Iveco Daily Euro 4. Repair Manual Mechanical Electric/Electronic

1132 Pages·87.416 MB·English

D A I LY EURO 4
REPAIR MANUAL
MECHANICAL
ELECTRIC/ELECTRONIC
IVECO
expert22 для http://rutracker.org
”Thisdocumentprovidesdata,characteristics,instructionsand
methodologytoperformrepairinterventionsonthevehicle
anditscomponents.
Anyhow, this document is addressed to qualified and
specialised personnel. Iveco commercial and assistance
network personnel as well as all Iveco authorised points of
assistance are specifically qualified andequipped to perform
therepairinterventionsthatareindicatedinthisdocument.
Before performing any intervention, check to have available
the document relating to the vehicle model on which the
intervention is being performed and also make sure that all
accidentpreventiondevices,suchas,asaroughguide,goggles,
helmet, gloves, shoes, as well as work tooling, lifting and
transporttooling,etc.,areavailable andefficient, andfurther
make sure that the vehicle is put such a way that an
interventioncanbemadeinsafetyconditions.
Making interventions strictly observing the indications given
here, as well as using specific tooling indicated, assures a
correctrepairintervention,executiontimingobservanceand
operators’safety.
Eachrepairinterventionmustbefinalisedtotherecoveryof
functionality,efficiencyandsafetyconditionsthatareprovided
byIveco.
Each intervention, on the vehicle, that is finalised to a
modification, alteration or else, which is not authorised by
Iveco, involves the exclusion of any responsibility for Iveco,
and,inparticular,wherethevehicleiscoveredbyaguarantee,
each such intervention involves an immediate lapse of the
guarantee.
Responsibility for Iveco in repair intervention execution is
excluded.
Ivecoisavailabletoprovideallclarificationsnecessarytomake
interventions, as well as to provide indications in cases and
situationsnotincludedinthisdocument.
Dataandinformationcontainedinthisdocumentcouldresult
nottobe updatedowingtomodificationsmadeby Ivecoat
anymomentfortechnicalorcommercialreasons,orbecause
of the need to adapt the vehicle to law requirements in
differentcountries.
Inthecaseofadifferencebetweenwhatcontainedhereand
what actually found on the vehicle, please contact Iveco
networkbeforemakinganyintervention.”
Thedatacontainedinthispublicationmightfailtoreflectthe
latestchangeswhichtheManufacturermayintroduceatany
time, for technical or sales purposes, or to meet the
requirementsoflocallegislation.
Copy,evenpartial,oftextanddrawingsisforbidden.
Producedby:
PublicationEditedby:
IVECOS.p.A.
CustomerService
LungoSturaLazio,15
B.U.TECHNICALPUBLISHING
10156Torino(TO)-Italy
IvecoTechnicalPublications
LungoSturaLazio,15
Print603.93.651- 1stEd.2006 10156Torino(TO)-Italy
PRELIMINARY REMARKS
ManualsforrepairsaresplitintoSections,eachoneofwhichismarkedbyanumeral;thecontentsofthesesectionsareindicated
inthegeneraltableofcontents.
EachsectionisgenerallydedicatedtoamainUnit(e.g.:engine,gearbox,electricsystem,etc.).
Sectionswithmechanicalcontentsincludetechnicaldata,tighteningtorquecollections,toollists,connections—disconnectionsof
unitsto/fromthevehicle,overhaulsatthebenchandrelatingtroubleshooting.
Ontheelectric/electronicsystemsectiontherearethedescriptionsoftheelectricnetworkandvehicleelectronicsystems,electric
schemes,componentselectriccharacteristics,componentscodesand troubleshootingrelatingtothecentralunitsspecificofthe
electricsystem.
Themanualusespropersymbolsinitsdescriptions;thepurposeofthesesymbolsistoclassifycontainedinformation.Inparticular,
therehavebeendefinedasetofsymbolstoclassifywarningsandasetforassistanceoperations.
SYMBOLS -WARNINGS
Dangerforpersons
Missingorincompleteobservanceoftheseprescriptionscancauseseriousdangerforpersons’safety.
Dangerofseriousdamageforthevehicle
Partialorcompletenonobservance ofthese prescriptionscan causeseriousdamagesto thevehicle andsometimes
guaranteelapsetoo.
Generaldanger
!
Itincludesthedangersofabovedescribedsignals.
Environmentprotection
Itindicatescorrectbehaviourinorderthatvehicleuseisenvironmentallyfriendlyasmuchaspossible.
NOTE Itindicatesanadditionalexplanationforapieceofinformation.
