Iveco Euro Trakker Tech Star Cursor 8 10 13 Repair Manual

Thispublicationdescribesthecharacteristics,thedata,the correctmethodologyoftherepairsthatcanbemadeoneach individualcomponentofthevehicle.

Bycomplyingwiththeinstructionssuppliedandusingthe specifictoolsitispossibletoperformanyrepairintervention correctly,withinthespecifiedtimeframes,whileprotectingthe techniciansagainstincidents.

Beforestartinganyrepairwork,makesurethatallaccident preventiondevicesarereadyathand.

Checkandweartheprotectivepersonalequipmentprovided forbythesafetystandards:goggles,helmet,gloves,shoes.

Checktheefficiencyofallprocessing,liftingandtransporttools beforeusingthem.

Thedatacontainedinthispublicationmightfailtoreflectthe latestchangeswhichtheManufacturermayintroduceatany time,fortechnicalorsalespurposes,ortomeetthe requirementsoflocallegislation.

Copy,evenpartial,oftextanddrawingsisforbidden.

Producedby:

PublicationEditedby: IVECOS.p.A.

T.C.O.-B.U.CustomerService LungoSturaLazio,15/19 10156Torino(Italy)

Printed 603.93.121 -1st Ed.2002

B.U.TECHNICALPUBLISHING C.soSvizzera,185 10149Torino(Italy)

ThismanualispartoftheaidsthattheTechnicalPublicationssectormakesavailabletoworkshoptechnicianstoallow thecorrectperformanceofmaintenanceand/orrepairoperationsanditisalsoagoodwaytofamiliarisewiththeIVECO product.

Theexperienceacquiredovermanyyearsinservicingandin editingtechnicalpublicationshasledustodevoteaspecial volumetotheelectricsystemfittedonthemodelsinquestion,consideringtheparticularityandcomplexityofthe subject.

Thismanualisintendedforpeoplewithprofessionalpreparationinthe”VehicleElectrician”sectorandatthesame timeavailofadequateandindispensabletestingand/ormeasurementequipmentforthemainelectricalratings.

Indraftingthetextsandrepresentingthegraphicswehavetakenaccountoftheparticularnecessitiesoftheoperator technicianinsomecasesstatingreferencesorrepeatingcertaindiagramsindifferentplacesthatmaybeobvioustoa designengineer.

Thecompletenessoftheinformationgiveninthewiringdiagrams,thesizechosenandtheeasewithwhichtheycan betakenallowtherepairoperatortoavailofalltheinformationexactlywhereitisneededmost,namely,onboard theactualvehicle.

INTRODUCTION

Thismanualcomprises5chapters, identifiedbyromannumerals:

ChapterIINTRODUCTION

ChapterIIGENERALDESCRIPTION

ChapterIIISPECIFICCIRCUITS

ChapterIVCIRCUITCHARTS

Thesubjectsdealtwithareupdatedatthedateofdraftingofthemanualwhichpracticallycorrespondstothedate ofgoingtopress.

Eachchapterhasitsownprogressivepagenumbertosimplifyupdating.

Thenumberingofthefiguresisdouble.Thefirstdigitreferstothechapternumberandthesecondisaprogressive number;thismakesiteasytofindfiguresiftheyaregivenasreferenceselsewhere.

Thepossibilityexiststhattheinformationgiveninthismanualmaynotbeuptodateasaresultof modificationsadoptedbytheManufactureratanytimefor reasonsofatechnicalorcommercialnatureortoadjust tothelawsinforceinthedifferentCountries.

Generalcautionsforelectric/electroniccomponents

NEVERDISCONNECTTHEBATTERIESOFTHESYSTEMOROPENTHEKNIFESWITCHWITHTHE ENGINERUNNING.

DONOTSTARTTHEENGINEWITHOUTFIRSTLYCONNECTINGTHEBATTERIESPERMANENTLY.

—Beforedoinganyworkonthevehiclechockthewheelsappropriately.

