 mm
B = -0.13 mm
C = 0.05 mm
S = 10,12 - (- 0,13) + 0,05 =
S = 10,12 + 0,13 + 0,05 = 10,30 mm.
Reinforced version
Example one:
A = 1,85 mm
B = +0,13 mm
C = 0.05 mm
S = 1,85 - (+ 0,13) + 0,05 =
S = 1,85 - 0,13 + 0,05 = 1,77 mm.
40085 Example two:
Position tool 99395027 complete with bearing (5, Figure 123) A = 1,85 mm
on the half-box, arrange the bearing (3, Figure 124). B = -0.13 mm
Hand-tighten the ring nut (1) and check rolling torque with the C = 0.05 mm
torque meter wrench (4), which must be 1,5 3,5 Nm, if not, S = 1,85 - (-0,13) + 0,05 =
adjust the ring nut (4). S = 1,85 +0,13 + 0,05 = 2,03 mm.
Figure 126
Figure 125
40084 40078
Heat the inner race (1) of the rear bearing and fit it on the
Again position the part (4) with the gauge previously zeroed bevelled pinion (2).
on the bearing (2) and measure any difference (dimension B).
Remove the part from tool 99395027.
The thickness S of the shim is given by the following formula:
S = A - ( B) + C
Figure 127
where:
A = Thickness of shim fitted to zero gauge;
11 + 0,20
B = Measured difference;
C = 0.05 mm co-efficient that takes account of bearing
dilation due to assembly interference on bevelled pinion.
Normal version
Example one:
A = 10,12 mm
B = +0,13 mm
C = 0.05 mm
S = 10,12 - (+0,13) + 0,05 = 39701
S = 10,12 -0,13 + 0,05 = 10,04 mm.

Fit the adjuster shim (2) on the bevelled pinion (1) to adjust
pinion position with respect to the crown with the bevel facing
downward. The thickness of the adjuster shim is determined
by the reference mark (3, ) punched on the bevelled pinion.
ASTRA
40082
With the hot air blower heat the intermediate bearing (1)
to 100C and fit it to the bevelled pinion (2). 71544
Fit the shim (4) and the adjuster ring (3) with the previously
Remove the eccentric (2).
measured thickness.
Insert into the differential box: the piston (6), the spring (5).
Fit the cap (3) with a new washer (4) and tighten to the
On vehicles with reinforced differential the positions
specified torque.
of the shim and adjuster ring are inverted.
Fit the guard plate (1).
Differential box mounting Figure 132

Figure 129
40415
40106
Fit the bevelled pinion (1) on the rooer bearing (1,
Set the differential box on the stand and fit the roller bearing Figure 128).
(1) with a suitable driver. Spread LOCTITE 573 sealant (2) on the contact surface.
40107
40.119A
Using fitting tool 99374372 (1) and grip 99370006 (2) fit the
o-ring. Lift and mount the half-box (2) on the differential box (1).
40123
40.120A
Position tool 99363310 (1) ,and using socket wrench
Tighten the screws (2) to the specified torque using the torque 99355081 (4), multiplier 99389816 (3), torque wrench (2),
wrench (1). On the bevelled pinion fit the shim and adjuster tighten the driven gear nut to the specified torque.
ring (3). Heat the bearing and fit it to the bevelled pinion.
Figure 138
Figure 135
40416
Using a suitable driver (1), steel the driven gear nut (2)
40.121A If the nut (2) is a numyer type, this is not necessary.

Fit the oil feed (2) fastening it with the screws (1) to the
specified torque.
Figure 139
Figure 136
40108
With a suitable hook lift the gearing box (1) complete with
bearings (2) and adjuster ring nut (3). Position it on the
40.122A differential box. Carefully arrange the ring nut on the
Fit the driven gear (1) on the bevelled pinion (2). differential box thread.
Figure 140 Gearing box bearing rolling torque

adjustment
Figure 142
40109
Fit the caps (2), temporarily tighten the screws (1) and check
that the ring nuts (3) tightens easily. Remove the screws one
40417
at a time, spread LOCTITE AVX on the threads and tighten
them with the torque wrench (4) to the specified torque..
Adjustment of gearing box bearing rolling torque is achieved
by measuring the total rolling torque.
Using torque wrench 99389819 (1) and the correct socket
(2), measure the specified rolling torque. If the indicated value
does not correspond, adjust the bearing adjuster ring nuts (3)
using wrench 99354001 (4).
This value must correspond to the value given in the
SPECIFICATIONS AND DATA paragraph. If the value is
different, loosen or tighten the nut to obtain the specified
value.
Figure 141
Adjustment of bevelled pair — pinion axial play

as follows:
- from the table given in the SPECIFICATIONS AND
DATA paragraph read the value for play between the
teeth, which varies according to the bevelled pair ratio.
39585
Position tool 99370133 (1) as shown to prevent excessive

spreading of the caps during adjustment.
40.114A 40160
- Position the magnetic base gauge (1) as shown in The imprint must be on both the drive face (1) and on the
Figure 143. thrust face (2), more or less at the centre of the tooth width.
- Lock pinion rotation and alternately rotate the crown and
with the gauge (1) check that the play between the two
sets of teeth is as specified.
Otherwise, adjust the ring nuts (3) with the wrench
99354001 (2). Figure 146
To avoid altering the previously set rolling torque, when
adjusting play between the pinion and crown teeth the ring nut
can be tightened, with wrench (99354001) to the same
degree to which the opposite adjuster nut is loosened.
When adjusted, check that the two adjuster nuts are

positioned such as to allow the safety plate to be fitted.
40110
Fit the safety plates (1). Tighten the screw with the torque
wrench (2) to torque of 51  5 Nm.
40159 40111
With a brush apply a thin coat of lead oxide (primer) to the Fit the differential lock sleeve (1).
crown wheel teeth.
Rotate the crown in both directions.
40078 40124
Fasten it in place with the circlip (1). Fit the differential-transfer group (1) into the half-box (2).
40113 40125
Fit the differential lock engage assembly (1-2-3-4) and tighten Fit the upper part (1) of the oil feed, tighten the screws (2) with
the screws to torque of 25  2 Nm. the wrench (3).

3 4 5 6
1
40.115A 40126
Fit the oil baffle (1) vertically as shown inFigure 150. In the inner part of the cover (1) fit the differential-transfer lock
Punch at the three points indicated by the arrows to prevent engage sleeve (2) and control assembly consisting of: spring
rotation. (3), fork (4), piston (5) with a new o-ring (6).
40127 40131
Spread LOCTITE AVX on the contact surface. Fit the cover and with the torque wrench (1) tighten the
Fit the cover (1) and with the torque wrench (2) tighten the screws (2) to the specified torque..
screws (3) to the specified torque.
40128 40132
Fit the input shaft bearing (1) with a suitable driver. Fit the flange (1) to the input shaft.
40129 40133
With fitting tool 99374233 fit the o-ring (1) in the cover. Rotate the group, tighten the nut with the torque wrench (1),
Replace the o-ring (2). reaction lever (2) and socket 99355081 (3) tighten to the
specified torque.
40149
With the press extract the bearing (1) from the output shaft
40134 (2).
With a suitable punch (1) steel the nut (2) as shown in the
detail (3). Checks on parts
Clean and check all parts of the drive output shaft replacing any
DRIVE OUTPUT SHIFT that are found damaged. Always replace the o-rings.
Dismantling
Assembly
Figure 161
Figure 164
ASTRA
40129
With fitting tool 99374013 fit the inner o-ring (1) in the cover
40145
and replace the outer o-ring (2).
Remove the punching from the flange retainer nut (3).
Arrange the reaction lever (1) and with socket wrench
99355081 (2) remove the nut. Extract the flange (3). Figure 165
Figure 162
40148
Refit the drive output shaft inverting the dismantling

operations and tightening the screws (1, Figure 162) to the
specified torque.
40147
Tighten the lock nut (1) to the specified torque.
Unscrew the screws (1), remove the cover (2) and extract the After tightening the nut (1) punch the collar of the nut.
output shaft (3) complete with bearing.

REAR AXLE
TANDEM
SECTION 12.5
HD9 Euro5 SECTION 12.5 REAR AXLE TANDEM 1
SECTION 12.5
Rear axle tandem

Page
DESCRIPTION 3
TOOLS 9
DIAGNOSTICS 14
AXLE OIL REPLACEMENT REAR TANDEM AXLE 16
GENERAL 16
- Drainage 17
- Filling 17
AXLE REMOVAL-REFIT REAR TANDEM AXLE 18
GENERAL 18
- Removal 20
- Refitting 22
2 REAR AXLE TANDEM SECTION 12.5 HD9 Euro5
REAR AXLE ASSEMBLY OVERHAUL OPERATIONS 23

- Removing the epicyclic reduction unit 23
- Removing the wheel hubs 26
WHEEL HUBS AND EPICYCLIC REDUCTION GEAR
COMPONENTS CHECK 27
WHEEL HUB MOUNTING 28
DIFFERENTIAL REMOVAL-REFITTING 33
- Removal 33
- Refitting 34
DIFFERENTIAL BOX DISMANTLING 35
REMOVING THE GEAR HOUSING 36
REMOVING THE BEVEL PINION SUPPORT 37
DIFFERENTIAL COMPONENTS CHECK 39
GEAR HOUSING ASSEMBLY 40
BEVEL PINION SUPPORT ASSEMBLY 41
- Procedure to determine the thickness of the bevel
pinion rolling torque adjusting ring 41
DIFFERENTIAL BOX FITTING 43
- Adjustment of bevelled pair — pinion axial play 45
DESCRIPTION
The rear axle is a double reduction type: the first reduction is The bevel pinion unit is adjusted through adjusting rings that
by means of the pinion - ring bevel gear unit and the second are fitted between the the two taper roller bearings.
is obtained through an epicyclic unit in the wheel hubs. The axle is equipped with a pneumatically controlled device
The differential housing, with the ring bevel gear , is supported to lock the differential.
by two taper roller bearings that can be adjusted through two The half shafts coming from the differential transmit the mo-
threaded ring nuts. tion to the epicyclic gears.
The pinion is supported by two taper roller bearings and a
third straight roller bearing.
Figure 1
39381
PICTORIAL CROSS SECTION OF THE DIFFERENTIAL

1. Coupling flange - 2.Oil seal - 3. Outer seal ring - 4. Front bearing - 5. Adjusting ring - 6. Screw - 7. Bevel pinion support -
8. Intermediate bearing - 9. Adjusting ring - 10. Rear bearing - 11. Adjusting ring nut - 12. Differential housing bearing -
13. Short pin - 14. Spider - 15. Planetary gear - 16. Crown wheel - 17. Cover - 18. Gear housing - 19. Cover - 20. Screw -
21. Screw - 22. Long pin - 23. Safety plate - 24. Engaging sleeve - 25. Sliding sleeve - 26. Shoulder washer - 27. Split ring -
28. Engaging fork - 29. Transmitter - 30. Spring - 31. Plug - 32. Differential housing - 33. Taper pinion - 34. Oil baffle -
35. Lock nut
Figure 2
39907
PICTORIAL CROSS SECTION OF EPICYCLIC REDUCTION GEAR AND WHEEL HUB

1. Brake drum - 2. Oil manifold - 3. Seal rings - 4. Intermediate ring for sealing rings - 5. Bearing shaft - 6. Half shaft -
7. Seal ring - 8. Screw - 9. Bearing - 10. Wheel hub - 11. Screw - 12. Seal ring - 13. Planetary gear support -
14. Crown wheel - 15. Cover - 16. Screw - 17. Crown wheel carrier - 18. Plug - 19. Collar nut - 20. Planetary gear -
21. Circlip - 22. Spacer screw - 23 Spacer ring - 24. Planetary gear needles - 25. Spacer rings - 26. Pin - 27. Planetary gear -
28. Gasket - 29. Spacer washer - 30. Bearing
Figure 3

B Shim
2. Total rolling torque
a 4  6 Nm (pinion rolling torque + O-rings)
Type of axle:
Carrier with dual reduction and ASTRA 453291/2D (IVECO R 8298 D001)
pneumatic command differential
locking
Bevelled pinion bearings 2 with taptered rollers and 1 with cylindrical rollers
27/32 (1.185) - 28/37 (1.321) - 23/36 (1.565) -

Bevelled pair reduction ratio
19/33 (1.737) - 21/40 (1.905) - 17/35 (2.059)

with adjuster shims
torque adjustment

3.3 - 3.4 - 3.5 - 3.6 - 3.7 - 3.8 - 3.9 - 4.0 - 4.1 - 4.2 - 4.3 - 4.4 -
for bevelled pinion rolling torque
4.5 - 4.6 - 4.7
adjustment mm

using ring nuts
and crown
WHEEL HUBS

protection
Nm 6  7 + (12  16)
O-rings
Nm 6  7 + (5  7)
bearings and O-rings run-in
Nm 6  7 Nm + (2.5  4.5 Nm)
Transfer shaft axial play mm 0.5  1
Axle oil (*)
Quantity Litres 16
kg 14.5
Figure 4
98975
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
2 Bevelled pinion support screw at differential box 165  15 16.5  1.5
4 Differential box to axle box fastening screw D 160  10 16  1
5 Bevelled pinion support screw at differential box D 280  15 28  1.5
7 Safety plate to gearing box cover fastening screw 60  6 6  0.6
8 Switch 35 3.5
9 Command cylinder cheese-headed fastening screw 25  2 2.5  0.2
10 Oil filler cap 40  4 4  0.5
11 Self-locking screw 120  10 12  1
D Lock with LOCTITE AVX

 Spread with LOCTITE 573 sealant
Figure 5
98970
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
1 Drum fastening flathead screw 25  3 2.5  0.3
2A Wheel nut 615  35 61.5  3.5
2B Wheel nut 415  35 41.5  3.5
3 Plant gear support cover screw h 50  5 5  0.5
4 Flathead screw 50  5 5  0.5
5 Carrier sleeve screw 295  30 29.5  3

h Apply LOCTITE 573 to threads
: Apply MOLYKOTE to the nut contact surfaces
TOOLS
99322225 Group support (applied to trolley 99322205)
99341015 Clamp
TOOLS
99341020 Link rod pair for grips
99341023 Grips
99355081 Differential tapered pinion nut wrench (60 mm) (use with
99370317)
TOOLS
99356001 Wheel brake shoe adjustment wrench

TOOLS
99370616 Differential removal-replacement support
99370617 Universal support for axles during removal and refitting
99371022 Bracket pair for supporting differential during overhaul (use with
99322205 and 99322225)
99372211 Tool for removing and refitting brake shoe retainer springs.
99374013 Differential bevelled pinion seal fitting tool (use with 99370006)
99374093 Driver for inserting bearing outer races (99370007)

TOOLS
99374094 Driver for inserting bearing outer races (134-215) (use with
99370007)
99395026 Tool for checking hub rolling torque

(use with torque wrench)
DIAGNOSTICS
Main axle faults:

2 - Noise
5 - Cornering noise
1 WHEEL HUBS NOISY
NO
YES
NO

YES
NO
are worn YES
2 NOISE
NO
damaged YES

YES
NO
bearings YES
3 NOISE AT RELEASE
NO

YES
NO
YES
5 CORNERING NOISE
wheels. YES
AXLE OIL REPLACEMENT REAR TANDEM

AXLE
Safety instructions

Vehicle preparation
Figure 6
2371801

short circuits;
Drainage Filling
Figure 7 Figure 9
178NM51 228NM234
- operating on both hubs, bring a screw (ref. 1) to lowest - fill until oil spills out the of the cap (1);
position;
remove both screws (1) and drain the lubricant com- Pour in the lubricant in several steps, so as to allow
pletely; time for the lubricant to reach the hub final
- tighten the screws. reductions. The operation terminates when the level
does not lower after at least five minutes.
Figure 8
- clean the level cap, check that the thread is in good condi-
tion, replace the sealing ring and replace the cap.
Final operations
Proceed as follows:
again.
228NM234

cap.
AXLE REMOVAL-REFIT REAR TANDEM

AXLE
Safety instructions

Figure 10
Safety component.
2371801

short circuits;
Proceed as follows:
appropriately;
touch the ground;
Rules for Use of the USE AND MAINTENANCE MAN-
UAL
Removal
Figure 11
220092

(2) differential lock warning light;
(5) parking brake, right side only;
220094
Figure 12 - by unloading the tension from the leaf spring, remove the
bolts (1) fastening the lower reaction rods to the axle;
Only for vehicles with stabiliser bar
Figure 14
220095
- from both sides, loosen the bolts (1) fastening the stabilizer
220093 bar bushing to the chassis;
- by unloading the tension from the leaf spring, remove the lizer bar to the axle and rotate it downwards;
bolts (1) fastening the upper reaction rods to the axle;
All vehicles Inspections and checks

Check support pads are intact, if necessary replace the dam-
Figure 15 aged component
Check that electrical components and connectors are intact:
if necessary replace damaged component .
Refitting
Final operations
220096

neath the axle;
- to facilitate the operation, unscrew from both sides the
screws (1) fastening the bracket (2), then lower the axle
to disengage both leaf springs;
REAR AXLE ASSEMBLY OVERHAUL

OPERATIONS Place a vessel under the wheel hub to collect the oil.
The removal and re-fitting into place operations for

the half-shafts, drums and brake shoes, air bleeder,
wheel hubs differential and epicyclic gears can all be Removing the epicyclic reduction unit
carried out with the units fitted on the vehicle.
Figure 18
Before setting the axle assembly on the stand to overhaul, un-

screw the axle casing lower plug todrain the oil.
Figure 16
40053
Remove the screws (2); remove the cover (3) and collect the
oil.
39627
Set the whole axle assembly on stand 99322215.
Figure 17
39628
Lock the sliding sleeve of the differential locking device with

a screw.
cylinder and in its place (1) fit a screw (M14 x 1.5).
At the same time, turn the axle mechanism so that the sliding
sleeve and enagagement sleeve are engaged. This will prevent
accidental movement of the sleeve while removing the half--
shaft.
Figure 19
40430

1. Brake drum — 2. Adjusting screw and nut — 3. Cover — 4. Gasket — 5. planetary gear pin and rollers — 6. Planetary gear carrier
— 7. Adjusting nut — 8. Crown wheel carrier — 9. Planetary wheel — 10. Crown wheel — 11. Crown wheel gear — 12. Half-shaft —
13. Bleeder — 14. Bracket — 15. Shoulder pin — 16. Axle casing — 17. Bearing shaft — 18. Braking unit — 19. Phonic wheel —
20. Oil cup — 21. Supporting ring — 22. Seal ring — 23. Seal ring — 24. Bearing — 25. Wheel hub — 26. Bearing — 27. Bolt
Figure 20 Figure 23
40338 39635
Using a socket wrench (2) unscrew the two drum retaining Use appropriate pliers to remove the circlip (2) withdraw the
screws (1); replace them with counteracting screws (5), planetary gear (3) from the half-shaft (1).
tighten to remove the drum (4) from the hub, then take it
away with a rope (3) and lifting equipment.
Figure 21 Figure 24
40054 39636
Remove the 3 retaining screws from the planetary gear sup- Screw tool 9937445 (1) into the shoulder pin seat and remove
port (3); insert the counteracting screws (1) and using a rope the half shaft (2) from the bearing shaft.
(2) remove the support (3) Remove the spacer ring (3)
Figure 22
40055
Withdraw the crown wheel (1) from the crown wheel carrier.
Take out the shoulder pin (2)
Figure 25 Figure 28
39639
40056 Withdraw the bearing shaft (1), the crown wheel carrier (2)
with the relevant bearing and complete wheel hub (3)
Remove the pins (2) from the planetary gear support (1).
Remove the planetary gears (3) from the support (1) and set Figure 29
aside the needles and spacer rings.
Removing the wheel hubs
Figure 26
71535
Check the surface of the ring (1), on which the hub seal ring
rotates, is not damaged or worn, if necessary, replace the ring
(1).
Using the extractor [comprising bridge 99341003 (8), grips
99341023 (3), tie rods 99341020 (6), press 99341015 (4) and
39637 reaction block 99345053 (7)], extract the ring (replacing if
necessary) and/or the internal ring (2) of the sleeve (5) taper
Using a suitable punch straighten the dents (1) on the adjusting
bearing.
nut.
Figure 30
Figure 27
39641
Check the bearing shaft (2) and if it is damaged, replace it.

39638
Using tool 99372217, release the brake shoes (3) and after un-
Using socket wrench 99354207 (1) unscrew the adjusting nut. screwing the hexagonal screws (1) locked with LOCTITE, re-
move the brake carrier plate with the bearing shaft.
Figure 31 Figure 33
39642 39644
With a suitable beater fitted in the holes on the crown wheel Check the oil manifold (1) and if it is damaged, replace it. To
carrier, remove the outer taper roller bearing (2) from the do this, extract it with a suitable beater inserted through the
crown wheel carrier (1). hub slots (3). Remove the shaped seal ring (2).
Figure 32
WHEEL HUBS AND EPICYCLIC REDUC-
TION GEAR COMPONENTS CHECK
the half shafts to ensure they are not strained. If
necessary straighten the half shafts under a hydraulic
press. If the results obtained are not satisfactory, re-
place the half-shafts. Check the wheel bolts, if the
threads are strained or damaged, replace them
under the press. After fitting in place check that the
orthogonality error does not exceed 0.3 mm.
Lubricate the bearings and turn the roller cage freely;
the rotation must be even with no signs of stiffness.
Check the threads on the bearing adjustment nut
and the bearing shafts; if necessary replace the nuts.
Check the oil manifold, if it is damaged replace it.
39643 All seal elements must be replaced with new ones.
Use a bronze beater (1) to drive out the inner bearing outer Carefully clean all the epicyclic gear components.
ring (2). Visually check the teeth of the crown wheel carrier,
The seal ring will come away with it. the crown wheel, the planetary wheels and planetary
In the same way extract the outer bearing outer ring. If necess- gear.
ary remove the phonic wheel. Check the spacer rings, bearing needles and support
pins.
Replace any worn or damaged parts.
WHEEL HUB MOUNTING Figure 36
Figure 34
40410
Finish fitting manually using grip 99370007. Rotate and repeat

39645 the same operation for the inner and outer bearing race.
After replacing the wheel studs (3), check, before fitting the
new ones, that the contact faces of the stud heads are free of
burring and residues. Figure 37
Once fitted check that the studs are prefectly flush on the hub

on the hub with sealant: LOCTITE 573.
Refit the phonic wheel (1) checking, once fitted, that it rests
perfectly on the hub seat.
Check with the centesimal comparator that the orthogonality
of the phonic wheel is no greater than 0.2 mm.
71537
With the hydraulic press and fitting tool 99374161 (1) and
complete with o-ring (2) positioned as shown, fit the brown
inner ring (3) in the wheel hub (4).
Figure 35
Figure 38
39646
Using driver 99374093 (2) fit (under the press) the outer race 71538
of the outer bearing (3) stopping the operation at circa 5 mm With the hydraulic press and fitting tool 99374161 (1)
from flush. Finish fitting manually using grip 99370007 (1). complete with o-ring (2) positioned as shown, fit the blue
inner ring (3), internally greased, in the wheel hub (4).
Figure 39 Figure 42
39648
71540
Place the o-ring on the carrier sleeve, spread LOCTITE AVX
on the contact faces between axle box and carrier sleeve. Fit Lubricate the o-ring lip and the sleeve.
the carrier sleeve (3) complete with brake plate (4) and dust Fit the complete hub (1) on the carrier sleeve (2).
boot. Fasten the screws (2) previously spread with LOCTITE Lubricate the O-ring (3) and fit it to the wheel hub (2).
AVX and tighten with the torque wrench (1) to torque of 280
 15 Nm.
Figure 40 Figure 43
40375 40377
Spread SQ321M sealant on the seat () of the o-rings (2) on With the blower heat the tapered roller bearing (1) to circa
the carrier sleeve (3). With the blower, hear the ring (2) and 100C and fit it, using a suitable driver, into its seat in the crown
fit it to the carrier sleeve (3). Heat the inner race (1) of the tap- wheel holder (2).
ered roller bearing to 100C and fit it to the carrier sleeve.
Figure 44
Figure 41
40067 39650
carrier sleeve (4).
Figure 45 Figure 48
40069
40070
Figure 49
Figure 46
40071 39636
Position tool (1) 99395026 and, with a torque meter wrench With tool 99374451 (1) introduce the transfer shaft (2) into
(2) measure the rolling torque of the wheel hub. the carrier sleeve (3).
Fit the double toothed short shaft in the differential

lock side carrier sleeve.
Figure 50
Figure 47
40072
39653
Figure 51 Push the satellite support (2) onto the hub. To facilitate en-
gagement of the teeth move the transmission drive flange al-
ternately to and fro. Take care to align the gear set fastening
holes with the hub.
Position the three screws (4) and tighten them with the torque
wrench (3) to the specified torque.
Figure 54
39654
Orient the crown wheel (1) with the bevel facing outwards
and position it on the holder.
Figure 52
39656
Fit the brake drum (1) to the gear set support. Fit the brake
drum with the two flathead screws (2) fastening them with the
torque wrench (3) to the specified torque.
Figure 55
26916
Spread grease on the rollers (1), position them with the three
shims (2) in the satellite (4) as shown in the figure.
Insert the satellite (4) in the satellite holder with the shim (5).
Insert the support pin (3) from the cover side pushing it fully
into its seat.
Repeat the same operation for the remaining two satellite
groups.
Figure 53
40073
Spread a thin layer of Hylomar SQ 321 M sealant paste on the

cover contact surfaces (3) and the satellite support (4).
Orient the cover such that the bevels of the support pins align
with the hollows in the cover.
Spread sealant paste on the threads of the screws (1) and
tighten them to the specifiedtorque using the torque wrench
(2).
39655
Spread a thin layer of Hylomar SQ 321 M sealant paste, or Re-

inzoplast on the satellite support (2) and wheel hub (1) con-
tact surfaces.
32
Figure 56
REAR AXLE TANDEM
SECTION 12.5
40431
DIFFERENTIAL UNIT COMPONENTS

1. Electric transmitter - 2. Seal and union ring - 3. Cover - 4. Seal ring - 5. Piston - 6. Fork - 7. Spring - 8. Bearing - 9. Cover - 10. Plate - 11. Screw - 12. Cover - 13. Washer - 15. Shoulder washer - 16. Half-box - 17. Bearing - 18. Ring - 19. Ring nut -
20. Oil baffle - 21. Crown wheel - 22. Seal ring - 23. Differential unit - 24. Flange - 25. Dust guard - 26. Seal ring - 27. 28. Bearing - 29. Pinion support - 30. 45. Bearing - 31. Adjusting ring - 32. Pinion - 33. Bearing - 34. Box - 35. Screw - 36. Crown
Wheel - 37. Pins and spider - 38. Screw - 39. Ring nut - 40. Sleeve - 41. Sliding sleeve - 42. Screw - 43. Screw - 44. Screw - 46. Rin - 47. Nut
HD9 Euro5
Figure 57 Figure 60
26924
The half shaft (1) end play is to be between 0.5 and 1 mm. To
obtain this, tighten the adjusting screw (2) to its stop, then
come back by half a turn and lock it with the hexagonal nut (3). 39659
Fit tool 9937445 (1) into the shoulder pin seat threads and
withdraw the half-shaft (2) from the bearing shaft
The flat surface of the hexagonal nut should be di-
rected towards the seal ring (4).
Figure 61
DIFFERENTIAL REMOVAL-REFITTING
Removal
Figure 58
39660
Using the specific eye hooks and a rope, lift the pinion support
39658 (1) and remove the four differential housing screws (2).
Remove the screws (1) fastening the differential housing to the
axle casing. Remove the cap screws and hexagonal socket screws.
Figure 59 Figure 62
40053
39661
Screw on the oil intake cap (1). Move one of the cover (3) hex
screws (2) to a low position and unscrew it. Drain the oil from Using the specific eye hooks (1) and a rope, lift the differential
the epicyclic gears on the wheels. housing (2).
Refitting
Figure 63 Figure 66
39665
Spread LOCTITE 573 (1) on surfaces.

39662
Form a bead of LOCTITE 510 around oil passage ho-
Fit the sliding coupling (1) to the double toothed transfer shaft les.
(2).
Figure 64 Figure 67
39666
Arrange the bevelled pinion support (1) on the differential

box (2).
39663 Tighten the screws to the specified torque using the torque
Spread LOCTITE AVX (1) on contact surfaces. wrench (3).
When fitting the differential box it is important to make sure
that the differential lock engagement fork is correctly inserted The threads of the screws (3) inserted in the open
into the seat in the sliding coupling. holes must be spread with LOCTITE 573.
Figure 68
Figure 65
40073
Spread a thin layer of “Hylomar SQ 321 M” sealant paste on

the contact surfaces of the cover (3) and the planet gear sup-
39664
port (4). Arrange the cover such that the bevels of the pins co-
Position the o-ring and fit the differential box (1). Using the incide with the hollows cut into the cover.
torque wrench tighten the external screws (2) and internal Spread sealant paste on the threads of the screws (1) and
screws (3) to the specified torque. tighten them to the specified torque using the torque wrench
(2).
DIFFERENTIAL BOX DISMANTLING
Figure 69 Figure 72
39667 39670
Position he complete differential box, with the gearing box Lift the gearing box cover (1).
cover (1) facing upwards, on rotary stand 99322205 (2) com-
plete with support 99322228 and bracket pair 99371022 (3).
Figure 73
Figure 70
39671
Using hook 99370509 lift the gearing box (2) complete with
39668 tapered roller bearings and external bearing rings.
Unscrew the screws (1) and remove the safety plate (2).
Repeat this operation on the opposite side.
Figure 74
Figure 71
39672
39669
Turn the differential box by 90.
Heat at the points indicated by the arrow with hot air blower Remove the retainer nut seal.
99305121 and unscrew the cover fastening screws (2) (fas- Apply to the transmission attachment flange reaction lever
tened with LOCTITE). 993701317 (2), loosen the retainer nut using socket wrench
99355081 (1).
Figure 75 Figure 78
39673 39676
Remove the screws and washers fastening the bevel pinion Withdraw the control piston (2) with the seal ring (3), engage-
support (1) to the differential housing (3). Insert the counter- ment fork (1) and compression spring (4).
acting screws (2) and take out the complete differential hous-
ing support.
REMOVING THE GEAR HOUSING
Figure 76
Figure 79
39674
39677
Use a beater to expel the bevel pinion straight roller bearing
(1) from its seat in the differential housing. Remove the split ring (1) and take away the differential locking
device engagement sleeve (3) from the gear housing cover (2).
Figure 77 Figure 80
39678
39675
Using puller 99347101 (1) equipped with a pair of gripping
Remove the two hexagonal socket head screws (1) and re- rings 99347182 (2), extension bar 99347361 (3) and counter
move the differential locking device control cylinder (2). block 99345055 (4), take out the taper roller bearing from the
gear housing.
Repeat the same operation on the other side.
Figure 81 Figure 84
39679 39682
Unscrew and remove the screws (1) that fasten the ring bevel Use a beater to remove the long pin (4) then the two short
gear (3) and cover (2) to the half-box (4). pins (3).

Figure 82 (2) by a long stripe for the long pin and two short
Remove the spider (2) and 4 planetary gears (1) with the
shoulder washers.
Remove the crown wheel and shoulder washer.
REMOVING THE BEVEL PINION SUPPORT
Figure 85
39680
Mark the cover and gear housing ( ).

Remove the gear housing cover (1) and release the ring bevel
gear (2)
Figure 83
39683
Remove the previously loosened lock nut and the coupling

flange (1).
If the flange removal is difficult, use a universal puller.
39681
Remove the crown wheel (2) with the relevant shoulder

washer (3) from the gear housing (1).
Figure 86 Figure 89
39684 39687
Take out the bevel pinion (1) with intermediate bearing and Withdraw the pinion location adjusting ring (2) from the bevel
adjusting ring from the support. It is suggested to use a press pinion (1)
for this operation, but if this is not possible, use a puller (2)
Figure 87 Figure 90
39685 39688
Remove the bearing adjusting nut (2) from the bevel pinion Remove the rear straight roller bearing inner ring (2) from the
(1). bevel pinion (1). This is a destructive operation.
Figure 88 Figure 91
39686 39689
With a universal puller 99348001 (1) remove the intermedi- Use a beater to take out the front and intermediate bearings
ate taper roller bearing (3) from the bevel pinion (2). outer rings (3 and 2) from the support (1).
DIFFERENTIAL COMPONENTS CHECK

Lubricate the bearings and rotate the roller cage freely. The
rotation must be even and without signs of stiffness.
Carefully clean all the threads in order to obtain exact

adjustments and accurate driving torques.
Check that the splined section for flange-pinion connection is

not badly worn, if it is, replace the pinion.
When replacing the crown wheel or pinion it is

necessary to replace both parts since they are sup-
plied in pairs.
GEAR HOUSING ASSEMBLY
Figure 92 Figure 95
39690
Lock the gear housing (1) in a vice and set the crown wheel
39693
(2) with shoulder ring (3) in its housing.
Set the crown wheel (2) with its shoulder washer (3) on the
planetary gears.
Figure 93 Fit in place the cover (1) on the housing matching the marking
made before removal.
Figure 96
39691
Set the 4 planetary gears (1) with the shoulder washers and
fit in the spider (2).
39694
Heat the bevel ring gear (2) to approx. 80C, fit it in its housing
Figure 94 on the gear housing (1) and lock it immediately with two
fastening screws.
Figure 97
39692
Insert the long pin (1) and two short pins.
The long (through) pin is inserted first.

The exact position of the pins is marked on the spider 39695
(2) by a long stripe for the long pin and two short Insert the rest of the fastening screws (2) and with a dynamo-
stripes for the short pins. metric wrench (1) tighten them to a torque of 300  10 Nm
(30  1 kgm).
39696
Heat the bearing (2) to a temperature of 100C for approx.

15 minutes then drive it in the gear housing cover using a suit- 39698
able beater (1). Repeat this operation on the other side. Fit tool 99395027 (6) in a vice and place on it:
BEVEL PINION SUPPORT ASSEMBLY - adjusting ring (4), already measured, and bearing (3)
Screw the ring nut (2) and lock it tightly.
Figure 99 Position the dial gauge fitted to element (1) of tool 99395027
(6) on the bearing (3) and set the gauge to zero on the end
of the tool (6).
Remove from the tool (6):
- element (1)
- ring nut (2)
- bearing (3)
- adjusting ring (4)
Figure 102
39697
Connect a new oil baffle to the pinion support (1).

Use beater 99374093 (2) to drive the intermediate bearing
outer ring and the front bearing outer ring right down into
their seats.
Procedure to determine the thickness of the

bevel pinion rolling torque adjusting ring
Figure 100
39699
Set the support (4, figure 91) on the bearing (5, figure 90); set
bearing (3) on the support.
Manually tighten the ring nut (2) and check the rolling torque
as indicated in figure 92.
39572
Measure the thickness of the removed adjusting ring (1) and

make a note of the value (value A).
39701
39700
On the bevel pinion (1) fit in place the adjusting ring (2) to set
Set the complete support on 2 parallel bars and with a dyna- the pinion with reference to the crown wheel and the
mometric wrench (1) applied on tool 99395027 find the roll- chamfer directed downwards. The thickness of the adjusting
ing torque which should be 1.5 to 3.5 Nm. If this is not so oper- ring depends on the reference value (3) engraved on the bevel
ate on the ring nut (2, figure 91). Place element (1, figure 91) pinion.
with the dial gauage set to zero, on the bearing (3) and find
the deviation, if any (value B) Determination of bevel pinion positioning shim ring with
respect to ring gear according to the specific table (see TECH-
Adjusting ring thickness “S” is obtained through the following NICAL DATA).
formula:
S = A - ( B) + C
where: Figure 105
A = Thickness of adjusting ring fitted to set the dial gauage to
zero;
B = Deviation value found;
C = 0.05 mm coefficient that takes into account the bearings
dilation cause by assembling interference on the bevel pinion;
First example
A = 13.12 mm
B = + 0.13 mm
C = 0.05 mm
S = 13.12 - (+ 0.13) + 0.05 = 39702
S = 13.12 - 0.13 + 0.05 = 13.04 mm.
Heat the rear straight roller bearing (2) inner ring (1) to a tem-
Second example perature of 100C and fit in place on the bevel pinion.
A = 13.12 mm
B = - 0.13 mm
C = 0.05 mm
S = 13.12 - (- 0.13) + 0.05 =
S = 13.12 + 0.13 + 0.05 = 13.35 mm.
Remove the elements from tool 9939507.
DIFFERENTIAL BOX FITTING
39706
39703
Use a beater to drive the rear straight roller bearing (1) into
its seat in the differential housing.
Heat the intermediate bearing (1) to approx. 100C and fit in
place on the bevel pinion (2).
Fit in place the adjusting ring (3) with the proper thickness. Figure 110
Figure 107
39707
Fit in place on the differential housing (3) the already as-

sembled bevel pinion support (2), insert 2 screws (4) with
39704
spring washers in diametrically opposite positions. With a dy-
namometric wrench (1) tighten to a prescribed torque.
Fit in place the support (1), already assembled, on the bevel
pinion (2). Fit in place the front bearing. With a connection de-
vice (3) fit in place the oil seal ring (4) Figure 111
Figure 108
39708
Lock the coupling flange rotation with counter lever

99370317 (1) and using socket wrench 99355081, multiplier
39705
(3) and dynamometric wrench (4) tighten the lock nut to a
Fit in place the coupling flange (1) using a suitable beater, then prescribed torque.
manually tighten the lock nut.
39671
39712
Using hook (1) 99370509 position the gearing box (2) com-
plete with roller bearings on the differential box. Using torque wrench 99389819 (1) and a suitable socket
wrench, check that the total rolling torque corresponds to the
specified value according to the bevelled pair ratio.
Figure 113
Figure 115
39709
Correctly fit the cover (3) aligning the marks made during dis- 2
mantling. Provisionally tighten the screws (2) and check that
the adjuster rings (4) fasten without difficulty.
Remove the screws again (2), spread LOCTITE AVX on the
threads and tighten them with the torque wrench (1) to the 39711
specified torque.
If a different value is found, using wrench 99354001 (1) adjust
the ring nuts (2) until obtaining the specified value.
Gearing box bearing rolling torque adjustment
Rolling torque is measured making certain that there is play

between the teeth of the bevelled pair. Total rolling torque
varies according to the ratio of the bevelled pair.
WHEELS AND TYRES
SECTION 13.1
HD9 Euro5 SECTION 13.1 WHEELS AND TYRES 1
SECTION 13.1
Wheels and tyres

Page
DESCRIPTION 3
- Tyre characteristics index 4
TOOLS 6
CHECKS AND REQUIREMENTS 6
WHEEL STATIC BALANCING 7
CORRECTING RESIDUAL STATIC IMBALANCE 8
TYRE PRESSURE 9
- How tyre behaviour depends on pressure 9
2 WHEELS AND TYRES SECTION 13.1 HD9 Euro5

DESCRIPTION
The tyre has the following functions:
- to absorb most of the jolts caused by roughness of the road surface by utilising the air’s elasticity;
- to generate on the ground the driving force of the engine required to move the vehicle;
- to ensure maximum grip established by contact between tyre and road, with satisfactory life;
- to withstand the force generated by sudden braking, by hard acceleration and by the thrust of centrifugal force on bends;
- to guarantee the stability of the vehicle at high speeds;
- to ensure vehicle directional control.
The tyre is identified by many elements. The most important are shown in the next figure.
1. characteristics 1st digit: single load capacity
2nd digit: twin load capacity
Letter: speed index
2. tyre without inner tube
3. section width in mm
4. radial-ply tyre
5. series= height/width nominal ratio
6. radial structure
7. retreadable tyre
8. inner diameter in inches (diameter of rim)
Figure 1
342B121001R
Tyre characteristics index Speed category

Load index Maximum speed that can be supported by the tyre for use
up to the foreseen load capacity.
Tyre maximum supportable load for use up to speed foreseen
by the related speed category.
Reduction in speed permits, within certain limits, an increase Figure 4
in load capacity.
Symbol km/h
Figure 2 D 65
E 70
F 80
G 90
J 100
K 110
L 120
N 130
M 140
P 150
342B121002R
The first index is valid for single use, the second for twin use.
Figure 3
LI kg LI kg
138 2360 161 4625
139 2430 162 4750
140 2500 163 4875
141 2575 164 5000
142 2650 165 5150
143 2725 166 5300
144 2800 167 5450
145 2900 168 5600
146 3000 169 5800
147 3075 170 6000
148 3150 171 6150
149 3250 172 6300
150 3350 173 6500
151 3450 174 6700
152 35550 175 6900
153 3650
154 3750
155 3875
156 4000
157 4125
158 4250
159 4375
160 4500

Front: single (*)
Rear: twin (**) or single (*)
* **
DIMENSION TYPE
(bar) (bar)
13R22.5 MICHELIN XZY2 8 8
MICHELIN XDY3 8 8
MICHELIN XZH 8 8
PIRELLI AP05 9 --
PIRELLI AT75 -- 9
PIRELLI AT99 8.5 8.5
PIRELLI FG85 9 9
PIRELLI TG85 9 9
PIRELLI FG88 9 9
PIRELLI TG88 9 9
CONTINENTAL HSC
CONTINENTAL HDC
315/80R22.5 MICHELIN XZY2 8.5 8
MICHELIN XDY3 8.5 8
MICHELIN XZE2 8.5 8
MICHELIN XDE2 8.5 8
MICHELIN XDE2+ 8.5 8
PIRELLI AP05 8 8
PIRELLI AT75 8 8
PIRELLI FG85 8 8
PIRELLI TG85 8 8
PIRELLI FG88 8.5 8.5
PIRELLI TG88 8.5 8.5
CONTINENTAL HSR1
CONTINENTAL HDR
495/45R22.5 MICHELIN XDA2 9 --
445/65R22.5 MICHELIN XZL 8 --
12.00R20 MICHELIN XDY 8.5 8.5
MICHELIN XZY2 8.5 8.5
MICHELIN XZL 8.5 8.5
MICHELIN XZY 8.5 8.5
PIRELLI AP05 9 --
PIRELLI AT75 -- 8.5
PIRELLI FG85 9 9
PIRELLI TG85 9 9
315/70R22.5 MICHELIN XZE2TL 9 9
MICHELIN XDE2TL 9 9
325/95R24 PIRELLI FG88 9 9
PIRELLI TG88 9 9
20.00R20 CONTINENTAL
385/68R22.5 MICHELIN XZY3 9 --
MICHELIN XFA1+ 8.5 --
365/85R20 MICHELIN XZL 7.5 --
365/80R20 MICHELIN XZL 6 --
16.00R20 MICHELIN XZL 7.6 7.6
14.00R20 MICHELIN XZL 7.6 7.6
PIRELLI PS22 PISTA 7 7
24.00R20.5 MICHELIN XS 6 --
385/95R24 MICHELIN X 9 --
385/55R22.5 MICHELIN XFA2 9 9
525/65R20.5 MICHELIN XS 8 --
395/85R20 MICHELIN XZL 8.5 --
525/80R25 MICHELIN XL 7 --
24R21 MICHELIN XZL 6 --
TIGHTENING TORQUES
DESCRIPTION TORQUE
Nm kgm
Wheel fixing screws 650 6,6
TOOLS
TOOL DESCRIPTION
99305037 Electronic unit for balancing the front wheels on the vehicle
CHECKS AND REQUIREMENTS

Wheels shall be checked periodically, e.g. when changing a tyre.
The driver shall perform the following operations accurately:
- Clean the coupling surfaces when removing a wheel from
the vehicle.
- Inspect the rim, along its whole circumference, and the disk
using special care to hub centering and fixing area.
- Check absence of defects, wear, corrosion or cracks which
can impair wheel reliable performances.
- Check whether all surfaces are correctly and suitably pro-
tected, especially tyre and vehicle faying surfaces. Repaint,
if required, after removing surface oxidation, if any and
after suitable priming avoiding excessive paint application
in the coupling areas.
Only minor repairs (e.g. removal of scratches or dents), apart
the above mentioned surface protection resetting, can be per-
formed on steel wheels. In case of serious damages the wheel
shall be repaired by skilled workers only, since tyre removal and
refitting when are not performed correctly can be dangerous
for the driver.
Never repair rims or disks by welding or adding material to re-
store wheel geometry since these areas which are already af-
fected by wear due to running stress, will break in a short time.
WHEEL STATIC BALANCING

Figure 6
Figure 5
16997
- Connect the cable (3) of the imbalance detector to unit

The front wheels can be balanced on the vehicle using the 99305037
electronic unit 99305037; this has the great advantage of
balancing the wheel together with the other rotating masses. - Make a reference mark on the tyre by drawing a radial
mark with chalk or using a strip of gummed paper
The operation must be carried out as follows :
- Turn switch (2) to the static balancing position and
- Raise the front of the vehicle and make sure that the wheels sensitivity switch (4) to notch no. 5 on the graduated scale
rotate freely
- Turn on switch (5) for instrument light (1) and strobe
- Position the imbalance detector (1) under the axle close to lamp switch (8).
the wheel being examined, arranging the height so that the
spin-up wheel of unit 99305037 (2) is in contact with the - Turn the spin-up switch (6) of unit 99305037 to the first
tyre; position a support stand under the opposite side of speed position so as to make the wheel rotate.
the axle and lower the hydraulic jack
Turn up the spin switch (6) to the second speed and place the
balancing machine against the tyre.
While the wheel is being spun, it will be found that the
stroboscopic effect on the wheel will make the reference
mark appear stationary; the pointer of the instrument (1),
moving from the value zero, reaches a maximum value on the
scale and then returns to zero.
When the pointer has begun to fall back, withdraw the
balancing machine, turn off the spin-up switch (6) completely
and brake the motor by means of the brake lever (7). The
wheel continues to revolve due to inertia and the reference
mark made on the tyre moves; the point to which the
reference mark has moved should therefore be noted.
Read off from the instrument (1) the value shown by the
pointer, multiply it by 10, giving the value of the balance weight
to be fitted to the rim.
Figure 7 - If the weight is in the zone marked with the letter A, this
means that it is too light, and in that case weight must be
added as indicated by the instrument (1, Figure 6).
- If the weight is in the bottom zone marked with the letter

C, this means that it is too heavy and in that case the weight
must be reduced as shown by the measuring instrument.
- If the weight is found to be in the zones marked with the

letters B or D, do not remove or add any weight but instead
move it 5 cm upwards in the direction of the arrows, see
16998 Figure 8.
Fit the balance weight calculated in this way as shown in the

figure. If during the test, the pointer of the instrument (1,
Figure 6) remains in the green area of the box, the wheel is
balanced.
If the weight required to balance the wheel is more

than 600 - 800 grammes, divide the weight in half and
position the two parts so formed with one half on the
inside and one half on the outside of the rim, making
sure that they are in the same position.
CORRECTING RESIDUAL STATIC

IMBALANCE
Figure 8
23885
To correct the residual imbalance, repeat the operations

already carried out above; depending to the new reading on
the instrument (1, Figure 6), refer to the diagram in Figure 8and
proceed as follows to adjust :
TYRE PRESSURE Figure 10

The tyre pressures must be checked with the tyres cold.
Take great care that the pressure is correct since, if it is higher
than required, a harsh ride and excessive wear of the centre of
the tread will result, while if it is lower, the load is not distributed
over the whole tread but is concentrated at either side, causing
premature wear of these areas and also damaging the internal
structure of the tyre.
Unequal pressures between tyres affects the driving stability of
the vehicle and impairs operating safety.
Abnormal wear of the tyres may appear in various areas of the
tyre treads.
+ 20%
How tyre behaviour depends on pressure

EFFICIENCY 90%
Schematic views to demonstrate how tyre behaviour and
performance depends on pressure.
Figure 11
(The value shown inside each tyre indicates the level
of pressure of the tyre, while the efficiency relates to
the life of the tyre.)
Figure 9
CORRECT
EFFICIENCY 100%
— 40%
EFFICIENCY 40%

BRAKES (Duplex)
SECTION 13.2 B
HD9 Euro5 SECTION 13.2 B BRAKES (Duplex) 1
SECTION 13.2 B
Brakes (Duplex)
Page
DESCRIPTION 3
- Automatic take-up device 4
DIAGNOSTICS 7
TOOLS 12
GENERAL 15
GENERAL 17
FRONT BRAKES PNEUMATIC CYLINDER REMOVAL-
REFITTING 17
- Removal 18
- Refitting 18
GENERAL 19
REAR BRAKES PNEUMATIC CYLINDER REMOVAL-
REFITTING 19
- Removal 20
2 BRAKES (Duplex) SECTION 13.2 B HD9 Euro5

- Refitting 20
FRONT BRAKES OVERHAUL 22
- Dismantling 22
- Drum turning 26
- Brake lining replacement 26
- Assembly 27
REAR BRAKES OVERHAUL 31
- Dismantling 31
DESCRIPTION
The vehicle is fitted with drum brakes. The stroke of the wedge unit rollers causes the command pins
The brakes are DUPLEX type. There are two actuators each to expand winning the resistance of the brake shoe return
comprising a register cylinder and an anchor cylinder. springs, pushing the brake shoe up against the drum to genera-
te braking power.
Each actuator operates a shoe and is the anchor pin for the
opposite one. In this way the two shoes (self-winding type) When the brake is released air pressure drops in the brake cy-
working symmetrically. linder membrane section.
Each braking group consists of a body housing the adjuster and As a result the wedge unit is returned to rest position.
command pins and wedge units.
The wedge units are operated by the cylinder rods that in turn
are driven by compressed air.
Figure 1
1. Brake lining - 2. Brake shoe holder - 3. Register cylinder - 4. Anchor cylinder - 5. Dust boot - 6. Return spring -
7. Wedge unit - 8. Wear indicator wire
Automatic take-up device Figure 4

Figure 2
1471304
1471302
when the brake pedal is released, the screw/sleeve group
returns to home position. However, since the pawl has
When the brake is engaged, screw (1) and adjusting sleeve (2) engaged the sleeve teeth stepped by one tooth, the latter is
move axially outwards. In this way the sleeve teeth move in obliged to rotate anti-clockwise, unscrewing in relation to the
relation to those of the pawl (3) causing compression of the adjusting screw.
pawl return spring (4);
Thus the screw protrudes in relation to the sleeve, reducing
Figure 3 the clearance between the shoe and the drum.
1471303
when the shoe drum distance (clearance) exceeds a certain

limit, enough to axially move the sleeve by a tooth pitch, the
pawl moves over the sleeve teeth and engages the stepped
teeth again by one tooth;
FRONT AXLES BRAKES DRUM BRAKES

Drum diameter:
- nominal  mm 410  410.4
 - 1st oversize  mm 412
- 2nd oversize  mm 414
Brake lining thickness:
- Nominal S mm 21.1
- 1st oversizing S mm 22.1
- 2nd oversizing S mm 23.1
- Minimum admitted S1* mm 4.7
* In correspondence to the last rivet of the shoe with wear-out sensor, on the side opposite the cylinder
Brake lining diameter:
- nominal  mm 407.5  409
 - 1st oversize  mm 409.5  411
- 2nd oversize  mm 411.5  413
Brake lining width:
L mm 180
G
Clearance between brake linings
and drum
G mm 0.8  1.2
Max. error of concentricity of drum

E diameter after skimming
E mm 0.04
WHEEL HUBS
Wheel hub bearings 2, taper roller bearings
Wheel hub bearing rolling torque

protection Nm 3 Nm + (7.5  9 Nm)
run-in bearings and new lubricated
seal rings Nm 3 Nm + (4  5 Nm)
run-in bearings and seal rings
Nm 3 Nm + (3  4 Nm)
Half shaft end play mm 0.5  1
REAR AXLES BRAKES DRUM BRAKES

Drum diameter:
- nominal  mm 410  410.4
 - 1st oversize  mm 412

- Nominal S mm 21.1
- 1st oversizing S mm 22.1
- 2nd oversizing S mm 23.1
- Minimum admitted S1* mm 4.7
- nominal  mm 407.5  409
j - 1st oversize  mm 409.5  411
- 2nd oversize  mm 411.5  413
Brake lining width:
L mm 200
G
and drum
G mm 0.8  1.2
Max. error of concentricity of

E drum diameter after skimming
E mm 0.04
WHEEL HUBS
Wheel hub bearings 2 taper roller bearings

protection Nm 3 Nm + (12  16 Nm)
run-in bearings and new lubricated
seal rings Nm 3 Nm + (5  7 Nm)
run-in bearings and seal rings
Nm 3 Nm + (2.5  4.5 Nm)
Half shaft end play mm 0.5  1

DIAGNOSTICS
Common faults
1- Automatic take-up does not function. 4- Inefficient braking.

2- The shoes do not detach from the drum. 5- Uneven braking.
3- Uneven wear of friction facings.
AUTOMATIC TAKE-UP DOES

1 NOT FUNCTION
Pawl spring broken. Replace the spring.

YES
NO
Pawl and sleeve teeth worn . Replace worn parts.

YES
NO
Take-up device parts corroded or locked. Overhaul device.

YES
NO
Adjusting screw too tight on sleeve. Adjust screw position correctly.

YES
NO
Shoe web not positioned correctly. Reposition the shoes.

YES
NO
Poor lubrication. Lubricate.

YES
THE SHOES DO NOT DETACH

2
FROM THE DRUM
Shoe return springs broken. Replace broken springs.

YES
NO
Adjustment cylinders locked. Overhaul take-up device.

YES
NO
Return spring wedge broken . Replace spring.

YES
NO
Insufficient spring pneumatic cylinder stroke (rear bra- Overhaul or replace pneumatic cylinder.
kes). YES
NO
Air leakage from spring pneumatic cylinder (rear bra- Replace pneumatic cylinder.
kes). YES
UNEVEN WEAR OF FRICTION

3
FACINGS
Shoes not arranged according to specifications. Attain to assembly specifications.

YES
NO
Grease on friction facings. Replace the facings: find and remove the cause of the
YES grease.
Irregular drum roughness. Grind or replace drum.

YES
NO
Taper or deformation of shoe. Grind or replace drum.

YES
NO
Uneven pressure in pneumatic cylinders. See pneumatic system diagnostics.

YES
4 INEFFICIENT BRAKING
Too much clearance. Take-up device not functioning, overhaul.

YES
NO
Worn friction facings. Replace facings and overhaul the brakes.

YES
NO
Grease on friction facings. Replace the facings: find and remove cause of grease.
YES
NO
Uneven pneumatic cylinders pressure. See pneumatic system diagnostics.

YES
5 UNEVEN BRAKING
Pneumatic cylinders assembly depth incorrect. Assemble correctly.

YES
NO
Worn friction facings. Replace the facings and overhaul the brakes.
YES
NO
Friction facings not all of the same material. Replace the facings.
YES
NO
Spring wedge group broken. Replace the spring.

YES
NO
YES grease.
NO

YES
For further information on the braking organs and sy-

stem diagnostics, see Section 16 - Pneumatic braking
system - services.
TIGHTENING TORQUES
DETAIL TORQUE
Nm (kgm)
Take-up pawl securing screws 30 (3)
Guiding pin securing screws 30 (3)
Shoe-rail clip securing screws 30 (3)
Dust guard securing screws 30 (3)
Pneumatic cylinder securing ring nut 300 (3.0)
Screws securing drum to reduction gear 25 (2.5)
Screws securing wheels 650 (66)
Planet gear set-hub support fastening screws 250 (25)
Reducer cover fastening screws 50 (4.9)
Figure 5
342B132B001R
TOOLS
99301001 Lathe for brake drums with accessories
99301006 Equipment for turning brake shoes
99305087 Riveter
99345030 Crane for combined brake cylinders disassembly and reassembly
99345037 Part for combined brake cylinders disassembly and reassembly (use
with 99345030)
99345094 Base for spring brake cylinders disassembly and reassembly (use
with 99345030 - 99345095)
99345095 Parts to use with 99345094
99356006 Wrench for removing/replacing combined brake cylinder ring nut
99372213 Equipment for turning brake drums (use with 99301001
99372217 Brake shoe return spring fitting/removal tool
99373002 Dust boot locking ring fitting tool

99395026 Hub rolling torque rolling torque test tool (use with torque
wrench)
99389819 Tool for measuring rolling torque for use with dynamometer
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 6
2371801
- Cut off the battery master switch or disconnect the

of short circuits.
- Restore vehicle operation at the end of the operations.
Proceed as follows:
Figure 7
- With the pedal in home position, adjust the stop screw

(1) to obtain the specified clearance between lever and
brake distributor push rod.
pedal clearance (B) = 0.5 — 1.0 mm
Since the distributor acts as stop for the brake pedal,

there is no need for pressed pedal adjustment.
FRONT BRAKES PNEUMATIC CYLINDER

REMOVAL-REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 8
2371801

of short circuits.
Make sure that residual pressure has been

completely discharged from the circuits and related
reservoirs.
- For easier operation, it may be opportune to remove the
wheel from the side involved in the operation, as Apply LOCTITE 573 sealant to the pneumatic
described in the Rules for Use of the USE AND cylinder threading.
MAINTENANCE MANUAL
- Carefully clean the area of operation to avoid foreign
matter entering into the drum.
- Fit the pneumatic cylinder and screw the ring nut without
fully tightening.
- Check correct direction of fitting, then tighten the ring
Use a vacuum cleaner to collect residues. nut to the specified torque.
Pneumatic cylinder locking ring nut: 295 Nm
- Connect the pneumatic fitting and the bleeding pipe.
Removal
Proceed as follows:
- Disconnect the pneumatic fitting (3) from the relevant
pneumatic cylinder. - If removed, refit the wheel on the side involved, following
the indications in the Instructions for use of the USE AND
- Disconnect the bleeding pipe (4); MAINTENANCE MANUAL.
- Loosen the ring nut (2) and unscrew the pneumatic
cylinder (1)

- Check that pneumatic pipes are intact: otherwise replace
any damaged part.
- Check that the ring nut and the thread are intact with no
damage or dents: otherwise replace the pneumatic
cylinder.
Figure 9
342B132B002R
REAR BRAKES PNEUMATIC CYLINDER

REMOVAL-REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 10
2371801

of short circuits.

reservoirs.
any damaged part.
Figure 11
cylinder.
Refitting
Proceed as follows:
Apply LOCTITE 573 sealant to the pneumatic

cylinder threading.
356A132A001R
fully tightening.
Proceed as follows: nut to the specified torque.
- Engage the parking brake to discharge the pneumatic Pneumatic cylinder locking ring nut: 295 Nm
pressure from the parking chamber (1). - Connect the pneumatic fitting/fittings and the bleeding
- Disengage the shoes unscrewing screw (2) completely. pipe.
wheel from the side involved in the operation, as Final operations
described in the Instructions for use of the USE AND Proceed as follows:
MAINTENANCE MANUAL
- If removed, refit the wheel on the side involved, following
- Carefully clean the area of operation to avoid foreign the indications in the Instructions for Use of the USE
matter entering into the drum. AND MAINTENANCE MANUAL.
Use a vacuum cleaner to collect residues.
Removal
Proceed as follows:
Single pneumatic cylinder (A)
- disconnect the pneumatic fitting (3) from the relevant
pneumatic cylinder;
- disconnect the bleeding pipe (4);
- loosen the ring nut (2) and unscrew the pneumatic
cylinder (1).
Spring type pneumatic cylinder (B)
pneumatic cylinder;
cylinder (1).
Figure 12
342B132B003R
FRONT BRAKES OVERHAUL Figure 15

Dismantling
Proceed as follows:
Figure 13
- Remove the screws fastening the brake drum (1) to the

wheel hub (2). Fit two screws to the holes on the drum
(arrow) and extract it from the wheel hub;
- Disconnect the brake lining wear indicator electrical con-
- Park the vehicle on a flat surface and loosen the wheel nection;
nuts.
Figure 16
- Lift the front of the vehicle and rest it on suitable supports;
- Position hydraulic trolley 99321024 (1) under the wheels.
- Remove the wheel nuts and remove the wheels.
Figure 14
- Disconnect electrical connection (1) for braking seal

wear indicator cable.
Figure 17
- Turn the wheel hub (I) such that the oil drain plug (2) is
facing downwards.
- Remove the plug and drain the oil from the group into a
container.
- To facilitate draining, also remove a screw (3) from the
cover (4).
- Remove the plug on the axle box to drain the oil from the
differential group into a suitable container.
- Once the oil is drained, replace the plugs in the drain ho-
les.
39489
- Detach the brake shoe return springs (1) with tool

99372217;
Figure 18 Figure 20
38500B
- Remove the wedge units from their seats;
Figure 21
- Remove the brake shoe and check the condition of the

slider clips:
dimension A< = 6.7 mm
Figure 19
38355
- Remove the metal snap ring (2) with a screwdriver;

- Remove the complete register cylinder (1) from the brake
body (3);
Figure 22
38.500A
- Disconnect the air lines (1) from the brake cylinders;

- With a suitable tool unlock the ring nut (2) and remove
both rotochambers (3);
38356
- Unscrew the piston guide pin (1) and extract the piston
from the brake housing.
Figure 23 - Check condition of brake shoes, if cracking is found,

replace.
- If the braking surface of the gaskets has traces of grease,
find the cause and remove it.
- Check the minimum thickness permitted for the braking
gaskets (See characteristics and data table).
- If the value found is below, or only slightly higher, replace.
- Check intactness and/or efficiency of the braking gasket
wear indication cable .
- Check intactness and/or efficiency of the shoe springs.
Figure 25
38500C
- Remove the metal snap ring a screwdriver.

- Unscrew the guide piston guide pin and extract the piston
- Repeat the same operations on the opposite actuator.

Figure 24
38357
- Separate the automatic adjustment units.

- Unscrew the adjustment bushings (3) from theadjust-
ment pins (2) then withdraw the sealing gaskets (1).
- Check wear on external helcoidal teeth of the adjustment
bushings, make sure the bushings slide smoothly when
screwing on the related adjustment pins.
Figure 26
41929
- Check condition of wear of pin seats on brake casings (1),

if there is excessive scoring or wear replace the complete
brake casing flanges following the instructions in the axles
section.
- Inspect wear on drums to decide if they can be re-used.
- Measure the drums diameter with a vernier caliper with-
out bending the arms of the same.
- Measure the diameter in several points to establish ovality
and wear, also taking into consideration the depth of scor-
ing on the braking surface. 38358
- Permitted ovality and/or eccentricity tolerance: 0.25 mm. - Withdraw the sealing gaskets (2) from the reaction pins
- If wear or scoring is found that cannot be restored by (1) .
grinding the braking surface, or if there are evident signs - Carefully clean all the individual components of the brak-
of overheating , replace the drums ( See characteristics ing units.
and data table ).
Figure 27 Figure 30
38359
- Check wear on the thrust pins (2) and reaction pins (1), - Check drum wear to determine whether they can be
check condition of slanting plane surfaces (3) where the used again.
shoes opening control rollers act.
- Measure the diameter of the drums with a sliding gauge
Figure 28 without angling the arms.
- Measure the diameter is several points to determine ova-
lisation and wear, also considering the depth of scoring on
the braking surface.
- Maximum admissible tolerance on ovality and/or out-of--
centre 0.25 mm.
- If wear or scoring is found of an entity that does not per-
mit rectification by brake surface boring-out, or evident
signs of overheating, replace the drum (see Specifications
and data table).
- Check the condition of the brake shoes, if cracked, repla-
ce them.
- If the shoe lining is greasy, ascertain the cause and remove
38360
it.
- Check wear on guide pins teeth (3), intactness of the - The minimum allowed brake lining thickness is 4.7 mm,
related compression springs (2), and the copper washers measured at the last rivet from the opposite side to the
(1). cylinder on the brake shoe with wear sensor.
Figure 29 - If the value is less or only a little greater, replace the shoes.
- Check the integrity and/or efficiency of brake lining wear
indicator wire.
- Check the integrity and/or efficiency of the brake shoe re-
turn springs.
35713
- Check that the wedge units slide easily and there are no
signs of abrasion.
If wear is found on wedge unit components, the

complete wedge unit has to be replaced..
Drum turning Brake lining replacement

- Measure drum diameter with a sliding gauge without an-
Figure 32
gling the arms to determine ovalisation and wear at seve-
ral points.
Figure 31
ASTRA
17255
- Remove the worn brake linings from the shoes with

40520
pneumatic press 99305087 (1).
- Fit tool 99372213 (2) to the brake drum (1). Remove the brake lining wear indicator wire from
the lower shoes.
- Mount this assembly on lathe 99301001 (3).
- On the spindle fit a series of shims to eliminate group axial
play, tighten the lock nut and apply the lathe support.
- Position the complete shoe (4) on the adjustable check
- Apply the anti-vibration clamp to the brake drum. plate (5).
- Turn the drum in several passages to remove the quantity - With the chisel (2) fitted to the press head (1), cut the ri-
of material necessary to eliminate any imperfections. vet heads (3).
- When finished, remove the drum from the lathe and pro- - Remove the rivets from the brake shoes.
ceed to thoroughly clean it.
- Thoroughly clean the brake shoes, washing and blowing
dry.
The maximum diameter oversize of the drum is
given on the drum itself. Figure 33
This limit must never be exceeded, as this would
jeopardise braking effectiveness and drum strength.
Fit suitably oversized brake shoes to the drums. Each

axle of the vehicle must be fitted with shoes of the
same type.
17256
- Apply the support pins (5) to the press support (4).

- Proceed to rivet the brake linings (3) to the shoes (2)
using the driver (1) fitted to the press head.
To correctly rivet the brake linings, begin from the

centre and work outwards to the edges.
Figure 34 Assembly
Proceed as follows:
Figure 36
40524
- Using tool 99301006 (2), turn the brake linings (1).

38364
Figure 35
- Fit the seals (2) to the adjuster pin units (1). Grease the
pin threads (1). Fully tighten the adjuster bush (3) and tho-
roughly grease its external diameter.
- Grease the internal diameter of the thrust pins (4).
When overhauling the brakes, replace the adjuster

and thrust pin seals.
Use Rockwell RBSK 0253 grease.
Figure 37
40876
- Using tool 99305079 (2) in place of 99301006, turn the

brake linings (1) after fitting them as instructed below.
Tool 99305079 can be used after removing the hub.

For further information regarding the hub removal--
refit procedure, see Section 11 (axle) and Section 38365
12 (front and rear axles).

- Fit the seals (1) to the thrust pins (3);
- Check that the seal fits correctly in the groove (2) on the
thrust pins. Grease the sliding surface (3) of the pins and
the inclined sliding surface of the wedge (4).
Figure 38 Figure 40
38366 38368
- Insert the thrust pin §(1) into the seat on the brake hou- - With tool 99373002 (1) press the seal metal ring into the
sing (3) such that the slot is facing the guide pin (2). brake housing (2).
- Grease and insert the complete guide pin (2) into the sat
Figure 41
in the brake housing (3); check that the washer is inserted
(5) and tighten a few turns.
The guide pin (2) must be inserted such that the

tooth (4) runs in the groove in the brake housing (3).
Figure 39
38369
- Insert the thrust pin (4) into the seat on the brake housing
(1) such that the slot is facing the guide pin hole (2). Grea-
se and tighten the guide pin (2) to the specified torque.
Before fitting the thrust pins (4) check the punch

markings on it. The letter “R” (right) or “L” (left)
38367 indicates right or left wheel brake.
- Insert the automatic adjuster unit (1) on the adjuster pin,

fit the seal metal ring (2) to the brake housing (4).
Tighten the guide pin (3) to the specified torque.
Figure 42 Figure 44
38370
38500D
- With tool 99373002 (2) press the seal metal ring (1) into
the brake housing. - Fully tighten the brake cylinders (2) in the corresponding
- Proceed to assemble the other brake shoe command seats such that the air connectors are in their original posi-
units as instructed above. tion and the discharge hole is open and facing down-
wards.
Figure 43 - Connect the air lines (1) to the brake cylinders.
Figure 45
17268
- Thoroughly grease the wedge units (1) and insert them 38373
in the corresponding seats on the brake housing (2) such
that the wedge unit roller rest on the corresponding races - Fully tighten the adjuster units (2), then unscrew by one
on the thrust pins. turn to give initial adjustment for automatic take-up; posi-
- Hand tighten the ring nut on the rotochamber sleeve, to tion them such that the slots (1) can engage with the
the end of its thread. shoes.
- Apply LOCTITE 573 sealing paste to the first few turns

of the sleeve thread.
Figure 46 Figure 48
39547
38374
- Fit the brake drum (1) to the wheel hub and fasten it with
- Fit the shoes (1) into the corresponding seats such that the two screws.
the punched arrow (2) is pointing in the direction of drum
forward travel.
- Attach the brake shoe return springs (3 and 5) with tool
99372217 (4).
Figure 47
9819Z
- Work on the adjuster cylinder guide pins to obtain shoe

diameter (d) 2 mm less than the diameter (D) of the drum
used.
d = D - 2 mm
REAR BRAKES OVERHAUL Figure 51
Dismantling
Proceed as follows:
Figure 49
40053
- Unscrew the screws (2), remove the cover (3) and reco-
ver the oil.
Figure 52
39950
- Park the vehicle on a flat surface and loosen the wheel

nuts.
- Lift the rear of the vehicle with a hydraulic jack and rest
it on suitable supports. Remove the wheels with hydraulic
trolley 99321024 (1).
Figure 50
40338
- With a recessed hexagonal wrench unscrew the two

drum retainer screws (1). Replace them with the extrac-
tor screws (5): then tighten these to detach the drum
from the hub.
- Remove the drum with suitable cables and lifting gear.
Dismantle and overhaul the braking group as

39351 instructed for the front brakes.
- Fully unscrew the combined cylinder (1) manual release

screw (2)
Figure 53 Figure 55
39656 39955
- Fit the brake drum (1) to the gear set support. - Fit the wheels (2) and tighten the nut (1) to specified tor-
que.
- Fasten the drum with the two countersunk screws and
tighten to specified torque. - Fit the opposite braking group.
- Start the vehicle for a sufficient time to recharge the sy-
Figure 54
stem.
- Repeatedly apply the brakes to settle the braking group
and take up play between linings and drum with vehicle
in motion.
39954
- Restore parking brake command cylinder function (1)1by

fully re-tightening the screw (2).
BRAKES (10 ton. version)
SECTION 13.2 C
HD9 Euro5 SECTION 13.2 C BRAKES (10 ton. version) 1
SECTION13.2 C
Brakes (10 ton. version)

Page
DESCRIPTION 3
- SIMPLEX front brakes 3
- DUPLEX front brakes 4
- Rear brakes 5
- Automatic backlash recovery device 6
DIAGNOSTICS 10
TOOLS 15
GENERAL 18
FRONT BRAKES PNEUMATIC CYLINDER REMOVAL--
REFITTING 20
GENERAL 20
- Removal 21
- Refitting 21
REAR BRAKES PNEUMATIC CYLINDER REMOVAL-
REFITTING 23
GENERAL 23
2 BRAKES (10 ton. version) SECTION 13.2 C HD9 Euro5
- Removal 24
- Refitting 24
FRONT BRAKE OVERHAUL 26
- Removal 26
- Drum turning 29
- Fitting in place 30
REAR BRAKES OVERHAUL 33
- Dismantling 33
- Drum turning 37
- Assembly 39
DESCRIPTION
SIMPLEX front brakes Each brake consists of a body which accommodates the ad-
The brakes are of the SIMPLEX drum type. An actuator con- justment pins, the control pins and the wedge.
sisting of two symmetric take-up units. The wedges are actuated by the cylinder rods which is turn
The actuators actuate the shoes which are hinged onto two are actuated by compressed air.
anchoring pins. The rollers of the wedge during their stroke expand the con-
In this way, one shoe is of the leading type and the other is trol pins which overcome the resistance of the jaw springs
of the trailing type. moving the shoes towards the drum and thus braking the ve-
hicle.
When the braking action ceases the air pressure in the brake
cylinder membrane section comes less.
The wedge is pulled back to the initial position as a conse-
quence.
Figure 1
307B132H001R
1. Shoes - 2. Shoe holder plate - 3. Take-up unit - 4. Spring - 5. Wedge

DUPLEX front brakes Each brake consists of a body which accommodates the ad-
The brakes are of the DUPLEX drum type. They present two justment pins, the control pins and the wedge.
actuators both with two take-up units: two wedge units are The wedges are actuated by the cylinder rods which is turn
also present. are actuated by compressed air.
Each actuators actuate both shoes at the same time. In this The rollers of the wedge during their stroke expand the con-
manner, the two jaws move in the horizontal direction and trol pins which overcome the resistance of the jaw springs
work symmetrically. moving the shoes towards the drum and thus braking the ve-
hicle.
When the braking action ceases the air pressure in the brake
cylinder membrane section comes less.
The wedge is pulled back to the initial position as a conse-
quence.
Figure 2
307B132H002R
1. Shoes - 2. Shoe holder plate - 3. Take-up unit - 4. Spring - 5. Wedge

Rear brakes
The brakes are DUPLEX type. There are two actuators each The stroke of the wedge unit rollers causes the command pins
comprising a register cylinder and an anchor cylinder. to expand winning the resistance of the brake shoe return
springs, pushing the brake shoe up against the drum to genera-
Each actuator operates a shoe and is the anchor pin for the
te braking power.
opposite one. In this way the two shoes (self-winding type)
working symmetrically. When the brake is released air pressure drops in the brake cy-
linder membrane section.
Each braking group consists of a body housing the adjuster and
command pins and wedge units. As a result the wedge unit is returned to rest position.
The wedge units are operated by the cylinder rods that in turn
are driven by compressed air.
Figure 3
1. Brake lining - 2. Brake shoe holder - 3. Register cylinder - 4. Anchor cylinder - 5. Dust boot - 6. Return spring -
7. Wedge unit - 8. Wear indicator wire
Automatic backlash recovery device

Front brakes As a consequence of this action, the front crenulations of the
Pressing the brake pedal feeds the membrane cylinder which ring (4) and of the ring (5) can reciprocally slide if the rota-
moves the wedge (1). tional movement exceeds the pitch of the crenulations skip-
Two rollers are arranged on the wedge. The rollers by pres- ping to the next tooth of the two components.
sing on ramps of the bushings (2) advance the ring (4), the When the brake pedal is released, the wedge (1) goes back
ring (5) and the screw (6) thus applying the vehicle brakes. to the initial position pulled by the shoe springs and so do the
Following the longitudinal movement of the bushing (2), the bushings (2) and the ring (4).
pin (9) compressed by the spring (8) is arranged by the side The pin (9), which previously allowed the rotation of the ring
of the helical groove. (4), now revolves in the opposite direction, if the backlash be-
This determines the rotation movement of the ring (4) pro- tween shoe and drum allowed the backlash recovery system
portioned to the stroke of the bushing, depends on the back- to skip to the next tooth. The ring (4) in its backward move-
lash present between shoe and drum. ment will pull the ring (5) in the same direction. This will un-
screw the pin (6) from the ring (5) and consequently recover
the created backlash.
Figure 4
000678t
Rear brakes Figure 7

Figure 5
1471304
1471302
When the brake pedal is released, the screw/sleeve group
returns to home position. However, since the pawl has
When the brake is engaged, screw (1) and adjusting sleeve (2)
engaged the sleeve teeth stepped by one tooth, the latter is
move axially outwards. In this way the sleeve teeth move in
obliged to rotate anti-clockwise, unscrewing in relation to the
relation to those of the pawl (3) causing compression of the
adjusting screw.
pawl return spring (4);
Thus the screw protrudes in relation to the sleeve, reducing
Figure 6 the clearance between the shoe and the drum.
1471303
When the shoe drum distance (clearance) exceeds a certain

limit, enough to axially move the sleeve by a tooth pitch, the
pawl moves over the sleeve teeth and engages the stepped
teeth again by one tooth;
FRONT AXLES BRAKES DRUM BRAKES

Drum diameter:
- nominal  mm 410  410,4
- 1st oversize  mm 412
- Nominal S mm 21,1
- 1st oversizing S mm 22,1
- 2nd oversizing S mm 23,1
- Minimum admitted S1* mm 4,7
- nominal  mm 407,5  409
- 1st oversize  mm 409,5  411
- 2nd oversize  mm 411,5  413
Brake lining width:
L mm 180
G
and drum
G mm 0,8  1,2
Max. error of concentricity of drum

E diameter after skimming
E mm
0,04
REAR AXLES BRAKES DRUM BRAKES

Drum diameter:
- nominal  mm 410  410,4
- 1st oversize  mm 412

- Nominal S mm 21,1
- 1st oversizing S mm 22,1
- 2nd oversizing S mm 23,1
- Minimum admitted S1* mm 4,7
- nominal  mm 407,5  409
j - 1st oversize  mm 409,5  411
- 2nd oversize  mm 411,5  413
Brake lining width:
L mm 200
G
and drum
G mm 0,8  1,2
Max. error of concentricity of

E drum diameter after skimming
E mm
0,04
DIAGNOSTICS
Common faults
1 - Automatic take-up does not function. 4 - Inefficient braking.

2 - The shoes do not detach from the drum. 5 - Uneven braking.
3 - Uneven wear of friction facings.
AUTOMATIC TAKE-UP DOES

1 NOT FUNCTION
Pawl spring broken. Replace the spring.

YES
NO
Pawl and sleeve teeth worn . Replace worn parts.

YES
NO
Take-up device parts corroded or locked. Overhaul device.

YES
NO
Adjusting screw too tight on sleeve. Adjust screw position correctly.

YES
NO
Shoe web not positioned correctly. Reposition the shoes.

YES
NO
Poor lubrication. Lubricate.

YES
THE SHOES DO NOT DETACH

2
FROM THE DRUM
Shoe return springs broken. Replace broken springs.

YES
NO
Adjustment cylinders locked. Overhaul take-up device.

YES
NO
Return spring wedge broken . Replace spring.

YES
NO
Insufficient spring pneumatic cylinder stroke (rear bra- Overhaul or replace pneumatic cylinder.
kes). YES
NO
Air leakage from spring pneumatic cylinder (rear bra- Replace pneumatic cylinder.
kes). YES
UNEVEN WEAR OF FRICTION

3
FACINGS
Shoes not arranged according to specifications. Attain to assembly specifications.

YES
NO
YES grease.
Irregular drum roughness. Grind or replace drum.

YES
NO
Taper or deformation of shoe. Grind or replace drum.

YES
NO

YES
4 INEFFICIENT BRAKING
Too much clearance. Take-up device not functioning, overhaul.

YES
NO
Worn friction facings. Replace facings and overhaul the brakes.

YES
NO
Grease on friction facings. Replace the facings: find and remove cause of grease.
YES
NO
Uneven pneumatic cylinders pressure. See pneumatic system diagnostics.

YES
5 UNEVEN BRAKING
Pneumatic cylinders assembly depth incorrect. Assemble correctly.

YES
NO
Worn friction facings. Replace the facings and overhaul the brakes.
YES
NO
Friction facings not all of the same material. Replace the facings.
YES
NO
Spring wedge group broken. Replace the spring.

YES
NO
YES grease.
NO

YES
For further information on the braking organs and sy-

stem diagnostics, see Section 16 - Pneumatic braking
system - services.
TIGHTENING TORQUES
DETAIL TORQUE
Nm (kgm)
Take-up pawl securing screws 30 (3)
Guiding pin securing screws 30 (3)
Shoe-rail clip securing screws 30 (3)
Dust guard securing screws 30 (3)
Pneumatic cylinder securing ring nut 300 (3.0)
Screws securing drum to reduction gear 25 (2.5)
Screws securing wheels 650 (66)
Planet gear set-hub support fastening screws 250 (25)
Reducer cover fastening screws 50 (4.9)
Figure 8
342B132B001R
TOOLS
99301001 Lathe for brake drums with accessories
99301006 Equipment for turning brake shoes
99305087 Riveter
99345030 Crane for combined brake cylinders disassembly and reassembly
99345037 Part for combined brake cylinders disassembly and reassembly

(use with 99345030)
99345094 Base for spring brake cylinders disassembly and reassembly (use
with 99345030 - 99345095)
99345095 Parts to use with 99345094
99356006 Wrench for removing/replacing combined brake cylinder ring nut
99372213 Equipment for turning brake drums (use with 99301001
99372217 Brake shoe return spring fitting/removal tool
99373002 Dust boot locking ring fitting tool

99395026 Hub rolling torque rolling torque test tool (use with torque
wrench)
99389819 Tool for measuring rolling torque for use with dynamometer
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 9
2371801

of short circuits.
Proceed as follows:
Figure 10
- With the pedal in home position, adjust the stop screw

(1) to obtain the specified clearance between lever and
brake distributor push rod.
pedal clearance (B) = 0.5 — 1.0 mm
Since the distributor acts as stop for the brake pedal,

there is no need for pressed pedal adjustment.
FRONT BRAKES PNEUMATIC CYLINDER

REMOVAL-REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 11
2371801

of short circuits.

reservoirs.
wheel from the side involved in the operation, as Apply LOCTITE 573 sealant to the pneumatic
described in the Rules for Use of the USE AND cylinder threading.
MAINTENANCE MANUAL
- Carefully clean the area of operation to avoid foreign
fully tightening.
Use a vacuum cleaner to collect residues. nut to the specified torque.
Pneumatic cylinder locking ring nut: 295 Nm
- Connect the pneumatic fitting and the bleeding pipe.
Removal
Proceed as follows:
- Disconnect the pneumatic fitting (3) from the relevant
pneumatic cylinder. - If removed, refit the wheel on the side involved, following
the indications in the Instructions for use of the USE AND
- Disconnect the bleeding pipe (4); MAINTENANCE MANUAL.
- Loosen the ring nut (2) and unscrew the pneumatic
cylinder (1)

any damaged part.
cylinder.
SIMPLEX front brakes

Figure 12
342B132K001R
DUPLEX front brakes

Figure 13
342B132B002R
REAR BRAKES PNEUMATIC CYLINDER

REMOVAL-REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 14
2371801

of short circuits.

reservoirs.
Figure 15 any damaged part.
cylinder.
Refitting
Proceed as follows:
Apply LOCTITE 573 sealant to the pneumatic

cylinder threading.
356A132A001R
Proceed as follows: fully tightening.
- Engage the parking brake to discharge the pneumatic - Check correct direction of fitting, then tighten the ring
pressure from the parking chamber (1). nut to the specified torque.
- Disengage the shoes unscrewing screw (2) completely. Pneumatic cylinder locking ring nut: 295 Nm
- For easier operation, it may be opportune to remove the - Connect the pneumatic fitting/fittings and the bleeding
wheel from the side involved in the operation, as pipe.
described in the Instructions for use of the USE AND
MAINTENANCE MANUAL Final operations
- Carefully clean the area of operation to avoid foreign Proceed as follows:
- If removed, refit the wheel on the side involved, following
the indications in the Instructions for Use of the USE
AND MAINTENANCE MANUAL.
Use a vacuum cleaner to collect residues.
Removal
Proceed as follows:
Single pneumatic cylinder (A)
- disconnect the pneumatic fitting (3) from the relevant
pneumatic cylinder;
cylinder (1).
Spring type pneumatic cylinder (B)
pneumatic cylinder;
cylinder (1).
Figure 16
342B132B003R
FRONT BRAKE OVERHAUL Figure 18
Check that all precautions have been taken and that

all aspects concerning safety of personnel involved
in the operations have been explained before started
any operation.
Read the instructions provided in SECTION 1 of this
manual.
If in doubt, consult an expert.
Follow all the general recommendations for
correctly performing maintenance operations.
Removal
307B121H009R
The procedure refers to the simplex version. For the - Remove the fastening screws (1) of the brake drum (2)
duplex version act in exactly the same way on both and extract the wheel hub from the latter.
wedge units.
Figure 19
Proceed as follows:
Figure 17
40866
- Disconnect the brake lining wear indicator cable electri-

cal connection (1).
Figure 20
40864
- Place the vehicle on flat ground; remove the wheel nut

covers and loosen the nuts.
- Lift the front of the vehicle and rest it on suitable stands.
- Place hydraulic truck 99321024 (1) under the wheels.
- Remove the nuts and the wheels.
40867
- Unhook the shoe (1) return springs (2) using pliers

99357111.
- Remove the shoes (1) releasing the brake linings wear
indicator cable from the brake-carrier plate clamps and
withdraw the cable.
Figure 21 Figure 23
40868 40870
- Disconnect the brake cylinder (2) feeding pipes (1). - Take away the wedge units (1) controlling the brake
Using wrench 99356006 (3) loosen the ring nuts and housing (2).
remove the brake cylinder (2).
Figure 22 Figure 24
40869 40871
- Take away the wedge units (1) controlling the brake - Remove the guide screws (2) and remove the thrust pins
housing (2). (1) with the adjustment bushes and relevant springs.
- Remove the opposite brake unit.

