Professional Documents
Culture Documents
6 TO 10 t
REPAIR MANUAL
Produced by:
Publication Edited by:
IVECO S.p.A.
Customer Service
Lungo Stura Lazio, 15
10156 Torino (TO) Italy
Printed 603.93.381 1st Ed. 2004
PRELIMINARY REMARKS
Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated
in the general table of contents.
Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.).
Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections disconnections of
units to/from the vehicle, overhauls at the bench and relating troubleshooting.
On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electric
schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the
electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS WARNINGS
Danger for persons
Missing or incomplete observance of these prescriptions can cause serious danger for persons safety.
General danger
It includes the dangers of above described signals.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
NOTE
Print 603.93.381
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fitting in place
Assembly
Compression ratio
Tighten to torque
Tolerance
Weight difference
Rolling torque
Press or caulk
Rotation
Regulation
Adjustment
Angle
Angular value
Visual inspection
Fitting position check
Preload
Measurement
Value to find
Check
Number of revolutions
Equipment
Temperature
bar
Pressure
Oversized
Higher than.
Maximum, peak
Undersized
Less than.
Minimum
Selection
Classes
Oversizing
Temperature < 0 C
Cold
Winter
Temperature > 0 C
Hot
Summer
Interference
Strained assembly
Thickness
Clearance
Lubrication
Damp
Grease
Sealant
Adhesive
Air bleeding
Replacement
Original spare parts
II
Print 603.93.381
PRODUCT CODE
Each title or subtitle concerning operations being performed is preceded by a sixfigure number named PRODUCT CODE.
This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES and
TROUBLE CODE document.
As a quick reference there are shown below the guide lines to read this code (see Repair Timing, too).
5 0
Product Code:
PRODUCT
7 6
UNIT
SUBASSEMBLY
COMPONENT
PRODUCT
UNIT
SUBASSEMBLY
COMPONENT
The first and second figures identify the PRODUCT within motor vehicle.
Example :
Product
Product
Product
Product
50
52
53
76
=
=
=
=
Vehicle chassis;
Axles;
Transmission;
Electric ssystem.
0 1
Unit Code:
PRODUCT
UNIT
0 3
SUBASSEMBLY
COMPONENT
PRODUCT
UNIT
SUBASSEMBLY
COMPONENT
The third and fourth figures identify the UNIT within the PRODUCT.
Example :
Product
Unit
Unit
Unit
50
01
02
03
=
=
=
=
Vehicle chassis;
Chassis;
Bumpers;
Alternator.
4 0
Subassembly Code:
PRODUCT
UNIT
1 3
SUBASSEMBLY
COMPONENT
PRODUCT
UNIT
SUBASSEMBLY
COMPONENT
The fifth and sixth figures exactly identify the SUBASSEMBLY and Component of a Unit within a PRODUCT.
Example :
Product
50
Unit
01
Subassembly 40
Subassembly 13
Print 603.93.381
=
=
=
=
Vehicle chassis;
Chassis;
Chassis cross members;
Rotor.
III
GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact
immediate superiors where a danger situation occurs which is not described.
Use both specific and generalpurpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on
the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the cooperator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
Learn operation and safety knowledge necessary relating to the vehicle prior to each intervention on it. Scrupulously
observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair
intervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph Controls
care of user of Use and Maintenance handbook.
In lack of visibility in operating from the vehicle, charge a person on the ground with assistance. Do not leave unmanned
a vehicle in motion during repair interventions.
Keep the vehicle stationary by proper chocks.
In the case of an intervention on a vehicle lifted from the ground, check the vehicle to be quite steady on special support
stands and, in the case of lifting by means of a lift, check manual/automatic safeties to be activated.
When it is necessary to perform an intervention on methanefed vehicles, observe the indications contained inside the
document, as well as all specific safety regulations provided.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful
materials 12point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids
according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids.
Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable
containers.
Worn out, damaged or consumable parts must be replaced by Iveco original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots.
Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
For every intervention on vehicle hydraulic, pneumatic, conditioning and AIR BAG systems, scrupulously observe
indications specified in relating manual sections.
IV
Print 603.93.381
GENERAL WARNINGS
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tightfitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate
outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred,
refer to 12point cards for provisions to make.
Clean units or assemblies detached from the vehicle and carefully check their integrity before overhaul. Tidy up detached
or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Selflocking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO commercial and assistance network is
available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
Print 603.93.381
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance
interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during key
memorisation:
1 Pay attention that jamming sources are not present in the cab or near the keys.
2. Keys not insered in the panel must be at least 1 meter away.
NOTE
Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.
VI
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Figure 1
1.
Figure 2
88039
2.
Print 603.93.381
VII
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular,
the data interconnection line between central units (CAN line) is to be considered inviolable.
Power
1 kW
1 kW
1 metric HP
1 metric HP
1 HP
1 Hp
=
=
=
=
=
=
1.36 metric HP
1.34 HP
0.736 kW
0.986 HP
0.746 kW
1.014 metric HP
Torque
1 Nm
1 kgm
=
=
0.1019 kgm
9.81 Nm
OF
THE
=
=
=
1.02 kg/cm2
0.981 bar
105 Pa
(Nm and bar units are converted according to 10:1 and 1:1 for the sake of simplicity)
1 kgm
1 kg/cm2
=
=
10 Nm
1 bar
Temperature
0 C = 32 F
1 C = (1 x 1.8 + 32) F
VIII
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EUROCARGO TECTOR
6 TO 10 t
Print 603.93.381 1st edition
Base October 2004
UPDATE DATA
Section
Print 603.93.381
Description
Page
Revision date
Print 603.93.381
INDEX OF SECTIONS
Section
Print 603.93.381
General Specifications
Engine
Clutch
Gearbox
Propeller shafts
Rear axles
Axles
Suspensions
Steering system
10
11
12
Scheduled maintenance
13
Electric system
14
Print 603.93.381
GENERAL SPECIFICATIONS
SECTION 1
General Specifications
Page
Print 603.93.381
11
FILLING UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13
GENERAL SPECIFICATIONS
Print 603.93.381
GENERAL SPECIFICATIONS
ML60E13
ML60E13/P
ML60E13R
ML60E13R/P
ML60E13K
ML60E13KR
ML60E15
ML60E15/P
ML60E15R
ML60E15R/P
ML60E15K
ML60E15KR
ML65E13
ML65E13/P
ML65E13R
ML65E13R/P
ML65E13K
ML65E13KR
ML65E15
ML65E15/P
ML65E15R
ML65E15R/P
ML65E15K
ML65E15KR
MODELS
UNITS
F4AE0481D
(130HP)
F4AE0481C
(150HP)
F4AE0481A
(170HP)
F4AE0681E
(180HP)
F4AE0681D
(210HP)
2855S.5
2855S.6
5833/1
4517
Front mechanical
Rear mechanical
Single plate
13
13/14
14
2865S.6
2870S.9
5833
4521
TRW-TAS 30
ZF 8090
Front pneumatic
Rear pneumatic
P
FP
D
K
R
Print 603.93.381
GENERAL SPECIFICATIONS
ML75E13
ML75E13/P
ML75E13R
ML75E13R/P
ML75E13K
ML75E13KR
ML75E15
ML75E15/P
ML75E15R
ML75E15R/P
ML75E15K
ML75E15KR
ML75E17
ML75E17/P
ML75E17R
ML75E17R/P
ML75E17K
ML75E17KR
ML75E18
ML65E18/P
ML75E18R
ML75E18R/P
ML75E18K
ML75E18KR
MODELS
UNITS
F4AE0481D
(130HP)
F4AE0481C
(150HP)
F4AE0481A
(170HP)
F4AE0681E
(180HP)
F4AE0681D
(210HP)
13
Single plate
13/14
14
2855S.5
2855S.6
5833/1
4517
Front mechanical
Rear mechanical
2865S.6
2870S.9
5833
4521
TRW-TAS 30
ZF 8090
Front pneumatic
Rear pneumatic
P
FP
D
K
R
Print 603.93.381
GENERAL SPECIFICATIONS
MODELS
UNITS
F4AE0481D
(130HP)
F4AE0481C
(150HP)
F4AE0481A
(170HP)
F4AE0681E
(180HP)
F4AE0681D
(210HP)
13/14
14
13
Single plate
ML80EL15
ML80EL15/P
ML80EL15R
ML80EL15R/P
ML80EL17
ML80EL17/P
ML80EL17R
ML80EL17R/P
ML80E17
ML80E17/P
ML80E17/FP
ML80E17D
ML80E17D/P
ML80E17R
ML80E17R/P
ML80E17R/FP
ML80E17DR
ML80E17DR/P
ML80E17K
ML80E17DK
ML80E17KR
ML80E17DKR
ML80E18
ML80E18/P
2855S.5
2855S.6
2870S.9
5833
2865S.6
5833/1
4517
4521
Front mechanical
Rear mechanical
TRW-TAS 30
ZF 8090
P
FP
D
K
R
Front pneumatic
Rear pneumatic
Print 603.93.381
GENERAL SPECIFICATIONS
MODELS
UNITS
F4AE0481D
(130HP)
F4AE0481C
(150HP)
F4AE0481A
(170HP)
F4AE0681E
(180HP)
F4AE0681D
(210HP)
ML80E18/FP
ML80E18D
ML80E18D/P
ML80E18R
ML80E18R/P
ML80E18R/FP
ML80E18DR
ML80E18DR/P
ML80E18K
ML80E18DK
ML80E18KR
ML80E18DKR
ML80E21
ML80E21/P
ML80E21/FP
ML80E21D
ML80E21D/P
ML80E21R
ML80E21R/P
ML80E21R/FP
ML80E21DR
ML80E21DR/P
ML80E21K
ML80E21DK
13
Single plate
13/14
14
2855S.5
2855S.6
2865S.6
2870S.9
5833
5833/1
4517
4521
TRW-TAS 30
ZF 8090
Front mechanical
Rear mechanical
P
FP
D
K
R
Front pneumatic
Rear pneumatic
Print 603.93.381
GENERAL SPECIFICATIONS
MODELS
UNITS
F4AE0481D
(130HP)
F4AE0481C
(150HP)
F4AE0481A
(170HP)
F4AE0681E
(180HP)
F4AE0681D
(210HP)
ML80E21KR
ML80E21DKR
ML90E17
ML90E17/P
ML90E17/FP
ML90E17D
ML90E17D/P
ML90E17R
ML90E17R/P
ML90E17R/FP
ML90E17DR
ML90E17DR/P
ML90E17K
ML90E17DK
ML90E17KR
ML90E17DKR
ML90E18
ML90E18/P
ML90E18/FP
ML90E18D
ML90E18D/P
ML90E18R
ML90E18R/P
ML90E18R/FP
13/14
14
13
Single plate
2855S.5
2855S.6
2865S.6
2870S.9
5833
5833/1
4517
4521
TRW-TAS 30
ZF 8090
Front mechanical
Rear mechanical
P
FP
D
K
R
Front pneumatic
Rear pneumatic
Print 603.93.381
GENERAL SPECIFICATIONS
MODELS
UNITS
F4AE0481D
(130HP)
F4AE0481C
(150HP)
F4AE0481A
(170HP)
F4AE0681E
(180HP)
F4AE0681D
(210HP)
ML90E18DR
ML90E18DR/P
ML90E18K
ML90E18DK
ML90E18KR
ML90E18DKR
ML90E21
ML90E21/P
ML90E21/FP
ML90E21D
ML90E21D/P
ML90E21R
ML90E21R/P
ML90E21R/FP
ML90E21DR
ML90E21DR/P
ML90E21K
ML90E21DK
ML90E21KR
ML90E21DKR
ML100E17
ML100E17/P
ML100E17/FP
ML100E17D
13
Single plate
13/14
14
2855S.5
2855S.6
2865S.6
2870S.9
5833
5833/1
4517
4521
TRW-TAS 30
ZF 8090
Front mechanical
Rear mechanical
P
FP
D
K
R
Front pneumatic
Rear pneumatic
Print 603.93.381
GENERAL SPECIFICATIONS
MODELS
UNITS
F4AE0481D
(130HP)
F4AE0481C
(150HP)
F4AE0481A
(170HP)
F4AE0681E
(180HP)
F4AE0681D
(210HP)
13/14
14
13
Single plate
ML100E17D/P
ML100E17R
ML100E17R/P
ML100E17R/FP
ML100E17DR
ML100E17DR/P
ML100E17K
ML100E17DK
ML100E17KR
ML100E17DKR
ML100E18
ML100E18/P
ML100E18/FP
ML100E18D
ML100E18D/P
ML100E18R
ML100E18R/P
ML100E18R/FP
ML100E18DR
ML100E18DR/P
ML100E18K
ML100E18DK
ML100E18KR
ML100E18DKR
2855S.5
2870S.9
5833
ZF 8090
Front mechanical
2855S.6
2865S.6
5833/1
4517
4521
TRW-TAS 30
Rear mechanical
Front pneumatic
Rear pneumatic
P
FP
D
K
R
Print 603.93.381
10
GENERAL SPECIFICATIONS
MODELS
UNITS
F4AE0481D
(130HP)
F4AE0481C
(150HP)
F4AE0481A
(170HP)
F4AE0681E
(180HP)
F4AE0681D
(210HP)
ML100E21
ML100E21/P
ML100E21/FP
ML100E21D
ML100E21D/P
ML100E21R
ML100E21R/P
ML100E21R/FP
ML100E21DR
ML100E21DR/P
ML100E21K
ML100E21DK
ML100E21KR
ML100E21DKR
2865S.6
2870S.9
5833
ZF 8090
Front mechanical
Rear mechanical
13
Single plate
13/14
14
2855S.5
2855S.6
5833/1
4517
4521
TRW-TAS 30
Front pneumatic
Rear pneumatic
P
FP
D
K
R
Print 603.93.381
GENERAL SPECIFICATIONS
11
Manufacturers plate
For vehicle identification to comply
with EC directions (under front
radiator grille)
Engine
Flywheel cover plate on the box (left side)
Chassis
Marking (on right side member
front end)
Print 603.93.381
12
GENERAL SPECIFICATIONS
FILLING UP
LUBRICANTS RECOMMENDED BY IVECO
Acea E3/E5
Urania LD5
Quantity
PARTS TO FILLED UP
Litres
kg
min.
5.3
4.8
max
8.3
7.5
0.9
min.
7.2
max
10.8
9.7
0.9
Engine 4 cylinders
Engine 6 cylinders
Tutela ZC 90
Tutela W140/M - DA
Gearbox
5.5
5.5
9
5
8.1
2870S.9
4.5
0.1
4517
2.7
4521
4.5
Tutela GI/A
Power
steering
Brake circuit
1.9
1.7
Clutch circuit
0.4
0.7
0.65
Paraflu11
Tutela LHM
2855S.5
2855S.6
2865S.6
TRW - TAS30
ZF 8090
Cooling system
Total capacity
Cab tipping system
Print 603.93.381
GENERAL SPECIFICATIONS
13
Description
FL Products
Engine oil
Compliant with ACEA E2 specifications
Urania Turbo
Engine oil
Compliant with ACEA E3 and ACEA E5 specifications
Urania LD5
SAE 80W/90
SAE 85W/140
Tutela ZC 90
Tutela GI/A
Tutela MR 2
Tutela MR 3
SP 349
Grease for general use, suitable for components not requiring special
grease (e.g., joints, pins and pivots, levers, tie rods, sliding shoes, brake
callipers, etc.)
Lithium-soap base grease, N.L.G.I. n. 2
Tutela Zeta 2
Tutela LHM
Arexons DP1
Paraflu 11
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14
GENERAL SPECIFICATIONS
Print 603.93.381
ENGINE
SECTION 2
Engine
Page
ENGINE IDENTIFICATION CODE . . . . . . . . . .
- Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE REMOVAL/REFITTING . . . . . . . . . . . .
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INJECTOR REPLACEMENT . . . . . . . . . . . . . . . .
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
Print 603.93.381
12
13
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
ENGINE F4 AE 0481 . . . . . . . . . . . . . . . . . . . . .
19
ENGINE F4 AE 0681 . . . . . . . . . . . . . . . . . . . . .
115
TROUBLESHOOTING GUIDE . . . . . . . . . . . . .
141
ENGINE
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ENGINE
4 = 4 cylind.
6 = 6 cylind.
