Iveco Trakker Euro 4 / Euro 5 2006 thru 2013, repair e-manual

Content

General information

• Vehicle identification data
• Commercial coding
• P.I.C. number coding
• Vehicle configuration
• Composition of the models
• Filling fluids

Engine

• Views of the engine
• Main data
• Assembly clearance data
• Tightening torques
• Tools
• Engine removal - refitting
• Electro-magnetic fan drive replacement
• Disassembling the engine
• Repair operations
• Cylinder block
• Cylinder liners
• Crankshaft
• Preliminary measurement of main and big end bearing shell selection data
• Piston-connecting rod
• Connecting rod
• Cylinder head
• Valve
• Valve guides
• Replacing injector holders
• Timing gear
• Valve springs
• Rocker shaft
• Assembling the engine
• Diagram showing the lower crankcase fixing screws tightening order
• Flywheel
• Engine completion
• Lubrication
• Cooling
• Turbocharger
• VGT turbocharger
• Repairing actions
• Fuel system

Hydrocar power take-off on timing system

Denox system

• General remarks
• Tank
• AdBlue fluid level gauge control
• Switch valve
• Pump module
• Dosing module
• Catalyst
• Exhaust gas temperature sensor
• Humidity detecting sensor

Diagnosis

Clutch

• Description
• Main data
• Troubleshooting
• Tightening torques
• Tools
• Removing and refitting the clutch
• Removing-refitting the thrust bearing
• Replacing the support bearing of the clutch shaft
• Removing-refitting the pedal unit
• Pedal
• Checking and adjusting stops on clutch pedal
• Hydraulic control
• Spring pin adjustment gearbox
• Specifications for gearbox assembly eurotronic 12 AS 1930/2330/2530
• Spring pin adjustment gearbox eurotronic 12 AS 1420 TD
• Bleeding clutch circuit

Gearbox

• Gearbox ZF 9 S 1310 T.O.
• Gearbox ZF 16 S 1620 T.D. - 2220 T.D. - 2520 T.O. 13
• ZF 16 S 1621 T.D. - 2221 T.D. - 2521 T.O. with intarder
• Eurotronic automated 12 AS 1420 T.D
• Eurotronic automated 12 AS 1930 T.D. 12 AS 2330 T.O
• Eurotronic automated with intarder 12 AS 1931 T.D. 12 AS 2331 T.O
• Eurotronic gearboxes diagnostics

Propeller shafts

• Description
• Main data
• Tightening torque
• Tools
• Experimental tools
• Removing - refitting total power take-off assembly
• Overhauling

Transfer box TC 1800-TC 2200

• Main data
• Version with P.T.O.
• P.T.O. specifications
• Using the transfer box
• Torque transfer
• Tightening torques
• Tools
• Lubrication
• Transfer box removing and refitting
• Disassembling the transfer box
• Cleaning and checking parts
• Replacing output shaft cover seals
• Replacing input shaft cover seal
• Input shaft
• Epicyclic torque transfer unit
• Countershaft
• Assembling the transfer box
• Adjusting the bearing pre-load
• Completing assembly

Axles

• Front axles
• Intermediate axles
• Rear axles
• Axles in tandem meritor

Wheel alignment

Suspensions

• Front and rear mechanical suspensions
• Main data
• Front shock absorbers
• Rear shock absorbers
• Air suspension
• Air suspension system diagrams
• Chassis adjustment

Wheels and tyres

Steering system

• Description
• Main data
• Troubleshooting
• Tightening torques
• Tools
• Steering control
• Hydraulic steering
• Removing-refitting the steering
• Control assembly
• Main operations
• Bleeding the power steering system
• Measuring steering box play at the steering wheel
• Checking the maximum pressure of the power steering system

Pneumatic system - brakes

Bodywork and chassis frame

• Cab
• Main data
• Tools
• Tightening torques
• Repair operations
• Bumper
• Cabin
• Levelling valve
• Cab tilt cylinder
• Mirrors
• Door
• Window
• Instrument panel
• Central switch dashboard
• Protections
• Driver seat
• Cabin refrigerator
• Cab air-conditioning
• Ventilation
• Additional air heater system
• Fault diagnosis
• Electric fan
• Heater radiator
• Compressor
• Сondenser

Programmed maintenance

• Diagram of points for checks and/or maintenance operations
• Maintenance services chart
• Timed operations

Electric / electronic system

• General warnings for electrical/ electronic components
• Component code
• Main changes
• Can lines
• Can line assembly drawing
• Power network
• Ground points
• Electrical equipotential braid
• Alternator
• Starter motor
• Junction connectors
• Diagnosis connector
• Bulkhead
• Central interconnecting unit
• Fuse
• Remote switches
• Fuse assembly body controller (IBC3)
• Supplementary fuses (70000)
• Instrument board
• Central dashboard controls
• Controls on the steering wheel
• Rearview mirrors and window regulator control adjustment
• Left light control 54033
• engine brake control and intarder
• Gear selection function
• Function engaging emergency mode (limp home)
• Cluster
• Body controller (IBC3
• Chassis electronic module (M.E.T.)
• S.W.I. (Steering wheel / steervator interface)
• Spiraled contact
• Tachograph
• Injection system
• Engine control unit operation strategies
• EDC (ECM) systems
• VCM (vehicle control module) electronic control unit
• Immobilizer
• ECAS suspensions
• Eurotronic automatic transmission
• Electronic center
• Transmission actuator
• Clutch actuator
• Intarder
• Automatic air conditioner
• Manual air conditioner
• SCR (selective catalytic reduction) system - DENOX 2
• CEntral locking with remote control

Circuit charts

• Direct positive to battery
• Positive after TGC
• Power supply
• Body controller
• IC Control unit
• Tachograph / diagnosis socket
• Steering wheel interface (SWI)
• DDM-BM control unit
• Thermal mirrors / centralised locking / window winders (without DDM-PDM)
• VCM control unit
• EDC
• Control unit UDS (DENOX 2)
• Control unit MET
• Line CAN-IDB / FMB / control unit / telematics / navigator
• Electric/electronic system TRAKKER EURO 4/5
• LINE CAN
• ECAS 4X2 P tractor
• ABS
• Ventilation
• Manually controlled climate control system
• Manually controlled additional air heater
• EUROTRONIC II
• Retarder ZF
• Control unit EM (PTO)
• Radio receiver
• General mechanical power switch (IGC)
• ADR

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