Iveco EuroCargo (12 to 26 t). Manual — part 187
Insert wear sensor (2) into its suitable seat on braking gasket
(3).
Assemble spring (1) proceeding in reverse with respect to
disassembling.
49161
49162
49163
Figure 103
Figure 104
Figure 105
Figure 106
Remove dirt and rust around the braking disc edge with a
scraper or an old screwdriver (2), resting on the caliper body,
making disk (1) rotate.
End the work with abrasive cloth. Remove residuals by using
a suction device or with canvasses and brush.
Do not use petrol or other petroleum derivatives that could
create brake failures.
Use only denatured alcohol with methanol or isopropyl
alcohol.
Accurately clean brake disc braking area surfaces.
!
Visually check dust-guarding casings conditions; if they
show distortions or breakages, it is necessary to
replace them; such operation implies the need of
disassembling the brake caliper, so that it is advisable
to detach the brake caliper body completed with
carrier plate for the complete revision.
Verify that the caliper freely rotates on its guides.
If anomalies are detected on one brake caliper only, it is
advisable to proceed with the complete revision of both brake
calipers.
Remove dirt from brake caliper using a metal brush and
avoiding to damage dust-guarding casings.
Clean braking gaskets sliding surfaces.
Check brake disc conditions and make sure that it is not
corroded, scored or grooved. Slight surface cracks are
acceptable, but it is necessary to go on grinding the brake disc
as described in the related chapter, otherwise if worn, replace
the brake disc.
If there occurs the need of replacing, it is advisable to replace
both brake discs.
Check springs and wear sensors conditions, if necessary
replace them.
Insert new gaskets in brake caliper (1) and check that they
freely slide into their own seats.
!
If it is necessary to replace the pair of braking gaskets,
always replace a complete series of them for every
axle.
78624
Using the wrench (1), act on the adaptator retriever pin to get
a play not lower than 0.7 mm between brake lining and brake
disk, which can be measured using the thickness gauge (2).
Replace the cover (4) and lubricate it with white grease
RENOLIT HLT2.
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49158
49165
49166
49167
Figure 107
Figure 108
Figure 109
Figure 110
Disconnection
Connect electric connection (1) and secure it to caliper body.
Assemble plate (4), small pin (3) and split pin (2).
Assemble wear sensor cables checking plate (1).
Using hydraulic trolley 99321024, assemble the wheels. Lower
the vehicle. Lock wheel rim securing nut at the required
tightening torque.
Apply protection cup to wheel hubs.
Proceed as described on the opposite side.
After having ended the repairs on vehicle brakes, repeatedly
actuate the brake pedal, with moving vehicle, along both
running directions, thereby settling the braking gaskets.
For disconnecting the braking gaskets, comply with what has
been previously described in the paragraph about ”Braking
gaskets replacement”. Remove clamps (2). Disconnect
membrane cylinder supply piping (1).
Unscrew nuts (4) and remove membrane cylinder (3).
Remove screws (3) and detach brake caliper (1) completed
with carrier plate (2).
!
Pay attention when disconnecting and transporting
the caliper (1) since it is heavy and floating on the
carrier plate (2).
Hold the caliper on its outer side only; never put your
fingers between caliper (1) and support plate (2).
!
Make sure that the outer protecting plug and the seal
ring are correctly fitted, in order to prevent water
leaks inside the play automatic retriever.
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Brake calipers disconnection and
reconnection
Visually check that gasket-holder ring (1) diameter is free from
dents or accidental abrasions.
Replace internal wheel hubs gaskets and if necessary ring (1)
complying with what is described in section about ”Front
axle”.
Verify through adjustment ring nut that threading (2) is free
from hardenings, otherwise take care of removing them with
appropriate means.
Carry out the opposite braking assembly disassembling,
keeping the components separate.
Settle with some axial mallet blows on wheel hub, rotate it in
both directions to free bearing rollers. Apply magnetic base
(1) completed with comparator (2) to wheel hub. Arrange
comparator (3) rod perpendicular to stub axle tang.
77206
36408
36407
38956
36411
Figure 111
Figure 112
Figure 113
Figure 114
Figure 115
520620
Wheel hubs disconnection and
reconnection
Disconnection
Reconnection
For reconnecting, reverse performed operations for
disconnecting and comply with the required
tightening torques.
Rotate wheel hub so that screw plug (1) is taken downwards;
unscrew the cap and drain oil in a special container.
Suitably lock wheel hub rotation and with wrench 99354207
(1) unscrew oil cover (2), by draining residual oil in the special
container provided.
Unscrew safety screw (3). With wrench 99388001 unscrew
adjustment ring nut (2), withdraw washer (4), external bearing
(1) and detach brake disc completed with wheel hub, spacer
and internal bearing.
!
Make sure that surfaces of all parts inside the hub are
accurately clean, free from slags and burrs.
Lubricate the bearings with SAE W 140/MDA oil.
Key-in wheel hub completed with brake disc on stub
axle. Insert internal spacer on stub axle, then place
external bearing and shoulder washer.
Screw and lock adjustment ring nut at the required
torque.
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Reconnection
49168
49170
49169
Take brake caliper to bench and lock it in a vice.
Remove clamp (3) and protection cups (1 and 2).
Remove sliding pins (2 and 3) and disassemble carried plate
(1) recovering washer (4).
Disassemble protection casing (3), rubber bush (1) and
through a suitable beater, brass bush (2).
36412
Reset the comparator with a pre-load of 1.5
÷ 2 mm.
Axially move, with the help of a lever, the wheel hub and check
that its axial clearance is 0.16 mm (maximum value).
After having obtained the provided axial clearance, lock
adjustment ring nut (4) check screw (5) at the required
torque.
Figure 116
Figure 117
Figure 118
Figure 119
Figure 120
Apply tool (1) 99395026 on wheel hub stud bolts and use
torque meter 99389819 (2) to check whether the wheel hub
rolling torque is at the set value.
Rotate the wheel hub until when hub cover (1) is positioned
as shown in the figure. Restore the prescribed quantity of oil
into the hub cover (1) through filling hole (2). Tighten the plug
on the hub cover (1) to the set torque.
78322
Deposit a sealing bead (Loctite type 574) exclusively
on the hub cover ledge surface and protect the
threaded part.
Tighten to torque the hub cover (1, Figure 117).
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PNEUMATIC SYSTEM - BRAKES
Base - February 2003
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