8 = DI. TCA
1 = Truck
2 = Bus
4 = M.T. vehicles
and tractors
6 = Marine
9 = Army
0681
0481
0681
0481
0681
0481
0681
0681
Print 603.93.381
A=
A=
B=
C=
D=
D=
E=
F=
202
125
176
110
154
95
134
202
kW kW kW kW kW kW kW kW -
(275 HP) 2700 rpm (170 HP) 2700 rpm (240 HP) 2700 rpm (150 HP) 2700 rpm (210 HP) 2700 rpm (130 HP) 2700 rpm (182 HP) 2700 rpm (275 HP) 2500 rpm -
ENGINE
Figure 1
70126
Injector
It is not necessary and permitted to disassemble the fuel
nozzle or the electromagnet.
Print 603.93.381
ENGINE
ENGINE REMOVAL/REFITTING
Figure 2
Removal
Lift the radiator grille and tilt the cab. Remove the
gearbox as described in the relevant section and
then proceed as follows:
- Drain engine coolant into a proper container.
- Drain power steering system oil into a proper container.
Working from the left side of the engine:
- Disconnect the pipes (18) from the turbosupercharger
(13) and the air cleaner and the intake pipe from the
turbine (on the right side).
- Loosen the relevant chassis fastening bolts to remove
the intake duct (16) including the support.
- Disconnect the air duct (15).
- Loosen the fastening screws (6), the nut (5), remove the
supporting bracket (4) and move the gearshift lever (17)
to the right.
- Disconnect delivery (11) and return (10) pipe from the
power steering pump.
- Loosen clamps (1) and remove the aftercooler pipe (2).
- Disconnect fuel delivery pipes (9) from the control unit
and the return pipes (12) from the fuel filter support.
- Disconnect sump oil filling pipe (3).
- Disconnect the connector (8) from the control unit and
also all engine connections arriving from chassis wiring.
62242
Print 603.93.381
ENGINE
Figure 3
62241
Print 603.93.381
Refitting
ENGINE
- that there are no oil leaks between the cover and the
cylinder head, between oil sump and engine block,
between heat exchanger oil filter and the relevant
housings and between the different pipes in the
lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes;
- check that the exhaust pipe and its elastic fixing elements
are not worn or about to deteriorate, replace if required;
- tighten screws or nuts to the specified torque;
General indications
Figure 4
Figure 5
3
4
Print 603.93.381
ENGINE
personal burns;
engine damages since system pressurisation is obtained only with coolant heating from cold engine.
542011
501430
Figure 6
70471
Print 603.93.381
ENGINE
INJECTOR REPLACEMENT
Removal
Figure 9
Figure 7
99220
70473
Figure 8
70133
Refitting
Figure 11
70131
Remove the nuts (7) and disconnect the electric cables from
the injectors (8).
Remove the screws (1) and disconnect injector wiring
support (2) including the seal.
Remove the screws (5) and disconnect the air
temperature/pressure sensor (6).
Remove the nuts (3) and remove fuel manifolds (4).
70338
Print 603.93.381
Fit a new sealing ring (2) lubricated with vaseline and a new
sealing washer (3) on the injector (1).
10
ENGINE
Figure 12
Figure 14
70342
70339
Fit injectors (1) into cylinder head seats directed with the fuel
hole (2) facing the fuel manifold seat side (3).
Screw the fastening screws without tightening them.
Figure 15
Figure 13
70346
91572
Fit a new sealing ring (3), lubricated with vaseline on the fuel
manifold (2) and insert it into the cylinder head seat to make
the position ball (5) coinciding with the relevant housing (4).
Print 603.93.381
ENGINE
11
Figure 16
four-cylinder engine
cylinder No.
intake
exhaust
1
-
2
*
3
*
-
4
*
*
Figure 17
1
*
*
six-cylinder engine
cylinder No.
1
2
intake
exhaust
*
2
*
-
3
*
3
*
-
4
*
4
-
5
*
-
6
*
*
Print 603.93.381
78256
Apply tool 99340055 (4) on the engine shaft front tang (2)
and drill the inner sealing ring (1) with a drilling machine (
3.5 mm) through the tool guide holes for a depth of 5
mm.Fasten the tool (4) to the ring (1) with the 6 provided
screws and remove the ring by tightening the screw (3).
12
ENGINE
REPLACEMENT
SEALING RING
Figure 18
OF
FLYWHEEL
CASE
Figure 20
78257
78258
Apply tool 99340056 on the engine shaft front tang (2) and
drill the inner sealing ring (1) with a drilling machine ( 3.5
mm) through the tool guide holes for a depth of 5 mm.
Fasten the tool (3) to the ring (1) with the 6 provided screws
and remove the ring by tightening the screw (2).
Remove the outer sealing ring as illustrated and described in
Figure 18.
Figure 19
Figure 21
70225
Apply tool 99346252 part (5) to the front output shaft tang
(6), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into front cover (7).
70216
Apply tool 99346252 part (5) to the rear output shaft tang
(6), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into flywheel housing (7).
Print 603.93.381
ENGINE
13
Figure 22
Lift the radiator grille, tilt the cab and then proceed as
follows:
- drain coolant partially into a proper container;
- disconnect the coolant pipe (2) from the
thermostat cover;
- disconnect the air duct (3) from the intake manifold;
- disconnect the following electrical connections:
(4) heater;
(12) injectors;
70474
Print 603.93.381
14
ENGINE
Figure 23
and
drain
pipes
from
70475
Print 603.93.381
ENGINE
Refitting
For refitting, reverse the removal procedure observing the
following indications:
cylinder head and engine block coupling surfaces shall be
clean;
take care not to foul the cylinder head gasket.
Fit the cylinder head and tighten the screws in three
successive stages following the sequence and the procedure
shown in the figures below.
15
Figure 24
4-cylinder engine
70337
Figure 25
6-cylinder engine
70476
Print 603.93.381
- that there are no oil leaks between the cover and the
cylinder head, between oil sump and engine block,
between heat exchanger oil filter and the relevant
housings and between the different pipes in the
lubricating circuit;
- that there are no fuel leaks from the fuel pipes;
- that there are no air leaks from pneumatic pipes;
- check also proper operation of the warning lights set on
the instrument panel and of the equipment
disconnected when engine was removed.
16
ENGINE
Print 603.93.381
ENGINE F4 AE 0481
70756
ENGINE F4 AE 0481
19
Engine F4 AE 0481
Page
Print 603.93.381
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .
21
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . .
24
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .
30
AUXILIARY COMPONENTS . . . . . . . . . . . . . . .
32
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
ENGINE OVERHAUL . . . . . . . . . . . . . . . . . . . . .
40
40
REPAIR OPERATIONS . . . . . . . . . . . . . . . . . . . .
48
CYLINDER UNIT . . . . . . . . . . . . . . . . . . . . . . . .
48
48
49
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
49
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
50
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
- Bush replacement . . . . . . . . . . . . . . . . . . . . . .
51
- Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
51
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .
52
52
54
54
54
55
55
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
56
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
57
- Split rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .
58
- Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
59
20
ENGINE F4 AE 0481
- Checking torsion . . . . . . . . . . . . . . . . . . . . . . .
Page
59
Page
86
- Checking bending . . . . . . . . . . . . . . . . . . . . . .
59
87
59
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
89
59
- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . .
91
60
- Viscous fan . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
60
BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
61
- Turbosupercharger . . . . . . . . . . . . . . . . . . . . .
92
62
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
62
- Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TURBOSUPERCHARGER ACTUATOR . . . . . . .
93
63
- Flywheel housing . . . . . . . . . . . . . . . . . . . . . . .
93
63
- Actuator replacement . . . . . . . . . . . . . . . . . . .
93
ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . .
64
TURBOSUPERCHARGER LAYOUT . . . . . . . . . .
95
64
COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . .
97
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .
68
- General Specifications . . . . . . . . . . . . . . . . . . .
97
68
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . .
99
69
101
69
FUEL PREFILTER . . . . . . . . . . . . . . . . . . . . . . . . .
103
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
70
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103
70
104
104
104
- Drain conditions . . . . . . . . . . . . . . . . . . . . . . .
104
105
106
- Operating principle . . . . . . . . . . . . . . . . . . . . .
107
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
110
INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
111
- Injection start . . . . . . . . . . . . . . . . . . . . . . . . .
111
- Injection end . . . . . . . . . . . . . . . . . . . . . . . . . .
111
111
71
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
71
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .
73
73
73
- Assembling electro-injectors . . . . . . . . . . . . . .
74
RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
75
- Rocker assembly . . . . . . . . . . . . . . . . . . . . . . .
75
76
- Intake manifold . . . . . . . . . . . . . . . . . . . . . . . .
77
- Wiring support . . . . . . . . . . . . . . . . . . . . . . . .
79
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .
83
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . .
85
Print 603.93.381
ENGINE F4 AE 0481
21
GENERAL SPECIFICATIONS
F4AE0481D
(.13)
Type
F4AE0481C
(.15)
Cycle
Power
Injection
F4AE0481A
(.17)
Direct
Number of cylinders
4 in-line
Bore
mm
102
Stroke
mm
120
cm3
3900
Compression ratio
Max. output
Max. torque
Print 603.93.381
17 : 1
kW
(HP)
95
(130)
110
(150)
125
(170)
rpm
Nm
(kgm)
2700
430
(43.9)
2700
490
(50)
2700
560
57.1
rpm
1200
1200
1200
Loadless engine
idling
rpm
750
Loadless engine
peak rpm
rpm
3000
22
ENGINE F4 AE 0481
F4AE0481D
(.13)
Type
F4AE0481C
(.15)
SUPERCHARGER
With intercooler
turbosupercharger type
GARRETT GT 22
F4AE0481A
(.17)
mm
bar
bar
LUBRICATION
bar
bar
bar
COOLING
ACEA E3/E5
Urania LD5
1.2
3.8
81 2 C
96 C
FILLING
Total capacity
1st filling:
litres
kg
- engine sump
litres
kg
Min. level.
5.3
4.8
Max. level
8.3
7.5
litres
6.3
9.3
kg
5.7
8.4
Print 603.93.381
ENGINE F4 AE 0481
F4AE0481D
(.13)
Type
F4AE0481C
(.15)
23
F4AE0481A
(.17)
TIMING
start before T.D.C.
end after B.D.C.
A
B
8.5
8.5
D
C
51
12.5
Checking timing
mm
mm
mm
0.20 to 0.30
mm
0.46 to 0.56
Bosch
X
X
Checking operation
X
FUEL FEED
Injection
Type:
Nozzle type
Injectors
Injection sequence
1-3-4-2
bar
Injection pressure
Print 603.93.381
bar
250 - 1450
24
ENGINE F4 AE 0481
CLEARANCE DATA
F4AE0481D
(.13)
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
1
X
1
X
2
F4AE0481C
(.15)
F4AE0481A
(.17)
mm
102.009 to 102.031
Cylinder barrels
Spare pistons
type:
Size
Outside diameter
Pin housing
X
60.5
1 101.731 to 101.749
2 40.010 to 40.016
60.5
101.781 to 101.799
40.008 to 40.014
0.116 to 0.134
Piston diameter
Piston protrusion
0.5
Piston pin
Piston pin pin housing
0.28 to 0.52
39.9938 to 40.0002
0.0098 to 0.0222
0.0078 to 0.0202
Print 603.93.381
ENGINE F4 AE 0481
F4AE0481D
(.13)
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
X1
X2
X3
S 1
S 2
S 3
X1*
X2
X3
Split rings
S 1*
S2
S3
F4AE0481C
(.15)
25
F4AE0481A
(.17)
mm
2.705 to 2.735
2.430 to 2.450
4.040 to 4.060
2.705 to 2.735
2.420 to 2.440
4.020 to 4.040
2.560 to 2.605
2.350 to 2.380
3.975 to 4.000
* measured on 99 mm
Split rings - slots
1
2
3
Split rings
X1
X2
0.100 to 0.175
0.040 to 0.90
0.020 to 0.065
0.5
X3
0.100 to 0.175
0.050 to 0.100
0.040 to 0.085
X1
X2
X3
0.30 to 0.40
0.60 to 0.80
0.25 to 0.55
42.987 to 43.013
72.987 to 73.013
4
3
S
Print 603.93.381
43.279 to 43.553
40.019 to 40.033
1.955 to 1.968
0.266 to 0.566
0.0188 to 0.0392
0.250; 0.500
26
ENGINE F4 AE 0481
F4AE0481D
(.13)
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
F4AE0481C
(.15)
F4AE0481A
(.17)
mm
X
Size
Max. tolerance
on connecting rod
axis alignment
1
S1
Journals
Crankpins
1
2
82.99 to 83.01
68.997 to 69.013
S1
S2
2.456 to 2.464
1.955 to 1.968
3
3
87.982 to 88.008
87.982 to 88.008
S 2
*provided as spare part
Main bearings
No. 1 3 4 5
No. 2
Half bearings Journals
No. 1 3 4 5
No. 2
0.041 to 0.103
0.041 to 0.103
0.033 to 0.041
0.250; 0.500
Shoulder journal
X1
37.475 to 37.545
X2
32.23
Shoulder half-rings
X3
32.30
X1
X2
0.07
Print 603.93.381
ENGINE F4 AE 0481
F4AE0481D
(.13)
Type
CYLINDER HEAD TIMING SYSTEM
1
F4AE0481A
(.17)
mm
F4AE0481C
(.15)
27
7.042 to 7.062
6.970 to 6.990
60o 0.25o
6.970 to 6.990
45o 0.25o
Valves:
0.052 to 0.092
34.837 to 34.863
34.837 to 34.863
Sinking
Between valve seat
and head
Valve seats
Print 603.93.381
34.917 to 34.931
60o
34.917 to 34.931
45o
0.59 to 1.11
0.96 to 1.48
0.054 to 0.094
0.054 to 0.094
-
28
ENGINE F4 AE 0481
F4AE0481D
(.13)
Type
CYLINDER HEAD TIMING SYSTEM
F4AE0481C
(.15)
F4AE0481A
(.17)
mm
H1
H2
free spring
47.75
H1
H2
35.33
25.2
Injector protrusion
Not adjustable
X
Camshaft bush
housings No. 1-5
59.222 to 59.248
Camshaft housings
No. 2-3-4
59.222 to 59.248
Camshaft journals:
15
1-2-3
53.995 to 54.045
59.222 to 59,248
Bush inside
diameter after driving
54.083 to 54.147
1 23 4 5
2
0.113 to 0.165
0.038 to 0.152
Cam lift:
H
6.045
7.582
Print 603.93.381
ENGINE F4 AE 0481
F4AE0481D
(.13)
Type
CYLINDER HEAD TIMING SYSTEM
F4AE0481C
(.15)
29
F4AE0481A
(.17)
mm
1
Tappet cap housing
on block
2
3
16.000 to 16.030
2
3
15.924 to 15.954
15.960 to 15.975
0.025 to 0.070
-
1
Rocker shaft
21.965 to 21.977
Rockers
22.001 to 22.027
2
Between rockers and shaft
Print 603.93.381
0.024 to 0.162
30
ENGINE F4 AE 0481
TIGHTENING TORQUE
COMPONENT
TORQUE
1st stage
2nd stage
3rdd stage
1st stage
2nd stage
Nm
15 3
50 6
80 6
kgm
1.5 0.3
5 0.6
8 0.6
90 5
82
12 2
77 12
47 5
24 4
10 2
81
24 4
24 4
24 4
36 4
60 5
0.8 0.2
1.2 0.2
7.7 1.2
4.7 0.5
2.4 0.4
1 0.2
0.8 0.1
2.4 0.4
2.4 0.4
2.4 0.4
3.6 0.4
6 0.5
60 5
43 5
105 5
24 4
24 4
36 5
12 2
8.5 0.35
50 5
82
24 4
77 12
24 4
20 2
35 5
4.3 0.4
10.5 0.5
2,4 0,4
2.4 0.4
3.6 0.5
1.2 0.2
0.85 0.035
5 0.5
0.8 0.2
2.4 0.4
7.7 1.2
2.4 0.4
2 0.2
3.5 0.5
55 5
5.5 0.5
90 5
90 5
36 5
3.6 0.5
24 4
2.4 0.4
20 2
2 0.2
24 4
2.4 0.4
10 2
1 0.2
24 4
2.4 0.4
1,5 0,25
0.15 0.025
77 8
7.7 0.8
24 4
2.4 0.4
contact + 3/4 turn
80 8
8 0.8
24 4
2.4 0.4
contact + 3/4 turn
Print 603.93.381
ENGINE F4 AE 0481
COMPONENT
TORQUE
{ pins
nuts
{ pins
nuts
Nm
24 4
10 2
43 6
24 4
22 2
10 2
10 2
53 5
50 5
kgm
2.4 0.4
1 0.2
4.3 0.6
2.4 0.4
2.2 0.2
1 0.2
1 0.2
5.3 0.5
5 0.5
90
68 7
24 4
43 6
43 6
85 10
49 5
10 2
24 4
12 2
24 4
82
82
20 3
61
35 5
20 3
61
12 2
M8
M8
71
43 6
M8
M8
71
24 4
Print 603.93.381
31
6.8 0.7
2.4 0.4
4.3 0.6
4.3 0.6
8.5 1
4.9 0.5
1 0.2
2.4 0.4
1.2 0.2
2.4 0.4
0.8 0.2
0.8 0.2
2 0.3
0.6 0.1
3.5 0.5
2 0.3
0.6 0.1
1.2 0.2
0.7 0.1
4 3 0.6
4.3
06
00.7
7 00.1
1
2.4 0.4
3.5 0.5
3.5 0.5
4.3 0.6
2.4 0.4
1 0.2
3 0.4
35 5
35 5
43 6
24 4
10 2
30 4
60 5
24 4
24 4
2.4 0.4
2.4 0.4
32
ENGINE F4 AE 0481
AUXILIARY COMPONENTS
COMPONENT
TORQUE
Air compressor:
5/8 nut for fastening control gear on compressor shaft
Nut M12 for fastening to flywheel housing
Alternator:
Screw M10 for fastening bracket to water inlet connector
Nut M10 for fastening alternator
Ventilation and heating unit:
Screw M10 for fastening bracket
Screw M10 for fastening compressor
Starter:
Screw for fastening starter
Nm
kgm
125 19
77 12
12.5 1.9
7.7 1.2
43 6
43 6
4.3 0.6
4.3 0.6
43 6
24 4
4.3 0.6
2.4 0.4
43 6
4.3 0.6
TOOLS
TOOL No.