Print603.93.651 I Base-March2006
SYMBOLS -ASSISTANCE OPERATIONS
Removal
Intake
Disconnection
Refitting
Exhaust
Connection
Removal
Operation
Disassembly
Fittinginplace ρ
Compressionratio
Assembly
Tolerance
Tightentotorque
Weightdifference
Tightentotorque+anglevalue Rollingtorque
α
Pressorcaulk Rotation
Regulation Angle
Adjustment Angularvalue
Visualinspection
Preload
Fittingpositioncheck
Measurement
Valuetofind Numberofrevolutions
Check
Equipment Temperature
Surfaceformachining
Pressure
Machinefinish bar
Oversized
Interference
Higherthan….
Strainedassembly
Maximum,peak
Undersized
Thickness
Lessthan….
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature<0°C
Sealant
Cold
Adhesive
Winter
Temperature>0°C
Airbleeding Hot
Summer
Replacement
Originalspareparts
Base-March2006 II Print603.93.651
PRODUCT CODE
Eachtitleorsubtitleconcerningoperationsbeingperformedisprecededbyasix-figurenumbernamedPRODUCTCODE.
This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES and
TROUBLECODEdocument.
Asaquickreferencethereareshownbelowtheguidelinestoreadthiscode(seeRepairTiming,too).
ProductCode: 5 0 7 6
PRODUCT UNIT SUB-ASSEMBLY PRODUCT UNIT SUB-ASSEMBLY
COMPONENT COMPONENT
ThefirstandsecondfiguresidentifythePRODUCTwithinmotorvehicle.
Example:
Product 50 = Vehiclechassis;
Product 52 = Axles;
Product 53 = Transmission;
Product 76 = Electricssystem.
UnitCode: 0 1 0 3
PRODUCT UNIT SUB-ASSEMBLY PRODUCT UNIT SUB-ASSEMBLY
COMPONENT COMPONENT
ThethirdandfourthfiguresidentifytheUNITwithinthePRODUCT.
Example:
Product 50 = Vehiclechassis;
Unit 01 = Chassis;
Unit 02 = Bumpers;
Unit 03 = Alternator.
Sub-assemblyCode: 4 0 1 3
PRODUCT UNIT SUB-ASSEMBLY PRODUCT UNIT SUB-ASSEMBLY
COMPONENT COMPONENT
ThefifthandsixthfiguresexactlyidentifytheSUB-ASSEMBLYandComponentofaUnitwithinaPRODUCT.
Example:
Product 50 = Vehiclechassis;
Unit 01 = Chassis;
Sub-assembly 40 = Chassiscrossmembers;
Sub-assembly 13 = Rotor.
Print603.93.651 III Base-March2006
GENERAL WARNINGS
Warningsshowncannotberepresentativeofalldangersituationspossiblyoccurring.Therefore,itissuggestedtocontact
! immediatesuperiorswhereadangersituationoccurswhichisnotdescribed.
Use both specific and general-purpose toolings according to the prescriptions contained in respective use and
maintenancehandbooks.Checkusestateandsuitabilityoftoolsnotsubjectedtoregularcheck.
Themanualhandlingofloadsmustbeassessedinadvancebecauseitalsodepends,besidesweight,onitssizeandon
thepath.
Handlingbymechanicalmeansmustbewithhoistersproperasforweightaswellasforshapeandvolume.Hoisters,
ropesandhooksusedmustcontainclearindicationsonmaximumcarryingcapacityacceptable.Theuseofsaidmeans
iscompulsorilypermittedtoauthorisedpersonnelonly.Staydulyclearoftheload,and,anyhow,neverunderit.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentallystrikingworkshoppersonnel.
Workshopjobsperformedinpairsmustalwaysbeperformedinmaximumsafety;avoidoperationswhich couldbe
dangerousfortheco-operatorbecauseoflackofvisibilityorofhis/hernotcorrectposition.
Keeppersonnelnotauthorisedtooperationsclearofworkingarea.
Learnoperationandsafetyknowledgenecessaryrelatingtothevehiclepriortoeachinterventiononit.Scrupulously
observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair
interventionhasbeencompleted,beforestartingupthevehicle,performallchecksindicatedonparagraph“Controls
careofuser”ofUseandMaintenancehandbook.
Inlackofvisibilityinoperatingfromthevehicle,chargeapersononthegroundwithassistance.Donotleaveunmanned
avehicleinmotionduringrepairinterventions.
Keepthevehiclestationarybyproperchocks.
Inthecaseofaninterventiononavehicleliftedfromtheground,checkthevehicletobequitesteadyonspecialsupport
standsand,inthecaseofliftingbymeansofalift,checkmanual/automaticsafetiestobeactivated.
Whenitisnecessarytoperformaninterventiononmethane-fedvehicles,observetheindicationscontainedinsidethe
document,aswellasallspecificsafetyregulationsprovided.
Onlyremoveradiatorcapwhentheengineiscoldbycautiouslyunscrewingitinordertoletsystemresidualpressure
out.