Proceed as follows:
- Check the wear of the pin seats on the brake housing for
scratches or excessive wear and replace faulty brake
bodies.
Figure 25
- Check drum wear to determine whether they can be

used again.
without angling the arms.
- Measure the diameter is several points to determine
35711 ovalisation and wear, also considering the depth of
scoring on the braking surface.
- Dis-assemble the automatic adjustment unit. - Maximum admissible tolerance on ovality and/or
- Carefully clean all the components of the braking unit. out-of-centre 0.25 mm.
- Check the wear on the adjusting bush teeth (2 and 3), - If wear or scoring is found of an entity that does not
ascertain that the bushes (2) slide freely screwing them permit rectification by brake surface boring-out, or
on the relevant adjusting pins (1). evident signs of overheating, replace the drum (see
Specifications and data table).
- Check the condition of the springs (4) and thrust pins (5).
- Check the condition of the brake shoes, if cracked,
replace them.
Figure 26 - If the shoe lining is greasy, ascertain the cause and
remove it.
- The minimum allowed brake lining thickness is 4.7 mm,
measured at the last rivet from the opposite side to the
cylinder on the brake shoe with wear sensor.
- If the value is less or only a little greater, replace the
shoes.
indicator wire.
- Check the integrity and/or efficiency of the brake shoe
return springs.
35713
- Check that the wedge units slide easily and that there are
no abrasions.
If wear is found on the wedge components the com-

plete unit must be replaced.

- Measure drum diameter with a sliding gauge without Figure 29
angling the arms to determine ovalisation and wear at
several points.
Figure 28
ASTRA
17255
- Remove the worn brake linings from the shoes with

pneumatic press 99305087 (1).
40520
the lower shoes.
play, tighten the lock nut and apply the lathe support. - Position the complete shoe (4) on the adjustable check
- Apply the anti-vibration clamp to the brake drum. plate (5).
- Turn the drum in several passages to remove the quantity - With the chisel (2) fitted to the press head (1), cut the
of material necessary to eliminate any imperfections. rivet heads (3).
- When finished, remove the drum from the lathe and - Remove the rivets from the brake shoes.
proceed to thoroughly clean it. - Thoroughly clean the brake shoes, washing and blowing
dry.
Figure 30
The maximum diameter oversize of the drum is gi-
ven on the drum itself.
This limit must never be exceeded, as this would jeo-
pardise braking effectiveness and drum strength.

same type.
17256
- Apply the support pins (5) to the press support (4).

- Proceed to rivet the brake linings (3) to the shoes (2)
using the driver (1) fitted to the press head.

Fitting in place
Figure 31 Figure 33
40524
- Using tool 99301006 (2), turn the brake linings (1). 40519
- Grease components (1,2 and 3) and fit them, in

sequence, in the thrust pin (4).
Figure 32
- Grease the interior of the brake housing (6) and fit in
place the thrust pins (4) restraining them through the
guide pins (5).
Figure 34
40876 35714
- Using tool 99305079 (2) in place of 99301006, turn the - Fit together the adjusting unit thoroughly greasing the
brake linings (1) after fitting them as instructed below. sliding surfaces.

For further information regarding the hub removal--
refit procedure, see Section 11 (axle) and Section 12
(front and rear axles).
Figure 35 Figure 37
39939 40874
- Fit the adjusting units (2) into the brake housing (1) - Fit the brake lining wear indicator cable in the clamp and
placing the clasp as shown in the figure. in the brake carrier plate hole.
- Fit in place the protection housing (3) in the brake - Fit in place the shoes (1) and hookup the return springs
housing groove (1). (2 and 3). Electrically connect (4) the wear indicator.
Figure 38
Figure 36
40875
- Loosen the adjusting units (1 and 2) equally to obtain

that diameter A is 2 mm less than the diameter of the
drum brake to be fitted.
diameter A =
diameter of the brake drum to be fitted - 2 mm
40523
- Fully fasten the take-up units (2) and the loosen them by
half a turn.
- In this manner, the automatic backlash take-up device is
ready to work.
- Align the milling of the shoe support block (1) with the
slot of the clip (3).
Figure 39 Figure 42
40879
307B121H032R
- Fasten the cylinder (2) fully in its seat.
- Fit the brake drum (1) and fix it to the wheel hub by - Check that the feeding holes are in the same position
means of the screws (2). found during disassembly; otherwise, loosen the cylinder
(2) as required and connect the feeding pipe (1).
Figure 40 - Feed the cylinder by pressing the service brake and use
tool 99356006 (4) to tighten the ring (3) at the specified
torque.
- Fit the wheels and tighten the fastening nuts at the
specified torque.
- Run the vehicle for the time needed to recharge the
system.
Repeatedly press the brake pedal to settle the braking
system and the backlash recovery device between lining
and drum.
- Restore vehicle working conditions.
- Take the vehicle for a test drive and check the correct
operation fo the braking system.
40878
- Do not brake violently or for a long time during the first
approximately 1000 km to allow the brake lining to settle
- Generously grease the wedge control units (1) and fit (run-in).
them in their seats on the brake housing so that the
wedge unit rollers rest in the thrust pin raceways.
Figure 41
39941
- Tighten the ring nut (1) by hand onto the shaft (2) to the
end of its stroke.
- Spread non hardening sealant paste LOCTITE 573 on
the three pin threads of the shaft (2).
REAR BRAKES OVERHAUL Figure 45

Dismantling
Proceed as follows:
Figure 43
40053
- Unscrew the screws (2), remove the cover (3) and reco-
ver the oil.
39950
Figure 46
- Park the vehicle on a flat surface and loosen the wheel
nuts.
- Lift the rear of the vehicle with a hydraulic jack and rest
it on suitable supports. Remove the wheels with hydraulic
trolley 99321024 (1).
Figure 44
40338
- With a recessed hexagonal wrench unscrew the two

drum retainer screws (1). Replace them with the extrac-
tor screws (5): then tighten these to detach the drum
from the hub.
- Remove the drum with suitable cables and lifting gear.
Figure 47
39351
- Fully unscrew the combined cylinder (1) manual release

screw (2)
39489
- Detach the brake shoe return springs (1) with tool

99372217;
Figure 48 Figure 50
38500B
- Remove the wedge units from their seats;
Figure 51
- Remove the brake shoe and check the condition of the

slider clips:
dimension A< = 6.7 mm
Figure 49
38355
- Remove the metal snap ring (2) with a screwdriver;

- Remove the complete register cylinder (1) from the brake
body (3);
Figure 52
38.500A
- Disconnect the air lines (1) from the brake cylinders;

- With a suitable tool unlock the ring nut (2) and remove
both rotochambers (3);
38356
- Unscrew the piston guide pin (1) and extract the piston
Figure 53 - Check condition of brake shoes, if cracking is found,

replace.
- If the braking surface of the gaskets has traces of grease,
find the cause and remove it.
- Check the minimum thickness permitted for the braking
gaskets (See characteristics and data table).
- If the value found is below, or only slightly higher, replace.
- Check intactness and/or efficiency of the braking gasket
wear indication cable .
- Check intactness and/or efficiency of the shoe springs.
Figure 55
38500C
- Remove the metal snap ring a screwdriver.

- Unscrew the guide piston guide pin and extract the piston
- Repeat the same operations on the opposite actuator.

Figure 54
38357
- Separate the automatic adjustment units.

- Unscrew the adjustment bushings (3) from theadjust-
ment pins (2) then withdraw the sealing gaskets (1).
- Check wear on external helcoidal teeth of the adjustment
bushings, make sure the bushings slide smoothly when
screwing on the related adjustment pins.
Figure 56
41929
- Check condition of wear of pin seats on brake casings (1),

if there is excessive scoring or wear replace the complete
brake casing flanges following the instructions in the axles
section.
- Inspect wear on drums to decide if they can be re-used.
- Measure the drums diameter with a vernier caliper with-
out bending the arms of the same.
- Measure the diameter in several points to establish ovality
and wear, also taking into consideration the depth of scor-
ing on the braking surface. 38358
- Permitted ovality and/or eccentricity tolerance: 0.25 mm. - Withdraw the sealing gaskets (2) from the reaction pins
- If wear or scoring is found that cannot be restored by (1) .
grinding the braking surface, or if there are evident signs - Carefully clean all the individual components of the brak-
of overheating , replace the drums ( See characteristics ing units.
and data table ).
Figure 57 Figure 60
38359
- Check wear on the thrust pins (2) and reaction pins (1), - Check drum wear to determine whether they can be
check condition of slanting plane surfaces (3) where the used again.
shoes opening control rollers act.
Figure 58 without angling the arms.
- Measure the diameter is several points to determine ova-
lisation and wear, also considering the depth of scoring on
the braking surface.
- Maximum admissible tolerance on ovality and/or out-of--
centre 0.25 mm.
- If wear or scoring is found of an entity that does not per-
mit rectification by brake surface boring-out, or evident
signs of overheating, replace the drum (see Specifications
and data table).
- Check the condition of the brake shoes, if cracked, repla-
ce them.
- If the shoe lining is greasy, ascertain the cause and remove
38360
it.
- Check wear on guide pins teeth (3), intactness of the - The minimum allowed brake lining thickness is 4.7 mm,
related compression springs (2), and the copper washers measured at the last rivet from the opposite side to the
(1). cylinder on the brake shoe with wear sensor.
Figure 59 - If the value is less or only a little greater, replace the shoes.
indicator wire.
- Check the integrity and/or efficiency of the brake shoe re-
turn springs.
35713
- Check that the wedge units slide easily and there are no
signs of abrasion.
If wear is found on wedge unit components, the

complete wedge unit has to be replaced..

- Measure drum diameter with a sliding gauge without an-
Figure 62
gling the arms to determine ovalisation and wear at seve-
ral points.
Figure 61
ASTRA
17255
Remove the worn brake linings from the shoes with pneuma-
40520
tic press 99305087 (1).
the lower shoes.
play, tighten the lock nut and apply the lathe support.
Position the complete shoe (4) on the adjustable check plate
- Apply the anti-vibration clamp to the brake drum. (5).
- Turn the drum in several passages to remove the quantity With the chisel (2) fitted to the press head (1), cut the rivet
of material necessary to eliminate any imperfections. heads (3).
Remove the rivets from the brake shoes.
- When finished, remove the drum from the lathe and pro- Thoroughly clean the brake shoes, washing and blowing dry.
ceed to thoroughly clean it.
Figure 63
The maximum diameter oversize of the drum is
given on the drum itself.
This limit must never be exceeded, as this would
jeopardise braking effectiveness and drum strength.

same type.
17256
Apply the support pins (5) to the press support (4).

Proceed to rivet the brake linings (3) to the shoes (2) using
the driver (1) fitted to the press head.

Figure 64 Assembly
Proceed as follows:
Figure 66
40524
Using tool 99301006 (2), turn the brake linings (1).

38364
Figure 65
- Fit the seals (2) to the adjuster pin units (1). Grease the
pin threads (1). Fully tighten the adjuster bush (3) and tho-
roughly grease its external diameter.
- Grease the internal diameter of the thrust pins (4).
When overhauling the brakes, replace the adjuster

and thrust pin seals.
Use Rockwell RBSK 0253 grease.
Figure 67
40876
Using tool 99305079 (2) in place of 99301006, turn the brake

linings (1) after fitting them as instructed below.

For further information regarding the hub
removal-refit procedure, see Section 11 (axle) and
Section 12 (front and rear axles). 38365
- Fit the seals (1) to the thrust pins (3);

- Check that the seal fits correctly in the groove (2) on the
thrust pins. Grease the sliding surface (3) of the pins and
the inclined sliding surface of the wedge (4).
Figure 68 Figure 70
38366 38368
- Insert the thrust pin §(1) into the seat on the brake hou- - With tool 99373002 (1) press the seal metal ring into the
sing (3) such that the slot is facing the guide pin (2). brake housing (2).
- Grease and insert the complete guide pin (2) into the sat
Figure 71
in the brake housing (3); check that the washer is inserted
(5) and tighten a few turns.
The guide pin (2) must be inserted such that the

tooth (4) runs in the groove in the brake housing (3).
Figure 69
38369
- Insert the thrust pin (4) into the seat on the brake housing
(1) such that the slot is facing the guide pin hole (2). Grea-
se and tighten the guide pin (2) to the specified torque.
Bfore fitting the thrust pins (4) check the punch

markings on it. The letter “R” (right) or “L” (left)
indicates right or left wheel brake.
38367
- Insert the automatic adjuster unit (1) on the adjuster pin,

fit the seal metal ring (2) to the brake housing (4).
Tighten the guide pin (3) to the specified torque.
Figure 72 Figure 74
38370
38500D
- With tool 99373002 (2) press the seal metal ring (1) into
the brake housing. - Fully tighten the brake cylinders (2) in the corresponding
- Proceed to assemble the other brake shoe command seats such that the air connectors are in their original posi-
units as instructed above. tion and the discharge hole is open and facing down-
wards.
Figure 73 - Connect the air lines (1) to the brake cylinders.
Figure 75
17268
38373
- Thoroughly grease the wedge units (1) and insert them
in the corresponding seats on the brake housing (2) such
that the wedge unit roller rest on the corresponding races - Fully tighten the adjuster units (2), then unscrew by one
on the thrust pins. turn to give initial adjustment for automatic take-up; posi-
tion them such that the slots (1) can engage with the
- Hand tighten the ring nut on the rotochamber sleeve, to shoes.
the end of its thread.
- Apply LOCTITE 573 sealing paste to the first few turns
of the sleeve thread.
Figure 76 Figure 78
38374 39656
- Fit the shoes (1) into the corresponding seats such that - Fit the brake drum (1) to the gear set support.
the punched arrow (2) is pointing in the direction of drum
forward travel. - Fasten the drum with the two countersunk screws and
tighten to specified torque.
- Attach the brake shoe return springs (3 and 5) with tool
99372217 (4). Figure 79
Figure 77
39954
Restore parking brake command cylinder function (1)1by fully

re-tightening the screw (2).
9819Z
- Work on the adjuster cylinder guide pins to obtain shoe

diameter (d) 2 mm less than the diameter (D) of the drum
used.
d = D - 2 mm
Figure 80
39955
- Fit the wheels (2) and tighten the nut (1) to specified tor-
que.
- Fit the opposite braking group.
- Start the vehicle for a sufficient time to recharge the sy-
stem.
- Repeatedly apply the brakes to settle the braking group
and take up play between linings and drum with vehicle
in motion.
FRONT SUSPENSIONS
SECTION 14.1
HD9 Euro5 SECTION 14.1 FRONT SUSPENSIONS 1
SECTION 14.1
Front suspensions
Page
DESCRIPTION 3
- First axle - parabolic springs suspension 3
- First axle - semi-elliptic spring suspension 4
- Second axle suspension 5
- Hydraulic shock absorbers 6
- Operation 6
- Noise 6
- Changes in braking effect 6
PNEUMATIC ALIGNMENT ADJUSTER 7
- Description 7
- Diagram 7
- Characteristics and data 7
- Operation 7
- Position of the components 8
CHARACTERISTICS AND SPECIFICATIONS 9

- Leaf springs 9
SHOCK ABSORBERS 9
TOOLS 10
DIAGNOSTICS 11
REMOVAL-REFITTTING LEAF SPRING 14
GENERAL 14
- Removal 15
2 FRONT SUSPENSIONS SECTION 14.1 HD9 Euro5

- Refitting 15
REMOVAL-REFITTING FRONT SHOCK ABSORBER 17
GENERAL 17
- Removal 18
- Refitting 18
REMOVAL-REFITTING FRONT STABILIZER BAR 19
GENERAL 19
- Removal 20
- Refitting 20
- Removing the rear leaf spring 21
- Checks 21
- Fitting in place the leaf spring 21
DESCRIPTION
First axle - parabolic springs suspension
The suspension system is comprised of a pair of longitudinally arranged single action leaf springs, supplemented by a pair of dual action
hydraulic telescope shock absorbers and two excursion limit elastic buffers for each spring.
The suspension is also fitted with a roll bar to control vehicle inclination when cornering.
Figure 1
1. Chassis 6. Axle (A) or drive axle (B)

2. Spring front mounting 7. Shock absorber mounting
3. Roll bar 8. Shackle
4. Buffer 9 Spring rear mounting
5. Anchor stirrup 10. Parabolic spring
First axle - semi-elliptic spring suspension

The suspension system is comprised of a pair of longitudinally arranged single action leaf springs, supplemented by a pair of dual action
hydraulic telescope shock absorbers and two excursion limit elastic buffers for each spring.
Figure 2

5. Anchor stirrup 10. Semi-elliptic spring
Second axle suspension

The suspension is similar to that of the first axle.
Besides the geometrical measurements it differs from the first axle in the leaf spring that has fewer leaves and the shock absorber
that is assembled slanted.
Figure 3

5. Anchor stirrup 10. Spring
Hydraulic shock absorbers Operation

The hydraulic shock absorbers are of the telescopic double act-
Figure 4
ing type.
These shock absorbers are also defined ”direct acting” since
their braking action is directly performed on the suspension el-
ements without levers.
They are fitted with thermostatically controlled valves, thus en-
suring that there are no noticeable differences in their perform-
ance, even following sharp changes in temperature.
Shock absorbers are divided into three different parts:
1. the cylinder part located above the piston (always filled
with oil);
2. the cylinder part located under the piston (always filled
with oil);
3. the oil reserve, i.e. the compartment between the cylinders
(5 and 6) (never completely filled with oil).
During the bouncing stage, i.e. when the shock absorber ex-
tends, the oil pushed by the piston (4) passes through the com-
partment, from the upper part of the piston to the lower part
of the cylinder.
During the compression stage, i.e. when the shock absorber
lengthens and piston goes downwards, the oil located under
the piston passes directly to the upper part of the cylinder.
For oil passing from one part of the piston to the other, a forcing
pressure intervenes acting on the piston and opposing piston
movement thus causing suspension braking.
Noise
This defect, which is often laid to shock absorbers, can have dif-
ferent origins. It is therefore recommended to inspect suspen-
sions carefully, including shock absorber connections to chassis
or leaf spring.
Check whether no shock absorber part is in ”metallic” touch
with the leaf spring or the chassis.
Shock absorber dust protection distortion, due to wheel rota-
tion, or short oil due to accidental leaks, can cause noise; in this
case the shock absorber must be replaced.
Changes in braking effect

A change in the braking effect can take place accidentally.
The decrease of the braking effect can be due to breakage of
internal parts, short oil or jams.
Replace the shock absorber in any case.
PNEUMATIC ALIGNMENT ADJUSTER

Description
The front suspensions can be equipped with an automatic pneumatic alignment adjuster.
For each front/rear axle, the device consists of:
- two pneumatic actuators, situated between the central part of the leaf spring and the frame and powered by a modulating
control valve;
- one modulating control valve is mounted on the frame and increases or reduces the actuator pressure as necessary. The valve
is activated by a lever connected to the steering coupling of the other rear axle, i.e. connected to an element which will stay
more or less at a constant distance from the ground even if the load varies.
TRAVEL DIRECTION
HD9ST0020MR
Diagram
1. Pneumatic actuator
2. First rear axle modulating control valve
3. Second rear axle modulating control valve
4. Service tank
A first front axle
B second front axle
Characteristics and data

Pressure: 1.6 bar
Load: 5000 N
Height: approximately 95 mm
This data refers to static load conditions (90000 N) for each of the two rear axles.
Operation
The system aims to keep the vertical alignment of the vehicle more or less the same when the front load changes.
An increase in the rear axle loads leads to pressure being sent by the actuators, increasing their height, discharging the suspension
and recovering the distance between the frame and the ground.
The opposite happens when the vehicle load is reduced.
Position of the components
The figure shows the components on a RHD 4 axle vehicle.
HD9ST0019MR
CHARACTERISTICS AND SPECIFICATIONS

Leaf springs
Type A spring (parabolic)

Mounting Spring characteristics
Vehicle
thickness length Flexibility
bearing bush leafs
[mm] [mm] [mm/kN]
2-axle standard on request 4 24 1800 3.001
1st axle
2nd axle standard on request 3 26 1600 2.155
Type B spring (semielliptical)

Mounting Spring characteristics
Vehicle
bearing bush leafs
[mm] [mm] [mm/kN]
2-axle standard - 10 15 1800 2.679
3-axle standard - 10 15 1800 2.679
4-axle - - - - - -
1st axle
2nd axle - - - - - -
1781404
SHOCK ABSORBERS
Lenght between eyebolts (mm)
open 650 ± 3
closed 427 ± 3
stroke 223
TIGHTENING TORQUES
Figure 5
A
A: first axle
B: second axle
PART TORQUE
Nm (Kgm)
1. Leaf spring retaining stirrup nuts 485 49
2. Shackle pin fastening bolts 625 64
3. Shackle screws on chassis 190 19
4. First axle front mounting screws 210 21
5. Second axle front mounting screws 150 15
6. Leaf spring pin cap fastening screws 130 13
TOOLS
99366201 Carriage pin rocking support pre-fitted ring nut

99321024 Trolley for wheel removal
DIAGNOSTICS
Main possible defects:
1 - Noisy suspension; 3 - Excessive suspension flexibility:

2 - The vehicle tends to drift to one side: 4 - Squeaking, knocking and noisiness in general.
1 NOISY SUSPENSION
Insufficient lubrication Lubricate carefully

YES
NO
Shock absorber are inefficient or noisy Renew shock absorbers

YES
NO
Wheel bearings worn and with excessive play Accurately check bearings and change damaged
YES components, if necessary.
NO
Hanger brackets loose Check hanger brackets and renew loose rivets fixing
YES brackets to chassis, if necessary.
NO
Leaf spring pack is loose as centre bolt is not perfect- Overhaul leaf springs and replace centre bolt self--
ly efficient YES locking nut.
NO
Leaf spring pack is loose as spring leaf U bolt rivets Check leaf spring U bolts and renew rivets, as re-
are broken YES quired.
2 THE VEHICLE TENDS TO DRIFT TO

ONE SIDE
Tyre pressure incorrect Check and accurately inflate tyres to the prescribed
YES pressure.
NO
Incorrect front wheel geometry Check and correct wheel geometry.

YES
NO
Incorrect front wheel bearing adjustment Adjust bearing play

YES
NO
Inefficient hydraulic shock absorbers Dismantle shock absorbers and service or replace
YES them.
NO
Efficient leaf spring Overhaul the leaf spring and carry out replacements
YES where necessary.
NO
Correct vehicle loading Check the load and arrange it evenly over the load-
YES ing area.
3 EXCESSIVE SUSPENSION FLEXIBILITY
Spring centre pin broken Replace the part.

YES
NO
Spring leaves inefficient Overhaul the spring and replace those parts which
YES cannot be used or, if necessary, the complete
spring.
4 SQUEAKING, KNOCKING AND

NOISINESS IN GENERAL
Incorrect fastening of leaf spring mountings Check mountings an if necessary replace the rivets
YES fastening the spring to the frame that are loose.
NO
Leaf spring pack is loose as central fastening pin is Overhaul leaf spring and replace central pin and
broken YES self-locking nut.
NO
Leaf spring pack is loose as fixing rivets for spring U Check leaf spring locking U bolts and change fixing
bolts are not efficient YES rivets.
NO
Wheel bearings worn with excessive play Carefully check the bearings and, if necessary, replace
YES any damaged parts.
Adjust the wheel bearing play.
REMOVAL-REFITTING LEAF SPRING

Very heavy parts
GENERAL
part of this manual. Specific safety instructions
Safety component.
Vehicle preparation

signboards.
Figure 6
2371801

of short circuits;
Figure 7
This procedure is valid for first axle and also for
second axle.
This procedure is valid for both half-elliptic spring

and for parabolic spring.
335B0141001R
Proceed as follows: - only for operations on left side: for easier operation,
disconnect the steering bar from the steering lever
- appropriately block the rear wheels; unscrewing the fastening nut and remove the ball joint
- raise the front of the vehicle using a hydraulic jack and rest (see arrow).
touch the ground;
Use appropriate lifting equipment to handle the leaf
- refit the wheel on the side of the operations;
spring.
Sling the leaf spring with appropriate belts keeping
Removal any sudden movements under control
Proceed as follows: Hazards caused by sharp edges.
- remove the nuts (9) and remove the leaf spring fastening
- remove the two fastening screws (1) of each leaf spring brackets (10) ;
front support cap, remove the cap (2) recovering the
spacers; - using the hydraulic lift, lower the axle to remove the
centring pin and manoeuvre appropriately to extract the
- remove the upper and lower bolts (3) that fasten the leaf leaf spring.
spring anchorage plate ;
- remove the leaf spring anchorage plates (4) and recover Inspections and checks
the spacers; Check end of travel pads are intact, if necessary replace the
- remove the shock absorber fastening nut (6); damaged component
- from both sides, loosen the bolts (7) fastening the Refitting
Final operations
Proceed as follows:
Figure 8
318A141001R
REMOVAL-REFITTING FRONT SHOCK

ABSORBER
Very heavy parts
GENERAL
Safety instructions
carry out maintenance jobs correctly. Safety component.
Tighten the upper and lower fastening bolts to the
specified torque.
Vehicle preparation

signboards.
Figure 9
2371801

of short circuits;
This procedure is valid for first axle and also for
second axle. Check bushings are intact, if necessary replace the damaged
component
Refitting
Proceed as follows:
- appropriately block the rear wheels; Final operations
Proceed as follows:
it on the two support stands so that the wheels no longer - refit the wheel on the side of the operations;
touch the ground;
Removal
Proceed as follows:
- remove the shock absorber upper (1) and lower (2) faste-
ning bolt
- remove the shock absorber(3) and recover the spacers.
Figure 10
318A141002R
REMOVAL-REFITTING FRONT
STABILIZER BAR
Very heavy parts
GENERAL
Safety instructions
specified torque.
Vehicle preparation

signboards.
Figure 11
2371801

of short circuits;
- lower the bar and recover the upper bushing (4);
This procedure is valid for first axle and also for - from both sides, remove the bolts (5) fastening the stabili-
second axle. zer bar (6) to the axle and remove it;
Check bushings are intact, if necessary replace the damaged
Removal component
Proceed as follows:
- from both sides, remove the bolts (1) fastening the stabili- Refitting
zer bar bushing to the chassis; To refit, follow the removal instructions in reverse order.
- from both sides, remove the lower cap (2) and bushing
(3);
Figure 12
335B0141002R
REPAIR OPERATIONS Checks

Use diesel or a suitable solvent to clean all the com-
Leaves are not to be replaced if the faulty spring is ponents.
made up of less than three leaves.
The remaining leaves of the faulty spring that need not
be replaced must not have visible scores or any shape
deformation that could compromise the conformity
to the working drawing.
Fitting in place the leaf spring

Ensure that the leaf contact surfaces are perfectly
clean and smooth.
Place together the leaves that form the pack, setting
Removing the rear leaf spring the relevant spacers between them and aligning the
central holes for the insertion of the coupling pin.
Figure 13 Lock the leaves between the vice clamps and insert
the central pin into the side coupling clips, and locking
with the relevant nut.
The clips must be locked so that they keep the leaves
aligned, but without obstructing the movement.
After assembly, use a punch to fit the central pin and
clip pins so that they are securely locked.
At every overhaul operation the spring centre pin and

the side clip pins and nuts are always to be replaced.
ASTRA
38745
Set the leaf spring in the vice on the bench (15)

clamping it near the central pin.
Remove the relevant nut and withdraw the central
coupling pin.
Unscrew the nuts that lock the side brackets then re-
move the brackets.
The individual leaves that make up the leaf spring will
now be free.

2-AXLE VEHICLES
REAR SUSPENSIONS
SECTION 14.2
HD9 Euro5 SECTION 14.2 2-AXLE VEHICLES REAR SUSPENSIONS 1
SECTION 14.2
2-axle vehicles rear suspensions

Page
DESCRIPTION 3
- 2-axle vehicle suspension 3
- Hydraulic shock absorbers 4
- Operation 4
- Noise 4
- Changes in braking effect 4
- Leaf springs 5
SHOCK ABSORBERS 5
DIAGNOSTICS 6
- 2-axle vehicles 9
REMOVAL-REFITTING LEAF SPRING 10
GENERAL 10
- Removal 11
- Refitting 11
REMOVAL-REFITTING REAR SHOCK ABSORBER 13
GENERAL 13
2 2-AXLE VEHICLES REAR SUSPENSIONS SECTION 14.2 HD9 Euro5
- Removal 14
- Refitting 14
- Removing the rear leaf spring 15
- Checks 15
- Fitting in place the leaf springs 15
DESCRIPTION
2-axle vehicle suspension
The suspension system is comprised of a pair of longitudinally arranged single action leaf springs.
It is supplemented by a pair of dual action hydraulic telescope shock absorbers.
Figure 1
1781410
1 - Chassis. - 2. Spring front mounting. - 3. Roll bar. - 4. Not used. - 5. Anchor stirrups. - 6. Drive shaft or axle. -
7. Shock absorber. - 8. Shackle. - 9. Spring rear mounting. - 10 Spring.
Hydraulic shock absorbers Operation

The hydraulic shock absorbers are of the telescopic double act-
Figure 2
ing type.
These shock absorbers are also defined ”direct acting” since
their braking action is directly performed on the suspension el-
ements without levers.
They are fitted with thermostatically controlled valves, thus en-
suring that there are no noticeable differences in their perform-
ance, even following sharp changes in temperature.
Shock absorbers are divided into three different parts:
1. the cylinder part located above the piston (always filled
with oil);
2. the cylinder part located under the piston (always filled
with oil);
3. the oil reserve, i.e. the compartment between the cylinders
(5 and 6) (never completely filled with oil).
During the bouncing stage, i.e. when the shock absorber ex-
tends, the oil pushed by the piston (4) passes through the com-
partment, from the upper part of the piston to the lower part
of the cylinder.
During the compression stage, i.e. when the shock absorber
lengthens and piston goes downwards, the oil located under
the piston passes directly to the upper part of the cylinder.
For oil passing from one part of the piston to the other, a forcing
pressure intervenes acting on the piston and opposing piston
movement thus causing suspension braking.
Noise
This defect, which is often laid to shock absorbers, can have dif-
ferent origins. It is therefore recommended to inspect suspen-
sions carefully, including shock absorber connections to chassis
or leaf spring.
Check whether no shock absorber part is in ”metallic” touch
with the leaf spring or the chassis.
Shock absorber dust protection distortion, due to wheel rota-
tion, or short oil due to accidental leaks, can cause noise; in this
case the shock absorber must be replaced.
Changes in braking effect

A change in the braking effect can take place accidentally.
The decrease of the braking effect can be due to breakage of
internal parts, short oil or jams.
Replace the shock absorber in any case.

Leaf springs
Parabolic springs
Spring characteristics
leafs
[mm] [mm] [mm/kN]
4 24
1800 0.865
1 50
SHOCK ABSORBERS
Lenght between eyebolts [mm]
open 650 ± 3
closed 427 ± 3
stroke 223
DIAGNOSTICS

1 NOISY SUSPENSION

YES
NO

YES
NO
NO
NO
NO

ONE SIDE
YES pressure.
NO

YES
NO

YES
NO
YES them.
NO
NO
YES ing area.

YES
NO
spring.

NO
NO
NO
TIGHTENING TORQUES
2-axle vehicles
Figure 3
1781413
PART TORQUE
Nm (Kgm)
2. Shackle pin fastening bolts 625 65
3. Spring mounting screws on chassis 455 46
4. Roll bar mounting screws 180 19
5. Leaf spring pin cap fastening screws 130 13,5
REMOVAL-REFITTING LEAF SPRING

Very heavy parts
GENERAL
Safety component.
Vehicle preparation

signboards.
Figure 4
2371801

of short circuits;
This procedure is valid for both half-elliptic spring Use appropriate lifting equipment to handle the leaf
and for parabolic spring. spring.
Sling the leaf spring with appropriate belts keeping
any sudden movements under control
Hazards caused by sharp edges.
- unscrew the nuts (9) and remove the leaf spring fastening
brackets (10) ;
- using the hydraulic lift, lower the axle to remove the
Preliminary operations centring pin and manoeuvre appropriately to extract the
leaf spring.
Proceed as follows:
- appropriately block the front wheels; Inspections and checks
- raise the rear of the vehicle using a hydraulic jack and rest Check end of travel pads are intact, if necessary replace the
it on the two support stands so that the wheels no longer damaged component
touch the ground;
- refit the wheel on the side of the operations; Refitting
Removal
- remove the two fastening screws (1) of each leaf spring Proceed as follows:
front support cap, remove the cap (2) recovering the - refit the wheel on the side of the operations;
spacers;
- remove the upper and lower bolts (3) that fasten the leaf
spring anchorage plate ;
- remove the leaf spring anchorage plates (4) and recover
the spacers;
- remove the shock absorber fastening nut (6);
- from both sides, loosen the bolts (7) fastening the
Figure 5
318A142001R
REMOVAL-REFITTING REAR SHOCK

ABSORBER
Very heavy parts
GENERAL
Safety instructions
specified torque.
Vehicle preparation

signboards.
Figure 6
2371801

of short circuits;
Preliminary operations Inspections and checks
Proceed as follows: Check bushings are intact, if necessary replace the damaged
component .
- appropriately block the front wheels;
- raise the rear of the vehicle using a hydraulic jack and rest Refitting
touch the ground; To refit, follow the removal instructions in reverse order.
- refit the wheel on the side of the operations. Final operations

Proceed as follows:
Removal - refit the wheel on the side of the operations.
Proceed as follows:
- remove the shock absorber upper (1) and lower (2) faste-
ning bolt;
- remove the shock absorber(3) and recover the rubber
bumpers.
Figure 7
A3501598
REPAIR OPERATIONS Fitting in place the leaf springs
Leaves are not to be replaced if the faulty spring is Ensure that the leaf contact surfaces are perfectly
made up of less than three leaves. clean and smooth.
The remaining leaves of the faulty spring that need not the relevant spacers between them and aligning the
be replaced must not have visible scores or any shape central holes for the insertion of the coupling pin.
deformation that could compromise the conformity Lock the leaves between the vice clamps and insert
to the working drawing. the central pin into the side coupling clips, and locking
After assembly, use a punch to fit the central pin and
Removing the rear leaf spring
Figure 8
At every overhaul operation the spring centre pin

with related absorber nut.
ASTRA
38745

coupling pin.
now be free.
Checks
ponents.

REAR TANDEM SUSPENSIONS
SECTION 14.3
HD9 Euro5 SECTION 14.3 REAR TANDEM SUSPENSIONS 1
SECTION 14.3
Rear tandem suspensions

Page
DESCRIPTION 3
- Suspension 3
- Leaf springs 5
DIAGNOSTICS 6
REMOVAL-REFIT - LEAF SPRING 10
GENERAL 10
- Refitting 11
- Removal 11
REMOVAL-REFITTING SWINGING SUPPORT
(CARRIAGE) 12
GENERAL 12
- Removal 13
- Refitting 14
2 REAR TANDEM SUSPENSIONS SECTION 14.3 HD9 Euro5
- Final operations 16 DESCRIPTION OF OPERATION 20

REMOVAL-REFITTING REAR SUSPENSION LOWER - Removal 20
TIE-ROD 17
GENERAL 17
- Refitting 20
REMOVAL-REFITTING REAR SUSPENSION JOINT 21
GENERAL 21
- Removal 18
- Removal 22
- Refitting 18
REMOVAL-REFITTING REAR SUSPENSION UPPER
TIE-ROD 19 - Refitting 23
GENERAL 19 - Final operations 23
- Safety instructions 19 - Removing the rear leaf spring 24
- Vehicle preparation 19 - Checks 24
- Very heavy parts 19 - Fitting in place the leaf springs 24
- Specific safety instructions 19 REPAIR OPERATIONS 24
DESCRIPTION
Suspension
The suspension system is comprised of a pair of longitudinally arranged single action leaf springs, which serve both axles of the
tandem.
The spring oscillates around a central pin, and the extremities of the springs slide on the axles themselves.
The suspension also has reaction bars between the axles and a central support for axial thrust control in braking and acceleration.
There are two possible types of leaf spring:
- Type A, parabolic spring, standard.
- Type B, semi-elliptical spring, on request.
Figure 1
1781411
Type A leaf springs (parabolic)

1 - Chassis. - 2. Front tandem axle. - 3. Spring. - 4. Lower reaction bars. - 5. Rear tandem axle. - 6. Centre carriage. -
7. Upper reaction bars.
Figure 2
1781411
Type B leaf springs (semielliptical)

1 - Chassis. - 2. Front tandem axle. - 3. Spring. - 4. Lower reaction bars. - 5. Rear tandem axle. - 6. Centre carriage. -
7. Upper reaction bars

Leaf springs
Parabolic spring
leafs
[mm] [mm] [mm/kN]
4 40 1400 0.228
Semielliptical spring
leafs
[mm] [mm] [mm/kN]
10 25 1400 0.229
DIAGNOSTICS

1 NOISY SUSPENSION

YES
NO

YES
NO
NO
NO
NO

ONE SIDE
YES pressure.
NO

YES
NO

YES
NO
YES them.
NO
NO
YES ing area.

YES
NO
spring.

NO
NO
NO
TIGHTENING TORQUES
Figure 3
1781414
PART TORQUE
Nm (Kgm)
2. Retaining stirrup bolts at axle 390 40
3. Reaction bar fastening bolts 455 46
4. Reaction bar screws on chassis 380 39
5. Central reaction bar fastening bolts 250 25.5
TOOLS
99366201 Carriage pin rocking support pre-fitted ring nut

99321024 Trolley for wheel removal
98343597 Oscillating central carriage locking ring pre-assembly support
REMOVAL-REFITTING - LEAF SPRING Very heavy parts

GENERAL

person. Read the instructions provided in the first Specific safety instructions
Vehicle preparation

Figure 4
2371801

short circuits;
DESCRIPTION OF OPERATION - loosen the fastening nuts and withdraw the guide
brackets (10) from both rear (A) and intermediate (B)
This procedure is valid for both half-elliptic spring and axles;
for parabolic spring. - remove the nuts (1) and remove the leaf spring fastening
brackets (2) fixed to the swinging support (3);
- using the hydraulic lift, lower the axle to remove the
Preliminary operations centring pin and manoeuvre appropriately to extract the
Proceed as follows: leaf spring.
- appropriately block the front wheels;
- raise the rear of the vehicle using a hydraulic jack and rest Inspections and checks
it on the two support stands so that the wheels no longer Check end of travel bridles are intact, if necessary replace the
touch the ground; damaged component
- remove the wheels on the side of the operations;
Refitting
Removal To refit, follow the removal instructions in reverse order.
Proceed as follows:
- park the vehicle on a flat surface and lock the front wheels Final operations
appropriately; Proceed as follows:
- refit the wheels on the side of the operations;
Use appropriate lifting equipment to handle the leaf
spring. Sling the leaf spring with appropriate belts
keeping any sudden movements under control.
Hazards caused by sharp edges.
Figure 5
REMOVAL-REFITTING SWINGING Very heavy parts

SUPPORT (CARRIAGE)

Always observe all the general recommendations to Be very careful as some components require very
carry out maintenance jobs correctly. high temperatures for removal and/or refitting.
Vehicle preparation

Figure 6
2371801

short circuits;
DESCRIPTION OF OPERATION - with an appropriate puller, remove the inner ring of the
external ball support (5) and the swinging support (6);
Proceed as follows: - with an appropriate puller, remove the inner ring of the
inner ball support (7)
- remove the two wheels from the side involved, following
the indications in the Rules for Use of the USE AND - remove the seal (8);
MAINTENANCE MANUAL;
- remove the leaf spring as described in the chapter
REMOVAL-REFITTING LEAF SPRING in this Section. Always replace the seal.
Removal
Proceed as follows:
- remove the cap(1) and seal ;
- remove the external rings of the ball supports (5) and (7)
- loosen the ring nut (3) fastening screw (2); from the swinging support.

clean the seat carefully and eliminate all traces of dirt and
The component is locked with sealant. foreign bodies.
removing.
- remove the ring nut (3) and the washer (4)
The component is locked with sealant.

removing.
Figure 7
307A142001R
Refitting Figure 10
Proceed as follows:
Figure 8
307A142005R
- Install pivoting support on journal using an appropriate lifting

device.
307A142003R Figure 11
- Insert outer races of ball joints (1) and (2) on pivoting
joint.
- Fit the seal (3) on side facing the chassis.
Figure 9
307A142006R
Heat the inner race of the ball joint support in oven

(100 ˚C - 130 ˚C).
307A142004R - Fit inner race of outer ball joint support (1) on pivoting sup-
port pin.
Heat the inner race of the ball joint support in oven Figure 12
(100 ˚C - 130 ˚C).
- Insert inner race of ball joint support (1) on pivoting sup-

port journal.
307A142007R
- Insert pins (1) in journal and washer (2) on pins.

Figure 13 Figure 15
307A142008R 307A142010R
- Loosen the ring nut by approximately 20˚ and then remove

Apply LOCTITE 270 sealant on threading.
the tool.
Figure 16
- Fit ring nut (1).
Figure 14
307A142011R
- Using a thickness gauge, check that the end play is within

the specified range. Adjust position of ring nut, if necessary.
Specified end play: 0.1 ± 0.05 mm
307A142009R
- Using tool 99366201, tighten the ring nut at a torque suffi-

cient to cancel the end play of the pivoting support.
These operations must be carried out before the ball

joint supports cools down, which would prevent
correct positioning.
Figure 17 Figure 18
307A142012R
307A142013R
Apply LOCTITE 242 sealant on threading. - Apply grease through grease nipple (1) until grease flows
out from the ball joint.
Figure 19
- Tighten ring nut fastening screw (1) at the required
torque.
Tightening torque: 80 ± 5 Nm
At the end of the operation, check that the pivoting

support can be turned with one hand.
307A142014R
- Fit the lid (1) with respective seal after having filled it with
grease.
Final operations
Proceed as follows:
- refit the leaf spring following the procedure described in the
LEAF-SPRING REMOVAL-REFIT chapter of this Section;
- refit the two wheels on the side involved in the operation
proceeding as described in the USE AND MAINTE-
NANCE HANDBOOK.
REMOVAL-REFITTING REAR SUSPENSION Very heavy parts

LOWER TIE-ROD

Vehicle preparation

Figure 20
2371801

short circuits;
Removal
Proceed as follows:
- raise the axle slightly so as to unload the rod and facilitate
the release of the fastening bracket;
Figure 21
335B142010R
- support the reaction rod with appropriate lifting

equipment;
- remove the bolts (1) from the front fastenings;
- remove the rear fastening bolts (2) and free the rod (3);
- remove the complete rod.

Check fastening brackets are intact, if necessary replace the
damaged component.
Check intactness of flexible joints if necessary replace
damaged component.
Refitting
REMOVAL-REFITTING REAR SUSPENSION Very heavy parts

UPPER TIE-ROD


Vehicle preparation

Figure 22
2371801

short circuits;

Removal Check intactness of flexible joints: if necessary replace
Proceed as follows: damaged component.
Check intactness of ball pin if necessary replace damaged
- position a hydraulic lift fitted with tool 99370617 component.
- raise the axle slightly so as to unload the rod and facilitate Refitting
the release of the fastening bracket; To refit, follow the removal instructions in reverse order.
- support the reaction rod with appropriate lifting
equipment;
- free all cables and piping fastened to the arm;
- remove the bolts (1) from the front fastenings;
- remove the rear fastening bolts (2) and free the rod (3);
- remove the complete rod (3).
Figure 23
1
REMOVAL-REFITTING
REAR SUSPENSION JOINT
GENERAL
Safety instructions

Vehicle preparation

Figure 24
2371801

short circuits;

Proceed as follows: - position a hydraulic lift fitted with tool 99370617
- as required, remove the lower tie-rod following the
indications in REMOVAL-REFITTING REAR LOWER - raise the axle slightly so as to unload the rod and facilitate
SUSPENSION TIE-ROD in this Section; the release of the fastening brackets;
- as required, remove the upper tie-rod following the
indications in REMOVAL-REFITTING REAR UPPER Figure 25
SUSPENSION TIE-ROD in this Section.
276C0836
- remove the circlip (1);

- remove the spacer (2, if present);
- remove the elastic bushing (3).

clean the seat carefully and eliminate all traces of dirt and
foreign bodies.
Do not mix the removed elements with the new

ones.
Eliminate all removed parts immediately.
Always replace all the joint elements. Never use
partial replacements.
Refitting Final operations

Proceed as follows:
Figure 26
- as required, refit tie-rod (12) or (13) following the
indications in REMOVAL-REFITTING REAR SUSPEN-
SION TIE-ROD in this Section;
- as required, refit triangular arm (17) or (18) following the
NO ANGLE indications in REMOVAL-REFITTING REAR SUSPEN-
SION TRIANGULAR ARM in this Section.
276C08038
Figure 27
276C08037
- Insert the flexible joint (1) into its seat.
Check whether the metal brackets of the joint are

correctly positioned with respect to the rod axle
(detail).
- Fit the whole rod complete with joint on mounting tool (c)
and fit mounting tool (b) on top;
- Insert the spacer (2, if present) and the circlip (3) into
mounting tool (b).
REPAIR OPERATIONS Checks

Leaves are not to be replaced if the faulty spring is ponents.
made up of less than three leaves.
The remaining leaves of the faulty spring that need not
be replaced must not have visible scores or any shape
deformation that could compromise the conformity
to the working drawing. Fitting in place the leaf springs
Ensure that the leaf contact surfaces are perfectly
clean and smooth.
the relevant spacers between them and aligning the
central holes for the insertion of the coupling pin.
Lock the leaves between the vice clamps and insert
Removing the rear leaf spring the central pin into the side coupling clips, and locking
Figure 28 After assembly, use a punch to fit the central pin and
At every overhaul operation the spring centre pin

with related absorber nut.
ASTRA
38745

coupling pin.
now be free.
STEERING SYSTEM
LHD
SECTION 15 A
HD9 Euro5 SECTION 15 A STEERING SYSTEM LHD 1
SECTION 15 A
Steering system LHD
Page
DESCRIPTION 5
- All 2-axle vehicles 5
- 3-axle vehicles standard version 5
- Hydraulic power steering system 6
- 3-axle vehicles with auxiliary pump 9
- Main circuit layout - vehicle right side 12
- Auxiliary circuit layout - vehicle right side 13
- Main circuit layout - vehicle left side 14
- Distribution valve 16
- 3-axle vehicles with pump and auxiliary cylinders 17
- Auxiliary circuit layout - vehicle left side 23
- 4-axle vehicles 25
- Auxiliary circuit layout - vehicle left side 31
- 3-axle vehicles with pump and auxliary cylinder 34
- Steering angles 35
2 STEERING SYSTEM LHD SECTION 15 A HD9 Euro5
DIAGNOSTICS 37 GENERAL 54
TIGHTENING TORQUES 42 - Safety instructions 54
- Power steering box 42 ADJUSTMENT OF AUTOMATIC STEERING
LIMITING DEVICES 55
- Linkages - 3 axle vehicles with auxiliary cylinder 43
- Linkages - 4 axle vehicles 44
TOOLS 45
FRONT WHEELS TOE-IN ADJUSTMENT 56
HYDRAULIC FLUID CHANGE STEERING SYSTEM 46
GENERAL 56
GENERAL 46
- Drainage 47
2 AND 3 AXLE VEHICLES WITHOUT AUXILIARY
- Filling 47 CYLINDER STEERING BOX REMOVAL-REFITTING 58
FLUID FILTER REPLACEMENT HYDRAULIC - Safety instructions 58
STEERING SYSTEM 48
GENERAL 48
- Removal 49
- Assembly 49
- Removal 59
STEERING ANGLE ADJUSTMENT 50
- Refitting 60
GENERAL 50
3 AXLE VEHICLES WITH AUXILIARY CYLINDER
DESCRIPTION OF OPERATION 51 STEERING BOX REMOVAL-REFITTING 62
- Preliminary operations 51 GENERAL 62
- Execution of operation 51 - Safety instructions 62
- Vehicles with IVECO live axle 52 - Vehicle preparation 62
- Vehicles with KESSLER live axle 52 - Very heavy parts 62
- Vehicles with live axle 53 - Hazardous and/or polluting substances 62
- Vehicles with drive axle 53 - Specific safety instructions 62
ADJUSTMENT OF AUTOMATIC STEERING DESCRIPTION OF OPERATION 63
LIMITING DEVICES 54
- Removal 63 - Hazardous and/or polluting substances 72

- Inspections and checks 63 - Specific safety instructions 72
- Refitting 64 DESCRIPTION OF OPERATION 73
- Final operations 65 - Preliminary operations 73
4 AXLE VEHICLES STEERING BOX REMOVAL- - Removal 73
REFITTING 66
- Refitting 73
GENERAL 66
STEERING FLUID TANK REMOVAL-REFITTING 74
GENERAL 74
- Removal 67
- Removal 75
- Refitting 68
- Refitting 75
MAIN STEERING PUMP REMOVAL-REFITTING 70
GENERAL 70
- Removal 71
- Refitting 71
SECONDARY STEERING PUMP REMOVAL-
REFITTING 72
GENERAL 72

DESCRIPTION The steering wheel operates the power steering, which per-
forms a direct mechanical connection with the steering lever on
All 2-axle vehicles the left wheel hub which operates the right-hand wheel
3-axle vehicles standard version through the quadrilateral steering links.
Steering control
The power steering is controlled by a pump fitted on the engine
The provided steering system is of the hydraulic power steering and supplied by a tank.
type.
A pressure relief valve protects the system against excess pres-
Purpose of this type of system is to reduce the driver’s efforts sure.
on the steering wheel to obtain vehicle steering.
Figure 1
357A015L201R
1. Steering wheel - 2. Steering column - 3. Steering box - 4. Steering link - 5. Steering khuckle lever head
Hydraulic power steering system
Diagram
2
1
5
150 bar
max
1781509
Illustration
1781508
1. Tank - 2. Filter - 3. Pump - 4. Tester connection - 5. Power steering
Layout
1. Tank - 2. Filter - 3. Pump - 4. Test connection - 5. Power steering 285A015001L

Component location
357A015001R
1. Power steering - 2. Tank - 3. Pump

3-axle vehicles with auxiliary pump The power steering is driven by a main pump activated by the
Steering control engine and by an auxiliary pump activated by the transmission.
The steering system is of the hydraulic power steering type. The system is provided with two tanks connected with each
Purpose of this type of system is to reduce the driver’s efforts other and feeding the pumps.
on the steering wheel to obtain vehicle steering. A pressure relief valve protects the system against excess pres-
The steering wheel operates the power steering, which sure.
performs a direct mechanical connection with the steering
lever on the left wheel hub which operates the right-hand
wheel through the quadrilateral steering links.
Figure 2
357A015L201R

Diagram
357A015002R
1. Power steering oil tank - 2. Vane pump (on compressor) - 3. Piston pump (on transmission) - 4. Power steering -
5. Test fitting - 6. Distribution valve
Illustration
357A015003R
1. Tank - 2. Tank - 3. Piston pump on transmission - 4. Vane pump on compressor - 5. Distribution valve -
6. Power steering
Main circuit layout - vehicle right side
357A015004R
1. Tank - 2. Tank - 4. Vane pump on compressor - 5. Distribution valve

Auxiliary circuit layout - vehicle right side
357A015005R
1. Tank - 2. Tank - 3. Piston pump on transmission - 5. Distribution valve

Main circuit layout - vehicle left side
357A015006R
6. Power steering
Component location
357A015007R
1. Power steering - 2. Tanks - 3. Main pump - 4. Emergency pump (on transmission or on transfer unit) -
5. Distribution valve
Distribution valve
357A015008R
P1. from main pump - P2. from emergency pump - A. to power steering - T. to tank 2
3-axle vehicles with pump and auxiliary The operation is facilitated by means of two hydraulic cylinders:
cylinders - the first is contained inside power steering system
Steering control
The steering system is of the hydraulic power steering type. - the second is fitted externally and works on the steering
lever.
Purpose of this type of system is to reduce the driver’s efforts
on the steering wheel to obtain vehicle steering. The power steering is driven by a main pump activated by the
engine and by an auxiliary pump activated by the transmission.
The steering wheel operates the power steering, which
performs a direct mechanical connection with the steering The system is provided with two tanks connected with each
lever on the left wheel hub which operates the right-hand other and feeding the three pumps.
wheel through the quadrilateral steering links. A pressure relief valve protects the system against excess pres-
sure.
Figure 3
357A015L202R
1. Steering wheel - 2. Steering column - 3. Steering box - 4. Steering link - 5. Steering khuckle lever head -
6. Auxiliary steering cylinder

Scheme
1. Power steering fluid tank - 2. Vane pump (on compressor) - 3. Piston pump (on transmission) - 4. Power steering -
5. Operator cylinder - 6. Flow indicator - 7. Test connector
Illustration
285A015011R
1. Main circuit fault warning light - 2. Auxiliary circuit fault warning light - 3. Not used - 4. Vane pump on compressor -
5. Not used - 6. Piston pump on transmission - 7. Power steering - 8. Not used - 9. Flow indicator -
10. Auxiliary cylinder - 11. Tank - 12. Tank
307A015A001R
1. Tank - 2. Tank - 4. Vane pump on compressor - 5. Flow indicator

307A015A002R
7. Power steering
307A015A003R
1. Tank - 2. Tank - 3. Piston pump on transmission - 5. Flow indicator
Auxiliary circuit layout - vehicle left side
307A015A004R
7. Power steering - 8. Operator cylinder

Component location
357A015009R
5. Flow indicator - 6. Operator cylinder
4-axle vehicles This operation is assisted by two hydraulic cylinders:

Steering control - the first cylinder is housed in the power steering and works
The provided steering system is of the hydraulic power on the first axle;
steering.
- the second cylinder is fitted separately and works on the
Purpose of this type of system is to reduce the driver’s efforts second axle.
The power steering is driven by a main pump activated by the
The steering wheel operates the power steering, which per- engine and by an emergency pump activated by the
forms a direct mechanical connection with the steering lever on transmission.
the left wheel hub of the 1st axle and, through transmission,
with the steering lever on the left wheel hub of the 2nd axle The system is provided with two tanks connected with each
which operate the other two wheels by means of the two other and feeding the three pumps.
quadrilateral steering links. A pressure relief valve protects the system against excess pres-
sure.
Figure 4
357A015L203R
1. Steering wheel - 2. Steering column - 3. Steering box - 4. Steering rod - 5. Steering knuckle lever head first axle -
6. Second axle control linkages - 7. Second axle steering cylinder - 8. Steering cylinder rod - 9. Steering knuckle lever head
second axle

Diagram
Illustration
285A015011R
1. Tank - 2. Tank - 3. Piston pump on transmission - 4. Vane pump on compressor - 5. Flow indicator - 6. Not used -
7. Power steering - 8. Actuating cylinder
307A015A100R
1. Tank - 2. Tank - 4. Vane pump on compressor - 5. Flow indicator

285A015003L
7. Power steering
307A015A003R
1. Tank - 2. Tank - 3. Piston pump on transmission - 5. Flow indicator

Auxiliary circuit layout - vehicle left side
307A015A004R

Component location
357A015010R
All 2-axle vehicles

3-axle vehicles standard version
ZF 8098 ball-bearing mounted with pressure relief

Power steering
valve
Variable working pressure 170 + 15 bar
Steering centre 22.2 :1
Variable reduction ratio
Maximum steering 26.2 :1
Power steering unit BOSCH
Assembly On compressor
Type with gear
No of maximum revs rpm 3000
Maximum pressure
(without pressure relief valve) bar 190
Regulated flow rate dm3/min 16
3-axle vehicles with auxiliary pump
ZF 8098 ball-bearings mounted with pressure relief

Power steering
valve
Power steering pump ZF ZF
On compressor Auxiliary on
Assembly
transmission
Type
Vane Piston
No of maximum revs rpm
3000 4500
Maximum pressure
(without pressure relief valve) bar
165 180
Regulated flow rate dm3/min
25 16
3-axle vehicles with pump and auxliary cylinder

All 4-axle vehicles
ZF 8099 ball bearings mounted with valve

Power steering pressure relief valve in circuits 1 and 2 and
check valve in circuit 1
Assembly On compressor Auxiliary on
transmission
Type
Vane Piston
3000 4500
Maximum pressure
(without pressure relief valve) bar 165 180
Regulated flow rate dm3/min 25 16
Operator cylinder (if present) ICOP
Useful stroke 180 mm

Steering angles
12.00.24 14.00.20
Tyres 13 R 22.5 12.00.20 315/80 13 R 22.5 12.00.20 315/80
SIMPLEX SIMPLEX
Position DUPLEX DUPLEX DUPLEX SIMPLEX SIMPLEX SIMPLEX
DUPLEX DUPLEX
A 45 45 45 40 40 40 40 40
B 3530’ 3530’ 3530’ 3242’ 3242’ 3242’ 3242’ 3242’

Figure 5
DIRECTION OF
TRAVEL
357A015L206R
Steering angles
Tyres
Position
Tyres 4 axle vehicles

Figure 6
Position
Tyres
Position
357A015L207R
DIAGNOSTICS
Main power steering operating faults :
1 - Steering stiff when turning right and left 5 - Torsional vibration of the steering wheel
2 - Steering stiff only when turning left or right 6 - Excessive play at the steering wheel
3 - Steering stiff when the wheel is turned quickly 7 - Loss of oil
4 - When steering, heavy jolts are felt at the wheel 8 - Insufficient pressure in the circuit
1 STEERING STIFF WHEN TURNING

RIGHT AND LEFT
Insufficient fluid in system Check fluid level with motor running, top up fluid to
YES upper mark on dipstick and bleed system
NO
Air in hydraulic system Check suction tube and pump shaft seal for leaks.
YES Top up fluid and bleed system
NO
Pump regulating valve jammed or blocked Dismantle valve, wash and check. Throttling orifice
YES must not be blocked
NO
Insufficient fluid pump delivery Overhaul or replace pump

YES
NO
Universal joint slides with difficulty Make joint free to slide by moving it to and fro several
YES times so that it tilts under its own weight
NO
Bearings for idle levers insufficiently lubricated Lubricate idle levers bearings
YES
Idle levers bearings worn (4-axle vehicles) Overhaul idle levers and replace any worn parts
YES
NO
Hydraulic cylinders not working (4-axle vehicles) Replace relevant cylinders

YES
NO
One of the hydraulic pumps not working (4-axle Overhaul or replace the hydraulic pump
vehicles) YES
2 STEERING STIFF ONLY WHEN

TURNING LEFT OR RIGHT
Internal seals not serviceable Send power steering to a ZF agent

YES
NO
Incorrect position of hydraulic centre (when steering Have valve adjusted by a ZF agent
wheel is released, the steering does not return to one YES
end of travel by itself)
3 STEERING STIFF WHEN THE WHEEL

IS TURNED QUICKLY
Regulating valve in pump blocked Dismantle valve, rinse and clean

YES
NO
Insufficient pump delivery Overhaul or replace the hydraulic pump

YES
NO
Air in steering system Check pump shaft seal and suction tube for leaks and
YES top up fluid. Bleed system
4 WHEN STEERING, HEAVY JOLTS

ARE FELT AT THE WHEEL
Play in universal joint Fit a new seal

YES
NO
Internal failure of power steering unit Send power steering unit to a ZF agent
YES
NO
Insufficient fluid in system Top up fluid and bleed system

YES
NO
Wheels geometry incorrect Check and adjust

YES
NO
Wheels out of balance Balance in accordance with instructions given in the

YES section ”Wheels and tyres”
NO
Steering rod joints loose on the arms Replace any worn parts
YES
NO
Irregular hydraulic pump operation Check, overhaul or replace pump if necessary.

YES
NO
Leakage of fluid from power steering circuit couplings Check coupling seals for serviceability, replacing any
YES which are worn
5 TORSIONAL VIBRATION OF THE

STEERING WHEEL
Wheels out of balance Balance in accordance with instructions given in the sec-
YES tion ”Wheels and tyres”
NO
Front wheels geometry incorrect Adjust in accordance with characteristic data given in
YES relevant section
NO
Air in hydraulic system Check pump shaft seal and suction tube for leaks. Top
YES up fluid and bleed system
6 EXCESSIVE PLAY AT THE

STEERING WHEEL
Clearance in ball joints and/or flexible supports loose Replace ball joints
YES
NO
Play in universal joint Replace universal joint

YES
NO
YES
7 LOSS OF FLUID
Tank cover not secured Secure cover

YES
NO
Deterioration of gaskets and seals Replace worn gaskets and seals, top up fluid and bleed
YES
8 INSUFFICIENT PRESSURE
IN THE CIRCUIT
Pump not operating correctly Overhaul or replace hydraulic pump

YES
NO
Fluid leaking from couplings in power steering Check coupling seals for serviceability, replacing any
circuit YES which are worn
NO
Insufficient oil level in the tank Top up level and bleed circuit
YES
NO
Oil leaking from gaskets in hydraulic circuit (4-axle Replace faulty cylinder
vehicles) YES
TIGHTENING TORQUES
Power steering box
Figure 7
357A015L205R
Linkages - 3 axle vehicles with auxiliary cylinder

A - Check that the split pins are correctly fitted. If, at the specified torque, the slit does not coincide with the hole, , continue to
tighten until it is possible to insert the pin.
Figure 8
309F015007R
Linkages - 4 axle vehicles

A - Check that the split pins are correctly fitted. If at the specified torque the notch does not coincide with the hole, proceed
with tightening until it is possible to insert the split pin.
B - Tighten the ring nut to 50 Nm and turn the lever to settle the bearings.
C - Tighten the ring at 65 Nm and turn the lever to settle the bearings.
Figure 9
341B015L001R
TOOLS
TOOL N. DESCRIPTION
99347068 Steering rod head pin extractor.
99374393 Tool with pressure gauge for checks on power steering hydraulic
pressure
99374399 Expanding chocks to lock wheels straight

HYDRAULIC FLUID CHANGE STEERING

SYSTEM
GENERAL
Safety instructions
Before starting any type of operation make sure all the

fully explained to those involved in the operations. If
in doubt, consult a more experienced person. Read
the instructions provided in the first part of this
manual.


- arrange a suitably sized container, remove the cap (see

arrow) from the power steering box and remove the cap
Drainage from the oil tank;
Vehicles without auxiliary cylinder - with engine off, turn the steering wheel from one limit to
Proceed as follows: the other until the oil stops flowing out;
- raise the vehicle until the front wheels are off the ground; - close the cap.
Figure 10
Filling
Proceed as follows:
- completely fill tank with specified fluid;
- with engine off, turn the steering wheel from one limit to
the other topping up the tank with fluid, at the same time,
until fluid level is stabilised;

- start the engine to fill the system with fluid: As the level will
drop sharply when this is done, oil must be continuously
poured into the tank WITHOUT AIR BEING DRAWN
INTO THE SYSTEM;
285A015018R - continue until the level stabilises.
- prepare an adequate container, disconnect the delivery Final operations

tubes (see arrow) from the power steering box and Proceed as follows:
remove the cap from the oil tank;
- with the engine at idle, turn the steering wheel from one
- with engine off, turn the steering wheel from one limit to limit to the other until any air present is eliminated.
the other until the oil stops flowing out;
- reconnect delivery tubes.
During this operation the level is to be continually
checked. If the above instructions have been
Vehicles with auxiliary cylinder scrupulously followed, when the engine is stopped,
Proceed as follows: the oil should not be more than 0.5 cm over the
- raise the vehicle until the front wheels are off the ground; upper notch, nor should it suddenly emulsify. This
would indicate a strong presence of air in the circuit
caused by an incorrect filling operation.
Figure 11
- for vehicles fitted with emergency steering pump run a

road test of approx. 10 km, then top up the level.
228NM238
FLUID FILTER REPLACEMENT

HYDRAULIC STEERING SYSTEM
GENERAL
Safety instructions

manual.

DESCRIPTION OF OPERATION Vehicles with auxiliary cylinder

Proceed as follows:
This operation is usually carried out when changing Figure 13

Removal
Vehicles without auxiliary cylinder
Proceed as follows:
Figure 12
342B015002R
- unscrew the fasteners (2);

- remove cover (3), seal (4) and spring (5);
- repeat the same operations on the second tank.
Assembly
Proceed as follows:
- replace the filtering cartridge (1);
342B015001R
- unscrew the fasteners (2); - replace the cover seal if it is deteriorated;
- remove cover (3), seal (4) and spring (5). - refit the cover;
- repeat the same operations on the second tank, if present.
Final operations
Check fluid level as described in USE AND MAINTENANCE
HANDBOOK.
STEERING ANGLE ADJUSTMENT

GENERAL
Safety instructions

manual.
Proceed as follows:
- work with the vehicle unladen;
- position each of the front wheels of the vehicle on a
revolving platform.
Proceed as follows:
This procedure refers to the figures on the next page.
- loosen the lock nut (1).

- fully steer the internal wheel and regulate the adjustment
screw (2) to obtain the specified value “Q” (see table).
- tighten the lock nut;
- repeat the operation for the other wheel;
For four-axle vehicles, repeat these operations for the

second front axle.
Continue with the adjustment of the automatic steering limiting

devices following the indications in STEERING AUTOMATIC
LIMITING DEVICES ADJUSTMENT in this Section.
Proceed as follows:
screw (2) to obtain the specified value “Q” reduced by 2
mm;
This operation is necessary to permit activation of the

power steering pressure limiting device BEFORE the
mechanical stop comes into contact with the axle.

- repeat the operation for the other wheel.
For four-axle vehicles repeat the operations

described for the second front axle
Vehicles with IVECO live axle Vehicles with KESSLER live axle
Table - Q position and respective X angle -

inner wheel LIVE AXLES
Table - ”Q” position and respective ”X” angle - for


inner wheel —LIVE AXLES

Vehicles with live axle

Figure 14
FWD
307A015L002R
Vehicles with drive axle
Figure 15
FWD
307A015L003R
ADJUSTMENT OF AUTOMATIC STEERING

LIMITING DEVICES
GENERAL
Safety instructions

manual.
ADJUSTMENT OF AUTOMATIC STEERING Execution of operation

LIMITING DEVICES Proceed as follows:
Appropriately signal engine start-up;

This power steering is fitted with automatic steering
angle adjustment.
It is absolutely essential that the angular shift of the
lever on the steering box BEFORE mounting and/or - start the engine and leave it idling:
adjusting of steering tie rods DOES NOT EXCEED
the maximum angular shift attainable AFTER - fully and slowly turn the steering wheel in both directions
adjustment of hydraulic pressure limit, because to reach max. steering angle or up to the limit for the
otherwise pressure would not decrease at steering mechanical end of stroke.
limit due to the altered positioning of the bushes.
Check that the limit for the mechanical stroke is
Figure 16 effectively reached; otherwise hydraulic power
steering power will be significantly reduced before
reaching the stop limit.
It is possible to perform a check as follows:
Figure 17
2151508
However, if this should happen, the adjuster bushes

MUST be replaced with new ones.
For the same reason, if a further reduction of the
originally set steering angle is required, new adjuster
bushes must be fitted . However, it is always possible
to increase the steering angle.
335B015002R
Preliminary operations - insert a pressure gauge (full scale minimum 200 bar) on the
check socket (see arrow) on the delivery pipe between
Proceed as follows:
pump and power steering;
- turn the steering wheel applying a torque of 50 ± 20 Nm
- position each of the front wheels of the vehicle on a (corresponding to 200 ± 80 N on steering wheel with a
revolving platform; diameter of 500 mm) up to the limit set for the mechanical
strole;
- check that length of steering tie-rods and position of
mechanical stops have the specified values; - measured pressure should be 50 ± 20 bar.
WHEELS TOE-IN ADJUSTMENT chapter of this Section. If pressure is too high, the adjuster bushes must be replaced
with new ones, and the adjustment operation repeated.
In case of excessively low pressure, check hydraulic system
functioning and seal.
FRONT WHEELS TOE-IN ADJUSTMENT

GENERAL
Safety instructions

manual.
DESCRIPTION OF OPERATION - check that the distances A and B, measured at the wheel
rim centre, at the same height from ground, correspond
Preliminary operations to specifications.
Proceed as follows:
- loosen the clamp bolts that fasten the heads (ref 1) to the
- make sure that: coupling bar (ref. 2);
- the vehicle is on a level surface and empty;
- rotate the bar to the right or to the left sufficiently to obtain
- the tyres are inflated to the correct pressure.
the required measurement;
Execution of operation - tighten the bolts fastening the ball joints terminals;
Proceed as follows: - repeat the steps for both axles.
- set the wheels in straight line position;
Reference Vehicle Fore carriage Size

A three axles axle B = A - (1 / 3 mm)
B three axles axle B = A - (1 / 3 mm)
1st axle B = A - (1 / 3 mm)
C four axles
2nd axle B=A
1st axle B = A - (1 / 3 mm)
D four axles
2nd axle B=A
1st axle B = A - (1 / 3 mm)
E four axles
2nd axle B=A
If this does not happen, adjust as follows:
Figure 18
A B
C D E
Final operations
- move the vehicle forward and backward, always in a
straight line, for at least one wheel turn, and recheck the
toe-in.
2 AND 3 AXLE VEHICLES WITHOUT Very heavy parts

AUXILIARY CYLINDER STEERING BOX
REMOVAL-REFITTING The following operation requires handling of heavy
GENERAL parts. To lift and transport, use appropriate
Safety instructions

necessary safety precautions have been taken and Hazardous and/or polluting substances
the instructions provided in the first part of this The operation described requires handling of
manual. hazardous and/or polluting substances
Observe all general recommendations for the correct Do not touch with the hands.
execution of maintenance work. Avoid contact with painted parts.
Vehicle preparation

the parking brake and apply the warning signboards. Safety component.
Tighten the fastening bolts of steering box to the
specified torque.
Tighten the fastening bolts of steering column flange
Figure 19 to the specified torque.
2371801

of short circuits;

Proceed as follows:
- drain off the fluid as described in HYDRAULIC FLUID
CHANGE in this Section.
Removal
Proceed as follows:
Figure 20
285A015013R
- disconnect the hydraulic return fitting from pump (b);

- disconnect the steering lever (11) from the steering rod
(1), removing the connection bolt;
- appropriately support the steering box (10), loosen the
fastening nuts and remove it.
285A015012R
Check hydraulic fittings and tubes are intact: if necessary
- open the front cowl; replace damaged component.
- disconnect the steering wheel column joint (arrow);
If there are difficulties in carrying out the following

operations tip up the cab as described in the USE
AND MAINTENANCE HANDBOOK.
Refitting
Proceed as follows:
Figure 22
307A015L001R
- fit the steering box (1) on the support bracket by

fastening the screws to the specified torque;
- set the steering lever (11) such that the notches A-A and
B-B coincide perfectly;
- position the tyres for straight line driving.
- work on the length of the steering rod (1) until it is

possible to insert the heads of the respective seats of the
steering lever (11) and of the axle (12) without changing
the position of the seats or applying force. Then tighten
the clamp nuts to the specified torque;
Figure 23
307A015L007R
- connect the steering column to the grooved pin (13) of

the steering box;
Position the steering column centre line in line with

the central notch on the steering box (arrow).
- connect the hydraulic fittings by reversing the removal

sequence.
Final operations
Proceed as follows:
- fill with the fluid as described in HYDRAULIC FLUID
- check limit stops as described in the STEERING
AUTOMATIC LIMITING DEVICES ADJUSTMENT in
this Section.
WHEELS TOE-IN ADJUSTMENT chapter of this
Section.
3 AXLE VEHICLES WITH AUXILIARY Very heavy parts

CYLINDER STEERING BOX REMOVAL-
REFITTING The following operation requires handling of heavy
Safety instructions

fully explained to those involved in the operations. If Hazardous and/or polluting substances
manual.
Vehicle preparation

Safety component.
Tighten the steering box fastener to the specified
torque.
Tighten the steering column flange fasteners to the
Figure 24 specified torque.
2371801

of short circuits;

Proceed as follows:
Removal
Proceed as follows:
Figure 25
307A015L004R
- disconnect the hydraulic lines:

(a) delivery from main pump
(b) return to the tank;
(c) delivery from supplementary pump
(d) return to the tank;
(e) to auxiliary cylinder
(f) to auxiliary cylinder
285A015012R
- open the front cowl; Figure 27


307B015L001R

(1) and from auxiliary cylinder (7) removing the
corresponding connection bolts;

replace damaged component.
Refitting
Proceed as follows:
Figure 28
357A015L201R

tightening the fastening nuts to the specified torque;

- set the tyres in straight line position, observing the toe-in
value indicated in the tables in the relevant Chapter;
- work on the length of the steering rod (1) and auxiliary
cylinder (7) until it is possible to insert the heads in the
respective seats of the steering lever (11) and of the axle
(12) without changing the position of the seats or
applying force. Then tighten the clamp nuts to the
specified torque;
Figure 29
307A015L007R

the steering box;


sequence.
Final operations
Proceed as follows:
this Section.
Section.
4 AXLE VEHICLES STEERING BOX Very heavy parts

REMOVAL-REFITTING

in doubt, consult a more experienced person. Read Hazardous and/or polluting substances
manual. The operation described requires handling of
Observe all general recommendations for the correct hazardous and/or polluting substances.
execution of maintenance work. Do not touch with the hands.
Vehicle preparation

switch off the engine, remove the ignition key, engage Specific safety instructions
Safety component.
Tighten the steering box fasteners to the specified
torque.
Figure 30 Tighten the steering column flange fasteners to the
specified torque.
2371801

of short circuits;

Proceed as follows:
Removal
Proceed as follows:
Figure 31
220071
- disconnect the hydraulic lines (1, 2, 3, 4, 5, 6);
220080
Figure 33
- open the front cowl;
- remove the bumper;
- disconnect the steering wheel column joint (1);
- disconnect the electrical connections.

220072
- disconnect the steering bar (2) and the tie rod (1) of the
steering lever (3) unscrewing the respective connecting
bolts;

Refitting
Proceed as follows:
Figure 34
220081

tightening the fastener nuts to the specified torque;
- mount the tie rod (3);
- mount the steering bar (4).
First axle
- connect the hydraulic fittings by reversing the removal the central notch on the steering box (arrow).
sequence.
- connect the electrical connections.
Figure 35
Final operations
Proceed as follows:
this Section.
Section.
220082
- connect the steering column to the grooved pin (1) of the

steering box.
MAIN STEERING PUMP REMOVAL- Very heavy parts

REFITTING

manual.
Observe all general recommendations for the correct The operation described requires handling of
execution of maintenance work. hazardous and/or polluting substances
Vehicle preparation

Safety component.
Figure 36
2371801

of short circuits;
DESCRIPTION OF OPERATION Refitting

To refit, follow the removal operations in reverse.
Proceed as follows:
Final operations
- drain off the fluid as described in the chapter HYDRAULIC Proceed as follows:
FLUID REPLACEMENT in this Section.
- restore fluid as described in the chapter HYDRAULIC
Removal
Proceed as follows:
- disconnect the intake (1) and delivery pipes (2) from the
pump;
- suitably support the pump, unscrew the fastening screws
and remove the complete pump (3).

operations.
- recover the driving joint (4) and the o-ring (5).
Always replace the o-ring.
Figure 37
285A015016R
SECONDARY STEERING PUMP REMOVAL- Very heavy parts

REFITTING

Observe all general recommendations for the correct hazardous and/or polluting substances
Vehicle preparation

Safety component.
Figure 38
2371801

of short circuits;

Preliminary operations To refit, follow the removal operations in reverse.
Proceed as follows:
Final operations
- drain off the fluid as described in the chapter HYDRAULIC
FLUID REPLACEMENT in this Section. Proceed as follows:
Removal FLUID REPLACEMENT in this Section.
Proceed as follows:
pump;

operations.
Figure 39
285A015017R
STEERING FLUID TANK REMOVAL-

REFITTING
GENERAL
Safety instructions

manual.