DEFINITION
99305018
99305047
99317915
99322205
Revolving stand for overhauling units (capacity 1000 daN, torque 120
daNm)
Print 603.93.381
ENGINE F4 AE 0481
33
TOOLS
TOOL No.
DEFINITION
99340055
99340056
99341001
99341009
Pair of brackets
99342101
99346252
Print 603.93.381
34
ENGINE F4 AE 0481
TOOLS
TOOL No.
DEFINITION
99346253
99355019
Wrench (10 mm) for hydraulic power steering pump retaining screw
99360076
99360183
99360268
99360292
Print 603.93.381
ENGINE F4 AE 0481
35
TOOLS
TOOL No.
DEFINITION
99360330
99360351
99360362
99360500
99360595
99360605
Band for fitting piston into cylinder barrel (60 125 mm)
Print 603.93.381
36
ENGINE F4 AE 0481
TOOLS
TOOL No.
DEFINITION
99361037
99363204
99367121
99370006
99370415
99389829
Print 603.93.381
ENGINE F4 AE 0481
37
TOOLS
TOOL No.
DEFINITION
99389834
99395216
Pair of gauges with 1/2 and 3/4 square head for angle tightening
99395220
99395363
99395603
99395687
Print 603.93.381
38
ENGINE F4 AE 0481
Figure 1
99221
Print 603.93.381
ENGINE F4 AE 0481
39
Figure 2
70478
Print 603.93.381
40
ENGINE F4 AE 0481
ENGINE OVERHAUL
540110 ENGINE REMOVAL
BENCH
AT
THE
Figure 5
Figure 3
70127
70125
Disconnect the pipe (3) from the connection (4) and from
supercharger (8).
Disconnect the fuel pipe (2) from the rail and from the high
pressure pump (9), remove the fastening screws (4 and 6) and
remove it from the engine block.
Figure 4
NOTE
70126
70128
Remove the screws (2) and remove the oil pipe (3) from the
supercharger pipe (1) and from the engine block.
Remove the starter (5) from the flywheel housing (4).
Apply brackets 99361037 to engine block and use them to
secure the engine to the revolving stand 99322205. Remove
sump cap and drain out oil.
Remove the fan from the output shaft pulley.
Print 603.93.381
ENGINE F4 AE 0481
41
Figure 7
78670
1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and
pressure sensor - 5. Output shaft sensor - 6. Injector - 7. Air temperature/pressure sensor - 8. Timing sensor - 9. Fuel heater
and fuel temperature sensor - 10. Pressure limiter - 11. EDC7 ECU.
Disconnect the engine cable by disconnecting the
connectors: (1) from injector wiring (6); (7) air
pressure/temperature sensor; (3) fuel pressure sensor; (11)
ECU; (10) high pressure pump sensor; (8) timing sensor; (2)
engine coolant temperature sensor on thermostat; (5)
engine speed sensor;
Figure 8
91576
Disconnect from the rail (2): the fuel pipe (4) according to
procedures described in figure (29). Disconnect fuel pipes (5)
from rail (2) and injector manifolds (3).
Remove the screws (1) and disconnect the rail (2).
Print 603.93.381
42
ENGINE F4 AE 0481
Figure 9
Figure 11
70130
70132
Figure 10
70133
70134
Remove screw (4), loosen clamp (2) and disconnect air duct
(1) from turbosupercharger (3).
Print 603.93.381
ENGINE F4 AE 0481
Figure 14
43
Figure 16
70137
70135
Remove the screw (4) fastening the oil pipe clamp (5) to the
exhaust manifold (1).
Disconnect the oil pipe (5) from the heat exchanger/oil filter
support (7).
Figure 15
70138
70136
Remove the screws (1) and disconnect the air duct (2)
including the heater. Remove the screws (4), and take out the
cover (3) and the thermostat set underneath.
Remove the cylinder head (6) fastening screws (5).
70139
Print 603.93.381
44
ENGINE F4 AE 0481
Figure 19
Figure 21
70140
70142
Remove the screws (1) and disconnect the ECU (2) including
the heat exchanger.
Figure 22
70141
70143
the oil
Figure 23
70144
Remove the screws (2) and the nuts (1-4) and disconnect the
air compressor (3).
Print 603.93.381
45
ENGINE F4 AE 0481
Figure 24
Figure 27
70145
Remove the nut (1) and disconnect the timing sensor (2).
Remove the nuts (3) and disconnect the high pressure pump
(4) including the feed pump (5).
Figure 25
70148
Remove the screws (1) and disconnect the water pump (2).
Remove the screw (3) and the roller (4).
Remove the screw (5) and disconnect the engine speed
sensor (6).
Figure 28
70149
Remove the screws (1) and take out the front cover (2).
70146
Figure 29
70340
Remove the screws (1) and disconnect the oil pump (2).
70150
Remove the screws (2) and remove the pulley (3) and the
damper flywheel (1).
Remove the screws (6) and remove the hub (5) and the
phonic wheel (4).
Print 603.93.381
46
ENGINE F4 AE 0481
Figure 30
Figure 33
70151
70154
70152
Screw two pins (2) having proper length into the output shaft
(3) holes.
Withdraw the engine flywheel (1) to sling it with the hoist
and put it into the proper container.
Figure 32
99222
Remove the screws (1) and disassemble the oil suction rose
pipe (3).
Remove the screws (2) and disassemble the stiffening plate
(4).
Figure 35
70153
Remove the screws (1) and take out the rear cover (2).
70156
Remove the screws (1) and remove the gear (3) from the
camshaft (2).
Print 603.93.381
47
ENGINE F4 AE 0481
Figure 36
Figure 39
70157
Remove the screws (2) and disconnect the timing gear case
(1).
NOTE Take note of screw (2) assembling positions since
they have different sizes.
Figure 37
70160
The second last main bearing cap (1) and the relevant
support are fitted with shoulder half-bearing (2).
NOTE Take note of lower and upper half-bearing
assembling positions since in case of reuse they
shall be fitted in the same position found at
removal.
Figure 40
70158
Remove the screws (1) fastening the connecting rod caps (2)
and remove them.
Withdraw the pistons including the connecting rods from the
top of the engine block.
NOTE Keep the half-bearings into their housings since in
case of use they shall be fitted in the same position
found at removal.
70161
Use tool 99360500 (1) and hoist to remove the output shaft
(2) from the block.
Figure 41
Figure 38
70162
70159
Remove the screws (1) and the main bearing caps (2).
Print 603.93.381
48
ENGINE F4 AE 0481
zs
REPAIR OPERATIONS
540410 CYLINDER UNIT
540420 Checks and measurements
Figure 42
Figure 45
70163
Figure 43
Figure 46
Withdraw carefully the camshaft (1) from the engine block.
Figure 44
70167
ENGINE F4 AE 0481
49
Figure 47
Figure 48
70170
70168
!
NOTE In case of regrinding, all barrels shall have the same
oversize (0.5 mm).
5412
541210
TIMING SYSTEM
Camshaft
Figure 49
70169
50
ENGINE F4 AE 0481
541211
Set the camshaft on the tailstock and using a 1/100 gauge set
on the central support, check whether the alignment error
is not exceeding 0.04 mm, otherwise replace the camshaft.
Check cam lift; found values shall be: 6.045 mm for exhaust
cams and 7.582 mm for intake cams, in case of different values
replace the camshaft.
541213
BUSHES
Figure 51
Figure 50
70172
Figure 52
85484
Print 603.93.381
541213
ENGINE F4 AE 0481
Bush replacement
51
Figure 53
70176
70174
To replace front and rear bushes (1), remove and refit them
using the beater 99360362 (2) and the handgrip 99370006
(3).
Lubricate the tappets (1) and fit them into the relevant
housings on the engine block.
Figure 56
70164
Lubricate the camshaft bushes and fit the camshaft (1) taking
care not to damage the bushes or the housings.
541224
Tappets
Figure 57
Figure 54
70238
70175
Set camshaft (3) retaining plate (1) with the slot facing the
top of the engine block and the marking facing the operator,
then tighten the screws (2) to the specified torque.
52
ENGINE F4 AE 0481
5408
540810
Figure 58
OUTPUT SHAFT
Measuring journals and crankpins
Figure 60
70179
70182
Figure 59
!
70180
Fit nozzles (2) and tighten the fastening screws (1) to the
specified torque.
Figure 61
70181
TABLE FOR VALUES RESULTING FROM ENGINE SHAFT MAIN JOURNAL AND CONNECTING ROD PIN
MEASUREMENT
* nominal value
Base October 2004
Print 603.93.381
53
ENGINE F4 AE 0481
Figure 62
70183
TOLERANCE CHARACTERISTIC
Roundness
Cilindricity
Parallelism
Verticality
Straightness
Concentricity or coaxiality
Circular oscillation
Total oscillation
Taper
GRAPHIC SYMBOL
f
/f/
//
GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
INTERMEDIATE MAIN
BEARINGS
70237
Print 603.93.381
54
ENGINE F4 AE 0481
549215
540811
Figure 65
Figure 63
70161
70186
- fit caps (1), including the half bearings (2) on the relevant
supports.
Figure 67
70187
ENGINE F4 AE 0481
55
Figure 68
Figure 70
70188
3rd
Figure 69
70190
540830
70189
Figure 71
70191
Print 603.93.381
56
ENGINE F4 AE 0481
540840 Pistons
Measuring piston diameters
Figure 72
Figure 75
32615
32613
Remove split rings (1) from piston (2) using pliers 99360183
(3).
Figure 73
Figure 76
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
70192
The clearance between the piston and the cylinder barrel can
be checked also with a feeler gauge (1) as shown in the figure.
Figure 74
79455
Print 603.93.381
540841
57
ENGINE F4 AE 0481
Piston pins
Figure 80
Figure 77
18857
32620
Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relevant housings on the piston (2), using
a feeler gauge (1).
Figure 81
32619
Lubricate the pin (1) and its seat on piston hubs with engine
oil; the pin shall be fitted into the piston with a slight finger
pressure and shall not be withdrawn by gravity.
540842
41104
Split rings
Figure 79
16552
Print 603.93.381
58
ENGINE F4 AE 0481
Figure 82
Figure 84
CONNECTING
WEIGHT
ROD NO.
70194
540830
Connecting rods
CONNECTING ROD
NO.
YEAR
DAY
Figure 83
70196
540834
Bushes
Check that the bush in the connecting rod small end is free
from scoring or seizing and that it is not loosen. Otherwise
replace.
ENGINE F4 AE 0481
59
Checking bending
Figure 85
Figure 87
61695
61696
Check that the axes of the connecting rods (1) are parallel
using tool 99395363 (5) as follows:
- fit the connecting rod (1) on tool 99395363 (5) spindle
and lock it with screw (4);
- set the spindle (3) on V-blocks by resting the connecting
rod (1) on the stop bar (2).
Checking torsion
Figure 86
70198
61694
60
ENGINE F4 AE 0481
Figure 89
Figure 92
70199
Connect piston (2) to connecting rod (4) with pin (3) so that
the reference arrow (1) for fitting the piston (2) into the
cylinder barrel and the numbers (5) marked on the
connecting rod (5) are read as shown in the figure.
Figure 90
70200
32614
Figure 91
70201
32613
Use pliers 99360183 (3) to fit the split rings (1) on the piston
(2).
Split rings shall be fitted with the marking TOP facing
upwards and their openings shall be displaced with each
other by 120.
Base October 2004
ENGINE F4 AE 0481
Figure 94
61
Figure 96
70204
70202
- Lubricate the screws (1) with engine oil and then tighten
them to the specified torque using the dynamometric
wrench (2).
Figure 97
540831
Figure 95
70205
Figure 98
70203
Print 603.93.381
70206
62
ENGINE F4 AE 0481
Figure 99
Figure 101
70207
70209
Figure 100
70208
70210
Print 603.93.381
63
ENGINE F4 AE 0481
Timing
540460
Figure 103
Flywheel housing
Figure 106
70214
70211
Use a felt pen to mark the driving gear (1) tooth fitted on the
output shaft (2) having the mark () for timing on the side
surface.
Figure 104
Direct the output shaft (4) and the camshaft (2) so that when
fitting the driven gear (1) on the camshaft the marks on the
gears (1 and 3) are coinciding.
Figure 107
Figure 105
70215
70213
Print 603.93.381
Refit the housing (1) to the engine block and screw the
fastening screws in the same position found at removal and
tighten them to the following torque values in the sequence
shown in the figure:
Screws M12
75 to 95 Nm
Screws M10
44 to 53 Nm
64
ENGINE F4 AE 0481
Figure 108
Figure 110
70152
70216
Apply tool 99346252 part (5) to the rear output shaft tang
(6), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into flywheel housing (7).
540850
Screw two pins (2) having suitable length into shaft holes (3)
and remove the engine flywheel (1) using proper sling and
hoister.
Figure 111
ENGINE FLYWHEEL
Figure 109
70218
540853
70219
Print 603.93.381
ENGINE F4 AE 0481
Figure 113
65
Figure 116
70223
70220
Remove the sealing ring (2) from the front cover (1), clean
accurately the coupling surfaces and smear them with IVECO
n. 2992595.
Figure 117
Figure 114
70224
70221
Clean accurately the front cover (2) surface and refit it.
Tighten the screws (1) to the specified torque.
Figure 118
Figure 115
70225
70222
Print 603.93.381
Apply tool 99346252 part (5) to the front output shaft tang
(6), secure it by screws (4) and fit the new sealing ring (3).
Position part (1) on part (5), screw nut (2) until completing
sealing ring (3) fitting into front cover (7).
66
ENGINE F4 AE 0481
Figure 119
Figure 122
99223
70363
Fit the plate (1), the rose pipe (2) and tighten the fastening
screws (3) to the specified torque.
Fit the phonic wheel (1) and the hub (2) on the output shaft.
Tighten the fastening screws (3) in two stages:
- 1st stage, tightening to 50 5 Nm torque with
dynamometric wrench;
Figure 120
Figure 121
70230
Fit the oil sump (1) and apply the plate (3) to it.
Tighten the screws (2) to the specified torque.
Print 603.93.381
ENGINE F4 AE 0481
Figure 124
67
Figure 126
70231
70234
Fit on the engine block: a new gasket (1), the heat exchanger
(2) a new gasket (3) and the oil filter support (4).