—Startingfromtheenginecompartmentmayonlybecarriedoutwhenthecabisfirmlyfastenedonitsmaximum openingpositionwiththehandbrakeengaged,gearboxinneutralandwheelschocked.

—Donotusequickchargerstostarttheengine.Startingmustonlybecarriedoutwithseparatebatteriesorwith thespecialtrolley.

—Makesurethatthebiasofthebatteryterminalsiscorrectwhenstartingfromanauxiliarytrolley.

—Theincorrectpolarisationofthepowervoltageofelectroniccontrolunits(forexampleincorrectpolarisation ofthebatteries)mayleadtotheirdestruction.

—Whenneedingtodisconnectthebatteriesfromthesystem,firstlyalwaysdisconnecttheframeearthcablefrom thenegativeterminalofthebatteries.

—Beforeconnectingthebatteriestothesystem,makesurethatitiswellinsulated.

—Theincorrectbiasofthesupplyvoltageofelectroniccontrolmodules(foeexampleincorrectbatterybias)may leadtotheirbreakage.

—Whenseekingacircuitfailureinsertawanderfusebetweenthenegativeterminalofthebatteryandtheframe earthcable(maincurrentswitchon).

—Beforeremovingelectricand/orelectroniccomponentsdisconnecttheearthcablefromthenegativeterminal ofthebattery.

—Electricalmeasurementsonelectroniccomponentsmustonlybecarriedoutwithappropriatemeasuring equipment.

—Disconnectthebatteriesfromthesystemwhenchargingthemwithexternalequipment.

—Disconnecttheexternalchargingequipmentfromthemainsbeforeremovingitsgrippersfromtheterminals ofthebatteries.

—Donotinsertorremovetheconnectorofelectroniccontrolunitswiththepoweron.

—Withtemperaturesabove80 °C(dryingovens)removetheelectroniccontrolunits.

—Duringelectricweldingwork,disconnecttheconnectorsofelectroniccontrolunits.

—Duringconnection,tightenthenutsoftheconnectors(temperature,pressuresensors,etc.)onlywiththe specifiedtighteningtorque.

—Carefullymakesurethatthebatteryterminalpolarityiscorrectbeforestartingfromanauxiliarytrolley.

—Donotdirectjetsofwateronfuseboxesandelectricalequipment.

—Donotdirectjetsofwateronthebatteries.

Measurementsinelectroniccontrolunits,plugconnectionsandelectricconnectionstocomponentsmay becarriedoutonlyonappropriatetestinglines,withspecialplugsandsockets.Neveruseimpropermeanssuch asmetalwires,screwdrivers,clipsorthelike.Inadditiontothedangerofashortcircuit,damagetotheplug connectorsmayalsoresultandthiswould subsequentlycausecontactproblems.

—Beforedisconnectingtheconnectorfroman electroniccontrolunit,isolatethesystem.(Figure oppositeref.A)

—Donotcausesparkstocheckwhetheracircuitis live.

—Donottouchthepinsoftheconnectorsof electroniccontrolunitswithyourfingers.

—Donotuseatestbulbtocheckthecontinuityof acircuit.Onlyusetheappropriatetestingdevices (ref.B)

—Donotdirectlypowerthecomponents associatedwithelectroniccontrolunitswiththe nominalpowerratingofthevehicle.

—Donotinserttheprodsofameasuringdevicein thepinsofconnectorsofelectroniccontrolunits. AnymeasurementsaremadeusingUNITESTER (ref.C).

—Makesurethatthewiringsofelectronicdevices (length,typeofcable,location,grouping, connectionofscreenbraiding,earthing,etc.) conformwiththeIVECOsystemandthattheyare carefullyrestoredafterrepairormaintenance work.Toavoidthepossiblemalfunctioningofthe electronicsystemsonboard,thewiringsof additionaldevicesmustfollowadifferentpath thanthatoftheabove-mentionedsystems.

—ReplacecomponentsonlywithoriginalIVECO components.