The operations described are also valid for vehicles operations.
with one tank only.
- disconnect the electric connector of the level sensor (3);

Figure 40
342B015003R
- remove the filler cap (1) from both tanks;

- with an appropriate suction device, empty the fluid
contained from both tanks.
If it is necessary to remove only one tank, remove also

the connection pipes (5).
342B015005R
Removal
Proceed as follows: - working from the rear unscrew the fastening screws
(arrow) and remove the tank (4).
Figure 41
Check intactness of hydraulic fittings and related piping: if
necessary replace the damaged component.
Refitting
Final operations
Proceed as follows:
- restore correct level of fluid in both tanks.
342B015004R
- disconnect the delivery (1) and fluid return pipes (2) from
both tanks;

STEERING SYSTEM
RHD
SECTION 15 B
HD9 Euro5 SECTION 15 B STEERING SYSTEM RHD 1
SECTION 15 B
Steering system RHD
Page
DESCRIPTION 5
- Main circuit layout - vehicle front side 14
- Distribution valve 16
- 3-axle vehicles with pump and auxiliary cylinders 17
- 3-axle vehicles with pump and auxliary cylinder 34
- Steering angles 35
2 STEERING SYSTEM RHD SECTION 15 B HD9 Euro5
DIAGNOSTICS 37 GENERAL 54
TIGHTENING TORQUES 42 - Safety instructions 54
- Power steering box 42 ADJUSTMENT OF AUTOMATIC STEERING
LIMITING DEVICES 55
- Linkages - 3 axle vehicles with auxiliary cylinder 43
- Linkages - 4 axle vehicles 44
TOOLS 45
FRONT WHEELS TOE-IN ADJUSTMENT 56
HYDRAULIC FLUID CHANGE STEERING SYSTEM 46
GENERAL 56
GENERAL 46
- Drainage 47
2 AND 3 AXLE VEHICLES WITHOUT AUXILIARY
- Filling 47 CYLINDER STEERING BOX REMOVAL-REFITTING 58
FLUID FILTER REPLACEMENT HYDRAULIC - Safety instructions 58
STEERING SYSTEM 48
GENERAL 48
- Removal 49
- Assembly 49
- Removal 59
STEERING ANGLE ADJUSTMENT 50
- Refitting 60
GENERAL 50
3 AXLE VEHICLES WITH AUXILIARY CYLINDER
DESCRIPTION OF OPERATION 51 STEERING BOX REMOVAL-REFITTING 62
- Preliminary operations 51 GENERAL 62
- Execution of operation 51 - Safety instructions 62
- Vehicles with IVECO live axle 52 - Vehicle preparation 62
- Vehicles with KESSLER live axle 52 - Very heavy parts 62
- Vehicles with live axle 53 - Hazardous and/or polluting substances 62
- Vehicles with drive axle 53 - Specific safety instructions 62
ADJUSTMENT OF AUTOMATIC STEERING DESCRIPTION OF OPERATION 63
LIMITING DEVICES 54
- Removal 63 - Hazardous and/or polluting substances 72

- Inspections and checks 63 - Specific safety instructions 72
- Refitting 64 DESCRIPTION OF OPERATION 73
- Final operations 65 - Preliminary operations 73
4 AXLE VEHICLES STEERING BOX REMOVAL- - Removal 73
REFITTING 66
- Refitting 73
GENERAL 66
STEERING FLUID TANK REMOVAL-REFITTING 74
GENERAL 74
- Removal 67
- Removal 75
- Refitting 68
- Refitting 75
MAIN STEERING PUMP REMOVAL-REFITTING 70
GENERAL 70
- Removal 71
- Refitting 71
SECONDARY STEERING PUMP REMOVAL-
REFITTING 72
GENERAL 72

DESCRIPTION The steering wheel operates the power steering, which per-
forms a direct mechanical connection with the steering lever on
All 2-axle vehicles the right wheel hub which operates the left-hand wheel
3-axle vehicles standard version through the quadrilateral steering links.
Steering control
The power steering is controlled by a pump fitted on the engine
The provided steering system is of the hydraulic power steering and supplied by a tank.
type.
A pressure relief valve protects the system against excess pres-
Purpose of this type of system is to reduce the driver’s efforts sure.
Figure 1
357A015R201R
Diagram
2
1
5
150 bar
max
1781509
Illustration
1781508
1. Tank - 2. Filter - 3. Pump - 4. Tester connection - 5. Power steering
Layout
285A015010R
1. Tank - 2. Filter - 3. Pump - 4. Test connection - 5. Power steering
Component location
357A015R202R
1. Power steering - 2. Tank - 3. Pump
3-axle vehicles with auxiliary pump The power steering is driven by a main pump activated by the
Steering control engine and by an auxiliary pump activated by the transmission.
The steering system is of the hydraulic power steering type. The system is provided with two tanks connected with each
Purpose of this type of system is to reduce the driver’s efforts other and feeding the pumps.
on the steering wheel to obtain vehicle steering. A pressure relief valve protects the system against excess pres-
The steering wheel operates the power steering, which sure.
performs a direct mechanical connection with the steering
lever on the right wheel hub which operates the left-hand
wheel through the quadrilateral steering links.
Figure 2
357A015R201R

Diagram
357A015002R
1. Power steering oil tank - 2. Vane pump (on compressor) - 3. Piston pump (on transmission) - 4. Power steering -
5. Test fitting - 6. Distribution valve
Illustration
357A015003R
1. Tank - 2. Tank - 3. Piston pump on transmission - 4. Vane pump on compressor - 5. Distribution valve -
6. Power steering
357A015R2003R
1. Tank - 2. Tank - 3. Piston pump on transmission - 5. Distribution valve

357A015R2004R
1. Tank - 2. Tank - 4. Vane pump on compressor - 5. Distribution valve

Main circuit layout - vehicle front panel
357A015R2005R
6. Power steering
Component location
357A015R2006R
5. Distribution valve
Distribution valve
357A015008R
P1. from main pump - P2. from emergency pump - A. to power steering - T. to tank 2
3-axle vehicles with pump and auxiliary The operation is facilitated by means of two hydraulic cylinders:
cylinders - the first is contained inside power steering system
Steering control
The steering system is of the hydraulic power steering type. - the second is fitted externally and works on the steering
lever.
Purpose of this type of system is to reduce the driver’s efforts
on the steering wheel to obtain vehicle steering. The power steering is driven by a main pump activated by the
engine and by an auxiliary pump activated by the transmission.
The steering wheel operates the power steering, which
performs a direct mechanical connection with the steering The system is provided with two tanks connected with each
lever on the right wheel hub which operates the left-hand other and feeding the three pumps.
wheel through the quadrilateral steering links. A pressure relief valve protects the system against excess pres-
sure.
Figure 3
357A015R213R
1. Steering wheel - 2. Steering column - 3. Steering box - 4. Steering link - 5. Steering khuckle lever head -
6. Auxiliary steering cylinder

Scheme
Illustration
357A015R2007R
1. Tank - 2. Tank - 3. Piston pump on transmission - 4. Vane pump on compressor -

5. Flow indicator - 6. Not used - 7. Power steering - 8. Not used - 8. Operator cylinder
7
4
285A015006R
1. Tank - 2. Tank - 4. Vane pump on compressor - 5. Flow indicator - 7. Power steering

285A015007R
7. Power steering
285A015008R
1. Tank - 2. Tank - 3. Piston pump on transmission - 5. Flow indicator - 7. Power steering

307A015105R

Component location
357A015R208R
4-axle vehicles This operation is assisted by two hydraulic cylinders:

Steering control - the first cylinder is housed in the power steering and works
The provided steering system is of the hydraulic power on the first axle;
steering.
- the second cylinder is fitted separately and works on the
Purpose of this type of system is to reduce the driver’s efforts second axle.
The power steering is driven by a main pump activated by the
The steering wheel operates the power steering, which per- engine and by an emergency pump activated by the
forms a direct mechanical connection with the steering lever on transmission.
the right wheel hub of the 1st axle and, through transmission,
with the steering lever on the right wheel hub of the 2nd axle The system is provided with two tanks connected with each
which operate the other two wheels by means of the two other and feeding the three pumps.
quadrilateral steering links. A pressure relief valve protects the system against excess pres-
sure.
Figure 4
357A015R214R
1. Steering wheel - 2. Steering column - 3. Steering box - 4. Steering rod - 5. Steering knuckle lever head first axle -
6. Second axle control linkages - 7. Second axle steering cylinder - 8. Steering cylinder rod - 9. Steering knuckle lever head
second axle

Diagram
Illustration
285A015019R
1. Tank - 2. Tank - 3. Piston pump on transmission - 4. Vane pump on compressor - 5. Flow indicator - 6. Not used -
7. Power steering - 8. Actuating cylinder
7
4
285A015006R
1. Tank - 2. Tank - 4. Vane pump on compressor - 5. Flow indicator - 7. Power steering

285A015007R
7. Power steering
285A015008R
1. Tank - 2. Tank - 3. Piston pump on transmission - 5. Flow indicator - 7. Power steering

285A015009R
Component location
357A015R209R
All 2-axle vehicles

3-axle vehicles standard version
ZF 8098 ball-bearing mounted with pressure relief

Power steering
valve
Power steering unit BOSCH
Assembly On compressor
Type with gear
No of maximum revs rpm 3000
Maximum pressure
(without pressure relief valve) bar 190
Regulated flow rate dm3/min 16
3-axle vehicles with auxiliary pump
ZF 8098 ball-bearings mounted with pressure relief

Power steering
valve
On compressor Auxiliary on
Assembly
transmission
Type
Vane Piston
3000 4500
Maximum pressure
(without pressure relief valve) bar
165 180
Regulated flow rate dm3/min
25 16
3-axle vehicles with pump and auxliary cylinder

All 4-axle vehicles
ZF 8099 ball bearings mounted with valve

Power steering pressure relief valve in circuits 1 and 2 and
check valve in circuit 1
Assembly On compressor Auxiliary on
transmission
Type
Vane Piston
3000 4500
Maximum pressure
(without pressure relief valve) bar 165 180
Regulated flow rate dm3/min 25 16
Operator cylinder (if present) ICOP
Useful stroke 180 mm

Steering angles
12.00.24 14.00.20
Tyres 13 R 22.5 12.00.20 315/80 13 R 22.5 12.00.20 315/80
SIMPLEX SIMPLEX
Position DUPLEX DUPLEX DUPLEX SIMPLEX SIMPLEX SIMPLEX
DUPLEX DUPLEX
A 45 45 45 40 40 40 40 40
B 3530’ 3530’ 3530’ 3242’ 3242’ 3242’ 3242’ 3242’

Figure 5
DIRECTION OF
TRAVEL
357A015R218R
Steering angles
Tyres
Position
4 axle vehicles
Tyres
Figure 6
Position
Tyres
Position
357A015R219R
DIAGNOSTICS
Main power steering operating faults :
1 - Steering stiff when turning right and left 5 - Torsional vibration of the steering wheel
2 - Steering stiff only when turning left or right 6 - Excessive play at the steering wheel
3 - Steering stiff when the wheel is turned quickly 7 - Loss of oil
4 - When steering, heavy jolts are felt at the wheel 8 - Insufficient pressure in the circuit
1 STEERING STIFF WHEN TURNING

RIGHT AND LEFT
Insufficient fluid in system Check fluid level with motor running, top up fluid to
YES upper mark on dipstick and bleed system
NO
Air in hydraulic system Check suction tube and pump shaft seal for leaks.
YES Top up fluid and bleed system
NO
Pump regulating valve jammed or blocked Dismantle valve, wash and check. Throttling orifice
YES must not be blocked
NO
Insufficient fluid pump delivery Overhaul or replace pump

YES
NO
Universal joint slides with difficulty Make joint free to slide by moving it to and fro several
YES times so that it tilts under its own weight
NO
Bearings for idle levers insufficiently lubricated Lubricate idle levers bearings
YES
Idle levers bearings worn (4-axle vehicles) Overhaul idle levers and replace any worn parts
YES
NO
Hydraulic cylinders not working (4-axle vehicles) Replace relevant cylinders

YES
NO
One of the hydraulic pumps not working (4-axle Overhaul or replace the hydraulic pump
vehicles) YES
2 STEERING STIFF ONLY WHEN

TURNING LEFT OR RIGHT
Internal seals not serviceable Send power steering to a ZF agent

YES
NO
Incorrect position of hydraulic centre (when steering Have valve adjusted by a ZF agent
wheel is released, the steering does not return to one YES
end of travel by itself)
3 STEERING STIFF WHEN THE WHEEL

IS TURNED QUICKLY
Regulating valve in pump blocked Dismantle valve, rinse and clean

YES
NO
Insufficient pump delivery Overhaul or replace the hydraulic pump

YES
NO
Air in steering system Check pump shaft seal and suction tube for leaks and
YES top up fluid. Bleed system
4 WHEN STEERING, HEAVY JOLTS

ARE FELT AT THE WHEEL
Play in universal joint Fit a new seal

YES
NO
YES
NO
Insufficient fluid in system Top up fluid and bleed system

YES
NO
Wheels geometry incorrect Check and adjust

YES
NO
Wheels out of balance Balance in accordance with instructions given in the

YES section ”Wheels and tyres”
NO
Steering rod joints loose on the arms Replace any worn parts
YES
NO
Irregular hydraulic pump operation Check, overhaul or replace pump if necessary.

YES
NO
Leakage of fluid from power steering circuit couplings Check coupling seals for serviceability, replacing any
YES which are worn
5 TORSIONAL VIBRATION OF THE

STEERING WHEEL
Wheels out of balance Balance in accordance with instructions given in the sec-
YES tion ”Wheels and tyres”
NO
Front wheels geometry incorrect Adjust in accordance with characteristic data given in
YES relevant section
NO
Air in hydraulic system Check pump shaft seal and suction tube for leaks. Top
YES up fluid and bleed system
6 EXCESSIVE PLAY AT THE

STEERING WHEEL
Clearance in ball joints and/or flexible supports loose Replace ball joints
YES
NO
Play in universal joint Replace universal joint

YES
NO
YES
7 LOSS OF FLUID
Tank cover not secured Secure cover

YES
NO
Deterioration of gaskets and seals Replace worn gaskets and seals, top up fluid and bleed
YES
8 INSUFFICIENT PRESSURE
IN THE CIRCUIT
Pump not operating correctly Overhaul or replace hydraulic pump

YES
NO
Fluid leaking from couplings in power steering Check coupling seals for serviceability, replacing any
circuit YES which are worn
NO
Insufficient oil level in the tank Top up level and bleed circuit
YES
NO
Oil leaking from gaskets in hydraulic circuit (4-axle Replace faulty cylinder
vehicles) YES
TIGHTENING TORQUES
Power steering box
Figure 7
357A015R216R
Linkages - 3 axle vehicles with auxiliary cylinder

A - Check that the split pins are correctly fitted. If, at the specified torque, the slit does not coincide with the hole, , continue to
tighten until it is possible to insert the pin.
Figure 8
357A015R217R
Linkages - 4 axle vehicles

A - Check that the split pins are correctly fitted. If at the specified torque the notch does not coincide with the hole, proceed
with tightening until it is possible to insert the split pin.
B - Tighten the ring nut to 50 Nm and turn the lever to settle the bearings.
C - Tighten the ring at 65 Nm and turn the lever to settle the bearings.
Figure 9
341B015R001R
TOOLS
TOOL N. DESCRIPTION
99347068 Steering rod head pin extractor.
99374393 Tool with pressure gauge for checks on power steering hydraulic
pressure
99374399 Expanding chocks to lock wheels straight

46 STEERING SYSTEM LHD SECTION 15 B HD9 Euro5
HYDRAULIC FLUID CHANGE STEERING

SYSTEM
GENERAL
Safety instructions

manual.


HD9 Euro5 SECTION 15 B STEERING SYSTEM LHD 47
- arrange a suitably sized container, remove the cap (see

arrow) from the power steering box and remove the cap
Drainage from the oil tank;
Vehicles without auxiliary cylinder - with engine off, turn the steering wheel from one limit to
Proceed as follows: the other until the oil stops flowing out;
- raise the vehicle until the front wheels are off the ground; - close the cap.
Figure 10
Filling
Proceed as follows:
- completely fill tank with specified fluid;
- with engine off, turn the steering wheel from one limit to
the other topping up the tank with fluid, at the same time,
until fluid level is stabilised;

- start the engine to fill the system with fluid: As the level will
drop sharply when this is done, oil must be continuously
poured into the tank WITHOUT AIR BEING DRAWN
INTO THE SYSTEM;
- continue until the level stabilises.
285A015R210R
- prepare an adequate container, disconnect the delivery

tubes (see arrow) from the power steering box and Final operations
remove the cap from the oil tank; Proceed as follows:
- with engine off, turn the steering wheel from one limit to - with the engine at idle, turn the steering wheel from one
the other until the oil stops flowing out; limit to the other until any air present is eliminated.
- reconnect delivery tubes.
During this operation the level is to be continually
Vehicles with auxiliary cylinder
checked. If the above instructions have been
Proceed as follows: scrupulously followed, when the engine is stopped,
- raise the vehicle until the front wheels are off the ground; the oil should not be more than 0.5 cm over the
upper notch, nor should it suddenly emulsify. This
would indicate a strong presence of air in the circuit
Figure 11 caused by an incorrect filling operation.
- for vehicles fitted with emergency steering pump run a

road test of approx. 10 km, then top up the level.
272D15017
FLUID FILTER REPLACEMENT

HYDRAULIC STEERING SYSTEM
GENERAL
Safety instructions

manual.

DESCRIPTION OF OPERATION Vehicles with auxiliary cylinder

Proceed as follows:
This operation is usually carried out when changing Figure 13

Removal
Vehicles without auxiliary cylinder
Proceed as follows:
Figure 12
342B015002R
- unscrew the fasteners (2);

- remove cover (3), seal (4) and spring (5);
- repeat the same operations on the second tank.
Assembly
Proceed as follows:
- replace the filtering cartridge (1);
342B015001R
- unscrew the fasteners (2); - replace the cover seal if it is deteriorated;
- remove cover (3), seal (4) and spring (5). - refit the cover;
- repeat the same operations on the second tank, if present.
Final operations
Check fluid level as described in USE AND MAINTENANCE
HANDBOOK.
STEERING ANGLE ADJUSTMENT

GENERAL
Safety instructions

manual.
Proceed as follows:
- position each of the front wheels of the vehicle on a
revolving platform.
Proceed as follows:
This procedure refers to the figures on the next page.

screw (2) to obtain the specified value “Q” (see table).
- repeat the operation for the other wheel;
For four-axle vehicles, repeat these operations for the

second front axle.
Continue with the adjustment of the automatic steering limiting

devices following the indications in STEERING AUTOMATIC
LIMITING DEVICES ADJUSTMENT in this Section.
Proceed as follows:
screw (2) to obtain the specified value “Q” reduced by 2
mm;
This operation is necessary to permit activation of the

power steering pressure limiting device BEFORE the
mechanical stop comes into contact with the axle.

- repeat the operation for the other wheel.
For four-axle vehicles repeat the operations

described for the second front axle
Vehicles with IVECO live axle Vehicles with KESSLER live axle
Table - Q position and respective X angle -




Vehicles with live axle

Figure 14
FWD
307A015L002R
Vehicles with drive axle
Figure 15
FWD
307A015L003R
ADJUSTMENT OF AUTOMATIC STEERING

LIMITING DEVICES
GENERAL
Safety instructions

manual.
ADJUSTMENT OF AUTOMATIC STEERING Execution of operation

LIMITING DEVICES Proceed as follows:
Appropriately signal engine start-up;

This power steering is fitted with automatic steering
angle adjustment.
It is absolutely essential that the angular shift of the
lever on the steering box BEFORE mounting and/or - start the engine and leave it idling:
adjusting of steering tie rods DOES NOT EXCEED
the maximum angular shift attainable AFTER - fully and slowly turn the steering wheel in both directions
adjustment of hydraulic pressure limit, because to reach max. steering angle or up to the limit for the
otherwise pressure would not decrease at steering mechanical end of stroke.
limit due to the altered positioning of the bushes.
Check that the limit for the mechanical stroke is
Figure 16 effectively reached; otherwise hydraulic power
steering power will be significantly reduced before
reaching the stop limit.
It is possible to perform a check as follows:
Figure 17
2151508
However, if this should happen, the adjuster bushes

MUST be replaced with new ones.
For the same reason, if a further reduction of the
originally set steering angle is required, new adjuster
bushes must be fitted . However, it is always possible
to increase the steering angle.
335B015002R
Preliminary operations - insert a pressure gauge (full scale minimum 200 bar) on the
check socket (see arrow) on the delivery pipe between
Proceed as follows:
pump and power steering;
- turn the steering wheel applying a torque of 50 ± 20 Nm
- position each of the front wheels of the vehicle on a (corresponding to 200 ± 80 N on steering wheel with a
revolving platform; diameter of 500 mm) up to the limit set for the mechanical
strole;
- check that length of steering tie-rods and position of
mechanical stops have the specified values; - measured pressure should be 50 ± 20 bar.
WHEELS TOE-IN ADJUSTMENT chapter of this Section. If pressure is too high, the adjuster bushes must be replaced
with new ones, and the adjustment operation repeated.
In case of excessively low pressure, check hydraulic system
functioning and seal.
FRONT WHEELS TOE-IN ADJUSTMENT

GENERAL
Safety instructions

manual.
DESCRIPTION OF OPERATION - check that the distances A and B, measured at the wheel
rim centre, at the same height from ground, correspond
Preliminary operations to specifications.
Proceed as follows:
- loosen the clamp bolts that fasten the heads (ref 1) to the
- make sure that: coupling bar (ref. 2);
- the vehicle is on a level surface and empty;
- rotate the bar to the right or to the left sufficiently to obtain
- the tyres are inflated to the correct pressure.
the required measurement;
Execution of operation - tighten the bolts fastening the ball joints terminals;
Proceed as follows: - repeat the steps for both axles.
- set the wheels in straight line position;
Reference Vehicle Fore carriage Size

A three axles axle B = A - (1 / 3 mm)
B three axles axle B = A - (1 / 3 mm)
1st axle B = A - (1 / 3 mm)
C four axles
2nd axle B=A
1st axle B = A - (1 / 3 mm)
D four axles
2nd axle B=A
1st axle B = A - (1 / 3 mm)
E four axles
2nd axle B=A
If this does not happen, adjust as follows:
Figure 18
A B
C D E
Final operations
- move the vehicle forward and backward, always in a
straight line, for at least one wheel turn, and recheck the
toe-in.
2 AND 3 AXLE VEHICLES WITHOUT Very heavy parts

AUXILIARY CYLINDER STEERING BOX
REMOVAL-REFITTING The following operation requires handling of heavy
Safety instructions

necessary safety precautions have been taken and Hazardous and/or polluting substances
the instructions provided in the first part of this The operation described requires handling of
manual. hazardous and/or polluting substances
Observe all general recommendations for the correct Do not touch with the hands.
execution of maintenance work. Avoid contact with painted parts.
Vehicle preparation

the parking brake and apply the warning signboards. Safety component.
Tighten the fastening bolts of steering box to the
specified torque.
Tighten the fastening bolts of steering column flange
Figure 19 to the specified torque.
2371801

of short circuits;

Proceed as follows:
Removal
Proceed as follows:
Figure 20
357A015R211R
- disconnect the hydraulic return fitting from pump (b);

(1), removing the connection bolt;
357A015R220R Inspections and checks
- open the front cowl; replace damaged component.

Refitting
Proceed as follows:
Figure 22
307A015R001R

- work on the length of the steering rod (1) until it is

possible to insert the heads of the respective seats of the
steering lever (11) and of the axle (12) without changing
the position of the seats or applying force. Then tighten
the clamp nuts to the specified torque;
Figure 23
357A015R221R

the steering box;


sequence.
Final operations
Proceed as follows:
this Section.
Section.
3 AXLE VEHICLES WITH AUXILIARY Very heavy parts

CYLINDER STEERING BOX REMOVAL-
REFITTING The following operation requires handling of heavy
Safety instructions

fully explained to those involved in the operations. If Hazardous and/or polluting substances
manual.
Vehicle preparation

Safety component.
Tighten the steering box fastener to the specified
torque.
Tighten the steering column flange fasteners to the
Figure 24 specified torque.
2371801

of short circuits;

Proceed as follows:
Removal
Proceed as follows:
Figure 25
272D15011

(b) return to the tank;
(d) return to the tank;
357A015R220R
- open the front cowl; Figure 27


357A015R212R

(1) and from auxiliary cylinder (7) removing the
corresponding connection bolts;

Refitting
Proceed as follows:
Figure 28
307A015R001R

tightening the fastening nuts to the specified torque;

- set the tyres in straight line position, observing the toe-in
value indicated in the tables in the relevant Chapter;
- work on the length of the steering rod (1) and auxiliary
cylinder (7) until it is possible to insert the heads in the
respective seats of the steering lever (11) and of the axle
(12) without changing the position of the seats or
applying force. Then tighten the clamp nuts to the
specified torque;
Figure 29
357A015R221R

the steering box;


sequence.
Final operations
Proceed as follows:
this Section.
Section.
4 AXLE VEHICLES STEERING BOX Very heavy parts

REMOVAL-REFITTING

Observe all general recommendations for the correct hazardous and/or polluting substances.
Vehicle preparation

Safety component.
Tighten the steering box fasteners to the specified
torque.
Figure 30 Tighten the steering column flange fasteners to the
specified torque.
2371801

of short circuits;

Proceed as follows:
Removal
Proceed as follows:
Figure 31
272D15011

(b) return to the tank
(d) return to the tank
357A015R220R
- open the front cowl;

- disconnect the steering wheel column joint (arrow); Figure 33

272D15012

(1) and track rod (4) removing the corresponding bolts;

Refitting
Proceed as follows:
Figure 34
307A015R001R

tightening the fastener nuts to the specified torque;
Figure 35
357A015R215R
- disconnect the steering links (1), (4), (5) and (6) and the
cylinder (7) from the relevant levers. Position the steering column centre line in line with
First axle the central notch on the steering box (arrow).
- Adjust steering link (1) length to enable heads fitting into
power steering and axle levers, without modifying lever
position. - connect the hydraulic fittings by reversing the removal
Second axle sequence.
- Position transfer arms (2) and (3) with vertical axis;
- adjust the length of the different steering links (4), (5) and Final operations
(6) and cylinder (7) to enable joints, fork and heads fitting Proceed as follows:
into the relevant seats on the levers, without modifying
lever positions.
Figure 36 - check limit stops as described in the STEERING
this Section.
Section.
357A015R221R

the steering box.
MAIN STEERING PUMP REMOVAL- Very heavy parts

REFITTING

manual.
Observe all general recommendations for the correct The operation described requires handling of
execution of maintenance work. hazardous and/or polluting substances
Vehicle preparation

Safety component.
Figure 37
2371801

of short circuits;

Proceed as follows:
Final operations
- drain off the fluid as described in the chapter HYDRAULIC Proceed as follows:
Removal
Proceed as follows:
pump;

operations.
- recover the driving joint (4) and the o-ring (5).
Always replace the o-ring.
Figure 38
285A015016R
SECONDARY STEERING PUMP REMOVAL- Very heavy parts

REFITTING

Observe all general recommendations for the correct hazardous and/or polluting substances
Vehicle preparation

Safety component.
Figure 39
2371801

of short circuits;

Preliminary operations To refit, follow the removal operations in reverse.
Proceed as follows:
Final operations
- drain off the fluid as described in the chapter HYDRAULIC
FLUID REPLACEMENT in this Section. Proceed as follows:
Removal FLUID REPLACEMENT in this Section.
Proceed as follows:
pump;

operations.
Figure 40
285A015017R
STEERING FLUID TANK REMOVAL-

REFITTING
GENERAL
Safety instructions

manual.


The operations described are also valid for vehicles operations.
with one tank only.
- disconnect the electric connector of the level sensor (3);

Figure 41
342B015003R
- remove the filler cap (1) from both tanks;

- with an appropriate suction device, empty the fluid
contained from both tanks.
If it is necessary to remove only one tank, remove also

the connection pipes (5).
342B015005R
Removal
Proceed as follows: - working from the rear unscrew the fastening screws
(arrow) and remove the tank (4).
Figure 42
Check intactness of hydraulic fittings and related piping: if
necessary replace the damaged component.
Refitting
Final operations
Proceed as follows:
- restore correct level of fluid in both tanks.
342B015004R
- disconnect the delivery (1) and fluid return pipes (2) from
both tanks;

PNEUMATIC SYSTEM - BRAKES
SECTION 16
HD9 Euro5 SECTION 16 PNEUMATIC SYSTEM - BRAKES 1
SECTION 16
Pneumatic system - brakes
Page
DESCRIPTION 5
- Pneumatic system 5
- Services system 5
- Service braking 5
- Anti-lock braking system (A.B.S.) 5
- Emergency braking 5
- Retarder - engine braking 5
- Retarder - transmission braking (if present) 5
- Parking brake 5
- Supplementary parking brake 5
BRAKING SYSTEM COMPONENTS LOCATION 6
- 2-axle vehicles 6
- 3-axle vehicles 8
PNEUMATIC SYSTEM MAIN COMPONENTS 12
COMPRESSOR 12
- Head fastening screws 12
- Installation and connections 12
A.P.U. AIR PROCESSING UNIT 13
- Pneumatic connections 13
- Thermostat resistor electric connections 13
- Pressure sensor electric connections 13
DUPLEX CONTROL VALVE 14
- Electrical connections 14
MANUAL DISTRIBUTOR (for vehicles suitable for
towing) 15
MANUAL DISTRIBUTOR (for free-standing vehicles) 15
MANUAL CONDENSATION DRAIN VALVE 15
2 PNEUMATIC SYSTEM - BRAKES SECTION 16 HD9 Euro5
RELAY VALVE 15 - Parking brake distributor 33

ANTICOMPOUND VALVE RELAY WITH INTEGRATED - Relay valve 34
UNIDIRECTIONAL VALVE 16
- Three-way servodistributor (if present) 35
- Membrane brake cylinder 36
TOW BRAKE CONTROL VALVE 17
- Braking corrector (vehicles without ABS only) 37
- Braking 38
UNIDIRECTIONAL VALVE 17
- Checks 45
TRAILER COUPLING HEADS 17
ADJUSTMENT OF BRAKING CORRECTOR
PROPORTIONAL REDUCER VALVE 17 (only vehicles without ABS) 47
DIAPHRAGM BRAKE CYLINDER (front A and rear B GENERAL 47
wheels) 18
COMBINED BRAKE CYLINDER (rear wheels) 18
BRAKING CORRECTOR (only vehicles without ABS) 19
- Brake corrector label 50
- Braking corrector ID plate 19
BRAKE CORRECTOR REMOVAL-REFIT
ABS ELECTROVALVE (only vehicles with ABS) 20 (only vehicles without ABS) 52
- Pneumatic connections 20 GENERAL 52
- ABS/EBL system electrical connections 20 - Safety instructions 52
- Front right wheel 20 - Vehicle preparation 52
- Front left wheel 20 - Specific safety instructions 52
- Rear right wheel 20 DESCRIPTION OF OPERATION 53
- Rear left wheel 20 - Removal 53
SPEED SENSOR AND PHONIC WHEEL (only vehicles - Inspections and checks 54
with ABS) 21
- Refitting 54
ABS ELECTRONIC CONTROL UNIT (only vehicles with
ABS) 22 - Final operations 54
- ABS control unit pin-out 23 REMOVAL-REFITTING OF PARKING BRAKE 55
- Connector X1 23 GENERAL 55
- Connector X2 23 - Safety instructions 55
TIGHTENING TORQUES 24 - Vehicle preparation 55
TOOLS 24 - Specific safety instructions 55
DIAGNOSTICS 25 DESCRIPTION OF OPERATION 56
- Compressor 25 - Removal 56
APU 30 - Inspections and checks 56
- Duplex distributor 32 - Refitting 56
- Final operations 56 - Very heavy parts 63

ABS SOLENOID VALVE REMOVAL-REFITTING 57 - Specific safety instructions 63
GENERAL 57 DESCRIPTION OF OPERATION 64
- Vehicle preparation 57 - Inspections and checks 64
- Specific safety instructions 57 - Refitting 64
DESCRIPTION OF OPERATION 58 - Final operations 64
- Removal 58 COMPRESSOR REMOVAL-REFITTING FOR
COMPRESSED AIR 65
GENERAL 65
- Refitting 58
RELAY VALVE REMOVAL-REFITTING 59
GENERAL 59
- Removal 66
- Removal 60
- Refitting 66
- Refitting 60
PIPES AND COUPLINGS 67
GENERAL 67
DRIER REMOVAL-REFITTING 61
- End forming on rigid pipes 67
GENERAL 61
- Bending rigid pipes 68
- Cutting rigid pipes 68
- Replacing flexible hoses with threaded couplings 69
- Replacing flexible hoses with quick-connection
DESCRIPTION OF OPERATION 62 fittings 70
- Removal 62 FITTINGS IN SYNTHETIC MATERIAL 71
- Inspections and checks 62 - Description 71
- Refitting 62 - Use 72
- Final operations 62 - Assembly 73
REMOVAL-REFITTING OF COMPRESSED - Disassembly 74
AIR TANK 63
BRAKING SYSTEM 75
GENERAL 63
- Vehicle braking system diagram two axles with
- Safety instructions 63 ABS suitable for towing 76
- Vehicle braking system diagram three axles with

ABS suitable for towing 78
- Vehicle braking system diagram three axles front
10 ton axle with ABS suitable for towing 80
- Vehicle braking system diagram four axles with
ABS suitable for towing 82
- Vehicle braking system diagram two axles with
ABS NOT suitable for towing 84
- Vehicle braking system diagram three axles with
- Vehicle braking system diagram three axles front
10 ton axle with ABS NOT suitable for towing 88
- Vehicle braking system diagram four axles with
- Vehicle braking system diagram four axles front
10 ton axle with ABS NOT suitable for towing 92
- Vehicle braking system diagram 2 axles without
ABS for towing 94
ABS for towing 96
- Vehicle braking system diagram four axles without
ABS for towing 100
ABS for towing 102
- Vehicle braking system diagram four axles without
- Vehicle braking system diagram four axles front
10 ton axle without ABS NOT suitable for towing 106
PNEUMATIC SERVICES SYSTEM DIAGRAMS 109
- 4x2 vehicles with F2B engine 110
- 6x4 - 6x6 - 8x4 - 8x6 - 8x8 vehicles 116
DESCRIPTION
Emergency braking
This chapter describes the main functions/compo- Incorporated in the service brakes. This dual circuit system
nents that may be installed on the vehicle. permits braking on one axle even with a failure on the other
Some functions/components may NOT be installed axle, by pressing the service brake pedal.
on certain vehicles.
Retarder - engine braking
Achieved with an engine braking device built-in to the engine.
Pneumatic system
The function of the system can be programmed by a selector
The system is powered by a compressor that provides the
lever: according to the selected mode, the device enters into
necessary quantity of air to the system through the APU
operation with the accelerator pedal released, or with the brake
distributor-drier.
pedal pressed, or by pressing a specific floor button.
The air is stored in suitable tanks for use according to vehicle
services and braking operational requirements. Retarder - transmission braking (if present)
Achieved by a specific hydraulic retarder built-in to the
Services system transmission group and controlled by an independent control
The system drives all the pneumatic systems installed on the lever. Permits various levels of deceleration.
vehicle,, drawing compressed air from a specific tank.
Each mechanism is actuated by command valves and actuators. Parking brake
Mechanically actuated by pneumatically released combined
Service braking cylinders acting on the vehicle rear brakes. Controlled by a
The service brakes are drum type. manual pneumatic distributor.
Pressing the brake pedal actuates the duplex distributor and
thereby application of pneumatic pressure to the membrane Supplementary parking brake
cylinders (front) and combined cylinders (rear). Pneumatically actuated, acting on the front brakes.
The pneumatic circuit consists of various independent sections: Can be applied only after engaging the parking brake, and for
- the first section for activating the front brakes, short periods with the engine running.
- the second section for activating the rear brakes

- the third section (if present) for trailer braking.
Il. In case of failure of one section, this sectioning of the
pneumatic system ensures the efficiency of the other sections.
Anti-lock braking system (A.B.S.)

The system is capable of prevent wheel lock, which could occur
when braking, in any vehicle load or wheel-road grip conditions,
in order to guarantee maximum braking performance and
better vehicle stability.
The system is enabled on starting and enters into operation
automatically for speeds greater than 5 kph if one or more of
the wheels shows a tendency to lock when braking.
The system is capable of controlling engine braking exclusion
and distributor locking (if present)
These are disabled if the tendency to lock is detected in one or
more of the tractor wheels.
These systems are automatically re-enabled when the action of
the A.B.S. system stops.
BRAKING SYSTEM COMPONENTS LOCATION

2-axle vehicles
1. Air compressor (on engine)
2. APU
3. Tanks (see detail)
4. Duplex distributor (in cabin)
5. Parking brake distributor (in cabin)
6. Relay valve (* vehicles with rear drive axle) (** vehicles with four-wheel drive)
7. Dual command valve (anticompound)
8. Three-way servodistributor (only vehicles suitable for towing)
9. ABS valve
10. Membrane cylinder
11. Combined membrane cylinder
12. ASR electrovalve (if fitted)
3 Detail of compressed air tank locations
A. front brakes
B. rear brakes
C. parking brake
357A016001R
2-axle vehicles
357A016002R
3-axle vehicles
2. APU
6. Relay valve (*vehicles with rear drive axle) (** vehicles with four-wheel drive)
9. ABS valve
A. front brakes
B. rear brakes
C. parking brake
357A016003R
3-axle vehicles
357A016004R
4-axle vehicles
2. APU
6. Relay valve
9. ABS valve
A. front brakes
B. rear brakes
C. parking brake
357A016005R
4-axle vehicles
357A016006R
PNEUMATIC SYSTEM MAIN Installation and connections

COMPONENTS
Figure 3
COMPRESSOR
Figure 1
000836t
000858t
The component, which is the same for all systems, generates

the compressed air required to recharge the pneumatic sys-
tem.
It is twin cylinder type, equipped with an Energy Saving device
that permits reduction of the power absorbed by the engine
when the systems are suitably served.
Head fastening screws

Figure 2 T207090
1. Intake path
2. Air filter
3. Flexible intake piping
4. Rigid intake piping
5. Delivery piping
060232
A.P.U. AIR PROCESSING UNIT
This consists of a drier with filter regeneration timer and a for-way protection valve with incorporated pressure reducer.
The drier serves to purify and dry the compressed air, regulating system pressure to the foreseen calibration value.
The four-way protection valve distributes the air to the various circuits assuring circuit operating pressure even in case of failure.
Calibration: 10.3 + 0.2 bar
Figure 4
107021
Pneumatic connections Thermostat resistor electric connections

1 - Compressor power supply 6.1 - Thermostat resistor negative
23 - To compressor for Energy Saving control 6.2 - Thermostat resistor positive
3 - Atmospheric discharge
21 - To rear brake air tank 10.3 + 0.2 bars Pressure sensor electric connections
22 - To front brake air tank 10.3 + 0.2 bars
23 - To parking brake air tank 8.5 bars 6.1 - Not used
24 - To utility system 8.5 bars 6.2 - Rear sensor signal
6.3 - Power positive
6.4 - Negative
6.5 - Front sensor signal
6.6 - Power positive
6.7 - Negative
DUPLEX CONTROL VALVE Figure 5

This is coaxial NON SELF-LIMITING type with a pneumatic
section and an electrical section.
The pneumatic section serves to distribute braking pressure to
the front axle, the rear axle and the trailer servo-control valve.
The electrical section assures transmission of the braking signal
to the EDC control unit and brake lights control relay.
336B016006R
Figure 6
000792t
Pneumatic connections Electrical connections

11 - Supply from the front axle tank 1 - Positive input
12 - Supply from the rear axle tank 2 - Positive for Body Computer (brake lights) + VCM
21 - Front axle relay valve output (EDC)
22 - Rear axles relay valve output 3 - Positive for VCM (EDC)
3 - Exhaust into atmosphere 4 - Not used
MANUAL DISTRIBUTOR (for vehicles MANUAL CONDENSATION DRAIN VALVE

suitable for towing)
Figure 7 Figure 9
001091t 0007511t
11 = Power The component is used to manually drain any condensation

21 = To anticompound relay valve accumulated in the system tanks.
22 = To trailer brake control valve
The component serves to actuate tractor and trailer parking
brake. RELAY VALVE
The parking brake is mechanical for the tractor and pneumatic
for the trailer. Figure 10
The device also permits checks on tractor braking effect. This
operation is indispensable when the vehicle is parked in high
load conditions or on gradient.
MANUAL DISTRIBUTOR (for free-standing

vehicles)
Figure 8
001010
Serves to reduce cut-in time of the circuit it is connected to.

The component is used to actuate axle service braking.
The component receives: power to connector ”1” from the
system tank while cut-in pressure to connector ”4” is provided
by the duplex distributor.
This determines an activation pressure at the outpus ”2” pro-
portional to the command received.
001088t
11 = Power
21 = To anticompound relay valve
The device on the tractor parking brake circuit permits vehicle
parking brake application, discharging compressed air from
spring cylinders.
ANTICOMPOUND VALVE RELAY WITH Figure 11

INTEGRATED UNIDIRECTIONAL VALVE
This serves the following functions:
- To prevent, in case of simultaneous parking and service
braking, doubling of the stress in the duo duplex brake
through command 41;
- Axle parking brake via command 42;
345B015004R
Figure 12
001529t
Pneumatic connections
1 - Power from parking brake system
21 - Output for parking brake cylinders
22 - Output for manual control valve
3 - Exhaust
41 - Command from manual control valve
42 - Command from duplex control valve
TOW BRAKE CONTROL VALVE TRAILER COUPLING HEADS
Figure 13 Figure 15
001119t
001116t
The device, controlled by two independent duplex distributor These serve to permit connection between the tractor pneu-
circuits and the tractor parking brake circuit, controls tractor matic system and that of the trailer.
service braking or parking brake. The component also permits
regulation of foreseen head pressure on the trailer braking con- The version for adjustable control is fitted with a yellow
trol through an incorporated valve. cover and a ”2” lateral safety protrusion, whereas the auto-
matic version has a red cover and a ”1” safety protrusion.
The device is fitted with a system to permit trailer parking brake
actuation even in case of failure of the adjustable command line The safety protrusions serve to prevent coupling errors.
(modulated servo switch). The coupling operation involves rotation of one head in rela-
tion to the other (tractor-trailer), on a guide that leads into
Pneumatic connections head locked position. The valves then close automatically.
11 = Power
12 = Trailer supply line
22 = Trailer control line
41 = From duplex output 21
42 = From duplex output 22
43 = Trailer brake control section PROPORTIONAL REDUCER VALVE
Figure 16
UNIDIRECTIONAL VALVE
Figure 14
The component is used when control or command pressure

has to be proportionally reduced.
The component used in the parking section serves to prevent
air return in case of fault upstream of the valve itself.
DIAPHRAGM BRAKE CYLINDER COMBINED BRAKE CYLINDER

(front A and rear B wheels) (rear wheels)
Figure 17 Figure 18
345B015006R
The component consists of two parts, a diaphragm for service

braking and a spring for parking and emergency braking.
Pulling the handbrake lever discharges the pneumatic pressure
that holds the spring in compression..
The spring is then free to act on the jaws, engaging the brake.
357A016007R Pneumatic connections

11 = From duplex control valve
12 = From duct 21 double control valve
11 = From duplex control valve
The component transmits drive force to the mechanical device
during service braking.
BRAKING CORRECTOR (only vehicles with- Braking corrector ID plate

out ABS)
Figure 20
Figure 19
(1)
(2)
The ID plate bears the information necessary for adjusting the

device, which includes:
39958 1. Dimension ”F” yield of leaf spring according to load.
2. Dimension ”L”, length of corrector control lever.
The component automatically regulates the pressure delivered 3. Rear axle loading for vehicle at full load.
from the duplex control valve to the axle brake cylinders in 4. Feed pressure to device for vehicle with full load
relation to the load bearing down on the rear axle.
5. Outlet pressure to device for vehicle with full load
6. Rear axle load for empty vehicle.
7. Feed pressure to device for vehicle empty
1 = Power supply
2 = Output 8. Output pressure to device for vehicle empty
4 = Command from Duplex control valve
ABS ELECTROVALVE (only vehicles with Figure 21

ABS)
This is a normally open electrovalve consisting of one power
coil and one discharge coil.
It is used to modulate braking pressure when the speed sensor
detects the tendency of the wheels to lock.
336B016007R
Figure 22
ABS/EBL system electrical connections
Front right wheel

6.1 Positive for discharge coil (ECU ABS-X2, pin 4)
6.2 Common negative
6.3 Positive for power coil (ECU ABS-X2, pin 1)
Front left wheel

6.2 Common negative
000821t
Rear right wheel

6.2 Common negative
1 Power supply Rear left wheel
2 Output for axle brake cylinder 6.1 Positive for discharge coil (ECU ABS-X2, pin 5)
3 Discharge 6.2 Common negative
SPEED SENSOR AND PHONIC WHEEL Obviously, the distance between sensor and wheel must have
(only vehicles with ABS) a predetermined value in order to provide the correct signals
(0.7  0.05 mm).
Figure 23
The resistance of each individual sensor measured at the con-
nector terminals is between 1 - 2 k.
Figure 24
000840t
The sensors continually provide the electronic control unit with

the information required to correctly pilot the electrovalves.
The signals are obtained from magnetic flux lines intersecting
the teeth of a metallic toothed wheel facing the sensor and ro- 000842t
tating with the wheel.

The open/closed effect caused by the presence/absence of a
tooth causes a variation in the magnetic flux sufficient to create
an induced electromotive force at the sensor terminals and
thereby an alternating electrical signal, which is transmitted to
the electronic control unit.
ABS ELECTRONIC CONTROL UNIT (only vehicles with ABS)
Figure 25
001014t
000846t
This manages the braking system, determining the deceleration The electronic control unit is equipped with a highly advanced
values based on the parameters received from the various self-diagnosis system and is capable of recognising and memo-
components of the system. rising, according to ambient conditions, any faults arising in the
system, even if intermittent, during its operation, thereby assur-
It communicates with the on-board electronic systems over a
ing more correct and reliable maintenance works.
CAN line and is connected to the vehicle harness by two pola-
rised connectors.
ABS control unit pin-out

Figure 26
000936t
Connector X1
Pin Cable Function

1 GN/VE CAN ”L” line
2 6245 Axle braking detection pressure sensor signal
3 WS/BI CAN ”H” line
4 0000 Ground
5 0049 Negative from ABS switch
6 -- Not used
7 8847 Power under key positive
8 7710 Direct power from battery positive
9 0000 Ground
10 2299 K line for diagnostics connector (pin 4)
11 1199 L line for diagnostics connector (pin 3)
12 --- Safety jumper pin 9 / 15
13 6672 Blink-code light
14 0029 Third brake exclusion negative
15 6670 ABS fault warning negative
Connector X2
Pin Cable Function

1 9920 Positive for front RH ABS power electrovalve
2 9931 Positive for rear LH ABS power electrovalve
3 9921 Positive for front LH ABS power electrovalve
4 9918 Positive for front RH ABS discharge electrovalve
5 9929 Positive for rear LH ABS discharge electrovalve
6 9919 Positive for front LH ABS discharge electrovalve
7 -- Not used
8 9930 Positive for rear RH ABS power electrovalve
9 9928 Positive for rear RH ABS discharge electrovalve
10 5571 Front RH sensor
11 5572 Rear LH sensor
12 5570 Front LH sensor
13 5571 Front RH sensor
14 5572 Rear LH sensor
15 5570 Front LH sensor
16 -- Not used
17 5573 Rear RH sensor
18 5573 Rear RH sensor
TIGHTENING TORQUES
DETAIL TORQUE
Nm (Kgm)
Compressor
Pulley nut 190  10 (19  1)
Head fastening screws 30  3 (3  0,3)
TOOLS
TOOL NO. NAME
99356606 Brake cylinder ring nut removal/replacement spanner

99387050 Nylon pipe shears
99395216 Angular fastening protractor
DIAGNOSTICS
Compressor
1 OIL LEAK FROM FLANGE

OUTER SIDE
Oil leaks from flange outer side Tighten screws to specified values
YES
NO
Flange body surfaces not perfectly flat Check seal surfaces. Replace or reface defective parts
YES
NO
Seal broken Replace the seal

YES
NO
Shaft seal damaged Replace the seal

YES
2 OIL LEAK FROM HEAD
Oil scraper worn (entire seal seat shiny) Replace complete piston
YES
NO
Oil scraper poorly fitted Fit with TOP indication facing up to the compressor
YES head
NO
Oil scraper and piston rings all on the same vertical line Fit with 120˚ offset one to the other
YES
NO
Cylinder scored or ovalised Rebore the cylinder with an oversize piston

YES
3 TOTAL LACK OF
COMPRESSION
Compression or intake valve deteriorated Replace worn parts

YES
NO
Piston rings all on same vertical line Fit rings with 120˚ offset one to the other
YES
NO
Hole in piston or failure of parts connected to piston Replace complete piston

YES
NO
Damaged gskets Replace gaskets

YES
NO
Energy-saving device open during charge phase Replace cylinder head

YES
4
POOR PERFORMANCE
Piston rings worn Replace piston (complete with piston rings)

YES
NO
Air leak between cylinder and head Replace gasket and tighten screws to specified torque
YES
NO
Worn energy-saving device, intake or compression Replace worn parts

valve YES
NO
Excessive play between piston and cylinder Rebore cylinder and fit oversize piston
YES
NO
Burnt oil particles between intake and compression Clean the valves
valves YES
5 MECHANICAL NOISE
Excessive play between connecting rod small end and Check tolerance of parts in question
gudgeon, between gudgeon and piston hole, between YES
shaft and connecting rod big end, between shaft and
bronze bearings and between flange and shafts
NO
Excessive play between piston and cylinder Rebore cylinder and fit oversize piston
YES
NO
Excessive burnt oil deposits on piston and cylinder head Decoke all parts and replace the valves
YES
6 WATER LEAKS
Head gaskets or coupling surfaces socred or irregular Replace damaged parts

YES
APU
EXCESSIVE QUANTITY OF
1
CONDENSATION IN CIRCUIT
Filter cartridge clogged Replace cartridge

YES
2 SET PRESSURE NOT REACHED

IN TANK
Air leak from safety valve Overhaul equipment replacing worn parts
YES
NO
Worn gaskets Overhaul equipment replacing worn parts

YES
3 AIR LEAK FROM DISCHARGE
Filter cartridge clogged Replace cartridge

YES
4 PRESSURE AT OUTLET CONNECTOR

NOT AS SET
Pressure at outlet connector not as set Calibrate the device

YES
NO
Leak from o-rings Overhaul, replace damaged parts

YES
NO
Worn piston and seat Replace

YES
Duplex distributor
1 AIR LEAK FROM DISCHARGE HOLE
Leak from outlet lines due to worn gaskets Overhaul, replacing worn parts
YES
2 VIBRATION DURING BRAKING PHASE
Worn springs Overhaul, replacing worn parts

YES
NO
Air leak caused by piston seals in the two sections Overhaul, replacing worn parts
YES
IRREGULAR BRAKE LIGHT CONTROL

3 FUNCTION
Electrical circuit not closing Replace switch

YES
NO
Electrical circuit not opening Replace switch

YES
Parking brake distributor
AIR LEAK FROM DISCHARGE WITH

1 CONTROL LEVER IN RELEASED
POSITION
Defective discharge valve, valve seat or o-ring Check and overhaul, replacing defective parts. Clean all
YES components

2 CONTROL LEVER IN ENGAGED
POSITION
Worn control valve, seals and component control valve Check and overhaul, replacing defective parts.
YES Carefully clean all components
3 DIFFICULTY ROTATING CONTROL

LEVER
Interference inside distributor Overhaul and lubricate all sliding parts

YES
Relay valve

1 CONTROL LINE ON DISCHARGE
Leak from intake or o-rings Overhaul, replacing defective parts

YES

2 SUPPLY TO CONTROL LINE
Leak from piston gasket or discharge valve Overhaul, replacing defective parts
YES
Three-way servodistributor (if present)
1 AIR LEAK FROM DISCHARGE IN IDLE

CONDITION
Leaks from gaskets Overhaul, replacing defective parts

YES
NO
Defective discharge valve and valve seat Overhaul, replacing defective parts
YES
2 OUTPUT PRESSURE
NOT AS SET
Air leak from gaskets Overhaul, replacing defective parts

YES
NO
Worn or defective pistons or seats Overhaul, replacing defective parts

YES
NO
Worn spring Overhaul, replacing defective parts

YES
Membrane brake cylinder
1 AIR LEAK FROM DISCHARGE OR

RETAINER CLAMP
Membrane perforated or torn Replace membrane

YES
NO
Clamp fasteners loose Tighten screws

YES
2 AIR LEAK FROM MEMBRANE SECTION

SUPPLY
Spring section components worn Overhaul

YES
Braking corrector (vehicles without ABS only)
1 AIR LEAK FROM DISCHARGE ON

BRAKING
Damaged seals on command piston Overhaul

YES
NO
Defective discharge valve and seat Overhaul

YES
2 AIR LEAK FROM CONNECTORS
Connectors loose Tighten connectors

YES
Braking
1 SERVICE BRAKING POOR

OR UNEVEN
Leaking or broken pipes Tighten or replace loose connectors. Replace damaged

YES pipes
NO
Duplex distributor inefficient Overhaul component

YES
NO
Brake linings worn or vitrified Replace linings

YES
NO
Brake cylinders inefficient Overhaul brake cylinders

YES
NO
Front brakes inefficient Overhaul brakes

YES
2 PARKING BRAKE POOR OR NON

EXISTENT

YES pipes
NO
Parking brake distributor inefficient Overhaul component

YES
NO
Combined/parking brake cylinders inefficient Overhaul brake cylinders

YES
NO

YES
NO
Relay valve inefficient Overhaul component

YES
3 DELAYED PARKING BRAKE

RELEASE

YES pipes
NO

YES
NO
Combined parking brake cylinders inefficient Overhaul brake cylinders

YES
NO
Relay valve inefficient Overhaul component

YES
4 VEHICLE PULLS TO ONE SIDE WHEN

BRAKING

YES pipes
NO

YES
NO

YES
NO

YES
NO
Defective brakes Overhaul brakes

YES
NO
Inefficient three-way servodistributor function (if Overhaul component

present) YES
5 PREMATURE BRAKE
LINING WEAR
Vehicle not used correctly Train personnel in correct use

YES
NO

YES
NO

YES
NO
Inefficient relay valve function Overhaul component

YES
NO
Inefficient three-way servodistributor function (if Overhaul component

present) YES
BRAKE WARNING
6
LIGHT ON
Compressor inefficient Overhaul component

YES
NO

YES pipes
7 TRAILER SERVICE BRAKING POOR OR

UNEVEN

YES pipes
NO

YES
NO
Three-way servodistributor inefficient Overhaul component

YES
NO
Trailer brakes inefficient Overhaul brakes

YES
TRAILER PARKING BRAKE POOR

8 OR NON EXISTENT

YES pipes
NO

YES
NO

YES
NO
Trailer brakes inefficient Overhaul brakes

YES
DELAYED TRAILER PARKING BRAKE

9 RELEASE

YES pipes
NO

YES
NO

YES
Checks
Since the vehicle braking system is approved to European code standards, periodic efficiency checks on the system and its
components using the 99305117 device are indispensable.
These checks must be carried out with the vehicle stationary, using the compressed air in the tanks charged, with engine running,
by the compressor
Always secure the vehicle before any works.

Periodically check pressure gauges, comparing readings with sample gauge.
DEVICE OPERATIONS
Compressor Check tightness of head, connectors and mountings
Check absence of coolant leaks.
Check absence of lubricant leaks.
APU Operate the bleed valve: air should bleed off without condensation.
Otherwise check function of electric elements (power supply)
Tanks (all) Check connector seal
Discharge any condensation: check efficiency of drier (APU)
Duplex distributor Press the pedal full down: when released the pedal must return immediately in home position.
Pressure limitation: 7.6 +- 0.3 bar
Check connector seal.
Relay valve Check function, assessing the rapidity of brake cylinder cut-in.
Parking brake distributor Pull the paring brake until the click: the gauge on the control must indicate pressure discharge
(0 bar) within 1 second.
Simultaneously on the trailer coupling (if present) pressure must be 8.5 bar.
ABS electrovalve (ABS vehicles Check connector seal.
only)
Check correct connection of the electrical connector.
Three-way servodistributor (if Fill the tank.
present)
Connect a pressure gauge to the automatic coupling head and another to the adjustable
coupling head.
Pressure of 1 bar delivered from the duplex distributor must correspond to a pressure
between 0.8 and 1.5 bar at the adjustable coupling head:
Carry out a full braking operation (vehicle stopped),
The specified braking pressure or reduced pressure of 0.5 bar must be available at the coupling
head:
Apply the parking brake. Pressure at the adjustable coupling head should remain unchanged
or reduced to 0.5 bar.
Trailer coupling heads (if present) Check the absence of dirt or damage on the coupling guides.
Once coupled, press the brake pedal and check seal and stability between the coupling heads
injecting air at 7.5 bar:
Check the absence of air leaks from the coupling seals.
Membrane brake cylinder Check connector seal and fastening.
The bleed hole must point downwards and must not be obstructed.
DEVICE OPERATIONS
Combined brake cylinder Check connector seal and fastening.
Brake corrector (only vehicles Check connector seal and fastening.
without ABS)
Piping and connectors Check that metal pipes are in perfect condition, without dents or cracks. Nylon pipes must
not have any abrasion or cuts.
Also check that pipes are clear of any sharp edges on the bodywork or chassis that could cause
damage.
Check that all pipe mounting brackets are secure. If loose, vibration could lead to pipe failure.
Check that nylon pipes do not come into contact with mineral oil, grease or solvents.
Press energetically on brake pedal and check that pipes do not swell.
Check the absence of leaks from the various connectors. If present, tighten them fully making
certain not to twist pipes when tightening.
In all the above cases, replace any parts if in doubt as to their efficiency. Apart from their
condition, it is advisable to replace flexible pipes after a certain mileage, or after a long period
of use, to prevent sudden failures due to ageing and fatigue.
Compressed air system seal with This check is made on threaded connectors injecting air into the system at pressure no less
engine stopped under the cut-in than 5 bar. After spreading thick soapy water on the joints and connectors with a soft brush
pressure there must be no leaks.
Air leak tolerance corresponds to one soap bubble of diam. 25 mm in 5 seconds, or a max.
pressure drop over 10 minutes of 2% disengage pressure = 0.22 + 0.02 bar.
Compressed air system seal in Pressure in the compressed air system must remain stable for 3 minutes. Carry out the check
partial braking range at 3 bar with parking brake disengaged.
ADJUSTMENT OF BRAKING CORRECTOR

(only vehicles without ABS)
GENERAL
Safety instructions

DESCRIPTION OF OPERATION Proceed as follows:

- check that the ground weight of the axle/s corresponds to
the information given on the plate.
To correctly adjust the device all braking system - connect a pressure gauge to the command control intake
controls must be in perfect working order. (4) and output (2) of the device.
Figure 27
335B016010R
Figure 28
4 4
A 5 B
335B016035R
1. braking corrector Execution of operation

2. rear axle Proceed as follows:
3. tandem axle connector rod (only for three/four axle
versions) - check and if necessary adjust the dimension “L” of the lever
4. lever (4) to correspond to the information on the plate.
5. tie rod - check that the air pressure in the tank has reached the reg-
A 2 axle vehicles ulator cut-in value
B 3 and 4 axle vehicles - press the brake pedal until reaching the required pressure
on the pressure gauge connected to the control (4).
- measure the output pressure on the pressure gauge con-
nected to the output (2) and compare it with the pressure
given on the plate.
- if the pressure is not as required, suitably adjust the tie rod
(5) until achieving the required value.
- disconnect the corrector tie-rods and raise the corrector
to full stroke to simulate full load conditions.
- Check that the output pressure is equal to the command
pressure;
- if the value is not as required, proceed to overhaul the cor-
rector.
Final operation
Remove the gauges from the equipment sockets.
Brake corrector label
Prex empty (5) Prex loaded (8)

Vehicle Suspension Height F (1) (mm) Height L (2) (mm)
(bar. +0.3 / -0.2) (bar. +0.3 / -0.2)
4x2 - 67.5 150 - -
4x2 tratt - 55.5 120 - -
6x4 33 ton 9-10x25 55 115 2.7 7.4
6x4 38 ton 9-10x25 69.5 115 2.6 7.6
6x4 tratt 9-10x25 54 85 2.5 7.6
6x6 33 ton 9-10x25 54.5 115 2.4 7.3
6x6 38 ton 9-10x25 69 115 2.7 7.6
6x6 tratt 9-10x25 54.5 85 2.2 7.6
ABU DHABI 10x25 56 95 3.6 7.6
8x4 40 ton 9-10x25 56.5 90 1.8 7.6
8x4 48 ton 9-10x25 70.5 130 1.7 7.4
8x6 40 ton 9-10x25 54.5 90 2.2 7.6
8x6 48 ton 9-10x25 70 130 1.7 7.3

BRAKE CORRECTOR REMOVAL-REFIT

(only vehicles without ABS)
GENERAL
Safety instructions

Vehicle preparation

Figure 29
2371801

short circuits;
Make sure that residual pressure has been completely

discharged from the circuits and related tanks.
Removal
Proceed as follows:
Figure 30
335B016011R
- disconnect the compressed air supply pipe (1); - disconnect the brake corrector control pipe from the
duplex distributor (4);
- disconnect the compressed air outlet pipe (2);
- disconnect the compressed air discharge pipe (3);
- free and remove the adjustment rod (6) from the axle
connection rod.
Figure 31
335B016012R
- unscrew and remove the two fastening nuts (1);

- remove the brake corrector from the vehicle chassis.

Check that pneumatic pipes are intact: otherwise replace any
damaged part.
Refitting
Final operations
Check that with the system under pressure there are no air
leaks from fittings:
- adjust the brake corrector as described in the chapter
BRAKE CORRECTOR ADJUSTMENT of this Section.
REMOVAL-REFITTING OF PARKING BRAKE

GENERAL
Safety instructions

Vehicle preparation

Figure 32
2371801

short circuits;

DESCRIPTION OF OPERATION - loosen and remove fastening screws (see arrow) support
bracket (1) of control device on dashboard ;
Removal
- disconnect air outlet (2) pipes;
Proceed as follows:
- disconnect air supply (3) pipes;
Figure 33
- disconnect air delivery pipes (4) to anticompound relay
valve;
- disconnect air delivery pipes (5) to trailer brake control
valve;
- disconnect the electric connection (6).
Figure 35
342B016001R
- withdraw the bottle holder (1) from its housing;

- loosen and remove fastening screws (see arrow) of plastic
fairing (2);
- remove the plastic fairing (2)
Figure 34
342B016003R
- loosen and remove the two fastening screws (see arrow)

and separate the control device from the bracket.

damaged part.
Refitting
Final operations
leaks from fittings.
342B016002R
ABS SOLENOID VALVE REMOVAL-REFIT-

TING
GENERAL
Safety instructions

Vehicle preparation

Figure 36
2371801

short circuits;


Removal
Proceed as follows:
Figure 37
335B016019R
335B016017R
- remove the solenoid valve from the vehicle chassis.

- disconnect the compressed air inlet pipe (1);
- disconnect the compressed air outlet pipe (2); damaged part.
Refitting
Figure 38 To refit, follow the removal instructions in reverse order.
Final operations
335B016018R
- disconnect the solenoid valve electric connection (1).

RELAY VALVE REMOVAL-REFITTING

GENERAL
Safety instructions

Vehicle preparation

Figure 40
2371801

short circuits;


Removal
Proceed as follows:
Figure 41
335B016022R

335B016020R - remove the valve from the vehicle chassis.
- disconnect the compressed air inlet pipe (1); Inspections and checks
- disconnect the compressed air outlet pipe (2);
damaged part.
- disconnect the pilot pipe (4);
Refitting
Figure 42 To refit, follow the removal instructions in reverse order.
Final operations
335B016021R

DRIER REMOVAL-REFITTING
GENERAL
Safety instructions

Vehicle preparation

Figure 44
2371801

short circuits;


Removal
Proceed as follows:
Figure 45
342B016005R
- disconnect the rear axle tank air delivery pipe (21);

- disconnect the front axles tank air delivery pipe (22);
- disconnect the parking brake tank air delivery pipe (23);
- disconnect the services tank air delivery pipe (24);
Figure 47
342B016004R
- disconnect the following electric connections:

1. thermostatic resistor
2. pressure sensors;
- Disconnect the compressed air discharge pipe (3);
- Disconnect the compressed air inlet pipe (4);
- Disconnect the Energy Saving control pipe (5);
342B016006R
- loosen and remove the three fastening screws (1);

- remove the drier from the support bracket.

damaged part.
Refitting
Final operations
REMOVAL-REFITTING OF COMPRESSED Very heavy parts

AIR TANK

Observe all the general recommendations to carry Make sure that residual pressure has been completely
out maintenance jobs correctly. discharged from the circuits and related reservoirs.
Vehicle preparation

Figure 48
2371801

short circuits;

Removal
Proceed as follows:
Figure 49
335B016030R
- remove the compressed air outlet fitting from the tank (1);
335B016028R
Figure 52
- with appropriate lifting equipment, sling the compressed
air tank (1) and sustain it before relasing;
Use appropriate belts.

Do not use chains or hooks to avoid damaging the
tank.
Figure 50
335B016031R
- loosen and remove fastening screws (1) of the

compressed air tank;
- remove the compressed air tank (2) withdrawing it from
below.

damaged part.
335B016029R
Refitting
- remove the compressed air inlet fitting from the tank (1); To refit, follow the removal instructions in reverse order.
Final operations
COMPRESSOR REMOVAL-REFITTING Very heavy parts

FOR COMPRESSED AIR

Observe all the general recommendations to carry Make sure that residual pressure has been completely
out maintenance jobs correctly. discharged from the circuits and related reservoirs.
Vehicle preparation

Figure 53
2371801

short circuits;

Proceed as follows:
- remove the main steering pump operating as described in
the chapter MAIN STEERING PUMP
REMOVAL-REFITTING in section 15.
Removal
Proceed as follows:
Figure 54
335B016034R
- remove fastening screws (1) and separate the compressor

from the engine.

Check intactness of air and lubrication oil fitting seals , if
necessary replace damaged components.
Refitting
335B016032R
Final operations
- disconnect the air delivery pipe (1); - Refit the main steering pump operating as described in the
- disconnect the lubrication oil pipe (2); chapter MAIN STEERING PUMP REMOVAL-REFITTING
in section 15.
- disconnect the air intake pipe (3);
- Fill with the fluid as described in HYDRAULIC FLUID
- disconnect the Energy Saving control pipe (4); CHANGE in Section 15.
Figure 55
335B016033R
- disconnect the lubrication oil pipe (1);

PIPES AND COUPLINGS
General Figure 59
The pipes in the braking systems of commercial vehicles are
currently of two types :
- Flexible nylon hose with single or two-ply structure and in ASTRA
the following diameters (Ø 6, 8, 10, 12, 16 mm) supplied
as spares by the metre.
- Rigid metal pipe of the following diameters (Ø 4.75, 6.35,
8, 10, 12 mm). Piping from Ø 4.75 to Ø 10 mm is supplied
as spares in straight lengths of 4, 5, 6 m, while those which
are over 10 mm diam are supplied as spares ready cut, bent
and flared.
31973
End forming on rigid pipes
Deburr pipe (1), insert union fitting (2) onto it and position it
Figure 57 between blocks (3) bearing against pin (5). Lock pipe (1) with
screw (4).
Figure 60
C 31971
TYPES OF END FORMING ON RIGID PIPES 31974
A Type end forming Move pin (4) to neutral position. Screw up screw (1) until die
(2) comes up against blocks (3), thus forming the end of pipe
Figure 58 (5).
B Type end forming

Figure 61
31972
Position on press 99386523 (3) the blocks (1) so that the

stamped numbers indicating the diameter of the piping to be
worked are facing towards the die (2). The choice of die de-
pends on the diameter of the pipe to be worked. And the di- 31975
ameter for which it may be used is stamped on every die (2). Fit die (2) to press 99386523 (1). For end forming process,
follow the directions given above for A type end forming.
C Type end forming

Figure 62 Figure 65
ASTRA
31976 31979
Install nut (2) and ring (3) onto piping (1). Position pipe (1) in tool (3) and bend pipe by pressing lever (2).
Figure 63 Figure 66
ASTRA
31980
31977
To release pipe (2) from tool (3), press catch (1).
Fit union (2) and tighten so that the ring (3, Figure 62) is locked
onto the pipe (1).
Bending rigid pipes Cutting rigid pipes

Figure 64 Figure 67
31978 31981
Position pipe (2) in tool (3) 99386523 and tighten screw (1).
Assemble tool (1) 99386523, choosing parts (2) and (3) ac- Holding pipe (2) stationary, rotate tool (3) until pipe is com-
cording to the diameter of the pipe to be bent. pletely cut.
After cutting the pipe, deburr and proceed to form the end as - End-form the seating bush, on fitting to the vehicle or on
described previously. the work bench, to a union.
- The pressure exerted and the final distance of the front
When tool (3) is rotated around pipe (2), screw edge of the compression ring from that of the reinforcing
(1) loosens. To cut the pipe completely, it is there- bush must be the value listed in the schedule as given in the
fore necessary to tighten the screw (1) as and table.
when it becomes loose.
Replacing flexible hoses with threaded If the fittings are badly assembled, do not re-use the
couplings hose after extracting the bush and seating ring.
Carefully follow the instructions below:
Figure 68 Pipe Distance “h” between Assembly

edge of bush and ring pressure
mm mm N/mm2
6x1 from 1 to 1,5 0,040

Single layer
8x1 from 2 to 2,5 0,050
10 x 1,5 from 2 to 2,5 0,050
Double layer 12 x 1,6 from 2 to 2,5 0,060
10397 16 x 2,34 from 3 to 3,5 0,060
- Use only approved hose

- Check the condition of the replacement hose; there must (*) See reference h, Figure 70.
be no cracks, cuts or incisions on it.
- Cut the hose to the required length, cutting at 90_ to the Figure 70
centreline using appropriate pipe cutting pliers 99387050.
Thread onto the hose, in the order given:
- nut (3), compression ring (2) (larger thickness towards the
nut (3)) and reinforcing bush (1);
- bush must be in perfect condition (it must not show any
distortion or signs of hammering).
Figure 69
ASTRA
10399
1. Reinforcing bush - 2. Compression ring - 3. Nut - 4. Union

5. Hose - h. Distance between edge of bush and edge of ring
10398
(see table).
FITTING REINFORCING BUSH

A = CORRECT METHOD OF FITTING Insert the end of the hose prepared in this way into the union
B = INCORRECT METHOD OF FITTING body until reinforcing bush flange bears against seating;
- To tighten nut onto union, first of all screw in by hand and
- Install reinforcing bush using tool 99372219, ensuring that then complete tightening using a polygon wrench fitted on
there is contact between its flange and the end of the the torque wrench, to be set according to the specified
hose; tightening torque.
- make sure that the end of the hose fits into the raked
groove in the flange.
When fitting the hose to the vehicle, some important points Replacing flexible hoses with quick-connection
requiring care should be borne in mind : fittings
- Bends must comply with minimum radii, so as to avoid Rotating fittings:
constrictions:
Figure 72
Diameter of pipe Minimum radius of curvature
mm mm
6x1  40
8x1  50
10 x 1,5  60
12 x 1,6  75
16 x 2,34  100
39306
Make sure that the hoses are not in contact with sharp
edges or with sharp metal parts or sources of heat, but
are at a minimum safety distance of 15 mm from these. Screw the fitting into the threaded seating provided on the air
valve and tighten it to the tightening torque indicated in the
table.
- When hoses run through chassis members or metal parts,

make sure that the holes through which they pass are fitted Swivelling fittings:
with rubber grommets and that these are in good
condition. Figure 73
- Avoid sliding the hose along sharp edges which might cause
cuts.
- Where the hose has to be attached to existing pipework,
take account of the additional heat to which it may be
subjected (power steering pipework); in this case, the hose
must be protected with shields.
- When the hose has been connected, check that it is not
under tension between the attachment points, instead
leaving it slightly slack to take up the more substantial
variations in temperature, especially for short lengths.
- Before fitting, thoroughly clean the hoses by blowing
compressed air through them to safeguard operation of the
system. 39307
Figure 71 - Check that the O-ring (1) is correctly fitted in its seat.
- tighten the fitting until the seal rests firmly on the valve.
- position the fitting and, holding the swivelling part still,
tighten the nut to the torque indicated in the table.
13132
- Protect the hoses if grinding or welding operations are THREADING TIGHTENIG TORQUE (Nm  10%)
carried out on the vehicle; a notice is fitted in the cabin
indicating the precautions to be observed carefully to avoid M 10 x 1,0 mm 22
damage.
M 12 x 1,5 mm 24
For greater safety and convenience in working, it is
advisable to remove the hoses during these oper- M 14 x 1,5 mm 28
ations.
M 16 x 1,5 mm 35
When fitting is finished, check that all seals (unions, couplings
M 22 x 1,5 mm 40
etc.) are completely free from leaks.
FITTINGS IN SYNTHETIC MATERIAL

Description
Figure 74
342B016007R
1. Fitting in synthetic material

2. Quick fitting
3. Rotating fitting
4. Pneumatic seal O-ring
5. Vibration seal O-ring
6. Fins for quick removal
Use
Fittings in synthetic material are interchangeable with conventional types
They are used in all positions, with the following exceptions:
- where not permitted by overall dimensions
- on the braking system starting from ABS valve outlet (vehicles with ABS) or starting from fitting on chassis (vehicles without
ABS) up to braking units.
1. APU: conventional fitting due to overall dimensions (reduced centre distance between fittings)
2. relay valve synthetic fitting
3. Rear relay valve : synthetic fitting
4. Front ABS valve : synthetic inlet (a), conventional outlet (b) fitting
5. Front braking unit: conventional fitting
Figure 75
342B016008R
Assembly Figure 79
Proceed as follows:
Figure 76
342B016009R
- remove the cap on the fitting to be coupled;
Figure 77
342B016012R
- press to obtain a second click.
Pneumatic seal is only ensured by the second click. In

this condition residual clearance (see arrow) is
approx. 1 mm.
342B016010R
- align comnponents;
Figure 78
342B016011R
- press to obtain the first click;
The first click ensures latching of components, but

does NOT guarantee pneumatic seal.
Disassembly Figure 82
Fitting disassembly requires a special tool.
Figure 80
342B016015R
342B016013R
- widen the fins;

KNIPEX 4621A21 pliers
Proceed as follows:
Figure 83
Figure 81
342B016016R
- keeping the fins widened, remove the fitting.
342B016014R
- insert the tips of the pliers into the fins housings;

BRAKING SYSTEM
Vehicle braking system diagram two axles with ABS suitable for towing
Key
1. Air compressor
2. A.P.U. with heater
3. Tank (30l)
4. Condensation bleeder valve
5. Relay valve
6. Anticompound relay valve
7. Non self-limiting Duplex distributor
8. Parking manual distributor
9. Trailer brake control valve
10. Automatic coupling head
11. Modulating coupling head
12. Brake cylinder
13. Combined brake cylinder
13a. Brake cylinder
14. Pressure switch
15. Test connection
16. ABS solenoid valve
17. ABS sensor
18. Pressure sensor
19. Tank (20l) (if installed)
20. Controlled pressure valve
21. ASR solenoid valve
22. Selector valve
A= Parking brake
B= Rear
C= Front
D= Services
Vehicle braking system diagram two axles with ABS suitable for towing
5949790723
Vehicle braking system diagram three axles with ABS suitable for towing
Key
1. Air compressor
3. Tank (30 l)
3a. Tank (20 l)
5. Relay valve
12. Brake cylinder
13a. Brake cylinder
14. Pressure switch
15. Test connection
17. ABS sensor
18. Pressure sensor
19. -
22. Selector valve
A= Parking brake
B= Rear
C= Front
D= Services
Vehicle braking system diagram three axles with ABS suitable for towing
5949791779
Vehicle braking system diagram three axles front 10 ton axle with ABS suitable for towing
Key
1. Air compressor
3. Tank (30 l)
3a. Tank (20 l)
5. Relay valve
12. Brake cylinder
13a. Brake cylinder
14. Pressure switch
15. Test connection
17. Pressure sensor
18. Regulating valve
A= Parking brake
B= Rear
C= Front
D= Services
Vehicle braking system diagram three axles front 10 ton axle with ABS suitable for towing
5949782699
Vehicle braking system diagram four axles with ABS suitable for towing
Key
1. Air compressor
3. Tank (30 l)
3a. Tank (20 l)
5. Relay valve
12. Brake cylinder
13. Second axle brake cylinder
14a. Brake cylinder
15. Pressure switch
16. Test connection
18. ABS sensor
19. Pressure sensor
22. Selector valve
A= Parking brake
B= Rear
C= Front
D= Services
Vehicle braking system diagram four axles with ABS suitable for towing
5949791785
Vehicle braking system diagram two axles with ABS NOT suitable for towing
Key
1. Air compressor
3. Tank (30 l)
5. Relay valve
9. -
10. -
11. -
12. Brake cylinder
13a. Brake cylinder
14. Pressure switch
15. Test connection
17. ABS sensor
18. Pressure sensor
19. Tank (20l) (if installed)
22. Selector valve
A= Parking brake
B= Rear
C= Front
D= Services
Vehicle braking system diagram two axles with ABS NOT suitable for towing
5949790724
Vehicle braking system diagram three axles with ABS NOT suitable for towing
Key
1. Air compressor
3. Tank (30 l)
3a. Tank (20 l)
5. Relay valve
9. -
10. -
11. -
12. Brake cylinder
13a. Brake cylinder
14. Pressure switch
15. Test connection
17. Pressure gauge
18. Pressure sensor
19. -
22. Selector valve
A= Parking brake
B= Rear
C= Front
D= Services
Vehicle braking system diagram three axles with ABS NOT suitable for towing
5949791782
Vehicle braking system diagram three axles front 10 ton axle with ABS NOT suitable for towing
Key
1. Air compressor
3. Tank (30 l)
3a. Tank (20 l)
5. Relay valve
9. Brake cylinder
10a. Brake cylinder
11. Pressure switch
12. Test connection
14. Pressure sensor
A= Parking brake
B= Rear
C= Front
D= Services
Vehicle braking system diagram three axles front 10 ton axle with ABS NOT suitable for towing
5949782698
Vehicle braking system diagram four axles with ABS NOT suitable for towing
Key
1. Air compressor
3. Tank (30 l)
3a. Tank (20 l)
5. Relay valve
9. -
10. -
11. -
12. Brake cylinder
14a. Brake cylinder
15. Pressure switch
16. Test connection
18. ABS sensor
19. Pressure sensor
22. Selector valve
A= Parking brake
B= Rear
C= Front
D= Services
Vehicle braking system diagram four axles with ABS NOT suitable for towing
5949791786
Vehicle braking system diagram four axles front 10 ton axle with ABS NOT suitable for towing
Key
1. Air compressor
3. Tank (30 l)
3a. Tank (20 l)
5. Relay valve
9. -
10. -
11. -
12. Brake cylinder
14a. Brake cylinder
15. Pressure switch
16. Test connection
19. Pressure sensor
22. Selector valve
A= Parking brake
B= Rear
C= Front
D= Services
Vehicle braking system diagram four axles front 10 ton axle with ABS NOT suitable for towing
5949782526
Vehicle braking system diagram 2 axles without ABS for towing

Key
1. Air compressor
3. Tank (30 l)
5. Relay valve
12 Brake cylinder
13 Combined brake cylinder
14 Pressure switch
15 Test connection
16 Braking corrector
A= Parking brake
B= Rear
C= Front
D= Services
5949782545

Key
1 Air compressor
2 A.P.U. with heater
3 Tank (30 l)
3a. Tank (20 l)
4 Condensation drain valve
5 Relay valve
6 Anticompound relay valve
7 Self-limiting Duplex Control Valve
8 Parking manual distributor
12 Brake cylinder
14 Pressure switch
15 Test connection
A= Parking brake
B= Rear
C= Front
D= Services
5949782547
Vehicle braking system diagram four axles without ABS NOT suitable for towing
Key
1 Air compressor
3 Tank (30 l)
3a. Tank (20 l)
5 Relay valve
12 Brake cylinder
13 -
15 Pressure switch
16 Test connection
A= Parking brake
B= Rear
C= Front
D= Services
5949782549

Key
1 Air compressor
3 Tank (30 l)
3a. Tank (20 l)
5 Relay valve
9 -
10 -
11 -
12 Brake cylinder
14 Pressure switch
15 Test connection
A= Parking brake
B= Rear
C= Front
D= Services
5949782546

Key
1 Air compressor
3 Tank (30 l)
3a. Tank (20 l)
5 Relay valve
9 -
10 -
11 -
12 Brake cylinder
14 Pressure switch
15 Test connection
A= Parking brake
B= Rear
C= Front
D= Services
5949782548
Key
1 Air compressor
3 Tank (30 l)
3a. Tank (20 l)
5 Relay valve
9 -
10 -
11 -
12 Brake cylinder
13 -
15 Pressure switch
16 Test connection
A= Parking brake
B= Rear
C= Front
D= Services
5949782550
Vehicle braking system diagram four axles front 10 ton axle without ABS NOT suitable for towing
Key
1 Air compressor
3 Tank (30 l)
3a. Tank (20 l)
5 Relay valve
9 -
10 -
11 Brake cylinder
12 Brake cylinder
13 -
15 Pressure switch
16 Test connection
A= Parking brake
B= Rear
C= Front
D= Services
Vehicle braking system diagram four axles front 10 ton axle without ABS NOT suitable for towing
5949782551

PNEUMATIC SERVICES SYSTEM DIAGRAMS
4x2 vehicles with F3B engine

Key
1. A.P.U.
2. VGT electrovalve control
3. Flywheel P.T.O. command electrovalve
5. Gearbox P.T.O. command electrovalve
6. Rear transverse differential lock command valve
7. Rear transverse differential lock actuator
8. Splitter command actuator on gearbox
9. Gearbox P.T.O. command actuator
10. Flywheel P.T.O. command actuator
11. VGT control actuator
12. Midiservo
13. Clutch pedal
14. Driver side pneumatic seat
15. Not used
16. Splitter enable valve on clutch command
17. Intarder command eletrovalve (optional)
7
6
8
9
5
17
4
10
3
14
16
13
11
2
1
12
5949782550

Key
1. A.P.U.
2. VGT electrovalve control
5. Gearbox P.T.O. command electrovalve
6. Distributor commande valve
7. Front transverse differential lock command valve
8. Longitudinal lock command valve
9. Rear transverse differential lock command valve
10. Rear transverse differential lock actuator
11. Central longitudinal differential lock actuator
12. Distributor command actuator
13. Front transverse differential lock actuator
14. Splitter command actuator on gearbox
15. Gearbox P.T.O. command actuator
16. Flywheel P.T.O. command actuator
18. Midiservo
19. Clutch pedal
20. Driver side pneumatic seat
21. Not used
22. Splitter enable valve on clutch command
23. Intarder command eletrovalve (optional)
10
8,9
11
12
6
7
13
15
14
23
5
4
16
3
20
22
19
17
2
1
18
342B016039R
6x4 - 6x6 - 8x4 - 8x6 - 8x8 vehicles

Key
1. A.P.U.
2. VGT solenoid valve
3. P.T.O. solenoid valve on flywheel
4. P.T.O. solenoid valve on flywheel
5. P.T.O. solenoid valve on transmission
6. Splitter unit control valve
7. Front transverse differential lock control valve
8. Longitudinal differential locks control valve
9. Rear transverse differential locks control valve
10. Central splitter unit lock control valve
11. Rear transverse differential locks actuators
12. Rear longitudinal differential lock actuator (tandem)
13. Central splitter unit lock control actuator
14. Splitter unit control actuator
15. Front longitudinal differential lock actuator (tandem)
16. Front transverse differential locks actuators
17. Splitter on transmission control actuator
18. P.T.O.on transmission control actuator
19. P.T.O. on flywheel control actuator
21. Midiservo
22. Clutch pedal
23. Pneumatic seat driver side
24. Not used
25. Splitter engagement on transmission control enable valve
26. Intarder solenoid valve (optional)
6x4 - 6x6 - 8x4 - 8x6 - 8x8 vehicles
8,9
11
10
12
13
6
14
15
7
16

17
18
5
26
4
19
3
23
22
25
20
2
1
21
342B016040R
ELECTRICAL\ELECTRONIC
SYSTEM
SECTION 17
HD9 Euro5 SECTION 17 ELECTRICAL\ELECTRONIC SYSTEM 1
SECTION 17
Electrical/electronic system
Page
MULTIPLEX SYSTEM 5
OVERVIEW 5
- Conventional control 5
- Multiplex control 6
MULTIPLEX SYSTEM STRUCTURE 7
- CAN line make-up 8
- Multiplex system 9
VDB COMMUNICATION LINE (Vehicle Data Bus) 10
- List of control units 10
ECB COM LINE (Engine Control Bus) 11
- List of control units 11
I.D.B. COM LINE (Infotainment Data Bus) 12
POSITIVE NETWORK 13
- Multiplex system ECU location 14
- Passenger side dashboard control unit locations 16
GROUND POINTS 17
- Overview 17
- Engine ground points 17
- Frame ground points 18
- Cabin ground points 20
ST JUNCTION CONNECTORS 21
OUTFITTERS CONNECTOR 22
- Pin-out connector ST14 (cables inlet side,
female on vehicle wiring) 23
- OUTFITTERS wiring 24
FUSE AND RELAY PLATE 25
- Fuse and relay plate location 25
- Fuse and relay plate 25
FUSES 26
- Fuse holder (70005) 26
2 ELECTRICAL\ELECTRONIC SYSTEM SECTION 17 HD9 Euro5
- Fuse holder (70602) 26 - “RH” Stalk unit - Vehicles: automated transmission

with button selector (V35) WITHOUT retarder 48
- “RH” stalk unit - Vehicles: automated transmission
- Fuse holder (70402) 27 with button selector (V35) WITH retarder 49
- Fuse holder (70403) 27 MIR - MOTORIZED MIRRORS CONTROL UNIT 50
- Auxiliary fuse 27 - ECU connector pinout 50
RELAYS 28 DRS - DOORS CENTRALISED LOCKING CONTROL
UNIT 51
- Glow plug relay location (code 25222) 29
- ECU connector pinout 51
IC - CLUSTER 30
MC NET - CAR RADIO INTERFACE CONTROL
- CLUSTER connector pinout 30 UNIT 52
- Connector “J” 31 - ECU connector pinout 52
- Connector “K” 32 DTCO - TACHOGRAPH 53
INSTRUMENT PANEL 33 - Pin-out 53
DISPLAY STRUCTURE 34 VEHICLE CONTROL MODULE (VCM) 54
- Section A 34 - ECU connector pinout 54
- Section B 34 PINOUT 55
- Section C 34 - Connector X1 55
- Section D 34 - Connector X2: not used 55
OPTICAL STATE INDICATORS ON DISPLAY 35 - Connector X3 55
IBC - BODY COMPUTER 36 - VCM main functions 56
- BODY COMPUTER connector pinout 37 - Vehicle security systems 56
- Connector “A” (black) 38 - Communications over CAN bus 56
- Connector “B” (white) 39 - Others 56
- Connector “C” (black) 39 IMMOBILIZER SYSTEM COMPONENTS 57
- Connector “D” (blue) 40 VCM / IMMOBILIZER PROCEDURES 58
- Connector “E” (white) 40 BULKHEAD PASSAGES 60
SWI (STEERING WHEEL/COMBI-SWITCH - Bulkhead passage “A” white 61
INTERFACE UNIT) 41
- Bulkhead passage “B” brown 62
- SWI ECU connector pinout 42
- Bulkhead passage “C” yellow 63
- Connectors 43
- Bulkhead passage “D” blue 64
STEERING WHEEL/STALK INTERFACE 44
- Bulkhead passage “E” green 65
- “LH” stalk unit 45
ECM ELECTRONIC CONTROL UNIT ECM 66
- “RH” Stalk unit - Vehicles: manual transmission
WITHOUT retarder - automated transmission - Electroinjector connector “A” 67
with lever selector (V33) WITHOUT retarder -
automatic transmission WITHOUT retarder 46 - Sensors connector “C” 68
- “RH” stalk unit - Vehicles: manual transmission - Frame connector “B” 69
WITH retarder - automatic transmission WITH
retarder 47
DCU (DOSING CONTROL UNIT) - ADBLUE - Diagram 9 - Body Computer IBC2 - Brake lights -
INJECTION CONTROL UNIT 70 Registration plate light - Front, rear and front side
lights - low beam and main beam - headlamps
- ECU location 70 geometry adjustment 102
DCU 15 - CONNECTOR VIEW 71 - Diagram 10 - Body Computer IBC2 - Input - trailer
lights 104
INTARDER CONTROL UNIT 72
- Diagram 11 - IBC2 body computer - Direction
- Connector J1 (Intarder sensors and actuators) 72 indicators - Windscreen wipers 106
- Connector J2 (vehicle interface) 72 - Diagram 12 - IC instrument panel 108
ABS 73 - Diagram 13 - IC instrument panel and DTCO
tachograph 110
- ABS control unit pin-out 73
- Diagram 14 - VCM Vehicle Control Module 112
- Connector X1 73
- Diagram 15 - VCM Vehicle Control Module 114
- Connector X2 73
- Diagram 16 - EDC connector B 116
DIAGNOSIS SOCKET 74
- Diagram 17 - EDC connector A/C engine F2B 118
- Diagnostic socket location and pinout 74
- Diagram 18 - EDC connector A/C engine F3B 120
OBD II SOCKET 76
- Diagram 19 - SCR pumping module 122
- Long term errors 76
- Diagram 20 - ABS 124
- OBD connector location and pinout 77
- Diagram 21 - VDB/IDB CAN line 126
CAN LINE EFFICIENCY TESTS 78
- Diagram 22 - ECB CAN line 128
CLOCK WIRE REPLACEMENT 81
- Diagram 23 - Heated and motorised mirrors -
FUNCTIONAL DIAGRAMS 85 Central locking system 130
- Function diagrams - Table of contents 85 - Diagram 24 - IC change type configuration 132
- Diagram 1 - Positive direct from battery +VB - - Diagram 25 - Heater. air conditioner 134
Ignition key power supply +15 86
- Diagram 26 - PTO set-up 136
- Diagram 2 - +30 power after manual TGC -
Voltage reducer 88 - Diagram 27 - Intarder EST-52 138
- Diagram 3 - Power supply +30 after manual TGC - - Diagram 28 - AS-TRONIC V33 transmission with
Pivotable headlights - Outfitters - Trailers 90 PTO management 140
- Diagram 4 - Power +30 after manual TGC 92 - Diagram 29 - AS-TRONIC V35 transmission with
PTOs 142
- Diagram 5 - Power supply services +15A - Air
conditioning - PTO - Synchroprotection - - Diagram 30 - AS-TRONIC V35 transmission with
Additional parking solenoid valve 94 PTOs Intarder version 144
- Diagram 6 - Power supply services +15A - CABLE COLOUR CODES 146
Electrically controlled windows - Reverse gear -
brakes air drier - Diesel filter water sensor - ERROR LIST/FAULTS SHOWN ON DISPLAY 221
Mirrors heating 96
INSTRUMENT BODY COMPUTER 2 (IBC) 222
- Diagram 7 - Power supply services +15B - DTCO -
I.C. - IBC2 - Fog lights - Working light - Daytime VEHICLE CONTROL MODULE (VCM) 225
lights - Alternator - Vehicle service equipment 98
VENGINE CONTROL MODULE (ECM) 233
- Diagram 8 - Power supply services +15B - ECM -
VCM - Centralised locking - ABS - SCR - Motor SELECTIVE CATALYST REDUCTION (SCR) 239
heated mirrors - Heated seats - Intarder -
automatic transmission 100 AS-TRONIC (ETC) 240
ANTI BLOCK SYSTEM (ABS) 249