Figure 125
Figure 127
70232
Lubricate the sealing ring (2) with engine oil and set it on the
oil filter (3).
Screw manually to seat the oil filter (3) on the support
connection (1) and then screw again the oil filter (3) by 3/4
turn.
70139
Figure 128
70235
68
ENGINE F4 AE 0481
Figure 129
Figure 132
70145
70320
Refit the high pressure pump (4) including the feed pump (5)
and tighten the nuts (3) to the specified torque. Fit the
support (4) with a new sealing ring, the timing sensor (2) with
a new sealing ring and tighten the relevant fastening nut (1)
to the specified torque.
Refit the ECU (3) including the heat exchanger to the engine
block and tighten the screws (2) to the specified torque.
Figure 130
540610
540662
CYLINDER HEAD
Removing the valves
Figure 133
70144
Refit the air compressor (3). Tighten the screws (2) and the
nuts (1 and 4) to the specified torque.
Figure 131
70319
Intake (1) and exhaust (2) valves have heads with the same
diameter.
The central notch () of the exhaust valve (2) head
distinguishes it from the intake valve.
NOTE Should cylinder head valves be not replaced,
number them before removing in order to refit
them in the same position.
70143
Refit the hydraulic power steering pump (2) including the oil
tank (4) to the air compressor (5).
Use wrench 99355019 to tighten the fastening screws (3) to
the specified torque.
Base October 2004
Print 603.93.381
ENGINE F4 AE 0481
69
Figure 134
Figure 136
70321
70323
Figure 135
70322
70324
Use a rule (2) and a feeler gauge (3) to check the cylinder
head (1) supporting surface.
Distortion found along the whole cylinder head shall not
exceed 0.20 mm.
If higher values are found grind the cylinder head according
to values and indications shown in the following figure.
Print 603.93.381
70
ENGINE F4 AE 0481
Figure 138
Figure 140
18625
70325
The rated thickness A for the cylinder head is 105 0.25 mm,
max. metal removal shall not exceed thickness B by 0.13 mm.
After grinding, check valve sinking. Regrind the valve
seats, if required, to obtain the specified value.
540662
VALVES
Figure 139
EXHAUST
VALVE
INTAKE
VALVE
18882
70326
70327
Use a magnetic base dial gauge (1) set as shown in the figure,
the assembling clearance shall be 0.052 to 0.092 mm.
Turn the valve (2) and check that the centering error is not
exceeding 0.03 mm.
Base October 2004
Print 603.93.381
540667
ENGINE F4 AE 0481
71
VALVE GUIDE
VALVE SEATS
Regrinding replacing the valve seats
Figure 143
Figure 144
70330
INTAKE
INTAKE
EXHAUST
EXHAUST
79457
Figure 145
EXHAUST
EXHAUST
INTAKE
INTAKE
85486
Print 603.93.381
72
ENGINE F4 AE 0481
Figure 146
EXHAUST
INTAKE
70332
Figure 147
70333
Print 603.93.381
540665
ENGINE F4 AE 0481
73
VALVE SPRINGS
Figure 148
Figure 150
50676
770321
Position on the cylinder head: the spring (4), the upper cap
(3); use tool 99360268 (1) to compress the spring (4) and
lock the parts to the valve (5) by the cotters (2).
H
H1
H2
Height
mm
47.75
35.33
25.2
Under a load of
N
Free
P1
339.8 19 Nm
P2
741 39 Nm
Lubricate the valve stems (1) and fit them into the relevant
valve guides according to the position marked at removal.
Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and
sealing rings (3) for exhaust valves are green.
Print 603.93.381
74
ENGINE F4 AE 0481
Assembling electro-injectors
Figure 152
Figure 154
70338
70336
Refit the cylinder head (1), tighten the screws (2) in three
successive stages according to the sequence and procedure
shown in the following figure.
Fit a new sealing ring (2) lubricated with vaseline and a new
sealing washer (3) on injector (1).
Figure 155
Figure 153
70339
Figure 156
70133
Use tool 99342101 (1) to fit the injector (2) into its seat.
Screw injector fastening screws without tightening them.
Print 603.93.381
ENGINE F4 AE 0481
541221
Figure 157
75
RODS
Figure 159
32655
91572
Fit a new sealing ring (3) lubricated with vaseline on the fuel
manifold (2) and fit it into the cylinder head seat so that the
positioning balls (5) coincide with the relevant housing (4).
501230
NOTE Disassembled fuel manifolds (2) must not be used
again, but however replaced with other new ones.
Rocker assembly
Figure 160
Figure 158
70343
70342
70344
76
ENGINE F4 AE 0481
Figure 164
70520
70345
Figure 163
cylinder No.
intake
exhaust
1
-
2
*
3
*
-
4
*
*
70346
Print 603.93.381
ENGINE F4 AE 0481
77
Intake manifold
Figure 165
70347
The intake manifold (4) houses the air heater (5) for cold
starting. In case of failure it shall be replaced by removing the
cap (6), the nuts (1), the sealing washers (2) and the washers
(3). Fit the new heater (5) following the removal operations
in reverse order.
Print 603.93.381
78
ENGINE F4 AE 0481
Figure 166
Figure 169
70348
99226
Figure 167
Connect the fuel pipe (2) to the rail (1) following the
procedure shown in the following figure.
99224
Fit the rail (2) and tighten the screws (1) to the specified
torque, connect the ground cable (3) to the intake manifold
(4) and tighten the fastening nut (5) to the specified torque.
Figure 170
Figure 168
70126
99225
Connect the fuel pipes (1) to rail (3) and injector manifolds
(2).
Print 603.93.381
540634
ENGINE F4 AE 0481
Wiring support
79
Figure 174
Figure 171
70352
70355
Figure 175
Figure 172
99229
99227
Fit the wiring support (2) and tighten the screws (1) to the
specified torque.
Figure 173
Fit the tappet cover (1) and tighten the nuts (2) to the
specified torque.
Figure 176
99228
70357
Connect the electrical cables (1) to the injectors (3) and use
the dynamometric wrench 99389834 (4) to tighten the
fastening nuts (2) to the specified torque.
Print 603.93.381
80
ENGINE F4 AE 0481
Figure 177
Figure 179
70358
70360
Connect pipe (14) to tappet cover (19) and timing case (6)
with connections (13-15) and new copper washers.
Connect pipe (7) to timing case (6) connection and lock it
by the elastic clamp (8).
Fit a new sealing ring on pipe (11) connection and fit it on the
tappet cover (10).
Secure the pipe (11) to the tappet cover (10) with the clip
and the nut (12), connect pipe (4) to connection (5) and air
compressor (3).
Connect the pipe (2) to the pressure limiter (1) as shown in
the following figure.
Figure 178
Figure 180
70134
70126
Print 603.93.381
ENGINE F4 AE 0481
81
Figure 181
78670
1. Injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and
pressure sensor - 5. Output shaft sensor - 6. Injector - 7. Air temperature/pressure sensor - 8. Timing sensor - 9. Fuel heater
and fuel temperature sensor - 10. Pressure regulator - 11. EDC7 control unit
Print 603.93.381
82
ENGINE F4 AE 0481
Figure 182
Figure 184
70362
70128
Refit the bracket (2) including the fuel filter support (1) to the
engine block, tighten the screws (3) to the specified torque.
Figure 185
Fit the oil pipe (3) with a new sealing ring into the engine
block and secure it to the turbosupercharger (1) by the
screws (2) tightened to the specified torque.
Figure 183
70125
Screw manually the fuel filter to the support (1), screw the
filter by 3/4 turn, connect the pipes (2-3-4) to the relevant
support connections (1) as shown in the following figure.
Figure 186
70127
70126
Print 603.93.381
5450
ENGINE F4 AE 0481
83
LUBRICATION
Figure 187
2
3
Print 603.93.381
84
ENGINE F4 AE 0481
Print 603.93.381
543010
OIL PUMP
85
ENGINE F4 AE 0481
Figure 188
70576
543110
HEAT EXCHANGER
Figure 189
5
6
1
4
70480
1. Heat exchanger body with filter support - 2. Internal gasket - 3. Water-oil heat exchanger - 4. Gasket between heat
exchanger unit and engine block - 5. Oil pressure relief valve - 6. By-pass valve to cut out clogged oil filter.
Clean accurately the heat exchanger components
Always replace the sealing gaskets.
Print 603.93.381
86
ENGINE F4 AE 0481
543075
Figure 190
Loosen the plug (1), withdraw the spring (3) and the relief
valve (4) from the support (5).
Check whether the valve (4) is not scored and is sliding
smoothly into its seat. The spring (3) shall not be broken or
yielded.
Pressure regulation at 100C oil temperature:
- 1.2 bar min pressure;
- 3.8 bar max. pressure
Figure 191
70481
Figure 192
Flow
70482
6432
Max blow-by:
22 cm3/1 at 0.8 bar pressure and 26.7C temperature
Print 603.93.381
540480
87
ENGINE F4 AE 0481
Figure 193
70484
Oil condensate
Oil vapours
1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine
The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed
and condenses a part of vapours at the same time.
Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3).
In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again
through pipe (2).
Print 603.93.381
88
ENGINE F4 AE 0481
Print 603.93.381
5432
ENGINE F4 AE 0481
89
COOLING SYSTEM
Figure 194
Print 603.93.381
70485
90
ENGINE F4 AE 0481
Print 603.93.381
543210
91
ENGINE F4 AE 0481
Water Pump
Viscous fan
Figure 195
Figure 196
Sec. A-A
70486
The water pump is located in a housing obtained in the engine block and is controlled by and a poly-V belt.
An automatic tensioner keeps the belt tension.
70487
Characteristics:
Print 603.93.381
2700 rpm
Operating temperature:
92
ENGINE F4 AE 0481
543250
Thermostat
Description
The booster system is composed of: air cleaner, turbosupercharger and intercooler.
Figure 197
79458
The thermostat (1) of the by-pass type is located in the cylinder head and doesnt need regulations.
Whenever doubts on its operation are present, replace it.
On the thermostat body are fitted the thermometric transmitter/switch and water temperature sensor.
BOOSTER
542410
Turbosupercharger
Figure 198
Exhaust
Compressed air
TURBOSUPERCHARGER GARRETT
Booster pressure: 1.5 bar.
Actuator (WASTEGATE) opening start: 1600 rpm
Print 603.93.381
ENGINE F4 AE 0481
93
Figure 200
4
5
6
62873
70490
Cover the air, exhaust gas and lubrication oil inlets and
outlets.
Carry out an accurate external cleaning of the turbosupercharger, using the anticorrosive and antioxidant solution and
perform the check on the actuator (6).
Remove the elastic clip (4) and withdraw the tie rod (3) from
the lever (5).
Remove the nuts (2) and remove the actuator (1) from the
supporting bracket. Fit the new actuator following the removal operations in reverse order and fitting a new clip (4),
tighten the nuts (2) to 5.6 6.8 Nm torque.
Position the tracer point of the gauge (2) on the tie rod (3)
end and set to zero the gauge (2).
Before refitting the turbosupercharger on engine, fill the central body with engine oil.
Print 603.93.381
94
ENGINE F4 AE 0481
Print 603.93.381
ENGINE F4 AE 0481
95
TURBOSUPERCHARGER LAYOUT
Figure 201
Inlet air
Hot compressed air
Cooled compressed air
Exhaust
70491
Print 603.93.381
96
ENGINE F4 AE 0481
Print 603.93.381
97
ENGINE F4 AE 0481
COMMON RAIL
General Specifications
In order to reduce PARTICULATES emissions, very high injection pressures are required.
The Common Rail system allows injecting the fuel up to pressures reaching 1350 bar, at the same time, the injection precision,
obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
System description
Electric system
Figure 202
78670
1. Injectors connections - 2. Fuel pressure sensor - 3. Engine coolant temperature sensor - 4. Engine oil temperature and
pressure sensor - 5. Output shaft sensor - 6. Injector - 7. Air pressure/temperature sensor - 8. Camshaft sensor - 9. Fuel
heater and fuel temperature sensor - 10. Pressure regulator - 11. EDC 7 control unit.
Through the sensors, present on the engine, the ECU controls the engine operation.
The outlet tension is proportional to the pressure or temperature obtained by the sensor.
Print 603.93.381
98
ENGINE F4 AE 0481
Injection control
The control unit, depending on information coming from
sensors, controls the pressure regulator, and changes
pre-injection and main injection modes.
Closed-loop control for injection pressure
Depending on engine load, measured by processing signals
coming from various sensors, the control unit controls the
regulator in order to always have the optimum pressure.
Pilot and main injection spark advance control
The control unit, depending on signals coming from various
sensors, computes the optimum injection point according to
an internal mapping.
Idle speed control
The control unit processes signals coming from various
sensors and adjusts the amount of injected fuel.
It controls the pressure regulator and changes the injection
time of injectors.
Within certain thresholds, it also takes into account the
battery voltage.
Maximum speed limiting
At 2700 rpm, the controlunit limits fuel flow-rate by reducing
the injectors opening time.
Over 3000 rpm it deactivates the injectors.
Cut Off
Fuel cut off upon release is controlled by the control unit
performing the following logics:
- it cuts off injectors supply;
- it re-activates the injectors shortly before idle speed is
reached;
- it controls fuel pressure regulator.
Smoke control upon acceleration
With strong load requests, the control unit, depending on
signals received by air inlet meter and engine speed sensor,
controls the pressure regulator and changes the injectors
actuation time, in order to avoid exhaust smokes.
Fuel temperature control
When the fuel temperature exceeds 75 C (measured by the
sensor placed on fuel filter) the control unit intervenes by
reducing injection pressure.
If the temperature exceeds 90 C, the power is reduced to
60%.
AC compressor engagement control
The control unit is able to drive engagement and
disengagement of the electromagnetic compressor clutch
depending on coolant temperature.
If the coolant temperature reaches about 105 C, it
disengages the clutch.
After Run
The control unit microprocessor allows storing certain
EPROM data, among which failure memory and Immobilizer
information, in order to make them available upon the
following startup.
Print 603.93.381
99
ENGINE F4 AE 0481
HYDRAULIC SYSTEM
Figure 203
High Pressure
Low Pressure
99230
1. Injector - 2. Common Rail - 3. Pressure limiter for fuel return - 4. Rail overpressure valve - 5. Prefilter assembled on
chassis - 6. High-pressure pump - 7. Mechanical rotor pump - 8. Fuel filter.
The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and
cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes
place in the related cylinder.
The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipings:
- piping connecting high-pressure pump outlet to rail;
- pipings supplying injectors from rail.
The low-pressure circuit is composed of the following pipings:
- fuel suction piping from tank to prefilter;
- pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter;
- pipings supplying the high-pressure pump through the fuel filter.
The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
Print 603.93.381
100
ENGINE F4 AE 0481
Print 603.93.381
ENGINE F4 AE 0481
101
Figure 204
EXHAUST
P = 0,5-1 bar
P = 1.2 bar
ECU
EDC7
P = 8,5 < 10 bars
with clogged filter
P = 5.56.5 bar
P = 1.2 bar
70493
1. High-pressure pump. 2. Pressure relief valve on high-pressure pump, 5 bars. 3. Pressure relief valve assembled on fuel return from injectors, 1.3 to 2 bars. 4. Rail overpressure valve.
5. Common Rail. 6. Pressure sensor. 7. Injector. 8. Return piping. 9. Control unit heat exchanger. 10. Mechanical priming pump. 11. Prefilter assembled on chassis.
12. Fuel tank. 13. Mechanical supply pump. 14. Fuel filter. 15. Pressure regulator. 16. High-pressure pump cooling piping. 17. By-pass valve. 18. By-pass valve.
Print 603.93.381
102
ENGINE F4 AE 0481
Print 603.93.381
ENGINE F4 AE 0481
FUEL PREFILTER
103
FUEL FILTER
Figure 205
Figure 206
70494
99377
If the warning light is on, it is necessary to immediately operate to remove its cause; the common
rail system components are quickly damaged by the
presence of water or impurities in the fuel.
Print 603.93.381
104
ENGINE F4 AE 0481
Drain conditions
Gear pump, fitted on the rear side of the high pressure pump
and used to supply it.
It is controlled by high pressure pump shaft
Figure 209
72594
72592
A Fuel inlet from tank, B fuel outlet to filter, 1-2 by-pass valves
in close position
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this
situation the by-pass valve (1) stays closed whereas by-pass
valve (2) opens due to inlet pressure, and fuel is drained out
through B.