—Donotinstalladditionalelectricaland/or electronicequipmentnotprovidedforbyIVECO orbylocallaws.

—Donotconnectthenegativeterminalsof additionalsystemstothenegativeterminalsof electronicsystems.

—Intheeventofelectricweldingonthevehicle, disconnectalltheelectroniccontrolunitsand/or disconnectthepowercablefromthebattery positiveterminalandconnectittotheframeearth (ref.D).

A B

Conceptofearthandelectromagneticcompatibility

Theelectricsystemistraditionallyasingle-polesystem.Thebody,theframe,themetalcontainerofelectromechanical componentsactasequipotentialreturnconductortothegenerator,asanypointoftheirmetalstructureoranynegative terminalnotisolatedisatthesamereferencepotential orEARTH.Thisiswhytheearthhasbeenchosenasreference tothewholesystem,conventionallygivingitthevalueofzero.

Duetoobviousreasonsofconstruction,inthenegativenetworkofthesystemtherearevariousearthpointslocated onthevehicleinrelationtothelocationofthecomponentsontheframe,engineorbody.

Ontheotherhand,ideally,alltheequipmentshouldbeconnectedtoonlyoneearthpointinordertoprovidethem, particularlyforelectronicdevices,aclearlydefinedearthreference.

Fortheabove-mentionedreasonsitisnecessarytodistinguishthesupplyearthorsystemearth,characterisedbystrong directcurrentintensity(>1Aforelectromechanicalcomponents),fromthe analogueearth,characterisedbywave shapesatdeterminatefrequenciesandverylowcurrentintensity(mA, µA)ofelectronicsystems.

ThedefinitionofsignalearthoranalogueearthdependsonthesensitivityoftheelectronicsystemstoEMC (electromagneticcompatibility),asparasitesignalsemittedbythesystemsonboardoroutsidethevehicle,induce failuresand/ordeteriorationofthesystemsthemselves.

Inordertominimisebothcontinuousandtransientdisturbanceorinterferencegeneratedbyparasiteradiations,itis oftheutmostimportancetoalwaysbearinmindthatthesatisfactoryefficiencyofthereferenceplaneorsystemearth dependsontheexcellentconductivitycharacteristics(contactresistancetendingtowardszero)ineachofitsconnection points.

Briefly,wecansaythattheearthunderstood asequipotentialelectricalconductor,i.e.aspotentialreferenceforallthe electric/electroniccomponentsonboard,issubdividedintosystemearthandanalogueearth.

ThesystemearthpointsarethoseforeseenbytheManufacturerandmust,ofcourse,befreeofpaint,oxidation,grease, dust,etc.

Practicaladvice

Thenegativecablesconnectedtoanearthpointmustbeas shortaspossibleandconnectedtooneanotherina“star” connection,tryingtotightenthemneatlyandadequately(Fig.I.4ref.M).

Additionally,forelectroniccomponentsthefollowinginstructionsshouldabsolutelybefollowed:

—Electroniccontrolunitsmustbeconnectedtothesystemearthwhentheyhaveametalcontainer.

—Thenegativecablesofcontrolunitsmustbeconnectedtobothasystemearthpoint,forexamplethedashboard earth(avoiding“serial”or“chain”connections), andtothenegativeterminalofthebattery/ies.

—Thoughtheyarenotconnectedtothesystemearth/batterynegativeterminal,analogueearths(sensors)must beperfectlyinsulated.Therefore,particularcareshouldbegiventotheparasiteresistancesoftheterminals: oxidation,clinchingdefects,etc.

—Themetalbraidingofscreenedcircuitsmustbeinelectricalcontactineachofitsendswiththecomponents ofthesystem.

—Onlyoneendofthescreeningbraidmustbeconnectedtothesystemearth.

—Inthepresenceofconnectorstheunscreenedsection d, nearthem,shouldbeasshortaspossible(Fig.I.5).

—Thecablesshouldbelaidonparallelwiththereferenceplane,i.e.asnearaspossibletotheframe/bodystructure.