INTARDER (EST) 252
EXPANSION MODULE (EM) 254
MULTIPLEX SYSTEM
OVERVIEW
Connections between the various control units could be realised by grouping them into a single central unit (solution too
complex), or by realising a communication network capable of carrying out the required data exchange both rapidly and reliably.
Rapid data exchange is of extreme importance in vehicle management systems. Reliability must be guaranteed for all applications
associated with safety and transmission controls (brakes, engine and control units) and no communication problems must arise
even in the presence of electromagnetic interference.
Many of the problems arising on vehicle electrical systems are related to connectors, such as corrosion or oxidation of a connector
terminal, wiring connections, worn insulation or faulty assembly.
Another cause of these problems could be sensor and actuator functional faults. Reducing wiring to a minimum also serves to
reduce vehicle servicing times and costs.
A wiring harness with the minimum number of components also makes electronic system diagnosis easier.
The overall length of the wiring can be several kilometres, and the more connections there are, the greater the risk of potential
faults. MULTIPLEX systems improve communication between the various electronic systems present on the vehicle and permit
simpler troubleshooting.
Conventional control
T269IE15
On conventional electrical systems each user is controlled by its own switch, that necessarily requires a wiring harness with a high
number of wires and, obviously, the risks mentioned above.
Multiplex control
DATA BUS
Multiplexer De ---Multiplexer
T269IE16
As opposed to conventional systems, in this case each switch is connected to a Multiplexer unit to which it transmits its status
(open or closed). A coded value, different for each switch, is sent to the Databus (CAN communication line). The signal is decoded
by a De-multiplexer unit that supplies the voltage necessary for the user concerned.
There are various transmission classes according to data transmission speed over the Databus:
class A: low speed (windscreen wiper motor and vehicle lights controls);
class B: medium speed (air-conditioner and stereo);
class C: high speed (ABS control systems, etc.).
The advantages of the Multiplex system can be summarised in the following points: less wiring, enhanced function, sensor signal
sharing between the various systems and improved on-board diagnostics.
The disadvantages include higher cost than conventional system, and greater technical training requirements.
module 1 module 2 module 3

73681
All the control units are connected by CAN (Control Area Network) line.
The MULTIPLEX structure is highly flexible: control units can be removed or added without interrupting system function.
If module 2 has to send a message to module 3, it puts the message on the bus. The message reaches all modules, by only module
3 accepts it.
MULTIPLEX SYSTEM STRUCTURE

The Multiplex system used on this range of vehicles consists of a series of electronic control units connected together by CAN
lines.
The entire system can be split into four different areas, namely:
- vehicle system controls (ABS, EDC, etc.)
- basic electric/electronic system
- driver information systems (radio)
- Multiplex system display and control (Body Computer, Cluster, etc.).
VEHICLE SYSTEMS BASIC SYSTEM

EDC = Engine Diesel Control IBC = Body Computer
INTARDER = Intarder VCM = Vehicle Control Module
IMMOBILIZER (Integrated in VCM) DISPLAY CONTROL
TACHOGRAPH IBC = Body Computer
EUROTRONIC = Automated transmission SWI = Steering Wheel Interface
ALLISON = Automatic transmission IC = Instrument Cluster
IBC = Body Computer
IC = Instrument Cluster INFORMATION SYSTEMS
ABS = Wheel anti-locking system RADIO = radio
EM = Expansion Module MC Net = radio interface
The CAN (Controller Area Network) lines used to connect the vehicle control units are dedicated cables that allow for high
volume data exchange between the various systems.
The Multiplex system has three: VDB, IDB, ECB..
VDB Vehicle Data Bus Vehicle systems CAN line

IDB Infotainment Data Bus Information CAN line
ECB Engine Control Bus Vehicle systems CAN line
CAN line make-up
A B 73652/A
A. Sheath - B. Twisted pair (white/green)
The wires used for the various ”CAN” lines present on the vehicle are twisted wires.
The twist serves to eliminate any electrical disturbance to the signals carried.
The sheaths are different colours:
- BLACK - VDB
- YELLOW - ECB
- BLUE - IDB
Multiplex system
342B017001R
VDB COMMUNICATION LINE (VEHICLE DATA BUS)

This is used to establish an interface between the various electronic systems of the vehicle.
This line also dialogues with the Cluster and Body Computer.
342B017002R
List of control units
Ref. Description
DTCO Tachograph
VCM Vehicle Control Module
I.C. Cluster
BC Body Computer
DIAGN. 30-pin diagnostics socket
ABS ABS control unit
INTARDER Intarder control unit
SWI Steering wheel interface ECU
MIRRORS Motorised mirror ECU
EUROTRONIC Automated transmission control unit
ALLISON Automatic transmission control unit
EM PTO control unit with automated ZF transmission
ECB COM LINE (Engine Control Bus)

This used to establish an interface between the engine control ECUs and sensors.
CABIN
FRAME
342B017003R
List of control units
Ref. Description
VCM Vehicle Control Module
EDC7 Engine control unit
DCU15 SCR pump module control unit
NOx NOx sensor with SCR
OBD II Connector 16-in OBD connector (on board diagnostics)
I.D.B. COM LINE (INFOTAINMENT DATA BUS)

This allows the MCnet and the Radio to interface.
342A017B001R
Ref. Description
Radio Radio
MCnet Radio interface ECU
POSITIVE NETWORK
Power to the basic electrical system is supplied by a generator (28V - 60/90A alternator) and by two 12V batteries connected
in series.
Battery disconnector
DISCONNECTOR
BATTERIES
CHARGE CHARGE
0050785t
The vehicle electrical system always has a switch (whether manual or electrical) known as a disconnector switch.
Its function is to interrupt current circulation in the system with the vehicle at rest.
This switch is on the POSITIVE pole of the battery in order to disconnect power to the system. This solution was chosen over
the previous one because it offers better electrical isolation of the system modules.
Multiplex system ECU location
342B017004R
1. SWI Stalk cluster interface

2. IC Instruments block
3. MIR Mirrors handling
4. DRS Centralised locking
5. MC NET auto radio interface
6. DTCO Tachograph
7. ABS Anti-lock brake system
8. VCM Vehicle control module
9. EST Intarder
10. IBC Body Computer
11. EDC Engine device control (on engine)
12. DCU AdBlue additive dosing control unit
13. TCU Automated ZF Transmission control unit
14. TCU Automatic Allison Transmission control unit
15. EM expansion module for PTO control
Multiplex system ECU location
HD9ST0018MR
Passenger side dashboard control unit locations
HD9ST0061MR
4. centralised locking
7. ABS
8. VCM
14. Allison automatic transmission control unit (TCU)
15. EM expansion module for PTO control
GROUND POINTS
Overview
Never disconnect the battery from the system with the internal combustion engine running.
Before connecting the battery to the system, check that the system is well isolated.
Disconnect the battery from the system when charging.
The purpose of the electrical system is to generate, regulate, accumulate and distribute the power required to operate vehicle
components.
Electrical power for the basic electrical system is provided by a generator (28V - 60A-90A alternator) and two 12V batteries
connected in series.
System rated voltage is thus 24V.
The equipotential negative connection points of the system are shown in the diagrams that follow.
The same negative electrical equipotential as the frame is connected to the vehicle cabin by a wire connected to the cabin front
and the front right side member.
The engine is connected to the same negative electrical equipotential as the frame by a wire connected to the right side of the
engine block and the front right side member.
Engine ground points

1. Engine components ground (part of engine harness, engine control unit connector A)
2. motor-vehicle interface components (part of vehicle harness)
T207010
Frame ground points

1. engine-frame ground
2. battery-frame ground
3. services-frame ground
4. cabin-frame ground (frame side)
DIRECTION
OF TRAVEL
Frame ground points
DIRECTION
OF TRAVEL
5. Rear utilities-to-frame earth

Cabin ground points

1. Cab-frame ground (cab side)
2. Services-cab ground LH side
3. Services-cab ground RH side
4. Services-cab upper ground
342B017007R
ST JUNCTION CONNECTORS
REF. DESCRIPTION
ST0 Obstructed air cleaner sensor connection
ST01 Ignition switch connection
ST02A steering column wiring connection
ST02B steering column wiring connection
ST03 IC change configuration connection
ST04 Optional set-up connection
ST06 Upper wire connection LH cab
ST07 Upper wire connection RH cab
ST08A Left door connection
ST08B Left door connection
ST09A Right door connection
ST09B Right door connection
ST14 Coachbuilder’s connection
ST14A Coachbuilder’s connection
ST24 PTO wiring connection
ST25 Cab Intarder wiring connection
ST26 Cab ABS wiring connection
ST28 Swivelling lights connection
ST31L Driver seat wiring connection
ST31R Passenger seat wiring connection
ST37/B Connection under cab
ST45 Radio sound system connection
ST52 Coachbuilder’s connection
ST55A DCU wire connection
ST55B DCU wire connection
ST67 DCU metering module solenoid valve connection
ST68 AdBlue level-temperature sensor connection
ST79A Pedal unit wiring connection
ST79B Pedal unit wiring connection
ST80 Ecosplit transmission connection
ST80B Ecosplit transmission connection
ST91 PTO 1 connection (flywheel)
ST92 PTO 2 connection (transmission)
ST93 PTO 3 connection (transmission)
ST TR Trailer connector cable connection
OUTFITTERS CONNECTOR
Inside the cab, behind the interconnection control unit on the passenger side, connector ST14 is available for use by the Outfitters.
342B017008R
Pin-out connector ST14 (cables inlet side, female on vehicle wiring)
Ter- Max.
minal Description Wire n. load Connected to Remarks
VCM - X3 - 27 Engine start:

- Ground = start engine (signal must be per-
1 Engine starting 8892 30 pin manently active until engine starts)
25 socket - Wire open = no action
Engine shutdown:
- Ground = stop engine (short activation is
2 Engine shutdown 0151 VCM - X3 - 26 sufficient to stop the engine)
- Wire open = no action
Signal indicating that the service brake pedal is
pressed:
3 Service brake 1165 200 mA VCM - X1 - 23 - 0 V = service brake not pressed
- +24 V = service brake pressed
Vehicle stopped signal
4 Vehicle stopped 5515 150 mA IC - K - 8 - 0 V = vehicle stopped
- +24 V = vehicle moving
5 Parking brake 6656 200 mA VCM - X1 - 10 Signal indicating that the parking brake is active
Bulkhead connector
6 Engine rpm 5584 E-36 85150 - 23 Engine rpm indication
Activation:
7 Horn 1116 25805 - 0 V = activated
- +24 V = not activated
Bulkhead connector -Engine state output (D + information):
0 V = engine stopped
8 Engine state 7778 200 mA E36 03000-1 - +24 V = engine running
Signal indicating transmission position:
9 Neutral 8050 200 mA VCM - X1 - 7 - 0 V = not idle
- +24 V = idle
Signal indicating reverse engagement:
10 Reverse 2268 150 mA C-K-1 - 0 V = reverse not engaged
- +24 V = reverse engaged
11 K15 8879 10 A 70001 - 8 k15 (after fuse)
CC SET+ input
12 CC SET+ 8156 VCM - X3 - 33 Open wire = SET+ not activated
Ground = SET+ on
CC SET input
13 CC SET 8157 VCM - X3 - 32 Open wire = SET not activated
Ground = SET on
CC OFF input
14 CC OFF 8154 VCM - X3 - 30 Open wire = OFF activated
Ground = OFF on
CC RES input
15 CC Resume 8155 VCM - X3 - 31 Open wire = RES not activated
Ground = RES on
CC selection Activation
16 inside/outside cab 0152 VCM - X3 - 49 0 V = on
+24 V = off
17 Ground 0000 11 A Ground
PTO 3 activation
18 PTO 3 0123 VCM - X3 - 45 Open wire = PTO 3 off
Ground = PTO 3 on
P.T.O.1 activation
19 PTO 2 0131 VCM - X3 - 47 Open wire = P.T.O.1 off
Ground = P.T.O.1 on
P.T.O.2 activation
20 PTO 1 0132 VCM - X3 - 46 Open wire = P.T.O.2 off
Ground = P.T.O.2 on
21 K30 7772 15 A 70001 - 7 K30 (after fuse)
To pick-up the signals needed for outfitting, contact the Dealership to procure the ”male” for connector ST14 (see drawing
n˚41200692 for the spare part code) to which a wire can be connected for each of the 21 pins (their function is described in
the previous pin-out
CAB WIRE OUTFITTER

SIDE WIRE SIDE
357A017201R
OUTFITTERS wiring
The OUTFITTERS wiring, supplied as an option, can be pre-installed on the vehicle or requested separately (contacting the Dealer-
ship). It is used to convert (by means of the relays it contains) positive signals, supplied by the Outfitter, to negative signals needed
by the vehicle.
It is fitted with two connectors: the ”male” connector has to be plugged into connector ST14, whereas the ”female” connector
remains available for the Outfitter.
Cab Outfitter
side side
ST 14 (female)
OUTFITTERS (female)
Optional wiring
357A017202R
FUSE AND RELAY PLATE

Fuse and relay plate location
HD9ST0068MR
Fuse and relay plate
342BNM023
FUSES
Fuse holder (70005)
POSITION FUNCTION CAPACITY (A)
1 DTCO — Cluster 3
2 DTCO — Cluster 5
3 IBC2 5
4 Left low beam, right main beam headlights and cab IBC2 10
5 Right low beam, left main beam headlights and symbol panel IBC2 10
6 Right side position lights and rear fog light IBC2 10
7 Left position side lights - braking lights IBC2 10
8 Turn indicators IBC2 10
9 Windshield wiper IBC2 10
10 Fog light — work headlight — day lighting 10
11 Reverse gear 10
12 Pivotable headlights — horn — air horns 15
13 Alternator - Vehicle service equipment 5
14 Solenoid valves VGT — Synchro protection — differential locks — solenoid valves PTO 10
15 Heated fuel pre-filter 15
16 Brakes air drier — fuel filter water detector sensor 5
17 Ignition key-brake pedal 3
18 Climate control - Heater 20
19 Cigar lighter — 24V/12V voltage reducer —MC net 20
20 Electric window risers 20
Fuse holder (70601)

1 Trailers ABS 30
2 ABS control unit 15
3 ABS control unit 5
4 OBD socket — refrigerator . 30-pole diagnostics socket 10
5 SCR control unit 10
6 SCR control unit 5
Fuse holder (70602)

1 ECM control unit 15
2 ECM control unit 5
3 VCM control unit 10
4 VCM control unit 5
5 + 30 outfitters 15
6 + 30 outfitters 10
Fuse holder (70401)

1 Mirror heater 10
2 Centralised closure — motor-heated mirrors 10
3 Centralised closure 10
4 + 30 trailer 20
Fuse holder (70402)

1 Heated seats 7,5
2 Intarder 10
3 Intarder 10
4 — —
Fuse holder (70403)

1 AsTronic/Allison control unit 10/15
2 AsTronic/Allison control unit 10/15
3 — —
4 — —
Auxiliary fuse
6633
A. Fuse holder (20A)
An in-line fuse holder carrying a 20A fuse is arranged near the batteries.
RELAYS
COMPONENT
REF. DESCRIPTION
CODE
001 Relay for climate control 25332
002 Emergency engine stop relay 25205
003 Automatic transmission reverse light relay 25030
004 Second speed limit request relay —
005 Horn relay 25805
006 Lights on relay 25806
007 Flywheel PTO engagement enable relay 25701
008 PTO diodes holder 61000
009 PTO1 engagement relay 25704
012 Engine starter relay (outfitters)
013 Engine stop relay (outfitters)
014 SET adjustment relay +( outfitters) (outfitters)
015 SET adjustment relay - ( outfitters) (outfitters)
016 PTO engaged confirmation relay (outfitters)
017 Idle gear confirmation relay (outfitters)
018 External cruise activation relay (outfitters)
019 PTO engagement relay with vehicle stationary (outfitters)
COMPONENT
REF. DESCRIPTION
CODE
A — —
B Vehicle blocking relay with doors open 25500
C — —
D — —
E Power steering 2 failure warning light control relay 25808
F PTO solenoid valves diodes holder (outfitters)
G Terminal 15a/50A relay 25,213A
H 40A engeine start relay 25200
I Fuel pre-filter heating relay 25825
L Terminal 15b/50A relay 25213B
1-X Contactor for electric TGC 25202

2-X Diode for electric TGC 61008
Glow plug relay location (code 25222)
357A017001R
IC - CLUSTER
Connector K
Connector J
272G17004
The cluster is the user interface with the Multiplex system. It is used to manage information to and from the user (driver).
CLUSTER connector pinout
Connector J
Connector K
20
26
7
26
20
1
272G17005
Connector “J”
WIRE COLOUR
REF. FUNCTION
CODES
1 Alternator warning light 7009
2 — —
3 Water in fuel pre-filter warning light 5530
4 Immobilizer on warning light 6150
5 Obstructed air cleaner warning light 6663
6 Fuel level sensor 5557
7 Outside temperature sensor 0512
8 Steering wheel input 1 5902
11 Steering wheel input 4 (up) 5900
12 Steering wheel input 4 (down) 5901
13 Steering wheel input 5 (+) 5906
14 24V power (+15 key) 8871
15 Steering system fault input 1 6631
16 Steering system fault input 2 6632
17 Transmission input A 1000
18 Transmission input B 6000
19 Transmission input C 5000
20 Reverse selected input 2226
21 Low Split selected input 6495
22 Steering wheel key Input 5 (-) 5905
23 Low gear selected input 9952
24 Rear fog lights warning light 2283
25 LH side door open input 0003
26 Splitter lock warning light 6602
Connector “K”
WIRE COLOUR
REF. FUNCTION
CODES
1 Reverse relay output for ST14 2268
2 24V power (battery) 7906
3 Earth 0000
4 — —
5 CAN L green
6 CAN H white
7 — —
8 PTO flywheel relay output for ST14 5515
9 Trailer brakes system fault input 6689
10 Trailer ABS fault input 6671
11 Seat belt fastened Input 5647
12 — —
13 Splitter reduced gears Input 6323
14 — —
15 Body raised Input 6607
16 — —
17 — —
18 — —
19 — —
20 — —
21 — —
22 — —
23 — —
24 — —
25 — —
26 — —
INSTRUMENT PANEL
342BNU026L
1) Engine cooling liquid level low warning light

Red. Indicates that engine cooling liquid level is too low
2) Engine oil low pressure warning light
Red. Indicates that engine oil pressure is too low
3) Engine oil pressure indicator.
4) Engine cooling liquid temperature indicator
5) Engine oil temperature high warning light
Red. Indicates engine oil temperature is too high
6) Engine cooling liquid temperature high warning light
Red. Indicates that the engine cooling liquid temperature is too high
7) Revs counter
8) Speedometer
9) LCD screen with hour and partial trip counter
10) Partial trip reset button
11) Fuel level indicator
12) Fuel reserve warning light
Red. Indicates that fuel level in tank is in reserve
13) AdBlue additive level indicator
14) AdBlue additive reserve warning light
Red. Indicates that AdBlue additive level in tank is in reserve
15) Instruments lighting adjustment button
A) Warning lights panel A

B) Warning lights panel B
C) Warning lights panel C
D) Display
DISPLAY STRUCTURE
A B C
D
357ANU002L
The display is divided into four sections (A,B,C,D). Each section contains specific information.
Section A
- Batteries power supply voltage (default)
- Tractor ABS failure
- Power steering 1 circuit failure
- Power steering 2 circuit failure
- Trailer braking system pressure low
- Trailer ABS failure
- Doors open
- Front/rear brakes wear
- Engine preheating
- Second speed limit engagement
- ASR deactivation
- ABS off-road engagement
- Programmed maintenance time-out
- Cruise control engagement
- Window washer liquid level low
- Container tipped
Section B
- Logo and outside temperature (default)
- Generic fault
- Serious fault
Section C
- Running condition indicator
Section D
- Date - Time - Station/track time (default)
- Steering system failure
- Scheduled maintenance due in 50 hours
- PTO (n˚): rpm
- Headlights geometry adjustment
- Mirrors selection for handling
- Menu
- Front/rear axles braking system pressure
- Engine/transmission oil temperature
OPTICAL STATE INDICATORS ON DISPLAY
This table indicates the symbols used on the display (Section A)
Meaning Symbol Colour Meaning Symbol Colour

Batteries power sup- Second speed limit
Grey Yellow
ply voltage activation
Tractor ABS failure Yellow ASR off Red
Power steering 1 -
power steering 2 cir- Red ABS off-road activation Grey
cuit failure
Trailer braking system Scheduled maintenance
Red Red
pressure low due
Cruise Control connec-

Trailer ABS failure Yellow Grey
tion
Window washer liquid

Doors open Red Red
level low
Front - rear brakes

Yellow Container tipped Yellow
wear
Engine preheating Yellow
This table indicates the symbols used on the display (Section B).
Logo and outside

temperature Grey Generic fault Yellow
Outside temperature
lower than 3 ˚C Grey Serious fault Red
(numbers in red)
For further information regarding the meanings of the symbols in section C of the display, see the chapter concerning
the type of transmission installed in the vehicle.
Automated transmis-
Manual transmission Grey Grey
sion
Automatic transmis-
Grey - Green
sion
IBC - BODY COMPUTER
Connector D
Connector A
Connector B
Connector E
Connector C
272G17006
The Body Computer is the central unit of the Multiplex system. It manages the peripheral and is located in the dashboard on passen-
ger side inside the UCI fuse holder.
BODY COMPUTER connector pinout
1 11 21 31
2 12 22 32 10 11 12
13 23 13 14 15 16 17 18 19 20
3 33
4 14 24 34
5 15 25 35
6 16 26 36 1 2 3 4 5 6 7 8 9
7 17 27 37
8 18 28 38
9
10
19 29
20 30
39
40
D
10 11 12 13 14 15 16 17 18 19 20
1
2
10
11 3 2 1
1 2 3 4 5 6 7 8 9 3 12
4 13
5 14 8 7 6 5 4
C B 6
7
15
16
8 17
9 18
E
E
272G17007
Connector “A” (black)

WIRE COLOUR
REF. FUNCTION
CODES
1 — —
2 Brake air pressure sensor power output 5560
3 Brake air pressure sensor earth 0050
4 Handbrake engaged switch negative 6662
5 Engine brake 50% request 8159A
6 — —
7 Parking light switch negative 2237
8 Rear fog light button negative 2279
9 Windscreen washer pump control negative 8886
10 — —
11 Headlight trim position signal input (pin 3) 9934
12 Headlight adjustment unit positive (pin 2) 9936
13 Rear brake air pressure sensor input . 5561
14 — —
15 — —
16 Engine brake 100% request 8159B
17 — —
18 — —
19 — —
20 Axle transverse differential lock signal stalk negative 0041
21 Front brake air pressure sensor input 5562
22 Hazard light button negative 1113
23 LH step light button negative 0003
24 Windscreen wiper negative 8882
25 RH direction indicator stalk negative (pin A3) 1103
26 Flasher button negative 2201
27 Set— 8157
28 Cruise OFF/RESUME request 8155
29 Windscreen wiper on negative 8822
30 Windscreen wiper on negative 8881
31 Internal lights switch negative 0010
32 External light switch negative 3333
33 RH step light button negative 0003
34 Stop light control positive 1117
35 LH direction indicator stalk negative (pin A1) 1109
36 Main beam on switch negative 2204
37 — —
38 Set+ 8156
39 Front wheel block wear N.C. switch negative 6012
40 Rear wheel block wear N.C. switch negative 6013
Connector “B” (white)
WIRE COLOUR
REF. FUNCTION
CODES
1 Rear PTO switch on indicator negative 6132
2 Side PTO switch on indicator negative 6131
3 — —
4 Longitudinal differential lock on indicator switch negative 6603
5 — —
6 Front differential lock on indicator switch negative 6659
7 Radiator liquid level low negative 5520
8 Low power steering liquid level sensor negative 5525
9 Windshield washer liquid level low Negative 5521
10 — —
11 — —
12 — —
13 — —
14 — —
15 — —
16 — —
17 — —
18 — —
Connector “C” (black)
WIRE COLOUR
REF. FUNCTION
CODES
1 — —
2 Body Computer power positive from direct battery positive 7768
3 Cab ceiling light positive 4441
4 RH main beam headlight positive 2221
5 LH low beam headlight positive 2231
6 Windscreen wiper motor positive (1st speed) 8881
7 Windscreen wiper motor positive (2nd speed) 8882
8 Windscreen washer pump positive 8886
9 Windscreen wiper motor positive (31B) 8873
10 Earth 0000
11 CAN ”L” line green
12 CAN ”H” line white
13 — —
14 Power input (positive after TGC) 2197
15 Step light positive 4408
17 Trailer LH indicator positive 1180
18 LH indicator positive 1120
19 Trailer RH indicator positive 1185
20 RH indicator positive 1125
Connector “D” (blue)
WIRE COLOUR
REF. FUNCTION
CODES
1 Dasboard controls backlight positive 4442
2 — —
3 Trailer rear fog light 2282
4 Tractor rear fog light 2283
5 RH rear light power output 3305
6 RH front parking light and RH front clearance light power output 3330
7 Rear clearance light power output 3308
8 LH trailer parking light power output 3334
10 RH low beam headlight - headlight trim enable power output 2223
11 LH main beam headlight power output 2219
14 Licence plate light power output 3307
15 LH rear parking light power output 3115
16 LH front parking light and LH front clearance light power output 3339
17 Trailer RH parking light power signal output 3338
18 LH stop light power output 1177
19 RH stop light power output 1172
20 Trailer stop light power signal output 1179
Connector “E” (white)
WIRE COLOUR
REF. FUNCTION
CODES
1 — —
2 — —
3 — —
4 Ignition key power input (+15) 8886
5 — —
6 — —
7 — —
8 — —
SWI (STEERING WHEEL/COMBI-SWITCH INTERFACE UNIT)
Connector B
Connector D
Connector C Connector A
272G17008
This is an electronic control unit located on the steering column. Its function is to group together all the commands coming from
the two steering wheel combi-switches.
It is connected to the vehicle electronics system via CAN line.
SWI ECU connector pinout
TOP VIEW
FRONT VIEW
50240
Connectors
B C D A
50240
Connector A — Right lever

PIN FUNCTION Right lever PIN
1 Negative from Cruise Control button (Resume/off - on) 4
2 Negative from Cruise Control button (Set+) 3
3 Gear down (gear reduction) 2
4 Negative from Intarder selector(pos.2) 7
7 Gear up (gear shift) 15
8 Negative from Cruise Control button(Set—) 11
11 Negative from Intarder selector (pos.5) 9
12 Ground 16
Connector B is not used

Connector C is not used
Connector D
WIRE
PIN FUNCTION COLOUR CODE
1 Positive direct from battery (+30) 7906
2 — —
3 CAN line “H” (ICB) WS/BI
4 CAN line “L” (ICB) GN/VE
5 Ground 0000
6 Lever illumination (input) 4442
7 — —
8 Horn negative (output) 1116
9 — —
10 — —
11 — —
12 — —
STEERING WHEEL/STALK INTERFACE

The steering wheel/stalk interface may be achieved in two ways, according to the version.
Version without SWI control unit. The connections of the right lever and the coiled contact are directly made to the vehicle wiring.
The left lever is directly connected to the Body Computer.
steering
wheel
clock
wire
lh rh
services services
357A017203R
Version with SWI control unit: in this case the right lever is connected to the SWI control unit, which interfaces with the vehicle
wiring. The left lever is directly connected to the Body Computer.
steering
wheel
clock
wire
lh rh
services services
357A017204R
“LH” stalk unit
357A017206R
Pin-out
WIRE COLOUR
REF. DESCRIPTION CODE
1 Windscreen wiper (maximun speed) 8881
2 Windscreen wiper (slow speed) 8882
3 Windscreen wiper (intermittent) 8822
4 Windscreen wiper (flick) 8881
5 — —
6 Main beam headlights on 2204
7 Beam flasher 2201
8 Ground 0000
9 Windscreen washer pump control 8886
10 — —
11 — —
12 — —
13 — —
14 — —
15 Right direction indicator 1103
16 Left direction indicator 1109
“RH” stalk unit

Vehicles: manual transmission WITHOUT retarder
automated transmission with lever selector (V33) WITHOUT retarder
automatic transmission WITHOUT retarder
342B017009R
Pin-out (lever is connected directly to vehicle wiring)

WIRE COLOUR
1 — —
2 — —
3 Cruise Control (Set+) 8156
4 Cruise Control (Resume/on) 8155
5 Exhaust brake 50% 8159A
6 — —
7 Exhaust brake 100% 8159B
8 — —
9 — —
10 — —
11 Cruise Control (Set—) 8157
12 — —
13 — —
14 — —
15 — —
16 Earth 0000
“RH” stalk unit

Vehicles: manual transmission WITH retarder
automatic transmission WITH retarder
342B017010R
Pin-out (lever is connected to SWI control unit)

Pin connector
REF. DESCRIPTION to SWI
1 Intarder (position 4) 5
2 — —
3 Cruise Control (Set+) 2
4 Cruise Control (Resume/on-off) 1
8 — —
11 Cruise Control (Set—) 8
12 — —
13 — —
14 — —
15 — —
16 Earth 12
“RH” stalk unit

Vehicles: automated transmission with button selector (V35) WITHOUT retarder
HD9ST0001MR

Pin connector
1 — -
2 Gear down (downshift) 3
3 Cruise Control (set +) 2
5 Engine brake 50% 9
6 — -
7 Engine brake 100% 4
8 — —
9 —
10 -
11 Cruise Control (set -) 8
12 — —
13 — —
14 — —
15 Gear up (upshift) 7
16 Earth 12
“RH” stalk unit

Vehicles: automated transmission with button selector (V35) WITH retarder
HD9ST0002MR

Pin connector
1 Intarder (Position 4) 5
2 Gear down (downshift) 3
3 Cruise Control (set +) 2
8 — —
11 Cruise Control (set -) 8
12 — —
13 — —
14 — —
15 Gear up (upshift) 7
16 Earth 12
MIR - MOTORIZED MIRRORS CONTROL UNIT

ECU connector pinout
342B017013R
WIRE COLOUR
1 LH wide-view mirror horizontal motor power 8843
2 RH wide-view mirror horizontal motor power 8853
3 RH main mirror vertical motor power 8858
4 LH main mirror vertical motor power 8808
5 RH main mirror adjustment motor power 8857
6 — —
7 Mirror selection signal 0956
8 — —
9 Mirror rightwards adjust signal 0953
10 Earth 0000
11 — —
12 — —
13 Mirror power 8879
14 RH wide-view mirror vertical motor power 8852
15 RH main mirror horizontal motor power 8859
16 LH wide-view mirror vertical motor power 8842
17 LH main mirror adjustment motor power 8806
18 LH main mirror horizontal motor power 8809
19 CAN ”L” (VDB) GN/VE
20 CAN ”H” (VDB) WS/BI
22 Mirror leftwards adjust signal 0954
23 — —
24 Mirror downwards adjust signal 0951
25 Mirror upwards adjust signal 0952
DRS - DOORS CENTRALISED LOCKING CONTROL UNIT

272G17011
WIRE COLOUR
1 Hazard light control (in parallel) 1113
2 Engine 1 9965
3 Fuel feed 7772
4 Earth 0000
5 Release position 0064
6 Lock position 0065
7 Power from +15 switch 8879
8 Engine 2 9964
MC NET - CAR RADIO INTERFACE CONTROL UNIT

342A017B003R
WIRE COLOUR
1 CAN ”L” line (IDB) GN/VE
2 CAN ”H” line (IDB) WS/BI
3 Not used —
4 CAN ”L” line (VDB) GN/VE
5 CAN ”H” line (VDB) WS/BI
6 Not used —
7 Fuel feed
8 Ground 0000
9 Not used —
DTCO - TACHOGRAPH
342B017014R
Pin-out
WIRE COLOUR
REF. FUNCTION
CODE
1 Positive battery direct (+30) 7768
2 Ideogram illumination 4442
Positive (+15) 8871
3
- -
4 CAN line “H” (VDB) WS/BI
A
Ground 0158
5
- -
6 Ground 0158
7 - -
8 CAN line “L” (VDB) GN/VE
1 Positive for tachograph transmitter (pin 1) 5514
2 Ground for tachograph transmitter (pin 2) 0058
3 Speed signal from transmitter (pin 3) 5517
4 Inverted signal from transmitter (pin 4) 5516
5 - -
B
Speed signal for Cluster 5540
6
Speed signal for Intarder 5540
7 Speed signal for EDC 5155
Distance travelled signal for Cluster 5518
8
Fitting 5518
C 1-8 - -
1-6 - -
D 7 K line: Cluster (pin A1) / Diagnosis (pin 14) 2297
8 - -
VEHICLE CONTROL MODULE (VCM)

18
19 36
37 54
PINOUT
Connector X1
WIRE COLOUR
REF. FUNCTION CODE
1 Immobilizer antenna —
3 Immobilizer antenna —
4 Positive +30 7993
5 +15 positive from Body Computer 8802
6 Earth 0000
7 Neutral position signal to ST14 8050
9 EDC fault system warning light power 6150
10 Parking brake signal to ST14 6656
13 Service brake signal to ST14 1165
15 EDC fault system warning light negative 0008
16 Starter relay positive 8808
Connector X2: not used
Connector X3
WIRE COLOUR
REF. FUNCTION CODE
1 CAN H (VDB) white
2 CAN L (VDB) green
8 Neutral position signal to ST14 8050
9 Engine brake pre-selection with accelerator pedal release 9025
10 Preselezione freno motore con freno servizio 9024
12 +50 ignition request 8837
13 Switch signal requested according to speed limit 9968
14 Secondary brake light signal to EDC 8158
15 Primary brake light signal to EDC 1117
17 Accelerator pedal sensor power 5158
19 CAN H ECB white
20 CAN L ECB green
26 Engine stop 0151
27 Engine start 8892
28 Parking brake on 8052
29 Release cab negative 0096
30 Cruise Control Off switch signal 8154E
31 Cruise Control Res switch signal 8155E
32 Cruise Control Set- switch signal 8157E
33 Cruise Control Set+ switch signal 8156E
34 Engine idling switch signal 0159
35 Accelerator pedal sensor signal 5157
45 PTO 3 0123
46 PTO 2 0132
47 PTO 1 0131
49 Cruise Control signal (int/ex) 0152
51 VCM clutch switch negative signal 0160
52 EDC first accelerator pedal negative signal 0158
53 Accelerator pedal to ECU negative signal 0157
54 VCM ECU diagnostic K line 2292
VCM main functions

- Driveability: accelerator pedal management and generation of required torque via CAN toward engine as per driveability
maps, Required torque = f (Engine revs, Accelerator pedal position).
- Arbitration of Torque and Revs demand from external systems (Brakes, Transmission, Coachbuilders, etc.) to the engi-
ne during braking, gear change, operations in PTO mode, VCM determines the demand with highest priority and transmits
the corresponding Torque of Engine Revs demand via CAN to the engine.
- Speed limiter (main, programmable and secondary) VCM determines the entity of the torque demand from the engine
assuring that active speed limits are not exceeded.
- Cruise Control: VCM regulates vehicle speed to the speed set on the Cruise Control, modulating the torque demand tran-
smitted via CAN to the engine (torque control or limitation), through the engine brake and intarder enable request, supple-
menting the engage and release control functions.
- Engine start/stop control logic and related safeties, management of cabin, engine bay, coachbuilder connection comman-
ds
- Power take off (PTO mode) management of engine revs regulation commands via CAN according to conditions related
to PTO 1, 2 and 3 (pre-programmed) modes with actuation by engine.
- Low idle regulation logic and High Idle dynamic management with demand from engine via CAN the VCM manages engi-
ne rev commands via CAN with actuation by engine.
- Engine Brake activation logic: management of driver demands and arbiration between demands from external systems
(Brakes, Transmission, Coachbuilders, etc.), transmission of value via CAN and actuation by engine.
- Right steering stalk: integrates the Eurotronic 2 gearbox UP/DOWN gear functions.
Vehicle security systems

- Immobilizer.
Communications over CAN bus

- Point to point communication from vehicle bus to engine and vice-versa.
- Interface for connection to Tester for CAN diagnosis of on-board systems.
Others
- Generation of HW signals for Coachbuilder connector.
IMMOBILIZER SYSTEM COMPONENTS

The IMMOBILIZER ECU is integrated in the VCM.
Ref. DESCRIPTION
1 Vehicle Control Module (VCM)
2 Code card
3 Electronic key
4 Antenna
5 Electronic injection control unit (EDC 7)
6 Electroinjectors
7 EDC (ECM) fault warning light on display cluster
8 IMMOBILIZER fault warning light on display cluster
VCM / IMMOBILIZER PROCEDURES
WORK-
SHOP
SITUATION / INSTRU-
ORDER INTERVENTIONS AND NOTES
NEED MENT
CONFIGU-
RATION
1) Order new VCM + 2 new keys from Ricambi.

2) Perform the VCM replacement procedure via Teleservice (Cost: 1 Coin).
3) Store the two new keys via Teleservice. (For this operation you will need: Ide1,
Ide2, Source Pin, Mechanical code).
4) Remove the VCM ECU + keys. Refit the old VCM.
At this point:
WITH
VCM + 5a) If the old VCM is legible:
TELE-
KEYS a- In Engine/VCM/Specific Function environment, select New VCM Recognition.
SERVICE
b-At the end of the procedure, refit the new VCM + the two new keys.
c- Start the engine.
5b) If the old VCM is not legible and therefore does not communicate:
a-Refit the new VCM + two new keys.
b-Also replace the EDC or have it cleared by Teleservice.
c-In Engine/EDC/Specific Function environment, select New EDC Recognition.
Note: This operation dissociates the VCM from the old EDC.
VCM Vers. 5.4 1) In the Engine/VCM Programming/Other environment, select Replacement.
Replacement 2) Fill in the new VCM request form and send it to Ricambi.
3) After having received the pre-programmed VCM from Ricambi, ask Market THD
for the release password to access the unit and store the keys. (You need: VIN,
old e-code, new e-code, instrument type and number).
4) At the end of the key storage procedure, remove the VCM ECU + keys, refit the
VCM old ECU.
already
WITHOUT
program- At this point:
TELE-
med by 5a) If the old VCM is legible:
SERVICE
Spares+ a- In Engine/VCM/Specific Function environment, select New VCM Recognition.
KEYS b-At the end of the procedure, refit the new VCM + the two new keys.
c-Start the engine.
5b) If the old VCM is not legible and therefore does not communicate:
a-Refit the new VCM + two new keys.
b-Also replace the EDC.
c-In Engine/EDC/Specific Function environment, select New EDC Recognition.
Note: This operation dissociates the VCM from the old EDC.
WORK--
SHOP
SITUATION / INSTRU-
ORDER INTERVENTIONS AND NOTES
NEED MENT
CONFIGU-
RATION
1) Order new VCM + 2 new keys from Ricambi.

2) Run the VCM replacement procedure via Teleservice (Cost: 1 Coin ). (You will
need Default Dataset, Alphacode, ECU part number, EOL TABLE part number, 4
TELE- VCM + ecuset).
SERVICE KEYS 3) Store the two new keys via Teleservice. (For this operation you will need: Ide1,
Ide2, Source Pin, Mechanical code).
VCM Vers. 4) In Engine/VCM/Specific Function environment, select New VCM Recognition.
6.5/7.5/8.5 5) Start the engine.
replacement 1) In the Engine/VCM Programming/Other environment, select Replacement.
2) Fill in the new VCM request form and send it to Ricambi.
VCM alrea-
WITHOUT 3) After VCM has been programmed by Ricambi, ask Market THD for the release
dy program-
TELE- password for accessing the data stored on the keys. (You need: VIN, old e-code,
med by Spa-
SERVICE new e-code, instrument type and number).
res + KEYS
4) In Engine/VCM/Specific Function environment, select New VCM Recognition.
5) Start the engine.
1) Remove the old EDC from the vehicle and fit the new one.
WITH/ 2) In Engine/EDC/Specific Function environment, select New EDC Recognition.
EDC
WITHOUT
replacement EDC
TELE- IMPORTANT:
procedure
SERVICE - This operation is not required on Euro 2/3 vehicles
- For this operation, it is necessary to enter the VCM e-code
1) Cut the key to the existing mechanical profile.

WITH/ 2) Obtain the code card (E-CODE)
Replacement of WITHOUT 3) From ENGINE/VCM Specific Functions, select ”MEMORISE KEYS”
a keyAdding TELE- Key Parts
keys SERVICE IMPORTANT:
In this procedure, also enter the remaining functional keys otherwise they will not
be able to be enabled for starting again.
Antenna
— Antenna Replace Antenna
Replacement
BULKHEAD PASSAGES
LH DRIVE
Connector A - White
Connector B - Brown
Connector C - Yellow
Connector D - Blue
Connector E - Green
12 1 39 28 20
A B C D E
19 11 40 38 27 85750
Bulkhead passage “A” white

WIRE COLOUR
PIN FUNCTION CODE
1 Work light power (fifth wheel light) 2224
2 Reverse light power 2226
3 Low trailer air pressure warning light 6689
4 Headlight trim corrector 9936
5 Fog light power 2228
6 LH low beam headlight power 2231
7 LH main beam headlight power 2219
8 RH low beam headlight power 2223
9 RH main beam headlight power 2221
10 LH front parking light 3339
11 RH front parking light 3330
12 +15 st coach builders to chassis ( ST52 ) 8879
13 Brake air pressure transmitter power 5560
14 All-wheel drive warning light 6602
15 RH rear parking light power 3315
16 LH rear parking light power 3305
17 Longitudinal differential lock warning light 6603
18 +15 ST coach builders to chassis (ST 69) 8879
19 Gearbox in neutral micro switch 8050
20 Reverse switch power 2268
21 Step-up gears switch power 9992
22 Water in pre-filter warning light 5530
23 Rear clearance light power 3308
24 RH clearance side lights 3338
25 LH clearance side lights 3334
26 Tipped body 6607
27 ST coach builders chassis parking lights 3333
28 Trailer rear fog light power 2282
29 Rear fog light power 2283
30 Trailer LH direction indicator 1180
31 Trailer RH direction indicator 1185
32 Pressure transmitter earth 0050
33 Rear brake air pressure transmitter 5561
34 Front brake air pressure transmitter 5562
35 Front transverse differential lock warning light 6659
36 Spare —
37 Obstructed air cleaner warning light 6663
38 Transverse differential lock on 0041
39 Spare —
40 Spare —
Bulkhead passage “B” brown

WIRE COLOUR
PIN FUNCTION CODE
1 Synchro Protection solenoid valve 9975
2 Emergency stop relay power 8035
3 Cab release 0096
4 Reduced gear splitter unit warning light 6323
5 Mirrors heating 8830
6 Low splitter 6495
7 RH rear direction indicator 1125
8 LH rear direction indicator 1120
9 Daytime lights 3390
10 Power steering circuit 1 fault warning light 6631
11 Power steering circuit 2 fault warning light 6632
12 Spare —
13 Spare —
14 LH brake indicator 1177
15 Trailer brake indicators 1179
16 RH brake indicator 1172
17 Tachograph speed sensor (power) 5514 grey
18 Tachograph speed sensor (inverted signal) 5516 purple
19 Tachograph speed sensor (straight signal) 5517 red
20 Tachograph speed sensor (earth) 0058 green
21 VGT turbine - Synchro Protection air block solenoid valve +15 power 8360
22 Fuel level indicator 5557
23 Air dryer power 8840
24 Additional brake valve supply 9977
25 Licence plate light power 3307
26 Rear brake block wear warning light 6013
27 Front brake block wear warning light 6012
28 Additional front brake warning light 6658
29 PTO engagement pressure sensor consent 0391
30 Fuel pre-filter heater 7753
31 Trailer ABS fault warning light 6671
32 Trailer ABS power 8847
33 PTO 3 on 6133
34 PTO 2 on 6132
35 PTO 1 on 6131
36 PTO 3 solenoid valve power 9123
39 Trailer socket power 7790
40 Tachograph and Body Computer battery voltage 7972
Bulkhead passage “C” yellow

WIRE COLOUR
PIN FUNCTION CODE
1 Spare —
2 Rear axle safety sensor 6245
3 Rear axle safety sensor positive 8847
4 RH front wheel speed sensor (black) 5571A
5 RH front wheel speed sensor (brown) 5571B
6 RH front wheel solenoid valve supply (pin3) 9920
7 Spare —
8 RH front wheel solenoid valve supply (pin1) 9918
9 Spare —
10 Spare —
11 RH rear wheel speed sensor (black) 5573A
12 RH rear wheel speed sensor (brown) 5573B
13 RH rear wheel solenoid valve supply (pin3) 9930
14 Spare —
15 RH rear wheel solenoid valve supply (pin1) 9928
16 Spare —
17 Closed contact with axle raised (lift axle) 0441
18 Open contact with axle raised (lift axle) 6695
19 Solenoid valve control axle lifting (lift axle) 6440
20 Black-speed sensor rear left wheel (lift axle) 5572C
21 Brown-speed sensor rear left wheel (lift axle) 5572D
22 Black-speed sensor rear right wheel (lift axle) 5573C
23 Brown-speed sensor rear right wheel (lift axle) 5573D
24 ASR solenoid valve negative supply (pin2) 0260
25 ASR solenoid valve positive supply (pin1) 9260
26 Spare —
27 Spare —
28 Spare —
29 LH rear wheel solenoid valve supply (pin3) 9929
30 Spare —
31 LH rear wheel solenoid valve supply (pin1) 9931
32 LH front wheel solenoid valve supply (pin3) 9919
33 Spare —
34 LH front wheel solenoid valve supply (pin1) 9921
35 Black-speed sensor front left wheel (black) 5570A
36 Brown-speed sensor front left wheel (brown) 5570B
37 Black-speed sensor rear left wheel (black) 5572A
38 Brown-speed sensor rear left wheel (brown) 5572B
39 Trailer ABS power supply 7772
40 Trailer ABS power supply 7772
Bulkhead passage “D” blue

WIRE COLOUR
PIN FUNCTION CODE
1 Astronic power terminal 15 after fuse 8101
2 Astronic ground 0000
3 Buzzer positive for transmission fault signal 6100
4 CAN L (AStronic V33 gear selector (lever)) GREEN
5 CAN H (AStronic V33 gear selector (lever)) WHITE
6 Power terminal 30 7101
7 K line for Astronic 2297
8 CAN L (Astronic) GREEN
9 CAN H (Astronic) WHITE
10 Spare —
11 Spare —
12 Spare —
13 Spare —
14 Spare —
15 Spare —
16 Spare —
17 Spare —
18 Spare —
19 Spare —
20 Spare —
21 Spare —
22 Data line for visualiser 6101
23 Buzzer signalling gearbox V35 fault (push button panel) 1101
24 Power supply terminal 30 gearbox V35 (push button panel) 7300
25 Power supply terminal 30 gearbox V35 (push button panel) 7300
26 CAN L (AStronic V35 gear selector (push button panel)) GREEN
27 CAN H (AStronic V35 gear selector (push button panel)) WHITE
28 Spare —
29 Spare —
30 Power supply AStronic V35 (push button panel) terminal 15 post fuse 8300
31 Spare —
32 Spare —
33 Spare —
34 Ground for Intarder AStronic V35 (push button panel) 0000
35 Ground for Intarder AStronic V35 (push button panel) 0000
36 Spare —
37 Spare —
38 Spare —
39 Spare —
40 Spare —
Bulkhead passage “E” green

WIRE COLOUR
PIN FUNCTION CODE
1 CAN L (EDC) f line GREEN
2 CAN H (EDC) f line WHITE
3 Low power steering oil level warning light 5525
4 Spare —
5 Spare —
6 Spare —
7 Terminal 15 alternator power 8876
8 Engine water level low 5520
9 Power supply intarder EST52 0000
10 Spare —
11 Power supply +30 intarder EST52 7300
12 Power supply +15 intarder EST52 8300
13 +15 ECM power 8051
14 Spare —
15 Spare —
16 Spare —
17 Spare —
18 CAN L ( VDB ) GREEN
19 CAN H ( VDB ) WHITE
20 Spare —
21 Spare —
22 EDC k line 2298
23 Starter motor (terminal 50) 8888
24 Spare —
25 UDS power after fuse (+30) 7540
26 UDS power after fuse (+15) 8540
27 UDS k line 2257
28 Conditioner pulley 9993
29 Spare —
30 Spare —
31 Spare —
32 Spare —
33 Spare —
34 Spare —
35 Second speed limit signal ground 0000
36 Battery charger warning light relay power 7009
37 Engine RPM signal 5584
38 Second speed limit signal 0172
39 +30 ECM power 7151
40 +30 ECM power 7151
ECM ELECTRONIC CONTROL UNIT ECM
A. Injector connector - B. Frame connector - C. Sensor connector

Electroinjector connector “A”
Colour key
Cable Colour
Function Function
ECU Pin colour cable
F3B F2B
F3B F2B
1 — Free B Electronic injector solenoid valve cylinder 5
2 — Free B Electronic injector solenoid valve cylinder 6
3 B Electronic injector solenoid valve cylinder B Electronic injector solenoid valve cylinder 4
(4-5-6)
4 — Free W Electronic injector solenoid valve cylinder 1
5 — Free G Electronic injector solenoid valve cylinder 3
6 Y Electronic injector solenoid valve cylinder 2 R Electronic injector solenoid valve cylinder 2
7 O Engine brake control solenoid valve O Engine brake control solenoid valve
8 N Engine brake control solenoid valve N Engine brake control solenoid valve
9 — Free — —
10 — Free — —
11 R Electronic injector solenoid valve cylinder Y Electronic injector solenoid valve cylinder 2
(1-2-3)
12 G Electronic injector solenoid valve cylinder 3 R Electronic injector solenoid valve cylinder 3
13 W Electronic injector solenoid valve cylinder 1 R Electronic injector solenoid valve cylinder 1
U Electronic injector solenoid valve cylinder 4 U Electronic injector solenoid valve cylinder 4
14
15 E Electronic injector solenoid valve cylinder 6 G Electronic injector solenoid valve cylinder 6
16 P Electronic injector solenoid valve cylinder 5 P Electronic injector solenoid valve cylinder 5
Sensors connector “C”
Colour key
Cable
Function
ECU pin colour
F3B
F3B
1 N Variable pitch turbine control solenoid valve
2 — Free
3 B Variable pitch turbine control solenoid valve
48 — Free
9 W Distribution sensor
10 R Distribution sensor
11  14 — Free
15 K Coolant temperature sensor
16  17 — Free
18 O/B Fuel temperature sensor
19 B Flywheel sensor
20 N Turbocompressore speed sensor
21  22 — Free
23 W Camshaft flywheel sensor
24 N Earth for engine oil pressure/temperature sensor
25 W Air pressure/temperature sensor power supply
26 Y Coolant fluid temperature sensor
27 O/B Oil temperature signal from engine oil pressure / temperature sensor
28 U Oil pressure signal from engine oil temperature/pressure sensor
29 — Free
30 W Turbocompressor speed sensor
31 — Free
32 O Engine oil pressure / temperature sensor power supply
33 R Air temperature /pressure sensor power supply
34 G Air pressure signal from air temperature / pressure sensor
35 W/R Fuel temperature sensor
36 O Air temperature signal from air temperature/pressure sensor
Frame connector “B”
Cable
Function
ECU Pin colour
F3B
F3B
2 7151 Positive +30
3 7151 Positive +30
5 0150 Ground
6 0150 Ground
8 7151 Positive +30
9 7151 Positive +30
10 0150 Ground
11 0150 Ground
12 0094 Pre-warming on enable relay ground
26 5173 Intake air relative humidity sensor signal with EDC
27 5174 Intake air temperature sensor signal with EDC
28 0173 Air intake temperature and relative humidity sensor ground
29 0000 Ground
32 9907 Start-up from engine compartment
33 5584 Engine rpm signal for ST14
34 GN/Ve CAN L line ECB
35 WS/Bi CAN H line ECB
40 8051 +15
47 9906 Shutdown from engine compartment
68 8173 Intake air temperature and relative humidity sensor power supply
75 9164 Pre-warming relay excitation signal for EDC
89 2298 EDC diagnostics K line
DCU (DOSING CONTROL UNIT) - AdBlue injection control unit
272G17012
ECU location
The ECU is installed in the urea pumping module and is used to send the right amount of urea to the injector in the exhaust.
DCU 15 - CONNECTOR VIEW
NOTE: The connector is seen from wire inlet side
WIRE COLOUR
REF. DESCRIPTION CODES
3 Urea filter outlet heater control 9546
5 SCR ECU diagnostic ”K” line 2257
7 Urea tank temperature sensor signal wire with SCR 6542
8 Catalyser inlet temperature sensor signal wire with SCR 6544
10 Catalyser output temperature sensor signal with SCR 6541
11 Ground wire for catalyser outlet temperature sensor with SRC 0541
12 Positive +15 8540
13 Urea tank heater solenoid valve ground 9542
17 Urea tank level and temperature sensor ground 0543
18 Urea tank level sensor signal wire with SCR 6543
19 Ground wire for catalyser inlet temperature sensor with SCR 0544
21 Ground 0000
22 Ground 0000
24 SCR module dosing solenoid valve control 9541
25 SCR module dosing solenoid valve power supply 7541
28 CAN - L line (ECB) Green
29 CAN - H line (ECB) White
30 CAN - L line (ECB) Green
31 CAN - H line (ECB) White
32 +30 power 7540
33 +30 power 7540
34 Urea filter outlet heater power 7542
35 Urea tank heating solenoid valve power supply 7542
INTARDER CONTROL UNIT

Connector J1 (Intarder sensors and actuators)
PIN FUNCTION
1 Negative for oil pressure transmitter
6 Positive for oil pressure transmitter
7 Signal for oil temperature transmitter
8 Positive for Intarder engagement solenoid valve
9 Positive for Intarder pressure control solenoid valve
17 Negative for water temperature transmitter
18 Negative for oil temperature transmitter
21 Positive for oil temperature transmitter
22 Positive for water temperature transmitter
24 Negative for Intarder pressure control solenoid valve
25 Negative for Intarder engagement solenoid valve
Connector J2 (vehicle interface)
CABLE COLOUR
PIN FUNCTION CODE
5 CAN line- ”L” (VDB) GR/VE
8 Positive from fuse 7300
17 Ground 0000
18 Ground 0000
23 CAN line - ”H” (VDB) WS/BI
ABS
ABS control unit pin-out
Connector X1
CABLE COLOUR
PIN FUNCTION CODE
1 CAN line - ”L” (VDB) GN/VE
2 Axle braking pressure detection sensor signal 6245
3 CAN line - ”H” (VDB) WS/BI
4 Ground 0000
5 Negative from ABS switch 0049
6 ABS off switch negative 0048
7 Power under key positive 8847
8 Power direct from battery positive 7710
9 Ground 0000
10 Diagnostic connector K line (pin 4) 2299
11 Diagnostic connector L line (pin 3) 1199
12 Safety jumper (pins 9-15) —
13 Blink code LED 6672
14 Third brake cut-out negative 0027
15 ABS failure warning light negative 6670
Connector X2
CABLE COLOUR
PIN FUNCTION CODE
1 Front right wheel ABS power supply solenoid valve positive (pin 3) 9920
2 Rear left wheel ABS power supply solenoid valve positive (pin 3) 9931
3 Front left wheel ABS power supply solenoid valve positive (pin 3) 9921
4 Front right wheel ABS discharge solenoid valve positive (pin 1) 9918
5 Rear left wheel ABS discharge solenoid valve positive (pin 1) 9929
6 Front left wheel ABS discharge solenoid valve positive (pin 1) 9919
7 Axle ASR solenoid valve negative (pin 2) 0260
8 Rear right wheel Abs power supply solenoid valve positive (pin 3) 9930
9 Rear right wheel ABS discharge solenoid valve positive (pin 1) 9928
10 Signal from front right wheel sensor (ABS) 5571
11 Signal from rear left wheel sensor (ABS) 5572
12 Signal from front left wheel sensor (ABS) 5570
13 Signal from front right wheel sensor (ABS) 5571
14 Signal from rear left wheel sensor (ABS) 5572
15 Signal from front left wheel sensor (ABS) 5570
16 Axle ASR solenoid valve positive (pin 1) 9260
17 Signal from rear right wheel sensor (ABS) 5573
18 Signal from rear right wheel sensor (ABS) 5573
DIAGNOSIS SOCKET
Diagnostic socket location and pinout
Diagnostic socket pinout

SYSTEM PIN FUNCTION WIRE COLOUR CODE
— 1 — —
EDC + Immobilizer 2 K 2298
— 3 — —
ABS 4 K 2299
— 5 — —
Intarder 6 K 2996
— 7 — —
— 8 — —
— 9 — —
— 10 — —
Key start services / Key to run 11 +15 8802
VCM 12 K 2292
— 13 — —
Tachograph Cluster 14 K 2997
— 15 — —
DCU 16 K 2257
— 17 — —
Eurotronic 18 K 2297
— 19 — —
— 20 — —
CAN line H VDB 21 CAN white
CAN line L VDB 22 CAN green
— 23 — —
— 24 — —
Engine start-up signal (+15) 25 Modus 8892
Ground 26 Modus 0000
— 27 — —
Engine revs sensor signal 28 n 5540
Ground 29 Modus 0000
Vbatt power 30 Modus 7797
OBD II SOCKET
The Police may connect to this socket using appropriate systems to interface with the engine control unit and determine the pre-
sence of errors concerning pollution prevention devices.
342B017016R
Long term errors

Situations which cause exceeding of legal limits are stored as long term errors for 9600 hours (equal to 400 days).
Some examples of long term errors:

- Insufficient urea level
- Muffler inlet temperature sensor fault
- Exceeding of exhaust gas polluting level
- Engine intake air temperature/pressure sensor fault
- Low urea system pressure, etc.
ACTIVE long term errors switch the cluster warning light on.
INTERMITTENT long term errors (solved but still present in the engine ECU) do not switch the cluster warning light on.
INTERMITTENT long term errors cannot be deleted from the

engine ECU error memory by any diagnostic tool.
They are stored for 9600 hours (equal to 400 days) and are au-
tomatically deleted upon expiration.
OBD connector location and pinout
342B017017R
WIRE COLOUR
REF. DESCRIPTION CODES
4 Earth 0000
5 Analogue signal earth 0050
6 CAN H ECB —
14 CAN L ECB —
16 +30 power 7797
CAN LINE EFFICIENCY TESTS

Some measurements on the lines are required to test the onboard CAN lines.
Disconnect the batteries before starting tests on the CAN line.
VDB line
Disconnect the X3 connector from the VCM ECU.
Insert a multimeter on pin 1 and 2 of the connector, wiring side, respectively.
Test values:
0 ohm ~ 120 Ω infinite
CAN short-circuit CAN line OK Interrupted CAN Line
or or
DTCO internal resistor short-circuit interrupted internal DTCO resistor
Insert a multimeter on pin 1 and 2 of the connector, ECU side, respectively.
Test values
Internal resistor short-circuit Internal resistor OK Internal resistor interrupted
342B017018R
ECB line
Disconnect the X3 connector from the VCM ECU.
Test values

or or
EDC internal resistor short-circuit interrupted internal EDC resistor
Test values

CABIN
FRAME
342B017019R
IDB line
Disconnect the MC Net ECU connector.
Test values:

or or
RADIO internal resistor short-circuit interrupted internal RADIO resistor
Test values

342A017B007R
CLOCK WIRE REPLACEMENT
The following procedure applies to versions with SWI ECU.
The clock wire is positioned under the steering wheel. Its function is to connect all the controls on the steering wheel to the SWI
ECU.
A. SWI ECU - B. Steering stalk

C. Clock wire - D. Ignition block
357A017205R
Follow the instructions precisely to prevent damage to the coiled wire inside the box and to assure correct steering wheel
alignment on disassembly.
Disconnect ground wire connector (4).
Remove the nut (1) and mark the steering wheel mounting position (3) on the shaft (2) and remove the steering wheel.
8 9 10 11
12
7
13
6
14
74000
Disconnect the SWI electrical connections (6 - 7).

Fasten the upper part of the clock wire (rotor) (9) to its container, inserting the key (10) in the slots (11 - 12). This operation
serves to prevent the rotor (9) and stator (8) rotating reciprocally while removing.
Maintain this locked condition until assembled. If there is no key, use an adequately sized screw and nut.
Carefully lift the clock wire so that the elastic retainer pins (13) slide from the support (14). Rest it down gently.
15
72857
To refit the contact follow the above instructions in reverse order.
Replacement clock wires are supplied with key (15) assembled as shown. After mounting on the steering column, turn the key
to break it at the point indicated by the arrow and store the key in the housing in the steering wheel (5).

FUNCTIONAL DIAGRAMS
Function diagrams - Table of contents
Page
Diagram 1 - Positive direct from battery +VB - Ignition key power supply +15 86
Diagram 2 - +30 power after manual TGC - Voltage reducer 88
Diagram 3 - Power supply +30 after manual TGC - Pivotable headlights - Outfitters - Trailers 90
Diagram 4 - Power +30 after manual TGC 92
Diagram 5 - Power supply services +15A - Air conditioning - PTO - Synchroprotection - Additional parking solenoid 94
valve
Diagram 6 - Power supply services +15A - Electrically controlled windows - Reverse gear - brakes air drier - Diesel 96
filter water sensor - Mirrors heating
Diagram 7 - Power supply services +15B - DTCO - I.C. - IBC2 - Fog lights - Working light - Daytime lights - Alternator 98
- Vehicle service equipment
Diagram 8 - Power supply services +15B - ECM - VCM - Centralised locking - ABS - SCR - Motor heated mirrors 100
- Heated seats - Intarder - automatic transmission
Diagram 9 - Body Computer IBC2 - Brake lights - Registration plate light - Front, rear and front side lights - low beam 102
and main beam - headlamps geometry adjustment
Diagram 10 - Body Computer IBC2 - Input - trailer lights 104
Diagram 11 - IBC2 body computer - Direction indicators - Windscreen wipers 106
Diagram 12 - IC instrument panel 108
Diagram 13 - IC instrument panel and DTCO tachograph 110
Diagram 14 - VCM Vehicle Control Module 112
Diagram 15 - VCM Vehicle Control Module 114
Diagram 16 - EDC connector B 116
Diagram 17 - EDC connector A/C engine F2B 1\8
Diagram 18 - EDC connector A/C engine F3B 120
Diagram 19 - SCR pumping module 122
Diagram 20 - ABS 124
Diagram 21 - VDB/IDB CAN line 126
Diagram 22 - ECB CAN line 128
Diagram 23 - Heated and motorised mirrors - Central locking system 130
Diagram 24 - IC change type configuration 132
Diagram 25 - Heater. air conditioner 134
Diagram 26 - PTO set-up 136
Diagram 27 - Intarder EST-52 138
Diagram 28 - AS-TRONIC V33 transmission with PTO management 140
Diagram 29 - AS-TRONIC V35 transmission with PTOs 142
Diagram 30 - AS-TRONIC V35 transmission with PTOs Intarder version 144
Diagram 1 - Positive direct from battery +VB - Ignition key power supply +15
(Key diagram 1)
20000 Starter battery
25205 Engine stop relay
25213A Relay for powering ignition switch powered utilities via +15
25213B Relay for powering ignition switch powered utilities via battery positive
40011 Electronic tachograph
50005 IC multiple instrument cluster module
52502 Ignition switch for utilities with cranking
52600 General current switch
70005 20-pin fuse holder
70058 1-pin fuse holder 20A
72021 30-pin vehicle diagnostic socket
72069 16-pin connector for OBD (On Board Diagnostics)
85140 SCR (Selective Catalytic Reduction) pump module
86029 Centralised door locking ECU
86116 Multiplex Body Computer ECU
89000 Cooler
Diagram 2 - +30 power after manual TGC - Voltage reducer

(Key diagram 2)
03000 Alternator
08000 Starter motor
19005 Thermo starter
25200 Starter relay
25222 Thermo starter enable relay
68005 24 V - 12 V power
72025 2-pin connector 12V for general power
85000 Cigar lighter
85150 EDC ECU
86129 MC-NET ECU
86132 VCM (Vehicle Control Module) ECU
ST14 Outfit interface connector
Diagram 3 - Power supply +30 after manual TGC - Pivotable headlights - Outfitters - Trailers
(Key diagram 3)
22000 Horn
25805 Horn relay
32010 Swivelling light
50031 Horn button
52015 Swivelling lights switch
72006 7-pin ABS/EBS tractor-trailer connector
72010 15-pin trailer electric connector
88000 ABS ECU
Diagram 4 - Power +30 after manual TGC

(Key diagram 4)
25825 Pre-filter heater relay
47113 Diesel pre-filter heater thermostat
61110 Diesel pre-filter heater resistor
86004 Automatic transmission ECU
86015 Retarder electronic ECU
Diagram 5 - Power supply services +15A - Air conditioning - PTO - Synchroprotection - Additional
parking solenoid valve
(Key diagram 5)
25213A Relay for powering ignition switch powered utilities via battery positive +15
25213B Relay for powering ignition switch powered utilities via battery positive +15
25332 Climate control system on relay
25704 PTO1 on relay
25879 PTO enable relay with engine stopped
25897 PTO2 on relay
25898 PTO3 on relay
42015 Front parking brake warning light switch
42379 PTO on transmission enable switch
42608 Coolant pressure indicator switch
52070 PTO2 switch (transmission)
52071 PTO1 switch (flywheel)
52329 Front parking brake switch
53606 Switch on clutch master cylinder 70% compressed
78009 Turbine shutoff circuit solenoid valve
78065 Front parking brake on solenoid valve
78182 Mechanical transmission synch protection solenoid valve
78208 Flywheel PTO solenoid valve
78251 Transmission 2 PTO solenoid valve
82010 Climate control ECU
84019 Electromagnetic pulley
Diagram 6 - Power supply services +15A - Electrically controlled windows - Reverse gear - brakes
air drier - Diesel filter water sensor - Mirrors heating
(Key diagram 6)
34000E Reversing light
52005 Mirror heater switch with built-in warning light
53300 Window winder switch driver’s door
53302L Window winder switch LH passenger’s door
53302R Window winder switch RH passenger’s door
53503 Reversing light switch
61104 Brake system air drier resistor
80000 Window winder motor passenger’s door
80001 Window winder motor driver’s door
85006 Electrically heated and adjusted rear-view mirror (main)
85007 Electrically heated and adjusted rear-view mirror (closing)
85008 Electrically heated and adjusted rear-view mirror (wide-angle)
85008 Front rear-view mirror
86013 Water in fuel filter sensor
Diagram 7 - Power supply services +15B - DTCO - I.C. - IBC2 - Fog lights - Working light - Daytime
lights - Alternator - Vehicle service equipment
(Key diagram 7)
03000 Alternator
25806 Various lights on enable with key on relay
25825 Pre-filter heater relay
30011 Fog lights
32005 Daytime light
34011 Fifth wheel light
47113 Diesel pre-filter heater thermostat
52009 Fifth wheel light switch with built-in warning light
52312 Headlight position corrector switch
52321 Fog light switch with built-in warning light
61110 Diesel pre-filter heater resistor
Diagram 8 - Power supply services +15B - ECM - VCM - Centralised locking - ABS - SCR - Motor
heated mirrors - Heated seats - Intarder - automatic transmission
(Key diagram 8)
85010 Rear-view mirror ECU
85036 Pneumatic heated seat driver’s side
85038 Pneumatic heated seat opposite driver’s side
85140 SCR pumping module
85144 Nitrogen oxide NOX detection sensor
85150 ECM ECU
86004 Automatic transmission ECU
Diagram 9 - Body Computer IBC2 - Brake lights - Registration plate light - Front, rear and front side
lights - low beam and main beam - headlamps geometry adjustment
(Key diagram 9)
30001 Clearance light
30001A Dipped beam headlight
30001B Main beam
30100 Headlight position corrector actuator
34000 Rear clearance light
34007 Brake light
35000 Number plate light
37001 Front clearance light
37002 Rear clearance light
52307 External light switch
52312 Headlight position corrector switch
53800 Stop indicator stalk
54031B Stalk (main beam headlights)
Diagram 10 - Body Computer IBC2 - Input - trailer lights

(Key diagram 10)

42031 Front brake air pressure gauge transmitter
42032 Rear brake air pressure gauge transmitter
44035 Low windscreen washer liquid indicator control
44036 Low radiator water level indicator control
44037 Low power steering liquid level indicator ECU
53504 Front different lock on indicator switch
53517 Rear transverse lock indicator switch
53521 Longitudinal lock on indicator switch
53536 PTO1 on switch (flywheel)
53568 PTO2 on switch (transmission)
61000 Three diode holder container for PTO signals
72000 Trailer electric connection 7 pin connector
Diagram 11 - IBC2 body computer - Direction indicators - Windscreen wipers

(Key diagram 11)

25806 Various lights on enable with key on relay
30011 Fog lights
33001 Side direction indicator
32002 Front direction indicator
32005 DRL front clearance light
33005 Left side direction indicator
33006 Right side direction indicator
34009 Rear fog light
34011 Fifth wheel light
39000 Cab interior light
39003 Map reading light
42102 Handbrake engaged indicator switch
52009 Fifth wheel light switch with built-in warning light
52021 Interior lights switch
52302 Hazard light switch with built-in warning light
52321 Fog light switch with built-in warning light
53315 Rear fog light switch
54031 Five-function stalk
54033 Six-function stalk
64000 Windscreen washer pump
65000 Windscreen washer
72010 15-pin trailer electric connector
86002 Front wheel chock wear indicator circuit sensors
86003 Rear wheel chock wear indicator circuit sensors
Diagram 12 - IC instrument panel

(Key diagram 12)

03000 Alternator
25034 Rear fog light on relay
42111 Trailer brake circuit fault indicator switch
42351 Obstructed air cleaner indicator switch
42623 Power steering switching valve switch approx. 1.5
42624 Power steering lock valve switch approx. 1.5
44031 Fuel level indicator transmitter
47033 External temperature thermometer transmitter
50005 Multiple instrument cluster module
53506 Splitter lock on indicator switch
53507 Low gears engaged indicator switch
53538 Tipped body indicator switch
54033A Six-function stalk
85036 Pneumatic heated seat driver’s side
85061 Engaged gear range indicator sensor
85062 Splitter on indication sensor
86013 Water in fuel filter indicator sensor
Diagram 13 - IC instrument panel and DTCO tachograph

(Key diagram 13)

25868 Hydraulic power steering warning light switch
40032 Speedometer and tachograph transmitter
42622 Hydraulic oil flow indicator switch 2
50005 Multiple instrument cluster module
Diagram 14 - VCM Vehicle Control Module

(Key diagram 14)

08000 Starter motor
25200 Starter relay
85140 SCR pumping module electronic control
85150 EDC ECU
Diagram 15 - VCM Vehicle Control Module

(Key diagram 15)

08000 Starter motor
25805 Horn relay
42393 Request switch according to speed limit
52324 Engine brake request control
53511 Cab released indicator switch
53512 Engine starter switch with parking brake released
53545 Transmission in neutral indicator switch
53565 Pressed brake pedal switch
53567 PTO3 on indicator switch
53606 Switch on clutch master cylinder transmission synch 70% compressed
53607 Clutch master cylinder switch for ECM
78182 Mechanical transmission synch protection solenoid valve
85150 EDC ECU
85152 Accelerator load sensor
Diagram 16 - EDC connector B

(Key diagram 16)

19005 Thermo starter
25222 Thermo starter enable relay
53006 Starter switch in the engine bay
53007 Engine compartment engine stop switch
85150 ECM ECU
85161 Combustion supporting air relative humidity and temperature sensors
Diagram 17 - EDC connector A/C engine F2B

(Key diagram 17)

42030 Engine oil pressure gauge transmitter
47032 Engine oil temperature indicator thermometer transmitter
47042 Fuel temperature sensor
48035 Engine rpm sensor
48042 Engine rpm sensor on timing side
48043 Turbocharger speed sensor
78050 Engine brake solenoid valve
78247 Electronic injection solenoid valve
78248 Variable geometry turbine control solenoid valve
85150 EDC ECU
85153 EDC coolant temperature sensor
85156 Supercharger air pressure and temperature signal
Diagram 18 - EDC connector A/C engine F3B

(Key diagram 18)

42030 Engine oil pressure gauge transmitter
47032 Engine oil temperature indicator thermometer transmitter
47042 Fuel temperature sensor
48035 Engine rpm sensor
48042 Engine rpm sensor on timing side
48043 Turbocharger speed sensor
78050 Engine brake solenoid valve
78247 Electronic injection solenoid valve
78248 Variable geometry turbine control solenoid valve
85150 EDC ECU
85153 EDC coolant temperature sensor
85156 Supercharger air pressure and temperature signal
Diagram 19 - SCR pumping module

(Key diagram 19)

25213 +15 key utility power relay
61150 Urea filter outlet heater with SCR
78266 Dosing module solenoid valve with SCR
78267 Engine coolant circulation solenoid valve for urea tank heating
85141 Catalyser output temperature sensor with SCR
85142 Urea tank level and temperature sensors with SCR
85143 Catalyser input temperature sensor with SCR
85144 Nitrogen oxide NOX detection sensor with SCR
85150 EDC ECU
85161 Combustion supporting air relative humidity and temperature sensors
Diagram 20 - ABS
(Key diagram 20)

25213 +15 key utility power relay
52056 ASR off switch
52057 ABS off switch
78052 ABS solenoid valve
78053 ASR solenoid valve
88000 ABS ECU
88001 ABS sensor
88010 Maximum braking activation sensor (ABS with EBL)
Diagram 21 - VDB/IDB CAN line

(Key diagram 21)

40001 Electronic speedometer
68000 Radio
86123 SWI steering stalk interface multiplex ECU
86129 ECU for MC-NET (Mobile Communication Network)
88000 ABS ECU
Diagram 22 - ECB CAN line

(Key diagram 22)

85144 Nitrogen oxide NOX detection sensor
86150 EDC ECU
Diagram 23 - Heated and motorised mirrors - Central locking system

(Key diagram 23)

12010 Passenger door lock motor
12011 Driver door lock motor
25213A Relay for powering ignition switch powered utilities via battery positive
52005 Mirror heater switch with built-in warning light
85006 Electrically heated and adjusted rear-view mirror (main)
85007 Electrically heated and adjusted rear-view mirror (closing)
85008 Electrically heated and adjusted rear-view mirror (wide-angle)
85009 Front rear-view mirror heater
85011/1 Control for selecting rear-view mirror adjustment
85011/2 Rear-view mirror adjustment control
Diagram 24 - IC change type configuration

(Key diagram 24)

25030 Reverse relay
34000E Rear reversing light
Diagram 25 - Heater. air conditioner

(Key diagram 25)

12000 Heater and windscreen defroster motor
12015 External air flap motor
25332 Climate control system on relay
42608 Coolant pressure indicator switch
61137 Current limiting resistor for supplementary water heater
82010 Climate control ECU
84019 Electromagnetic pulley
Diagram 26 - PTO set-up

(Key diagram 26)

03000 Alternator
25805 Horn relay
85150 EDC ECU
F Diode holder container
012 Engine starter relay (outfitters)
013 Engine stop relay (outfitters)
014 SET + relay (outfitters)
015 SET - relay (outfitters)
016 PTO on confirmation relay (outfitters)
017 Transmission in neutral confirmation relay (outfitters)
018 External Cruise Control relay (outfitters)
019 PTO with vehicle standing relay
Diagram 27 - Intarder EST-52

(Key diagram 27)

86015 EST52 retarder ECU
Y1 Intarder control solenoid valve
Y2 Intarder switching solenoid valve
B9 Coolant temperature transmitter
B12 Oil temperature transmitter
E46 Oil pressure transmitter
Diagram 28 - AS-TRONIC V33 transmission with PTO management

(Key diagram 28)

22043 Alarm buzzer for AS_TRONIC transmission
25030 Reverse relay
25500 Gear lock with door open relay
25704 PTO1 on relay
25879 PTO enable relay with engine stopped
25897 PTO2 on relay
25898 PTO3 on relay
34000E Reversing light
50002 AS_TRONIC transmission gear display
52059 AS_TRONIC transmission gear selector
78208 Flywheel PTO solenoid valve
86004 ECU for AS_TRONIC transmission on transmission
Diagram 29 - AS-TRONIC V35 transmission with PTOs

(Key diagram 29)

25030 Reverse relay
25704 PTO1 on relay
25897 PTO2 on relay
25898 PTO3 on relay
52118 ”off road” switch
52220 PTO3 switch (transmission 2)
53068 Automatic transmission NEUTRAL position switch
53069 Automatic transmission REVERSE position switch
53070 Automatic transmission DRIVE position switch
54030 RH stalk (with gear selector)
78208 Flywheel PTO1 solenoid valve
86004 AS_TRONIC V35 transmission ECU (transmission)
86004A ECU for AS_TRONIC V35 transmission on transmission
86005 Vehicle inductive speed sensor
86126 EM (Expansion Module) ECU
ST27 E3-E5 configuration connector
ST33 Cab wiring CAN connector
Diagram 30 - AS-TRONIC V35 transmission with PTOs Intarder version

(Key diagram 30)

25030 Reverse relay
25704 PTO1 on relay
25897 PTO2 on relay
25898 PTO3 on relay
52118 ”off road” switch
53068 Automatic transmission NEUTRAL position switch
53069 Automatic transmission REVERSE position switch
53070 Automatic transmission DRIVE position switch
53567 PTO3 on switch (transmission 2)
53568 PTO2 on switch (transmission 1)
54030 RH stalk (with gear selector retarder)
78208 Flywheel PTO1 solenoid valve
86004 AS_TRONIC V35 transmission ECU (transmission)
86004A ECU for AS_TRONIC V35 transmission on transmission
86005 Vehicle inductive speed sensor
86126 EM (Expansion Module) ECU
ST27 E3-E5 configuration connector
ST33 Cab wiring CAN connector
CABLE COLOUR CODES
COMPONENT
CODE DESCRIPTION
0000 Earth in general
0001 Insulated radio earth
0002 Emergency light control earth
0003 Earth for switch turning on roof lamp (switch on door pillar-switch)
0004 UNIC design: insulated running lights (vehicles for transport of dangerous goods)
0005 Earth for remote control switch on trailer brake slave to engine brake
0006 Earth for indicator lights connected to rheostat
0007 Earth for remote control switch cutting out stop request indicator lights
0008 Earth operating start-up remote control switch
0009 Windshield wiper fixed stop
0010 Roof light switch on earth (switch/lamp)
0011 Earth for warning light for rear door open
0012 Earth for general current remote control switch
0013 Earth for remote control switch operating engine brake
0014 Earth for remote control switch connecting ventilator motors
0015 Earth for additional heater water recycling pump motor
0016 Earth for remote control switch activating electric heater and windshield defrosting system through water
additional heater
0017 Earth for front door open indicator light
0018 Hydraulic brake signal
0019 Earth to control unit “MS6” terminal 8
0020 Heated mirror relay pick-up earth relay control unit
0021 Insulated earth to control unit “MS6” terminal 25
0022 Insulated earth for additional heater
0023 Earth for visual indicators for flashing lights
0024 Earth for indicators connected to push button for lamp test
0025 Earth for emergency warning light through central safety control
0026 Earth for open driver’s door for connected external light signalling relay or Power supply for brake wear
sensors and air pressure sensors with EBS
0027 Relay terminal 85 controlling A.B.S retarder
0028 KICKDOWN signal
0029 Hydraulic cab tilting relay control earth after radiator cowling opening indication switch
COMPONENT
CODE DESCRIPTION
0030 Feed to sensor 1 earth for engine r.p.m. diagnostics (n=1/1) and electronic r.p.m. sensor
0031 Feed to sensor 2 earth for engine r.p.m. diagnostics (n=1/1)
0032 Feed to sensor earth for engine r.p.m. diagnostics (n=1/2, on injection pump)
0033 Solenoid valve controlling hydraulic brakes
0034 Solenoid valve letting out hydraulic brakes
0035 Relay control thermometric switch for diesel fuel heating
0036 Earth for main door open warning light
0037 Relay pick-up earth for “belt fastened” light
0038 Earth for electromagnet preventing key rotation
0039 Control from heated fuel line (Thermoline) temperature sensor
0040 Control for transverse differential locking disconnected
0041 Control for transverse differential locking disconnected
0043 Insulated earth on engine brake control circuit
0044 Belt fastened indicator light
0045 Insulated earth to resistance “R2” for engine brake
0046 EBS trailer proportional solenoid valve earth
0047 Signal for low air pressure in EBS system
0048 A.S.R. disconnection
0049 A.B.S. disconnection
0050 Generic earth for analogic signal
0051 Control for A.B.S. relay No. 1
0052 Control for A.B.S. relay No. 2
0053 Remote switch pick-up for PTO cut-out
0054 Feed to pressure switch for PTO connection
0055 Insulated earth for switch on rear axle
0056 Negative “forward” limit switch signal to power takeoff ECU
0057 Negative “backward” limit switch signal to power takeoff ECU
0058 Electronic tachograph sender insulated negative
0059 Speed limiter solenoid valve disconnection signal with gear in neutral
0060 Earth cable after diode Z for board indicator lights attenuation for Military Vehicles
0061 Earth cable feeding indicator lights for Military Vehicles (with switching into dimmed light through diode 7)
0062 Control cable to door centralised locking switch-opening