72593
Print 603.93.381
ENGINE F4 AE 0481
105
The following work must be carried out on the feed pump / high-pressure pump assembly:
- replacing the drive gear;
- replacing the pressure regulator.
Figure 210
72595
1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Pressure regulator - 4. Control gear - 5. Fuel inlet fitting from filter 6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger - 8. Fuel outlet fitting from supply
pump to filter - 9.Mechanical supply pump
Print 603.93.381
106
ENGINE F4 AE 0481
sec. B-B
sec. C-C
70498
1. Cylinder. 2. Three-lobe element. 3. Cap intake valve. 4. Ball delivery valve. 5. Piston. 6- Pump shaft. 7.
Low-pressure fuel inlet. 8. Pumping elements supplying fuel ducts.
Print 603.93.381
ENGINE F4 AE 0481
107
Operating principle
Figure 212
Sec. B B
Sec. D D
72597
1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Pumping element - 4. Pump shaft - 5. Pumping element supply duct 6. Pressure regulator supply duct - 7. Pressure regulator
Print 603.93.381
108
ENGINE F4 AE 0481
Figure 213
Sec. C C
Figure 214
72598
72601
Sec. A A
Figure 213 shows low pressure fuel paths inside the path and
highlights: main pumping element supply duct (4), pumping
element supply ducts (1 3 6), pump lubrication ducts (2),
pressure regulator (5), 5 bar pressure relief valve (8) and fuel
drain duct (7).
Print 603.93.381
Operation
The cylinder is filled through the cap intake valve only if the
supply pressure is suitable to open the delivery valves set on
the pumping elements (about 2 bars).
ENGINE F4 AE 0481
109
RAIL
Figure 215
99232
Print 603.93.381
110
ENGINE F4 AE 0481
Figure 216
91577
Print 603.93.381
ENGINE F4 AE 0481
INJECTOR
111
Injection start
Figure 218
15
70506
15
Injection end
When coil (4) is de-energised, shutter (6) goes back to its
closing position, in order to re-create such a force balance as
to make plunger (2) go back to its closing position and end
the injection.
NOTE The injector cannot be overhauled and therefore
it must not be disassembled.
70505
Figure 219
70507
A
Print 603.93.381
112
ENGINE F4 AE 0481
Print 603.93.381
ENGINE F4 AE 0681
70757
ENGINE F4 AE 0681
115
Engine F4 AE 0681
Page
Print 603.93.381
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .
117
120
128
128
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
129
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
129
131
133
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .
135
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
136
BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137
- Turbosupercharger . . . . . . . . . . . . . . . . . . . . .
137
TURBOSUPERCHARGER LAYOUT . . . . . . . . .
139
116
ENGINE F4 AE 0681
Print 603.93.381
ENGINE F4 AE 0681
117
GENERAL SPECIFICATIONS
F4 AE 0681E
(.18)
Type
F4 AE 0681D
(.21)
Cycle
Power
Injection
Direct
Number of cylinders
6 in-line
Bore
mm
102
Stroke
mm
120
5900
Compression ratio
Max. output
Max. torque
17 : 1
kW
(HP)
132
(180)
154
(210)
rpm
Nm
(kgm)
2700
570
(58)
2700
680
(69)
rpm
1200 to 2100
1200 to 2100
650
rpm
3000
Print 603.93.381
118
ENGINE F4 AE 0681
F4 AE 0681E
(.18)
Type
SUPERCHARGING
F4 AE 0681D
(.21)
With intercooler
Turbosupercharger type
mm
bar
bar
LUBRICATION
bar
COOLING
1.2
3.8
By centrifugal pump, regulating thermostat, radiator, heat exchanger, intercooler
Through belt
81 2 C
96 C
FILLING
Total capacity
1st filling:
liters
kg
ACEA E3/E5
Urania LD
Min. level
Max. level
liters
kg
8
7.2
10.8
9.7
liters
kg
9
8.1
11..8
10.6
- engine sump
Print 603.93.381
ENGINE F4 AE 0681
F4 AE 0681E
(.18)
Type
119
F4 AE 0681D
(.21)
TIMING
start before T.D.C.
end after B.D.C.
A
B
8,5
8.5
D
C
51
12.5
Checking timing
mm
mm
mm
0.20 to 0.30
mm
0.45 to 0.55
X
X
Checking operation
X
FUEL FEED
Injection
Type:
Bosch
Nozzle type
Injectors
Injection sequence
bar
Print 603.93.381
1-5-3-6-2-4
Injection sequence
bar
250 - 1450
Injection pressure
bar
120
ENGINE F4 AE 0681
F4 AE 0681E
(.18)
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
1
X
1
X
2
2
mm
1
X
Cylinder barrels:
Measuring height
Spare pistons:
type:
Size
Outside diameter
Pin housing
F4 AE 0681D
(.21)
102.009 to 102.031
0.260 to 0.300
1
Piston diameter
60.5
101.721 to 101.739
40.010 to 40.016
0.5
X
Piston protrusion
Piston pin
Piston pin pin housing
0.28 to 0.52
39.9938 to 40.0002
0.0098 to 0.0222
Print 603.93.381
ENGINE F4 AE 0681
F4 AE 0681E
(.18)
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
X1
X2
X3
S 1
S 2
S 3
X 1*
X2
X3
121
F4 AE 0681D
(.21)
mm
2.705 to 2.735
2.430 to 2.450
4.040 to 4.060
* measured on 99 mm
Split rings
S 1*
S2
S3
2.560 to 2.605
2.350 to 2,380
3.975 to 4.000
* measured on 99 mm
Split rings - slots
1
2
3
Split rings
X1
X2
X3
0.100 to 0.175
0.050 to 0.100
0.040 to 0.085
0.5
0.30 to 0.40
0.60 to 0.80
0.25 to 0.55
42.987 to 43.013
72.987 to 73.013
4
3
S
Print 603.93.381
43.279 to 43.553
40.019 to 40.033
1.955 to 1.968
0.266 to 0.566
0.0188 to 0.0392
-
122
ENGINE F4 AE 0681
F4 AE 0681E
(.18)
Type
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
F4 AE 0681D
(.21)
mm
X
Size
Max. tolerance on
connecting rod axis
alignment
1
Journals
Crankpins
1
2
82.99 to 83.013
68.987 to 69.013
2.456 to 2.464
1.955 to 1.968
S 2
*provided as spare part
Main bearings
No. 1 3 4 5 6 7 3
No. 2
3
87.982 to 88.008
87.982 to 88.008
0.041 to 0.103
0.041 to 0.103
0.033 to 0.041
0.250 to 0.500
Shoulder journal
X1
37.475 to 37.545
Shoulder main
bearing
X2
32.23
Shoulder
half-rings
X3
32.30
X 1
X 2
0.07
Print 603.93.381
ENGINE F4 AE 0681
F4AE0681E
(.18)
Type
CYLINDER HEAD TIMING SYSTEM
1
F4AE0681D
(.21)
mm
123
7.042 to 7.062
Valves:
6.970 to 6.990
60 0.25
6.970 to 6.990
45 0.25
0.052 to 0.092
34.837 to 34.863
34.837 to 34.863
Sinking
Between valve seat
and head
Valve seats
Print 603.93.381
34.917 to 34.931
60
34.917 to 34.931
45
0.59 to 1.11
0.96 to 1.48
0.054 to 0.094
0.054 to 0.094
-
124
ENGINE F4 AE 0681
F4AE0681E
(.18)
Type
CYLINDER HEAD TIMING SYSTEM
F4AE0681D
(.21)
mm
H 1
H 2
free spring
47.75
H1
H2
35.33
25.2
Injector protrusion
not adjustable
59.222 to 59.248
Camshaft housings
No. 2-3-4-5-6
59.222 to 59.248
Camshaft journals:
17
123
53.995 to 54.045
59.222 to 59.248
Bush inside
diameter after driving
54.083 to 54.147
2 6
7
2
0.113 to 0.165
0.038 to 0.152
Cam lift:
H
6.045
7.582
Print 603.93.381
ENGINE F4 AE 0681
F4AE0681E
(.18)
Type
CYLINDER HEAD TIMING SYSTEM
125
F4AE0681D
(.21)
mm
1
Tappet cap housing
on block
2
3
2
16.000 to 16.030
15.924 to 15.954
15.960 to 15.975
0.025 to 0.070
Tappets
1
Rocker shaft
21.965 to 21.977
Rockers
22.001 to 22.027
2
Between rockers and shaft
Print 603.93.381
0.024 to 0.162
126
ENGINE F4 AE 0681
Figure 1
99233
Print 603.93.381
ENGINE F4 AE 0681
127
Figure 2
70509
Print 603.93.381
128
ENGINE F4 AE 0681
540110
Figure 3
99234
70125
Figure 4
70126
70511
Print 603.93.381
5412
541210
ENGINE F4 AE 0681
129
TIMING SYSTEM
Camshaft
Figure 7
79459
BUSHES
Figure 8
*
79460
130
ENGINE F4 AE 0681
Figure 9
*
**
70577
Figure 10
INTERMEDIATE MAIN
BEARINGS
70237
TOLERANCES
SHAPE
DIRECTION
POSITION
OSCILLATION
TOLERANCE CHARACTERISTIC
Roundness
Cilindricity
Parallelism
Verticality
Straightness
Concentricity or coaxiality
Circular oscillation
Total oscillation
Taper
GRAPHIC SYMBOL
f
/f/
//
GRAPHIC SYMBOL
CRITICAL
IMPORTANT
SECONDARY
Print 603.93.381
ENGINE F4 AE 0681
131
Figure 11
70514
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES
*Nominal value
5406
Figure 12
EXHAUST
EXHAUST
85485
Print 603.93.381
132
ENGINE F4 AE 0681
Figure 13
EXHAUST
INTAKE
70332
Figure 14
INTAKE
EXHAUST
85486
Print 603.93.381
ENGINE F4 AE 0681
133
Figure 17
Figure 15
70520
70336
Figure 16
70476
1
-
2
*
3
*
-
4
*
5
*
-
6
*
*
1
*
*
2
*
-
3
*
4
*
-
5
*
6
-
Print 603.93.381
134
ENGINE F4 AE 0681
Print 603.93.381
5450
ENGINE F4 AE 0681
135
LUBRICATION
Figure 18
70516
Print 603.93.381
136
5432
ENGINE F4 AE 0681
COOLING SYSTEM
Figure 19
Print 603.93.381
70517
ENGINE F4 AE 0681
137
BOOSTER
542410 Turbosupercharger
Figure 20
85487
Print 603.93.381
138
ENGINE F4 AE 0681
Print 603.93.381
ENGINE F4 AE 0681
139
TURBOSUPERCHARGER LAYOUT
Figure 21
Incoming air
Hot compressed air
Exhaust
70518
Print 603.93.381
140
ENGINE F4 AE 0681
Print 603.93.381
ENGINE
141
Troubleshooting guide
Page
Print 603.93.381
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . .
143
143
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . .
145
142
ENGINE
Print 603.93.381
ENGINE
143
FOREWORD
A good diagnosis is carried out above all with electronic diagnostic instruments (Modus/IWT/IT200) developed by Iveco.
When a vehicle enters the workshop, information provided by vehicle driver are kept under right consideration, but the first
thing to do is connecting Modus/IWT/IT2000 and carefully performing a complete diagnosis.
- failure memory reading
- parameters reading
- engine test
- etc.
It is useful to print the results, especially in case the Help Desk assistance has to be requested.
70729
Print 603.93.381
144
ENGINE
Print 603.93.381
ENGINE
145
DIAGNOSTICS
Main engine operating anomalies:
12345-
YES
Efficient batteries.
NO
NO
NO
NO
YES
Efficient starter.
YES
YES
YES
Replace.
NO
(continued)
Print 603.93.381
146
ENGINE
YES
YES
Efficient injector.
NO
NO
YES
YES
(continued)
Base October 2004
Print 603.93.381
ENGINE
147
YES
Efficient thermostat.
Replace.
NO
YES
Efficient radiator.
NO
YES
YES
YES
Replace.
NO
YES
Efficient fan.
Replace.
NO
Print 603.93.381
148
ENGINE
YES
YES
Efficient thermostat.
Replace.
NO
YES
YES
NO
NO
YES
YES
(continued)
Base October 2004
Print 603.93.381
ENGINE
149
YES
YES
YES
Check restore.
NO
Replace.
NO
YES
Efficient injectors.
NO
YES
(continued)
Print 603.93.381
150
ENGINE
Efficient injectors.
NO
NO
YES
Print 603.93.381
ENGINE
151
ENGINE
YES
YES
NO
NO
NO
NO
YES
NO
Print 603.93.381
152
ENGINE
YES
Replace.
NO
YES
INSUFFICIENT OR EXCESSIVE
OIL PRESSURE
YES
YES
YES
Print 603.93.381
10
ENGINE
153
YES
Replace.
NO
Print 603.93.381
154
ENGINE
Print 603.93.381
CLUTCH
SECTION 3
Clutch
Page
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
- Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
- Friction gaskets . . . . . . . . . . . . . . . . . . . . . . . .
10
11
11
HYDRAULIC CONTROL . . . . . . . . . . . . . . . . . .
12
- Mini servoclutch . . . . . . . . . . . . . . . . . . . . . . .
12
- Connections . . . . . . . . . . . . . . . . . . . . . . . . . .
12
13
13
13
Print 603.93.381
14
14
14
CLUTCH
Print 603.93.381
CLUTCH
DESCRIPTION
Clutch
The clutch is of the singleplate, dryoperating type, with
engagement mechanism of the pull type with baffle spring. The
VALEO
Type
Dry singleplate
Engagement mechanism
Driven plate
External gaskets
mm
Internal gaskets
mm
mm
8.5 0.3
mm
0.2
Load on platepusher
Disengagement load
mm
1.5
Detachment stroke
mm
10 +20
mm
Hydraulic control
Oil type
Print 603.93.381
A.P.
330
194.5
200
10100
10500
2000
14
13.6
CLUTCH
13/14 CLUTCH
with gearboxes: 2855S.5 2855S.6
Engine: 6 cylinders
VALEO
Type
Dry singleplate
Engagement mechanism
Driven plate
External gaskets
mm
330
Internal gaskets
mm
194.5
mm
9.4 0.3
mm
0.2
Load on platepusher
12000
Disengagement load
2900
mm
1.5
Detachment stroke
mm
10
mm
12.2
Hydraulic control
Oil type
+2
0
Print 603.93.381
CLUTCH
14 CLUTCH
with gearboxes: 2865S.6 2870S.9
Engine: 6 cylinders
VALEO
Type
Dry singleplate
Engagement mechanism
Driven plate
mm
350
Internal gaskets
mm
195
mm
9.4 0.3
mm
0.2
Load on platepusher
12000
Disengagement load
2900
mm
1.5
Detachment stroke
mm
10
mm
12.2
Oil type
Print 603.93.381
External gaskets
Hydraulic control
+2
0
CLUTCH
DIAGNOSTICS
Main clutch operating anomalies:
1 Noises when the pedal is lowered;
2 Noises when the pedal is released;
3 The clutch jerks;
NO
NO
NO
Print 603.93.381
CLUTCH
YES
NO
NO
NO
YES
NO
(continued)
Print 603.93.381
CLUTCH
NO
NO
YES
YES
The driver must avoid this wrong attitude and rest his
foot on the clutch pedal only when it is necessary.
NO
Print 603.93.381
CLUTCH
TIGHTENING TORQUES
TORQUE
Nm
(kgm)
23.5 2.5
(2.4 0.2)
46 5
(4.7 0.5)
19 2
(1.9 0.2)
PART
Hexagonal screw securing disk pusher to flywheel
Hexagonal nut for securing clutch timing case to engine
Screw stud securing clutch case with engine
TOOLS
TOOL No.
DENOMINATION
99306010
99370306
99370547
Print 603.93.381
10
CLUTCH
Figure 1
Friction gaskets
Replace the entire driven plate if gaskets are excessively worn
or dirty with oil or grease, or burning traces or removal from
the driving plate are visible.
Figure 3
33696
Refitting
Figure 4
505254
CLUTCH
540852
11
Figure 5
Figure 6
33698
Use the proper pliers to open the safety split ring (2) and
withdraw the thrust bearing (1).
For refitting reverse removal operations.