Inflammablefuelandallinflammablefluidsandliquidsmustbehandledwithcare,accordingtowhatcontainedonharmful
materials12-pointcards.Refuellingmustbeperformedoutdoorswiththeengineoff,avoidinglitcigarettes,freeflames
orsparksinordertopreventsuddenfires/bursts.Adequatelystoreinflammable,corrosiveandpollutingfluidsandliquids
accordingtowhatprovidedbyregulationsinforce.Compulsorilyavoidtousefoodcontainerstostoreharmfulliquids.
Avoidtodrillorborepressurisedcontainers,andthrowclothsimpregnatedwithinflammablesubstancesintosuitable
containers.
Wornout,damagedorconsumablepartsmustbereplacedbyIvecooriginalspares.
Duringworkshopactivity,alwayskeeptheworkplaceclean;timelyclearorcleanfloorsfromaccidentalliquidoroilspots.
Electricsocketsandelectricequipmentnecessarytoperformrepairinterventionsmustmeetsafetyrules.
For every intervention on vehicle hydraulic, pneumatic, conditioning and AIR - BAG systems, scrupulously observe
indicationsspecifiedinrelatingmanualsections.
Base-March2006 IV Print603.93.651
GENERAL WARNINGS
Puton,whererequiredbytheintervention,garmentsandprotectionsprovidedinaccidentpreventionrules;contact
with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels,
scarves,etc.
Donotleavetheengineinmotionatworkshoplocationsnotprovidedwithapipetoscavengeexhaustgasoutside.
Avoidtobreathefumescomingfromheatingorfrompaintweldingbecausetheycancausedamagestohealth;operate
outdoorsorinsuitablyventilatedareas.Putonproperinspiratorifpaintpowderispresent.
Avoidcontactwithhotwaterorsteamcomingfromtheengine,radiatorandpipingsbecausetheycouldcauseserious
burns.Avoiddirectcontactwithliquidsandfluidspresentinvehiclesystems;whereanaccidentalcontacthasoccurred,
referto12-pointcardsforprovisionstomake.
Cleanunitsorassembliesdetachedfromthevehicleandcarefullychecktheirintegritybeforeoverhaul.Tidyupdetached
ordisassembledpartswiththeirsecuringelements(screws,nuts,etc.)intospecialcontainers.
Checkfortheintegrityofthepartswhichpreventscrewsfrombeingunscrewed:brokenwashers,dowels,clips,etc.
Self-lockingnutswithaninsertmadeofnylonmustalwaysbereplaced.
Avoidcontactofrubberpartswithdieseloil,petrolorothernotcompatiblesubstances.
Beforewashingunderpressuremechanicalparts,protectelectricconnectors,andcentralunits,ifpresent.
Tighteningscrewsandnutsmustalwaysbeaccordingtoprescriptions;IVECOcommercialandassistancenetworkis
availabletogiveallclarificationsnecessarytoperformrepairinterventionsnotprovidedinthisdocument.
Beforewelding:
- Disconnectallelectroniccentralunits,takepowercableoffbatterypositiveterminal(connectittochassisbonding)
anddetachconnectors.
- Removepaintbyusingpropersolventsorpaintremoversandcleanrelevantsurficeswithsoapandwater.
- Awaitabout15minutesbeforewelding.
- Equipwithsuitablefireresistantprotectionstoprotecthosesorothercomponentswherefluidsorothermaterials
flowwhichmaycatchfireeasilyonwelding.
Shouldthevehiclebesubjectedtotemperaturesexceeding80°C(dryerovens),disassembledriveelectroniccentral
units.
Thedisposalofallliquidsandfluidsmustbeperformedwithfullobservanceofspecificrulesinforce.
Print603.93.651 V Base-March2006
GENERAL WARNINGS ON THE ELECTRIC SYSTEM
Ifaninterventionhastobemadeontheelectric/electronicsystem,disconnectbatteriesfromthesystem;inthiscase,
! alwaysdisconnect,asafirstone,thechassisbondingcablefrombatteriesnegativeterminal.
Beforeconnectingthebatteriestothesystem,makesurethatthesystemiswellisolated.
Disconnecttheexternalrechargingapparatusfromthepublicutilitynetworkbeforetakingapparatuspinsoffbattery
terminals.
Donotcausesparkstobegeneratedincheckingifthecircuitisenergised.
Donotuseatestlampincheckingcircuitcontinuity,butonlyusepropercontrolapparatuses.
Makesurethattheelectronicdeviceswiringharnesses(length,leadtype,location,strapping,connectiontoscreening
braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance
interventions.
Measurementsindriveelectroniccentralunits,pluggedconnectionsandelectricconnectionstocomponentscanonly
bemadeonpropertestinglineswithspecialplugsandplugbushes.Neveruseimpropermeanslikewires,screwdrivers,
clipsandthelikeinordertoavoidthedangerofcausingashortcircuit,aswellasofdamagingpluggedconnections,which
wouldlatercausecontactproblems.