COMPONENT
CODE DESCRIPTION
0063 Control cable to door centralised locking switch-locking
0064 Control cable to centralised locking door lock-opening
0065 Control cable to centralised locking door lock-docking
0066 Tachograph clock earth
0067 Earth for remote control switch inserting engine for automatic clutch
0068 Earth for remote control switch operating start-up from automatic clutch control unit
0069 Earth for reverse light remote control switch from automatic clutch control unit
0070 Earth for automatic clutch warning light feed remote control switch
0071 Earth for buzzer from automatic clutch control unit
0072 Earth for automatic clutch position sensor
0073 Earth for accelerator pedal sensor for automatic clutch
0074 Earth for gearbox lever position sensor for automatic clutch
0075 Direct battery earth for air drier
0076 Relay coil self-pickup return for electrical battery disconnection device
0077 Stop light signal from brake valve transmitter with EBS
0078 D + alternator after power diode
0079 Ex (i) own safety circuit cable with TMP vehicle for electr. tachograph (0 V)
0080 Earth for cab interior and step lighting after timed remote switch
0081 Negative to terminal 30 for engine brake control relay with service brake
0082 Negative to terminal 30 for engine brake control relay with accelerator pedal
0083 Feed to switch for centralised locking from door module with Mux
0084 Solenoid valve actuating automatic clutch (earth)
0085 Earth for automatic clutch control unit from push button on doors
0087 Diesel fuel pre-heating relay control signal from EDC
0088 Stop 1 light switch signal to EBS electronic control unit
0089 Stop 2 light switch signal to EBS electronic control unit
0090 Earth from sensor to “EGR” control unit
0091 Insulated earth for alternator by-pass remote switch control ( D+ to earth)
0092 Earth for start-up safety control with cab raised or engine compartment door open (bus)
0093 Earth for start-up safety remote control switch
0094 Earth for pre-heating connection relay
0095 Earth for relay control for ground acceleration gate switch with tilted cab
COMPONENT
CODE DESCRIPTION
0096 Cab locking indicator light-after diode
0097 Electronic horn earth
0098 Centralized lubrication control after push-button
0099 EBS front axle proportional solenoid valve earth
0100 Earth for display for semiautomatic gearbox
0101 Earth for speed sensor (Input) for semiautomatic gearbox
0102 Earth for screen braiding for speed sensor (Input) for semiautomatic gearbox
0103 Earth for screen braiding for speed sensor (Output) for semiautomatic gearbox
0104 Earth for speed sensor (Output) for semiautomatic gearbox
0105 Earth for screen braiding for display for semiautomatic gearbox
0106 Earth for accelerator pedal position sensor for semiautomatic gearbox
0107 Earth for diagnosis for semiautomatic gearbox
0109 Internal light touch switch signal
0110 Earth for gearbox control solenoid valve unit for semiautomatic gearbox
0111 Earth for reduced gears solenoid valve unit for semiautomatic gearbox
0112 Earth for gearbox brake solenoid valve for semiautomatic gearbox
0114 Earth for solenoid valve keeping clutch disengagement for semiautomatic gearbox
0115 Earth for semiautomatic gearbox “gears in” speed unit sensor
0116 Earth for semiautomatic gearbox “gears in” sensor
0117 Slow gears signal cable inserted upstream
0118 Earth for ABS right front solenoid valve
0119 Connected engine brake signal to semiautomatic gearbox gear selector
0121 Boost earth on injection pump actuator for semiautomatic gearbox
0122 ABS front left solenoid valve earth
0123 PTO 3 request cable
0124 PTO 4 request cable for stop brake or clutch engaged
0125 Forward gear cable with automatic transmission
0126 Reverse gear cable with automatic transmission
0127 Cable for engaging forward gear with automatic transmission
0128 Cable for engaging reverse gear with automatic transmission
0129 Control cable for enabling hydraulic cab releasing remote switch with hand brake on
0130 Solenoid valve, brake system, front axle (power)

COMPONENT
CODE DESCRIPTION
0131 PTO 1 request cable (rear with semiautomatic gearbox)
0132 PTO 2 request cable (side with semiautomatic gearbox)
0133 Pressed brake pedal signal to semiautomatic gearbox gear selector
0134 PTO 1 relay pick-up, automatic gearbox
0135 Insulated earth for connected engine brake warning light
0136 PTO 2 relay pick-up, automatic gearbox
0137 Pickup cable for PTO 3
0138 Pickup cable for PTO 4 remote switch for stop brake or clutch engaged
0139 Cable earth for distance control with ACC (Adaptive Cruise Control)
0140 EDC needle lift sensor return
0141 Earth for diagnosis output with automatic gearbox
0142 Radio - amplifier, remote on connection cable
0143 Driver’s door opening signal to semiautomatic gearbox gear selector
0144 Earth for diagnosis switch with automatic gearbox
0145 Earth for activated ISO diagnosis with automatic gearbox
0146 Reverse gear relay pick-up, automatic gearbox
0147 Indication cable for automatic neutral position with automatic gearbox
0148 Remote switch energisation for power take off rev. increase with automatic gearbox
0150 Components return connection to EDC control unit
0151 Engine stop with EDC indication cable
0152 Feed to external cruise control EDC switch with Mux
0153 Feed to (internal-external) cruise control EDC switch with Mux
0155 Main relay for EDC indication cable
0156 Diagnosis request push-button for EDC
0157 Earth from accelerator pedal to MS6 control unit
0158 Earth after EDC accelerator pedal idle switch
0159 Signal from idle engine switch for engine control system
0160 Signal from clutch switch for EDC or VCM (Vehicle Control Modul)
0161 Power window control cable with terminal “15”
0162 “Data Link” cable for engine electronic control unit (-)
0163 EDC system diagnostic switch power
0164 Terminal 15 remote switch pick-up for EDC

COMPONENT
CODE DESCRIPTION
0165 Earth for boosting sensor for EDC
0166 Control from PTO 1 switch to EDC control unit
0167 Control from PTO 2 switch to EDC control unit
0168 Control from Eco-Power switch to EDC control unit
0169 Eco-Power control, EDC control unit
0170 Earth for rocker cam rev sensor for EDC
0171 Earth for Eco-Power on warning light
0172 Second speed limiter signal
0173 Ground cable for combustion air relative humidty and temperature sensors with EDC
0174 Timing sensor earth for EDC control unit
0175 Earth for fuel temperature sensor for EDC
0176 Control cable for NOTAUS (Emergency Disconnection) TGC with ADR (TGC “+” control)
0177 Feed to switch NOTAUS (Emergency Disconnection) ADR after fuse (TGC “+” control)
0178 Control cable for TGC connection with ADR (TGC “+” control)
0179 Cable actuation ACC (Adaptive Cruise Control)
0180 Control cable for solenoid valve for adjusting device for value required on engine for natural gas engine
0181 Ground cable for adjusting device for value required on engine for natural gas engine
0182 Feed to lambda probe heater resistor (12 V) for natural gas engine
0184 Ground cable (shielding) for output shaft rev sensor (12 V) for natural gas engine
0189 Neutral position control cable from neutral position remote switch for natural gas engine
0190 Solenoid valve by-pass control cable for natural gas engine
0191 Min speed control cable for natural gas engine
0192 Control cable for reduced gas solenoid valve for natural gas engine
0193 Ground cable for runaway speed rate solenoid valve and idle solenoid valve for natural gas engine
0194 Cable for limit value transmitter engine stop (tachograph) for natural gas engine
0197 Feed to Pin D gas regulator for natural gas engine
0198 Common earth for window regulator switches
0199 Ground cable for solenoid valve, supercharging pressure sensor, supercharging air temperature for natural
gas engine
0200 Headlight washer remote control switch control cable
0201 Earth for front window regulator switch on passenger’s side
0202 Earth for rear window regulator switch on driver’s side (on door)
0203 Earth for rear window regulator switch on passenger’s side

COMPONENT
CODE DESCRIPTION
0210 Input signal - Horn
0211 Input signal for solenoid valve of air horn
0217 Redundant solenoid valve earth for rear axle breaking in case of EBS control unit failure
0224 Ground cable for front RH brake wear sensor with EBS 2
0226 Ground cable for front LH brake wear sensor with EBS 2
0240 Heated windscreen control “on”
0266 Control cable for brake engagement in the event of accidental reverse ARB for EBS
0303 Cable for retarder with automatic gearbox connection indication
0309 Hydraulic eddy-current brake temperature sensor earth signal
0310 Return signal from hydraulic eddy-current brake connecting solenoid valve
0311 Intarder rail solenoid valve earth
0315 Hydraulic eddy-current brake disconnection with ABS connected
0320 ADM connecting control to electronic control unit
0321 ADM connecting control after disconnecting switch
0322 Feed to ADM system (electronic differential lock) steering angle sensor
0326 Low air pressure indication of ADM system (electronic differential lock)
0350 Insulated earth from relay to Martin horn compressor for Fire Fighting Vehicles
0351 Insulated earth from switch to electronic alarm horn for urban/extra-urban switchover for Fire Fighting
Vehicles
0391 PTO 1 connection cable
0400 Sensor earth for ECAS chassis level adjustment
0402 Earth for ECAS remote control (suspension levelling and third axle lifting)
0410 Brake pedal to ECU (negative)
0411 Brake pedal to ECU (control signal 1)
0412 Brake pedal to ECU (control signal 2)
0441 Lifting axle raising control after switch
0442 Lifting axle lowering control after touch switch
0443 Brake wear rear axle right (negative)
0444 Brake wear rear axle left (negative)
0446 Gate switch for hydraulic pump relay connection with a pressure lower than 30 bar during axle lowering
COMPONENT
CODE DESCRIPTION
0450 Feed from thermal switch on hydraulic pump for lifting axle
0451 Hydraulic pressure indication during lifting axle raising
0452 Min. hydraulic pressure indication during lifting axle lowering
0453 Load indication for driving axle for lifting axle
0454 Max. hydraulic pump pressure indication for lifting axle
0460 Control for pick-up disconnection after touch switch
0461 Control for pick-up connection after touch switch
0491 Low pressure control in third steering axle hydraulic circuit
0501 Additional heater activation switch
0503 Feed to thermic switch earth of cab internal temperature thermostat with water temperature above 50
˚C for additional heater
0504 Control for blower relay earth - speed 1 through adjustable thermic switch of cab internal temperature
thermostat for additional heater
0505 Earth pickup for fan-speed 1 relay through heat switch 25 ˚C of additional heater internal temperature
thermostat
0506 Fuel metering pump earth for additional heater (also through overtemperature switch)
0507 Earth supply for temperature sensor and flame control probe with additional heater
0508 Earth supply for burner control motor relay with additional heater
0510 Control cable for inserted supplementary heater
0511 Electronic pulse generator earth pickup for additional heater glow plug
0512 Feed to ambient temperature sensor with additional heater
0535 EDC control unit failure warning light to blink code
0538 Control cable, SCR wear trigger control
0539 Control cable, SCR return lead
0540 Catalyst negative signal (input/output)
0541 Ground cable for output catalyst temperature sensor with SCR (Selective Catalytic Reduction)
0543 Ground cable for urea tank temperature and level sensors with SCR (Selective Catalytic Reduction)
0544 Ground cable for intput catalyst temperature sensor with SCR (Selective Catalytic Reduction)
0545 Cable earth to temperature sensor on solenoid valve of metering module with SCR (Selective Catalytic
Reduction)
0546 CRT (Continuous Regeneration Trap) maintenance warning pilot light grounding
0547 Exhaust gas temperature sensor (output)
0548 Exhaust gas temperature sensor (input)
0549 Return cable, SCR pump module

COMPONENT
CODE DESCRIPTION
0550 Sensor earth and servomotor potentiometer (AGND) air conditioning system
0555 Earth for air conditioning system blower
0560 APU ground cable with ECAD (Electron. Controlled Air Drier)
0562 Earth for air delivery servomotor for “foot compartment” (-FOOT) air conditioning system
0564 Earth for air delivery servomotor for windscreen defrosting (-DEF) air conditioning system
0566 Earth for servomotor for air recirculation or for external air intake (-RYC) air conditioning system
0568 Earth for servomotor for “air mixing” (-MIX) air conditioning system
0582 Air conditioning system blower control from 18 bar pressure switch
0583 Air conditioning system blower control from 22 bar pressure switch
0590 Conditioner heater fan power
0609 Diode internal light switch connecting cable
0610 Earth “1” for lighting roof lights from switch
0611 Earth “2” for lighting roof lights from switch
0615 Pressure transducer earth (methane system)
0616 Fuel level adjusting device earth (methane system)
0622 ECAS (negative) control, rear axle distance sensor
0630 POTR - Vocal microphone signal - earth
0631 POTR - Vocal TEL phone signal - earth
0632 POTR - MP3 audio signal - earth
0650 Diesel fuel prefilter relay insulated earth
0651 Insulated earth for air pressure sender
0652 Insulated earth for fuel level gauge
0715 EBS (negative) control, rear axle module
0716 EBS (negative) control, front axle module
0770 Earth for ESP
0800 Earth battery to manual battery disconnecting switch
0801 Info engine running from diodes to relay contact
0802 Earth running engine relay from diodes to relay contact
0803 Earth actuation diode defrosting to relay defroster feeding
0804 Earth running engine for CS
0805 Earth CAN control unit MUX
0806 Earth CAN J1939 dashboard

COMPONENT
CODE DESCRIPTION
0807 Earth CAN powertrain
0808 Earth starting relay to control unit VCM or methane engine control unit
0809 Earth from control unit MUX to failure acquisition switch
0810 Info control unit MUX to parking brake contact
0811 Info control unit MUX to passenger counter switch
0812 Info control unit MUX to pressure switch parking brake release
0813 Earth methane engine control unit to vehicle motion relay
0814 Info control unit MUX to switch methane throttle opening or switch fuel filter heater
0815 Info control unit MUX to solenoid valve parking brake release
0816 Info contact methane hatch to control unit MUX body
0817 Earth control unit MUX to switch ecological bell
0818 Earth speedometer to speed sensor
0819 Info warm/ cold driver’s place to Webasto programmer
0820 Info air suction control unit to switch air suction control or switch flap control
0821 Earth ECM to sensor particulate filter pressure
0822 Earth ECM to sensor particulate filter temperature
0823 Earth ECM to sensor ambient air humidity
0824 Info control unit MUX to switch tractor diagnosis
0825 Earth ECM to rear control engine start/stop
0827 Earth ECM to preheater relay
0829 Earth ECM to fuel preheater relay
0831 Earth ECM to potentiometer accelerator pedal
0833 Earth control unit MUX to sensor oil tank full
0834 Earth control unit ABS6 to rear LH solenoid valve
0835 Earth control unit ABS6 to front RH solenoid valve
0836 Earth control unit ABS6 to central RH solenoid valve
0837 Earth control unit ABS6 to central LH solenoid valve
0839 Info control unit MUX vertical lifting to switch vehicle lifting control
0840 Info control unit MUX vehicle emergency raising to switch control urgent vehicle lifting
0841 Earth bending control unit to front RH sensor
0842 Earth bending control unit to front LH sensor
0843 Earth bending control unit to rear RH sensor no. 1

COMPONENT
CODE DESCRIPTION
0844 Earth bending control unit to rear LH sensor no. 1
0845 Earth bending control unit to rear RH sensor no. 2
0846 Earth bending control unit to rear LH sensor no. 2
0847 Info control unit MUX to switch reverse motion buzzer cut-off
0848 Earth DCU to urea tank heater
0849 Earth DCU to sensor urea level and temperature
0850 Earth DCU to sensor temperature before catalysation (up)
0851 Earth DCU to sensor temperature after catalysation (down)
0852 Earth control unit urea injection DCU to solenoid valve
0853 Earth oil level sensor from oil level display unit
0854 Earth control unit MUX to sensors clogging oil and fuel tanks
0856 Earth gearbox control unit to LIMP-HOME
0859 Earth control unit MUX to sensor engine compartment temperature
0860 Earth control unit CAMU to sensor sensitive carpet and sensitive edge disabled people handrail
0861 Earth monitors
0862 Earth video surveillance
0864 Earth control unit methane engine to pressure relief valve
0865 Earth control unit methane engine to power relay
0866 Earth control unit methane engine to sensor pressure of relief valve
0867 Earth control unit methane engine to sensor catalyst temperature
0868 Connection control unit MUX to methane engine control unit for engine failure warning or info preheating
of active air in Diesel
0869 Info MUX sensor engine side tailgate RH open
0900 Signal cable from term. 50 key switch with Multiplex
0901 Control cable for pivotable headlight after switch
0902 Control cable from front transverse differential lock. touch switch
0903 Control cable from front longitudinal differential lock. touch switch
0904 Control cable from rear transverse differential lock. touch switch
0915 Signal cable from term. 15 key switch with Multiplex
0922 Hydraulic cab releasing control during lowering with Mux
0923 Hydraulic cab releasing control during lifting with Mux
0927 Cable from trailer brake hand lever switch (brake light)
0941 Internal white light control

COMPONENT
CODE DESCRIPTION
0942 Internal red light control
0949 Jumper cable for passenger door module identification with Multiplex
0950 Feed to rear-view mirror adjustment switch from door module with Mux
0951 Signal cable for rear-view mirror downward adjustment for door module with Mux
0952 Signal cable for rear-view mirror upward adjustment for door module with Mux
0953 Signal cable for rear-view mirror rightward adjustment for door module with Mux
0954 Signal cable for rear-view mirror leftward adjustment for door module with Mux
0955 Feed to heated rear-view mirror switch and selection from door module Mux
0956 Rear-view mirror selection signal cable for door module with Mux
0957 Rear-view mirror heating signal cable for door module with Mux
0960 Feed to passenger door power window from door module with Mux
0961 Open passenger door power window signal cable for door module with Mux
0962 Closed passenger door power window signal cable for door module with Mux
0965 Feed to driver door power window from door module with Mux
0966 Open driver door power window signal cable for door module with Mux
0967 Closed driver door power window signal cable for door module with Mux
0970 Hatch opening control signal cable for cab computer (BC) with Mux
0971 Hatch closing control signal cable for cab computer (BC) with Mux
0972 Sun visor lifting control
0973 Sun visor lowering control
0974 Control from sun visor limit stop switch
0975 “Minus” output cable for Expansion Module (HS OUT 2) with inserted terminal 15
0977 Signal cable for main current remote switch disconnection with Multiplex
0978 Signal cable for main current remote switch connection with Multiplex
0982 Control cable to driver’s door lock for door open
0983 Control cable to passenger’s door lock for door open
0984 Control cable to door lock for central door locking - opening
0985 Control cable to switch for central door locking - closing
0986 Engine fan solenoid valve power (Baruffaldi)
0987 Pickup cable for engine fan electromagnetic coupling connection remote switch (Baruffaldi)
0990 “Minus” connection cable for Expansion Module (ID MINUS) application
0991 Input signal cable for Expansion Modul (DIG IN 11) for bodybuilders
COMPONENT
CODE DESCRIPTION
0992 Input signal cable for Expansion Modul (DIG IN 12)
0997 “OFF-ROAD MODE2 signal cable (increase of revolutions)
0998 Shielding
0999 Ground cable for CAN-Bus shielding
1100 Connection between “IVECO CONTROL” control units (second/third level)
1101 Feed to warning bell unit for semiautomatic gearbox
1102 “Tx” line for VDI (Vehicle Data Interface
1103 From steering column switch to control unit (RH)
1104 Feed to Hostess bell unit
1105 Feed to stop request
1108 Feed to revolving light II
1109 From steering column switch to control unit (LH)
1110 Feed to reversing switch controlling flashing light
1111 Feed to flashing turn indicator (normal circuits)
1112 Vehicle flashing turn signal indicator light
1113 Feed to relay for emergency lights terminal 30
1114 Flashing emergency warning light visual indicator
1115 Feed to revolving light
1116 Feed to horn
1117 Cab control connection - stopping indicator switch
1118 Trailer flashing turn signals indicator light
1119 Feed to electric or pneumatic horns switch
1120 Rear left-hand turn indicator
1121 Feed to winch switch warning light
1122 Feed to of rear window regulator inhibition switch LED
1123 Front right-hand turn indicator
1124 Side right-hand turn indicator - Not tested
1125 Rear right-hand turn indicator

COMPONENT
CODE DESCRIPTION
1126 Side left-hand indicator - Not tested
1127 Feed to trailer braking hand lever switch
1129 Front left-hand turn indicator
1131 Feed to front power steering failure buzzer
1133 Horn, electro-pneumatic road equipment: from switch to horn
1139 Feed to stop request gate control switch and Hostess call unit
1140 Radio set - amplifier connecting cable, right sound channel
1144 Buzzer indicating maximum r.p.m. of transmission shaft with ES
1145 Radio set - amplifier connecting cable, left sound channel
1146 Pick-up switching relay for emergency indicator lights
1147 Remote control switch for emergency lights
1150 IVECO CONTROL: Tail light - STOP - tail foglight (tractor left-hand)
1151 IVECO CONTROL: Front left-hand light - front right-hand clearance light (tractor)
1152 IVECO CONTROL: Tail light - STOP - tail foglight (tractor right-hand)
1153 IVECO CONTROL: Number plate lamp
1154 IVECO CONTROL: Front right-hand light - front left-hand clearance light (tractor)
1155 IVECO CONTROL: Tractor alarm
1156 IVECO CONTROL: Trailer alarm
1157 Fog lights optical indicator
1158 Converter exclusion optical indicator
1159 Engine fan exclusion buzzer supply
1163 Safety warning horn
1165 Stop light signal for bodybuilders
1166 Connection distance alarm buzzer with ACC (Adaptive Cruise Control)
1167 Feed from ABS infomodul (AK) position (with ABS infomodul for 12 V trailer socket)
1168 Feed to trailer 12 V stop light before diode (with ABS infomodul)
1169 Feed to trailer stop light before diode (with ABS infomodul for 12 V trailer socket)
1170 From flashing light to control unit (front and rear left-hand circuit)
1171 Cable for stop lights after dimmed lights switch (left-hand terminal 54) for Military Vehicles
1172 Rear right-hand stop indicator
1173 ABS-INFO-Modul stop lights/IVECO-Control stop lights
1174 Feed to 12 V trailer socket - stop light

COMPONENT
CODE DESCRIPTION
1175 Feed to stop warning lights
1176 Stop lights relay control
1177 Rear left-hand stop indicator
1178 From flashing light to control unit (front and rear right-hand circuits)
1179 Trailer stop lights
1180 Trailer rear left-hand turn indicator light
1181 Trailer turn indicator light warning light power or Feed to 12 V trailer socket - left turn signal light
1182 Feed to 12 V trailer socket - right turn signal light
1183 Right-hand channel loudspeaker ( )
1184 Right-hand channel loudspeaker (+)
1185 Trailer rear right-hand turn signal light
1186 Left-hand channel loudspeaker ( )
1187 Loudspeaker jumper, left sound channel
1188 Left-hand channel loudspeaker (+)
1189 Loudspeaker jumper, right sound channel
1190 “L” line - Body control diagnostics
1191 Diagnostic “L” line for ADM control unit (electronic differential lock)
1192 Engine cycle diagnostics
1193 Diagnostic “L” line for retarder suspension control unit
1194 Diagnostic “L” line for pneumatic suspension control unit
1195 Diagnostic “L” line for additional heater control unit
1196 Diagnostic “L” line for air-conditioning control unit
1197 Diagnostic “L” line for automatic gearbox
1198 Control unit “MS6” diagnostic “L” line
1199 Diagnostic “L” line for ABS/speed limiter control unit
1200 Diagnostic “L” line for methane control unit
1310 Glow plug relay diagnostic to EDC
1311 Glow plug check from EDC
1351 Front left-hand revolving light for Fire Fighting Vehicles
1352 Front right-hand revolving light for Fire Fighting Vehicles
1355 Deep tone horn for Fire Fighting Vehicles
1356 High tone horn for Fire Fighting Vehicles

COMPONENT
CODE DESCRIPTION
1358 Additional indicator light on left-hand rear side upperworks for Fire Fighting Vehicles
1359 Additional indicator light on right-hand rear side upperworks for Fire Fighting Vehicles
1361 Rear left-hand revolving light for Fire Fighting Vehicles
1362 Rear right-hand revolving light for Fire Fighting Vehicles
1600 Diagnosis line L bending ELF 1 & ELF 2 (18M)
1601 Actuator of frequency modulator control unit SESALY
1602 Feeding of frequency modulator SESALY to loudspeaker no. 1
1603 Feeding of frequency modulator SESALY to loudspeaker no. 2
1604 Feeding of stop lights from control unit MUX to stop lights and ABS
1605 Feeding of rear fog light LH from control unit MUX to rear fog lights G
1606 Feeding of tail lights LH + side lights rear LH or rear number plate illumination LH from control unit MUX
to lights
1607 Feeding of tail lights RH + side lights rear RH or rear number plate illumination RH from control unit MUX
to lights
1610 Direction indicator side lights rear RH from control unit MUX to lights
1611 Direction indicator side lights rear LH from control unit MUX to lights
1612 Direction indicator lights rear RH from control unit MUX to lights
1613 Direction indicator lights rear LH from control unit MUX to lights
1614 Feeding of reversing buzzer
1619 Feeding of control unit to buzzer for vehicle lifting
1620 Feeding buzzer for outer handrail buzzer from control unit MUX to buzzer
1621 Info assistance before diode
1622 Info assistance after diode
1623 Buzzer signal from differential lock switch
1624 Feed to rear window regulator switch on driver’s side
1625 Feed to rear window regulator switch on passenger’s side
1626 Feeding of stop lights (roof)
1630 POTR Microphone voice signal MIC +
1631 POTR Phone voice signal TEL OUT +
1632 POTR mute phone
1633 POTR MP3 audio signal - left
1634 POTR MP3 audio signal - right
1950 Can Bus “B” low serial line

COMPONENT
CODE DESCRIPTION
2200 Feed to right-hand and left-hand main beams (from switch to fuses)
2201 Feed to right-hand and left-hand low beams (from switch to fuses)
2202 “Rx” line for VDI (Vehicle Data Interface)
2203 Feed to winkling light (from switch to fuses)
2204 Winkling light control
2219 Feed to left-hand main beam
2220 Reversing switch (double)
2221 Feed to right-hand main beam
2222
2223 Feed to right-hand low beam
2224 Feed to loading surface lighting
2226 Feed to backing light
2227 Feed to backing light (control unit-light)
2228 Feed to foglights
2229 Feed to auxiliary long-distance lights
2231 Feed to left-hand low beam
2235 Feed to outside lights switch
2237 Feed to main beams and low beams: from outside lights switch to control unit
2239 Feed to main beams and low beams: from control unit to headlamps switch
2242 Feed to Rh low beam/Lh main beam from U.C.I. to Body Control
2243 Feed to Lh low beam/Rh main beam from U.C.I. to Body Control
2246 Feed to black-out headlamps
2257 Diagnostic “K” line for SCR control unit (Selective Catalytic Reduction)
2262 Diagnostic “K” line for VDI control unit (Vehicle Data Interface)
2267 Feed to 12 V trailer plug - Backup light
2268 Feed to switch for backing light
2269 Feed to auxiliary long-distance lights switch
2270 Trailer rear fog light
2278 Feed to 12 V trailer plug - Rear fog light
2279 Remote control switch for rear fog light self-retaining device
2280 Remote control switch for tail foglight
2281 Feed before fuse to tail foglight

COMPONENT
CODE DESCRIPTION
2282 Feed to rear fog light system after fuse
2283 Feed to tail foglight (general or after fuse)
2284 Feed to tail foglight with foglights connected
2285 Main beams indicator light
2286 Feed to tractor tail foglight, after IVECO control
2287 Indicator light for tail foglight
2288 Indicator light for tail foglight (only for connections downstream from diode, if any)
2289 Remote control switch for foglights
2291 Diagnostic “K” line for ADM control unit (electronic differential lock)
2292 Diagnostic “K” line for immobilizer control unit or VCM (Vehicle Control Modul)
2293 Diagnostic “K” line for retarder suspension control unit
2294 Diagnostic “K” line for pneumatic suspension control unit
2295 Diagnostic “K” line for additional heater control unit
2296 Diagnostic “K” line for air-conditioning control unit
2297 Diagnostic “K” line for automatic gearbox
2298 Control unit “MS6” diagnostic “K” line
2299 Diagnostic “K” line for ABS/speed limiter control unit
2300 “K” line vehicle on-computer computer
2301 “K” line computerized instrument panel
2302 “K” line tachograph
2303 Diagnostic “K” line - Body Control
2304 Diagnostic “K” line for methane control unit
2351 Work headlamp after fuse for Fire Fighting Vehicles
2500 Diagnosis Line K ECM or accelerator CNG
2501 Diagnosis Line K DCU
2502 Diagnosis Line K CAMU
2503 Diagnosis Line K VCM
2504 Diagnosis Line K GMU Time Keeper optical guide
2505 Feeding of side light LH from control unit MUX to lights
2506 Feeding of side light RH from control unit MUX to lights
2507 Feeding of hazard warning lights before diode
2508 Diagnosis Line K control unit articulation

COMPONENT
CODE DESCRIPTION
2509 Feeding of front fog light from control unit MUX to lights
2510 Feeding of flashing light front RH from control unit MUX to lights
2511 Feeding of dimmed headlight front LH from control unit MUX to lights
2512 Diagnosis Line K dashboard
2950 LOW CAN BUS “C” line signal
2951 CAN BUS L serial line for engine
2990 Diagnostic “K” line for passenger door centralized locking control unit with Mux
2991 Diagnostic “K” line for driver door centralized locking control unit with Mux
2992 Diagnostic “K” line for bed module control unit with Mux
2993 Diagnostic “K” line for cab module control unit with Mux
2994 Diagnostic “K” line for “Instrument Cluster” control unit with Mux
2995 Diagnostic “K” line for “Body Computer” control unit with Mux
2996 Diagnostic “K” line for DMI (Data Management Interface) control unit or EM (Expansions Modul)
2997 Diagnostic “K” line for tachograph (MTCO)
2998 Diagnostic “K” line for front frame computer (FC) with Mux
2999 Diagnostic “K” line for rear frame computer (FC) with Mux
3300 Left-hand general feed to IVECO control control-unit lights after fuse
3301 Right-hand general feed to IVECO control control-unit lights after fuse
3302 Pick-up relay for parking lights, tail foglights. Front foglights turning on
3304 Feed to parking and left-hand front clearance lights after IVECO control unit
3305 Feed to left-hand rear parking light after IVECO control unit
3306 Feed to left-hand trailer parking light after IVECO control unit
3307 Feed to number-plate light after IVECO control unit
3308 Feed to left-hand and right-hand rear clearance lights after IVECO control unit
3314 Feed to parking and right-hand front clearance lights after IVECO control unit
3315 Feed to right-hand rear parking light after IVECO control unit
3316 Feed to right-hand trailer parking light after IVECO control unit
3320 Feed to right front sidelight
3321 Feed to left front sidelight
3322 Feed to right rear sidelight
3323 Feed to left rear sidelight
3324 Feed to left front S.M.L. light

COMPONENT
CODE DESCRIPTION
3325 Feed to right front S.M.L. light
3326 Feed to left side S.M.L. light
3327 Feed to right side S.M.L. light
3328 Feed to left rear S.M.L. light
3329 Feed to right rear S.M.L. light
3330 Right-hand front and left-hand rear parking lights. Right-hand trailer light. Left-hand front clearance light
(Germany and Italy). Right-hand clearance light (France and Sweden). Right-hand number-plate light
3331 UNIC design: Right-hand clearance light. Left-hand side gabarit light (France). Right-hand rear gabarit light
(tractors for France). Right-hand rear parking and clearance light. Right-hand number-plate light (trailer)
3332 UNIC design: Left-hand clearance light. Right-hand gabarit light (France). Left-hand rear gabarit light
(tractors for France). Left-hand rear parking and clearance light. Right-hand number plate light (trailer)
3333 Running lights (normal circuits)
3334 Left-hand rear and right-hand front parking lights. Right-hand number-plate light. Right-hand clearance light
(*)
3335 Right-hand rear and left-hand front parking lights. Left-hand number-plate light. Left-hand clearance light.
Electrically insulated trailer lights (socket 4 on additional trailer connection) (*)
3337 Number-plate light
3338 Left-hand front and right-hand rear parking lights. Left-hand trailer light. Right-hand front clearance light
(Germany and Italy). Left-hand clearance light (France and Sweden). Left-hand number-plate light
3339 Left-hand front and right-hand rear parking lights. Left-hand trailer light. Right-hand front clearance light
(Germany and Italy). Left-hand clearance light (France and Sweden). Left-hand number-plate light
3347 Dimmed rear parking light
3348 Dimmed stop lights
3349 Dimmed additional rear lights (for NATO vehicles)
3350 Feed to fuse holder terminals 58 from relay for Fire Fighting Vehicles
3354 Pick-up relay terminals 58 for Fire Fighting Vehicles
3375 Light cable terminal 58 for bodybuilders on frame
3377 Trunk or luggage-rack lighting (special use)
3380 General feed to parking lights (control-unit switch)
3381 12 V trailer socket power - RH parking light
3382 12 V trailer socket power - LH parking light
3383 Feed to parking lights from U.C.I. to Body Control
3384 Connected external light signalling before relay
3385 Connected external light signalling before bell powering relay
3390 General feed to parking and clearance lights
3391 UNIC design: Normal feed to parking lights (*)

COMPONENT
CODE DESCRIPTION
3393 EOL data entering line for intarder control unit
3397 EOL data entering line for automatic gearbox control unit
(*) For vehicles carrying dangerous goods
4101 Feed to display lighting for semiautomatic gearbox
4110 Feed to left sliding side door light
4111 Feed to central ceiling light
4112 Feed to right sliding side door light
4113 Feed to rear door light
4155 Feed to fluorescent lamp for internal lighting

COMPONENT
CODE DESCRIPTION
4400 Feed No. 1 interior light switch (buses)
4401 Feed No. 2 interior light switch (buses)
4402 No. 1 switch: first row of lamps (buses)
4403 No. 1 switch: second row of lamps (buses)
4405 No. 2 switch: first row of lamps (buses)
4406 No. 2 switch: second row of lamps (buses)
4407 Engine compartment lighting
4408 Front running-boards lighting
4409 Rear running-boards lighting
4410 Feed to 12 V spot lights
4411 “All-lights on” indicator
4412 12 V courtesy light after fuse
4413 Main door running-boards lighting
4418 Trucks: roof lamp with separate switch No. 2
4420 Feed to ashtray light
4421 Feed to blued lights and driver’s seat light
4422 Feed to blued lights courtesy lights
4423 Feed to driver’s seat light
4440 Feed to courtesy light
4441 Trucks: roof lamp with separate switch No. 1
4442 Feed to dashboard
4443 Feed to light for cigarette lighter
4444 Lighting instrument panel after rheostat (or switch)
4445 Feed to running-board lights
4447 Under bonnet lighting
4448 Tool compartment lighting
4449 Trunk or luggage-rack lighting
4542 Feed to instrument cluster after remote switch
4801 Feeding of tell-tales illumination after control unit MUX
4803 Feeding + battery of speedometer after protection
4810 Tell-tale electrical accelerator

COMPONENT
CODE DESCRIPTION
4811 Feeding of optical guide lights after relay contact
4812 Feeding of working lights relay after GMU Time Keeper
4813 Warning signals on dashboard VDO
4814 Feeding of tell-tale failure of optical guide - red
4815 Feeding of tell-tale enabled optical guide /active - green
4816 Feeding of tell-tale optical guide standby/ awaiting - orange
4824 Illumination of range
4825 Illumination of range
4826 Illumination of route indicators
4827 Actuator illumination route indicators
4828 Push button selection number of line (route indicator)
4829 Push button selection number of line (route indicator)
4830 Common push button selection number of line (route indicator)
4831 Push button selection destination (route indicator)
4941 Roof lamp with separate switch - mux
4950 Can Bus “B” high serial line
5102 Speed sensor signal (Input) on semiautomatic gearbox Or Vehicle speed signal cable “input” to engine
ECU
5103 Speed sensor signal (Output) for semiautomatic gearbox or Vehicle speed signal cable “return” to engine
ECU
5104 Feed to speed sensor (Output) for semiautomatic gearbox
5106 Feed to sensor for accelerator pedal position for semiautomatic gearbox
5107 Signal for sensor for accelerator pedal position for semiautomatic gearbox
5109 Signal for accelerator pedal minimum switch for semiautomatic gearbox
5110 Feed to pedal accelerator minimum switch for semiautomatic gearbox
5111 Feed to “Kick Down” switch for semiautomatic gearbox
5112 Signal for “Kick Down” switch for semiautomatic gearbox
5113 Signal from speed sensor amplifier for semiautomatic gearbox
5115 Semiautomatic gearbox “gears in” speed unit sensor signal
5116 Semiautomatic gearbox “gears in” sensor signal
5118 TRISTATE signal for automatic gearbox
5120 5V power for pressure transducer (methane system)
5121 Signal from pressure transducer (methane system)

COMPONENT
CODE DESCRIPTION
5122 +15 power for fuel level adjusting device (methane system)
5150 Contact “W” alternator for EDC
5151 Air temperature sensor for EDC
5152 Booster pressure sensor signal for EDC
5153 Booster pressure sensor feed for EDC
5154 Water temperature sensor for EDC
5155 Speed impulse for EDC (B7 tachograph)
5156 Positive key-controlled powering for tachograph
5157 Accelerator pedal sensor signal for EDC
5158 Feed to accelerator sensor signal for EDC
5159 Speed signal to navigator
5160 Control unit programming enable for EDC
5161 Accelerator pedal position control for EDC
5162 “Data Link” cable for engine electronic control unit (+)
5163 EDC diagnostic system connecting switch power
5164 Speed signal to rear differential locking
5166 Signal from temperature sensor for engine fan connection
5167 Signal from switch for engine fan exclusion to EDC
5173 Combustion air relative humidity sensor cable with EDC
5174 Combustion air temperature sensor cable with EDC
5180 Engine failure warning light power for engine control system
5181 Engine stop warning light power for engine control system or Adjusting device indication cable for required
value on engine for natural gas engine
5182 Low voltage lambda probe power for natural gas engine
5183 High voltage lambda probe power for natural gas engine
5184 Low exhaust brake signal for engine control system or Sensor cable for output shaft rev (12V) for natural
gas engine
5185 Average exhaust brake signal for engine control system or “REF Low” data transmission cable for ignition
system for natural gas engine
5186 Max cooling water level signal to engine control unit or “REF High” data transmission cable for ignition
system for natural gas engine
5187 Engine fan on signal for engine control system or “EST” data transmission cable for ignition system for
natural gas engine
5188 “BYP” data transmission cable for ignition system for natural gas engine
5189 Supercharging air temperature indication cable for natural gas engine
COMPONENT
CODE DESCRIPTION
5195 Natural gas reserve pressure sender indication cable for natural gas engine
5197 Pin A gas regulator indication cable for natural gas engine
5198 Synchronous engine rpm indication cable from EDC electronic control unit or Throttle valve position
indication cable for natural gas engine
5199 Supercharging pressure sensor cable for natural gas engine
5309 Feed to temperature sensor for hydraulic eddy-current brake
5410 ECAS front axle chassis level adjustment sensor signal
5421 ECAS rear axle right-hand chassis level adjustment sensor signal
5422 ECAS rear axle left-hand chassis level adjustment sensor signal
5440 Cable for air pressure sensor signal on front axle for measuring axle load with ECAS
5441 Right-hand pressure sensor signal on ECAS lifting axle
5442 Left-hand pressure sensor signal on ECAS lifting axle
5443 Right-hand pressure sensor signal on axle for ECAS
5444 Left-hand pressure sensor signal on axle for ECAS
5445 Air pressure sensor signal on pneumatic lifting device for third axle with ECAS
5500 Potentiometer on injection pump for “EGR”
5501 Warning light for engine cylinder block high temperature
5503 Warning light for minimum oil pressure
5504 Warning light for maximum oil temperature
5505 Engine oil level sensor
5506 Engine oil level sensor
5507 Oil pressure transmitter
5508 Transmitter positive feed engine oil pressure
5510 Speedometer signal from adapter to repeater
5511 Electronic speedometer transmitter - feed
5512 Electronic rev. counter transmitter - feed
5513 Electronic speedometer transmitter - signal or speedometer signal feed
5514 Electronic tachograph transmitter - feed
5515 Electronic tachograph stop signal
5516 Electronic tachograph transmitter (reversing signal)
5517 Electronic tachograph transmitter - speed indicator
5518 Electronic tachograph transmitter - distance covered indicator
5519 Rev. counter transmitter (signal) and speedometer switch signal for mechanical rev. counter
COMPONENT
CODE DESCRIPTION
5520 Warning light for cooling water minimum level
5521 Warning light for windshield wiper tank water minimum level
5522 Engine temperature indication cable after flame start system control unit
5523 Transmitter for engine cylinder block high temperature thermometer
5524 Resistor powering with engine temperature transmitter disconnection
5525 Warning light for insufficient liquid in hydraulic steering
5527 Minimum level transmitter for cooling water
5528 Warning light for maximum water temperature
5530 Indicator light for water in pre-filter
5531 Feet to clogged fuel filter warning light
5532 External temperature sensor
5535 Warning light for EDC system failure (from V4 node)
5540 Speed impulse coming from tachograph
5541 Speed impulse coming from signal repeater
5542 Programmable speed threshold indicator signal (PTS)
5543 Signal for space covered by signal repeater
5545 Speed impulse from signal repeater to diagnostic tap
5550 Oil temperature transmitter
5551 Excess engine speed indicator (visual or sound signal)
5552 Water temperature transmitter
5553 Pre-heating completed indicator light
5555 Minimum fuel level indicator light
5556 Warning light for engine oil low level
5557 Fuel level indicator (unipolar)
5558 Signal from control unit to engine oil level indicator
5559 Oil change temperature transmitter
5560 Feed to brake system air pressure transmitter
5561 Air pressure transmitter (rear brakes)
5562 Air pressure transmitter (front brakes)
5568 Air pressure transmitter (emergency brake)
5570 Front left-hand wheel sensor (A.B.S. equipment)
5571 Front right-hand wheel sensor (A.B.S. equipment)

COMPONENT
CODE DESCRIPTION
5572 Rear left-hand wheel sensor (A.B.S. equipment)
5573 Rear right-hand wheel sensor (A.B.S. equipment)
5574 Wheel sensor for second front LH axle
5575 Wheel sensor for second front RH axle
5577 Pre-heating/after-heating control sensor
5578 Own safety circuit cable Ex (i) with TMP vehicle for elect. tachograph (+23 V) time remote switch (76
h)
5579 Own safety circuit cable Ex (i) with TMP vehicle for elect. tachograph (+23 V)
5580 Absolute pressure sensor for “ERG” (barometric)
5581 Feed from “ERG” control unit
5583 “ERG” control unit failure warning light
5584 Signal sensor cable 1 for engine rpm diagnostics (n=1/1) and electronic rpm sensor
5585 Signal sensor cable 2 for engine rpm diagnostics (n=1/1)
5586 Signal sensor cable for engine rpm diagnostics (n=1/2, on injection pump)
5587 Engine speed signal for body builder connector
5588 Voltage adjusted to engine oil level indicator
5590 Feed to fuel pressure sensor for EDC
5591 Signal for fuel pressure sensor for EDC
5592 Fuel temperature signal for EDC
5595 “ERG” diagnostic control unit
5598 Sensor for centralized lubrication check
5600 Sensor signal for fluid low pressure in automatic clutch accumulator
5601 Sensor signal for fluid low pressure in automatic clutch accumulator
5602 Signal from automatic clutch position sensor
5603 Signal from gearbox position sensor for automatic clutch (forward position)
5604 Signal from gearbox position sensor for automatic clutch (back position)
5605 Signal from gearbox position sensor for automatic clutch (common)
5606 Signal from accelerator pedal sensor for automatic clutch
5607 Signal from gearbox lever position sensor for automatic clutch (position X)
5608 Signal from gearbox lever position sensor for automatic clutch (position Y)
5609 Signal from cowl position sensor for automatic clutch (position NA)
5610 Signal from cowl position sensor for automatic clutch (common)
5611 Signal from cowl position sensor for automatic clutch (position NC)
COMPONENT
CODE DESCRIPTION
5612 Cruise Control signal from automatic clutch control unit
5613 Signal from EDC accelerator pedal for automatic clutch control unit
5614 Engine r.p.m. signal from EDC for automatic clutch control unit
5615 Signal from engine r.p.m. sensor for automatic clutch control unit
5617 Engine r.p.m. signal for diagnostic tap t.d.s.a.
5618 Engine idling increase request, 1st threshold
5619 Engine idling increase request, 2nd threshold
5620 Automatic gearbox 2nd range position program enabling
5621 Signal open hood for theft prevention device
5622 Signal hand brake securely applied
5630 Sensor airbag driver
5632 Sensor airbag passenger
5634 Sensor pretensioning device driver
5636 Sensor pretensioning device passenger
5638 Sensor pretensioning device central
5640 Sensor impact lateral right
5642 Sensor impact device left
5644 Selector inibition airbag passenger
5646 Airbag on front right door
5647 Seat belt fastened indication
5648 Airbag on front left door
5800 Sender max. level for water cooling
5801 Info sender air pressure front brakes tank (APU) from control unit MUX to desiccator
5802 Info fuel level
5804 Info speed speedometer to dashboard
5805 Info speed speedometer to optical guide
5806 Info speed speedometer control unit CAMU
5807 Info speed null on dashboard
5809 Info speed speedometer for optional version no. 1

COMPONENT
CODE DESCRIPTION
5816 Info vehicle gear not engaged from gearbox to control unit MUX and before resistance
5817 Info sensor oil injection from MUX to sensor oil tank full
5819 Feeding ABS sensor rear RH from MUX to sensor
5820 Feeding ABS sensor front RH from MUX to sensor no. 1
5821 Feeding ABS sensor front RH from MUX to sensor no. 2
5822 Feeding ABS sensor rear LH from MUX to sensor
5823 Feeding ABS sensor front LH from MUX to sensor
5825 Info limit 2 sensitive edge bending before sensor no. 1
5831 Info front LH bending from ELF to sensor
5832 Rear axle of ECAS frame level correction RH sensor No. 2 warning
5833 Rear axle of ECAS frame level correction LH sensor No. 2 warning
5834 Info sensitive board handrail from control unit CAMU to sensor
5835 Info sensitive carpet handrail from control unit CAMU to sensor
5836 Info gearbox forcing at dead centre to MUX
5838 Sensor ABS central LH
5839 Sensor ABS central RH
5842 Signal temperature sensor engine compartment sensor to control unit MUX
5843 Info STOP rear engine control units MUX before diode
5844 Control of heater defrosting block from MUX to defrosting block
5845 Info ECM STOP rear engine before diode
5846 Info end stop engine tailgate from control unit MUX before diode
5875 Feeding of relay preheating resistance
5876 Feeding preheating resistance after relay contact
5981 Input signal cable for Expansion Modul (AN IN 1)
5991 Input pulse cable for Expansion Modul (FREQ IN 1)

COMPONENT
CODE DESCRIPTION
5992 Input pulse cable for Expansion Modul (FREQ IN 2)
6000 Electronic accelerator alarm warning light
6001 Chassis lowering indicator light
6002 Lamp test
6003 Warning light, upstream from diode for (main) door II open
6004 Power for front and rear brake pad wear sensors
6005 Indicator light for A.B.S. connection
6007 Indicator light for “not running” levelling adjustment
6008 Warning light for failure in pneumatic suspension
6009 ETC warning light
6011 Warning light for low pressure in rear axle pneumatic suspension
6012 Warning light upstream from diode for wear on front brake shoe
6013 Warning light upstream from diode for wear on rear brake shoe
6014 Flashing indicator light for stop request
6015 Visual indicator for revolving light “I”
6018 Brake 1 valve transmitter signal for EBS
6019 Brake 2 valve transmitter signal for EBS
6020 Feed to led for front and rear brake wear with EBS
6021 Feed to 15 pole, pin 10 plug
6022 Warning light for front brake wear (control unit-warning light)
6023 Warning light for rear brake wear (control unit-warning light)
6024 Feed to RH front brake wear sensor
6025 RH front brake wear sensor signal
6026 Feed to LH front brake wear sensor
6027 LH front brake wear sensor signal
6028 Feed to brake 1 valve transmitter for EBS
6029 Feed to brake 2 valve transmitter for EBS
6030 Rear brake sensor cable
6034 Feed to lifting axle RH rear brake wear sensor
6035 Lifting axle RH rear brake wear sensor signal
6036 Feed to lifting axle LH rear brake wear sensor
6037 Lifting axle LH rear brake wear sensor signal

COMPONENT
CODE DESCRIPTION
6039 Warning light for heated fuel line (Thermoline)
6041 Warning light for heated fuel line (Thermoline) II
6046 Feed to air pressure sensor in EBS trailer proportional solenoid valve
6047 Air pressure sensor signal in EBS trailer proportional solenoid valve
6050 Brake wear, rear axle, right (power)
6051 Brake wear, rear axle, right (control)
6052 Brake wear, rear axle, left (power)
6053 Brake wear, rear axle, left (control)
6068 Warning light for front axle differential locking off
6069 Warning light for longitudinal differential locking off
6092 Feed to immobilizer warning light
6100 Feed to display for semiautomatic gearbox
6101 “Date” line for display for semiautomatic gearbox
6102 “Clock” line for display for semiautomatic gearbox
6103 Warning light for air low pressure for semiautomatic gearbox
6104 “TX” diagnosis line for semiautomatic gearbox
6105 “RX” diagnosis line for semiautomatic gearbox
6106 ”Data” line for diagnosis for semiautomatic gearbox
6107 Feed to diagnosis for semiautomatic gearbox
6108 ISO-CAN H connection for semiautomatic gearbox control unit
6109 ISO-CAN L connection for semiautomatic gearbox control unit
6112 Feed to automatic gearbox warning light
6118 LIMP HOME signal for semiautomatic gearbox control unit
6127 Retarder on signal
6128 Power to warning light for automatic transmission mode operatiom
6131 Return signal cable for PTO 1 on (rear with semiautomatic gearbox)
6132 Return signal cable for PTO 2 on (side with semiautomatic gearbox)
6133 Return signal cable for PTO 3 on
6134 Return signal cable for PTO 4 on for stop brake or clutch engaged
6150 Feed to EDC system failure warning light
6164 Retarder disconnection indication cable with automatic gearbox
6171 Feed to Eco-power on warning light

COMPONENT
CODE DESCRIPTION
6176 Connection tell-tale ACC (Adaptive Cruise Control) “on”.
6177 Cable small distance control ACC (Adaptive Cruise Control)
6178 Cable return from distance selector with ACC (Adaptive Cruise Control)
6179 Connection tell-tale distance regulation ACC (Adaptive Cruise Control) reached
6180 Deltec function warning light power for natural gas engine
6190 Failure warning light power for natural gas engine
6245 Safety sensor signal for max. rear axle braking with front axle failure with ABS
6301 Hydraulic eddy-current brake warning light connected
6320 Feed to indicator light for ADM system failure (electronic differential lock)
6321 Correctly connected distributor diagnostic with ADM system (electronic differential lock)
6322 ADM system (electronic differential lock) steering angle sensor signal
6323 Feed to indicator light for “gear reduction” transfer box
6326 Left wheel revolution number sensor for rear axle
6327 Right wheel revolution number sensor for rear axle
6350 Warning light for tool compartment open flaps for Fire Fighting Vehicles
6351 Indicator light for front left-hand revolving light control for Fire Fighting Vehicles
6352 Indicator light for front right-hand revolving light control for Fire Fighting Vehicles
6353 Indicator light preset for Fire Fighting Vehicles
6354 Indicator light preset for Fire Fighting Vehicles
6355 Warning light for connected power take-off for Fire Fighting Vehicles
6356 Indicator light for operation flood light telescopic support when extended or for protruding stabilizer screw
down jacks for Fire Fighting vehicles
6357 Warning light for connected water pump for Fire Fighting Vehicles
6358 Warning light for connected 220 V alternator for Fire Fighting Vehicles
6359 Warning light for connected winch for Fire Fighting Vehicles
6361 Indicator light for rear left-hand revolving light control for Fire Fighting Vehicles
6362 Indicator light for rear right-hand light control for Fire Fighting Vehicles
6401 Indicator light for insufficient air pressure for pneumatic suspension system
6402 CLOCK line on ECAS suspension control push-botton panel
6403 DATA line on ECAS suspension control push-botton panel
6410 Brake pedal to ECU (power)
6440 Warning light for lifted axle
6442 Feed to trailer lift axle warning light

COMPONENT
CODE DESCRIPTION
6460 Warning light for help at pickup “on”
6490 Warning light for running third steering axle
6491 Feed to warning light for low pressure in third steering axle hydraulic circuit
6499 Warning light for locked third steering axle system
6500 Feed to warning light for failure in additional heater
6540 Feed to SCR (Selective Catalytic Reduction) system diagnostic warning light
6541 Indication cable to output catalyst temperature sensor with SCR (Selective Catalytic Reduction)
6542 Indication cable to urea tank temperature sensor with SCR (Selective Catalytic Reduction)
6543 Indication cable to uera tank level sensor with SCR (Selective Catalytic Reduction)
6544 Indication cable to intput catalyst temperature sensor with SCR (Selective Catalytic Reduction)
6545 Cable signal to temperature sensor on solenoid valve of metering module with SCR (Selective Catalytic
Reduction)
6546 Red CRT (Continuous Regeneration Trap) maintenance warning pilot light
6547 Yellow CRT (Continuous Regeneration Trap) maintenance warning pilot light
6548 Green CRT (Continuous Regeneration Trap) maintenance warning pilot light
6550 SCR pressure sensor signal
6600 Front door open warning light
6601 Indicator light for meshing drive insertion on gearbox
6602 Indicator light for integral drive connection
6603 Indicator light for differential locking on distributor
6604 TELMA retarder indicator light
6605 Feed to indicator light for connected additional heater
6606 Led for locked external emergency handle indication
6607 Body tipping indicator light
6608 Visual indicator for revolving light “II”
6609 Front door I open indicator light upstream from diode
6610 Led for open hatch indication
6611 Clutch wear indicator light
6612 Connection between remote control switches for connect. and disconnect. of stop request indicator
6613 Indicator light for brake system failure - generic
6614 Oil-water-air repeater indicator light
6615 Refrigerator on indicator light
6616 Indicator light for heated windscreen

COMPONENT
CODE DESCRIPTION
6617 KHD engine heating connected indicator light
6618 Indicator light for oil filter blockage in hydraulic circuit for engine compartment ventilation
6619 Heated glass warning light in front light unit
6620 Transverse differential locking control unit (terminal 4)
6621 Transverse differential locking control unit (terminal 2)
6622 Indicator light for forced ventilation
6623 Warning light for pre-wear on brake seals
6624 Warning light for rear door open
6627 Engine brake indicator light on
6628 Warning light for automatic snow chains connection
6629 Stop request indicator
6630 Optical indicator for open electric hatch indication
6631 Warning light for circuit “I” and/or “II” front axle power steering failure
6632 Warning light for circuit “I” front axle power steering failure
6633 Interior heating indicator light
6634 Indicator light for interior ventilation motors
6635 Indicator light for engine compartment ventilation failure
6636 Warning light for fuel heating on
6637 Alternator charge indicator light (upstream from diode)
6638 Load compartment door condition indicator light
6640 Warning light for automatic clutch system failure
6641 Body Control failure warning light
6642 Brake failure signal to ABS control unit
6643 Control cable for inserted front axle longitudinal differential lock
6644 Indicator light for auxiliary alternator charge
6645 Reading light indicator
6647 Feed to “main door open” warning light
6651 Warning light for rear axle brake-fluid minimum level
6652 Indicator light for heated rear-view mirror
6653 Optical indicator heated rear window “ON”
6655 Indicator light for additional heater
6656 Hand brake signal for bodybuilders

COMPONENT
CODE DESCRIPTION
6657 Indicator light for FREON compressor connection
6658 Stop brake indicator light
6659 Indicator light for (front) transverse differential locking
6660 Indicator light for transverse differential locking
6661 Warning light for brake fluid minimum level
6662 hand-brake indicator light
6663 Warning light for air-filter blockage
6664 Warning light for wear on axle brake seals
6665 Warning light for low pressure in axle pneumatic suspension
6666 Cab release signal indicator light
6667 Warning light for wear on rear axle brake seals or on seals generally
6668 Indicator light for hooking of coupling joints
6669 Engine buzzer alarm device
6670 Engine A.B.S./C.E.F. failure warning light
6671 Trailer A.B.S. failure warning light
6672 A.S.R. failure warning light or speed limiter
6673 Indicator light for front manhole cover open or EBS warning light power
6674 Indicator light for rear manhole cover open
6675 Warning light for trailer A.B.S. disconnection
6676 Repeater indicator light for door open
6677 ICP (hydraulic brake failure) warning light
6678 OBD (On Board Diagnose) warning light power
6679 FREON compressor disconnection indicator light
6680 Warning light for minimum air pressure in rear brakes
6681 Stop request indicator light upstream from diode
6682 Warning light for minimum air pressure in parking brakes
6683 Pneumatic suspension minimum air pressure warning light
6684 Warning light for minimum air pressure in front brakes
6685 Warning light for distributor in neutral
6686 Warning light for non-lowered rail for TMP tank truck
6687 Chassis lifting indicator light
6688 Feed to “gear reduction on” indicator light

COMPONENT
CODE DESCRIPTION
6689 Warning light for minimum air pressure in trailer brakes
6691 First rear axle temperature indication cable
6692 Second rear axle temperature indication cable
6693 Warning light for low pressure in oil converter
6694 Indicator light for vehicle front part lifting
6695 Indicator light for vehicle rear part lifting
6696 Feed to air pressure sensor in EBS front axle proportional solenoid valve
6697 Air pressure sensor signal in EBS front axle proportional solenoid valve
6698 Warning light for failure in centralized lubrication
6699 Feed warning light for excess gearbox oil temperature
6722 Feed to airbag warning light
6799 Interconnection between two sensors pad wear central brakes
6800 Emergency actuator from control unit CAMU to emergency push button
6802 Info multiplex maintenance from control unit MUX to key switch (IT) - Info diagnosis (wake-up input) from
control unit MUX to interdiagnosis
6804 Info alternator 2 under charge form control unit MUX to alternator charge resistance
6805 Info alternator 1 under charge form control unit MUX to alternator charge resistance
6806 Info wake-up dashboard VDO from control unit MUX to sensor
6807 Info end stop side tailgate from control unit MUX to sensor
6808 Info end stop engine tailgate after diode to sensor
6809 Interconnection between two sensors pad wear rear brakes
6810 Info failure air pressure charging cylinder from control unit MUX to pressure switch low/ high pressure
6811 Info sensor air filter clogging from control unit MUX to sensor
6812 Info water level probe from control unit MUX to central display oil level
6813 Info pressure gauge main brake from control unit MUX to pressure gauge
6814 Info pressure gauge parking brake jammed from control unit MUX before diode
6815 Info pressure gauge low pressure for accessories from control unit MUX to pressure gauge
6816 Info pressure gauge low pressure for parking brake from control unit MUX to pressure gauge
6817 Info sender air pressure rear brakes tank (APU) from control unit MUX to sensor
6819 Info pressure small tank power-assisted steering from control unit MUX to sensor
6820 Signal from speed sensor to speedometer
6821 Illumination of time tachograph on mobile dashboard
6822 Info programmer electronic timer to control unit thermo 300

COMPONENT
CODE DESCRIPTION
6823 Interconnection between sensors air conditioning HP/BP
6824 Info compressor clutch air conditioner from compressor to pressure sensor and body
6825 Info failure ZF gearbox control unit from control unit MUX to feeding relay retarder off
6826 Info pedal brake contact after diode and before relay contact
6827 Contact under brake pedal (NO) before diode
6828 Contact under brake pedal (NC)
6829 Feeding after relay contact to pedal brake contact
6830 Info contact under brake pedal (NO) after diode to engine control unit
6832 Info particulate filter pressure to ECM
6833 Info ECM engine rpm
6834 Info sensor particulate filter temperature to ECM
6835 Info ambient air temperature
6836 Info sensor ambient air humidity to ECM
6837 Request of diagnosis tractor from control unit MUX to gas engine control unit
6840 Info vehicle bend from control unit MUX to diode
6841 Info vehicle bend after diode to bending control unit no. 1
6842 Info bending failure from bending control unit to control unit MUX no. 1
6843 Info braking for ELF 1 from control unit MUX to bending control unit
6844 Info bending failure from bending control unit to control unit MUX no. 2
6846 Info sensor retracted handrail to control unit MUX
6847 Info sensor extended handrail to control unit MUX
6848 Info after diode for sensor holding brake
6849 Info pressure switch holding brake control unit MUX before diode
6850 Info pressure switch stop brake after diode
6852 Info sensor urea tank level to control unit DCU
6853 Info low engine oil level from control unit MUX to oil level display unit
6856 Info engine start from gas engine control unit before switch to inhibit engine start
6857 Info sender air pressure service brake tank from control unit MUX to sensor no. 1
6860 Info speed selector to dead centre for starting VCM
6861 Info speed selector to dead centre for starting before relay (case ZF)
COMPONENT
CODE DESCRIPTION
6862 Request of engine starting from control unit CAMU to VCM
6863 Info end stop engine door after diode towards switch to inhibit engine start (rear)
6864 Check of extinguisher engine compartment (+)
6865 Check of extinguisher engine compartment (-)
6866 Feeding temperature sensor extinguisher engine compartment
6867 Earth temperature sensor extinguisher engine compartment
6868 Info end stop engine tailgate switch to inhibit starting (rear) to VCM
6869 Info pressure gauge parking brake jammed from control unit MUX after diode to pressure gauge
6870 Info pressure gauge parking brake jammed from control unit MUX to VCM
6871 Info gear engaged from control unit MUX to gearbox control unit
6872 Info pressure sensor from pressure reducing valve to gas engine control uni
6873 Info speed displayed from MUX control unit to methane engine control unit
6874 Output idle speed methane engine control unit to relay contact
6875 Info engine failure control unit MUX to methane engine control unit
6934 VIDAC2(22) output OUTD14
6935 VIDAC2(73) input IND3
6938 VIDAC(16) input IND13
6939 VIDAC2(81) VS4
6940 VIDAC2(98) IREF1
6941 VIDAC2(92) FREQ0+ (+Input frequency) Speed Signal from Tachograph
6981 Output control cable for Expansion Modul (LS OUT 1) for parking brake
6983 Output control cable for Expansion Modul (LS OUT 3) for active neutral gearbox
6985 Output control cable for Expansion Modul (HS OUT 5)
COMPONENT
CODE DESCRIPTION
6995 Check of 2OFF ROAD MODE” switching on (increase of the number of revolutions in function)
7000 Pick-up relay for (front and rear) interior heating motors half-speed
7001 Pick-up relay for (front and rear) interior heating motors full-speed
7002 Feed to (front and rear) interior heating motors half-speed downstream from relay
7003 Feed to (front and rear) interior heating motors full-speed downstream from relay
7004 Feed to partially open function additional heater
7005 Feed to totally open function additional heater
7006 +24V supply cut for blackout function
7009 Feed to relay for indicator light for battery charge
7010 Feed to trap door opening control
7011 Feed to trap door closing control
7015 Feed to outswinging door
7017 Feed through switch for line end EDC programming control
7029 Feed to hydraulic cab releasing system
7035 Diesel fuel heating system supply
7036 Diesel fuel heating resistor supply
7038 Heated fuel line (Thermoline) supply after fuse
7039 Heated fuel line (Thermoline) supply
7040 Heated fuel line (Thermoline) II supply after fuse
7041 Heated fuel line (Thermoline) II supply
7042 Feed to voltage reducer, radio set and amplifier after fuse
7043 Feed to air drier system heated after fuse
7050 Gear in neutral signalling switch
7060 Feed to front/rear internal heating motor half speed from relay
7061 Feed to front/rear internal heating motor max. speed from relay
7062 Feed to internal heating motor 5 max. speed from relay
7063 Feed to internal heating motor 6 max. speed from relay
7070 Ex (i) own safety circuit cable with TMP vehicle for disconnecting the general emergency remote control
switch
7071 Ex (i) own safety circuit cable with TMP vehicle for connecting the general remote control switch
COMPONENT
CODE DESCRIPTION
7073 Feed to relay for electrical battery disconnecting device after diode
7076 Feed to self-pickup relay coil for electrical battery disconnecting device
7077 Ex (i) own safety circuit positive cable with TMP vehicle
7079 Feed to ADR electronic speedometer
7082 Driver door power window (front-rear) switch connecting cable
7084 Driver door power window (front-rear) switch connecting cable
7097 Remote switch pick-up for diagnostic switching (Allison-ISO)
7101 Feed to automatic transmission system after fuse
7102 Feed to door external switch
7150 Feed to EDC/MS6 system from main relay
7151 Feed to EDC system after fuse
7152 Feed to relay for pre-heating connection
7153 Feed to Cruise Control EDC switch (internal-external)
7154 Feed to Cruise Control EDC switch from steering column stalk
7155 Feed to MS6 control unit from main relay
7156 Feed to external Cruise Control EDC switch
7157 Control cable for EDC engine stop with TGC disconnected
7158 Timing sensor feed for EDC control unit
7166 Feed to DMI system (Data Management Interface) or EM (ExpansionsModul) after fuse
7172 Feed to second speed limiter
7180 Feed to natural gas system after fuse
7300 Feed to ADR system
7320 Feed to ADM system (electronic differential lock) after fuse
7321 ADM system control (electronic differential lock)
7350 Feed to revolving light relay or alarm switch for Fire Fighting Vehicles
7351 Feed to amperometric relay for front revolving light connection coming from control relay for Fire Fighting
Vehicles
7352 Pick-up for front revolving light connection relay or feed to rear revolving light switch
from alarm switch for Fire Fighting Vehicles
7355 Feed to Fiamm/Martin horn relay for Fire Fighting Vehicles
7356 Feed to Fiamm/Martin horn relay for Fire Fighting Vehicles
7357 Feed to transceiver switch from fuse for Fire Fighting Vehicles
7358 Feed to transceiver from switch for Fire Fighting Vehicles

COMPONENT
CODE DESCRIPTION
7359 Feed to power point from fuse for Fire Fighting Vehicles
7361 Feed to amperometric relay for rear revolving light coming from control relay for Fire Fighting Vehicles
7362 Feed to amperometric relay for rear revolving light coming from alarm switch for Fire Fighting Vehicles
7410 Brake system (power terminal 30)
7440 Feed to lifting axle system after fuse
7450 Feed to Dual relay (methane system)
7451 Feed to lambda sensor from Dual relay (methane system)
7452 Feed to control unit + batt. from Dual relay (methane system)
7453 Feed to gas reducer from Dual relay (methane system)
7454 Feed to ignition coil from Dual relay (methane system)
7455 Ignition coils 2-3 power connection (methane system)
7456 Ignition coils 1-4 power connection (methane system)
7470 Feed to front door closing switch
7502 Feed to switches for cab and/or engine heating with additional heater
7503 Cab heating control after diode
7504 Feed to relay for blower - speed 1
7505 Feed to relay for blower - speed 2
7506 Additional heater control with micro-switch passing on heating cock control level
7507 Cab heating control
7508 Additional heater control after engine heating switch
7509 Additional heater control after cab heating switch
7510 Feed to additional heater control signal
7511 Feed to electronic pulse generator for additional heater glow plug
7512 Feed to ambient temperature sensor with additional heater
7513 Additional heater on signal from timer or autom. condition. according to remote switch
7514 Feed to main current remote switch holding control from additional heater
7515 Feed to additional heater thermic feeler
7516 Feed to control feeler for additional heater flame
7517 Control for additional heater request from automatic conditioning
7519 Feed to additional heater warning light after diodes
7520 Feed to cab internal temperature sensor
7521 Control for disconnecting the additional heating when connecting the PTO, TMP vehicle
COMPONENT
CODE DESCRIPTION
7540 Feed to SCR system (Selective Catalytic Reduction) after fuse
7541 Feed to metering module solenoid valve with SCR (Selective Catalytic Reduction)
7542 Feed to SCR (Selective Catalytic Reduction) urea heating pipes
7543 Feed to urea tank level sensor with SCR (Selective Catalytic Reduction)
7544 Power to SCR pressure sensor and level
7545 Power to fan valve and engine start/stop switch
7550 Feed to air conditioning system change
7551 Feed to air conditioning system blower
7552 Feed to remote control switch for TOP FLAP door open
7553 Feed to remote control switch for TOP FLAP door close
7554 Feed to control unit for blower regulator (TGMV) air conditioning system
7555 Feed to control unit for blower regulator (GMV) air conditioning system
7556 Relay control for air conditioning system battery disconnector
7560 Feed to potentiometer for servomotors (VPOT) air conditioning system
7561 Servomotor potentiometer signal for “foot compartment” air delivery (PFOOT) air conditioning system
7562 Feed to servomotor for “foot compartment” air delivery (+FOOT) air conditioning system
7563 Servomotor potentiometer signal for air delivery for windscreen defrosting (PDEF) air conditioning system
7564 Feed to servomotor for air delivery for windscreen defrosting (+DEF) air conditioning system
7565 Servomotor potentiometer signal for air recirculation or for external air intake (PRYC) air conditioning
system
7566 Feed to servomotor for air recirculation or for external air intake (+RYC) air conditioning system
7567 Servomotor potentiometer signal for air conditioning system “air mixing”
7568 Feed to servomotor for “air mixing” (+MIX) air conditioning system
7571 Water temperature sensor signal (TAS) air conditioning system
7572 Water temperature sensor signal (TEVAP) air conditioning system
7573 External temperature sensor signal (TEXT) air conditioning system
7574 Sun radiation sensor signal (SUNLOAD) air conditioning system
7579 Feed to windscreen defrosting - average speed
7580 Feed to windscreen defrosting - high speed
7590 Feed to ventilation system for air conditioner
7591 Feed to heater fan “ON” with air conditioner connected
7600 Feed to automatic clutch system
7601 Motor feed for automatic clutch

COMPONENT
CODE DESCRIPTION
7605 Feeding of solenoid valve high pressure gas (roof)
7606 Feeding DCU +30 after fuse
7609 Feeding + 15 after fuse to engine control unit
7610 Feeding + battery after terminal block on chassis
7611 Control of circulation pump after relay contact
7612 Info dead centre to actuate gearbox control unit from control unit MUX
7613 Control actuated by methane engine or ECM from control unit CAMU before resistance to emergency
switch
7615 Positive after relay for checking brake light in an emergency - circuit 1
7616 Positive after relay for checking brake light in an emergency - circuit 2
7618 Feed to passenger’ s stop request, after fuse
7619 Positive for ABS, after fuse
7620 Positive for checking circuit of every door, after fuse
7700 Connection for C1 additional heater control unit and heating system switch (feed to water temperature
adjusting device)
7701 Feed to amperometric relay for revolving light
7702 Pick-up for remote control switch, operating additional heater compensation tank filling motor
7703 12V positive after diode (radio feed)
7704 Feed to radio amplifier
7705 Feed to additional heater spark plug
7706 Feed to interior (front) heating motors
7707 Feed before fuse for A.B.S.
7708 Feed to additional heater
7709 Feed to (rear) interior heating motors
7710 Feed after relay No. 1 for A.B.S. control unit
7711 Feed to trap door closing control
7712 12 V cable after voltage reducer for revolving light
7715 “Stop request” resetting control relay
7720 Feed after relay No. 2 for A.B.S. control unit
7721 Cigarette lighter feed
7722 Feed to air blower motor for additional heater cab heating
7724 Ignition key feed (positive after fuse)
7725 Positive cable connecting clock timer terminal 6 to control relay

COMPONENT
CODE DESCRIPTION
7726 Cable connecting relay for disconnection of air conditioning when using additional heater
7727 Feed to VDI (Vehicle data interface) system
7728 Feed to emergency flashing light
7729 Servoassisted cab tilt control relay
7730 Feed to hydraulic pump for servoassisted cab tilt control relay
7731 Pick-up positive before ignition key
7732 Feed to diesel fuel filter heating system
7733 Diesel fuel heater feed
7734 Diesel fuel heating feed (before fuse)
7735 Refrigerator motor feed
7736 Feed to thermostat regulating additional heater air temperature
7740 Feed to EBS rear axle air pressure control modulator
7741 Feed to antitheft coil on drive
7742 Power for closing the tool compartment after fuse
7743 Power for closing the tool compartment after switch
7744 Engine compartment ventilation on feed control
7745 Feed to engine compartment ventilation motor
7746 Feed to remote control switch retarder through light switch
7748 Feed to advance unit on injection pump excluded from ignition key
7750 Feed from “V4” node to EDC adjusting control switch relay
7751 Engine acceleration feed from outside after “NA” relay contact
7752 “EDC” adjusting control feed after “NC” relay contact
7753 Feed to settler precleaner for heated diesel fuel
7754 Remote switch pick up for PTO cut-out
7755 Feed to circuit retarder relay terminal r downstream from diode
7756 Charge recording relay pick-up (for alternator with separate regulator)
7757 Feed to diesel fuel prefilter heating system
7759 Positive cable to clock timer, after air conditioning switch
7760 Passenger door power window (front-rear) switch connecting cable
7761 Feed to power window switch
7762 Passenger door power window (front-rear) switch connecting cable
7764 Feed to door centralised locking system

COMPONENT
CODE DESCRIPTION
7766 Feed to comburent air pump motor and additional heater ignition coil
7768 Continuous tachograph feed
7770 Positive after dropping resistance or 12V positive before diode (radio feed)
7771 Positive upstream from ammeter
7772 Positive after fuse
7773 Generator or alternative pick-up
7774 Feed to horn (from switch to fuse)
7775 Feed to additional heater through switch
7776 Separate feed to battery switch (vehicles for transport of dangerous goods)
7777 Direct positive on battery (not protected)
7778 Indicator light for generator or alternator charge
7779 Feed to remote control switch for disconnection of additional heater via central safety control system
7780 D + alternator downstream from diode
7781 Feed to timer indicator light electronic control unit, and thermostats regulating pre-heating or additional
heater water temperature. For BUS temperature of 65/70 ˚C
7782 Emergency control unit auxiliary relay pick-up connection
7783 Feed to additional fuel pump and additional heater fuel interception solenoid valve
7784 Feed to thermostat regulating additional heater water temperature at 80/85 ˚C
7785 Feed to motor for additional heater water circulating pump
7786 Independent water heating system pump gate switch
7788 Feed to additional heater pre-heating thermostat
7789 Alternator charge indicator light (for alternator with separate regulator)
7790 Feed to trailer socket after fuse for T.M.P. users
7791 Electronic feed to TGC control combined with emergency disconnection after fuse
7792 Electromagnet before fuse controlling fuel enrichment delivery
7793 General feed upstream from relay to (front and rear) interior heating motor
7794 Electromagnet after fuse controlling fuel enrichment delivery
7795 Supply cable for bodybuilder connector on chassis after fuse
7796 Supply cable for bodybuilder connector on cabin after fuse
7797 Feed to diagnostic connecting joint (+)
7798 Feed to centralized lubrication system after fuse
7799 Feed upstream control switch of relay pick-up for half-speed and full-speed
7800 +30 after fuse

COMPONENT
CODE DESCRIPTION
7801 +30 before fuse (contact 30 of CB)
7802 +30 before fuse (contact 50 of CB)
7804 #NOME?
7805 Feeding of auxiliary heater + battery after relay contact emergency actuator before fuse
7806 Feeding + battery after fuse to thermo 300 and timer for air conditioning
7807 + emergency to natural gas engine control unit
7808 + BAT after DCU fuse
7809 + BAT after NOX / OBD fuse
7810 Feeding after fuse for accessories outlet 24 V no. 1
7811 Feeding after fuse for accessories outlet 24 V no. 2
7812 Feeding protected by thermal switch after main switch
7813 Feeding + 15 contact starting key switch (IT)
7815 Feeding ECM engine start enabling before start inhibiting switch
7816 Feeding of control unit CAMU and dashboard in +30 after fuse
7817 Info sensor driver gate from control unit CAMU
7818 + Batt after MUX chssis control unit fuse
7819 +30 after fuse control unit MUX frame
7820 +30 after fuse control unit MUX front LH
7821 + Batt after front left MUX control unit fuse
7822 +30 after fuse control unit MUX front RH
7823 + Batt after front right MUX control unit fuse
7824 +30 after fuse control unit MUX rear engine
7825 + Batt after rear MUX engine control unit fuse
7826 Winch positive to battery disconnection
7827 Battery positive to battery disconnection
7828 + 30 of alarm ECU
7833 Addressing CAN MUX chassis
7834 CAN H MUX chassis
7835 CAN L MUX chassis
7836 CAN H MUX dashboard
7837 CAN L MUX dashboard
7838 Bridge control unit MUX rear engine

COMPONENT
CODE DESCRIPTION
7840 Feeding of solenoid valve exhaust gas after fuse to methane engine control unit and solenoid valve
7842 Info switch enabling side and rear line indicators to body
7843 Feeding of switch enabling side and rear line indicators through body
7844 Control of engine gas throttle no. 1
7845 Control of engine gas throttle no. 2
7846 Control of switch RH rearview mirror from control unit to rearview mirror (MH.MV)
7847 Control of switch LH rearview mirror from control unit to rearview mirror (MH)
7848 Control of switch LH rearview mirror from control unit to rearview mirror (MV)
7851 Info presence of water in fuel control unit MUX to sensor
7852 Control of solenoid valve condensate drain control unit MUX
7853 Control of circulation pump by Webasto
7855 Feeding after relay contact of Webasto
7856 Feeding after fuse air distribution flap
7857 Control opening air distribution flap from control unit to flap motor
7858 Control closing air distribution flap from control unit to flap motor
7859 Relay high speed heating for trailer unit heater control unit MUX to relay
7860 Relay low speed heating for trailer unit heater control unit MUX to relay
7861 Feeding rear RH unit heater from control unit MUX to unit heater
7862 Feeding rear LH unit heater from control unit MUX to unit heater
7863 Feeding front RH unit heater from control unit MUX to unit heater
7864 Feeding front LH unit heater from control unit MUX to unit heater
7865 Control low speed unit heaters with turboblower for passengers - control unit MUX to control of
passenger unit heaters
7866 Control high speed unit heaters with turboblower for passengers - control unit MUX to control of
passenger unit heaters
7867 Switch automatic air conditioning controls from control unit MUX to switch
7868 Switch driver’s air conditioner controls from control unit MUX to switch
7869 Feeding air conditioning trailer to body
7870 Control compressor air conditioning no. 1 via body
7871 Control compressor air conditioning no. 2 via body
7872 Control retarder cut-off from control unit MUX to relay
7873 Feeding electrical accelerator brake contact pedal to methane engine control unit
7876 Feeding ECM to sensor particulate filter pressure

COMPONENT
CODE DESCRIPTION
7881 Control solenoid valve VGT cut-off from control unit MUX to solenoid valve
7884 Feeding articulation control unit after fuse
7885 Control vehicle lifting from control unit MUX to bending control unit
7886 Info vehicle bent from control unit MUX after diode to bending control unit
7887 Feeding sensor front RH bending for bending control unit
7888 Feeding sensor front LH bending for bending control unit
7889 Feeding sensor rear RH bending for bending control unit
7890 Feeding sensor rear LH bending for bending control unit
7891 Feeding solenoid valve control unit front/rear bending for bending control unit
7892 Feeding sensor for LH rear trailer bending for bending control unit
7893 Feeding sensor for LH rear trailer bending for bending control unit
7894 Feeding solenoid valve control unit rear bending for bending control unit
7895 Control motor handrail (-) from control unit MUX
7896 Control motor handrail (+) from control unit MUX
7897 Feeding normal switch/ without protection and emergency door opening control from control unit MUX
to switch
7898 Feeding switch partial protection cut-off from control unit MUX to switch
7899 Feeding control unit MUX GEARBOX control unit and ABS control unit after relay contact
7901 Feed to rear frame computer (FC) after fuse (NR1) with Mux
7902 Feed to rear frame computer (FC) after fuse (NR2) with Mux
7903 Feed to front frame computer (FC) after fuse (NR1) with Mux
7904 Feed to front frame computer (FC) after fuse (NR2) with Mux
7905 Power to body-computer multiplex control unit after fuse
7906 Power to control unit and multiplex signal control unit after fuse from beds (bed module)
7907 Power to multiplex instrument unit module after fuse
7908 Power to multiplex control unit for interfacing with steering gear shaft after fuse
7909 + 30 of window regulator on passenger’s side
7910 + 30 of window regulator on passenger’s side
7914 Plus after relay to assess brake clearance in case of emergency circuit 1
7915 Plus after relay to assess brake clearance in case of emergency circuit 2
7930 Info control unit for ZF automatic gearbox in neutral position to control unit MUX
7933 Feeding optical guide between fuse and relay contact
7934 Feeding optical guide after relay contact

COMPONENT
CODE DESCRIPTION
7935 Control heater unit trailer low speed after relay contact
7936 Control heater unit trailer high speed after relay contact
7937 Control heater unit trailer (fuse - relay)
7944 Line CAN H
7945 Line CAN L
7946 Bridge on IOU rear door (CAN line terminal)
7947 Cable connection roof hatch (4) control unit with front moving group rear roof hatch - 18m (12)
7948 Feeding air suction turbines from compartment
7949 Feeding turbines air suction from compartment after control relay
7950 Feeding +30 sound reproduction system + stamping machines
7951 Loudspeaker common LH side no. 1
7952 Loudspeaker common LH side no. 2
7953 Loudspeaker common RH side no. 1
7954 Loudspeaker common RH side no. 2
7955 Loudspeaker RH no. 1
7957 Loudspeaker LH no. 1
7961 Info actuation bistable contactor cutting out battery to control unit CAMU
7962 Info central brake pad wear from sensor to control unit MUX
7963 RH (+) rear loudspeaker
7964 RH (-) rear loudspeaker
7965 LH (-) rear loudspeaker
7966 LH (+) rear loudspeaker
7972 Positive battery cable after fuse with Mux
7990 Feed to passenger door module after fuse with Mux
7991 Feed to driver door module after fuse with Mux
7993 Feed to cab module control unit
8000 Feed to control circuits indicator light
8001 Feed to (central) motor for interior ventilation - Exhaust