33699
Print 603.93.381
12
CLUTCH
HYDRAULIC CONTROL
The hydraulic control to disengage clutch is made up of a mini servoclutch with builtin oil tank and of a clutch disengaging cylinder.
Mini servoclutch
This cylinder adopts an airassisted system of operation, activation of which is regulated by a spring type load sensor characterised
by a threshold value. The initial part of the stroke of the piston, below the activation threshold, is not powerassisted whereas,
above this threshold, the air pressure, suitably regulated by a set of valves, is activated in order to activate the piston at constant.
Figure 7
99176
1. Piston 2. Master cylinder 3. Air vent 4. Oil outlet 5. Oil reservoir 6. Air supply fitting
Travel 38 mm Tank capacity min. 150 cm3 / max. 200 cm3
Connections
Air supply pressure (Fitting 6)
10 bar
50 bar
Travel
Tank capacity
38 mm
min. 150 cm3
max. 200 cm3
87559
Print 603.93.381
CLUTCH
13
87560
87561
87562
14
CLUTCH
Dimension control must be performed with lock nut beating against pedals set support body. The lock nut must be from
an original supply (4.8 mm height).
Figure 11
99177
Print 603.93.381
GEARBOXES
SECTION 4
Gearboxes
Page
Print 603.93.381
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX 2865S.6 . . . . . . . . . . . . . . . . . . . . . .
43
GEARBOX 2870S.9 . . . . . . . . . . . . . . . . . . . . . .
77
GEARBOXES
Print 603.93.381
GEARBOXES
DIAGNOSTICS
Main gearbox operating anomalies:
1
2
Noises;
Spontaneous gears disengagement and engagement
irregularities;
Gears engagement difficulty and hardness.
NOISES
NO
NO
NO
YES
YES
NO
Forks breakage.
(continued)
Print 603.93.381
GEARBOXES
NO
NO
NO
Print 603.93.381
GEARBOXES
Figure 1
91581
1. Gears control lever 2. Reaction plate secured to gears control 3. Adjustment tierod 4. Bearing support
5. Adjustable fixed tierod 6. Telescopic tierod 7. Gears lever
Figure 2
62591
Print 603.93.381
GEARBOXES
Figure 3
Figure 5
62592
62594
Figure 4
Figure 6
62593
Print 603.93.381
5302
Page
Print 603.93.381
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
10
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
13
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . .
21
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . .
25
25
31
33
36
36
36
37
37
37
37
38
39
41
Print 603.93.381
DESCRIPTION
The IVECO 2855S.6 gearbox is of the mechanical type with
1st, 2nd gear engagement through a doublecone
synchronising ring and 3rd, 4th, 5th and 6th gear engagement
with freering synchronising rings. The reverse motion
engagement is with a quickconnection sliding sleeve.
The gearbox case is made of light alloy and is composed of a
front halfcase and a rear halfcase.
Three openings are obtained in the rear halfcase for the
possible application of a power takeoff.
Motion transmission is realised through a series of gears,
always meshed and with helical teeth.
Figure 1
79431
Print 603.93.381
10
2855S.5
Type
Gears
2855S.6
Mechanical
Gears
Mechanical
Power takeoff
Upon request
Gears engagement:
1st 2nd
Doublecone synchronizer
3rd 5th
Freering synchronizer
3rd 6th
Freering synchronizer
Reverse gear
Gears antidisengagement
Quickconnection type
Sliding sleeve holding through rollers and springs.
Gears
Gear ratio
First
Second
Third
Fourth
Fifth
Sixth
Reverse gear
1 : 6.339
1 : 3.643
1 : 2.308
1 : 1.484
1 : 1.000
1 : 5.455
1 : 6.433
1 : 3.643
1 : 2.308
1 : 1.484
1 : 1.000
1 : 0.783
1 : 5.630
Oil type
Amount
TUTELA ZC 90
5 kg. (5.5 litres)
100 C to 130 C
Print 603.93.381
Print 603.93.381
0 to 0.05
Through rings
85 C
11
12
Figure 2
98988
Print 603.93.381
13
TIGHTENING TORQUES
PART
1
Flanged
g hexagonal
g
head screw for securingg front cover
1st step
p
2nd step
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TORQUE
Nm
(kgm)
20 1
(2 0.1)
25
45.5 4.5
(4.6 0.5)
22.5 2.5
(2.3 0.2)
39 2
(4.0 0.2)
14.5 1.5
(1.5 0.1)
27.5 2.5
(2.8 0.3)
38 4
(3.9 0.4)
19 2
(1.9 2)
30 3
(3.0 0.3)
27.5 2.5
(2.8 0.3)
58 6
(5.9 0.6)
43 4
(4.4 0.4)
467 23
(47.6 2.3)
9.5 0.5
(0.96 0.05)
33.5 3.5
(3.4 0.4)
19 2
(1.9 2)
45.5 4.5
(4.6 0.5)
45.5 4.5
(4.6 0.5)
Print 603.93.381
14
TOOLS
TOOL No.
DENOMINATION
99305121
Hotair apparatus
99322205
99222225
99340205
Percussion extractor
99341003
Simpleeffect bridge
99341009
Pair of brackets
Print 603.93.381
15
TOOLS
TOOL No.
DENOMINATION
99341015
Clamp
99341017
99341019
99341020
99341025
Holds
99342143
Print 603.93.381
16
TOOLS
TOOL No.
DENOMINATION
99348004
99370006
99370007
99370317
99370349
Keyer for drive shaft front gasket assembling (use with 99370006)
99370466
Print 603.93.381
17
TOOLS
TOOL No.
DENOMINATION
99370629
99374092
99374201
99395604
Comparator (0 10 mm)
99396031
Print 603.93.381
18
Print 603.93.381
19
Figure 3
Removal
Refitting
Suitably reverse the operations carried out for
disengagement and tighten securing screws and
nuts at the required torque.
Print 603.93.381
20
Print 603.93.381
21
GEARBOX DISASSEMBLY
Figure 4
Figure 7
71666
71699
Figure 5
71667
Figure 6
Figure 8
78685
71670
Print 603.93.381
22
Figure 9
Figure 12
71671
78164
Take off spring (3) and take out push rod (4).
Figure 13
Figure 10
71672
79432
Unscrew screws (2) and take fork pin (1) off both gearbox
sides.
Figure 11
Figure 14
71673
72866
Figure 15
23
Figure 17
71676
72867
Figure 16
98989
Remove cylindric roller bearing from motion inlet shaft (1) and
heat contact surface (2) of front halfcase. With a plastic
hammer extract motion inlet shaft (1) completed with ball
bearing.
Figure 19
71677
Print 603.93.381
24
Checks
GEARBOX CASE
Figure 20
SHAFTS GEARS
Shaft seats for bearings and gear toothings must not be
damaged or worn.
71682
Figure 21
BEARINGS
Roller bearings or roller cages must be in perfect conditions
and not show traces of wear or overheatings.
By keeping bearings manually pressed and making them
simultaneously rotate along two directions, no roughness or
noise when sliding must be detected.
72868
Extract sealing gasket (2) from motion inlet shaft cover (1).
Figure 22
71684
Print 603.93.381
25
GEARBOX ASSEMBLY
Butter with hermetic type B the threaded part of all
screws that must be screwed in the throughholes.
Clean the joining surfaces of case and covers and
apply LOCTITE 510 putty, before assembling, on
one of the two components.
Figure 23
71685
98991
FRONT HALFCASE
THICKNESS (S)
Figure 24
61957
72869
Print 603.93.381
26
First method
Figure 27
98992
Assemble on rear halfcase (1) cover (2), spacer (1, Figure 19)
and with beater 99374092 equipped with handle 99370007,
assemble external race (3) of roller bearing, settling it till it
abuts.
See Figure 30 for adjusting beater 99374092.
Fit inner control shaft bushing into its seat, put in rib washer
(5) and screw TORX mark screw (4) with prescribed torque.
Figure 28
After having computed the thickness value of the adjustment
ring, disassemble again secondary shaft and cover from rear
halfcase.
Figure 29
71690
REAR HALFCASE
61956
98993
Print 603.93.381
Figure 30
27
Figure 33
32447
72871
98994
72870
Slightly heat the ball bearing seat, assemble motion inlet shaft
(1) completed with bearing (4), adjustment ring (3) and elastic
ring (2). Settle the bearing till it abuts.
Print 603.93.381
72867
Assemble motion inlet shaft cover (2), screw screws (1) and
tighten them at the required torque.
Base October 2004
28
Figure 35
Figure 37
71859
79433
Disassemble previouslyassembled flange and nut and assemble rear halfcase (1). Screw union screw between rear
halfcase and front halfcase and tighten them at the required
torque.
NOTE
Figure 36
Figure 38
79432
71860
Print 603.93.381
Figure 39
29
Figure 42
79434
71865
Put in push rod (4), spring (3), mount cover (1) and screw
down screws (2) tightening them with rated torque.
Figure 40
Figure 43
71863
71671
Assemble shoulder rings, placing them into their own seat and
reverse gear (3) with cylindric roller bearing. Assemble reverse
gear supporting shaft (2) with a suitable beater, paying attention that the arrow (1) punched on the shaft is facing the peg
insertion hole.
Figure 41
71866
71864
30
Figure 48
Figure 45
71867
79435
Figure 46
Figure 49
71669
Assemble rear cover (1), screw screws (3) and tighten them
at the required torque. Assemble motion outlet flange (2).
Figure 47
71667
31
Figure 50
33618
Figure 51
33621
Remove 5th speed gear (1) and roller bearing below it.
Figure 54
33619
33622
Figure 52
33623
33620
Print 603.93.381
4th
32
Figure 56
Figure 59
33624
33627
Remove 3rd and 4th gear sliding sleeve (1) recovering check
springs and rollers.
Turn the shaft over and extract reverse gear (5) with roller
bearing below it, shoulder ring (4) and rolling halfrace (3)
with holds 99341025 (2), tierods 99341019 (7), bridge
99341003 (1) and clamp 99341015 (6).
Figure 57
Figure 60
33625
3rd
4th
3rd
Extract
and
speed fixed hub (2) and
speed
synchronising ring with holds 99341025 (5), tierods
99341019 (7), bridge 99341003 (1) and clamp 99341015 (6).
Remove 3rd speed coupling body (4).
33628
Figure 58
33629
1st
33626
Remove 3rd speed gear (1) and roller bearing below it.
Extract
speed gear (3) together with roller bearing and
fixed sleeve (2) for reverse gear with holds 99341023 (4),
tierods 99341020 (6), bridge 99341003 (1) and clamp
99341015 (5).
Print 603.93.381
33
Figure 64
33630
33632
Figure 63
Figure 65
33631
33633
Assemble sliding sleeve (1) for 1st and 2nd speed gears, springs
2nd
Print 603.93.381
34
Figure 69
Figure 66
33634
33637
Figure 67
Figure 70
33635
33638
Turn the shaft over in a clamp, assemble roller bearing and 3rd
speed gear (1).
Figure 71
Figure 68
33639
33636
Print 603.93.381
Figure 72
35
Figure 75
33640
33643
Assemble sliding sleeve (2) for 3rd and 4th speed gears, springs
Heat the fixed hub (2) for 5th and 6th speed gears at a
temperature of 100 C to 130 C and install it on the primary
shaft with the chamfer heading towards the 5th speed gear.
When keying the hub pay attention that synchronising ring
tangential stops are inserted into respective hub seats.
Assemble elastic ring (1) with a suitable thickness so that the
fixed hub has no axial clearance (max allowed 0.03 mm).
33641
Assemble roller bearing and 4th speed gear (2). Heat bush (3)
at a temperature of 100 C to 130 C, and assemble it on
primary shaft (4). Assemble elastic ring (1).
Figure 76
Figure 74
33644
33642
Assemble roller bearing, 5th speed gear (2), coupling body (1)
and synchronising ring (3) for 5th speed gear.
Print 603.93.381
Assemble sliding sleeve (2) for 5th and 6th speed gears, springs
and rollers. Assemble synchronising ring (3) and coupling body
(1) for 6th speed gear.
36
Figure 77
Figure 80
71869
71872
Assemble ball bearing (1) on motion inlet shaft (2) and carry
out its adjustment.
Figure 78
Figure 79
62455
71871
Print 603.93.381
37
Figure 82
Figure 84
71869
71873
33651
Remove elastic ring (1) from secondary shaft (3), extract bevel
roller bearings (2 and 4) with a suitable punch (destructive
operation).
Print 603.93.381
38
Figure 89
Figure 86
33655
33658
Tighten the shaft going out of the box in a clamp, remove plug
(1) and disassemble cover (2).
Unscrew screw (1) and remove spacer, upper cup (3) and
spring (2). Remove lower cup.
Figure 90
Figure 87
78166
78167
Remove the snap ring (4) and use a punch tool (5) having the
right diameter to push the extraction washer (1) and remove
flexible plugs (2) and (3).
Figure 91
Figure 88
33660
33657
Extract, from the control shaft (2), control selector (1) and
box (3).
Print 603.93.381
Figure 92
39
Figure 95
71880
NOTE
33661
Extract, from the control box (3), sealing gasket (1) and bushes
(2) with a suitable beater.
Figure 96
78168
Insert the extraction washer (1) and use a punch tool having
the right diameter to install the first plug (2). Install the second
plug (3) and the snap ring (4).
33661
Figure 97
Assemble, in control box (3), sealing gasket (1) and bushes (2)
with a suitable beater.
Figure 94
78169
33660
40
Figure 98
Figure 101
33663
78170
Install the pin (2), the spring (1) and apply sealer LOCTITE
518 ().
Figure 99
Figure 102
33658
33655
Install the spring (2), the upper cap (3), the spacer and the
screw (1) and apply threading sealer LOCTITE 270 on the
screw itself.
Tighten the screw (1) to 30 Nm (3.1 kgm).
Figure 100
33657
Clean joining surfaces of control box and cover (2) and apply
LOCTITE 510 adhesive on one of the two components.
Assemble cover (2) and tighten screws (1) at a torque of 36.5
Nm (3.7 kgm).
Apply threading sealer LOCTITE 270 on the screws (1).
Base October 2004
Print 603.93.381
41
NOTE
Figure 103
idle gearbox!
62456
Print 603.93.381
42
Print 603.93.381
GEARBOX 2865S.6
5302
43
Gearbox 2865S.6
Page
Print 603.93.381
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
45
47
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
49
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
55
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
55
- Reengagement . . . . . . . . . . . . . . . . . . . . . . . .
55
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . .
57
60
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . .
61
62
66
69
71
72
72
72
73
73
73
74
76
44
GEARBOX 2865S.6
Print 603.93.381
GEARBOX 2865S.6
45
DESCRIPTION
The IVECO 2865S.6 gearbox is of the mechanical type with
1st, 2nd gear engagement through a doublecone
synchronising ring and 3rd, 4th, 5th and 6th gear engagement
with freering synchronising rings. The reverse motion
engagement is with a quickconnection sliding sleeve.
The gearbox case is made of light alloy and is composed of a
front halfcase and a rear halfcase.
Three openings are obtained in the rear halfcase for the
possible application of a power takeoff.
Motion transmission is realised through a series of gears,
always meshed and with helical teeth.
Figure 1
79436
Print 603.93.381
46
GEARBOX 2865S.6
Figure 2
Sec. AA
78719
Print 603.93.381
GEARBOX 2865S.6
47
2865S.6
Type
Mechanical
Gears
Mechanical
Power takeoff
Upon request
Gears engagement:
1st 2nd
3rd 4th 5th 6th
Reverse gear
Gears antidisengagement
Gears
Doublecone synchronizer
Freering synchronizer
Quickconnection type
Sliding sleeve holding through rollers and
springs.