Tostartuptheengine,donotusefastchargers.Startupmustonlybeperformedwitheitherseparatebatteriesorspecial
truck.
Awrongpolarisationofsupplyvoltageindriveelectroniccentralunits(forinstance,awrongpolarisationofbatteries)
cancausethemtobedestroyed.
Disconnectthebatteriesfromthesystemduringtheirrechargingwithanexternalapparatus.
On connecting, only screw up connector (temperature sensors, pressure sensorsetc.) nutsat prescribedtightening
torque.
Beforedisconnectingthejunctionconnectorfromanelectroniccentralunit,isolatethesystem.
Donotdirectlysupplyelectroniccentralunitsservocomponentsatnominalvehiclevoltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Oncetheinterventionontheelectricsystemhasbeencompleted,recoverconnectorsandwiringharnessesaccording
tooriginalarrangement.
Keymemorisationproceduresareinfluencedbyelectromagneticjamming(mobilephones,etc.).Therefore,duringkey
memorisation:
1 Payattentionthatjammingsourcesarenotpresentinthecabornearthekeys.
2. Keysnotinseredinthepanelmustbeatleast1meteraway.
NOTE Connectorspresentmustbeseenfromcableside.Connectorsviewscontainedinthemanualarerepresentativeofcable
side.
Base-March2006 VI Print603.93.651
Bonding and screening
Negativeleadsconnectedtoasystembondedpointmustbebothasshortandpossible and“star“-connectedtoeachother,trying
thentohavetheircenteringtidilyandproperlymade(Figure1,re.M).
Further,followingwarningsaretobecompulsorilyobservedforelectroniccomponents:
- Electroniccentralunitsmustbeconnectedtosystembondingwhentheyareprovidedwithametallicshell.
- Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening
bonding(avoiding“serial“or“chain“connections),andtobatterynegativeterminal.
- Analogbonding(sensors),althoughnotconnectedtobatterynegativesystem/terminal bonding,musthaveoptimalisolation.
Consequently,particularlyconsideredmustbeparasiticresistancesinlugs:oxidising,clinchingdefects,etc.
- Screenedcircuitsbraidingmustonlyelectricallycontacttheendtowardsthecentralunitenteredbythesignal(Figure2).
- Ifjunctionconnectorsarepresent,unscreenedsectiond,nearthem,mustbeasshortaspossible(Figure2).
- Cablesmustbearrangedsuchastoresulttobeparalleltoreferenceplane,i.e.ascloseaspossibletochassis/bodystructure.
Figure1
1. NEGATIVECABLES“STAR“CONNECTIONTOSYSTEMBONDING M
Figure2
88039
2. SCREENINGTHROUGHMETALLICBRAIDINGOFACABLETOANELECTRONICCOMPONENT—C.CONNECTOR
d.DISTANCE!0
Print603.93.651 VII Base-March2006
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS
Accessories mounting, additions and modifications on the vehicle are to be performed complying with IVECO mounting
instructions(specificdocument“Instructionsfortransformationandpreparation”isavailableatAssistanceNetworkworkshops).
Itisremindedthat,especiallyabouttheelectricsystem,severalelectricsocketsareprovidedforasseries(oroptional)socketsin
ordertosimplifyandnormalisetheelectricalinterventionthatiscareofpreparationpersonnel.
Foranyexceptiontomountinginstructions,IVECO’sauthorisationisnecessary.
Lackofobservanceofabovedescribedprescriptionsinvolvesguaranteelapse.
Itisabsolutelyforbiddentomakemodificationsorconnectionstoelectriccentralunitswiringharnesses;inparticular,
thedatainterconnectionlinebetweencentralunits(CANline)istobeconsideredinviolable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE
INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1kW = 1.36metricHP
1kW = 1.34HP
1metricHP = 0.736kW
1metricHP = 0.986HP
1HP = 0.746kW
1HP = 1.014metricHP
Torque
1Nm = 0.1019kgm
1kgm = 9.81Nm
Revolutionspertimeunit
1rad/s = 1rpmx0.1046
1rpm = 1rad/sx9.5602
Pressure
1bar = 1.02kg/cm2
1kg/cm2 = 0.981bar
1bar = 105Pa
Whereaccuracyisnotparticularlyneeded:
- Nmunitisforthesakeofsimplicityconvertedintokgmaccordingtoratio10:1
1kgm = 10Nm;
- barunitisforthesakeofsimplicityconvertedintokg/cm2accordingtoratio1:1
1kg/cm2 = 1bar.
Temperature
0°C = 32°F
1°C = (1x1.8+32)°F
Base-March2006 VIII Print603.93.651