COMPONENT
CODE DESCRIPTION
8002 Connection 1 between right-hand side window winder switches
8003 Connection 1 between left-hand side window winder switches
8004 Feed to electric heater switch (remote control switch - switch)
8005 Resistance feed for indicator showing pre-heating complete
8006 Feed to heated front window (light unit)
8007 Feed to interior heating motors and forced ventilation switches
8008 Feed to fourth speed heater fan
8009 Feed to air conditioning system remote control switch
8010 Feed to speed limiter system without fuse
8011 Feed to remote control switch operating interior ventilation motors
8012 Feed to remote control switch disconnecting stop request indicator light
8013 Feed to solenoid operating fuel-enrichment electromagnet
8014 Feed to chassis lifting
8015 Feed to chassis lowering
8016 Brake cable wear (rear sensors)
8017 Brake cable wear (front sensors)
8018 Cable to front brake wear sensors
8019 Feed to relay for connection of evaporator motor
8020 Feed to heated windscreen
8021 Rear heated window power
8022 Feed to evaporator motor
8023 Feed to forced ventilation system relay
8024 Winkling light relay control
8025 Relay for delayed disconnection of terminal 15 to disconnected battery (TGC)
8026 Relay pick-up cable for backing light
8027 Relay pick-up cable for automatic light control
8028 Jumper on speed limiter control unit for unlimited r.p.m. function
8029 Relay pick-up cable for start-up with gear in neutral
8030 Relay pick-up for gear disengagement with speed limiter
8031 Feed to heated driver seat
8032 Feed to heated passenger seat
8033 Feed to TELMA intarder remote control switch, stage 3

COMPONENT
CODE DESCRIPTION
8034 Gate switch cable from reverse gear with automatic drive
8035 Relay pick-up for holding T.G.C
8036 Diesel fuel heating activation control
8037 Feed from terminal “50” of key commutator for device preventing start-up with engine running
8038 Relay pick-up for inserting bell for connected external lights
8039 Heated fuel line (Thermoline) connection cable
8040 Timed relay controls for heated windscreen before resistor
8042 Feed to voltage reducer, radio set and amplifier after fuse
8043 Feed to heating air drier system
8044 Feed to TELMA intarder remote control switch, stage 4
8045 general current pick-up relay with key switch
8046 Time relay pick-up for heated windscreen
8047 Running signal relay control for hydraulic brake system
8048 Relay control for disconnecting cruise control with connected retarder
8049 Neutral position input signal for engine load reduction from “Stop” (Allison)
8050 Gear in neutral signalling switch
8051 Feed +15 control unit “MS6” after relay
8052 External starting control after hand brake switch
8053 Relay pick-up for PTO disconnection
8054 Relay pick-up for PTO
8055 Starting system control after fuse
8056 Diesel fuel prefilter heating relay pick-up
8057 Feed to rear window regulator under fuse
8059 Feed to speed limiter solenoid valve disconnecting relay during gear shifting
8060 Positive cable after diode Z for board indicator lights or instrument indicator lights attenuation with Military
Vehicles
8061 Indicator light feed positive cable for Military Vehicles (switching into dimmed light through diode Z)
8062 Feed to instrument indicator lights for Military Vehicles (switching into dimmed light through diode Z)
8063 Feed to control unit with sun visor control motor - upwards
8064 Feed to control unit with sun visor control motor - downwards
8065 Sun visor power supply (electronic and motor) downwards max. “with parking brake on”
8066 Differential locking system power supply
8067 Transverse differential locking control for front axle after speed switch (25 km/h)
COMPONENT
CODE DESCRIPTION
8068 Front axle differential locking control
8069 Four-wheel drive engagement indication cable after pressure switch for differential locking control
8070 Remote switch pick-up for black out light control
8071 Common feed to backlight wiper and washer
8072 Feed to backlight wiper
8073 Feed to backlight wiper motor
8074 Feed to backlight washer pump
8075 Terminal board 15 connected starting cable on chassis for bodybuilders
8080 Terminal board 15 remote switch pick-up after diode
8081 Feed to 15-pole outlet, Pin 14
8082 Terminal board 15 control after timed relay
8087 Feed to various components after relay
8088 Feed (No. 1) from differential lock to switch warning light
8089 Feed (No. 2) from differential lock to switch warning light
8090 Direct supply to air suspension E.C.U. (E.C.A.S.)
8091 Power supply from switches to rear suspension E.C.U. (E.C.A.S.)
8092 Feed to IMMOBILIZER system
8094 Control cable for hydraulic cab releasing during lowering
8095 Control cable for hydraulic cab releasing during lifting
8097 Solenoid (No. 1) for differential lock system
8101 Feed to semiautomatic gearbox system after fuse
8102 Feed to neutral position switch after fuse for semiautomatic gearbox
8103 Feed to semiautomatic gearbox system after switch
8104 Neutral position switch signal for anti-start for semiautomatic gearbox
8105 Feed to neutral position switch for anti-start for semiautomatic gearbox
8106 Gear in neutral signal for anti-starting after diode unit
8107 Feed to low air pressure switch on semiautomatic gearbox
8108 Signal for up-shifting from semiautomatic gearbox lever
8109 Signal for down-shifting from semiautomatic gearbox lever
8110 Feed to gearshift switch for semiautomatic gearbox

COMPONENT
CODE DESCRIPTION
8111 Signal for reverse gear engagement from gearshift for semiautomatic gearbox
8112 Feed to clutch position switch for semiautomatic gearbox
8113 Signal for clutch position switch for semiautomatic gearbox
8114 Running retarder signal for semiautomatic gearbox
8115 Connection from speed unit switch to semiautomatic gearbox “gears in” switch
8116 Semiautomatic gearbox “gears in” signal
8118 Signal for speed unit connection for semiautomatic gearbox
8119 Feed to LIMP HOME for semiautomatic gearbox
8120 Signal from engine brake switch on semiautomatic gearbox
8123 Neutral position signal from direction preselector on semiautomatic gearbox
8124 Neutral position signal from direction preselector to gearshift on semiautomatic gearbox
8125 Signal for forward gear from direction preselector switch on semiautomatic gearbox
Cab release enabling signal cable
8129 Control cable for enabling hydraulic cab releasing after switch
8130 Return cable from clutch switch for EDC
8131 Feed to semiautomatic gearbox rear power take off relay
8132 Feed to semiautomatic gearbox side power take off relay
8133 Cable for engaging power take off 1 with automatic gearbox
8134 Cable for engaging power take off 2 with automatic gearbox
8140 Radio set - amplifier connecting cable, remote on
8141 Signal to semiautomatic gearbox (PBM/PWM) ABS system
8142 Signal to semiautomatic gearbox (MPS/MUX) ABS system
8143 Remote switch energisation for exhaust brake after diode with automatic gearbox
8144 Remote switch energisation for exhaust brake with automatic gearbox
8147 Remote switch energisation for automatic neutral position with automatic gearbox
8149 Feed to semiautomatic gearbox reverse gear relay
8150 EDC feeder
8151 EDC control unit interface signal with further electronic system (PBM)
8152 EDC control unit interface signal with further electronic system (MPS)
8153 Signal from main stop light switch for EDC or Brake on signal cable for EDC
8154 Signal from Cruise Control for interlock cancelling switch for EDC
8155 Signal from Cruise Control return switch for EDC

COMPONENT
CODE DESCRIPTION
8156 Signal from Cruise Control speed increasing switch for EDC
8157 Signal from Cruise Control speed lowering switch for EDC
8158 Signal from secondary stop light switch for EDC
8159 Signal from engine brake switch for EDC
8161 Feed to EDC after Cruise Control disconnection relay
8162 Switch for engine r.p.m. increase with connected air conditioner for EDC
8163 Connection to 3-level pressure switch for air conditioner
8164 Feed to EDC after engine stop relay
8165 Hand brake on signal for engine control system
8166 Feed to DMI system (Data Management Interface) or EM (ExpansionsModul) after fuse
8167 Sensor pressure engine cooling water (signal)
8170 Feed +15 control unit “MS6” from interconnection control unit to relay
8171 Feed to main door switch
8172 Feed to front door switch
8173 Combustion air relative humidity and temperature sensor power with EDC
8175 Feed to power window automatic opening/closing
8176 Feed to ACC (Adaptive Cruise Control) after fuse
8179 Cable 5 V Plus for distance control with ACC (Adaptive Cruise Control) great distance
8180 Feed to natural gas engine system after fuse
8181 Feed to adjusting device for value required on engine for natural gas engine
8182 Feed to lambda probe heating resistor (12V) for natural gas engine
8184 Feed to output shaft rev sensor (12V) for natural gas engine
8185 Feed to ignition system (12V) for natural gas engine
8190 Feed to equipment (12V) for by-pass solenoid valve, min speed control, natural gas reserve meter
8191 Exhaust brake control cable from exhaust brake remote control switch for natural gas engine
8192 Control cable for min rpm solenoid valve and neutral disengagement solenoid valve for natural gas engine
8193 Exhaust brake remote control switch activation for natural gas engine
8194 Connection cable for natural gas engine with Allison gearbox
8197 Feed to Pin B gas regulator for natural gas engine
8199 Feed to throttle valve and supercharging pressure sensor (5 V) for natural gas engine
8207 Trailer ABS system power
8223 Signal for second speed limit insertion

COMPONENT
CODE DESCRIPTION
8270 ESC for EBS system power
8275 SAS (steering angle sensor) for EBS power
8280 Sensor 1st exhaust gas tempetature (signal)
8281 Sensor 1st exhaust gas tempetature (earth)
8282 Sensor 2st exhaust gas tempetature (signal)
8283 Sensor 2st exhaust gas tempetature (earth)
8284 Sensor particulate filter (plus)
8285 Sensor particulate filter (minus)
8286 Sensor particulate filter (signal)
8290 Probe lambda (warm up)
8291 Probe lambda (current)
8292 Probe lambda (voltage)
8293 Probe lambda (regulate current)
8294 Probe lambda (virtual earth)
8300 Feed to hydraulic eddy-current brake system
8301 Feed to intarder/retarder lever switch
8320 Feed to ADM system (electronic differential lock) after fuse
8321 Feed to differential lock emergency switch
8322 Feed to ADM system (electronic differential lock) steering angle sensor
8350 Feed from control relay to fuse holder terminal 15 for Fire Fighting Vehicles
8351 Warning horn after fuse for Fire Fighting Vehicles
8352 Warning horn control for Fire Fighting Vehicles
8353 Double-tone horn for Fire Fighting Vehicles
8354 Martin horn relay pick-up for Fire Fighting Vehicles
8355 Feed to terminal 15 users after fuse for Fire Fighting Vehicles
8356 Terminal 15 relay pick-up for Fire Fighting Vehicles
8357 Feed to power take-off switch control hourmeter for Fire Fighting Vehicles
8358 Feed to control unit “MS6” terminal 20 before switch on clutch
8360 Feed +15 solenoid valve for “VGT” turbine air pipes
8361 Feed +15 frequency converter for “VGT” turbine
8362 Feed to control unit “MS6” terminal 31 before brake pedal switch
8401 Power for ECAS remote control (suspension levelling and third axle lifting)
COMPONENT
CODE DESCRIPTION
8402 Not running chassis levelling power supply system
8403 Feed to air pressure sensors after ECAS control unit
8407 Feed to shock absorber electromagnets
8410 Axle “running” levelling adjustment control
8411 Relay pick-up for axle “running” levelling adjustment self-hold
8420 Rear axle “running” levelling adjustment control
8421 Relay pick-up for rear axle “running” levelling adjustment self-hold
8422 Feed for chassis rear lowering
8423 Control for rear axle “running” stop remote control switch
8433 Timed remote switch pick-up for lifting axle lowering pulse
8435 Control for lowering switch activation with raised lifting axle
8436 Lifting axle lowering control
8437 Control for first diode self-holding remote switch with lowered lifting axle
8438 Control for self-holding remote switch with lowered lifting axle
8439 Feed to relay for lifting axle with < 2 Km/h speed
8440 Feed to lifting axle system after fuse
8441 Feed to axle lifting after push-button
8442 Feed to axle lowering after push-button
8443 Feed to pressure switch 11 ton for lifting axle
8444 Feed to lifting axle after speed switch
8445 Feed to lifting axle lowering or lifting switch
8446 Feed to relay for axle lowering
8447 Feed to relay for axle lifting
8448 Feed to relay for axle lifting/lowering
8449 Feed to axle lifting after relay
8450 Feed to relay for lifting axle hydraulic pump control
8451 Signal from hydraulic pressure switch for lifting axle hydraulic pump disconnection
8452 Feed for lifting axle hydraulic pump control system
8453 Signal after pressure switch 11 ton for lifting axle
8454 Signal after pressure switch 11 ton for lifting axle after diode
8455 Feed after time relay in condition lower than 11 ton
8456 Feed to relay for lifting axle lowering from chassis levelling system during lowering
COMPONENT
CODE DESCRIPTION
8457 Feed to relay for air solenoid valves reversal during lifting axle lowering
8458 Axle lifting relay control after diode
8459 Control for self-holding remote switch with raised lifting axle
8460 Feed to help at pick-up after push-button
8461 Feed to help at pick-up after time relay
8462 Relay connection gate switch for help at pick-up below 13 ton
8463 Relay autofeed for help at pick-up
8464 Help at pick-up disconnection
8465 Help at pick-up relay disconnection
8466 Pick-up feed with  25 Km/h speed
8467 Remote switch pick-up for help at pick-up, under 13 ton
8468 Help at pick-up relay disconnection with  25 Km/h speed
8469 Help at pick-up relay
8470 Feed to main door closing switch or Control for starting auxiliary device after relay with lifting 3rd axle for
Italian market
8471 Excitation of relay to connect starting auxiliary device with lifting 3rd axle for Italian market
8472 Cable control starting auxiliary device after double tip switch with lifting 3rd axle for Italian market
8490 Feed to third steering axle system
8491 Signal from axle straight-away motion positioning switch
8492 Signal from rear axle straight-away motion positioning switch
8493 Self-feed to relay for running third steering axle system signal
8494 Feed to relay for third steering axle system after speed switch
8495 Third steering axle control to hydraulic control unit with non-lifted axle
8496 Feed to third steering axle to hydraulic control in running position and straight gears
8497 Third steering axle control to hydraulic control with steered front axle
8498 Hydraulic steering axle control with front axle steered and > 45 Km/h speed
8501 Locked feed after autonomous heating relay
8538 Control driver’s place heating (pos. 1) with 3 position control switch
8539 Feeding driver’s place heating after fuse
8540 Feed to SCR system (Selective Catalytic Reduction) after fuse
8541 Control driver’s place heating (pos. 2) with 3 position control switch
8542 Control inductive locking engine tailgate
8544 Feeding relay pressure pump after diode bridge

COMPONENT
CODE DESCRIPTION
8545 Enabling monitor central door
8546 Enabling monitor 2nd central door (for bus 18m)
8547 Enabling monitor rear door
8548 Enabling monitor reverse motion
8549 CRT (Continuous Regeneration Trap) maintenance warning control unit power supply
8591 Feed from medium pressure switch for checking air conditioner fan revolutions
8600 Feed to automatic clutch system
8601 Feed to remote control switches and buzzer from automatic clutch control unit
8602 Feed to automatic clutch position sensor
8603 Feed to accelerator pedal sensor for automatic clutch
8604 Feed to gearbox lever position sensor for automatic clutch
8610 ECAS distance sensor supply (front axle)
8611 Windscreen wiper-level 1 interval
8614 Windscreen wiper-cleaning pulse
8615 Windscreen wiper-cleaning pulse
8621 ECAS distance sensor supply (rear axle - right)
8622 ECAS distance sensor supply (rear axle - left)
8650 +15 feed to inertia switch
8651 Feed to +15 control unit from inertia switch
8652 Feed to +15 control unit from Dual relay (methane system)
8653 Feed to +15 control unit upstream cylinder fuse (methane system)
8654 Feed connection to +15 control unit from Dual relay (methane system)
8655 +15 feed to first methane cylinder main bearings
8656 +15 feed downstream filling solenoid valve fuse (methane system)
8657 +15 feed to second methane cylinder main bearings
8700 Gate switch for equipment operation at alternator delivery
8710 Feed +15 arranged for external body builders (max = 10 A)
8773 Feeding GEARBOX/ ABS control unit from control unit CAMU
8800 Gate switch connecting solenoid valve for engine brake
8801 Feed to remote control switch operating deaeration outlet and fresh air inlet of open defrosting system
COMPONENT
CODE DESCRIPTION
8802 Relay pick-up for services with ignition key
8803 Feed cable for various users after black-out lights switch (terminal 49)
8804 Motor feed for ventilation in diffuser vent
8805 Motor feed for ventilation in permanent vent
8806 Feed to motor adjusting main left-hand rear view mirror
8807 Feed before fuse for A.B.S.
8808 Feed to motor adjusting main left-hand rear view mirror in vertical direction
8809 Feed to motor adjusting main left-hand rear view mirror in horizontal direction
8810 Feed to levelling adjustment system after fuse
8811 Remote control switch feed cutting in motor for ventilation in diffuser vent
8812 Running levelling adjustment control
8813 Windshield wiper control (8-function switch)
8814 Brake wear cable (returning from interconnecting housing to cab control unit and connection to sensors)
8815 Feed to remote control switch for general current remote control switch
8816 Feed to A.B.S. trailer from infomodule
8817 Feed to “RK” line infomodule for A.B.S.
8818 Feed to “AK” line infomodule for A.B.S.
8819 Heated mirror relay pick-up
8820 Headlamp wipers: feed from remote control switch
8821 Headlamp wipers: electropump feed
8822 Intermittent feed for windshield wipers
8823 Feed to headlamp wipers
8824 Remote control switch feed cutting in motor for ventilation in permanent vent
8825 Feed to remote control switch disconnecting forced ventilation at high-speeds
8826 Headlamp wipers: connection between motors
8827 Feed to remote control switch operating oil pump for brakes
8828 Feed to oil pump for brakes
8829 Heated mirror control and/or positioning after fuse
8830 Resistance feed to heated rearview mirrors
8831 Feed (15) to light indicating presence of water in pre-filter
8832 Pick-up relay opening diesel fuel heater
8833 Feed to relay operating front interior heating motors or relay control for water circulating pump motor
and solenoid valve for oil-water exchanger
COMPONENT
CODE DESCRIPTION
8834 Feed to remote control switch operating rear interior heating motors
8835 Feed to (front) interior ventilation motor - Intake
8836 Feed to motor adjusting overtaking rear view mirror on driver opposite side
8837 Relay control thermometric switch for diesel fuel heater
8838 Feed to motor adjusting overtaking rear view mirror in vertical direction on driver opposite side
8839 Feed to motor adjusting overtaking rear view mirror in horizontal direction on driver opposite side
8840 Feed for brake system air drier resistance
8841 Feed to motor adjusting wide angle rear view mirror on driver side
8842 Feed to motor adjusting wide angle rear view mirror in vertical direction on driver side
8843 Feed to motor adjusting wide angle rear view mirror in horizontal direction on driver side
8844 Feed to (front) interior ventilation motor - Exhaust
8845 Feed to (central) interior ventilation motor - Intake
8846 Control relay for feed to advance regulator on injection pump (K.S.B.)
8847 Feed after fuse for A.B.S./speed limiter
8848 Feed to advance regulator on injection pump (K.S.B.)
8849 Feed to general services with ignition key and cutting out operation during starting
8850 Pick-up relay cutting out operation during starting
8851 Feed to motor adjusting wide angle rear view mirror on driver opposite side
8852 Feed to motor adjusting wide angle rear view mirror in vertical direction on driver opposite side
8853 Feed to motor adjusting wide angle rear view mirror in horizontal direction on driver opposite side
8854 PTO control after connection indication switch
8855 Feed to (rear) interior ventilation motor - Intake
8856 Feed to (rear) interior ventilation motor - Exhaust
8857 Feed to motor adjusting main right-hand rear view mirror
8858 Feed to motor adjusting main right-hand rear view mirror in vertical direction
8859 Feed to motor adjusting main right-hand rear view mirror in horizontal direction
8860 Feed to KHD pre-heating motor
8861 Feed to controls for right-hand side window adjustment
8862 Connection 2 between right-hand side window winder switches
8863 Feed to motor for right-hand side window adjustment
8864 Feed to position corrector motor
8865 Return cable from side window winder motor

COMPONENT
CODE DESCRIPTION
8866 Positive from TELMA
8867 Connection 2 between left-hand side window winder switches
8868 Feed to sun visor control system
8869 Feed to electromagnet to prevent key rotation
8870 Feed to starter pre-heater, after fuse
8871 Feed to device checking running of vehicle, after fuse
8872 Central feed for flashing light, after fuse
8873 Windshield wiper fixed stop
8874 Feed to hydraulic brake solenoid valves, after fuse
8875 Feed to pre-heating, starter before use
8876 Feed to device checking engine running, after fuse
8877 Connection between intermittence and windshield wiper switch
8878 Feed to “ERG” control unit
8879 Feed to general servo-components after fuse
8880 Feed to windshield wiper motor - separate fuse
8881 Feed to windshield wiper motor - high speed
8882 Feed to windshield wiper motor - low speed
8883 Feed to air-conditioning motor - high speed
8884 Feed to air-conditioning motor - low speed
8885 Feed to pre-heating remote control switch
8886 Feed to windshield washer pump
8887 Feed to general services before fuse
8888 Remote control switch or electromagnet for starter motor
8889 Feed to trailer brake remote control switch
8890 Feed to trailer services with terminal “15”
8891 Feed to switch for electric heater and windshield defrosting system (fuse-switch or fuse-remote control
switch)
8892 Engine start-up under cab
8893 Remote control switch pick-up connecting recirculating water pump during additional heater starting phase
8894 Feed to selector switch for hand or pedal operated control TELMA intarder
8895 Relay control running signal for hydraulic brake
8896 Air conditioner motor power supply- Medium speed
8897 Control cable from clutch switch

COMPONENT
CODE DESCRIPTION
8898 Feed to centralized lubrication system after fuse
8899 Feed to 12V or 24V radio equipment
8900 Relay control for powering engine control unit on-board computer
8901 Positive actuator powering to rear door
8902 Negative actuator powering to rear door
8903 Positive actuator powering to side door
8904 Negative actuator powering to side door
8905 Positive actuator powering to front door
8906 Negative actuator powering to front door
8907 Relay control for keeping main current remote switch closed with running engine
8908 Engine starting circuit (down-stream start cut out switch)
8909 Relay for keeping main current remote switch closed with running engine
8910 Engine starting circuit (upstream start cut out switch)
8911 Circuit for keeping main current remote switch closed with running engine upstream diode
8912 Signal from volumetric sensor to antitheft E.C.U.
8917 Feed to diesel fuel filter preheated resistance
8918 Feed to engine management control unit upstream fuse
8920 Starting signal to Body Control
8921 Output for window regulator motor on passenger’s side, lifting
8922 Output for window regulator motor on passenger’s side, lowering
8923 Output for window regulator motor on driver’s side, lifting
8924 Output for window regulator motor on driver’s side, lowering
8925 Negative input of widow regulator command on passenger’s side, lowering
8926 Negative input of widow regulator command on passenger’s side, lifting
8927 Positive output for lighting of window regulator plates
8928 Output for window regulator motor on passenger’s side, lifting
8929 Output for window regulator motor on passenger’s side, lowering
8930 Rear window regulator motor on passenger’s side (up)

COMPONENT
CODE DESCRIPTION
8931 Rear window regulator motor on passenger’s side (down)
8932 Rear window regulator motor on driver’s side (up)
8933 Rear window regulator motor on driver’s side (down)
8950 HIGH CAN BUS “C” serial line
8951 CAN BUS H serial line for engine
8987 Pick-up cable for electromagnetic motor fan connection remote switch (Baruffaldi)
8990 “Plus” connection cable for Expansion Module (ID PLUS) application
8991 Rear engine power supply due to internal heating at low speed
8992 Rear engine power supply due to internal heating at medium speed
8993 Rear engine power supply due to internal heating at high speed
8994 Rear internal aeration motor on-switch power supply
9000 Feed to solenoid valve opening main door
9001 Feed to solenoid valve closing main door
9002 Feed to solenoid valve operating spring emergency release cylinders
9003 Pick-up for gear selection relay
9004 Feed to gear selection relay
9005 Connection between engine brake switch not connected in series, and switch on brake pedal
9006 Connection between safety switch and pressure switch reopening rear door
9007 Automatic gear control
9008 Feed to automatic gear
9009 Feed to solenoid valve closing front door
9010 (Main) door II relay control
9011 Connection from electronic accelerator control unit terminal 30 to accelerator pedal transmitter terminal
3 and actuator terminal 1
9012 Connection from electronic accelerator control unit terminal 21 to accelerator pedal transmitter terminal 6
9014 Connection from electronic accelerator control unit terminal 15 to accelerator pedal transmitter terminal 2
9016 Connection from electronic accelerator control unit terminal 16 to actuator terminal 3
9018 Connection from electronic accelerator control unit terminal 22 to actuator terminal 2
9022 Connection from electronic accelerator control unit terminal 1 to actuator terminal 2 (engine)
COMPONENT
CODE DESCRIPTION
9023 Connection from electronic accelerator control unit terminal 10 to actuator terminal 1 (engine)
9024 Exhaust brake enabling coupled to service brake
9025 Exhaust brake enabling coupled to accelerator pedal releasing
9027 Feed cable to reduction unit valve after pressure switch for door I
9028 Feed cable to reduction unit valve after pressure switch for door II
9029 Feed to hydraulic cab releasing pump motor (+ with lowering)
9031 Feed to stop brake solenoid valve
9032 Engine starting exchange relay control (engine compartment or driver side)
9033 Relay control for parking brake limit switch interlocking
9034 Engine starting circuit from compartment (upstream control)
9035 Speedometer relay control 1st threshold speed
9036 Speedometer relay control 2nd threshold speed
9037 Relay control for running engine load gate switch
9038 Engine starting circuit from compartment (downstream control)
9040 Control for solenoid valve I for axle levelling adjustment
9041 Hot water circuit shutter solenoid valve control for rear heater
9042 Remote control switch power supply for hot water circuit shutter solenoid valve control for rear heater
9043 Feed to heated air drier solenoid valve
9044 Negative input from door lock motor status deviators, lock
9045 Negative input from door lock motor status deviators, unlock
9046 Feed to EBS trailer proportional solenoid valve
9047 Door lock switch, unlock command
9048 Door lock switch, lock command
9049 Negative input from door lock motor status deviators, lock of door on passenger’s side
9050 Control for solenoid valve I for rear axle levelling adjustment
9051 Negative input from door lock motor status deviators, unlock of door on passenger’s side
9052 Negative input from door lock motor status deviators, lock of door on driver’s side
9053 Negative input from door lock motor status deviators, unlock of door on driver’s side
9054 Feed to centralised door lock motor - opening
9055 Feed to centralised door lock motor - closing
9056 Relay valve (backup valve)
9057 Relay valve (dump valve)

COMPONENT
CODE DESCRIPTION
9058 Pre-resistance feed for speed limiter proportional solenoid valves
9059 Remote control switch power supply for condenser cooling fan low speed
9060 Feed to quick vent solenoid valve for gear disengagement with speed limiter
9061 Feed to modulating solenoid valve (MV1) for speed limiter
9062 Feed to modulating solenoid valve (MV2) for speed limiter
9063 Feed to front axle differential lock solenoid valve
9064 Feed to manual air conditioner thermostat
9065 Feed to compressor connection warning light
9066 Manual air conditioner control relay
9067 Feed to compressor relay
9068 Feed to max speed fan relay
9069 Feed to capacitor cooling fan low speed
9070 Antitheft ground from switch on roof lamp
9071 Connection to fan power
9072 Driver’s door lock position signal
9073 Passenger’s door lock position signal
9074 Signal from switch on rh side door
9075 Signal from switch on lh side door
9076 Signal from switch on rear door
9077 Central door locking actuator power
9078 Central door locking power
9080 Additional tank presetting relay control
9081 Winch enabling command from switch
9082 Winch disabling command from switch
9083 Consent to winch enabling under relay from battery disconnection
9084 Consent to winch disabling under relay from battery disconnection
9085 “UP” or “DOWN” headlight position power
9086 “MODE” and “MODE+” headlight position power
9087 “MODE-” headlight position power
9090 Longitudinal acceleration signal
9091 Stabilised voltage signal to acceleration sensor
9092 Side acceleration signal

COMPONENT
CODE DESCRIPTION
9093 Test signal to yaw sensor
9094 Reference signal to yaw sensor
9095 Indication signal to yaw sensor
9096 Ground signal to yaw sensor
9101 Feed to solenoid valve unit for gearbox control (No. 1) on semiautomatic gearbox
9109 Feed to solenoid valve unit for reduced gears “A” on semiautomatic gearbox
9110 Feed to solenoid valve unit for reduced gears “B” on semiautomatic gearbox
9112 Feed to gearbox brake solenoid valve on semiautomatic gearbox
9114 Feed to solenoid valve for keeping clutch disengagement on semiautomatic gearbox
9115 Signal for engine brake disconnection on semiautomatic gearbox
9116 Feed to solenoid valve for clutch signal on semiautomatic gearbox
9117 Engine negative on injection pump actuator on semiautomatic gearbox
9118 Engine positive on injection pump actuator on semiautomatic gearbox
9119 Signal for limit switch on injection pump actuator on semiautomatic gearbox
9120 Feed to limit switch on injection pump actuator on semiautomatic gearbox
9121 Boost feed on injection pump actuator on semiautomatic gearbox
9122 Boost signal on injection pump actuator on semiautomatic gearbox
9123 Feed to PTO 3 solenoid valve
9124 Feed to PTO 4 solenoid valve for stop brake or clutch engaged
9131 Feed to PTO 1 solenoid valve (rear with semiautomatic gearbox)
9132 Feed to PTO 2 solenoid valve (side with semiautomatic gearbox)
9133 “Foreward” end of stroke positive signal to P.T.O. E.C.U.
9134 “Backward” end of stroke positive signal to P.T.O. E.C.U.
9135 Positive P.T.O. actuator powering
9136 Negative P.T.O. actuator powering

COMPONENT
CODE DESCRIPTION
9137 Positive “opening” solenoid valve powering for dump body
9138 Positive “closing” solenoid valve powering for dump body
9139 Negative “opening” solenoid valve powering for dump body
9140 (+15) power to antitheft siren
9141 (+30) power to antitheft siren
9142 Signal from antitheft E.C.U. to siren
9143 Negative “closing” solenoid valve powering for dump body
9144 Signal from switch on dump body
9150 Pump rod position sensor for EDC (terminal 1)
9151 Injection pump rod stroke actuator for EDC
9152 Engine r.p.m. sender for EDC
9153 Pump rod position sensor for EDC (terminal 5)
9154 Standard pump rod position sensor for EDC
9155 Solenoid valve for engine stop during emergency for EDC
9156 Injection pump diesel fuel capacity actuator for EDC
9157 Electro-magnet for injection pump advance control for EDC
9158 Sensor for injector internal needle lifting for EDC
9160 Signal from timing sensor to EDC control unit
9164 Preheating remote switch pickup cable for EDC
9165 Braking signal to “MS4” / “MS6” for ground engine acceleration gate switch
9166 Feed to engine fan solenoid valve
9180 Feed to solenoid valve for adjusting device for value required on engine for natural gas engine
9181 Connection of ABS ECU to ABS unit module

COMPONENT
CODE DESCRIPTION
9191 Connection of ABS ECU to relay contact
9197 Feed to Pin C gas regulator for natural gas engine
9201 Control feeding ECM after pressed emergency push button
9202 Signal from front window regulator switch on driver’s side
9203 Signal from front window regulator switch on passenger’s side
9204 Signal from rear window regulator switch on driver’s side (on dashboard)
9205 Signal from rear window regulator switch on passenger’s side (on dashboard)
9206 Signal from rear window regulator switch on driver’s side (on door)
9207 Signal from rear window regulator switch on passenger’s side (on door)
9208 Signal of rear window regulator inhibition switch
9209 Alarm siren
9210 Alarm siren
9211 Alarm siren
9212 Backlight wiper command switch
9213 Backlight washer command switch
9217 Feed to redundant solenoid valve for rear axle breaking in case of EBS control unit failure
9218 Control solenoid valve angular braking via articulation control unit
9219 Info relay contact accelerator inhibition doors opening to methane engine control unit
9220 From actuator to control unit electrical accelerator methane engine no. 1
9223 From actuator to control unit electrical accelerator methane engine no.4
9227 From sensor accelerator pedal to control unit electrical accelerator methane engine no. 1
9233 Connection to electrical accelerator to methane engine control unit

COMPONENT
CODE DESCRIPTION
9234 Info speed of connection methane engine processor to electrical accelerator
9235 Info speed of methane engine to connect engine processor to electrical accelerator
9236 Info ASR from methane engine control unit to electrical accelerator
9237 Info brake between engine control unit and electrical accelerator
9238 Info gearbox control unit to neutral position from methane engine control unit to electrical accelerator
9239 Info pressed emergency push button for optical guide before pressed emergency switch
9240 Info emergency for optical guide after contact of pressed emergency switch
9241 Redundancy insulation motor for optical guide direction
9242 Outlet buzzer control unit optical guide
9243 Redundancy buzzer optical guide no. 1
9244 Backup buzzer optical guide no. 2
9245 Energising of relay optical orientation via GMU Time Keeper
9246 Feeding GMU Time Keeper for switch enabling optical guide
9247 Feeding GMU Time Keeper for switch on optical guide cap
9248 Feeding GMU Time Keeper to clean glass of optical guide box
9249 Feeding GMU Time Keeper for temperature of optical guide control unit
9262 Feed to solenoid valve for third axle braking cut-out with ASR
9301 Position 1 control for hydraulic eddy-current brake
9307 Feed from push-botton on lever change-over switch for hydraulic eddy-current brake
9308 Feed to lever change-over switch for hydraulic eddy-current brake
9310 Feed to hydraulic eddy-current brake connecting solenoid valve
9311 Feed to hydraulic eddy-current brake oil accumulator solenoid valve
9315 EBS (solenoid valve) control, rear axle module
9316 EBS (solenoid valve) control, front axle module
9321 Emergency control for differential lock solenoid valve
9323 Feed to central longitudinal differential lock solenoid valve (transfer box)
9324 Feed to rear longitudinal differential lock solenoid valve

COMPONENT
CODE DESCRIPTION
9325 Feed to rear transverse differential lock solenoid valve
9400 Feed to ECAS solenoid valves after control unit
9402 Feed to solenoid valves II for chassis levelling in running condition
9410 Feed to solenoid valves I and II for chassis front lowering
9413 Feed to front axle ECAS solenoid valve
9417 Feed to left axle shock absorber electromagnet
9418 Feed to right axle shock absorber electromagnet
9420 Feed to solenoid valves I and II for chassis rear lowering
9422 Control for solenoid valve II for adjusting rear axle “running” chassis level
9423 Feed to rear axle ECAS solenoid valve unit
9424 Feed to right-hand valve rear axle ECAS solenoid valve unit
9425 Feed to left-hand valve rear axle ECAS solenoid valve unit
9427 Feed to left rear axle shock absorber electromagnet
9428 Feed to right rear axle shock absorber electromagnet
9437 Feed to left lifting axle shock absorber electromagnet
9438 Feed to right lifting axle shock absorber electromagnet
9440 Feed to solenoid valve for lifting axle lowering
9441 Feed to solenoid valve for cantilever lifting
9442 Feed to solenoid valve for cantilever lowering
9443 Feed to solenoid valve for axle lifting (with air blow off from springs)
9444 Feed to solenoid valve relay for connecting valves controlled by air pressure
9445 Feed to solenoid valve for connecting valves controlled by air pressure
9446 Feed to air exhaust right-hand air spring rear axle ECAS solenoid valve unit
9447 Feed to air exhaust left-hand air spring rear axle ECAS solenoid valve unit
9460 Feed to solenoid valve for help at pick-up disconnection above 13 ton
9490 Feed to third steering axle solenoid valve unit
9499 Feed to third steering axle locking solenoid valve
9506 Feed to water circulation locking solenoid valve in engine circuit with additional heating
9507 Feed to solenoid valve for water circulation switching in engine circuit or cab
9540 Control cable, SCR refrigerant valve
9541 Control cable for metering module solenoid valve with SCR (Selective Catalytic Reduction)
9542 Control cable for engine water solenoid valve for urea tank heating with SCR (Selective Catalytic
Reduction)
COMPONENT
CODE DESCRIPTION
9543 Control cable for urea pumping module supply heating pipe with SCR (Selective Catalytic Reduction)
9544 Control cable for urea pumping module recovery heating pipe with SCR (Selective Catalytic Reduction)
9545 Control cable for compensation pressure heating pipe with SCR (Selective Catalytic Reduction)
9546 Control cable for carbamide filter output heater with SCR (Selective Catalytic Reduction)
9549 Control cable, SCR pump module
9551 Feed to timing valve (1) air conditioning system
9552 Feed to timing valve (2) air conditioning system
9570 Feed to TOP-FLAP motor from air conditioning system relay
9571 Feed to TOP-FLAP motor from manual air conditioning system microswitch
9590 Feed to air conditioner heater fan
9591 Air conditioner fan motor low speed rotation control
9601 Feed to engine for automatic clutch after remote control switch
9602 Solenoid valve actuating automatic clutch (feed)
9701 Feed to injector 1 (methane system)
9710 Signal from idle actuator (methane system)
9720 Signal from throttle valve position inductive sensor
9723 Signal from external air temperature sensor (methane system)
9724 Signal from lambda sensor (methane system)
9725 Signal from lambda sensor (methane system)
9726 Signal from manifold pressure sensor (methane system)
9727 Signal from manifold pressure sensor (methane system)
9728 Signal from timing sensor (methane system)
9729 Signal from engine water temperature sensor
9730 Signal from immobilizer (methane system)

COMPONENT
CODE DESCRIPTION
9731 Presetting between control unit and total PTO (methane system)
9801 Control solenoid valve lubrication constant oil level from control unit MUX to solenoid valve
9802 Control solenoid valve fan check from control unit MUX to solenoid valve
9803 Control solenoid valve ABS front axle LH for ABS control unit
9804 Excitation solenoid valves front/rear bending
9805 Actuation of ABS control unit solenoid valve bending rear RH
9806 Actuation of ABS control unit solenoid valve bending rear LH
9807 Actuation of ABS control unit solenoid valve bending front RH
9808 Actuation of ABS control unit solenoid valve bending front LH
9809 Actuation of ABS control unit solenoid valve bending rear trailer RH
9810 Actuation of ABS control unit solenoid valve bending rear trailer LH
9811 Excitation solenoid valves rear trailer bending
9812 Control from CAMU of solenoid valves immobilising brake with open door
9813 Actuation control unit DCU of radiator pump to metering unit
9814 Actuation control unit DCU of radiator tank to pump
9815 Actuation control unit DCU of radiator pump to tank
9816 Actuation control unit DCU of solenoid valve urea injection
9818 Actuation control unit DCU to temperature sensor before catalyst (up)
9819 Actuation control unit DCU to temperature sensor after catalyst (down)
9820 Actuation control unit DCU to sensor urea level and temperature
9821 Feeding control unit DCU to solenoid valve urea injection
9827 Info sensor oil filter clogging from control unit MUX to pressure gauge
9828 Info sensor fuel filter clogging from control unit MUX to pressure gauge
9829 Feeding + 15V from control unit MUX to oil level display unit
9831 Switch economic performance selector gearbox use program
9832 Bridge gearbox control unit to connect CAN resistance
9833 Actuation opening battery disconnect relay
9834 Actuation CAMU sealed switch brake release
9835 Actuation MUX switch emergency lifting on bending
9836 Info switch methane tank from control unit MUX to switch (IT)
9837 Actuation CAMU sealed switch articulation release
9839 Actuation CAMU sealed switch brake release

COMPONENT
CODE DESCRIPTION
9844 Actuation MUX switch tell-tales testing (IT)
9867 Actuation MUX solenoid valve climatization front box
9900 Feed to solenoid valve opening front doors
9901 Feed to “EV” solenoid valve for RH wheel second front rear axle (ABS 6 channels)
9902 Feed to solenoid valve opening rear doors
9903 Engine stop control
9904 Feed to “EV” solenoid valve for LH wheel second front rear axle (ABS 6 channels)
9905 Control for feed connection/disconnection relay coil + 15 MS6 control unit
9906 Engine stop cntrol from battery main switch
9907 Start-up gate switch
9908 Feed to “AV” solenoid valve for RH wheel second front rear axle (ABS 6 channels)
9909 Feed to “AV” solenoid valve for LH wheel second front rear axle (ABS 6 channels)
9910 Feed to TELMA retarder: second position
9911 Feed to TELMA control switch
9912 Feed to TELMA retarder: fourth position
9913 Feed to TELMA retarder: first position
9914 Feed to solenoid valve operating permanent ventilation channel vent
9915 Feed to cutting out supplementary retarder when A.B.S. is operating
9916 Feed to TELMA retarder: third position
9917 Cut-off feed for EDC
9918 Feed to right-hand front wheel “AV” solenoid valve (A.B.S. equipment)
9919 Feed for “AV” solenoid valve Front LH wheel (ABS system)
9920 Feed to right-hand front wheel “EV” solenoid valve (A.B.S. equipment)
9921 Feed to left-hand front wheel “EV” solenoid valve (A.B.S. equipment)
9922 Feed to oil-water heat exchanger solenoid valve
9923 Third axle lifting control
9924 Feed to injectors for EDC
9925 Pressure control for EDC
9926 Feed to solenoid valve controlling 1/3 opening-permanent ventilation channel vent
9928 Feed to right-hand rear wheel “AV” solenoid valve (A.B.S. equipment)
9929 Feed to left-hand rear wheel “AV” solenoid valve (A.B.S. equipment)
9930 Feed to right-hand rear wheel “EV” solenoid valve (A.B.S. equipment)
COMPONENT
CODE DESCRIPTION
9931 Feed to left-hand rear wheel “EV” solenoid valve (A.B.S. equipment)
9932 Rocker cam rev. sensor for EDC
9933 Feed to relay controlling electromagnetic clutch
9934 Headlamp setting adjustment
9935 Headlamp setting adjustment (position C)
9936 Headlamp setting adjustment (position B)
9937 Headlamp setting adjustment (position A)
9938 1st feed to actuator controlling fresh air intake vents and respective indicator light
9940 Control on TELMA retarder remote control switch housing: second position
9942 Control on TELMA retarder remote control switch housing: fourth position
9943 Control on TELMA retarder remote control switch housing: first position
9944 Connection from electronic accelerator control unit terminal 18 to retarder control unit terminal 3
9946 Control on TELMA retarder remote control switch housing: third position
9948 2nd feed to actuator controlling fresh air intake vents and respective indicator light
9950 Trailer brake control solenoid valve (Germany) (Trailer 7-pole socket)
9951 Feed to solenoid valve controlling differential locking
9952 Feed to solenoid valve I, axle levelling adjustment
9953 Feed to solenoid valve II, axle levelling adjustment
9954 Feed to meshing drive solenoid valve control
9955 Connection from electronic accelerator control unit terminal 26 to ABS/ASR control unit terminal 14
9958 Controls for 2-speed AR axle remote control switch
9959 Solenoid valve control regulating gas blow-by for “EGR”
9960 Solenoid valve for r.p.m. reduction with A.S.R. or speed limiter
9961 Solenoid valve for A.S.R. right-hand side
9962 Solenoid valve for A.S.R. left-hand side
9963 Hydraulic converter on
9964 Electromechanical clutch control for engine ventilation from temperature sensor or Motor power supply
from door “open” ECU
9965 Electromechanical clutch control for engine ventilation from EGR control unit or Motor power supply from
door “closed” ECU
9966 Feed to solenoid valve operating engine brake

COMPONENT
CODE DESCRIPTION
9967 Feed to solenoid valve for engine brake cut out with A.B.S.
9968 Speed reducer
9969 Feed to longitudinal differential locking solenoid valve with ABS (four-wheel drive)
9970 Speed limiter (feed+15)
9971 Feed to solenoid valve: gear shift jump prevented
9972 Feed to solenoid valve: fuel delivery
9973 Feed to reduction unit control solenoid valve (normal gears)
9974 Feed to solenoid valve line shift at the same level prevented (gearbox ZF)
9975 Feed to solenoid valve for mechanical gearbox synchrocone protection
9976 Pressure switch activated when shifting from a normal to a reduced gear
9977 Feed to hydraulic brake solenoid valve
9978 Feed to solenoid valve, adjusting fuel according to altitude
9980 Controls for vehicle (front) pneumatic suspensions
9981 Controls for vehicle (rear) pneumatic suspensions
9982 Feed to solenoid valve I for rear axle levelling adjustment
9983 Feed to solenoid valve II for axle levelling adjustment
9985 Tachograph - speed limiter remote control
9987 Feed to engine fan electromagnetic coupling (Baruffaldi)
9988 Feed to accelerator locking control solenoid valve
9989 Feed to trailer brake solenoid valve
9990 Solenoid valve control for deaeration channel vent
9991 Induction detector: vehicle speed
9992 Feed to gear reduction unit control
9993 Feed to electromagnetic clutch for air conditioning system
9994 Solenoid valve control for distributor channel vent
9995 Output control cable for Expansion Module (HS OUT 1) for clutch solenoid valve
9996 Pulse corrector controls (2-speed axle)
9997 Feed to solenoid valve controlling reduction unit (reduced gears)

ERROR LIST/FAULTS SHOWN ON DISPLAY

The errors/faults present in the vehicle are displayed on the CHECK screen.
“CHECK” screen
How to read the error/fault:
Indicate the Show the fault Show the fault

code related to
ECU type mode
the fault
HD9ST0062MR
ECU type
ECM ECM Engine ECU
ABS ABS Brake/traction control ECU
UDS UDS AdBlue additive metering control unit
VCM VCM Vehicle control ECU
IBC IBC Body computer ECU
ETC ETC Automated transmission ECU
EST EST Intarder ECU
INSTRUMENT BODY COMPUTER 2 (IBC)

Notes /
First Second Signal
ECU type ECU pin Fault source Operation Fault type Colour
code code type
type
EEPROM
IBC 01 0C — — IBC2 ECU Generic Yellow
interna
IBC 02 0C — — IBC2 ECU ECU heating Generic Yellow
00 — —
Check
01 — —
IBC 03 Line 1 power connection to Generic Yellow
03 — —
IBC2
04 — —
00 — —
Check
01 — —
03 — —
IBC2
04 — —
00 — —
Check
01 — —
03 — —
IBC2
04 — —
00 — —
Check
01 — —
03 — —
IBC2
04 — —
00 — —
Check
01 — —
03 — —
IBC2
04 — —
Tractor RH di- Check tractor
IBC 08 05 — — rection indica- RH direction Generic Yellow
tors indicators
Trailer RH di- Check trailer
IBC 09 05 — — rection indica- RH direction Generic Yellow
tors indicators
Tractor or Check tractor
trailer RH di- or trailer RH
IBC 0A 06 — — Generic Yellow
rection indica- direction indi-
tors cators
Tractor LH di- Check tractor
IBC 0B 05 — — rection indica- LH direction Generic Yellow
tors indicators
Trailer LH di- Check trailer
IBC 0C 05 — — rection indica- LH direction Generic Yellow
tors indicators
trailer LH di- or trailer LH
IBC 0D 06 — — Generic Yellow
rection indica- direction indi-
tors cators
Front LH par- Check LH par-
king lights, RH king lights, RH
IBC 0E 05 — — Generic Yellow
front clearance front clearance
light light
Check RH
RH rear par-
IBC 0F 05 — — rear parking Generic Yellow
king lights
lights
Licence plate Check licence
IBC 10 05 — — Generic Yellow
lights plate lights
Notes /
First Second Signal
code code type
type
Check front
Front LH par-
LH parking
king lights,
lights, front
front RH clea-
RH clearance
rance light or
light or rear
IBC 11 06 — — rear RH par- Generic Yellow
RH parking
king lights or
lights or trac-
tractor or trai-
tor or trailer li-
ler licence pla-
cence plate
te lights
lights
Front RH par- Check RH
king lights, LH parking lights,
front clearance LH front clea-
light rance light
LH rear par- Check LH rear
king lights parking lights
Rear RH and Check RH and
IBC 14 05 — — LH parking LH rear par- Generic Yellow
lights king lights
Check front
Front RH par-
RH parking
king lights,
lights, front LH
front LH clea-
clearance light
rance light or
or rear LH
IBC 15 06 — — rear LH par- Generic Yellow
parking lights
king lights or
or tractor or
tractor or trai-
trailer RH and
ler RH and LH
LH parking
parking lights
lights
Tractor rear Check tractor
fog lights rear fog lights
IBC 17 06 — — trailer rear fog or trailer rear Generic Yellow
lights fog lights
Check tractor
Tractor LH
IBC 18 05 — — LH brake Generic Yellow
brake lights
lights
Check tractor
Tractor RH
IBC 19 05 — — RH brake Generic Yellow
brake lights
lights
LH brake lights Check LH bra-
or RH tractor ke lights or RH
brake lights or tractor brake
IBC 1A 06 — — Generic Yellow
LH and RH lights or LH
trailer brake and RH trailer
lights brake lights
Check direc-
Direction indi-
IBC 1B 02 — — tion indicator Generic Yellow
cator switches
switches
Windscreen Check win-
IBC 1C 02 — — Generic Yellow
wiper dscreen wiper
Check engine
Engine brake
IBC 1D 02 — — brake mode Generic Yellow
mode selector
selector
Notes /
First Second Signal
code code type
type
Check rear
Rear transver-
transverse
IBC 1E 02 — — se differential Generic Yellow
differential
lock
lock switch
00 — —
01 — — Check front
Front axle bra-
axle brake
IBC 1F 02 — — ke pressure Severe Red
pressure
03 — — sensor
sensor
04 — —
00 — —
01 — — Check rear
Rear axle bra-
axle brake
IBC 20 02 — — ke pressure Severe Red
pressure
03 — — sensor
sensor
04 — —
00 — —
01 — — Check brake
Brake pressure
IBC 2B 02 — — pressure Severe Red
sensor power
03 — — sensor power
04 — —
Check
CAN VDB
IBC 2C 02 — — connection to Generic Yellow
line
VDB
IBC2 not
IBC 2D 31 — — IBC2 ECU correctly Generic Yellow
programmed
VEHICLE CONTROL MODULE (VCM)

Notes /
First Second Signal
code code type
type
02 Check
VCM 14 1 IN Primary brake connection to Generic Yellow
04 VCM
02 Check
Secondary
VCM 15 2 IN connection to Generic Yellow
04 brake
VCM
02 Check
Second speed
VCM 0B 3 IN connection to Generic Yellow
04 limit
VCM
02 Check
Ignition
04 request
VCM
02 Check
Cruise
03 Control SET+
VCM
02 Check
Cruise
03 Control SET-
VCM
02 Cruise Check
VCM 03 7 IN Control connection to Generic Yellow
03 RESUME VCM
02 Check
Cruise
03 Control OFF
VCM
02 Check
VCM 32 9 IN Clutch switch connection to Generic Yellow
03 VCM
Check
Adjustable
VCM 0A 03 10 IN connection to Generic Yellow
speed limit
VCM
Internal/ Check
VCM 05 03 11 IN external cruise connection to Generic Yellow
control VCM
02 Check
Shift up/down
03 request
VCM
Check
Economy
VCM 07 03 13 IN connection to Generic Yellow
mode
VCM
Check
Engine brake
request
VCM
Check
Engine brake
VCM 1A 03 14 IN connection to Generic Yellow
request
VCM
Check
Engine brake
request
VCM
Check
Engine brake
request
VCM
Check
Neutral
switch
VCM
Notes /
First Second Signal
code code type
type
Check
VCM 46 03 17 IN Released cab connection to Generic Yellow
VCM
02 Check
VCM 19 18 IN Parking brake connection to Generic Yellow
03 VCM
02 Engine start Check
VCM 47 19 IN from engine connection to Generic Yellow
03 compartment VCM
02 Engine stop Check
VCM 48 20 IN from engine connection to Generic Yellow
03 compartment VCM
Check
VCM 0F 03 21 IN PTO 1 connection to Generic Yellow
VCM
Check
VCM 10 03 22 IN PTO 2 connection to Generic Yellow
VCM
Check
VCM 11 03 23 IN PTO 3 connection to Generic Yellow
VCM
02
03 Check
VCM 3C 04 24 IN Engine idling connection to Generic Yellow
05 VCM
08
03 Check
Accelerator
04 pedal
VCM
02 Check
VCM 3B 03 26 IN Clutch switch connection to Generic Yellow
04 VCM
03 Check
VCM 20 27 IN Baruffaldi joint connection to Generic Yellow
04 VCM
03 Check
VCM 21 28 IN Baruffaldi joint connection to Generic Yellow
04 VCM
02 Check
Gear indicator
03 D
VCM
02 Check
Gear indicator
03 R
VCM
02 Check
Gear indicator
03 N
VCM
02 Check
Shift up
03 request
VCM
02 Check
Shift down
03 request
VCM
Notes /
First Second Signal
code code type
type
02 Check
Manoeuvring
03 mode
VCM
02 Check
Manoeuvring
VCM 3A 35 IN connection to Generic Yellow
03 mode
VCM
02
03 Check
Accelerator
VCM 3D 04 1 AN IN connection to Generic Yellow
pedal
0D VCM
0E
03 Check
Accelerator
VCM 5B 2 AN IN connection to Generic Yellow
04 pedal
VCM
02
03 Check
Analogue
VCM 5F 04 3 AN IN connection to Generic Yellow
input
0D VCM
0E
Check
0D
Accelerator connection to
VCM 60 — — Generic Yellow
pedal pedale
0E
acceleratore
03 Check
HSD Neutral
VCM 22 04 1 connection to Generic Yellow
OUT switch
05 VCM
03 Check
HSD
VCM 23 04 2 Gear switch connection to Generic Yellow
OUT
05 VCM
03 Check
HSD
VCM 26 04 3 Parking brake connection to Generic Yellow
OUT
05 VCM
03 Check
HSD
VCM 27 04 4 Gear switch connection to Generic Yellow
OUT
05 VCM
03 Check
HSD
VCM 28 04 5 Service brake connection to Generic Yellow
OUT
05 VCM
03 Programmabl Check
HSD
VCM 29 04 6 e speed connection to Generic Yellow
OUT
05 threshold VCM
03 Check
HSD
VCM 4A 04 7 Ignition relay connection to Generic Yellow
OUT
05 VCM
03 Check
04 LSD
VCM 4B 1 Ignition relay connection to Generic Yellow
05 OUT
06 VCM
03 Check
LSD
VCM 2A 04 2 Clutch pedal connection to Generic Yellow
OUT
05 VCM
Notes /
First Second Signal
code code type
type
03 Check
LSD Immobilizer
VCM 50 04 3 connection to Generic Yellow
OUT LED
05 VCM
02 Check
VCM F0 03 — — +15 power connection to Generic Yellow
04 VCM
02 Check
Accelerator
VCM 3E — — connection to Generic Yellow
04 pedal power
VCM
02 Cruise Check
VCM 5C 03 — — Control connection to Generic Yellow
04 power VCM
0B Check
Cruise control
VCM 5A 0C — — connection to Generic Yellow
sensor
0D VCM
Check
Cruise control
VCM 5E 0E — — connection to Generic Yellow
sensor
VCM
03 Excessively Check
VCM 41 04 — — frequent connection to Generic Yellow
0A inputs VCM
Check
Cruise control
VCM 5D 0D — — connection to Generic Yellow
sensor
VCM
0C Check
VCM F2 0D — — Internal error connection to Severe Red
0E VCM
0D Check
VCM FD 0E — — Internal error connection to Generic Yellow
1F VCM
02 Check
VCM FB — — Internal error connection to Severe Red
0D VCM
0B Check
0C
VCM FE 0D — — Internal error connection to Severe Red
0E VCM
0C Check
VCM FF — — Internal error connection to Severe Red
0D VCM
Check
VCM F3 0D — — Internal error connection to Severe Red
VCM
Check
VCM F4 02 — — Internal error connection to Generic Yellow
VCM
02
0B Check
VCM B4 0C — — Immobilizer connection to Generic Yellow
0D VCM
0E
02 Check
VCM B5 — — Immobilizer connection to Generic Yellow
0B VCM
0C Check
VCM B6 0D — — Immobilizer connection to Generic Yellow
0E VCM
Notes /
First Second Signal
code code type
type
02 Check
0B VCM
Check
VCM B8 02 — — Immobilizer connection to Generic Yellow
VCM
02
Check
07
0B
VCM
0C
Check
Auxiliary user
VCM BA 02 — — connection to Generic Yellow
1
VCM
Check
Auxiliary user
VCM BB 02 — — connection to Generic Yellow
2
VCM
Check
Auxiliary user
VCM IBC 02 — — connection to Generic Yellow
3
VCM
Check
Auxiliary user
VCM BD 02 — — connection to Severe Red
4
VCM
Check
Auxiliary user
VCM BE 02 — — connection to Severe Red
5
VCM
00
01 Check
VCM 64 0B — — Engine brake connection to Generic Yellow
0C VCM
12
Check
VCM
Check
VCM
Check
VCM
Check
VCM
Check
VCM
Check
VCM 6A 0B — — Engine brake connection to Generic Yellow
VCM
Check
NORTH
VCM 6F 13 — — connection to Generic Yellow
function
VCM
Notes /
First Second Signal
code code type
type
Check
NORTH
VCM 70 0D — — connection to Generic Yellow
function
VCM
Check
NORTH
VCM 71 12 — — connection to Generic Yellow
function
VCM
Check
NORTH
function
VCM
Check
NORTH
VCM 73 0B — — connection to Generic Yellow
function
VCM
00
01 Check
VCM 74 0B — — Tachograph connection to Generic Yellow
0C VCM
12
02 Check
VCM 75 0B — — Speed sensor connection to Generic Yellow
13 VCM
02 Engine Check
VCM 76 0B — — temperature connection to Generic Yellow
13 sensor VCM
00 Cruise
Check
Control
external
11 VCM
control
01
02 Check
Expansion connection to
VCM 78 0C — — Module VCM Generic Yellow
10 interface
11
Check
VCM 79 0B — — Speed sensor connection to Generic Yellow
VCM
Check
VCM 7A 0B — — Speed sensor connection to Generic Yellow
VCM
Check
VCM 7B 0B — — Speed sensor connection to Generic Yellow
VCM
02 Check
Cruise
VCM 7D — — connection to Generic Yellow
0C Control
VCM
Check
Cruise
VCM 7F 02 — — connection to Generic Yellow
Control
VCM
Check
Cruise
VCM 80 0B — — connection to Generic Yellow
Control
VCM
Cruise
0C Check
Control
VCM 81 — — connection to Generic Yellow
external
0B VCM
control
Notes /
First Second Signal
code code type
type
Gear sensor Check
VCM 84 0C — — on connection to Generic Yellow
transmission VCM
02 Check
Vehicle
VCM 88 — — connection to Generic Yellow
0E driveability
VCM
Check
AS-Tronic
ECU
VCM
Check
AS-Tronic
ECU
VCM
Check
AS-Tronic
ECU
VCM
02 Check
AS-Tronic
VCM 9A — — connection to Generic Yellow
0C ECU
VCM
02 Check
AS-Tronic
VCM 9B — — connection to Generic Yellow
0C ECU
VCM
Check
VCM 9C 0C — — Service brake connection to Severe Red
VCM
Check
VCM 9D 0C — — Intarder connection to Generic Yellow
VCM
Check
Engine cooling
VCM 9E 0C — — connection to Generic Yellow
fan
VCM
Check
VCM 9F 0C — — Engine brake connection to Generic Yellow
VCM
01
02 Check
CAN VDB
VCM C9 03 — — connection to Generic Yellow
line
04 VCM
0C
01
02 Check
CAN VDB
VCM CA 03 — — connection to Generic Yellow
line
04 VCM
06
06 Check
CAN VDB
VCM CB — — connection to Generic Yellow
08 line
VCM
Check
CAN VDB
VCM CC 01 — — connection to Generic Yellow
line
VCM
CAN VDB Check

VCM CD 01 — — connection to Generic Yellow
line
VCM
01 Check
CAN VDB
VCM CE — — connection to Generic Yellow
02 line
VCM
Notes /
First Second Signal
code code type
type
Check
CAN VDB
VCM CF 06 — — connection to Generic Yellow
line
VCM
Check
CAN VDB
VCM D0 09 — — connection to Generic Yellow
line
VCM
0A Check
connection to
VCM D2 — — CAN ECB line VCM Generic Yellow
13
01
02
04 Check
VCM D3 06 — — CAN ECB line connection to Generic Yellow
07 VCM
09
0F
01 Check
VCM D4 — — CAN ECB line connection to Generic Yellow
02 VCM
Check
VCM D5 09 — — CAN ECB line connection to Generic Yellow
VCM
13 Check
VCM DC — — CAN ECB line connection to Generic Yellow
0A VCM
01 Check
VCM DD — — CAN ICB line connection to Generic Yellow
06 VCM
Check
VCM DF 01 — — CAN ICB line connection to Generic Yellow
VCM
Check
VCM E2 02 — — CAN ICB line connection to Generic Yellow
VCM
01 Check
VCM E3 — — CAN ICB line connection to Generic Yellow
02 VCM
13 Check
VCM E6 — — CAN FMS line connection to Generic Yellow
0A VCM
01
02
03
04
Check
05
VCM E7 — — CAN FMS line connection to Generic Yellow
06 VCM
07
08
09
0A
ENGINE CONTROL MODULE (ECM)

First Second Signal Notes / Ope-
ECU type code code ECU pin type Fault source ration type Fault type Colour
03 — — Check battery
ECM 26 Batteries flat Generic Yellow
04 — — charge
03 — — Check
ECM 27 Engine brake operation of Generic Yellow
04 — — engine brake
03 — — Check main
ECM 28 Main relais Generic Yellow
04 — — relay
02 — — Check
VGT operation of
ECM 2B 03 — — pneumatic VGT Generic Yellow
actuator pneumatic
04 — — actuator
02 — — Engine Check engine
03 — — coolant coolant
ECM 31 Generic Yellow
04 — — temperature temperature
0C — — sensor sensor
02 — —
Check VGT
03 — — VGT pressure
ECM 34 pressure Generic Yellow
04 — — sensor
sensor
0C — —
03 — — Fuel Check fuel
ECM 35 temperature temperature Generic Yellow
04 — — sensor sensor
02 — —
Check oil
03 — — Oil pressure
04 — — sensor
sensor
0C — —
02 — —
Oil Check oil
03 — —
ECM 3A temperature temperature Generic Yellow
0C — —
02 — — Check fuel
Fuel pressure
ECM 3D 03 — — pressure Severe Red
sensor
04 — — sensor
03 — — Check
Crankshaft
ECM 41 crankshaft Generic Yellow
04 — — sensor
sensor
Check
Crankshaft
ECM 42 04 — — crankshaft Generic Yellow
sensor
sensor
03 — — Check
Crankshaft
04 — — sensor
sensor
03 — — Check
Crankshaft
0C — — sensor
sensor
02 — —
03 — — Check cylinder
ECM 51 Cylinder 1 Generic Yellow
04 — — 1
0C — —

02 — —
04 — — 2
0C — —
02 — —
04 — — 3
0C — —
02 — —
04 — — 4
0C — —
02 — —
04 — — 5
0C — —
02 — —
04 — — 6
0C — —
02 — —
04 — — 1
0C — —
02 — —
04 — — 2
0C — —
02 — —
04 — — 3
0C — —
02 — —
04 — — 4
0C — —
02 — —
04 — — 5
0C — —
02 — —
04 — — 6
0C — —
02 — —
04 — — 1
0C — —
02 — —
04 — — 2
0C — —
02 — —
04 — — 3
0C — —

02 — —
ECM 6A Cylinder 4 Generic Yellow
04 — — 4
0C — —
02 — —
ECM 6B Cylinder 5 Generic Yellow
04 — — 5
0C — —
02 — —
ECM 6C Cylinder 6 Generic Yellow
04 — — 6
0C — —
02 — —
03 — — Cylinder Check cylinder
04 — — alignment alignment
0C — —
02 — —
0C — —
02 — —
0C — —
02 — —
0C — —
02 — —
03 — — Check engine
ECM 7C Engine stop Generic Yellow
04 — — stop
0C — —
02 — — Check injection
ECM 7E 03 — — Injection limit Generic Yellow
system
04 — —
04 — — Incorrect
Check engine
ECM 7F engine Generic Yellow
0C — — programming
programming
02 — — Check VGT
VGT pressure
ECM 91 03 — — pressure Generic Yellow
sensor
04 — — sensor
02 — — Check VGT
03 — — VGT pressure
04 — — sensor
sensor
0C — —
02 — —
03 — — VGT speed Check VGT
04 — — sensor speed sensor
0C — —
03 — —
ECM 98 PCR error PCR error Generic Yellow
04 — —
02 — —
ECM 99 03 — — PCR error PCR error Generic Yellow
04 — —

02 — —
ECM 9A PCR error PCR error Generic Yellow
03 — —
VGT high
ECM 9B 03 — — speed and Check VGT Generic Yellow
high pressure
03 — — Torque
ECM 9D Check engine Generic Yellow
04 — — limiter
03 — — Torque
ECM 9E Check engine Generic Yellow
04 — — limiter
CAN A, B, C Check CAN A,
ECM B1 03 — — Generic Yellow
lines B, C lines
Check
ECM B5 02 — — VCM timeout connection to Generic Yellow
centralina VCM
Check
ECM B4 02 — — IBC timeout connection to Generic Yellow
centralina IBC
MIL warning Check exhaust
ECM B9 03 — — Generic Yellow
light system
ECM IBC 02 — — Generic Yellow
light system
ECM BD 02 — — Generic Yellow
light system
ECM BF 02 — — Generic Yellow
light system
02 — — Torque
ECM C8 Check engine Generic Yellow
03 — — limiter
Check
connection to
ECM C2 02 — — ETC timeout Generic Yellow
ETC control
unit
02 — — Torque
ECM C6 Check engine Generic Yellow
03 — — limiter
Check
DTCO
ECM C3 02 — — connection to Generic Yellow
timeout
DTCO
Check
ECM C9 02 — — TF timeout connection to Generic Yellow
TF
Communica- Check CAN
ECM D1 03 — — Severe Red
tion error line
ECM D3 0C — — Severe Red
tion error line
ECM D4 0C — — Generic Yellow
tion error line
02 — —
ECM D5 04 — — Generic Yellow
tion error line
0C — —
tion error line
02 — — Controllare
ECM D7 Dataset ECM Severe Red
0C — — dataset ECM
tion error line

02 — —
03 — — Communication Check CAN
ECM D9 Generic Yellow
04 — — error line
0C — —
02 — —
Communication Check CAN
ECM E1 03 — — Generic Yellow
error line
04 — —
Check
ECM E2 04 — — Immobilizer Immobilizer Severe Red
programming
ECM E3 03 — — Severe Red
error line
error line
03 — — Battery charge Check battery
ECM E5 Generic Yellow
04 — — sensor charge
error line
ECM EA 04 — — Severe Red
error line
ECM F1 0C — — Generic Yellow
error line
ECM F2 Generic Yellow
ECM F5 03 — — Generic Yellow
error line
03 — —
ECM F7 04 — — Generic Yellow
error line
0C — —
error line
error line
ECM FA 0C — — Generic Yellow
error line
ECM FB 0C — — Generic Yellow
error line
03 — — Check
Temperature
temperature
ECM FC 04 — — sensor on Generic Yellow
sensor on
0C — — exhaust 1
exhaust 1
Check exhaust
Exhaust gas
ECM FD 0C — — temperature Generic Yellow
temperature
sensor

03 — — Check
Temperature
temperature
ECM FE 04 — — sensor on Generic Yellow
sensor on
0C — — exhaust 2
exhaust 2
Check urea
ECM FF 03 — — Urea injection injection Generic Yellow
system
Check urea
Exhaust gas
ECM 4F — — — injection Generic Yellow
emission level
system
SELECTIVE CATALYST REDUCTION (SCR)

Notes /
First Second Signal
code code type
type
Check
03 — — Post-cat
post-cat
SCR 15 temperature Generic Yellow
temperature
04 — — sensor
sensor
02 — — Check urea
Urea pressure pressure
SCR 19 03 — — Generic Yellow
sensor sensor
04 — — connection
05 — — Check urea
SCR 21 Urea heater heater electric Generic Yellow
0A — — connection
07 — —
Urea pump Check urea
module pump module
0B — —
05 — — Urea cooling Check urea
SCR 55 Generic Yellow
0B — — fan cooling fan
Urea cooling Check urea
SCR 56 0C — — Generic Yellow
fan cooling fan
SCR 58 0B — — Generic Yellow
fan cooling fan
SCR 59 0B — — Generic Yellow
fan cooling fan
Check urea
Low urea
SCR 74 02 — — system Generic Yellow
pressure
pressure
SCR 78 Generic Yellow
08 — — fan cooling fan
SCR 7A Generic Yellow
07 — — fan cooling fan
Urea circuit Check urea
leakage system
Urea circuit Check urea
SCR 9A 11 — — Generic Yellow
leakage system
Check
14 — — Post-cat
post-cat
SCR E1 temperature Generic Yellow
temperature
19 — — sensor
sensor
14 — — Pre-cat Check pre-cat
SCR E2 temperature temperature Generic Yellow
Check urea
SCR E3 0B — — Generic Yellow
sensor sensor
connection
Check urea
SCR EA 11 — — Generic Yellow
sensor sensor
connection
09 — — Exhaust gas Check
SCR A2 Generic Yellow
0A — — temperature exhaust
07 — — Very high urea Check urea
SCR D4 Generic Yellow
0C — — temperature temperature
AS-TRONIC (ETC)
Notes /
First Second Signal
code code type
type
AS-Tronic Check
ETC 02 05 — — transmission connection to Severe Red
(splitter valve) splitter valve
AS-Tronic Check
AS-Tronic
Check
transmission
ETC 04 05 — — connection to Severe Red
(selector
selector valve
valve)
AS-Tronic
Check
transmission
(selector
selector valve
valve)
AS-Tronic Check
(shift valve) shift valve
AS-Tronic Check
Check
AS-Tronic
transmission
ETC ECU
Check
Cambio
AS-Tronic
ETC ECU
AS-Tronic Check
ETC 0A 05 — — transmission connection to Severe Red
(main valve) main valve
Check PTO 1
PTO 1 to
ETC 0D 00 — — connection to Severe Red
transmission
transmission
Check PTO 2
PTO 2 to
ETC 0E 00 — — connection to Severe Red
transmission
transmission
AS-Tronic Check
ETC 11 05 — — transmission connection to Generic Yellow
(brake valve) brake valve
AS-Tronic Check
(clutch valve) clutch valve
AS-Tronic Check
(clutch valve) clutch valve
AS-Tronic Check
(clutch valve) ETC ECU
Check
AS-Tronic
transmission
ETC ECU
Notes /
First Second Signal
code code type
type
Check
connection to
ETC 1A 04 — — CAN line Generic Yellow
rest of CAN
line
Check
Incoherent
ETC 1B 08 — — parameters Generic Yellow
parameters
set in EOL
Check
ETC 1C 08 — — Intarder connection to Generic Yellow
Intarder
Check hot
Engine oil
ETC 1D 08 — — engine oil Generic Yellow
temperature
temperature
Check
Incoherent
ETC 1E 08 — — parameters Generic Yellow
parameters
set in EOL
Check
ETC 1F 08 — — Intarder connection to Generic Yellow
Intarder
Check
ETC 20 08 — — Intarder connection to Generic Yellow
Intarder
Check
connection to
ETC 21 04 — — CAN line Generic Yellow
rest of CAN
line
AS-Tronic Check
ETC 22 0A — — transmission connection to Severe Red
AS-Tronic Check
AS-Tronic
Check
transmission
ETC 24 0A — — connection to Severe Red
(selector
selector valve
valve)
AS-Tronic
Check
transmission
(selector
selector valve
valve)
AS-Tronic Check
AS-Tronic Check
Check
AS-Tronic
transmission
ETC ECU
Check
AS-Tronic
transmission
ETC ECU
Notes /
First Second Signal
code code type
type
AS-Tronic Check
ETC 2A 0A — — transmission connection to Severe Red
Check PTO 1
PTO 1 to
ETC 2D 00 — — connection to Generic Yellow
transmission
transmission
Check PTO 2
PTO 2 to
ETC 2E 00 — — connection to Generic Yellow
transmission
transmission
AS-Tronic Check
ETC 31 0A — — transmission connection to Generic Yellow
Check
ETC 32 0A — — Clutch valve off connection to Generic Yellow
clutch valve
Check
Clutch valve
ETC 33 0A — — connection to Generic Yellow
on
clutch valve
Check
ETC 34 0A — — Clutch valve off connection to Generic Yellow
clutch valve
Check
Clutch valve
ETC 35 0A — — connection to Generic Yellow
on
clutch valve
Check
AS-Tronic
transmission
ETC ECU
Check PTO 1
PTO 1 to
ETC 3B 08 — — connection to Generic Yellow
transmission
transmission
Check PTO 2
PTO 2 to
ETC 3C 08 — — connection to Generic Yellow
transmission
transmission
Check PTO 1
PTO 1 to disconnection
ETC 3D 08 — — Generic Yellow
transmission from
transmission
Check PTO 2
PTO 2 to disconnection
ETC 3E 08 — — Severe Red
transmission from
transmission
Check PTO 1
PTO 1 to
ETC 3F 08 — — on from Severe Red
transmission
transmission
Check PTO 2
PTO 2 to
ETC 40 08 — — on from Generic Yellow
transmission
transmission
AS-Tronic Check
Notes /
First Second Signal
code code type
type
AS-Tronic Check
AS-Tronic
Check
transmission
(selector
selector valve
valve)
AS-Tronic
Check
transmission
(selector
selector valve
valve)
AS-Tronic Check
AS-Tronic Check
Check
AS-Tronic
transmission
ETC ECU
Check
AS-Tronic
transmission
ETC ECU
AS-Tronic Check
ETC 4A 06 — — transmission connection to Generic Yellow
Check PTO 1
PTO 1 to
ETC 4D 06 — — connection to Generic Yellow
transmission
transmission
Check PTO 2
PTO 2 to
ETC 4E 06 — — connection to Generic Yellow
transmission
transmission
AS-Tronic Check
Check
Clutch valve
off
clutch valve
Check
Clutch valve
on
clutch valve
Check
Clutch valve
off
clutch valve
Check
AS-Tronic
ETC 55 06 — — connection to Generic Yellow
transmission
clutch valve
Check
AS-Tronic
transmission
ETC ECU
Notes /
First Second Signal
code code type
type
Check
connection to
ETC 5A 09 — — CAN line Severe Red
rest of CAN
line
Check
connection to
ETC 5B 04 — — CAN line Generic Yellow
rest of CAN
line
Check
ETC 5C 08 — — ABS connection to Generic Yellow
ABS
Check
ETC 5D 08 — — ASR connection to Generic Yellow
ASR
Check
ETC 5E 08 — — ASR connection to Generic Yellow
ASR
Check
Cruise connection to
ETC 5F 08 — — Generic Yellow
Control Cruise
Control
Check
Cruise connection to
ETC 60 08 — — Generic Yellow
Control Cruise
Control
Engine speed Check engine
signal speed sensor
signal speed sensor
signal speed sensor
signal speed sensor
ETC 65 08 — — Severe Red
signal speed sensor
signal speed sensor
signal speed sensor
Check battery
ETC 68 01 — — High voltage Generic Yellow
charge
Check battery
ETC 69 02 — — Low voltage Severe Red
charge
Battery Check battery
ETC 6B 02 — — Generic Yellow
voltage charge
Check
ETC 6C 00 — — Gear selector connection to Generic Yellow
gear selector
Check Check
connection to
ETC 6E 00 — — CAN line Generic Yellow
rest of CAN
line

Check clutch
ETC 71 04 — — Clutch Generic Yellow
operation
Check clutch
ETC 72 00 — — Clutch Severe Red
operation
Check clutch
operation
Check clutch
disengagement
Check clutch
disengagement
Check clutch
disengagement
Check clutch
disengagement
Check clutch
ETC 7A 00 — — Clutch Generic Yellow
engagement
Check clutch
ETC 7B 00 — — Clutch Generic Yellow
engagement
Check clutch
ETC 7C 00 — — Clutch Generic Yellow
engagement
Pressure Check pressure
ETC 7E 03 — — Generic Yellow
sensor sensor
Check
Temperature
ETC 7F 03 — — temperature Generic Yellow
sensor
sensor
Check
Temperature
ETC 80 00 — — temperature Generic Yellow
sensor
sensor
Gear shift Check gear
sensor shift sensor
sensor shift sensor
ETC 83 0A — — Generic Yellow
sensor shift sensor
sensor shift sensor
sensor shift sensor
sensor shift sensor
ETC 87 0A — — Generic Yellow
sensor shift sensor
sensor shift sensor
sensor shift sensor
ETC 8A 05 — — Generic Yellow
sensor shift sensor
ETC 8B 0A — — Generic Yellow
sensor shift sensor
ETC 8C 00 — — Severe Red
sensor shift sensor
Check
ETC 8D 06 — — Splitter unit connection to Generic Yellow
splitter unit

Check
ETC 8E 05 — — Splitter unit connection to Generic Yellow
splitter unit
Check
ETC 8F 0A — — Splitter unit connection to Generic Yellow
splitter unit
Check
ETC 90 00 — — Splitter unit connection to Severe Red
splitter unit
Gear Check gear
ETC 91 00 — — engagement/ engagement/ Generic Yellow
disengagement disengagement
Check gear
Gear
engagement/
ETC 92 00 — — engagement/ Generic Yellow
disengagement
disengagement
marce
Gear Check gear
ETC 93 00 — — engagement/ engagement/ Severe Red
ETC 94 00 — — Splitter unit Splitter not off Generic Yellow
Check gear
Gear
engagement/
ETC 95 00 — — engagement/ Generic Yellow
disengagement
disengagement
marce
ETC 96 00 — — Splitter unit Splitter not on Severe Red
Selector Selector
cylinder cylinder not off
Gear Check gear
ETC 98 00 — — engagement/di engagement/di Generic Yellow
sengagement sengagement
Selector Selector
cylinder cylinder not on
Gear Check gear
ETC 9A 00 — — engagement/ engagement/ Severe Red
Gear Check gear
ETC 9B 00 — — engagement/ engagement/ Severe Red
Gear Check gear
ETC 9C 00 — — engagement/ engagement/ Severe Red
Gear Check gear
ETC 9D 00 — — engagement/ engagement/ Generic Yellow
Gear Check gear
ETC 9E 00 — — engagement/ engagement/ Generic Yellow
Gear Check gear
ETC 9F 00 — — engagement/ engagement/ Generic Yellow
Gear Check gear
ETC A0 00 — — engagement/ engagement/ Generic Yellow

Check
Engine-gearbox
ETC A3 00 — — engine-gearbox Generic Yellow
connection
connection
Check
Engine-gearbox
ETC A4 08 — — engine-gearbox Generic Yellow
connection
connection
Incorrect
Accelerator
ETC A5 08 — — accelerator Generic Yellow
pedal
pedal position
Check various
Permanent
ETC A6 00 — — connections to Generic Yellow
”useless” signal
transmission
Check various
Permanent
ETC A8 08 — — connections to Generic Yellow
”useless” signal
transmission
Check cut-off
ETC A9 00 — — Cut-off relay Severe Red
relay state
Check electric
power to
ETC AA 00 — — Fuel feed Severe Red
transmission
ECU
Check
Engine-gearbox
ETC AB 08 — — engine-gearbox Generic Yellow
connection
connection
Check
Engine-gearbox
ETC AE 08 — — engine-gearbox Generic Yellow
connection
connection
Check
Engine-gearbox
ETC AF 04 — — engine-gearbox Generic Yellow
connection
connection
Check
connection to
ETC B1 04 — — CAN line Severe Red
rest of CAN
line
Check
ETC B2 04 — — CAN line connection to Severe Red
rest of CAN
Check
rest of CAN
Check
rest of CAN
Check
rest of CAN
Check
ETC B6 04 — — CAN line connection to Generic Yellow
rest of CAN
Check
ETC B7 04 — — CAN line connection to Generic Yellow
rest of CAN
Notes /
First Second Signal
code code type
type
Check
connection to
ETC B8 04 — — CAN line Generic Yellow
rest of CAN
CAN line
Check ETC
ETC IBC 00 — — ETC ECU Severe Red
ECU
Check ETC
ETC BD 00 — — ETC ECU Severe Red
ECU
Check
Incoherent
ETC BE 00 — — parameters Severe Red
parameters
set in EOL
Check
Incoherent
ETC BF 00 — — parameters Severe Red
parameters
set in EOL
Check ETC
ETC C0 00 — — ETC ECU Generic Yellow
ECU
Check ETC
ETC C1 01 — — ETC ECU Severe Red
ECU
Check ETC
ETC C2 00 — — ETC ECU Generic Yellow
ECU
Check
connection to
ETC C5 08 — — CAN line Generic Yellow
rest of CAN
line
Check
connection to
ETC C7 04 — — CAN line Generic Yellow
rest of CAN
line
Check
connection to
ETC E2 00 — — CAN line Severe Red
rest of CAN
line
Check
connection to
rest of CAN
line
Check
connection to
rest of CAN
line
Check
connection to
ETC F1 00 — — CAN line Severe Red
rest of CAN
line
Check
connection to
ETC F6 00 — — CAN line Severe Red
rest of CAN
line
Check
connection to
ETC FD 00 — — CAN line Severe Red
rest of CAN
line
ANTI BLOCK SYSTEM (ABS)

Notes /
First Second Signal
code code type
type
01
02
03
04
05
Front RH Check front
06
ABS 01 12, 15/18 — phonic wheel RH phonic Generic Yellow
07
sensor wheel sensor
08
09
0A
0B
0C
01
02
03
04
05
Front RH Check front
06
07
sensor wheel sensor
08
09
0A
0B
0C
01
02
03
04
05 Rear LH Check rear
06
ABS 03 11, 14/18 — phonic wheel LH phonic Generic Yellow
07
sensor wheel sensor
08
09
0A
0B
0C
01
02
03
04
05
Rear RH Check rear
06
07
sensor wheel sensor
08
09
0A
0B
0C
03 Check
Front LH ABS connection to
ABS 07 05 3, 6/18 — Generic Yellow
solenoid valve front LH ABS
06 solenoid valve
Notes /
First Second Signal
code code type
type
03 Check
Front LH ABS connection to
solenoid valve front LH ABS
06 solenoid valve
03 Check
Rear LH ABS connection to
solenoid valve rear LH ABS
06 solenoid valve
03 Check
Rear RH ABS connection to
ABS 0A 05 8, 9/18 — Generic Yellow
solenoid valve rear RH ABS
06 solenoid valve
03
Check ABS
ABS 0D 05 14/15 — ABS ECU Generic Yellow
ECU
06
04
Check ABS
ABS 0E 05 8, 9/14 — ABS ECU Generic Yellow
ECU
07
03
04
Check ABS
ABS 0F 05 — — ABS ECU Generic Yellow
ECU
06
07
03 Check ABS
ABS 10 2/15 — ABS ECU Generic Yellow
05 ECU
03
Check ABS
ABS 12 05 7, 16/18 — ABS ECU Generic Yellow
ECU
06
03
Check ABS
ABS 13 05 13/15 — ABS ECU Generic Yellow
ECU
06
Check ABS
ABS 17 05 15/15 — ABS ECU Generic Yellow
ECU
02
05
06
07 Check ABS
ABS E7 1, 3/15 — ABS ECU Generic Yellow
08 ECU
09
0A
0C