—Additionalelectromechanicalsystemsshouldbecarefullyconnectedtothesystemearthandmustnotbeset atthesideofthecablesofelectroniccomponents.

Structureoftheelectricnetwork

–Unipolarsystem:currentreturnfromusertosourcevianegativenetworkandmetallicstructureofthevehicle (earth). N.B. Thecircuitofthetachographandauxiliaryheater(optional)arealwayslive

A B C D E

–Batterycompartment(12Vx2)locatedontheleftsidemember

–Systemcanbemodulatedthroughthemaincontrolbox(UCI)locatedinthecabintheelectriccompartmentand twowallconnectors:oneatthefrontandtheotherattherearofthecab.

Themaincablesare:powercable cabcable roofcable exteriorlightingcable enginecable ABS/EBSwheelanti-lockcable

–Tiltablecabwithcabuncoupledindicator.

–Safetycircuitforstartingandstopping theenginefromtheenginecompartment.

–Enginestopping(fromcab)byresettingtheignitionswitch.

–BASESYSTEMELECTRONICCOMPONENTS

-Tachograph

-ABS/EBSantiwheellocksystem -Directionindicatorflasher

-InjectioncontrolbyelectronicEDCMS6.5system

-ECASairsuspensions -Immobilizer.

OperatingSynoptics

Themodularityofthetwoareasisensuredby3familiesofcables(cab,engineandframe)throughtheMain InterconnectingControlBox(UCI)

ConceptofCANLINE

Overthepastfewyearselectronicsystemsonindustrialvehicleshavedevelopedrapidlyandtheydetermine satisfactoryoperationofthevehicle.

Whatbeforewasacomplementarysciencehasnowbecomeakeysectoroftechnology.Currentlyelectronic systemsmakethevehicleworkanddeterminetheeffectivenesswithwhichthesinglecomponentsinteractwithone another.IncreasinglyoftenwemeetthetermCANusedinthiscontext.

ThetermCANmeansControllerAreaNetwork.Thisisadedicatedwiringthatconnectsthecontrolunitsofa vehicle(ECU)tooneanother,therebycreatingastructuresimilartoanervoussystem.

Thissystemenablestheinstantaneousexchangeoflargequantitiesofdatabetweenthevariouselectronicsystems onboardthevehicle.

ItisaTWO-WAYcommunicationmodethatisbecomingincreasinglywidespreadinthefieldofvehicles,owing tothereductionofthenumberofleadsandinterferences.

Theinformationtravelsrespectingaprotocolwhichdefinestheconversationmodes:

—Synchronisationoftheinformation

—Callandanswermodebetweenthevarioussystems

—Identificationandcorrectionofanytransmissionerrors

—Etc.

Operatingfeatures

Toobtainnewoperatingfeaturesitisimportantthat thevariouselectronicsystemscommunicatewithone another.

Oneoftheseoperatingfeatures,forinstance,isthe reductionoftorqueduringgearshifting,whichistheresultobtainedfrominteractionoftheengineandtransmissioncontrolunits.

Theconnectionbetweenthedifferentcontrolunits maytakeplaceeithergroupingtheminasinglemainunit (solutionrejectedduetothecomplexityofthemanagementprogrammeandbecausethesystemwouldbetoo rigidandexpensiveinthecaseofalterationsandupdates)orusingacommunicationnetworkcapableoftransferringthedataquicklyandreliably.Fastdatatransferis fundamentalforefficientmanagementofvehicledriving, whilereliabilitymustbeguaranteedforapplicationsconnectedwithsafety(transmission,enginecontrolsand controlunits)andtheremustnotbeanycommunication problemsespeciallyinthepresenceofelectromagnetic influences.

About60%oftheproblemsconcerningtheelectronicsofavehicleinvolveconnectiontechnologyandcan beidentifiedinthecorrosionofthecontactsofaconnectorandintheconnectionsofcables,wearoftheinsulatingsheathorfaultyassembly.