With helical teeth
Gear ratio
Print 603.93.381
First
Second
Third
Fourth
Fifth
Sixth
Reverse gear
1 : 9.007
1 : 5.015
1 : 3.206
1 : 2.066
1 : 1.370
1 : 1.000
1 : 8.170
Oil type
Amount
TUTELA ZC 90
8.1 Kg. (9 lt)
100 C to 130 C
By means of rings
4.04.14.24.34.44.54.6
4.74.84.95.05.15.25.3
Supplied in a kit
85 C
48
GEARBOX 2865S.6
Figure 3
98995
Print 603.93.381
GEARBOX 2865S.6
49
TIGHTENING TORQUES
PART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
TORQUE
Nm
(kgm)
32 3
(3.3 0.3)
545 55
(55.5 5.6)
45.5 4.5
(4.6 0.5)
22.5 2.5
(2.3 0.2)
39 2
(4.0 0.2)
27.5 2.5
(2.8 0.3)
38 4
(3.9 0.4)
19 2
30 3
27.5 2.5
58 6
43 4
467 23
33.5 3.5
19 2
9.5 0.5
46.5 4.5
(1.9 0.2)
(3.0 0.3)
(2.8 0.3)
(5.9 0.6)
(4.4 0.4)
(47.6 2.3)
(3.4 0.4)
(1.9 0.2)
(0.96 0.05)
(4.6 0.4)
Print 603.93.381
50
GEARBOX 2865S.6
TOOLS
TOOL No.
DENOMINATION
99305121
Hotair apparatus
99322205
99322225
99340205
Percussion extractor
99341003
Simpleeffect bridge
99341009
Pair of brackets
Print 603.93.381
GEARBOX 2865S.6
51
TOOLS
TOOL No.
DENOMINATION
99341015
Clamp
99341017
99341019
99341020
99341023
Holds
99341025
Holds
Print 603.93.381
52
GEARBOX 2865S.6
TOOLS
TOOL No.
DENOMINATION
99342143
99348004
99355081
99355174
99370006
99370007
Print 603.93.381
GEARBOX 2865S.6
53
TOOLS
TOOL No.
DENOMINATION
99370317
99370349
Keyer for drive shaft front gasket assembling (use with 99370006)
99370466
Comparator basis
99370629
99374092
99374201
Print 603.93.381
54
GEARBOX 2865S.6
TOOLS
TOOL No.
DENOMINATION
99395604
Comparator (0 10 mm)
99396032
Print 603.93.381
GEARBOX 2865S.6
55
Figure 4
Disengagement
Lift the calender and turn the cabin over.
Reengagement
Suitably reverse the operations carried out for
disengagement and tighten securing screws and
nuts at the required torque.
Print 603.93.381
71004
56
GEARBOX 2865S.6
Print 603.93.381
GEARBOX 2865S.6
57
GEARBOX DISASSEMBLY
Figure 5
Figure 8
33552
33555
Figure 6
Figure 9
33553
33556
Figure 7
Figure 10
33554
33557
Print 603.93.381
58
GEARBOX 2865S.6
Figure 11
Figure 13
33558
35560
35561
Beat with a punch (1) and push the elastic peg till it abuts.
Figure 15
Figure 12
35562
35559
Print 603.93.381
GEARBOX 2865S.6
Figure 16
59
Figure 19
79438
33566
Figure 17
33564
98996
33565
Extract box (2) with bridge 99341003 (1) equipped with the
pair of brackets 99341017 (3).
Print 603.93.381
60
GEARBOX 2865S.6
530514
Figure 21
Figure 24
35568
35571
Extract from primary shaft cover (1) the sealing gasket (2) with
a suitable beater.
Figure 22
35569
Figure 25
Figure 23
35572
35570
Extract from motion entry shaft cover (2) the sealing gasket
(1) with a suitable beater.
Base October 2004
Checks
GEARBOX 2865S.6
61
GEARBOX ASSEMBLY
GEARBOX CASE
Gearbox case and related covers must not show cracks.
Contact surfaces between covers and gearbox case must not
be damaged or distorted.
Bearing seats must not be damaged or excessively worn.
SHAFTS GEARS
Shaft seats for bearings and gear toothings must not be
damaged or worn.
Figure 26
BEARINGS
Roller bearings or roller cages must be in perfect conditions
and not show traces of wear or overheating.
Keeping the bearings pressed with a hand and making them
simultaneously rotate along the two directions, no
roughnesses or noises when sliding must be detected.
33573
Print 603.93.381
62
GEARBOX 2865S.6
Figure 30
Figure 28
33601
33575
BACK COVER
61956
33576
THICKNESS (S)
61957
Print 603.93.381
GEARBOX 2865S.6
Figure 31
63
Figure 34
33604
Place, into the secondary shaft bearing seat on front cover (1),
the adjustment ring (2) whose thickness is equal to the
previouslyobtained one.
Figure 32
33606
Slightly heat the ball bearing seat, assemble motion entry shaft
(1) completed with ball bearing, rolling halfraces and ring nut
(2). Settle bearing (3) till it abuts.
32447
Figure 35
Figure 33
98998
Print 603.93.381
33607
64
GEARBOX 2865S.6
Figure 38
Figure 36
79439
Figure 37
Figure 39
33609
79438
Put in push rod (1), spring (2), mount cover (3) and screw
down screws (4) tightening them with rated torque.
Print 603.93.381
GEARBOX 2865S.6
Figure 40
65
Figure 43
33611
33614
Assemble shoulder rings, placing them into their own seat and
reverse gear (1) with the cylindrical roller bearing. Assemble
reverse gear supporting shaft with a suitable beater.
Slightly heat ball bearing halfrace and assemble it into its own
seat on primary shaft. Assemble the odometer controlling
phonic wheel (1).
Figure 44
Figure 41
33612
33615
Figure 42
Figure 45
33613
33616
Print 603.93.381
66
GEARBOX 2865S.6
Figure 49
33617
33618
Figure 47
Figure 50
33554
33619
33553
33620
Print 603.93.381
GEARBOX 2865S.6
67
Figure 55
Figure 52
33621
Remove 5th speed gear (1) and roller bearing below it.
33624
Remove 3rd and 4th gear sliding sleeve (1) recovering check
springs and rollers.
Figure 56
Figure 53
33625
33622
3rd
4th
3rd
Extract
and
speed fixed hub (2) and
speed
synchronising ring with holds 99341025 (5), tierods
99341019 (7), bridge 99341003 (1) and clamp 99341015 (6).
Remove 3rd speed coupling body (4).
Figure 54
Figure 57
33623
4th
Remove
speed gear (7) together with roller bearing and
bush (3) and coupling body (6) with holds 99341025 (4),
tierods 99341019 (2), bridge 99341003 (1) and clamp
99341015 (8). Remove synchronising ring (5).
Print 603.93.381
33626
Remove
3rd
68
GEARBOX 2865S.6
Figure 58
Figure 61
33627
Turn the shaft over and extract reverse gear (5) with roller
bearing below it, shoulder ring (4) and rolling halfrace (3)
with holds 99341025 (2), tierods 99341019 (7), bridge
99341003 (1) and clamp 99341015 (6).
33630
Figure 59
33628
33631
2nd
33629
Extract 1st speed gear (3) together with roller bearing and
fixed sleeve (2) for reverse gear with holds 99341023 (4),
tierods 99341020 (6), bridge 99341003 (1) and clamp
99341015 (5).
Base October 2004
Print 603.93.381
GEARBOX 2865S.6
69
Figure 65
33632
33634
Figure 66
33635
Figure 67
33633
Assemble sliding sleeve (1) for 1st and 2nd speed gears, springs
33636
Print 603.93.381
70
GEARBOX 2865S.6
zz
Figure 68
Figure 71
33637
33640
Assemble sliding sleeve (2) for 3rd and 4th speed gears, springs
Figure 69
33638
33641
Turn the shaft over in a clamp, assemble roller bearing and 3rd
speed gear (1).
Assemble roller bearing and 4th speed gear (2). Heat bush (3)
at a temperature of 100 C to 130 C, and assemble it on
primary shaft (4). Assemble elastic ring (1).
Figure 70
Figure 73
33639
33642
Assemble roller bearing, 5th speed gear (2), coupling body (1)
and synchronising ring (3) for 5th speed gear.
Print 603.93.381
GEARBOX 2865S.6
71
Figure 76
33643
5th
6th
33645
Figure 77
33646
33644
Assemble sliding sleeve (2) for 5th and 6th speed gears, springs
and rollers. Assemble synchronising ring (3) and coupling body
(1) for 6th speed gear.
Print 603.93.381
33647
Extract the other rolling halfrace (2) from motion entry shaft
(1) with a suitable punch.
72
GEARBOX 2865S.6
Figure 79
Figure 81
33650
33648
33651
Remove elastic ring (1) from secondary shaft (3), and extract
tapered roller bearings (2 and 4) with a suitable punch
(destructive operation).
33649
33652
Print 603.93.381
GEARBOX 2865S.6
73
Figure 86
Figure 84
33655
33653
Tighten the shaft going out of the box in a clamp, remove plug
(1) and disassemble cover (2).
Figure 87
78166
Figure 88
33654
33657
74
GEARBOX 2865S.6
Figure 89
Figure 92
33658
33661
Unscrew screw (1) and remove spacer, upper cup (3) and
spring (2). Remove lower cup.
Extract, from the control box (3), sealing gasket (1) and bushes
(2) with a suitable beater.
Figure 93
78167
33661
Remove the snap ring (4) and use a punch tool (5) having the
right diameter to push the extraction washer (1) and remove
flexible plugs (2) and (3).
Assemble, in control box (3), sealing gasket (1) and bushes (2)
with a suitable beater.
Figure 91
Figure 94
33660
33660
Extract, from the control shaft (2), control selector (1) and
box (3).
Print 603.93.381
GEARBOX 2865S.6
Figure 95
75
Figure 98
71880
33663
Figure 96
Figure 99
78168
Insert the extraction washer (1) and use a punch tool having
the right diameter to install the first plug (2). Install the second
plug (3) and the snap ring (4).
Figure 97
33658
Install the spring (2), the upper cap (3), the spacer and the
screw (1) and apply threading sealer LOCTITE 270 on the
screw itself.
Tighten the screw (1) to 30 Nm (3.1 kgm).
Figure 100
78169
33657
NOTE
Print 603.93.381
Clean joining surfaces of control box and cover (2) and apply
LOCTITE 510 adhesive on one of the two components.
Assemble cover (2) and tighten screws (1) at a torque of 36.5
Nm (3.7 kgm).
Apply threading sealer LOCTITE 270 on the screws (1).
Base October 2004
76
GEARBOX 2865S.6
Figure 102
Figure 101
33655
78170
Install the pin (2), the spring (1) and apply sealer LOCTITE
518 ().
NOTE
Figure 103
gearbox with engaged
reverse gear
idle gearbox!
62456
Print 603.93.381
GEARBOX 2870S.9
5302
77
Gearbox 2870S.9
Page
Print 603.93.381
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
79
80
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
83
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84
GEARBOX 2870S.9
DISENGAGEMENT/REENGAGEMENT . . . .
89
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
89
- Reengagement . . . . . . . . . . . . . . . . . . . . . . . .
89
GEARBOX DISASSEMBLY . . . . . . . . . . . . . . . . .
91
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
95
GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . .
96
96
102
103
105
105
106
106
106
106
106
107
107
108
111
111
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .
113
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116
78
GEARBOX 2870S.9
Print 603.93.381
GEARBOX 2870S.9
79
DESCRIPTION
Gearbox 2870S.9 is a ninegear mechanic type gearbox with 1st, 4th, 5th, 8th and 9th gears engaged by free ring synchronising rings,
2nd, 3rd, 6th and 7th gears by double cone synchronising ring.
The reverse gear engagement is with quickengagement sliding sleeve.
It is composed of a front section, comprising five ratios and reverse gear, and of a rear section comprising two ratios obtained through
epicyclic reduction gear.
The gear switch is carried out mechanically through doubleH control; the epicyclic reduction gear engagement is carried out
mechanically with pneumatic switching.
The gearbox is equipped with an oil pump for its lubrication.
Figure 1
SEC AA
78684
Print 603.93.381
80
GEARBOX 2870S.9
2870S.9
Type
Mechanical
Gears
Gears engagement
control
Mechanical
Power takeoff
Upon request
Gears engagement:
1st
2nd 3rd
4th 5th
6th 7th
8th 9th
F
Free
ring
i synchronising
h i i gear
Reverse gear
Quickconnection type
Gears antidisengagement
Gears
Gear ratio
First
Second
Third
Fourth
Fifth
Sixth
Seventh
Eighth
Ninth
Reverse gear
1 : 13.200
1 : 9.036
1 : 6.473
1 : 4.691
1 : 3.548
1 : 2.547
1 : 1.824
1 : 1.322
1 : 1.000
1 : 11.650
Print 603.93.381
GEARBOX 2870S.9
81
TUTELA ZC 90
4.5 Kg. (5lt)
100 C to 130 C
Secondary shaft
bearings
Secondary shaft
bearings
preloading
adjustment
Secondary shaft
preloading
adjustment rings
thickness
Secondary shaft
bearings assembly
temperature
Motion entry shaft
bearings adjusting
rings thicknesses
Print 603.93.381
Through rings
82
GEARBOX 2870S.9
Figure 2
Sec. AA
98999
Print 603.93.381
GEARBOX 2870S.9
83
TIGHTENING TORQUES
PART
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
TORQUE
Nm
(kgm)
19 2
(1.9 0.2)
33.5 3.5
(3.4 0.4)
23.5 2.5
(2.5 0.3)
372.5 19.5
(38 2)
9.5 0.5
(0.96 0.05)
Flanged hexagonal head screw for securing spring check flange on external control
Flanged hexagonal head screw for securing upper external control support cover
Screw for securing reduction gear control valve
Ring nut for securing sun gear on primary shaft
Flathead screw with TORX mark to secure rib washer *
Flanged hexagonal head screw for securing pneumatic reduction gear control cylinder to rear
35.5 3.5
halfcase
Flanged hexagonal head screw for securing rear cover on primary shaft
44.5 4.5
Output flange locking ring nut on planetary gearholder shaft
559.5 29.5
Flanged hexagonal head screw for securing read cover on secondary shaft
58 6
Oil filter on halfcase
320 30
Threaded plug with external manoeuvre hexagon for oil discharge
27.5 2.5
Hexagonal head screw for securing oil pump body to case
33.5 3.5
Flanged hexagonal head screw for securing transverse axle cover on drive *
19 2
Transverse axle screw *
30 3
Flanged hexagonal head screw for securing covers on side power takeoff connection windows
38 4
Screw for securing fork control rod hub
39 2
Idle positioner
78 8
Flanged hexagonal head screw for joining clutch cup and case
45.5 4.5
Flanged hexagonal head screw for securing front cover
1st step
20 1
2nd step
Flanged hexagonal head screw for securing clutch disengagement lever support
Ovalheaded screw for securing reduction gear reaction plate
Threaded plug with external manoeuvre hexagon for oil level
Flanged hexagonal head screw for securing upper internal controls cover (only for righthand
drive)
(3.6 0.4)
(4.4 0.5)
(57 3)
(5.9 0.6)
(32.6 3.1)
(2.8 0.3)
(3.4 0.4)
(1.9 0.2)
(3.1 0.3)
(3.9 0.4)
(4.0 0.2)
(8.0 0.8)
(4.6 0.6)
(2 0.1)
25
46.5 4.5
21 2
27.5 2.5
(4.6 0.4)
(2.1 0.2)
(2.8 0.3)
45.5 4.5
(4.6 0.5)
Print 603.93.381
84
GEARBOX 2870S.9
TOOLS
TOOL No.
DESCRIPTION
99305121
Hotair equipment
99322205
99322225
99340205
Percussion puller
99341003
99341004
Print 603.93.381
GEARBOX 2870S.9
85
TOOLS
TOOL No.
DESCRIPTION
99341009
Pair of brackets
99341015
Clamp
99341017
99341019
99341020
99341025
Grips
Print 603.93.381
86
GEARBOX 2870S.9
TOOLS
TOOL No.
DESCRIPTION
99342143
Peg for removing reverse gear shaft (to use with 99340205)
99345058
99348004
99355081
99355131
99370006
Print 603.93.381
GEARBOX 2870S.9
87
TOOLS
TOOL No.
DESCRIPTION
99370007
99370130
Tool for holding the sun gear during nut removal and refitting
99370317
99370349
Tool for fitting gasket on gearbox front cover (to use with
99370006)
99370466
Gauge base for transmission shaft bearing adjustment (to use with
99395604)
99370629
Print 603.93.381
88
GEARBOX 2870S.9
TOOLS
TOOL No.
DESCRIPTION
99374092
99374229
99381125
99395604
Comparator (0 : 10 mm)
99396031
Gauged rings for adjusting transmission shaft bearings (to use with
99370466)
Print 603.93.381
GEARBOX 2870S.9
89
Disengagement
Lift the calender and turn the cabin over.