Check fuel feed

ABS FB 03 8/15 — Fuel feed ECU Generic Yellow
(supercharger)
02 Check
Incoherent
ABS FD — — parameters set Generic Yellow
0C parameters
in EOL
05
08 Check ABS
ABS FE — — ABS ECU Generic Yellow
09 ECU
0C
INTARDER (EST)
Notes /
First Second Signal
code code type
type
Check
Pin 1 / Recharge connection to
EST 01 05 — Generic Yellow
AD1 valve recharge valve
(earth)
Check
Pin 1 / Recharge connection to
AD1 valve recharge valve
(positive)
Check
Pin 1 / Recharge
EST 03 0A — connection to Generic Yellow
AD1 valve switch
recharge valve
Check
Pin 4 / Proportioning connection to
AIP valve proportioning
valve (earth)
Check
connection to
Pin 4 / Proportioning
EST 1A 06 — proportioning Generic Yellow
AIP valve
valve
(positive)
Check
EST 1B 0A — Generic Yellow
AIP valve switch proportioning
valve switch
Check
EST 1C 09 — Generic Yellow
AIP valve switch proportioning
valve switch
Check
EST 1D 05 — Generic Yellow
ADM1 valve proportioning
valve
Check
EST 1E 06 — Generic Yellow
ADM1 valve proportioning
valve
Check
Speed sensor connection to
Pin 8 /
EST 22 04 — on output speed sensor Generic Yellow
EF1
shaft on output
shaft
Check
Pin 9 / Temperature connection to
EST 25 0A — Generic Yellow
ER1 sensor temperature
sensor
Check
Pin 9 / Temperature connection to
ER1 sensor temperature
sensor
Check
Proportioning connection to
EST 27 02 — — Generic Yellow
valve proportioning
valve
Notes /
First Second Signal
code code type
type
Check
Proportioning connection to
EST 28 01 — — Generic Yellow
valve proportioning
valve
Pin 54 /
+30 power Check +30
EST 29 0A VPE1 Pin — Generic Yellow
interrupted power line
55 / Vpe2
Pin 53 / Check +15
EST 2A 01 VPI1 Pin — +15 power power line Generic Yellow
31 / VPI2 (overload)
Pin 53 / Check +15
EST 2B 02 VPI1 Pin — +15 power power line Generic Yellow
31 / VPI2 (underload)
Check
connection to
EST 2C 03 — — CAN line Generic Yellow
rest of CAN
line
Check
Incoherent
EST 2D 00 — — parameters Generic Yellow
parameters
set in EOL
Check hour
EST 2E 00 — — Hour meter Generic Yellow
meter (lost)
Check error
EST 2F 00 — — Error memory Generic Yellow
memory (lost)
Pin 22 /
CAN
Check
F-H, Pin
connection to
EST 31 04 49 / — CAN line Generic Yellow
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Check EST
EST 33 00 — — EST ECU Generic Yellow
ECU
Pin 22 /
CAN
Check
F-H, Pin
connection to
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Pin 22 /
CAN
Check
F-H, Pin
connection to
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Notes /
First Second Signal
code code type
type
Pin 22 /
CAN
Check
F-H, Pin
connection to
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Pin 22 /
CAN
Check
F-H, Pin
connection to
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Pin 22 /
CAN
Check
F-H, Pin
connection to
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Pin 22 /
CAN
Check
F-H, Pin
connection to
EST 3A 04 49 / — CAN line Generic Yellow
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Pin 22 /
CAN
Check
F-H, Pin
connection to
EST 3E 04 49 / — CAN line Generic Yellow
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Pin 22 /
CAN
Check
F-H, Pin
connection to
EST 3F 04 49 / — CAN line Generic Yellow
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Pin 22 /
CAN
Check
F-H, Pin
connection to
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Notes /
First Second Signal
code code type
type
Pin 22 /
CAN
Check
F-H, Pin
connection to
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Pin 22 /
CAN
Check
F-H, Pin
connection to
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
Pin 22 /
CAN
Check
F-H, Pin
connection to
rest of CAN
CANF-L,
line
Pin 24 /
VMH-F
EXPANSION MODULE (EM)

Notes /
First Second Signal
code code type
type
Above normal
Solenoid valve voltage, check
EM 22 03 - — Generic Yellow
PTO1 for short
circuit
Above normal
PTO1 for short
circuit
Below normal
Solenoid valve
EM 22 05 - — current or Generic Yellow
PTO1
open circuit
Above normal
PTO2 for short
circuit
Above normal
PTO2 for short
circuit
Below normal
Solenoid valve
PTO2
open circuit
Above normal
PTO3 for short
circuit
Above normal
PTO3 for short
circuit
Below normal
Solenoid valve
PTO3
open circuit
PTO module:
Incorrect,
activation
EM 30 02 - — intermittent or Generic Yellow
PTO1
wrong data
limitation
PTO module: Incorrect,
EM 31 02 - — PTO1 stop intermittent or Generic Yellow
condition wrong data
PTO module:
activation Special
EM 32 OD - — Generic Yellow
PTO1 instructions
timeout
PTO module:
deactivation Special
PTO1 instructions
timeout
PTO module:
activation Special
PTO1 not instructions
requested
Notes /
First Second Signal
code code type
type
PTO module:
requested
PTO module:
Incorrect,
activation
EM 36 02 - — intermittent or Generic Yellow
PTO2
wrong data
limitation
EM 37 02 - — PTO2 stop intermittent or Generic Yellow
PTO module:
activation Special
PTO2 instructions
timeout
PTO module:
PTO2 instructions
timeout
PTO module:
activation Special
EM 3A OD - — Generic Yellow
requested
PTO module:
EM 3B OD - — Generic Yellow
requested
PTO module:
Incorrect,
activation
EM 3C 02 - — intermittent or Generic Yellow
PTO3
wrong data
limitation
EM 3D 02 - — PTO3 stop intermittent or Generic Yellow
PTO module:
activation Special
EM 3E OD - — Generic Yellow
PTO3 instructions
timeout
PTO module:
EM 3F OD - — Generic Yellow
PTO3 instructions
timeout
PTO module:
activation Special
requested
PTO module:
requested

CABIN AND CHASSIS LHD
SECTION 18 A
HD9 Euro5 SECTION 18 A CAB AND CHASSIS LHD 1
SECTION 18 A
Cabin and chassis LHD

Page
CABIN 7
DESCRIPTION 7
CABIN REMOVAL-REFITTING 9
GENERAL 9
- Removal 10
- Reassembly 18
DOOR REMOVAL-REFITTING 19
GENERAL 19
- Removal 20
- Refitting 21
COWL REMOVAL-REFITTING 23
GENERAL 23
2 CAB AND CHASSIS LHD SECTION 18 A HD9 Euro5
DESCRIPTION OF OPERATION 24 - Inspections and checks 30

- Removal 24 - Final operations 30
- Inspections and checks 24 BUMPER REMOVAL-REFITTING 31
- Refitting 24 GENERAL 31
- Final operations 24 - Safety instructions 31
WINDSCREEN WASHER ARM REMOVAL- - Vehicle preparation 31
REFITTING 25
GENERAL 25
- Removal 32
- Refitting 32
- Removal 26
- Refitting 26
STEERING COLUMN REMOVAL-REFITTING 33
GENERAL 33
CABIN FRONT SHOCK ABSORBER REMOVAL-
REFITTING 27 - Safety instructions 33
GENERAL 27 - Vehicle preparation 33
- Safety instructions 27 - Very heavy parts 33
- Very heavy parts 27 DESCRIPTION OF OPERATION 34
- Specific safety instructions 27 - Removal 34
DESCRIPTION OF OPERATION 28 - Replacement 40
- Preliminary operations 28 STEERING COLUMN PNEUMATIC CYLINDER
REMOVAL-REFITTING 41
- Removal 28
GENERAL 41
- Refitting 28
CABIN REAR SHOCK ABSORBER REMOVAL-
REFITTING 29 - Specific safety instructions 41
- Safety instructions 29 - Preliminary operations 42
- Very heavy parts 29 - Removal 42
- Specific safety instructions 29 - Steering control components 43
- Preliminary operations 30 - Determination of adjuster shim thickness 44
- Removal 30 - Refitting 45
PEDAL UNIT REMOVAL-REFITTING 46 GENERAL 58

GENERAL 46 - Safety instructions 58
- Safety instructions 46 - Vehicle preparation 58
- Vehicle preparation 46 - Hazardous and/or polluting substances 58
- Hazardous and/or polluting substances 46 DESCRIPTION OF OPERATION 59
DESCRIPTION OF OPERATION 47 - Removal 59
- Removal 47 INNER DOOR LINING REMOVAL-REFITTING 60
DASHBOARD REMOVAL-REFITTING 49 - Vehicle preparation 60
GENERAL 49 - Hazardous and/or polluting substances 60
- Safety instructions 49 DESCRIPTION OF OPERATION 61
- Vehicle preparation 49 - Removal 61
DESCRIPTION OF OPERATION 50 - Refitting 62
- Removal 50 DOOR WINDING WINDOW REMOVAL-
REFITTING 63
- Refitting 50
GENERAL 63
CENTRAL DASHBOARD REMOVAL-REFITTING 51
GENERAL 51
- Removal 52
- Removal 64
- Refitting 52
- Refitting 64
DASHBOARD (INSTRUMENT PANEL) REMOVAL-
REFITTING 53 - Final operations 64
GENERAL 53 DOOR WINDOW WINDER DEVICE REMOVAL-
REFITTING 65
GENERAL 65
- Removal 54
- Removal 66
- Refitting 57
- Refitting 66
SEAT REMOVAL-REFITTING 58
DOOR LOCK REMOVAL-REFITTING 67 - Hazardous and/or polluting substances 74

- Refitting 68 FIXED DOOR WINDOW REPLACEMENT 80
DOOR HANDLE REMOVAL-REFITTING 69 - Safety instructions 80
- Safety instructions 69 - Specific safety instructions 80
DESCRIPTION OF OPERATION 70 DESCRIPTION OF OPERATION 81
- Preliminary operations 70 - Preliminary operations 81
- External handle 70 - Inspections and checks 81
- Internal handle 70 - Refitting 82
- Refitting 70 - Final operations 82
- Final operations 70 CABIN TIPPING DEVICE 83
REAR-VIEW MIRRORS REMOVAL-REFITTING 71 DESCRIPTION 83
GENERAL 71 - Component location 83
- Safety instructions 71 - Cabin tipping system diagram 84
- Vehicle preparation 71 CABIN TIPPING HYDRAULIC FLUID CHANGE 85
DESCRIPTION OF OPERATION 72 GENERAL 85
- Removal 72 - Safety instructions 85
- Main mirrors and supplementary mirror on door 72 - Hazardous and/or polluting substances 85
- Close-proximity mirror (right-hand door only) 73 DESCRIPTION OF OPERATION 86
- Refitting 73 - Drainage 86
WINDSCREEN REPLACEMENT 74 - Filling 86
GENERAL 74 CABIN LIFTING PUMP REMOVAL-REFITTING 87
- Safety instructions 74 GENERAL 87
- Vehicle preparation 74 - Safety instructions 87
- Very heavy parts 74 - Vehicle preparation 87
- Specific safety instructions 74 - Hazardous and/or polluting substances 87
DESCRIPTION OF OPERATION 88 COMPRESSOR REMOVAL-REFITTING CLIMATE

CONTROL 98
GENERAL 98
- Removal 88
- Refitting 88
CABIN TIPPING CYLINDER REMOVAL-REFITTING 89
GENERAL 89
- Removal 99
- Refitting 99
CLUTCH REMOVAL-REFITTING ELECTRO-
- Preliminary operations 90 MAGNETIC COMPRESSOR CLIMATE CONTROL 100
- Removal 90 GENERAL 100
- Inspections and checks 90 - Safety instructions 100
- Refitting 90 - Vehicle preparation 100
CABIN CLIMATE CONTROL 91 - Preliminary operations 101
- Overview 91 - Removal 101
VENTILATION 91 - Refitting 101
- Description 91 - Final operations 102
- Climate controlled air flow orientation 91 CLIMATE CONTROL UNIT REMOVAL-REFITTING 103
AIR CONDITIONING 92 GENERAL 103
- Description 92 - Safety instructions 103
- Conditioning 92 - Vehicle preparation 103
- Heating 92 - Very heavy parts 103
- Air conditioning 92 - Hazardous and/or polluting substances 103
- Air conditioning control group 92 DESCRIPTION OF OPERATION 104
DIAGNOSTICS 93 - Preliminary operations 104
- Troubleshooting guide 93 - Removal 104
- Introduction 93 - Refitting 105
- Troubleshooting by symptoms 93 - Final operations 105
GENERAL RECOMMENDATIONS 97 PROCEDURE FOR DRAINING AND RECHARGING
THE AIR-CONDITIONER WITH R134a COOLANT 106
- R134a coolant recharge and recovery station

(99305146) 106
SAFETY STANDARDS 107
CONTROL PANEL 108
OPERATIONS FLOW DIAGRAM 110
REFRIGERANT RECOVERY FROM SYSTEM ON
VEHICLE 111
CREATING VACUUM IN SYSTEM 113
RESTORING SYSTEM OIL LEVEL 115
CHARGING PLANT WITH REFRIGERANT 116
CHECKING SYSTEM PRESSURES 118
OPERATIONS PRIOR TO REMOVING
STATION FROM SYSTEM 118
LEAK DETECTOR FOR AIR CONDITIONING
SYSTEMS WITH HFC R134a (9905147) 118
CABIN
DESCRIPTION
The cab is hinged at the front and suspended both to front and
rear on the chassis:
- to the front by two longitudinal arms with springs, shock
absorbers, buffers and anti-roll torque bar;
- to the rear by two control arms with springs, shock absor-
bers and buffers.
The cabin can be tipped forward by means of a manually con-
trolled hydraulic cylinder.
Figure 1
357A018001R
TIGHTENING TORQUES
357A018002R
CABIN REMOVAL-REFITTING Very heavy parts

GENERAL
Vehicle preparation

signboards.
Safety component.
Tighten the fasteners to the specified torque.
Figure 2
2371801

of short circuits;

Proceed as follows: - tip the cab as described in the Use section of the USE
- drain off the fluid from the climate control as described AND MAINTERNANCE HANDBOOK.
in CLIMATE CONDITIONER FLUID CHANGE in this - For versions with manual/servo-assisted transmission
Section; only: disconnect the manual gear control lever (1);
- drain off the fluid from the cooling system as described in
the Maintenance section of the USE AND MAINTEN- Mark the matching points of the parts.
ANCE HANDBOOK;
- open the cowl as described in the Use section of the USE
- disconnect the quick couplings (2) and (3) of the reservoir
- For versions with manual/servo-assisted transmission
bleeding pipes;
only: drain off the clutch control circuit as described in the
CLUTCH CONTROL OIL CHANGE chapter in Section
4. Fluid may leak out during these operations.
- lower the cab as described in the Use section of the USE

only: draw up the hydraulic fluid from the cab tipping
system oil tank as described in the Maintenance section
Figure 3
357A018003R
- loosen the fastening screws (arrow) and remove the - disconnect the main electric power supply cable (3) and
cover (1); withdraw the cable from behind the reservoir;
- disconnect the following from the main chock (2): - disconnect the ground cable (4);
A. WHITE connector
- disconnect the right direction indicator connector (5);
B. BROWN connector.
C. YELLOW connector
D. BLUE connector (if present) The left direction indicator connector is part of the
E. GREENconnector cab wiring.
Proceed as follows:
- raise the cover (a)
- disconnect the low coolant level sensor connector (6);
- turn the stop lever (b)
- remove all the remaining clamps and free the wiring from
- take out the connector (c) the steering plate, resting it on the front bumpers;
Figure 4
357A018200R
- remove the clamps and disconnect the engine coolant

piping (1) and (2) from the cab heater; Pay attention to recuperate the O-rings. Replace
them if they appear damaged.
- remove the clamp and disconnect the piping (3) from the
engine coolant expansion tank;

More coolant may leak out during these operations.
only: disconnect the fitting (6) of the cab tipping hydraulic
system.
Hydraulic fluid may leak out during these operations.

- disconnect the conditioner coolant delivery (4) and
return (5) pipes from the evaporator;
Figure 5
357A018005R
- disconnect the joining plates of the air piping :

(1) cab services
(2) duplex brakes valve
(3) cab services
proceeding as follows (see detail):
 unscrew the half-plate connecting screws
 disconnect the services air piping separating the half-
plate (A) from half-plate (B);
only: disconnect the splitter control supply pipe (4);
Figure 6
357A018006R
- check that the vehicle wheels are straight: if not, align - remove the locking nut (2) and withdraw the cab lifting
them; cylinder fastening screw;
- unscrew the clamping bolts and free the steering sleeve - rest the cylinder (3) on the chassis;
joint (1) from the groove of the steering box;
- remove the front shock absorber plastic protection (not
shown) from both sides;
Do not move the vehicle front wheels so that the - remove the upper and lower locking nuts of the front
steering remains centred when reassembling.
shock absorbers (see arrow);
it is recommended to mark the matching positions
of the parts. - remove the right (5) and left (6) shock absorbers from the
front supports.
Figure 7
357A018007R
- unscrew and remove the five fastening bolts (1) that - unscrew and remove the four fastening bolts (2) that
clamp the right cab support to the chassis; clamp the left cab support to the chassis;
Figure 8
357A018008R
- open both the vehicle doors;

For better cab balance during the operations, place
- using suitable lifting gear, fit the equipment to the upper brackets as shown in the figure (detail).
part of the cab so that the brackets attach correctly to the
horizontal part of the door frame;
Figure 9
357A018009R
- Slightly lift the cab to relieve the suspension springs; - Using a large screwdriver, lift the safety locking plates (1)
from both sides until they release;
Figure 10
357A018010R
- check with extreme care that all elements have been dis-
connected and that all the clamps grouping together wir-
ing and pipes have been severed;
- cautiously lift the cab until fully removing it from the
vehicle;
- place the cab on an appropriate trolley taking care to
centre the locators in their housings :
A. front support corresponding to the hinge pins: insert
the pins in the relevant housings and secure them
turning the end in the bracket.
B. rear support corresponding to the safety hooks:
make certain that both hooks are engaged.
Figure 11
357A018011R
Reassembly Final operations

To refit, follow the removal instructions in reverse order. Start the engine and warm it up until the thermostat opens,
Pay attention to correctly reconnect all previously discon- then check that:
nected electrical connections;
- there is no coolant leakage from the engine cooling or
Carry out the following operations. cab heating system sleeves:
- fill the cooling system as described in the Maintenance - the braking system functions correctly;
Section of the USE AND MAINTENANCE HAND-
- warning lights and instruments function correctly;
BOOK;
- the climate control system functions correctly;
- fill the window washer reservoir as described in the Main-
tenance section of the USE AND MAINTENANCE - the windscreen washer system functions correctly.
HANDBOOK;
CONTROL SYSTEM FLUID CHANGE in this Section.
only: top-up the cab tipping system oil level as described
in the Maintenance section of the USE AND MAINTEN-
ANCE HANDBOOK.
only: fill the clutch control circuit as described in the
4;
- adjust the pre-load of the front shock absorbers as
described in CABIN FRONT SHOCK ABSORBERS RE-
MOVAL-REFITTING in this Section.
DOOR REMOVAL-REFITTING Very heavy parts

GENERAL
Vehicle preparation

signboards.
Figure 12
2371801

of short circuits;
DESCRIPTION OF OPERATION - using suitable lifting means, sling the door and support it
before disconnecting the hinges.
Proceed as follows:
Use suitable belts.
- right door only: remove the close-proximity rear-view Do not use chains or hooks to prevent damaging the
mirror as described in the CLOSE-PROXIMITY REAR-- door.
VIEW MIRROR REMOVAL-REFITTING chapter in this Manoeuvre the door very carefully.
section;
- remove the rear-view mirror as described in the REAR--
VIEW MIRROR REMOVAL-REFITTING chapter in this
section; Figure 14
- remove the winding window as described in the WIND-
ING WINDOW REMOVAL-REFITTING chapter in this
section;
- remove the internal and external handles as described in
the HANDLES REMOVAL-REFITTING chapter in this
section;
- remove the lock as described in the LOCK REMOVAL--
REFITTING chapter in this section;
If the fixed window must be recovered, remove it as

described in the FIXED WINDOW
REPLACEMENT chapter in this section.
Removal
Proceed as follows:
Figure 13
357A018101R
- loosen the screws fastening the upper (A) and lower (B)
hinges to the cab and remove the door;
- remove any shims arranged between hinge and cab;
- carefully remove any sealant paste.

357A018100R
Check integrity of the door seals and replace the damaged
component if needed.
- remove the fairlead (1) from the door;
- remove the wiring carefully to prevent damaging the
sheaths;
Refitting Figure 16
Proceed as follows:
Using suitable lifting means, sling the door and support it by
approaching it to the cab.
Use suitable belts.

Do not use chains or hooks to prevent damaging the
door.
Manoeuvre the door very carefully.
Figure 15
357A018102R
- close the door carefully and check that the gap between
door and door frame is approximately constant (see
arrow);
- in case of need, loosen the fastening screws and adjust the
gap using suitable shims to be inserted between door and
frame;
- refit the lock as described in the LOCK REMOVAL-RE-
FITTING chapter in this section;
- refit the internal and external handles as described in the
HANDLES REMOVAL-REFITTING chapter in this sec-
357A018101R tion;
- position the door so as to be able to fasten the hinges; - close the door carefully and check that the lock is cor-
rectly coupled with the striker on the pillar;
- fasten the screws fastening the upper (A) and lower (B)
- if needed, loosen the lock fastening screws and adjust the
hinges to the cab without tightening;
reciprocal position of lock and striker;
- remove the support belts.
- close the door carefully and check that the pressure on
the seals is correct;
- add or remove shims under the hinges (front door side)
and/or adapt the position of the lock striker (rear door
side) if needed.
Final operations
Proceed as follows:
- refit the fixed window as described in FIXED WINDOW
REPLACEMENT chapter in this section;
- refit the winding window as described in the WINDING
WINDOW REMOVAL-REFITTING chapter in this sec-
tion;
- refit the rear-view mirror as described in the REAR-VIEW
MIRROR REMOVAL-REFITTING chapter in this section;
- right door only: refit the close-proximity rear-view mirror
as described in the CLOSE-PROXIMITY REAR-VIEW
MIRROR REMOVAL-REFITTING chapter in this section.
COWL REMOVAL-REFITTING
GENERAL
Safety instructions

the instructions provided in the initial section of this
manual.
Very heavy parts


Preliminary operation Check integrity of the hinges, if needed, to replace the dam-
Proceed as follows: aged component.
- open the cowl as described in the Use section of the USE Refitting
AND MAINTENANCE HANDBOOK .
Removal
Final operations
Proceed as follows:
Open and close the cowl several times to check correct cen-
- using suitable lifting means, sling the cowl and support it tring and correct closing.
before disconnecting the hinges;
Use suitable belts.

cowl.
- remove from both the split pin (2), remove the pin (1) and
recover the thrust washers (3);
- remove the screws (4) fastening the hinge to the cab and
remove the cowl (5) on both sides.
Figure 17
357A018103R
WINDSCREEN WASHER ARM REMOVAL-

REFITTING
GENERAL
Safety instructions

manual.
Proceed as follows:
Removal
Figure 18
357A018104R
Proceed as follows:
- disconnect the windscreen washer tube (1) from the arm;
- remove the fastening nut (2);
- remove the arm (3) from the pin levering carefully.
Refitting
Final operations
Proceed as follows:
- close the cowl as described in the Use section of the USE
CABIN FRONT SHOCK ABSORBER

REMOVAL-REFITTING
GENERAL
Safety instructions

Very heavy parts

Safety component.

Preliminary operations Check intactness of pins and threading, if necessary replace
the damaged component
Proceed as follows:
To refit, follow the removal operations in reverse and tighten
the fastening nuts.
Removal
To adjust the spring pre-load proceed as follows:
Proceed as follows:
Figure 20
Figure 19
357A018013R
- with an appropriate tool (1) turn the pre-load ring nut to

position 2;
357A018012R
- remove the plastic protection (1); To adjust the spring pre-load use a wrench type
USAG 282/92-95-100 or equivalent.
- remove the lower fastening nut (2) and recover the
washer;
- remove the upper fastening nut (3) and recover the - the ring nut position can be changed according to the spe-
washer; cific use requirements of the vehicle :
- remove the shock absorber (4) withdrawing it sideways. - Position < 2: spring less stiff
- Position > 2: spring more stiff
- fit the plastic protection.
Final operations
Proceed as follows:
CABIN REAR SHOCK ABSORBER

REMOVAL-REFITTING
GENERAL
Safety instructions

Very heavy parts

Safety component.

Proceed as follows:
- tip the cab as described in the Use section of the USE Refitting
To refit follow the removal operations in reverse and tighten
the fastening nuts.
Removal
Proceed as follows:
Figure 22
Figure 21
357A018013R

position 2;
357A018014R
To adjust the spring pre-load use a wrench type

- remove the lower fastening nut (1) and take out the USAG 282/92-95-100 or equivalent.
screw (2), recovering the washers;
- remove the upper fastening nut (3) and take out the
screw (4);
- the ring nut position can be changed according to the spe-
- remove the shock absorber (5) withdrawing it sideways. cific use requirements of the vehicle :
- Position < 2: spring less stiff
- Position > 2: spring more stiff.
Final operations
Proceed as follows:
- tip the cab as described in the Use section of the USE
BUMPER REMOVAL-REFITTING Very heavy parts

GENERAL
Vehicle preparation

signboards.
Figure 23
2371801

of short circuits;
DESCRIPTION OF OPERATION - unscrew the side fastening screws (4) from both sides;
Preliminary operations - unscrew the front fastening screws (1) from both sides
Proceed as follows: and recover the counter-plate (5);
- open the cowl as described in the Use section of the USE - remove the bumper.
AND MAINTENANCE HANDBOOK;
- open the front light clusters as described in the Mainten- Refitting
ance section of the USE AND MAINTENANCE HAND- To refit, follow the removal instructions in reverse order.
BOOK.
Removal Proceed as follows:
Proceed as follows: - reposition the front light cluster as described in the Main-
- appropriately sustain the bumper; tenance section of the USE AND MAINTENANCE
HANDBOOK;
- disconnect the front light cluster connector (2) from both
sides; - close the cowl as described in the Use section of the USE
- disconnector the direction indicators connector (3) from
both sides;
Figure 24
357A018015R
STEERING COLUMN REMOVAL- Very heavy parts

REFITTING

Vehicle preparation

signboards.
Figure 25
2371801

of short circuits;
DESCRIPTION OF OPERATION - disconnect the ground wire connection (3);

Removal - remove the nut (4) and mark the fitting position of the
Proceed as follows: steering (2) on the shaft (5) and remove the steering whe-
el;
- enable the steering lock by removing the key from the
ignition switch; - extract the interconnection box stopper key (6) from the
housing;
- remove the cover (1) from the steering wheel (2);
Figure 26
357A18027R
- remove the pushbutton panels (1) and (5); - disconnect the electrical connections (4);
- unscrew the screws (2) and (6). - remove the instrument panel and deposit it safely;
- unscrew the screws (3) and (7); - unscrew the screws (8) and (9) and remove the side co-
vers (10) and (11);
Figure 27
357A18028R
From the steering control support (4), remove the This operation serves to prevent the rotor (9) and
interconnection box (2) strictly following the the stator (8) reciprocally rotating during
procedure given below. This is to prevent damaging dismantling.
the spiral cable contained in the box itself and to Maintain this locked condition until reassembled.
prevent incorrect steering wheel angle reading once Without the keys, use a nut and screw of adequate
reassembled. length.
- Disconnect the electrical connections (5 and 6); - grip the interconnection box (2), lift it carefully such that
the retainer pins (3) slip out from the support (4) and sui-
- Disconnect the electrical connections (10 and 11);
tably deposit them.
- fasten the cover (1) of the interconnection box (2) to the
box itself, inserting the keys (7) into the slots (8) and (9);
Figure 28
272C18032
- unscrew the screws (2) and remove the bracket (1). - Unscrew the screws (5);
- Disconnect the electrical connections (4); - remove the steering column cover screws (7);
- unscrew the screws (3) and remove the left and right - unscrew the steering column boot screws (8)
combiswitch controls;
- remove the steering column cover screws (9);
- unscrew the screws (6) and remove the SWI control unit;
- remove the steering column cover (10) from the vehicle;
Figure 29
357A018016R
- mark the fitting position of the upper shaft on the support - unscrew the fastening screws (6) and remove the steering
(3) and on the UV joint (2); command support (4) from the pedal board (5) (arrow);
- loosen the screw (1) and extract the UV joint (2) from - working from outside the cabin, on the power steering
the upper shaft; box (10) and the UV joint (8) mark the fitting position of
the cardan shaft;
Do not move the wheels to permit correct steering
wheel centring on reassembly. Do not move the wheels to permit correct steering
wheel centring on reassembly.
- disconnect the steering column pneumatic adjuster pipe

(13); - loosen the screw (9) and extract the UV joint (8) from
the shaft on the power steering box.
- remove the corrugated sheath (7) from the steering com-
mand support; - remove the cardan shaft (12) from the boot (11) working
in the direction indicated by the arrow.
Figure 30
357A018017R
Replacement
Specifically:
- pay particular attention to making all electrical connec-
tions correctly;
- the replacement interconnection box (1) is supplied with
the stopper key assembled as shown in the figure;
Figure 31
272C18035
- after fitting the key (2) on the steering command suport,

turn it to break it at the indicated point (arrow) and repla-
ce it in the housing in the steering wheel.
STEERING COLUMN PNEUMATIC Very heavy parts

CYLINDER REMOVAL-REFITTING

concerning safety of the personnel involved in the Specific safety instructions
part of this manual. Make sure that residual pressure has been
Always observe all the general recommendations to completely discharged from the circuits and related
carry out maintenance jobs correctly. reservoirs.
Vehicle preparation

signboards.
Figure 32
2371801

of short circuits;

Proceed as follows:
- remove the steering column operating as described in the
STEERING COLUMN REMOVAL-REFITTING chapter
of this section.
Removal
Proceed as follows:
Figure 33
272C18037
- in the hole in the cylinder air supply (3) fasten a suitable

connector (5) and introduce air at 8  12 bar pressure;
The air pressure must be maintained for the entire

removal operation, this being a necessary condition
for assuring release of the pneumatic cylinder (3).
- fully shift the steering control shaft-group (6) toward the

outside (arrow);
272C18036
- Mark the fitting position of the screw (7) on the support
- remove the shock absorber (1) removing the nuts (2 and (9);
3); - remove the nut (1), extract the screw (7) with the wa-
shers (2 and 8);
- remove the support (9), the pneumatic cylinder (3) the
adjuster shim (4) and the steering control shaft group (6);
Figure 35
272C18038
Steering control components

1. Pneumatic cylinder
2. Adjuster shim
3. Connector
4. Support
5. Washer
6. Screw
7. Shock absorber
8. Steering control shaft group
9. Nut
10. Washer
11. Nut

Determination of adjuster shim thickness
Proceed as follows:
Figure 36
272C18041
- In the air supply hole in the new cylinder (3) fasten a suita-
ble connector (2) and introduce air at 8  12 bar pressure;
272C18039
- With a suitable instrument (precision class 0.05 mm) measurement and subsequent assembly period.
measure the distance A between the sliding surfaces of
the support (1).
- Rest the pneumatic cylinder (3) on the check plate and
Figure 37 fit the adjuster shim (1) to the piston.
- Using a suitable tool (4), measure the distance (D)
- The thickness S of the shim is given by:
S = A - (B+C+D+ 0,2)
A = distance between support sliding surfaces
B = distance between inner surface of support and sliding
surface
C = distance between inner surface of support and sliding
surface
0,2 =play in mm
272C18040
- In the support (1) position the steering control shaft sup-

port (2).
- With a suitable instrument (3) measure the distances B
and C between the inner surface of the support (2) and
the sliding surfaces (1).
Refitting Figure 41
Figure 39
272C18044
272C18042 - Fit the shock absorber (1), tighten the nuts (2) and (3) to
- Insert the support (2) in the support (1). - Check tightness of the cylinder (4): applying a traction for-
- Position the cylinder (4) taking care that the pin (5) is cor- ce of 300 N (30 kg) to the steering control shaft in the
rectly inserted in the support guide groove (2). direction of the driver. The cylinder must not shift with
respect to the support (3).
- Choose the adjuster shim (3) from those provided as re-
placements, of the thickness calculated by the previous Refit the steering control assembly to the vehicle as described
measurements. in the corresponding chapter.
- .Lubricate the adjuster shim (3) with the specified grease
and insert it between the cylinder (4) and the support (1). Final operations
Proceed as follows:
Figure 40 - refit the steering column operating as described in the
STEERING COLUMN REMOVAL-REFITTING Chapter
of this section.
272C18043
- Fit a new screw (7) with washer (8) positioning it at the

point marked on dismantling.
- Fit the washer (2).
- Apply LOCTITE 270 to the thread of the new nut (1) and
fasten it on the screw (3) until determining, between the
washer (2) and the support (3), play of 0.1  0.2 mm.
- Check excursion of the steering control shaft support (8)
on the support (3) in all directions.
- Set the steering control shaft support (6) in the excursion
start position (minimum steering wheel height).
- Remove the pneumatic connection (4) from the pneuma-
tic cylinder (5).
PEDAL UNIT REMOVAL-REFITTING Hazardous and/or polluting substances

GENERAL
Vehicle preparation

signboards.
Figure 42
2371801

of short circuits;

Proceed as follows:
Final operations
- remove the steering column as described in STEERING
Proceed as follows:
COLUMN REMOVAL-REFITTING in this Section.
4;
4.
- refit the steering column as described in STEERING COL-
Removal UMN REMOVAL-REFITTING in this Section.
Proceed as follows:
- unscrew the plate fastening screws and disconnect the air
piping from the brakes valve (2):
- disconnect the splitter control pneumatic fitting (3);
- disconnect the stop signal electric connector on the
brakes valve (4);
- disconnect the servoshift signal electric connector on the
clutch control (5);
- operating inside the cab, disconnect the electrical con-
nections (6), withdraw the rubber chock (7) and bring the
wiring out externally;
In the case of difficulty, dismantle the separate

connectors.
- unscrew the seven fastening screws (see arrow);

connected and that all wiring clamps and pipes con-
nectors have been severed;
- bring the pedal unit (1) outwards, until it is completely
released from the vehicle.
Figure 43
357A018018R
DASHBOARD REMOVAL-REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 44
2371801

of short circuits;

Removal
Proceed as follows:
Figure 45
77067
342B016001R
- remove the bottle holder (1) from the seat;

- loosen and remove the fastening screws (see arrow)
from the plastic fairing (2);
- remove the plastic fairing (2);
Figure 46
357A018135A
- For Euro 3 versions only: disconnect the electric

connectors and remove the light switch units (3);
- loosen the screws (1) fastening the dashboard (1);
- disconnect the electric connections (4) and (5);
- remove the dashboard.
Refitting
77066
- For Euro 3 versions only: remove the switch-warning light

unit (1) by operating the fastening tabs;
- remove the plugs (2).
CENTRAL DASHBOARD REMOVAL-

REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 48
2371801

of short circuits;

Removal
Proceed as follows:
Figure 49
90054
- remove the frame (2);

- loosen the screws (1) fastening the climate control dash-
board (4):
90052
- release the central dashboard (3);
- remove the mat (1); - disconnect the electric connections from the switches;
- remove the plugs (2) and loosen the screws (3);
Mark the electric connections to assist reassembly.
Figure 50
- remove the central dashboard.
Refitting
90053
- remove the lid (2) and disconnect the electric connector

from the power socket (3);
- remove the cover (4);
- loosen the screws (5);
DASHBOARD (INSTRUMENT PANEL) Hazardous and/or polluting substances

REMOVAL-REFITTING
Vehicle preparation

signboards.
Figure 52
2371801

of short circuits;

Proceed as follows:
- remove the dashboard as described in the DASHBOARD
REMOVAL-REFITTING chapter in this section;
- remove the central dashboard as described in the CEN-
TRAL DASHBOARD REMOVAL-REFITTING chapter in
this section.
Removal
At least two people are required for the described
procedure.
90002
Proceed as follows:
- loosen the screws (1) and remove the steering column
lining (2);
Figure 53
Figure 56
77107
77116
lining (2);
- loosen the screws (3) fastening the curtain guard (1) on
the steering column;
Figure 54
- loosen the screws (2) fastening the lining to the steering
column.
77108
- remove the mat (5);

- loosen the screws (4) fastening the kick plate (3);
- remove the kick plate (3) from the vehicle;
- remove the floor air vent (2) by means of the fastening
tabs (see arrow);
- repeat the same operations on the other side;
- loosen the side screws (1) fastening the steering column
lining;
Figure 57 Figure 59
357A018106R
- loosen the screws (1) fastening the pneumatic line sup-

port base (2).
357A018105R
- partially remove the door frame seal (1);

- remove the snap-fitted plug (2) and loosen the screw
underneath;
- disconnect the windscreen pillar lining (3);
Figure 58
77116
- loosen the screws (1) and remove the grab handle (4);
- loosen the screws (2) and remove the lining (3);
Figure 60 Figure 62
90056
357A018107R
- remove the snap-fitted plugs (3); - loosen the screws (1) and remove the storage compart-
- loosen the fastening screws (2) and release the panel (1) ment (2);
of the differential locks;
Figure 63
Figure 61
357A018108R
90057 - loosen the screws (1) and tip the fuse box (2);
- loosen the screws (1) and remove the lining (2); Figure 64
77114
- remove the nuts (1) and the screws (3);

- Cut the clips and disconnect the air delivery pipe (2) from
the climate control unit.
Figure 65
77115
- Loose the nuts (2).

- cut the clips and disconnect the air delivery pipe (1) from
the climate control unit;
Figure 66
90058
- loosen the upper screws (1);

- loosen the lower screws (3);
- remove the dashboard (2).
Refitting
Final operations
Proceed as follows:
- refit the central dashboard as described in the CENTRAL
DASHBOARD REMOVAL-REFITTING chapter in this
section;
- refit the dashboard as described in the DASHBOARD
REMOVAL-REFITTING chapter in this section.
SEAT REMOVAL-REFITTING Hazardous and/or polluting substances

GENERAL
Vehicle preparation

signboards.
Figure 67
2371801

of short circuits;

Proceed as follows:
- disconnect the pneumatic connection (1);
- disconnect the electrical connection (2) (if present);
- make the seat slide forwards and tip the backrest, then
loosen the seat rear fastening screws (3, see arrow) of the
seat;
- arrange the seat back and open the front compartment
flap, then loosen the front fastening screws (4, see arrow)
of the seat;
- remove the seat from the support.
Figure 68
357A018109R
INNER DOOR LINING REMOVAL-

REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 69
2371801

of short circuits;

Removal
Proceed as follows:
Figure 70
357A018111R
90046
- loosen the upper fastening screws (1);
- disconnect the control panel (2) of the armrest (1); - remove the plugs and loosen the fastening screws (2);
- disconnect the electric connections (3) and (4) from the - remove the armrest (3);
panel (2);
Figure 73
Figure 71
90047
- loosen the screw (2) and remove the knob (1);

- compress the tabs of the pin (4) and remove the handle
357A018110R
(3).
- remove the plugs and loosen the fastening screws (1);

- disconnect the electrical connection of the speaker, if
present;
- remove the storage compartment (2);
Figure 74
357A018112R
- loosen the fastening screws on the pillar (1) and in the

vent (2);
- remove the panel (3) being careful when removing the
wires (4) from the slot;
Figure 75
357A018113R
- remove the adhesive lining from the door.
Refitting
DOOR WINDING WINDOW REMOVAL- Specific safety instructions

REFITTING
GENERAL Handle the windows with care to prevent injuries.
In case of breakage, apply an adhesive sheet or
Safety instructions adhesive tape on the surface to withhold the glass
fragments using removal.
Before carrying out any operation make certain to Clean up the area with a vacuum cleaner to pick up
have taken all precautions and clarified all aspects all residues and glass fragments.
Vehicle preparation

signboards.
Figure 76
2371801

of short circuits;

Proceed as follows:
- remove the interior lining as described in the INTERIOR
LINING REMOVAL-REFITTING chapter in this section.
Removal
The operation must be carried out with the window

all down.
Figure 77 73274
- temporarily turn vehicle electrical system back on;

- provisionally connect the electric connections to the
control panel and lift the window until the clip (2) can be
reached;
- cut off the vehicle electrical system on;
- disconnect the electric connections on the panel;
- disconnect the electric window winder device (3) from
the window (1) by removing the clip;
Figure 80
73272
Proceed as follows:
- remove the internal and external lower seals (1) from the
window compartment;
Figure 78
73275
- lift the window (1) and remove it from the upper part.
Refitting
Reverse the removal sequence to refit.
Final operations
73273
Proceed as follows:
- remove the guiding seal from the window frame (1); - refit the interior lining as described in INTERIOR LINING
REMOVAL-REFITTING in this section.
DOOR WINDOW WINDER DEVICE

REMOVAL-REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 81
2371801

of short circuits;

Preliminary operations Reverse the removal sequence to refit.
Proceed as follows:
Final operations
Proceed as follows:
tion. - refit the winding window as described in the DOOR
WINDING WINDOW REMOVAL-REFITTING chapter
Removal in this section.
Figure 82
357A018114R
Proceed as follows:
- remove the screws (1), (3) and (4) fastening the window
winder device;
Figure 83
73277
- remove the window winder device (1) from the door.

DOOR LOCK REMOVAL-REFITTING

GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 84
2371801

of short circuits;

Proceed as follows:
Removal
Figure 85
73280
- release the clip (3) from the linkage (4);

- disconnect the linkage of the lever (5) of the internal
handle;
- remove the screws (1) and remove the lock (2) of the
door.
Refitting
73278 Reverse the removal sequence to refit.

- release the clip (2) from the linkage (3); Proceed as follows:
- disconnect the linkage from the transfer (1); - refit the interior lining as described in the INTERIOR LIN-
ING REMOVAL-REFITTING chapter in this section.
- if present, disconnect the electric connections (4) and (5)
of the lock (6);
Figure 86
73279
- disconnect the linkage (1) of the lever (2) of the external

handle (3);
DOOR HANDLE REMOVAL-REFITTING

GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 88
2371801

of short circuits;

Proceed as follows:
Removal
External handle
Figure 89
73283
- remove plugs (1) and (2);

- loosen the nuts (3) and remove the external handle (4).
Internal handle
Figure 92
73281
Proceed as follows:
- disconnect the linkage from the transfer (1) of the lock
(4);
Figure 90
73284

handle (4);
- loosen the screws (3) and remove the handle (4).
Refitting
Final operations
Proceed as follows:
- refit the interior lining as described in the INTERIOR LIN-
73282

handle (4);
- disconnect the linkage (3) from the external handle (4);
REAR-VIEW MIRRORS REMOVAL-

REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 93
2371801

of short circuits;

Removal
Main mirrors and supplementary mirror on door
Figure 94
357A018117R
- loosen the upper (6) and (7) lower screws;

- remove the mirror.
357A018115R

- remove the upper (3) and lower (4) lids;
Figure 95
357A018116R
- disconnect the electrical connections (5);

Close-proximity mirror (right-hand door only)
Figure 97
357A018118R

Figure 98
357A018119R

- disconnect the electric connection located behind the
bracket and remove the mirror.
Refitting
WINDSCREEN REPLACEMENT Very heavy parts

GENERAL

signboards.
Handle the windows with care to prevent injuries.

Figure 99 In case of breakage, apply an adhesive sheet or
adhesive tape on the surface to withhold the glass
Clean up the area with a vacuum cleaner to pick up
all residues and glass fragments.
2371801

of short circuits;

Proceed as follows:
Figure 100
357A018121R
- open the door and remove the fastening screws (1);

- remove the lower baffle (2);
357A018120R
Figure 102
- if present, remove the fastening screws and remove the
sun curtain (1);
- removethecowlasdescribedin theCOWL-REMOVAL--
- remove the windscreen wiper arms as described in the
WINDSCREEN WIPER ARMS REMOVAL-REFITTING
chapter in this section.
357A018122R
- remove the fastening screws (3);

- remove the upper baffle (4);
- repeat the same operations on the other side.
Removal
Proceed as follows:

procedure.
Figure 103
357A018123R
- using a suitable tool (chisel or cutter), cut the protruding

part of the seal along the entire entire of the windscreen;
- cut the sealant (dotted line) along the sides and the upper
part of the windscreen;
- support the windscreen with suitable tools (suction caps)
from the outside and remove the windscreen from the
inside outwards.
If necessary, heat the edge of the windscreen to

facilitate removal.

Proceed as follows:
- carefully clean the seat in depth eliminating all traces of
sealant;
- check for absence of corrosion on metal in seat: proceed
with rust-proofing treatment followed by painting, if
needed.
Refitting
Proceed as follows:
Figure 104
357A018124R
- Arrange the seal (1) on the windscreen (2).
The metal seat groove must be inside the windscreen.

If the ambient temperature is low, it is advisable to slightly warm the seal (e.g. by submerging it in hot water).
- Insert a strong wire (3), approximately 5 mm diameter (e.g. an electric wire) in the metal seat groove
The wire must fully engage the seal and be twisted for a given length in the lower part of the windscreen (see arrow).
Figure 105
357A018125R
- Support the windscreen with suitable tools (suction caps) from the outside and rest it in seat.
The two ends of the wire must fall inside the cab
Figure 106
357A018126R
- Working from the inside, pull the wire to force the seal to pass over the edge and knock the zone near the working point
of the wire at the same time from the outside.
Figure 107
357A018127R
- Settle the seat at the same time knocking along the edge of the window to uniform adherence and eliminate small wrinkles.
Figure 108
357A018128R
- Working from the outside, apply sealant paste of the

required type in the side and upper peripheral zone
between body and seal.
Sealant: HENKEL TEROLAN-4201/A
- Carefully remove all sealant in excess at the end.
Final operations
Proceed as follows:
- refit the upper and lower baffle on both sides by reversing
the removal order;
- refit the windscreen wiper arms as described in the
chapter in this section;
- refit the cowl as described in the COWL REMOVAL-RE-
- refit the sun curtain, if present, by reversing the removal
sequence.
FIXED DOOR WINDOW REPLACEMENT Hazardous and/or polluting substances

GENERAL

Vehicle preparation fragments using removal.
signboards.
Figure 109
2371801

of short circuits;
Proceed as follows:
section;
Removal
Proceed as follows:
The window is glued.

The window may smash during removal: apply plenty
of adhesive tape on the surface and proceed with
care.
Figure 110
73287
- apply the adhesive handle (2) to the window;

- using a suitable cutter, cut the sealant bead (1) and
remove the window from its seat.

Proceed as follows:
sealant;
Be careful not to scratch the paint. It this happens,

apply suitable rust protection and paint the
concerned area.

needed.
Refitting Figure 113

Proceed as follows:
Figure 111
357A018129R
- clean the edge of the window with suitable detergent (e.g.

isopropyl alcohol) before applying the sealant;
Figure 112
357A018131R
- apply the window into its seat exerting a uniform pressure

for approximately 60 minutes.
Final operations
Proceed as follows:
ING REMOVAL-REFITTING chapter in this section;
357A018130R
- apply a bead of required sealant past on the inner edge.
Do not apply the sealant in the upper part shown

(detail).
Sealant: SIKA SIKAFLEX 221

CABIN TIPPING DEVICE
DESCRIPTION
The vehicle is equipped with a driving cab tipping system.
Do not remain in front or behind the cab during the

tipping.
Never leave the cab in a partially tipped position.
Component location
1. Actuating assembly
2. Release device
3. Cylinder
Figure 114
357A018019R
Cabin tipping system diagram

(a) Manual pump
(b) Overpressure valve
(c) Tank
(d) Directional valve
2. Release device
3. Cylinder
4. Gear-control rod (for versions with manual/servo-assisted transmission only)
Figure 115
CAB
CAB COUPLING
GEAR-CONTROL
ROD
CAB COUPLING
5949779109
CABIN TIPPING HYDRAULIC FLUID

CHANGE
GENERAL
Safety instructions


Drainage
Proceed as follows:
Figure 116
272NM009MY
- clean the area of the cap (see arrow), then remove it;
- using a syringe and an appropriate flexible extension,
draw up all the fluid contained in the tank;
Filling
Proceed as follows:
- fill with the required quantity of the specified fluid; then
close the cap.
CABIN LIFTING PUMP REMOVAL- Hazardous and/or polluting substances

REFITTING
Vehicle preparation

signboards.
Figure 117
2371801

of short circuits;

Proceed as follows:
Final operations
- drain off the fluid as described in CABIN TIPPING
Proceed as follows:
HYDRAULIC FLUID CHANGE in this Section.
- fill with the fluid as described in CABIN TIPPING
Removal HYDRAULIC FLUID CHANGE in this Section.
Proceed as follows:
Figure 118
357A018020R
- disconnect the intake (1) and delivery (2) pipes from the
pump;
Fluid may leak from the pipes during these

operations.
Figure 119
357A018021R
- loosen the supporting bracket fastening screws (1) and

remove the pump (2);
CABIN TIPPING CYLINDER REMOVAL- Very heavy parts

REFITTING

Always observe all the general recommendations to hazardous and/or polluting substances
carry out maintenance jobs correctly. Do not touch with the hands.
Vehicle preparation
Take the vehicle onto a suitable flat, solid surface, Specific safety instructions
signboards. Safety component.
Figure 120
2371801

of short circuits;
DESCRIPTION OF OPERATION - acting on the upper coupling, remove the clamping nut
(3) and withdraw the screw (4) from the cab lifting cylin-
Preliminary operations der;
Proceed as follows:
- drain off the fluid as described in CABIN TIPPING Figure 123
Removal
Proceed as follows:
This operation is to be carried out with cab lowered.
Figure 121
357A018024R
357A018022R
- acting on the lower coupling remove the clamping nut (5)

- place a container under the cylinder to collect the system
oil; from the cab lifting cycliner;
- disconnect the oil piping (1) and (2); - remove the cab lifting cylinder recovering the washers.
Hydraulic fluid may leak out during these operations. Inspections and checks
Proceed as follows:
- Check hydraulic fittings and tubes are intact: if necessary
Figure 122 - Check intactness of pins and bushings : if necessary
Refitting
Final operations
Proceed as follows:
357A018023R
CABIN CLIMATE CONTROL VENTILATION

Overview Description
The air conditioning system serves to render the cabin interior Ventilation draws cool external air, filtering out pollen and
comfortable in terms of: dust through a specific filter, or recirculates the air within the
cabin.
- temperature and relative humidity of the outside air;
The system consists of an envelope, configured to house the
- temperature and relative humidity inside the cabin.
fan group, air passage ducts, fresh air intake and recirculated
The system subjects the air to thermodynamic transforma- air intake.
tions that modify air temperature, relative humidity and purity.
The fan can run at different speeds in order to draw in and cir-
This is achieved by: culate large quantities of air.
- ventilation, or the introduction of outside air into the ca-
bin (with the same temperature and relative humidity as Climate controlled air flow orientation
the surrounding air); 1. Windshield defrosting air outlets
- air-conditioning, or the cooling and dehumidification of 2. Side ventilation air outlets
the air with the possibility of post-heating the air as requi- 3. Door windows defrosting air outlets
red to vary the temperature and humidity inside the cabin. 4. Central ventilation air outlets
5. Foot ventilation air outlets
j cool air
J warm air
Figure 124
34BNU43L
AIR CONDITIONING Heating

Description Heating is realised by a radiator, present inside the heater
group, in which engine coolant circulates.
Air conditioning is achieved by the integration of a conditio-
ning system and a heating system. Specific shutters permit passage of air through the radiator on-
ly when heating is required.
This integration permits variations in cabin temperature and
humidity.
Air conditioning
Conditioning The main components of the conditioning system are:
Conditioning is realised by exploiting the high capacity of cer- - the compressor;
tain gases, referred to as “refrigerant”, to determine significant - the condenser;
cooling on expansion, such as to absorb heat from the cabin.
- the filter/drier (built-in to the condenser);
This condition is achieved through two different levels of pres-
sure (high, in which the refrigerant fluid is in a liquid state, and - the three-level pressure switch;
low, in which the fluid is in gaseous state) that are established - the expansion valve;
and maintained during system function..
- the evaporator;
- the heater/fan group;
- the anti-pollen filter.
Air conditioning control group
Figure 125
342BNU44L
1. Temperature adjustment control

2. Four-speed electric fan control
3. Air distribution control knob (see symbols)
4. Internal recirculation control:
- not pressed: external air inlet,
-pressed: internal recirculation.
5. Conditioner control with incorporated warning light
(only climate control version)
DIAGNOSTICS
Troubleshooting guide
Introduction
By analysing the problems detected, diagnosis, or troubleshooting, permits a guided search for the causes of faults that lead to
functional problems in the system, and precise instructions for the repair works necessary to restore the system to full efficiency.
For faults of a predominantly electrical-electronic nature follow the troubleshooting by symptoms.
Troubleshooting by symptoms
Air-conditioning system 3. Unusual noise with clutch engaged
1. System not working 4. Unusual noise with clutch disengaged
2. System noisy 5. Cooling insufficient.
1 SYSTEM NOT WORKING
Inefficient electrical system Check the electrical system

YES
NO
Compressor drive belt not in normal working Check the belt: if slack or too tight, if necessary replace
conditions and inefficient. YES it.
NO
The electromagnetic clutch coil is inefficient. Check whether current reaches the coil, if necessary
YES replace the coil.
NO
The system connectors and piping are inefficient. Check and if necessary replace the faulty parts.
YES
NO
Irregular play between front disk and electromagnetic Check play and if necessary remove the compressor
clutch. YES and adjust
NO
Compressor inefficient. Discharge the system as described in the

YES
corresponding chapter, remove the compressor and
replace it.
2 SYSTEM NOISY
Insufficient compressor oil level. Drain and refill as described in the corresponding
YES chapter.
NO
Insufficient coolant in system. Drain and refill as described in the corresponding

YES chapter.
NO
NO
Insufficient coolant in system (indicator green) Drain and refill as described in the corresponding
YES chapter.
NO
System not hermetic. Check the system and the compressor for leaks with
YES instrument 9905147 and repair any coolant fluid leaks.
NO
The electromagnetic clutch does not work correctly. Check clutch electrical connections and if necessary
YES replace the electromagnetic clutch.
NO
Water in system. Drain and refill as described in the corresponding

YES chapter.
NO
Compressor inefficient. Drain as described in the corresponding chapter,

YES disconnect the compressor and replace it.
UNUSUAL NOISE WITH CLUTCH

3 ENGAGED
Compressor fasteners loose Check and tighten compressor screws and bolts to
YES correct torque.
NO
Electromagnetic clutch inefficient. Check whether the fault is due to mechanical or

YES electrical causes and repair as necessary.
NO
YES chapter.
NO
Compressor inefficient. Drain the system and replace the compressor.

YES

4
DISENGAGED OR VIBRATION
clutch pulley. YES and adjust
NO
Electromagnetic clutch power supply inefficient. Check the electrical system

YES
5 COOLING INSUFFICIENT

YES chapter.
NO
Discharge pressure high and intake pressure low due Discharge the coolant, replace the filter/drier, bleed air
to presence of air in system. YES from system and recharge as described in the
corresponding chapter.
NO
Discharge pressure high and intake pressure low with As described in the corresponding chapters, discharge
presence of water or ice on filter drier or on the pipe YES the coolant, eliminate any piping kinks or replace faulty
between condenser output and expansion valve. components. Bleed system of air and proceed to
rechrage.
NO
Discharge pressure normal and intake pressure If necessary replace the trinary pressure switch.
low-high due to irregular electromagnetic clutch YES
engagement.
GENERAL RECOMMENDATIONS Figure 126

Check that the replacement parts (filter, condenser, evapora-
tor, piping and connectors) are supplied complete with caps
to protect them from dust and damp.
these sould only be removed once the component is ready
for connection.
To prevent water penetration the compressor (sometimes
the exchangers and filters as well) is supplied slightly pressuri-
sed.
Check that gas is released when the protective cap is remo-
ved, as proof that the component has been correctly stored.
Check that pipe connections, whether pipe to pipe or pipe to
component, assure prefect seal. Coolant leaks not only cause
the system to stop, but also cause premature wear to the
compressor,
Therefore check the presence of the o-ring on the male part
86739
of the connector. Dampen it with system oil (considering that
this varies according to the type of coolant) and when fitting
prevent any damage to the connector contact faces that could Insert the male part into the female part of the connector by
cause leaks. hand with extreme care, until the collar (2) comes into con-
Follow the instructions given below. tact with the corresponding metal seat in the female part.
This contact provides the required mechanical support for the
pipe. The o-ring (1) pressed between the internal cylindrical
part and the hole instead assures the hydraulic seal.
Do not use oversize or doubled o-rings that may offer hydrau-
lic seal for a short time but that do not provide the necessary
mechanical support, which will eventualy cause the hydraulic
seal to fail.
When disconnecting the pipes from the system,

block the pipes and any other coolant passages to
prevent dirt or water from enetering, all of which
could jeopardise correct system function
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
GAS PIPE CONNECTIONS
5/8” - 18 UNF 15.9 1.6
3/4” - 18 UNF 15.9 1.6
1” - 14 UNF 29.8 3

CLIMATE CONTROL

Vehicle preparation

signboards.
Figure 127
2371801

of short circuits;
DESCRIPTION OF OPERATION - disconnect the supply connector (3);

Preliminary operations - unscrew the fastening screws (4);
Proceed as follows: - remove the compressor (5) from the engine.
- drain off the climate control fluid as described in CLI-
MATE CONTROL SYSTEM HYDRAULIC FLUID Inspections and checks
CHANGE in this Section Check belt is intact, if necessary replace the damaged compo-
- loosen the automatic belt tightener and withdraw the belt nent
from the compressor as described in COMPRESSOR
BELT REMOVAL-REFITTING in Section 3. Refitting
Removal
- remove the fastening screws and remove the compressor Proceed as follows:
inlet (1) and outlet (2) tubes;
- refit the belt on the compressor as described in COM-
PRESSOR BELT REMOVAL-REFITTING in Section 3;
Recover the seals. - fill the climate control system with the fluid as described
Replace them if they appear damaged. in CLIMATE CONTROL SYSTEM FLUID CHANGE in
Seal the tubes to prevent entry of humidity. this Section.
Figure 128
357A018025R
CLUTCH REMOVAL-REFITTING
ELECTRO-MAGNETIC COMPRESSOR
CLIMATE CONTROL
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 129
2371801

of short circuits;

Proceed as follows:
- remove the climate control compressor as described in
CLIMATE CONTROL COMPRESSOR REMOVAL-RE-
FITTING in this Section.
Removal
Proceed as follows:
Figure 130
39855
- with puller 99341001 (1) fitted with bracket 99341009

(2), take out the pulley (3);
- remove the plate fastening screw with wrapping from the
compressor;
Figure 133
39852
- lock the front disk (1) rotation and unscrew the locking
nut (2) then remove the spacer beneath;
Figure 131 39856
- unscrew the screw (4) releasing the electric power supply

cable (3) of the magnetic coil (1);
- with the round tip pliers remove the retaining split ring (2)
and remove the magnetic coil (1);
Refitting
Proceed as follows:
Figure 134
ASTRA
39854
- with a round tip pliers remove the split ring (1) that retains
the pulley (2);
39915
- fit the new magnetic coil (1), so that the centring pin (2)
inserts into the relevant hole (3).
39919
39916 - with a thickness gauge (3) check that play between front
disk (1) and pulley (2) is 0.4  0.8 mm mm;
- fit the split ring (2); Tighten the screw (3) and fasten the
electric power supply cable (4) of the coil (1) to the com- Figure 139
pressor casing;
Figure 136
ASTRA
39920
- if the play between front disk and pulley is not within the
39917 specified value, remove the front disk and replace the ad-
juster shim (1) with one of an adequate thickness.
- assemble the pulley (2) then the split ring (3) and the ad-
juster shim (1); Final operations
Proceed as follows:
Figure 137
- refit the climate control compressor as described in CLI-
MATE CONTROL COMPRESSOR REMOVAL-REFIT-
TING in this Section.
39852
- fit the front disk (1) lock the rotation and tighten the
retaining nut (2) to a torque of 35  40 Nm (3.5  4 Kgm);
CLIMATE CONTROL UNIT REMOVAL- Very heavy parts

REFITTING

Vehicle preparation

signboards.
Figure 140
2371801

of short circuits;

Proceed as follows:
Figure 142
Figure 141
357A018132R
357A018133R
- working inside the cab, turn the cab temperature adjust- - remove the clips and disconnect the engine coolant deliv-
ment handle (1) so as to completely open the engine ery (1) and return (2) pipes from the cab heater;
coolant valve;
- drain off the climate control fluid as described in the CLI- Figure 143
MATE CONTROL SYSTEM HYDRAULIC FLUID
CHANGE chapter in this section;
the Maintenance section of the USE AND MAINTEN-
ANCE HANDBOOK;
357A018134R
- remove the fastening screws and disconnect the A/C sys-

tem coolant fluid delivery (3) and return (4) pipes from
the evaporator;
Replace the seals when refitting.

77122 77125
- loosen the screws (1), remove the cover (2) and the - disconnect the clips (1) from the wiring bundles;
pollen filter;
- disconnect the screws (2) fastening the heater (5) to the
crossmember of the cab;
Figure 145
- disconnect the connectors (4) and disconnect the
respective electric wiring (3);
- remove the climate control unit (5) of the vehicle.
Refitting
Final operations
Proceed as follows:
77124 Section of the USE AND MAINTENANCE HAND-
BOOK
- loosen the fastening screws (1) of the air manifolds (2) to
- fill the climate control system with the fluid as described
the climate control unit (3);
in CLIMATE CONTROL SYSTEM FLUID CHANGE in
- disconnect the air manifolds (2) from the climate control this Section
unit (3);
PROCEDURE FOR DRAINING AND RE-

CHARGING THE AIR-CONDITIONER WITH This procedure does not describe refrigerant
charging/discharging from external/internal
R134a COOLANT
containers or maintenance phases. Refer to the
R134a coolant recharge and recovery station equipment use and maintenance handbook.
(99305146)
The station is designed for use on all vehicle air-conditioning
systems that use RI34a. The station consists of:
By connecting the station to a cooling system the gas contai- 1 Control panel
ned in it can be recovered, cleaned and prepared for rechar-
ging into the system, or transferred to an external container. 2 Container for restoring any oil recovered during draining
It is also possible to assess the quantity of oil removed from 3 Flexible pipes
the system, restore it and “empty” the system.
4 Container for accumulating oil recovered from system
To function the station has to absorb circa 3 kg of refrigerant.
5 Charging cylinder with rotary graduated scale
For rapid use it is recommended to have at least 2 kg of refrige-
rant in the cylinders and to keep the station as level as possible.
Figure 147
50631
SAFETY STANDARDS - do not expose or work with the unit in acidic or damp en-
vironment or in the vicinity of open containers with in-
flammable substances;
This station is destined for use exclusively by
professionally trained operators who must be - the unit must be used in areas with good ventilation and
familiar with cooling systems, refrigerant gases and air change;
the potential hazards of pressurised equipment, - do not change the settings of safety valves and control sy-
therefore: stems;
- do not use gas bottles or other storage containers that
are not approved and that are not fitted with safety valves;
- always use protective gloves and goggles when working
with refrigerant gases. Direct contact between eyes and - never fill any container to over 80% of its maximum capa-
refrigerant fluid may cause blindness; city;
- avoid contact with skin (low boiling temperature —30C - do not leave the unit powered up if it is not to be used
may cause frostbite); immediately. Switch off the mains power supply if the unit
is not being used.
- avoid inhaling refrigerant gas vapours;
- before making connections between station and system
or external container check that all valves are closed; The station is fitted with special connectors to prevent conta-
mination with system that use R12. Do not attempt to adapt
- before disconnecting the station check that the cycle is
thise unit for use with R12.
finished and that all valves are closed, to prevent refrige-
rant gas escaping into the atmosphere;
CONTROL PANEL
Figure 148
50634
Figure 149
CHARGE CYLINDER OIL RESERVOIR
50632
Key to dashboard controls diagram

M1 Low pressure gauge
M2 High pressure gauge
M3 Charge cylinder pressure gauge
LOW Low pressure valve
HIGH High pressure valve
REF Refrigerant charge/discharge valve
V1 Valve on low pressure pipe
V2 Valve on high pressure pipe
V3 Oil injection valve for A/C system
V5 Oil drain valve
V9 Service valve for A/C system coolant cleaning
10 Humidity indicator
VS Safety and discharge valve
L3 Alarm warning light
L4 Maximum level indicator
L5 Minimum level indicator
A Tank resistance/unit process switch
LA1 Unit process indicator
LA2 Tank resistance indicator
B Refrigerant process/vacuum process switch
LB1 Refrigerant process indicator
LB2 Vacuum process indicator
C Recycle/recharge recovery cycle switch
LC1 Recovery recycle cycle indicator
LC2 Charge indicator
D Vacuum/vacuum test switch
LD1 Vacuum indicator
LD2 Vacuum test indicator
Charge cylinder key

1 Pressure values in bar (vertical lines, upper rotatable cylin-
der).
2 Charge weight value in grams (oblique lines, upper rotata-
ble cylinder), subdivision 50 g between lines.
3 Tank level display (internal cylinder).
OPERATIONS FLOW DIAGRAM
Station preparation
First recovery
Wait 3-5 minutes
Second recovery
System oil
drain off
Works on system
Vacuum for 5-10 minutes

with first vacuum test
Are any NO Vacuum for 30 minutes

leaks present? with second vacuum test
YES
NO Are any
leaks present? YES
Fill system
with oil
Search for leaks with Charge refrigerant

electronic leak detector up to 200 gr.
Are any NO System full Search for leaks in the system

leaks present? charge with electronic leak detector
YES
Pressure NO Are any YES

check leaks present?
Are the values

acceptable?
NO
YES
Detachment of
station from system
REFRIGERANT RECOVERY FROM SYSTEM - Connect the pipe marked LOW (the output socket is the
ON VEHICLE one on the larger diameter pipe (LO).
Proceed as follows: - Open valves V1 e V2.
- Connect the pipe marked HIGH (the input socket is the - Open the LOW and HIGH valves.
one on the smaller diameter pipe (HI).
Figure 150
357A018026R
- Connect the station to the mains power supply (220V 50 - Return switches A, B and C to position 0.
Hz).
- Close valves V1, V2, LOW and HIGH.
- Turn switch A (Process Unit) to position 1.
The corresponding indicator LA1 comes on.
- Turn switch B (Refrigerant Process) to position 1.
- The corresponding indicator LB1 comes on.
- Turn switch C (Recovery Recycle) to position 1.
The recovery and recycling operation will start automati-
cally, indicator LC1 on indicates operation in progress.
On completing the operation the unit will stop automati- If the refrigerant reaches maximum level (maximum
cally and indicator LC1 will go out. Wait for a few minutes level indicator L4 on), the recovery cycle must be
for any remaining low pressure refrigerant in the system stopped immediately by turning switch C to position
to increase pressure, absorb heat and be recovered. The 0 and decanting the refrigerant from the charge
station will automatically repeat the recovery cycle, if the cylinder to a suitable external tank.
above conditions are present.
- Continue the operations following the instructions on the
next pages.
Figure 151
50636
CREATING VACUUM IN SYSTEM After a few minutes operation (maximum 10) if the system is
free of any leaks, indicator LD2 VACUUM TEST also comes
This operation should be carried out once all repairs have be- on. From this moment on evacuation must continue for at
en completed and the system components have been correc- least two hours to achieve adequate drainage.
tly reassembled. This operation precedes recharging, and is
carried out as follows:
If vacuum test indicator LD2 does not come on, a

Do not carry out the vacuum cycle if there is even leak is present. Interrupt evacuation, rectify the leak
minimal pressure present in the station or the and repeat the evacuation procedure.
system.
- At the end of the programmed evacuation time turn

- Connect the pipes to the correct sockets on the system switch D (vacuum test) to position 2 and leave the sy-
and open valves V1-V2/LOW and HIGH. stem for 3-5 minutes in these conditions.
VACUUM TEST indicator LD2 on indicates that the sy-
- Turn switch A (Process Unit) to position 1. stem seal is good. VACUUM TEST indicator LD2 off indi-
The corresponding indicator LA1 comes on. cates a leak. Rectify the leak and repeat the vacuum cycle.
- Turn switch B (Vacuum Process) to position 2. - Return switches D and B to position 0 and proceed to the
The corresponding indicator LB2 comes on. next phase.
- Turn switch D (Vacuum) to position 1. The system eva-
cuation process will start automatically and the corre-
sponding indicator LD1 will come on, indicating opera-
tion in progress.
Figure 152
50637
It is possible that at the end of each recovery cycle the station 3 Quantify and adjust the quantity of oil discharged.
has also recovered lubricant from the compressor, which
4 Dispose of the recovered oil correctly.
must be discharged into the graduated container provided (1).
This oil cannot be used again.
1 Slowly open valve V5 (Oil Discharge). The same quantity of oil as removed must be replaced in
the system.
2 When all the oil has been discharged into the container, re-
close valve V5.
Figure 153
50638
RESTORING SYSTEM OIL LEVEL - Disconnect the meter (1) from injection valve V3 and re-
place the protective cap.
If oil has been discharged from the system during the recovery
and recycling phase, this must be replaced.
- Take the meter provided filled with the correct or pre- Keep oil containers sealed to prevent contamination.
viously measured amount of oil for the system in ques- Remember that the oil is extremely sensitive to
tion. moisture:
- Connect the meter (1) to the lubricant input valve V3..
- Open valve V3 and run system vacuum for a few seconds. - Never open oil injection valve V3 if the system is under
- Open the valve on the meter container (1) The oil will positive pressure.
be sucked into the system. - Oil must only be injected with the system under negative
- Close valve V3 and the valve on the recipient once the pressure.
required quantity of oil has been taken in to the system. - The oil level should not drop below the suction pipe level
(to prevent air entering the system).
Figure 154
50639
CHARGING PLANT WITH REFRIGERANT

For transferring refrigerant from an external tank to
Before recharging it is good practise to be familiar with a num- the charge cylinder and vice-versa, refer to the
ber of important rule: equipment manual.
- Know how much refrigerant to use (normally written on Considering that the quantity of refrigerant is related
an adhesive label applied to the vehicle). to its pressure, to find the effective weight turn the
- The charging cylinder has a minimum level check that pre- outer part of the charge cylinder until the line of the
vents non-condensable gas entering the system. diagram coincides with that of the level indicator.
For this reason the last 600 g of refrigerant it contains can- This gives the exact quantity of refrigerant contained
not be used. in the cylinder (starting weight).
- Therefore, before charging check that the cylinder con- When calculating the weight of refrigerant, in
tains a sufficient quantity for the charge (maximum usable addition to the 600 g not usable remember to
quantity 3800 g). increase the charge by circa 100 g (this is the weight
of refrigerant contained in the two station-system
- If the pressure in the charge cylinder displayed on the gau- connector pipes). The correct quantity of refrigerant
ge (2) is greater than the required value visible on the to charge into the plant is therefore given by: 600 gr.
charge cylinder glass 10 bar max, discharge the excess + 100 gr. + (system capacity quantity).
pressure through valve (1) on the pressure gauge group
until bringing it to the correct level, reading the value on Before charging always check that the spyhole on the
the gauge. ‘console’ indicates that the refrigerant is free of
moisture. If this is the case, the spyhole indicates an
intense green colour, otherwise replace the station
internal filters as instructed in the equipment manual.
Figure 155
50640
When the cylinder contains the required quantity for charging, - After charging 200  500 g of refrigerant, according to
(the two pipes must already be connected to the sockets on system dimensions, stop charging by turning switch C
the system, since the vacuum operation has already been per- (charge) to position 0.
formed), proceed as follows:
- Using the electronic leak detector, search for any leaks in
- Close the LOW, valve keeping the HIGH and V1 - V2 the system.
valves open.
- Complete charging the system until the pre-calculated re-
- Turn switch B (Refrigerant Process) to position 1, indica- sidual weight in the cylinder has been reached.
tor LB1 comes on. (Residual weight = Total weight — system capacity
weight).
- Turn switch C (Charge) to position 2, the corresponding
indicator LC2 will come on and refrigerant will flow from - Complete the charge, turn switches C - B and A to posi-
the station to the system. tion 0 (A having been turned to create vacuum).
Re-check for any leaks.
- Close the HIGH valve.
If during charging the refrigerant level in the cylinder
drops below the foreseen quantity, the system will
stop and the minimum Level warning light will come
on (L5).
Figure 156
50641
CHECKING SYSTEM PRESSURES LEAK DETECTOR FOR AIR

After completing the charge, leave the pipes connected and CONDITIONING SYSTEMS WITH HFC
perform the following check: R134a (9905147)
- Close valves V1, V2, LOW and HIGH. Tool L-780A permits precise identification of HFC 134A gas
leaks from the system, in the order of 3.3 gr. per year with the
- Switch on the engine, switch on the air conditioner and selector turned to maximum sensitivity.
check on gauges M1 and M2 that pressures correspond,
normally: low pressure no lower than 1 bar, high pressure The instrument does not require calibration. The operator
15  18 bar, according to system characteristics. only has to set the required sensitivity.
Any gas leak is indicated by an acoustic signal and a LED that
OPERATIONS PRIOR TO REMOVING blinks in proportion to the concentration of gas.
STATION FROM SYSTEM The LED off also serves as low battery charge indicator
Carry out the following operations, observing the previously
Operating temperature is between 0 and 50C.
described safety standards:
The instrument has a flexible probe to reach particularly inac-
- Check that all the valves (LOW - HIGH V1 - V2.) are clo-
cessible connections and parts.
sed.
The two sensitivity levels are:
- Disconnect the pipes from valves V1 - V2 and replace the
caps on the system valves. - Low sensitivity = 16.5 g/year.
- Re-check the system with the leak detector. - High sensitivity = 3.3 g/year.
Normally, with the air-conditioner operating, air Before making checks on the vehicle, wait for the
should come out from the outlets at a temperature engine to cool. Hot engine components may cause
below 5C after a the time necessary for reading errors.
temperature to stabilise in the ducts.
50642
50643
CABIN AND CHASSIS RHD
SECTION 18 B
HD9 Euro5 SECTION 18 B CAB AND CHASSIS RHD 1
SECTION 18 B
Cabin and chassis RHD

Page
CABIN 7
DESCRIPTION 7
CABIN REMOVAL-REFITTING 9
GENERAL 9
- Removal 10
- Reassembly 18
DOOR REMOVAL-REFITTING 19
GENERAL 19
- Removal 20
- Refitting 21
COWL REMOVAL-REFITTING 23
GENERAL 23
2 CAB AND CHASSIS RHD SECTION 18 B HD9 Euro5

- Inspections and checks 24 BUMPER REMOVAL-REFITTING 31
WINDSCREEN WASHER ARM REMOVAL- - Vehicle preparation 31
REFITTING 25
GENERAL 25
- Removal 32
- Refitting 32
- Removal 26
- Refitting 26
STEERING COLUMN REMOVAL-REFITTING 33
GENERAL 33
CABIN FRONT SHOCK ABSORBER REMOVAL-
REFITTING 27 - Safety instructions 33
- Safety instructions 27 - Very heavy parts 33
- Very heavy parts 27 DESCRIPTION OF OPERATION 34
- Specific safety instructions 27 - Removal 34
DESCRIPTION OF OPERATION 28 - Replacement 40
- Preliminary operations 28 STEERING COLUMN PNEUMATIC CYLINDER
REMOVAL-REFITTING 41
- Removal 28
GENERAL 41
- Refitting 28
CABIN REAR SHOCK ABSORBER REMOVAL-
REFITTING 29 - Specific safety instructions 41
- Very heavy parts 29 - Removal 42
- Specific safety instructions 29 - Steering control components 43
- Preliminary operations 30 - Determination of adjuster shim thickness 44
- Removal 30 - Refitting 45
PEDAL UNIT REMOVAL-REFITTING 46 GENERAL 58

GENERAL 46 - Safety instructions 58
- Safety instructions 46 - Vehicle preparation 58
- Hazardous and/or polluting substances 46 DESCRIPTION OF OPERATION 59
DESCRIPTION OF OPERATION 47 - Removal 59
- Removal 47 INNER DOOR LINING REMOVAL-REFITTING 60
DASHBOARD REMOVAL-REFITTING 49 - Vehicle preparation 60
GENERAL 49 - Hazardous and/or polluting substances 60
- Safety instructions 49 DESCRIPTION OF OPERATION 61
DESCRIPTION OF OPERATION 50 - Refitting 62
- Removal 50 DOOR WINDING WINDOW REMOVAL-
REFITTING 63
- Refitting 50
GENERAL 63
CENTRAL DASHBOARD REMOVAL-REFITTING 51
GENERAL 51
- Removal 52
- Removal 64
- Refitting 52
- Refitting 64
DASHBOARD (INSTRUMENT PANEL) REMOVAL-
REFITTING 53 - Final operations 64
GENERAL 53 DOOR WINDOW WINDER DEVICE REMOVAL-
REFITTING 65
GENERAL 65
- Removal 54
- Removal 66
- Refitting 57
- Refitting 66
SEAT REMOVAL-REFITTING 58
DOOR LOCK REMOVAL-REFITTING 67 - Hazardous and/or polluting substances 74

- Refitting 68 FIXED DOOR WINDOW REPLACEMENT 80
DOOR HANDLE REMOVAL-REFITTING 69 - Safety instructions 80
- Safety instructions 69 - Specific safety instructions 80
DESCRIPTION OF OPERATION 70 DESCRIPTION OF OPERATION 81
- Preliminary operations 70 - Preliminary operations 81
- External handle 70 - Inspections and checks 81
- Internal handle 70 - Refitting 82
- Refitting 70 - Final operations 82
- Final operations 70 CABIN TIPPING DEVICE 83
REAR-VIEW MIRRORS REMOVAL-REFITTING 71 DESCRIPTION 83
GENERAL 71 - Component location 83
- Safety instructions 71 - Cabin tipping system diagram 84
- Vehicle preparation 71 CABIN TIPPING HYDRAULIC FLUID CHANGE 85
DESCRIPTION OF OPERATION 72 GENERAL 85
- Removal 72 - Safety instructions 85
- Main mirrors and supplementary mirror on door 72 - Hazardous and/or polluting substances 85
- Close-proximity mirror (left-hand door only) 73 DESCRIPTION OF OPERATION 86
- Refitting 73 - Drainage 86
WINDSCREEN REPLACEMENT 74 - Filling 86
GENERAL 74 CABIN LIFTING PUMP REMOVAL-REFITTING 87
- Safety instructions 74 GENERAL 87
- Vehicle preparation 74 - Safety instructions 87
- Very heavy parts 74 - Vehicle preparation 87
- Specific safety instructions 74 - Hazardous and/or polluting substances 87
DESCRIPTION OF OPERATION 88 COMPRESSOR REMOVAL-REFITTING CLIMATE

CONTROL 98
GENERAL 98
- Removal 88
- Refitting 88
CABIN TIPPING CYLINDER REMOVAL-REFITTING 89
GENERAL 89
- Removal 99
- Refitting 99
CLUTCH REMOVAL-REFITTING ELECTRO-
- Preliminary operations 90 MAGNETIC COMPRESSOR CLIMATE CONTROL 100
- Removal 90 GENERAL 100
- Inspections and checks 90 - Safety instructions 100
- Refitting 90 - Vehicle preparation 100
CABIN CLIMATE CONTROL 91 - Preliminary operations 101
- Overview 91 - Removal 101
VENTILATION 91 - Refitting 101
- Description 91 - Final operations 102
- Climate controlled air flow orientation 91 CLIMATE CONTROL UNIT REMOVAL-REFITTING 103
AIR CONDITIONING 92 GENERAL 103
- Description 92 - Safety instructions 103
- Conditioning 92 - Vehicle preparation 103
- Heating 92 - Very heavy parts 103
- Air conditioning 92 - Hazardous and/or polluting substances 103
- Air conditioning control group 92 DESCRIPTION OF OPERATION 104
DIAGNOSTICS 93 - Preliminary operations 104
- Troubleshooting guide 93 - Removal 104
- Introduction 93 - Refitting 105
- Troubleshooting by symptoms 93 - Final operations 105
GENERAL RECOMMENDATIONS 97 PROCEDURE FOR DRAINING AND RECHARGING
THE AIR-CONDITIONER WITH R134a COOLANT 106
- R134a coolant recharge and recovery station

(99305146) 106
SAFETY STANDARDS 107
CONTROL PANEL 108
OPERATIONS FLOW DIAGRAM 110
REFRIGERANT RECOVERY FROM SYSTEM ON
VEHICLE 111
CREATING VACUUM IN SYSTEM 113
RESTORING SYSTEM OIL LEVEL 115
CHARGING PLANT WITH REFRIGERANT 116
CHECKING SYSTEM PRESSURES 118
OPERATIONS PRIOR TO REMOVING
STATION FROM SYSTEM 118
LEAK DETECTOR FOR AIR CONDITIONING
SYSTEMS WITH HFC R134a (9905147) 118
CABIN
DESCRIPTION
The cab is hinged at the front and suspended both to front and
rear on the chassis:
- to the front by two longitudinal arms with springs, shock
absorbers, buffers and anti-roll torque bar;
- to the rear by two control arms with springs, shock absor-
bers and buffers.
The cabin can be tipped forward by means of a manually con-
trolled hydraulic cylinder.
Figure 1
357A018R200R
TIGHTENING TORQUES
357A018002R
CABIN REMOVAL-REFITTING Very heavy parts

GENERAL
Vehicle preparation

signboards.
Safety component.
Figure 2
2371801

of short circuits;

Proceed as follows: - tip the cab as described in the Use section of the USE
- drain off the fluid from the climate control as described AND MAINTERNANCE HANDBOOK.
in CLIMATE CONDITIONER FLUID CHANGE in this - For versions with manual/servo-assisted transmission
Section; only: disconnect the manual gear control lever (1);
the Maintenance section of the USE AND MAINTEN- Mark the matching points of the parts.
ANCE HANDBOOK;
- disconnect the quick couplings (2) and (3) of the reservoir
bleeding pipes;
4. Fluid may leak out during these operations.
- lower the cab as described in the Use section of the USE

only: draw up the hydraulic fluid from the cab tipping
system oil tank as described in the Maintenance section
Figure 3
357A018003R
- loosen the fastening screws (arrow) and remove the - disconnect the main electric power supply cable (3) and
cover (1); withdraw the cable from behind the reservoir;
- disconnect the following from the main chock (2): - disconnect the ground cable (4);
A. WHITE connector
- disconnect the right direction indicator connector (5);
B. BROWN connector.
C. YELLOW connector
D. BLUE connector (if present) The left direction indicator connector is part of the
E. GREENconnector cab wiring.
Proceed as follows:
- raise the cover (a)
- disconnect the low coolant level sensor connector (6);
- turn the stop lever (b)
- remove all the remaining clamps and free the wiring from
- take out the connector (c) the steering plate, resting it on the front bumpers;
Figure 4
357A018R201R
- remove the clamps and disconnect the engine coolant

piping (1) and (2) from the cab heater; Pay attention to recuperate the O-rings. Replace
them if they appear damaged.
- remove the clamp and disconnect the piping (3) from the
engine coolant expansion tank;

More coolant may leak out during these operations.
only: disconnect the fitting (6) of the cab tipping hydraulic
system.
Hydraulic fluid may leak out during these operations.