Anotherthirdoftheseproblemsiscausedbyoperatingfaultsinthesensorsandactuators.Singalowerquantityofcablesandreducingthenumberofsensors,the stoppagetimeduetovehiclesoutofservicewillbeminimised,resultinginloweroperatingcosts.Awiringwith lesscomponentswillmakeitpossibletodiagnosethe electronicsystemmoreeasily.

Thetotallengthofthecablescanreachseveralkilometresand,asmentionedpreviously,thehighernumber ofcomponentsincreasestheriskoffaults.TheMultiplex systemsofferbettercommunicationbetweenthesystemsandsimplifytrouble-shooting.

TheMultiplexerunitreceivestheinformationabout thestatusoftheswitches.Acodedvaluewhichisdifferentforeveryswitch,istransmittedtotheDatabus.The De-Multiplexerdecodifiesthevaluesandactivatesthe voltagetosupplytheappropriatelamp.

InMultiplexersystemsvarioustypesofcablesare used:themostcost-effectivealternativeisthatofsingle cables.Furtheralternativesare:doubleordualcable,twistedpaircables,opticalfibres.Thechoiceofthecabledependsonthefollowingrequirements:signalspeed,signal noiseandinterferencesandthischoiceaffectstheoverall costofthesystem.

Differentclassesexistdependingonthedifferentdata transmissionspeedontheDatabus:

-classA:lowspeed(example:windscreenwiper andvehiclelightscontrol).

- ClassB:mediumspeed(example:airconditioning andsoundsystems).

- ClassC:highspeed(example:ABSandTraction Controlsystems).

AllinalltheadvantagesofaMultiplexsystemcanbe summarisedin:lowercostsduetothelowerlengthofthe cables,higherfunctionality,sharingofthesignalsofthe sensorsbythevarioussystemsandbetterdiagnostic functions.Againstthishowever,theoverallnumberof connectionsincreases,technicaltrainingrequisitesarehigher,functionreadingisnotpossiblethroughthewiring diagramandaboveallhighercostscomparedwithaconventionalsystem.

Thedifferentmanufacturersusetheirownstandards ontheirvehicles.InGermanyBOSCHhasdevelopedthe BusCAN(ControlAreaNetwork).

Allthenodes,i.e.electroniccontrolunits,areconnectedontheDatabus.

ThestructureoftheBusCANisextremelyflexible; oneormorenodesmaybeaddedorremovedeasilyand continueworkingintheeventofafaultofoneormore ofthem.

Ifnode2sendsamessage,node3whichisconcerned acceptsthemessage,whilenode1ignoresit.ItisimportanttoknowthatthemessageshavebeenreceivedcorrectlyontheDatabus;inthecaseofanerrorthemessage issentagain:thereceivingnodeconfirmsreceptionofthe message.

Theunitsornodescansharetheinformationofmany sensors.

Asforanyformofcommunicationcertainconditions mustbemet.CANcommunicationneedstherighthardware,ataskthatwasinitiallyperformedbyasinglemicrochipbutwhichlatelyhasbeenincreasinglyintegrated inmicrocontrollers:theCan-ChipdevelopedbyBosch makesthevariouscontrolunitscommunicatewithone anotherwithCANprotocolthroughthesame”language”viabus;astransmitteritconfersthemessagestoeveryoneandasreceiveritiscapableofidentifyingthemessagesaddressedtoitamongmanymessages.

Sinceallthecomponentsthattakepartincommunicationcansendmessagessimultaneouslyonthe bus,thereceivingcomponentconcernedwillfirstly receivethemessagewiththehighestprioritywhile theotherswillreturntothesenderandbetransmittedagain:forexampleconcerningvehicledrivingare ofprimaryimportanceandthereforethevehiclemust reactimmediatelytochangesofthepedalposition;it isalsotruethatifimportantmessagesaretransmitted constantly,thelessimportantinformationwillrarely orneverreachitsdestination.

Forthisreasondifferentbusesareused.