- disconnect the conditioner coolant delivery (4) and
return (5) pipes from the evaporator;
Figure 5
357A018R202R
- disconnect the joining plates of the air piping :

(1) cab services
(2) duplex brakes valve
(3) cab services
proceeding as follows (see detail):
 unscrew the half-plate connecting screws
 disconnect the services air piping separating the half-
plate (A) from half-plate (B);
only: disconnect the splitter control supply pipe (4);
Figure 6
357A018R203R
- check that the vehicle wheels are straight: if not, align - remove the locking nut (2) and withdraw the cab lifting
them; cylinder fastening screw;
- unscrew the clamping bolts and free the steering sleeve - rest the cylinder (3) on the chassis;
joint (1) from the groove of the steering box;
- remove the front shock absorber plastic protection (not
shown) from both sides;
Do not move the vehicle front wheels so that the - remove the upper and lower locking nuts of the front
steering remains centred when reassembling.
shock absorbers (see arrow);
it is recommended to mark the matching positions
of the parts. - remove the right (5) and left (6) shock absorbers from the
front supports.
Figure 7
357A018R204R
- unscrew and remove the four fastening bolts (1) that - unscrew and remove the four fastening bolts (2) that
clamp the right cab support to the chassis; clamp the left cab support to the chassis;
Figure 8
357A018R205R
- open both the vehicle doors;

For better cab balance during the operations, place
- using suitable lifting gear, fit the equipment to the upper brackets as shown in the figure (detail).
part of the cab so that the brackets attach correctly to the
horizontal part of the door frame;
Figure 9
357A018009R
- Slightly lift the cab to relieve the suspension springs; - Using a large screwdriver, lift the safety locking plates (1)
from both sides until they release;
Figure 10
357A018010R
connected and that all the clamps grouping together wir-
ing and pipes have been severed;
- cautiously lift the cab until fully removing it from the
vehicle;
- place the cab on an appropriate trolley taking care to
centre the locators in their housings :
A. front support corresponding to the hinge pins: insert
the pins in the relevant housings and secure them
turning the end in the bracket.
B. rear support corresponding to the safety hooks:
make certain that both hooks are engaged.
Figure 11
357A018011R
Reassembly Final operations

To refit, follow the removal instructions in reverse order. Start the engine and warm it up until the thermostat opens,
Pay attention to correctly reconnect all previously discon- then check that:
nected electrical connections;
- there is no coolant leakage from the engine cooling or
Carry out the following operations. cab heating system sleeves:
- fill the cooling system as described in the Maintenance - the braking system functions correctly;
Section of the USE AND MAINTENANCE HAND-
- warning lights and instruments function correctly;
BOOK;
- the climate control system functions correctly;
- fill the window washer reservoir as described in the Main-
tenance section of the USE AND MAINTENANCE - the windscreen washer system functions correctly.
HANDBOOK;
CONTROL SYSTEM FLUID CHANGE in this Section.
only: top-up the cab tipping system oil level as described
in the Maintenance section of the USE AND MAINTEN-
ANCE HANDBOOK.
4;
- adjust the pre-load of the front shock absorbers as
described in CABIN FRONT SHOCK ABSORBERS RE-
MOVAL-REFITTING in this Section.
DOOR REMOVAL-REFITTING Very heavy parts

GENERAL
Vehicle preparation

signboards.
Figure 12
2371801

of short circuits;
DESCRIPTION OF OPERATION - using suitable lifting means, sling the door and support it
before disconnecting the hinges.
Proceed as follows:
Use suitable belts.
- left door only: remove the close-proximity rear-view mir- Do not use chains or hooks to prevent damaging the
ror as described in the CLOSE-PROXIMITY REAR-VIEW door.
MIRROR REMOVAL-REFITTING chapter in this section; Manoeuvre the door very carefully.
section;
Figure 14
- remove the winding window as described in the WIND-
ING WINDOW REMOVAL-REFITTING chapter in this
section;
- remove the internal and external handles as described in
the HANDLES REMOVAL-REFITTING chapter in this
section;
- remove the lock as described in the LOCK REMOVAL--
If the fixed window must be recovered, remove it as

described in the FIXED WINDOW
REPLACEMENT chapter in this section.
Removal
Proceed as follows:
Figure 13
357A018101R
- loosen the screws fastening the upper (A) and lower (B)
hinges to the cab and remove the door;
- remove any shims arranged between hinge and cab;
- carefully remove any sealant paste.
357A018100R Inspections and checks

Check integrity of the door seals and replace the damaged
- remove the fairlead (1) from the door; component if needed.
- remove the wiring carefully to prevent damaging the
sheaths;
Refitting Figure 16
Proceed as follows:
Using suitable lifting means, sling the door and support it by
approaching it to the cab.
Use suitable belts.

door.
Manoeuvre the door very carefully.
Figure 15
357A018102R
- close the door carefully and check that the gap between
door and door frame is approximately constant (see
arrow);
- in case of need, loosen the fastening screws and adjust the
gap using suitable shims to be inserted between door and
frame;
- refit the lock as described in the LOCK REMOVAL-RE-
- refit the internal and external handles as described in the
HANDLES REMOVAL-REFITTING chapter in this sec-
357A018101R tion;
- position the door so as to be able to fasten the hinges; - close the door carefully and check that the lock is cor-
rectly coupled with the striker on the pillar;
- fasten the screws fastening the upper (A) and lower (B)
- if needed, loosen the lock fastening screws and adjust the
hinges to the cab without tightening;
reciprocal position of lock and striker;
- remove the support belts.
- close the door carefully and check that the pressure on
the seals is correct;
- add or remove shims under the hinges (front door side)
and/or adapt the position of the lock striker (rear door
side) if needed.
Final operations
Proceed as follows:
- refit the fixed window as described in FIXED WINDOW
REPLACEMENT chapter in this section;
tion;
MIRROR REMOVAL-REFITTING chapter in this section;
- left door only: refit the close-proximity rear-view mirror
as described in the CLOSE-PROXIMITY REAR-VIEW
COWL REMOVAL-REFITTING
GENERAL
Safety instructions

manual.
Very heavy parts


Preliminary operation Check integrity of the hinges, if needed, to replace the dam-
Proceed as follows: aged component.
Removal
Final operations
Proceed as follows:
Open and close the cowl several times to check correct cen-
- using suitable lifting means, sling the cowl and support it tring and correct closing.
before disconnecting the hinges;
Use suitable belts.

cowl.
- remove from both the split pin (2), remove the pin (1) and
recover the thrust washers (3);
- remove the screws (4) fastening the hinge to the cab and
remove the cowl (5) on both sides.
Figure 17
357A018103R
WINDSCREEN WASHER ARM REMOVAL-

REFITTING
GENERAL
Safety instructions

manual.
Proceed as follows:
Removal
Figure 18
357A018104R
Proceed as follows:
- disconnect the windscreen washer tube (1) from the arm;
- remove the fastening nut (2);
- remove the arm (3) from the pin levering carefully.
Refitting
Final operations
Proceed as follows:
CABIN FRONT SHOCK ABSORBER

REMOVAL-REFITTING
GENERAL
Safety instructions

Very heavy parts

Safety component.

Proceed as follows:
To refit, follow the removal operations in reverse and tighten
the fastening nuts.
Removal
Proceed as follows:
Figure 20
Figure 19
357A018013R

position 2;
357A018012R
- remove the plastic protection (1); To adjust the spring pre-load use a wrench type
USAG 282/92-95-100 or equivalent.
- remove the lower fastening nut (2) and recover the
washer;
- remove the upper fastening nut (3) and recover the - the ring nut position can be changed according to the spe-
washer; cific use requirements of the vehicle :
- remove the shock absorber (4) withdrawing it sideways. - Position < 2: spring less stiff
- Position > 2: spring more stiff
- fit the plastic protection.
Final operations
Proceed as follows:
CABIN REAR SHOCK ABSORBER

REMOVAL-REFITTING
GENERAL
Safety instructions

Very heavy parts

Safety component.

Proceed as follows:
- tip the cab as described in the Use section of the USE Refitting
To refit follow the removal operations in reverse and tighten
the fastening nuts.
Removal
Proceed as follows:
Figure 22
Figure 21
357A018013R

position 2;
357A018014R
To adjust the spring pre-load use a wrench type

- remove the lower fastening nut (1) and take out the USAG 282/92-95-100 or equivalent.
screw (2), recovering the washers;
- remove the upper fastening nut (3) and take out the
screw (4);
- the ring nut position can be changed according to the spe-
- remove the shock absorber (5) withdrawing it sideways. cific use requirements of the vehicle :
- Position < 2: spring less stiff
- Position > 2: spring more stiff.
Final operations
Proceed as follows:
- tip the cab as described in the Use section of the USE
BUMPER REMOVAL-REFITTING Very heavy parts

GENERAL
Vehicle preparation

signboards.
Figure 23
2371801

of short circuits;
DESCRIPTION OF OPERATION - unscrew the side fastening screws (4) from both sides;
Preliminary operations - unscrew the front fastening screws (1) from both sides
Proceed as follows: and recover the counter-plate (5);
- open the cowl as described in the Use section of the USE - remove the bumper.
AND MAINTENANCE HANDBOOK;
- open the front light clusters as described in the Mainten- Refitting
ance section of the USE AND MAINTENANCE HAND- To refit, follow the removal instructions in reverse order.
BOOK.
Removal Proceed as follows:
Proceed as follows: - reposition the front light cluster as described in the Main-
- appropriately sustain the bumper; tenance section of the USE AND MAINTENANCE
HANDBOOK;
- disconnect the front light cluster connector (2) from both
sides; - close the cowl as described in the Use section of the USE
- disconnector the direction indicators connector (3) from
both sides;
Figure 24
357A018015R
STEERING COLUMN REMOVAL- Very heavy parts

REFITTING

Vehicle preparation

signboards.
Figure 25
2371801

of short circuits;
DESCRIPTION OF OPERATION - disconnect the ground wire connection (3);

Removal - remove the nut (4) and mark the fitting position of the
Proceed as follows: steering (2) on the shaft (5) and remove the steering whe-
el;
- enable the steering lock by removing the key from the
ignition switch; - extract the interconnection box stopper key (6) from the
housing;
- remove the cover (1) from the steering wheel (2);
Figure 26
357A18027R
- remove the pushbutton panels (1) and (5); - disconnect the electrical connections (4);
- unscrew the screws (2) and (6). - remove the instrument panel and deposit it safely;
- unscrew the screws (3) and (7); - unscrew the screws (8) and (9) and remove the side co-
vers (10) and (11);
Figure 27
357A18028R
From the steering control support (4), remove the This operation serves to prevent the rotor (9) and
interconnection box (2) strictly following the the stator (8) reciprocally rotating during
procedure given below. This is to prevent damaging dismantling.
the spiral cable contained in the box itself and to Maintain this locked condition until reassembled.
prevent incorrect steering wheel angle reading once Without the keys, use a nut and screw of adequate
reassembled. length.
- Disconnect the electrical connections (5 and 6); - grip the interconnection box (2), lift it carefully such that
the retainer pins (3) slip out from the support (4) and sui-
- Disconnect the electrical connections (10 and 11);
tably deposit them.
- fasten the cover (1) of the interconnection box (2) to the
box itself, inserting the keys (7) into the slots (8) and (9);
Figure 28
272C18032
- unscrew the screws (2) and remove the bracket (1). - Unscrew the screws (5);
- Disconnect the electrical connections (4); - remove the steering column cover screws (7);
- unscrew the screws (3) and remove the left and right - unscrew the steering column boot screws (8)
combiswitch controls;
- remove the steering column cover screws (9);
- unscrew the screws (6) and remove the SWI control unit;
- remove the steering column cover (10) from the vehicle;
Figure 29
357A018R206R
- mark the fitting position of the upper shaft on the support - unscrew the fastening screws (6) and remove the steering
(3) and on the UV joint (2); command support (4) from the pedal board (5) (arrow);
- loosen the screw (1) and extract the UV joint (2) from - working from outside the cabin, on the power steering
the upper shaft; box (10) and the UV joint (8) mark the fitting position of
the cardan shaft;
Do not move the wheels to permit correct steering
wheel centring on reassembly. Do not move the wheels to permit correct steering
wheel centring on reassembly.
- disconnect the steering column pneumatic adjuster pipe

(13); - loosen the screw (9) and extract the UV joint (8) from
the shaft on the power steering box.
- remove the corrugated sheath (7) from the steering com-
mand support; - remove the cardan shaft (12) from the boot (11) working
in the direction indicated by the arrow.
Figure 30
357A018R207R
Replacement
Specifically:
- pay particular attention to making all electrical connec-
tions correctly;
- the replacement interconnection box (1) is supplied with
the stopper key assembled as shown in the figure;
Figure 31
272C18035
- after fitting the key (2) on the steering command suport,

turn it to break it at the indicated point (arrow) and repla-
ce it in the housing in the steering wheel.
STEERING COLUMN PNEUMATIC Very heavy parts

CYLINDER REMOVAL-REFITTING

concerning safety of the personnel involved in the Specific safety instructions
part of this manual. Make sure that residual pressure has been
Always observe all the general recommendations to completely discharged from the circuits and related
carry out maintenance jobs correctly. reservoirs.
Vehicle preparation

signboards.
Figure 32
2371801

of short circuits;

Proceed as follows:
- remove the steering column operating as described in the
STEERING COLUMN REMOVAL-REFITTING chapter
of this section.
Removal
Proceed as follows:
Figure 33
272C18037
- in the hole in the cylinder air supply (3) fasten a suitable

connector (5) and introduce air at 8  12 bar pressure;

removal operation, this being a necessary condition
for assuring release of the pneumatic cylinder (3).
- fully shift the steering control shaft-group (6) toward the

outside (arrow);
272C18036
- Mark the fitting position of the screw (7) on the support
- remove the shock absorber (1) removing the nuts (2 and (9);
3); - remove the nut (1), extract the screw (7) with the wa-
shers (2 and 8);
- remove the support (9), the pneumatic cylinder (3) the
adjuster shim (4) and the steering control shaft group (6);
Figure 35
272C18038
Steering control components

1. Pneumatic cylinder
2. Adjuster shim
3. Connector
4. Support
5. Washer
6. Screw
7. Shock absorber
8. Steering control shaft group
9. Nut
10. Washer
11. Nut

Determination of adjuster shim thickness
Proceed as follows:
Figure 36
272C18041
- In the air supply hole in the new cylinder (3) fasten a suita-
ble connector (2) and introduce air at 8  12 bar pressure;
272C18039
- With a suitable instrument (precision class 0.05 mm) measurement and subsequent assembly period.
measure the distance A between the sliding surfaces of
the support (1).
- Rest the pneumatic cylinder (3) on the check plate and
Figure 37 fit the adjuster shim (1) to the piston.
- Using a suitable tool (4), measure the distance (D)
- The thickness S of the shim is given by:
S = A - (B+C+D+ 0,2)
A = distance between support sliding surfaces
B = distance between inner surface of support and sliding
surface
C = distance between inner surface of support and sliding
surface
0,2 =play in mm
272C18040
- In the support (1) position the steering control shaft sup-

port (2).
- With a suitable instrument (3) measure the distances B
and C between the inner surface of the support (2) and
the sliding surfaces (1).
Refitting Figure 41
Figure 39
272C18044
272C18042 - Fit the shock absorber (1), tighten the nuts (2) and (3) to
- Insert the support (2) in the support (1). - Check tightness of the cylinder (4): applying a traction for-
- Position the cylinder (4) taking care that the pin (5) is cor- ce of 300 N (30 kg) to the steering control shaft in the
rectly inserted in the support guide groove (2). direction of the driver. The cylinder must not shift with
respect to the support (3).
- Choose the adjuster shim (3) from those provided as re-
placements, of the thickness calculated by the previous Refit the steering control assembly to the vehicle as described
measurements. in the corresponding chapter.
- .Lubricate the adjuster shim (3) with the specified grease
and insert it between the cylinder (4) and the support (1). Final operations
Proceed as follows:
Figure 40 - refit the steering column operating as described in the
STEERING COLUMN REMOVAL-REFITTING Chapter
of this section.
272C18043
- Fit a new screw (7) with washer (8) positioning it at the

point marked on dismantling.
- Fit the washer (2).
- Apply LOCTITE 270 to the thread of the new nut (1) and
fasten it on the screw (3) until determining, between the
washer (2) and the support (3), play of 0.1  0.2 mm.
- Check excursion of the steering control shaft support (8)
on the support (3) in all directions.
- Set the steering control shaft support (6) in the excursion
start position (minimum steering wheel height).
- Remove the pneumatic connection (4) from the pneuma-
tic cylinder (5).
PEDAL UNIT REMOVAL-REFITTING Hazardous and/or polluting substances

GENERAL
Vehicle preparation

signboards.
Figure 42
2371801

of short circuits;

Proceed as follows:
Final operations
- remove the steering column as described in STEERING
Proceed as follows:
COLUMN REMOVAL-REFITTING in this Section.
4;
4.
- refit the steering column as described in STEERING COL-
Removal UMN REMOVAL-REFITTING in this Section.
Proceed as follows:
- unscrew the plate fastening screws and disconnect the air
piping from the brakes valve (2):
- disconnect the splitter control pneumatic fitting (3);
- disconnect the stop signal electric connector on the
brakes valve (4);
- disconnect the servoshift signal electric connector on the
clutch control (5);
- operating inside the cab, disconnect the electrical con-
nections (6), withdraw the rubber chock (7) and bring the
wiring out externally;
In the case of difficulty, dismantle the separate

connectors.
- unscrew the seven fastening screws (see arrow);

connected and that all wiring clamps and pipes con-
nectors have been severed;
- bring the pedal unit (1) outwards, until it is completely
released from the vehicle.
Figure 43
357A018R208R
DASHBOARD REMOVAL-REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 44
2371801

of short circuits;
The illustrations in the procedure that follows refer

to the LHD version.
Removal
Proceed as follows:
Figure 45
77067
342B016001R
- remove the bottle holder (1) from the seat;

- loosen and remove the fastening screws (see arrow) 357A018135A
from the plastic fairing (2);
- remove the plastic fairing (2);
- For Euro 3 versions only: disconnect the electric
connectors and remove the light switch units (3);
- loosen the screws (1) fastening the dashboard (1);
Figure 46 - disconnect the electric connections (4) and (5);
- remove the dashboard.
Refitting
77066
- For Euro 3 versions only: remove the switch-warning light

unit (1) by operating the fastening tabs;
- remove the plugs (2).
CENTRAL DASHBOARD REMOVAL-

REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 48
2371801

of short circuits;

to the LHD version.
Removal
Proceed as follows:
Figure 49
90054
- remove the frame (2);

- loosen the screws (1) fastening the climate control dash-
board (4):
- release the central dashboard (3);
- disconnect the electric connections from the switches;
Mark the electric connections to assist reassembly.

90052

- remove the plugs (2) and loosen the screws (3); - remove the central dashboard.
Figure 50 Refitting
90053
- remove the lid (2) and disconnect the electric connector

from the power socket (3);
DASHBOARD (INSTRUMENT PANEL) Hazardous and/or polluting substances

REMOVAL-REFITTING
Vehicle preparation

signboards.
Figure 52
2371801

of short circuits;
DESCRIPTION OF OPERATION - remove the floor air vent (2) by means of the fastening
tabs (see arrow);
to the LHD version. - loosen the side screws (1) fastening the steering column
lining;
Figure 55
Proceed as follows:
- remove the central dashboard as described in the CEN-
TRAL DASHBOARD REMOVAL-REFITTING chapter in
this section.
Removal
procedure.
90002
Proceed as follows:
Figure 53 lining (2);
Figure 56
77107
- loosen the screws (1) and remove the steering column 77116
lining (2);
- loosen the screws (3) fastening the curtain guard (1) on
Figure 54 the steering column;
- loosen the screws (2) fastening the lining to the steering
column.
77108

- loosen the screws (4) fastening the kick plate (3);
- remove the kick plate (3) from the vehicle;
Figure 57 Figure 59
357A018106R
- loosen the screws (1) fastening the pneumatic line sup-

port base (2).
357A018105R
- partially remove the door frame seal (1);

- remove the snap-fitted plug (2) and loosen the screw
underneath;
- disconnect the windscreen pillar lining (3);
Figure 58
77116
- loosen the screws (1) and remove the grab handle (4);
- loosen the screws (2) and remove the lining (3);
Figure 60 Figure 62
90056
357A018107R
- remove the snap-fitted plugs (3); - loosen the screws (1) and remove the storage compart-
- loosen the fastening screws (2) and release the panel (1) ment (2);
of the differential locks;
Figure 63
Figure 61
357A018108R
90057 - loosen the screws (1) and tip the fuse box (2);
- loosen the screws (1) and remove the lining (2); Figure 64
77114
- remove the nuts (1) and the screws (3);

- Cut the clips and disconnect the air delivery pipe (2) from
the climate control unit.
Figure 65
77115
- Loose the nuts (2).

- cut the clips and disconnect the air delivery pipe (1) from
the climate control unit;
Figure 66
90058
- loosen the upper screws (1);

- loosen the lower screws (3);
- remove the dashboard (2).
Refitting
Final operations
Proceed as follows:
- refit the central dashboard as described in the CENTRAL
DASHBOARD REMOVAL-REFITTING chapter in this
section;
SEAT REMOVAL-REFITTING Hazardous and/or polluting substances

GENERAL
Vehicle preparation

signboards.
Figure 67
2371801

of short circuits;

Proceed as follows:
- disconnect the pneumatic connection (1);
- disconnect the electrical connection (2) (if present);
- make the seat slide forwards and tip the backrest, then
loosen the seat rear fastening screws (3, see arrow) of the
seat;
- arrange the seat back and open the front compartment
flap, then loosen the front fastening screws (4, see arrow)
of the seat;
- remove the seat from the support.
Figure 68
357A018109R
INNER DOOR LINING REMOVAL-

REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 69
2371801

of short circuits;

Removal
Proceed as follows:
Figure 70
357A018111R
90046
- loosen the upper fastening screws (1);
- disconnect the control panel (2) of the armrest (1); - remove the plugs and loosen the fastening screws (2);
- disconnect the electric connections (3) and (4) from the - remove the armrest (3);
panel (2);
Figure 73
Figure 71
90047
- loosen the screw (2) and remove the knob (1);

- compress the tabs of the pin (4) and remove the handle
357A018110R
(3).
- remove the plugs and loosen the fastening screws (1);

- disconnect the electrical connection of the speaker, if
present;
- remove the storage compartment (2);
Figure 74
357A018112R
- loosen the fastening screws on the pillar (1) and in the

vent (2);
- remove the panel (3) being careful when removing the
wires (4) from the slot;
Figure 75
357A018113R
- remove the adhesive lining from the door.
Refitting
DOOR WINDING WINDOW REMOVAL- Specific safety instructions

REFITTING
GENERAL Handle the windows with care to prevent injuries.
Safety instructions adhesive tape on the surface to withhold the glass
Before carrying out any operation make certain to Clean up the area with a vacuum cleaner to pick up
have taken all precautions and clarified all aspects all residues and glass fragments.
Vehicle preparation

signboards.
Figure 76
2371801

of short circuits;

Proceed as follows:
Removal
The operation must be carried out with the window

all down.
Figure 77 73274
- temporarily turn vehicle electrical system back on;

- provisionally connect the electric connections to the
control panel and lift the window until the clip (2) can be
reached;
- cut off the vehicle electrical system on;
- disconnect the electric connections on the panel;
- disconnect the electric window winder device (3) from
the window (1) by removing the clip;
Figure 80
73272
Proceed as follows:
- remove the internal and external lower seals (1) from the
window compartment;
Figure 78
73275
- lift the window (1) and remove it from the upper part.
Refitting
Final operations
73273
Proceed as follows:
- remove the guiding seal from the window frame (1); - refit the interior lining as described in INTERIOR LINING
REMOVAL-REFITTING in this section.
DOOR WINDOW WINDER DEVICE

REMOVAL-REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 81
2371801

of short circuits;

Preliminary operations Reverse the removal sequence to refit.
Proceed as follows:
Final operations
Proceed as follows:
tion. - refit the winding window as described in the DOOR
WINDING WINDOW REMOVAL-REFITTING chapter
Removal in this section.
Figure 82
357A018114R
Proceed as follows:
- remove the screws (1), (3) and (4) fastening the window
winder device;
Figure 83
73277
- remove the window winder device (1) from the door.

DOOR LOCK REMOVAL-REFITTING

GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 84
2371801

of short circuits;

Proceed as follows:
Removal
Figure 85
73280

handle;
- remove the screws (1) and remove the lock (2) of the
door.
Refitting
73278 Reverse the removal sequence to refit.

- release the clip (2) from the linkage (3); Proceed as follows:
- disconnect the linkage from the transfer (1); - refit the interior lining as described in the INTERIOR LIN-
- if present, disconnect the electric connections (4) and (5)
of the lock (6);
Figure 86
73279

handle (3);
DOOR HANDLE REMOVAL-REFITTING

GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 88
2371801

of short circuits;

Proceed as follows:
Removal
External handle
Figure 89
73283
- remove plugs (1) and (2);

- loosen the nuts (3) and remove the external handle (4).
Internal handle
Figure 92
73281
Proceed as follows:
- disconnect the linkage from the transfer (1) of the lock
(4);
Figure 90
73284

handle (4);
- loosen the screws (3) and remove the handle (4).
Refitting
Final operations
Proceed as follows:
73282

handle (4);
- disconnect the linkage (3) from the external handle (4);
REAR-VIEW MIRRORS REMOVAL-

REFITTING
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 93
2371801

of short circuits;

Removal
Main mirrors and supplementary mirror on door
Figure 94
357A018117R

- remove the mirror.
357A018115R

- remove the upper (3) and lower (4) lids;
Figure 95
357A018116R
- disconnect the electrical connections (5);

Close-proximity mirror (left-hand door only)
Figure 97
357A018R209R

Figure 98
357A018R210R

- disconnect the electric connection located behind the
bracket and remove the mirror.
Refitting
WINDSCREEN REPLACEMENT Very heavy parts

GENERAL

signboards.

Figure 99 In case of breakage, apply an adhesive sheet or
2371801

of short circuits;

Proceed as follows:
Figure 100
357A018121R
- open the door and remove the fastening screws (1);

- remove the lower baffle (2);
357A018120R
Figure 102
- if present, remove the fastening screws and remove the
sun curtain (1);
- removethecowlasdescribedin theCOWL-REMOVAL--
- remove the windscreen wiper arms as described in the
chapter in this section.
357A018122R
- remove the fastening screws (3);

- remove the upper baffle (4);
- repeat the same operations on the other side.
Removal
Proceed as follows:

procedure.
Figure 103
357A018123R
- using a suitable tool (chisel or cutter), cut the protruding

part of the seal along the entire entire of the windscreen;
- cut the sealant (dotted line) along the sides and the upper
part of the windscreen;
- support the windscreen with suitable tools (suction caps)
from the outside and remove the windscreen from the
inside outwards.
If necessary, heat the edge of the windscreen to

facilitate removal.

Proceed as follows:
sealant;
needed.
Refitting
Proceed as follows:
Figure 104
357A018124R
- Arrange the seal (1) on the windscreen (2).
The metal seat groove must be inside the windscreen.

If the ambient temperature is low, it is advisable to slightly warm the seal (e.g. by submerging it in hot water).
- Insert a strong wire (3), approximately 5 mm diameter (e.g. an electric wire) in the metal seat groove
The wire must fully engage the seal and be twisted for a given length in the lower part of the windscreen (see arrow).
Figure 105
357A018125R
- Support the windscreen with suitable tools (suction caps) from the outside and rest it in seat.
The two ends of the wire must fall inside the cab
Figure 106
357A018126R
- Working from the inside, pull the wire to force the seal to pass over the edge and knock the zone near the working point
of the wire at the same time from the outside.
Figure 107
357A018127R
- Settle the seat at the same time knocking along the edge of the window to uniform adherence and eliminate small wrinkles.
Figure 108
357A018128R
- Working from the outside, apply sealant paste of the

required type in the side and upper peripheral zone
between body and seal.
Sealant: HENKEL TEROLAN-4201/A
- Carefully remove all sealant in excess at the end.
Final operations
Proceed as follows:
- refit the upper and lower baffle on both sides by reversing
the removal order;
- refit the windscreen wiper arms as described in the
chapter in this section;
- refit the cowl as described in the COWL REMOVAL-RE-
- refit the sun curtain, if present, by reversing the removal
sequence.
FIXED DOOR WINDOW REPLACEMENT Hazardous and/or polluting substances

GENERAL

Vehicle preparation fragments using removal.
signboards.
Figure 109
2371801

of short circuits;
Proceed as follows:
section;
Removal
Proceed as follows:
The window is glued.

The window may smash during removal: apply plenty
of adhesive tape on the surface and proceed with
care.
Figure 110
73287
- apply the adhesive handle (2) to the window;

- using a suitable cutter, cut the sealant bead (1) and
remove the window from its seat.

Proceed as follows:
sealant;
Be careful not to scratch the paint. It this happens,

apply suitable rust protection and paint the
concerned area.

needed.
Refitting Figure 113

Proceed as follows:
Figure 111
357A018129R
- clean the edge of the window with suitable detergent (e.g.

isopropyl alcohol) before applying the sealant;
Figure 112
357A018131R
- apply the window into its seat exerting a uniform pressure

for approximately 60 minutes.
Final operations
Proceed as follows:
ING REMOVAL-REFITTING chapter in this section;
357A018130R
- apply a bead of required sealant past on the inner edge.
Do not apply the sealant in the upper part shown

(detail).
Sealant: SIKA SIKAFLEX 221

CABIN TIPPING DEVICE
DESCRIPTION
The vehicle is equipped with a driving cab tipping system.
Do not remain in front or behind the cab during the

tipping.
Never leave the cab in a partially tipped position.
Component location
2. Release device
3. Cylinder
Figure 114
357A018019R
Cabin tipping system diagram

(a) Manual pump
(b) Overpressure valve
(c) Tank
(d) Directional valve
2. Release device
3. Cylinder
4. Gear-control rod (for versions with manual/servo-assisted transmission only)
Figure 115
CAB COUPLING
GEAR-CONTROL
ROD
CAB COUPLING
5949779109R
CABIN TIPPING HYDRAULIC FLUID

CHANGE
GENERAL
Safety instructions



to the LHD version.
Drainage
Proceed as follows:
Figure 116
272NM009MY
- clean the area of the cap (see arrow), then remove it;
- using a syringe and an appropriate flexible extension,
draw up all the fluid contained in the tank;
Filling
Proceed as follows:
- fill with the required quantity of the specified fluid; then
close the cap.
CABIN LIFTING PUMP REMOVAL- Hazardous and/or polluting substances

REFITTING
Vehicle preparation

signboards.
Figure 117
2371801

of short circuits;

to the LHD version. Final operations
Proceed as follows:
Preliminary operations HYDRAULIC FLUID CHANGE in this Section.
Proceed as follows:
Removal
Proceed as follows:
Figure 118
357A018020R
- disconnect the intake (1) and delivery (2) pipes from the
pump;
Fluid may leak from the pipes during these

operations.
Figure 119
357A018021R
- loosen the supporting bracket fastening screws (1) and

remove the pump (2);
CABIN TIPPING CYLINDER REMOVAL- Very heavy parts

REFITTING

Vehicle preparation
Take the vehicle onto a suitable flat, solid surface, Specific safety instructions
signboards. Safety component.
Figure 120
2371801

of short circuits;
DESCRIPTION OF OPERATION - acting on the upper coupling, remove the clamping nut (3)
and withdraw the screw (4) from the cab lifting cylinder;
The illustrations in the procedure that follows refer Figure 123
to the LHD version.
Proceed as follows:
Removal
Proceed as follows:
This operation is to be carried out with cab lowered.
Figure 121
357A018024R
- acting on the lower coupling remove the clamping nut (5)

from the cab lifting cycliner;
- remove the cab lifting cylinder recovering the washers.
Proceed as follows:
357A018022R
- Check hydraulic fittings and tubes are intact: if necessary
- place a container under the cylinder to collect the system replace damaged component.
oil; - Check intactness of pins and bushings : if necessary
- disconnect the oil piping (1) and (2); replace damaged component.
Hydraulic fluid may leak out during these operations. Refitting
Final operations
357A018023R
CABIN CLIMATE CONTROL VENTILATION

Overview Description
The air conditioning system serves to render the cabin interior Ventilation draws cool external air, filtering out pollen and
comfortable in terms of: dust through a specific filter, or recirculates the air within the
cabin.
- temperature and relative humidity of the outside air;
The system consists of an envelope, configured to house the
- temperature and relative humidity inside the cabin.
fan group, air passage ducts, fresh air intake and recirculated
The system subjects the air to thermodynamic transforma- air intake.
tions that modify air temperature, relative humidity and purity.
The fan can run at different speeds in order to draw in and cir-
This is achieved by: culate large quantities of air.
- ventilation, or the introduction of outside air into the ca-
bin (with the same temperature and relative humidity as Climate controlled air flow orientation
the surrounding air); 1. Windshield defrosting air outlets
- air-conditioning, or the cooling and dehumidification of 2. Side ventilation air outlets
the air with the possibility of post-heating the air as requi- 3. Door windows defrosting air outlets
red to vary the temperature and humidity inside the cabin. 4. Central ventilation air outlets
5. Foot ventilation air outlets
j cool air
J warm air
Figure 124
357A018R211R
AIR CONDITIONING Heating

Description Heating is realised by a radiator, present inside the heater
group, in which engine coolant circulates.
Air conditioning is achieved by the integration of a conditio-
ning system and a heating system. Specific shutters permit passage of air through the radiator on-
ly when heating is required.
This integration permits variations in cabin temperature and
humidity.
Air conditioning
Conditioning The main components of the conditioning system are:
Conditioning is realised by exploiting the high capacity of cer- - the compressor;
tain gases, referred to as “refrigerant”, to determine significant - the condenser;
cooling on expansion, such as to absorb heat from the cabin.
- the filter/drier (built-in to the condenser);
This condition is achieved through two different levels of pres-
sure (high, in which the refrigerant fluid is in a liquid state, and - the three-level pressure switch;
low, in which the fluid is in gaseous state) that are established - the expansion valve;
and maintained during system function..
- the evaporator;
- the heater/fan group;
- the anti-pollen filter.
Air conditioning control group
Figure 125
342BNU44L
1. Temperature adjustment control

2. Four-speed electric fan control
3. Air distribution control knob (see symbols)
4. Internal recirculation control:
- not pressed: external air inlet,
-pressed: internal recirculation.
5. Conditioner control with incorporated warning light
(only climate control version)
DIAGNOSTICS
Troubleshooting guide
Introduction
By analysing the problems detected, diagnosis, or troubleshooting, permits a guided search for the causes of faults that lead to
functional problems in the system, and precise instructions for the repair works necessary to restore the system to full efficiency.
For faults of a predominantly electrical-electronic nature follow the troubleshooting by symptoms.
Troubleshooting by symptoms
Air-conditioning system 3. Unusual noise with clutch engaged
1. System not working 4. Unusual noise with clutch disengaged
2. System noisy 5. Cooling insufficient.
1 SYSTEM NOT WORKING
Inefficient electrical system Check the electrical system

YES
NO
Compressor drive belt not in normal working Check the belt: if slack or too tight, if necessary replace
conditions and inefficient. YES it.
NO
The electromagnetic clutch coil is inefficient. Check whether current reaches the coil, if necessary
YES replace the coil.
NO
The system connectors and piping are inefficient. Check and if necessary replace the faulty parts.
YES
NO
NO
Compressor inefficient. Discharge the system as described in the

YES
corresponding chapter, remove the compressor and
replace it.
2 SYSTEM NOISY
YES chapter.
NO
Insufficient coolant in system. Drain and refill as described in the corresponding

YES chapter.
NO
NO
Insufficient coolant in system (indicator green) Drain and refill as described in the corresponding
YES chapter.
NO
System not hermetic. Check the system and the compressor for leaks with
YES instrument 9905147 and repair any coolant fluid leaks.
NO
The electromagnetic clutch does not work correctly. Check clutch electrical connections and if necessary
YES replace the electromagnetic clutch.
NO

YES chapter.
NO
Compressor inefficient. Drain as described in the corresponding chapter,

YES disconnect the compressor and replace it.

3 ENGAGED
Compressor fasteners loose Check and tighten compressor screws and bolts to
YES correct torque.
NO
Electromagnetic clutch inefficient. Check whether the fault is due to mechanical or

YES electrical causes and repair as necessary.
NO
YES chapter.
NO
Compressor inefficient. Drain the system and replace the compressor.

YES

4
DISENGAGED OR VIBRATION
clutch pulley. YES and adjust
NO
Electromagnetic clutch power supply inefficient. Check the electrical system

YES
5 COOLING INSUFFICIENT

YES chapter.
NO
Discharge pressure high and intake pressure low due Discharge the coolant, replace the filter/drier, bleed air
to presence of air in system. YES from system and recharge as described in the
corresponding chapter.
NO
Discharge pressure high and intake pressure low with As described in the corresponding chapters, discharge
presence of water or ice on filter drier or on the pipe YES the coolant, eliminate any piping kinks or replace faulty
between condenser output and expansion valve. components. Bleed system of air and proceed to
rechrage.
NO
Discharge pressure normal and intake pressure If necessary replace the trinary pressure switch.
low-high due to irregular electromagnetic clutch YES
engagement.
GENERAL RECOMMENDATIONS Figure 126

Check that the replacement parts (filter, condenser, evapora-
tor, piping and connectors) are supplied complete with caps
to protect them from dust and damp.
these sould only be removed once the component is ready
for connection.
To prevent water penetration the compressor (sometimes
the exchangers and filters as well) is supplied slightly pressuri-
sed.
Check that gas is released when the protective cap is remo-
ved, as proof that the component has been correctly stored.
Check that pipe connections, whether pipe to pipe or pipe to
component, assure prefect seal. Coolant leaks not only cause
the system to stop, but also cause premature wear to the
compressor,
Therefore check the presence of the o-ring on the male part
86739
of the connector. Dampen it with system oil (considering that
this varies according to the type of coolant) and when fitting
prevent any damage to the connector contact faces that could Insert the male part into the female part of the connector by
cause leaks. hand with extreme care, until the collar (2) comes into con-
Follow the instructions given below. tact with the corresponding metal seat in the female part.
This contact provides the required mechanical support for the
pipe. The o-ring (1) pressed between the internal cylindrical
part and the hole instead assures the hydraulic seal.
Do not use oversize or doubled o-rings that may offer hydrau-
lic seal for a short time but that do not provide the necessary
mechanical support, which will eventualy cause the hydraulic
seal to fail.
When disconnecting the pipes from the system,

block the pipes and any other coolant passages to
prevent dirt or water from enetering, all of which
could jeopardise correct system function
TIGHTENING TORQUES
TORQUE
DETAIL
Nm kgm
GAS PIPE CONNECTIONS
5/8” - 18 UNF 15.9 1.6
3/4” - 18 UNF 15.9 1.6
1” - 14 UNF 29.8 3

CLIMATE CONTROL

Vehicle preparation

signboards.
Figure 127
2371801

of short circuits;
DESCRIPTION OF OPERATION - disconnect the supply connector (3);

Preliminary operations - unscrew the fastening screws (4);
Proceed as follows: - remove the compressor (5) from the engine.
- drain off the climate control fluid as described in CLI-
MATE CONTROL SYSTEM HYDRAULIC FLUID Inspections and checks
CHANGE in this Section Check belt is intact, if necessary replace the damaged compo-
- loosen the automatic belt tightener and withdraw the belt nent
from the compressor as described in COMPRESSOR
BELT REMOVAL-REFITTING in Section 3. Refitting
Removal
- remove the fastening screws and remove the compressor Proceed as follows:
inlet (1) and outlet (2) tubes;
- refit the belt on the compressor as described in COM-
PRESSOR BELT REMOVAL-REFITTING in Section 3;
Recover the seals. - fill the climate control system with the fluid as described
Replace them if they appear damaged. in CLIMATE CONTROL SYSTEM FLUID CHANGE in
Seal the tubes to prevent entry of humidity. this Section.
Figure 128
357A018025R
CLUTCH REMOVAL-REFITTING
ELECTRO-MAGNETIC COMPRESSOR
CLIMATE CONTROL
GENERAL
Safety instructions

Vehicle preparation

signboards.
Figure 129
2371801

of short circuits;

Proceed as follows:
- remove the climate control compressor as described in
CLIMATE CONTROL COMPRESSOR REMOVAL-RE-
FITTING in this Section.
Removal
Proceed as follows:
Figure 130
39855
- with puller 99341001 (1) fitted with bracket 99341009

(2), take out the pulley (3);
- remove the plate fastening screw with wrapping from the
compressor;
Figure 133
39852
- lock the front disk (1) rotation and unscrew the locking
nut (2) then remove the spacer beneath;
Figure 131 39856
- unscrew the screw (4) releasing the electric power supply

cable (3) of the magnetic coil (1);
- with the round tip pliers remove the retaining split ring (2)
and remove the magnetic coil (1);
Refitting
Proceed as follows:
Figure 134
ASTRA
39854
- with a round tip pliers remove the split ring (1) that retains
the pulley (2);
39915
- fit the new magnetic coil (1), so that the centring pin (2)
inserts into the relevant hole (3).
39919
39916 - with a thickness gauge (3) check that play between front
disk (1) and pulley (2) is 0.4  0.8 mm mm;
- fit the split ring (2); Tighten the screw (3) and fasten the
electric power supply cable (4) of the coil (1) to the com- Figure 139
pressor casing;
Figure 136
ASTRA
39920
- if the play between front disk and pulley is not within the
39917 specified value, remove the front disk and replace the ad-
juster shim (1) with one of an adequate thickness.
- assemble the pulley (2) then the split ring (3) and the ad-
juster shim (1); Final operations
Proceed as follows:
Figure 137
- refit the climate control compressor as described in CLI-
MATE CONTROL COMPRESSOR REMOVAL-REFIT-
TING in this Section.
39852
- fit the front disk (1) lock the rotation and tighten the
retaining nut (2) to a torque of 35  40 Nm (3.5  4 Kgm);
CLIMATE CONTROL UNIT REMOVAL- Very heavy parts

REFITTING

Vehicle preparation

signboards.
Figure 140
2371801

of short circuits;

Proceed as follows:
Figure 142
Figure 141
357A018132R 357A018R212R
- working inside the cab, turn the cab temperature adjust- - remove the clips and disconnect the engine coolant deliv-
ment handle (1) so as to completely open the engine ery (1) and return (2) pipes from the cab heater;
coolant valve;
- drain off the climate control fluid as described in the CLI- Figure 143
MATE CONTROL SYSTEM HYDRAULIC FLUID
CHANGE chapter in this section;
the Maintenance section of the USE AND MAINTEN-
ANCE HANDBOOK;
357A018R213R
- remove the fastening screws and disconnect the A/C sys-

tem coolant fluid delivery (3) and return (4) pipes from
the evaporator;
Replace the seals when refitting.

77122 77125
- loosen the screws (1), remove the cover (2) and the - disconnect the clips (1) from the wiring bundles;
pollen filter;
- disconnect the screws (2) fastening the heater (5) to the
crossmember of the cab;
Figure 145
- disconnect the connectors (4) and disconnect the
respective electric wiring (3);
- remove the climate control unit (5) of the vehicle.
Refitting
Final operations
Proceed as follows:
77124 Section of the USE AND MAINTENANCE HAND-
BOOK
- loosen the fastening screws (1) of the air manifolds (2) to
- fill the climate control system with the fluid as described
the climate control unit (3);
in CLIMATE CONTROL SYSTEM FLUID CHANGE in
- disconnect the air manifolds (2) from the climate control this Section
unit (3);
PROCEDURE FOR DRAINING AND RE-

CHARGING THE AIR-CONDITIONER WITH This procedure does not describe refrigerant
charging/discharging from external/internal
R134a COOLANT
containers or maintenance phases. Refer to the
R134a coolant recharge and recovery station equipment use and maintenance handbook.
(99305146)
The station is designed for use on all vehicle air-conditioning
systems that use RI34a. The station consists of:
By connecting the station to a cooling system the gas contai- 1 Control panel
ned in it can be recovered, cleaned and prepared for rechar-
ging into the system, or transferred to an external container. 2 Container for restoring any oil recovered during draining
It is also possible to assess the quantity of oil removed from 3 Flexible pipes
the system, restore it and “empty” the system.
4 Container for accumulating oil recovered from system
To function the station has to absorb circa 3 kg of refrigerant.
5 Charging cylinder with rotary graduated scale
For rapid use it is recommended to have at least 2 kg of refrige-
rant in the cylinders and to keep the station as level as possible.
Figure 147
50631
SAFETY STANDARDS - do not expose or work with the unit in acidic or damp en-
vironment or in the vicinity of open containers with in-
flammable substances;
This station is destined for use exclusively by
professionally trained operators who must be - the unit must be used in areas with good ventilation and
familiar with cooling systems, refrigerant gases and air change;
the potential hazards of pressurised equipment, - do not change the settings of safety valves and control sy-
therefore: stems;
- do not use gas bottles or other storage containers that
are not approved and that are not fitted with safety valves;
- always use protective gloves and goggles when working
with refrigerant gases. Direct contact between eyes and - never fill any container to over 80% of its maximum capa-
refrigerant fluid may cause blindness; city;
- avoid contact with skin (low boiling temperature —30C - do not leave the unit powered up if it is not to be used
may cause frostbite); immediately. Switch off the mains power supply if the unit
is not being used.
- avoid inhaling refrigerant gas vapours;
- before making connections between station and system
or external container check that all valves are closed; The station is fitted with special connectors to prevent conta-
mination with system that use R12. Do not attempt to adapt
- before disconnecting the station check that the cycle is
thise unit for use with R12.
finished and that all valves are closed, to prevent refrige-
rant gas escaping into the atmosphere;
CONTROL PANEL
Figure 148
50634
Figure 149
CHARGE CYLINDER OIL RESERVOIR
50632
Key to dashboard controls diagram

M1 Low pressure gauge
M2 High pressure gauge
M3 Charge cylinder pressure gauge
LOW Low pressure valve
HIGH High pressure valve
REF Refrigerant charge/discharge valve
V1 Valve on low pressure pipe
V2 Valve on high pressure pipe
V3 Oil injection valve for A/C system
V5 Oil drain valve
V9 Service valve for A/C system coolant cleaning
10 Humidity indicator
VS Safety and discharge valve
L3 Alarm warning light
L4 Maximum level indicator
L5 Minimum level indicator
A Tank resistance/unit process switch
LA1 Unit process indicator
LA2 Tank resistance indicator
B Refrigerant process/vacuum process switch
LB1 Refrigerant process indicator
LB2 Vacuum process indicator
C Recycle/recharge recovery cycle switch
LC1 Recovery recycle cycle indicator
LC2 Charge indicator
D Vacuum/vacuum test switch
LD1 Vacuum indicator
LD2 Vacuum test indicator
Charge cylinder key

1 Pressure values in bar (vertical lines, upper rotatable cylin-
der).
2 Charge weight value in grams (oblique lines, upper rotata-
ble cylinder), subdivision 50 g between lines.
3 Tank level display (internal cylinder).
OPERATIONS FLOW DIAGRAM
Station preparation
First recovery
Wait 3-5 minutes
Second recovery
System oil
drain off
Works on system
Vacuum for 5-10 minutes

with first vacuum test
Are any NO Vacuum for 30 minutes

leaks present? with second vacuum test
YES
NO Are any
leaks present? YES
Fill system
with oil
Search for leaks with Charge refrigerant

electronic leak detector up to 200 gr.
Are any NO System full Search for leaks in the system

leaks present? charge with electronic leak detector
YES
Pressure NO Are any YES

check leaks present?
Are the values

acceptable?
NO
YES
Detachment of
station from system
REFRIGERANT RECOVERY FROM SYSTEM - Connect the pipe marked LOW (the output socket is the
ON VEHICLE one on the larger diameter pipe (LO).
Proceed as follows: - Open valves V1 e V2.
- Connect the pipe marked HIGH (the input socket is the - Open the LOW and HIGH valves.
one on the smaller diameter pipe (HI).
Figure 150
357A018R214R
- Connect the station to the mains power supply (220V 50 - Return switches A, B and C to position 0.
Hz).
- Close valves V1, V2, LOW and HIGH.
- Turn switch A (Process Unit) to position 1.
The corresponding indicator LA1 comes on.
- Turn switch B (Refrigerant Process) to position 1.
- The corresponding indicator LB1 comes on.
- Turn switch C (Recovery Recycle) to position 1.
The recovery and recycling operation will start automati-
cally, indicator LC1 on indicates operation in progress.
On completing the operation the unit will stop automati- If the refrigerant reaches maximum level (maximum
cally and indicator LC1 will go out. Wait for a few minutes level indicator L4 on), the recovery cycle must be
for any remaining low pressure refrigerant in the system stopped immediately by turning switch C to position
to increase pressure, absorb heat and be recovered. The 0 and decanting the refrigerant from the charge
station will automatically repeat the recovery cycle, if the cylinder to a suitable external tank.
above conditions are present.
- Continue the operations following the instructions on the
next pages.
Figure 151
50636
CREATING VACUUM IN SYSTEM After a few minutes operation (maximum 10) if the system is
free of any leaks, indicator LD2 VACUUM TEST also comes
This operation should be carried out once all repairs have be- on. From this moment on evacuation must continue for at
en completed and the system components have been correc- least two hours to achieve adequate drainage.
tly reassembled. This operation precedes recharging, and is
carried out as follows:
If vacuum test indicator LD2 does not come on, a

Do not carry out the vacuum cycle if there is even leak is present. Interrupt evacuation, rectify the leak
minimal pressure present in the station or the and repeat the evacuation procedure.
system.
- At the end of the programmed evacuation time turn

- Connect the pipes to the correct sockets on the system switch D (vacuum test) to position 2 and leave the sy-
and open valves V1-V2/LOW and HIGH. stem for 3-5 minutes in these conditions.
VACUUM TEST indicator LD2 on indicates that the sy-
- Turn switch A (Process Unit) to position 1. stem seal is good. VACUUM TEST indicator LD2 off indi-
The corresponding indicator LA1 comes on. cates a leak. Rectify the leak and repeat the vacuum cycle.
- Turn switch B (Vacuum Process) to position 2. - Return switches D and B to position 0 and proceed to the
The corresponding indicator LB2 comes on. next phase.
- Turn switch D (Vacuum) to position 1. The system eva-
cuation process will start automatically and the corre-
sponding indicator LD1 will come on, indicating opera-
tion in progress.
Figure 152
50637
It is possible that at the end of each recovery cycle the station 3 Quantify and adjust the quantity of oil discharged.
has also recovered lubricant from the compressor, which
4 Dispose of the recovered oil correctly.
must be discharged into the graduated container provided (1).
This oil cannot be used again.
1 Slowly open valve V5 (Oil Discharge). The same quantity of oil as removed must be replaced in
the system.
2 When all the oil has been discharged into the container, re-
close valve V5.
Figure 153
50638
RESTORING SYSTEM OIL LEVEL - Disconnect the meter (1) from injection valve V3 and re-
place the protective cap.
If oil has been discharged from the system during the recovery
and recycling phase, this must be replaced.
- Take the meter provided filled with the correct or pre- Keep oil containers sealed to prevent contamination.
viously measured amount of oil for the system in ques- Remember that the oil is extremely sensitive to
tion. moisture:
- Connect the meter (1) to the lubricant input valve V3..
- Open valve V3 and run system vacuum for a few seconds. - Never open oil injection valve V3 if the system is under
- Open the valve on the meter container (1) The oil will positive pressure.
be sucked into the system. - Oil must only be injected with the system under negative
- Close valve V3 and the valve on the recipient once the pressure.
required quantity of oil has been taken in to the system. - The oil level should not drop below the suction pipe level
(to prevent air entering the system).
Figure 154
50639
CHARGING PLANT WITH REFRIGERANT

For transferring refrigerant from an external tank to
Before recharging it is good practise to be familiar with a num- the charge cylinder and vice-versa, refer to the
ber of important rule: equipment manual.
- Know how much refrigerant to use (normally written on Considering that the quantity of refrigerant is related
an adhesive label applied to the vehicle). to its pressure, to find the effective weight turn the
- The charging cylinder has a minimum level check that pre- outer part of the charge cylinder until the line of the
vents non-condensable gas entering the system. diagram coincides with that of the level indicator.
For this reason the last 600 g of refrigerant it contains can- This gives the exact quantity of refrigerant contained
not be used. in the cylinder (starting weight).
- Therefore, before charging check that the cylinder con- When calculating the weight of refrigerant, in
tains a sufficient quantity for the charge (maximum usable addition to the 600 g not usable remember to
quantity 3800 g). increase the charge by circa 100 g (this is the weight
of refrigerant contained in the two station-system
- If the pressure in the charge cylinder displayed on the gau- connector pipes). The correct quantity of refrigerant
ge (2) is greater than the required value visible on the to charge into the plant is therefore given by: 600 gr.
charge cylinder glass 10 bar max, discharge the excess + 100 gr. + (system capacity quantity).
pressure through valve (1) on the pressure gauge group
until bringing it to the correct level, reading the value on Before charging always check that the spyhole on the
the gauge. ‘console’ indicates that the refrigerant is free of
moisture. If this is the case, the spyhole indicates an
intense green colour, otherwise replace the station
internal filters as instructed in the equipment manual.
Figure 155
50640
When the cylinder contains the required quantity for charging, - After charging 200  500 g of refrigerant, according to
(the two pipes must already be connected to the sockets on system dimensions, stop charging by turning switch C
the system, since the vacuum operation has already been per- (charge) to position 0.
formed), proceed as follows:
- Using the electronic leak detector, search for any leaks in
- Close the LOW, valve keeping the HIGH and V1 - V2 the system.
valves open.
- Complete charging the system until the pre-calculated re-
- Turn switch B (Refrigerant Process) to position 1, indica- sidual weight in the cylinder has been reached.
tor LB1 comes on. (Residual weight = Total weight — system capacity
weight).
- Turn switch C (Charge) to position 2, the corresponding
indicator LC2 will come on and refrigerant will flow from - Complete the charge, turn switches C - B and A to posi-
the station to the system. tion 0 (A having been turned to create vacuum).
Re-check for any leaks.
- Close the HIGH valve.
If during charging the refrigerant level in the cylinder
drops below the foreseen quantity, the system will
stop and the minimum Level warning light will come
on (L5).
Figure 156
50641
CHECKING SYSTEM PRESSURES LEAK DETECTOR FOR AIR

After completing the charge, leave the pipes connected and CONDITIONING SYSTEMS WITH HFC
perform the following check: R134a (9905147)
- Close valves V1, V2, LOW and HIGH. Tool L-780A permits precise identification of HFC 134A gas
leaks from the system, in the order of 3.3 gr. per year with the
- Switch on the engine, switch on the air conditioner and selector turned to maximum sensitivity.
check on gauges M1 and M2 that pressures correspond,
normally: low pressure no lower than 1 bar, high pressure The instrument does not require calibration. The operator
15  18 bar, according to system characteristics. only has to set the required sensitivity.
Any gas leak is indicated by an acoustic signal and a LED that
OPERATIONS PRIOR TO REMOVING blinks in proportion to the concentration of gas.
STATION FROM SYSTEM The LED off also serves as low battery charge indicator
Carry out the following operations, observing the previously
Operating temperature is between 0 and 50C.
described safety standards:
The instrument has a flexible probe to reach particularly inac-
- Check that all the valves (LOW - HIGH V1 - V2.) are clo-
cessible connections and parts.
sed.
The two sensitivity levels are:
- Disconnect the pipes from valves V1 - V2 and replace the
caps on the system valves. - Low sensitivity = 16.5 g/year.
- Re-check the system with the leak detector. - High sensitivity = 3.3 g/year.
Normally, with the air-conditioner operating, air Before making checks on the vehicle, wait for the
should come out from the outlets at a temperature engine to cool. Hot engine components may cause
below 5C after a the time necessary for reading errors.
temperature to stabilise in the ducts.
50642
50643
TOWING DEVICES
SECTION 21 A
HD9 Euro5 SECTION 21 A TOWING DEVICES 1
SECTION 21 A
Towing devices
Page
DESCRIPTION 3
- Type-approval plate 4
- Operation 4
- Tilting thrust ring 5
- Fixed thrust ring 6
- Tilting thrust ring 7
DIAGNOSTICS 8
ADJUSTMENT OF CLOSURE MECHANISM 9
GENERAL 9
FORCED OPENING OF CLOSING MECHANISM 10
GENERAL 10
THRUST WASHER REMOVAL-REFIT 11
GENERAL 11
2 TOWING DEVICES SECTION 21 A HD9 Euro5
- Removal 12
- Refitting 12
OVERHAUL — FIXED THRUST RING TYPE J38C 13
- Support removal 13
- Support refit 13
- Closing mechanism removal-refit 14
- Ring removal-refit 15
- Clamp removal-refit 15
- Blocking device removal-refit 16
- Safety lever removal-refit 17
- Stop removal-refit 17
OVERHAUL — FIXED THRUST RING TYPE J50 18
- Support removal-refit 18
- Bushings removal-refit 18
OVERHAUL — TILTING THRUST RING 20
- Support removal 20
- Support refit 21
- Rocker arm removal 22
- Rocker arm refit 23
- Rocker arm overhaul 25
- Closing mechanism removal-refit 26
- Ring removal-refit 27
- Clamp removal-refit 27
- Blocking device removal-refit 28
- Safety lever removal-refit 29
- Stop removal-refit 29
DESCRIPTION
This Section gives a brief description of the features and procedures related to the JOST type pivoting thrust rings.
For further information see the documentation of the Supplier.
For other types of thrust rings see the documentation of the Supplier.
The pivoting thrust rings are the connecting component between tractor and semi-trailer.
They are to be assembled on a tractor.
The pivoting thrust rings and the assembly plates are clamping components for semi-trailers, to be type-approved and are to give
maximum guarantee of safety.
Any modification and/or the use of spare parts that are not originals shall exclude the right of warranty , invalidate the
type-approval and therefore cancel the overall vehicle inspection.
For the use of the pivoting thrust rings, semi-trailer tractors and semi-trailers, the relevant safety standards in force in
each country are valid (for example, in Italy from the Higher Institute for accident prevention and safety in the workplace
- ISPESL).
Figure 1
307A021A001R
1. Thrust ring
2. Release control
3. Assembly plate
Type-approval plate
1. EC Homologation
2. Value ”D” permitted in kN
3. Permitted load on ring in t
4. Item number and type
5. Factory N˚
Figure 2
1 2 3
4 5
307A021A002R
Operation
Thrust ring ready for clamping
1. Hand lever
2. Latch
3. Clamp
4. Knuckle pin
Thrust ring closed and locked

1. Hand lever
2. Latch
3. Clamp
4. Knuckle pin
Tilting thrust ring

The tilting type thrust ring, besides the normal longitudinal oscillation (A) also permits transverse oscillation (B).
307A021A003R
Transverse oscillation can only be enabled for off-road use.

When on the road the transverse oscillation is to be blocked for safety reasons, especially when driving at high speed.
To enable transverse oscillation for off-road use:

Loosen the hex head screws (1) each side.
Withdraw the two locking teeth (2) to the end of the slot
stroke.
Tighten the hex head screws (1) with a tightening torque of
80 Nm.
To block transverse oscillation for use on the road:

Loosen the hex head screws (1) each side.
Insert the two locking teeth (2) to the end of the slot stroke.
Tighten the hex head screws (1) with a tightening torque of
80 Nm.
TIGHTENING TORQUES
Fixed thrust ring
ONLY FOR TYPE J50
307A021A004R
TIGHTENING TORQUES
Tilting thrust ring
307A021A005R
DIAGNOSTICS
Problem Cause Remedy
The thrust ring doesn’t 1. Knuckle pin too high in relation to the 1. The semi-trailer counter-plate is to be at
close. thrust ring plate. the same height or approx. 50 mm lower
than the thrust ring plate.
2. The semi-trailer counter-plate is not level
and causes an irregular position of the 2. Replace the semi-trailer counter-plate.
knuckle pin. Max.plane tolerance: 2 mm.
3. Knuckle pin not correct size or damaged. 3. Replace knuckle pin.
4. Deformed clamp. 4. Replace clamp.
5. Poor maintenance. 5. Clean with care and grease.
6. Faulty double spring. 6. Replace double spring.
7. Warped lever and/or hand lever. 7. Replace/straighten the lever and/or hand
lever.
The thrust ring doesn’t open 1. Semi-trailer not level or is under traction. 1. Bring the semi-trailer level. Brake the
semi-trailer and, with tractor in reverse
gear, back slowly by a few centimetres.
2. Poor maintenance, damaged clamp or 2. The thrust ring can be forced open as de-
latch, closing mechanism wrongly set. scribed in the relevant Section.
The thrust ring mechanism 1. Deformed clamp. 1. Replace clamp.

does not remain in position
2. Faulty spring. 2. Replace spring.
“ready for clamping”
3. Poor maintenance. 3. Clean with care.
The thrust ring mechanism 1. Deformed blocking device. 1. Replace the blocking lever and hexago-
does not remain in open nal bolt.
position
2. Faulty spring. 2. Replace spring.
Movement between thrust 1. Too much clearance in supports. 1. Fixed thrust ring JSK 38 C. If neces-
ring and semi-trailer (kick-- sary replace the upper rubber pads, low-
back) er rubber pads and hexagonal bolt.
Fixed thrust ring JSK 50. If necessary
replace the bushings. Tighten the safety
screw.
Tilting thrust ring JSK 38 G. If nec-
essary replace the bushings, shim wash-
ers. Tighten the hexagonal bolt.
2. Too much clearance in closing mecha- 2. Check wear on knuckle pin, if necessary
nism. replace. If even with the new pin there is
still clearance, adjust the closure me-
chanically. If it is not possible to eliminate
the clearance completely by adjustment,
replace the clamp, the ring, the latch and
the latch pin.
ADJUSTMENT OF CLOSURE MECHANISM
GENERAL DESCRIPTION OF OPERATION

Safety instructions Preliminary operations
Proceed as follows:
Before carrying out any operation make certain to - park the vehicle on a flat, solid surface;
have taken all precautions and clarified all aspects - unclamp the semi-trailer;
person. Read the instructions provided in the first Execution of operation
part of this manual. Proceed as follows:
carry out maintenance jobs correctly. Figure 4
Vehicle preparation

signboards.
Figure 3
307A021A008R
- loosen the lock-nut (1);

- unscrew the adjustment screw (2), by approx.10 turns;
Figure 5
2371801

of short circuits;
- clamp the semi-trailer;

- slope the hand lever (4) in the travel direction (see
arrow) and have it held in this position by a second
person;
- tighten the adjustment screw (2) until the hand lever (4)
starts to move;
- to obtain the recommended basic clearance of 0,3 mm,
tighten the adjustment screw (2) by another turn and
tighten the lock-nut (1);
- if there is still considerable clearance, replace the ring and
the clamp.
FORCED OPENING OF CLOSING

MECHANISM
GENERAL DESCRIPTION OF OPERATION
Safety instructions Preliminary operations
Proceed as follows:
Before carrying out any operation make certain to - park the vehicle on a flat. solid surface;
have taken all precautions and clarified all aspects - unhook the semi trailer
operation. If in doubt, consult a more experienced Execution of operation
Always observe all the general recommendations to This procedure is only to be used when the thrust
carry out maintenance jobs correctly. ring is blocked in closed position.
Proceed as follows:
Figure 7
Vehicle preparation

signboards.
Figure 6
307A021A009R
- loosen the lock-nut of the adjustment screw (ref. 1), then

tighten the screw (ref. 2, max. 30 Nm) to pre-load the
closing mechanism;
- move the hand lever forward to release the block;
Figure 8
2371801

of short circuits;
307A021A006R
- with the aid of another person, on the opposite side of

the thrust ring , with a round bar (  20 mm, length
approx. 600 mm) knock the tip of the latch through the
specific hole on the ribbing (see arrow) to release the
mechanism;
Final operations
Proceed as follows:
- carry out the maintenance required, check the damage
and if necessary repair the parts of the closing
mechanism;
- re-adjust the mechanism.
THRUST WASHER REMOVAL-REFIT

Safety instructions
Safety component.
Tighten the fastening nuts to the specified torque.
Vehicle preparation

signboards.
Figure 9
2371801

of short circuits;

- park the vehicle on a flat. solid surface; - with appropriate lifting equipment sling the thrust ring (1);
- unhook the semi trailer - unscrew the fastening screws (2);
- slightly lift the thrust ring checking it is balanced. then re-
move it and place it on a flat surface.
Refitting
Repeat the removal operations in reverse order.
Figure 10
307A021A007R
OVERHAUL — FIXED THRUST RING TYPE Figure 13

J38C
Before starting any type of operation make sure all

the necessary safety precautions have been taken
and fully explained to those involved in the
operations.
Read the applicable instructions in SECTION 1 of
this manual.
Support removal
The operations described are valid for both

supports. - remove the rubber pad (60).
Support refit
Figure 11 Figure 14
- overturn the thrust ring on the work bench; - assemble, following the procedure in reverse;
- remove the screws (59); - make sure that the arrows on the pads (60) and (57) and
also on the support (61) indicate the direction of travel.
Figure 12
- remove the support (61) and the support axle (58);

Closing mechanism removal-refit Figure 17

Proceed as follows:
Figure 15
- Slope the closing mechanism sideways (details 26, 28 and

34) and withdraw it in the direction of the arrow;
- Assemble, following the procedure in reverse;
- release the double spring (27); - At assembly lubricate all moving parts;
- Adjust the closing mechanism operating as described in
Figure 16 the relevant section.
- unscrew the screws (30) and screwed connections (19);

Ring removal-refit Clamp removal-refit

Figure 18 Figure 20
- unscrew the fastening screw (1); - remove the ring operating as indicated in the previous
section;
Figure 19 - extract the hand lever and block it with a screwdriver as
shown in the figure;
Figure 21
- with a lever, remove the ring (2);

- assemble, following the procedure in reverse.
- release the spring (20);

Figure 22 Blocking device removal-refit

Proceed as follows:
Figure 24
- extract the pin (24);
Figure 23
Figure 25
- remove the clamp (23) as indicated in the figure;

- unscrew the screws (21) and remove the blocking lever

(22);
Safety lever removal-refit Figure 28

Proceed as follows:
Figure 26
- with a pin extractor remove the spring pins (17);
Figure 29
- unscrew the screw (14) and remove the safety lever (13);
Stop removal-refit
Proceed as follows:
Figure 27
- remove the block (18) and compression springs (16);

- unscrew the screw (19) and remove the locking block

(15);
OVERHAUL — FIXED THRUST RING TYPE Bushings removal-refit

J50
Before starting any type of operation make sure all supports.
operations.
Read the applicable instructions in SECTION 1 of Proceed as follows:
this manual.
If in doubt, contact someone with more experience. Figure 31
Support removal-refit

supports.
Proceed as follows:
Figure 30
- remove the support operating as previously described;

- push the parallel pins (44) inwards with a  12 mm pin
extractor;
Figure 32
- overturn the thrust ring on the work bench;

- unscrew the screws (62) and extract the plate (64) with
pin;
- remove the support (67);
- assemble operating in reverse;
- at assembly lubricate all moving parts;
- at assembly check that the support is turned with the cav- - with a pin remove the bushing;
ity facing outward.
Figure 33 Figure 35
- lightly grease the new bushing (42); - in the bushings (42) drill  12 mm holes to insert the new
parallel pins with notches (44);
- with a pin cautiously push the bushing into the support
(43); - with a  12 mm punch insert the parallel pins with
notches.
Figure 34
With a reamer adjust the parallel pins with notches
(44) if they protrude from inside the bushings.
For all the other operations see the descriptions in

the previous section (Type J38C).
- check that the bushing (42) has entered the seat (43) by
3 mm;
OVERHAUL — TILTING THRUST RING Figure 38
Before starting any type of operation make sure all

operations.
Read the applicable instructions in SECTION 1 of
this manual.
Support removal

supports.
- remove the O-Ring (41) and the shim washer (47);
Proceed as follows:
Figure 39
Figure 36
- extract the tapered grease nipple (46) push the parallel

pins (44) inwards with a  12 mm pin extractor;
- overturn the thrust ring on the work bench;
- remove the safety ring (48), the shim washer (39) and the Figure 40
O-ring (41) from the support (43);
Figure 37
- with a  104.5 mm pin, remove the bushing.
- remove the support (43);

Support refit Figure 43

Proceed as follows:
Figure 41
- in the bushings (42) drill  12 mm holes to insert the new

- with a  12 mm punch insert the parallel pins with
- lightly grease the new bushing (42); notches i;
- with a  104,5 mm pin, cautiously push the bushing into
the support (43); With a reamer adjust the parallel pins with notches
Figure 42
- in the bushing (42) drill  5 mm holes to assemble the

tapered grease nipples (46);
- tighten the tapered grease nipples (46).
- check that the bushing (42) has entered the seat (43) by
3 mm;
Rocker arm removal Figure 46

Proceed as follows:
Figure 44
- unscrew the screws (37);

- remove the safety plates (38) and the locking plate (44);
- remove the supports as described in the previous section;

Figure 47
- release and unscrew the screws (36);
- remove the safety plate (51) and the locking plate (50);
Figure 45
- remove the pin (49);
Figure 48
- turn the thrust ring;

- release and unscrew the screw (36);
- extract the rocker arm (45) and the washers (39);

- remove the O-rings (not shown).
Rocker arm refit Figure 51

Proceed as follows:
Figure 49
- push the pin (49) into the rocker arm (45) by approx. 2/3
of the full length;
- at the same time insert the flat tip screwdriver between
- before assembly lightly grease inside the bushings; the rocker arm (45) and the rocker arm bearing as shown,
to offset the difference in height;
The arrows on the rocker arm (45) are to indicate
the travel direction. Figure 52
- insert the rocker arm (45) in the thrust ring plate;

- insert the washers (39) between the suspension arm (45)
and the rocker arm bearing;
To insert the washers (39), slightly slope the rocker

arm (45). This will prevent the washers coming out
of place.
Figure 50
- lightly grease the second O-ring (41) and insert it be-

tween the bushing (42) and the washer (39);
- push the pin (49) completely inside;
- lightly grease the O-ring (41) and insert it between the

bushing (42) and the shim washer (39);
Figure 53 Figure 55
- tighten the new safety plate (38) and the plate (40) with - Position the new safety plate (51) and the plate (50) with
the screws (37); the screws (36);
- Assemble the supports as indicated in the previous sec-
Figure 54 tion.
- tighten the screws (36) and bend the metal safety strip
(38);
Rocker arm overhaul Figure 59

Proceed as follows:
Figure 56
- check that the bushing (42) is in the seat (45) by 3 mm

on both sides;
- remove the rocker arm as indicated in the previous sec-
tion;
Figure 60
- push the parallel pins with notches (44) into the holes
using a  12 mm pin extractor;
Figure 57
- in the bushings (42) drill  12 mm holes to insert the new

- with a  94 mm pin, remove the bushings from both
- with a  12 mm punch insert the parallel pins with
sides;
notches.
Figure 58
With a reamer adjust the parallel pins with notches
- lightly grease the new bushings (42);

- with a  94 mm pin, cautiously push the bushing into the
support (45);
Closing mechanism removal-refit Figure 63

Proceed as follows:
Figure 61
- slope the closing mechanism sideways (details 26, 28 and

34) and withdraw it in the direction of the arrow;
- assemble operating in reverse order;
- release the double spring (27); - at assembly lubricate all moving parts;
- adjust the closing mechanism as described in the relevant
Figure 62 section.
- unscrew the screws (30) and screws connections (19);

Ring removal-refit Clamp removal-refit

Figure 64 Figure 66
- unscrew the fastening screws (1); - remove the ring as described in the previous section;
- extract the hand lever and block it with a screwdriver as
Figure 65 indicated in the figure;
Figure 67
- with a lever, remove the ring (2);

- assemble, following the procedure in reverse .
Figure 68 Blocking device removal-refit

Proceed as follows:
Figure 70
- extract the pin (24);
Figure 69
Figure 71
- remove the clamp (23) as indicated in the figure;

- unscrew the screws (21) and remove the blocking lever

(22);
Safety lever removal-refit Stop removal-refit

Figure 72 Figure 73
- unscrew the screw (14) and remove the safety lever (13); - unscrew the screw (19) and remove the locking block
(15);
Figure 74
- with a pin extractor remove the spring pins (17);
Figure 75
- remove the block (18) and compression springs (16);


TOWING DEVICES
SECTION 21 B
HD9 Euro5 SECTION 21 B TOWING DEVICES 1
SECTION 21 B
Towing devices
Page
DESCRIPTION 3
- Type-approval plate 4
- Operation 4
TRAILER HOOK REMOVAL-REFIT 6
GENERAL 6
- Removal 7
- Refitting 7
OVERHAUL 8
- Mechanical unit and coupling pin replacement 8
- Bell head replacement 8
- Lower bushing insert replacement 9
- Bushing replacement 9
- Mechanism spring replacement 10
- Bell lock pin replacement 11
- Safety device replacement 11
2 TOWING DEVICES SECTION 21 B HD9 Euro5

DESCRIPTION
E 50 series tow hitches are designed to be used with central rigid axle trailers and steering axle trailers equipped with 50 mm draw-
bar eye, according to Class D50 of Directive 94/20/EC and ISO 1102.
Figure 1
307A021B001R
1 Protective nut boot

3 Crown nut
7a Attachment flange
7b Counterflange
9 Linkage
13 Bell head
14 Tow hitch
18e Safety pins
20a Mechanism assembly
22 Opening lever
Type-approval plate
1. Serial number
2. Type-approval plate
Figure 2
307A021B002R
Operation
Open coupling Hook coupling
The lever is up and the pin is raised to allow to insert the draw- The lever is down and the pin is lowered to lock the drawbar
bar eye. eye (not shown).
Figure 3
307A021B011R
TIGHTENING TORQUES
Figure 4
307A021B003R
TRAILER HOOK REMOVAL-REFIT

Safety instructions
Safety component.
Tighten the fastening nuts to the specified torque.
Vehicle preparation

signboards.
Figure 5
2371801

of short circuits;

Preliminary operations - Support the coupling with appropriate lifting means.
- park the vehicle on a flat. solid surface; - Remove the boot (1).
- unhook the semi trailer - Remove the split pin (2).
- Loosen the lock nut (3).
- Remote the rear flange (4) and the shock pad (8a).
- Remove the coupling (9) with shock pad (8b) and front
flange (5b).
- If needed, loosen the fastening bolts (24) and remove the
attachment flange (7a) and the counterflange (7b).
Refitting
Reverse the removal operation sequence to refit.
Figure 6
307A021B004R
OVERHAUL Bell head replacement
Before carrying out any operation, check that all Make sure that the coupling is closed (control lever
precautions have been taken and all aspects down).
regarding safety of the personnel involved have been
clarified.
this manual. Proceed as follows:
If in doubt, speak to a more experienced person. - Remove the mechanical assembly and the coupling pin as
Respect all general recommendations for correct described above.
Figure 9
Mechanical unit and coupling pin replacement
Make sure that the coupling is closed (control lever

down).
Proceed as follows:
Figure 7
307A021B007R
- Loosen the 3 screws (12d), remove the spring attach-

ment plate (12c), the spring (12b), and the snap ring
(26b).
- Remove the bell head (13) downwards and extract it
307A021B005R
from its seat.
- Loosen the fastening screws (21) and retrieve the - Assemble by reversing the removal sequence.
washers.
Figure 8
307A021B006R
- Remove the mechanical assembly (20a) then remove the

coupling pin (14).
- Assemble by reversing the removal sequence.
Lower bushing insert replacement Bushing replacement
Make sure that the coupling is closed (control lever Make sure that the coupling is closed (control lever
down). down).

- Remove the mechanical assembly and the coupling pin as - Remove the coupling from the vehicle.
described above.
- Remove the mechanical assembly and the coupling pin as
described above.
Figure 10
- Remove the bell head as described above.
- Remove the bushing insert as described above.
The bushing insert needs to be replaced when the

bushings are replaced.
Figure 11
307A021B008R
- Loosen the fastening screws and remove the insert (25).

307A021B009R
- Remove the upper bushing (6) and the lower bushing

(26a) from the coupling (9).
Figure 12
307A021B010R
When refitting, make sure that he lower bushing pin

is centred in the corresponding seat (detail).

Mechanism spring replacement Figure 15

down).
Proceed as follows:
described above;
Figure 13
307A021B013R
- Remove the mechanism assembly (20a), the opening

lever (22) retrieving the springs (17a - 17b) and the mech-
anism lever (15).
Figure 16
307A021B005R
- Loosen the fastening screws (21) and retrieve the

washers.
- Remove the mechanism assembly.
Figure 14
307A021B014R
- Insert the mechanism lever (15) in the mechanism assem-

bly being careful to insert the eyebolts of the new springs
(17a - 17b) into the mechanical lever pins (15, see detail).
- Refit the opening lever (22).
307A021B012R
- Loosen the lock nut (26) from both sides, remove the
washer (27), the shim (28) and the o-ring (30).
Figure 17 Safety device replacement

down).
Proceed as follows:
Figure 19
307A021B012R
- Insert the o-ring (30), the shim (28), the washer (27) from
both sides and fasten the lock nut (26).
- Fit the mechanism assembly.
Bell lock pin replacement

down).
Proceed as follows:
described above.
307A021B015R
Figure 18
b
- Extract the snap ring (18b), remove the o-ring (18a), the
support washer (18c), the safety spring (18d) and the
safety pin (18e) from both sides.
307A021B016R
- Remove the lock pin (16a) and the springs (16b).


Adjustment of bevelled pair — pinion axial play Figure 118

as follows:
Figure 116
39704

crown wheel teeth.
Rotate the pinion and measure the contact imprint of the pin-
ion teeth on the crown wheel teeth.
The possible imprint types and methods for correcting any
error are shown in the following figures
39710
- Position the magnetic base gauge (1) as shown; Figure 119

- Lock rotation of the bevelled pinion with reaction lever
99370317, invert rotation of the crown and measure play
between the teeth of the two gears with the gauge.
Otherwise, adjust the ring nut (2) with the wrench
(99354001) (1, Figure 117).
Figure 117
40160
thrust face (2), more or less at the centre of the tooth width.
Figure 120
39711

can be tightened, with wrench (99354001) to the same de-
gree to which the opposite adjuster nut was tightened.
40161A
If the imprint on the drive fact (toward the outer diameter)

and on the thrust face (toward the inner diameter) is shift, this
means the pinion is too close to the crown.
Remedy: Increase the thickness of the adjuster shim between
40161B
If the imprint on the drive face is shifted toward the internal 26609
diameter and the imprint on the thrust face is shifted toward Insert the compression spring (1) into the differential box. Fit
the outer diameter of the crown, it means that the pinion is the engage fork (2) such that the fork excursion stop (a) corre-
too far from the crown axis. sponds to the limit stop (b) on the differential box.
Remedy: Decrease the thickness of the adjuster shim between
Figure 125
Figure 122
39715
39713
Fit a new o-ring (1) on the command cylinder (2) and grease
Fit the engage coupling (1) to the splines of the gearing box it.
and position the snap ring (2) in its groove using a screwdriver. Insert the command piston (2) into the engage fork (3) in the
compression spring and then into the specific hole made in the
differential box.
Remove the bevelled pinion support again.
Figure 123 Fitting differential into axle box.
1 Fit the sliding coupling to the transfer shaft.
2 Fit the gearing box making certain that the command fork
engages with the grooves in the sliding coupling.
3 Tighten the screw and at the same time push the transfer
shaft such that the sliding coupling engages with the engage
coupling on the differential.
4 Apply LOCTITE 573 to the thread and under the head
of the screws and fasten to specified torque using the torque
wrench.
5 Apply LOCTITE 573 to the contact surface and refit the
pinion support, tightening the screws to the specified torque.
39714
Fit the differential locking device engagement assembly, con-

sisting of command cylinder, piston (2), engage fork (!) and
compression spring (3).

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WORKSHOP

ASTRA Veicoli Industriali

General Specifications 2 from 1 to 14

Engine F3B 3 from 1 to 180

Power take-off 5 from 1 to 24

Transmission ZF 16SXX20 6 from 1 to 74

Hydraulic retarder Intarder 3 8 from 1 to 44

Reduction gear unit VG 2700 9.1 from 1 to 66

Splitter-Transfer unit TC 2200 9.2 from 1 to 38

Propeller shafts 10 from 1 to 14

Second front axle 12.2 from 1 to 44 Towing devices 21 A from 1 to 30

Single rear axle 12.3 from 1 to 44 Towing devices 21 B from 1 to 12

Intermediate axle in tandem 12.4 from 1 to 56

Rear axle tandem 12.5 from 1 to 46

Wheels and tyres 13.1 from 1 to 10

Brakes (Duplex) 13.2 B from 1 to 32

Brakes (10 ton. version) 13.2 C from 1 to 42

Front suspensions 14.1 from 1 to 20

2-axle vehicles rear suspensions 14.2 from 1 to 16

Rear tandem suspensions 14.3 from 1 to 24

Steering system LHD 15 A from 1 to 76

Steering system RHD 15 B from 1 to 76

Pneumatic system - Brakes 16 from 1 to 114

Electrical\electronic system 17 from 1 to 258

Page left intentionally blank

Definitions adopted in the current Manual

The current Manual applies essentially to authorised workshop technical staff.

Procedures, technical information and precautions which must be highlighted.

Ø 1 = Housing for connecting rod small end bush

Graphs and symbols

Driving torque + angular value Rolling torque

Face for machining

MEASURES (INTERNATIONAL SYSTEM)

Force in N (Newton) Pressure in kPa (kilopascal)

Other units in use:

Conversion: I kg/cm2 = 1 bar *

(*) Nm and bar are converted according to the ratios 10:1

STANDARD TIGHTENING TORQUES

Screws and nuts with metric thread

Maximum tightening torques for metric threads in daNm

GENERAL OPERATING INSTRUCTIONS - When dismantling, carefully examine any interference,

- Check for any faulty components and loose connectors.

Disconnecting hydraulic lines After dismantling

1730102 Prevention of rust and dust penetration

Tightening of screw and nuts Connecting hydraulic lines

- Cross-tighten bolts and nuts, to apply torque in a uniform

- When connecting pipes, first hand-tighten from both

Interchangeable components Figure 7

A: internal side (presence of pressure)

- Bearings that are not separable that require pressure

Snap rings and circlips

- If the bearings have to be fitted with pressure on the inner

Welding must be carried out exclusively by trained personnel Figure 12

POSITION OF VEHICLE IDENTIFICATION Imprinting of the vehicle chassis

Punch marked at the front end of the right-hand side mem-

Vehicle identification plate

Located on the side walls of the cab (Fig. 1A vers. LHD,

a. right side member - b. rear axle front leaf spring

Vehicle registration number 1. Approved type number marking

IVECO F2B (Cursor 8) IVECO F3B WG (Cursor 13)

MANUAL TRANSMISSION AUTOMATED TRANSMISSION

AUTOMATIC TRANSMISSION TRANSFER DISTRIBUTOR

Figure 11 STEYR VG 2700/400