- loosen securing bolt (23), unscrew securing nuts (24)
and detach air piping supporting bracket (22);
- unscrew securing nut (2) and detach air piping
supporting bracket (1);
- unscrew securing nuts (19) and detach bracket (20) of
reaction tierod (18);
- loosen securing screw (6) and detach from gearbox the
gears control lever completed with tierod (3) and
reaction tierod (18);
- disconnect reverse gear switch electric connection (16)
and rangechange switch electric connection (8);
- unscrew securing nuts (21) of clutch bell to engine that
will be able to be reached with difficulty from the lower
vehicle part.
- rotate deadening guard locking rivets below the gearbox
and remove the deadening guard;
- detach transmission shaft (9) as described in the related
section;
- disconnect air piping (13) from exhaust piping (11);
- detach terminal exhaust piping, operating on securing
clip (14) bolt and on support band (12) bolt (10);
- unscrew securing screws (4) and detach clutch control
operating cylinder (5);
- disconnect electric connection (15) of odometer sensor;
- unscrew securing screw (17) and detach air piping
support bracket;
- place an hydraulic jack equipped with support 99370629
under the gearbox;
- unscrew the remaining securing nuts of clutch bell to
engine, move the gearbox backwards and lowering the
jack remove it from below the vehicle.
Reengagement
Suitably reverse the operations carried out for
disengagement and tighten securing screws and
nuts at the required torque.
Print 603.93.381
90
GEARBOX 2870S.9
Print 603.93.381
GEARBOX 2870S.9
91
GEARBOX DISASSEMBLY
Figure 4
Figure 7
79429
71886
79440
79442
Figure 6
Figure 9
79441
Apply reaction lever 99370317 (1) and with key 99355081 (2)
loosen nut securing motion outlet flange (3).
Print 603.93.381
71888
92
GEARBOX 2870S.9
Figure 10
Figure 13
79444
71889
Unscrew screws (4), dismount cover (5), take off spring (3)
and take out push rod (2).
Figure 14
71893
71890
Figure 12
71894
79443
Print 603.93.381
GEARBOX 2870S.9
Figure 16
93
Figure 18
71895
71897
NOTE
Figure 17
Figure 19
71896
71898
Lift and remove primary shaft (1) together with internal drive
shaft (2).
Remove synchronizing rings (3).
Base October 2004
94
GEARBOX 2870S.9
Figure 20
Figure 23
71678
99000
98989
Remove cylindric roller bearing from motion inlet shaft (1) and
heat front halfcase contact surface (2). With a plastic
hammer, extract motion inlet shaft (1) completed with ball
bearing.
Figure 24
Figure 22
98990
71683
Extract sealing gasket (2) from motion inlet shaft cover (1).
Print 603.93.381
GEARBOX 2870S.9
95
Checks
GEARBOX CASE
BEARINGS
SHAFTS GEARS
Shaft seats for bearings and gear toothings must not be
damaged or worn.
NOTE
Print 603.93.381
96
GEARBOX 2870S.9
GEARBOX ASSEMBLY
Butter with hermetic type B the threaded part of all
screws that must be screwed in the throughholes.
71687
71688
FRONT HALFCASE
THICKNESS (S)
Figure 25
61957
71686
Print 603.93.381
GEARBOX 2870S.9
Figure 28
97
Figure 31
INTERMEDIATE CASE
71900
Figure 29
Assemble and simultaneously rotate, till it abuts, the secondary
shaft (3, Figure 30) completed with bearings in rear case. Place
calibrated rings 99396031 (2, Figure 30) on the case (4,
Figure 30). Arrange, as shown in the figure, base 99370466
completed with previouslyzeroed comparator (1, Figure 30);
the comparator rod must abut on the external bearing ring.
Carry out the measure on two diametricallyopposite points
and perform the arithmetic mean.
First method
71901
99001
Mount oil piping (5), fit inner control shaft bushing into its seat,
put in rib washer (5) and screw TORX mark screw with
prescribed torque.
After having computed the thickness value of the adjustment
ring, disassemble again secondary shaft (3, Figure 30) and oil
pump (1, Figure 29).
Print 603.93.381
98
GEARBOX 2870S.9
Figure 32
Figure 35
98993
71693
Slightly heat the ball bearing seat, assemble motion inlet shaft
(1) completed with bearing (4), adjustment ring (3) and elastic
ring (2). Settle the bearing till it abuts.
Figure 33
32447
98994
71679
Print 603.93.381
GEARBOX 2870S.9
Figure 37
99
Figure 39
71678
71903
Assemble motion inlet shaft cover (2), screw screws (1) and
tighten them at the required torque.
Figure 38
Figure 40
71898
Print 603.93.381
71904
100
GEARBOX 2870S.9
Figure 41
Figure 43
71905
78164
Put in push rod (4), spring (3), mount cover (1) and screw
down screws (2) tightening them with rated torque.
Figure 44
Figure 42
71907
78165
Assemble shoulder rings, placing them into their own seat and
reverse gear (3) with cylindric roller bearing. Assemble reverse
gear supporting shaft (2) with a suitable beater, paying
attention that the arrow (1) punched on the shaft is facing the
peg insertion hole.
Print 603.93.381
GEARBOX 2870S.9
Figure 45
101
Figure 48
71911
71908
Figure 46
71912
71909
Assemble oil pump (1) and tighten screws (2) at the required
torque, assemble cover (3) and tighten screws (4) at the
required torque.
Figure 47
71886
71910
Print 603.93.381
102
GEARBOX 2870S.9
Figure 52
Figure 51
79441
79440
Figure 53
gearbox with engaged
reverse gear
idle gearbox
62457
Print 603.93.381
GEARBOX 2870S.9
103
Figure 57
35481
35478
Figure 58
35482
35479
Figure 59
Figure 56
35483
35480
Print 603.93.381
104
GEARBOX 2870S.9
Figure 60
Figure 63
35484
35487
Figure 61
35485
35488
Figure 65
Figure 62
35486
35489
Print 603.93.381
GEARBOX 2870S.9
105
Figure 68
Figure 66
71869
- Fixed hubs (1) for 1st and reverse, 2nd 3rd 4th 5th
speed gears must be heated at a temperature of 100 to
130 C and driven into the primary shaft, paying attention
that synchronising ring stops (2) are inserted into the
respective fixed hub seats.
71870
Figure 70
71871
35491
106
GEARBOX 2870S.9
Figure 71
Figure 73
33651
71872
Assemble ball bearing (1) on motion inlet shaft (2) and carry
out its adjustment.
Remove elastic ring (1) from secondary shaft (3) and extract
bevel roller bearings (2 and 4) with a suitable punch
(destructive operation).
Figure 72
62455
Figure 74
GEARBOX 2870S.9
107
Figure 75
1
2
3
5
Figure 76
8
6
7
35431
79445
Secure the assembly in a vice, unscrew the four screws (1) and
disassemble valve (2) of epicyclic reduction gear drive.
Figure 77
Tighten the shaft going out of the box in a clamp, remove plug
(1) and disassemble cover (2).
Figure 78
78166
108
GEARBOX 2870S.9
Figure 79
Figure 82
33657
33660
Extract, from the control shaft (2), control selector (1) and
box (3).
Figure 80
Figure 83
33658
33661
Unscrew screw (1) and remove spacer, upper cup (3) and
spring (2). Remove lower cup.
Extract, from the control box (3), sealing gasket (1) and bushes
(2) with a suitable beater.
Figure 84
78167
33661
Remove the snap ring (4) and use a punch tool (5) having the
right diameter to push the extraction washer (1) and remove
flexible plugs (2) and (3).
Assemble, in control box (3), sealing gasket (1) and bushes (2)
with a suitable beater.
Print 603.93.381
GEARBOX 2870S.9
109
Figure 87
Figure 85
33660
78168
Insert the extraction washer (1) and use a punch tool having
the right diameter to install the first plug (2). Install the second
plug (3) and the snap ring (4).
Figure 88
Figure 86
71880
78169
Print 603.93.381
110
GEARBOX 2870S.9
Figure 89
Figure 92
33663
78170
Install the pin (2), the spring (1) and apply sealer LOCTITE
518 ().
Figure 90
Figure 93
33658
33655
Install the spring (2), the upper cap (3), the spacer and the
screw (1) and apply threading sealer LOCTITE 270 on the
screw itself.
Tighten the screw (1) to 30 Nm (3.1 kgm).
Figure 94
Figure 91
33657
Clean joining surfaces of control box and cover (2) and apply
LOCTITE 510 adhesive on one of the two components.
Assemble cover (2) and tighten screws (1) at a torque of 36.5
Nm (3.7 kgm).
Apply threading sealer LOCTITE 270 on the screws (1).
Base October 2004
79445
GEARBOX 2870S.9
111
72458
SLOW GEAR ENGAGEMENT (1st 2nd 3rd 4th 5th AND REVERSE GEAR)
Air coming from services tank, passing through a reduction gear, is reduced to the pressure of 6.5 to 6.9 bars and reaches consent
valve at union I.
By pressing the clutch, operate on the gearbox lever to engage a gear (12345RG); cam (A) is moved upwards and pushes
pin (B) leftwards.
The pin abuts on piston (C) valve and by lifting it, closes the supply to union 21.
By discharging air contained into the cylinder through the vent hole (D), air will then go out of union 22 thereby keeping gearbox
piston in slow gears.
Print 603.93.381
112
GEARBOX 2870S.9
Figure 96
72459
Print 603.93.381
GEARBOX 2870S.9
113
DISASSEMBLY
Figure 97
Figure 100
71916
71913
Remove rod with fork (1), withdraw phonic wheel (3) and
remove synchronising ring (2).
Figure 101
Figure 98
71917
71914
Figure 99
Figure 102
71915
Lift case (2) in order to free outlet shaft (3) and rod (1) for
synchronising drive fork.
Print 603.93.381
71918
114
GEARBOX 2870S.9
Figure 103
Figure 106
71922
71919
Figure 104
Figure 107
71920
35514
In order to remove sliding sleeve (1) from crown (2), use small
pins (3) with diameter 2 to 2.3 mm and a length of 10 mm.
Figure 105
Figure 108
35515
71921
GEARBOX 2870S.9
Figure 109
115
Figure 112
71923
71926
Extract sealing gasket (4) from cover (2), unscrew screws (1)
and disassemble cover (2) and support (3).
Check that ball bearing (2), when rotating along the two
directions, does not show roughness or noise when sliding.
In case of a replacement of the bearing itself, slightly heat
support (1) seat before disassembling it.
Figure 110
71924
Figure 111
Checks
Check that all parts composing the epicyclic reduction gear
assembly do not shown traces of excessive wear, seizures or
breakages.
Replace the affected parts.
116
GEARBOX 2870S.9
ASSEMBLY
Figure 113
Figure 116
71930
71927
By using a punch (2), assemble elastic peg (2) checking pin (3).
Figure 117
Figure 114
71928
71931
Figure 115
Figure 118
71932
71929
GEARBOX 2870S.9
Figure 119
117
Figure 122
35523
Figure 120
71935
71933
71936
Figure 121
71934
Arrange springs, pins and rollers (1), apart from the central
ones (), into the hub.
Print 603.93.381
71937
118
GEARBOX 2870S.9
Figure 125
Figure 128
71925
71940
Figure 126
71938
Figure 127
71941
71939
GEARBOX 2870S.9
Figure 130
119
Figure 133
71958
71944
Figure 131
71945
Figure 135
Figure 132
71946
Keyin flange (1) and screw nut (2) without blocking it.
71943
NOTE
120
GEARBOX 2870S.9
Print 603.93.381
PROPELLER SHAFTS
SECTION 5
Propeller shafts
Page
Print 603.93.381
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
10
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
10
- Reengagement . . . . . . . . . . . . . . . . . . . . . . . .
10
11
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
11
- Reengagement . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
PROPELLER SHAFTS
Print 603.93.381
PROPELLER SHAFTS
DESCRIPTION
Motion transmission from enginegearbox to rear axle
occurs through a propeller shaft that is sliding in a single
section or in two sections composed of a fixed front shaft and
a sliding rear shaft.
The sliding shaft is connected to the sleeve keyed to the
differential tapered pinion by means of cardan joints.
Figure 1
VIEW FROM A
VIEW FROM B
61963
Print 603.93.381
PROPELLER SHAFTS
Figure 2
VIEW FROM A
VIEW FROM B
61964
Figure 3
VIEW FROM A
61965
Print 603.93.381
PROPELLER SHAFTS
Figure 4
61966
VIEW FROM A
DETAIL C
VIEW FROM B
Figure 5
VIEW FROM A
VIEW FROM C
VIEW FROM B
61967
Print 603.93.381
PROPELLER SHAFTS
Figure 6
61968
VIEW FROM A
VIEW FROM B
Print 603.93.381
PROPELLER SHAFTS
2700
3105
3330
L
mm
L
mm
L
mm
max
min
max
min
L1
mm
L
mm
min
L1
mm
max
4455
L
mm
min
L1
mm
max
4815
L
mm
min
L1
mm
max
L
mm
ENGINE
GEARBOX TYPE
ML 60E..
4 cylinders
2855.5/2855.6
1340 to 1440
1720 to 1830
ML 65E..
4 cylinders
2855.5/2855.6
1340 to 1440
1720 to 1830
ML 75E1315
4 cylinders
2855.5/2855.6
1340 to 1440
1720 to 1830
ML 75E17
4 cylinders
2855.5/2855.6
1340 to 1440
1720 to 1830
ML 75E18
6 cylinders
2855.5/2855.6
1220 to 1330
1630 to 1740
1850 to 1960
ML 80EL..
4 cylinders
2855.5/2855.6
1330 to 1440
1720 to 1830
ML 80E..
4 cylinders
2855.6
1360 to 1460
1760 to 1870
ML 80E..
4 cylinders
2870.9
1600 to 1270
1560 to 1660
1790 to 1900
1180
960 to 1070
1180
1450 to 1560
1180
1720 to 1830
1610
1650 to 1760
ML 80E..
6 cylinders
2855.6
1250 to 1360
1650 to 1760
1850 to 1960
ML 80E..
6 cylinders
2865.6
1200 to 1310
1600 to 1710
1830 to 1940
1235
960 to 1070
1235
1450 to 1560
1235
1720 to 1830
1662
1650 to 1760
ML 80E..
6 cylinders
2870.9
1040 to 1150
1440 to 1550
1660 to 1770
1070
960 to 1070
1070
1450 to 1560
1070
1720 to 1830
1500
1650 to 1760
ML 90E..
4 cylinders
2855.6
1360 to 1460
1760 to 1870
ML 90E..
4 cylinders
2870.9
1160 to 1270
1560 to 1660
1790 to 1900
1180
960 to 1070
1180
1450 to 1560
1180
1720 to 1830
1610
1650 to 1760
ML 90E..
6 cylinders
2855.6
1250 to 1360
1650 to 1760
1850 to 1960
ML 90E..
6 cylinders
2865.6
1200 to 1310
1600 to 1710
1830 to 1940
1235
960 to 1070
1235
1450 to 1560
1235
1720 to 1830
1662
1650 to 1760
ML 90E..
6 cylinders
2870.9
1040 to 1150
1440 to 1550
1660 to 1770
1070
960 to 1070
1070
1450 to 1560
1070
1720 to 1830
1500
1650 to 1760
ML 100E..
4 cylinders
2855.6
1360 to 1460
1760 to 1870
ML 100E..
4 cylinders
2870.9
1160 to 1270
1560 to 1660
1790 to 1900
1180
960 to 1070
1180
1450 to 1560
1180
1720 to 1830
1610
1650 to 1760
ML 100E..
6 cylinders
2855.6
1250 to 1360
1650 to 1760
1850 to 1960
ML 100E..
6 cylinders
2865.6
1200 to 1310
1600 to 1710
1830 to 1940
1235
960 to 1070
1235
1450 to 1560
1235
1720 to 1830
1662
1650 to 1760
ML 100E..
6 cylinders
2870.9
1040 to 1150
1440 to 1550
1660 to 1770
1070
960 to 1070
1070
1450 to 1560
1070
1720 to 1830
1500
1650 to 1760
max
4185
MODEL
Print 603.93.381
min
3690
min
max
PROPELLER SHAFTS
PITCH
L1
mm
3690
L
mm
max
L
mm
min
L1
mm
max
4455
L
mm
max
L
mm
min
L1
mm
max
L
mm
ENGINE
GEARBOX TYPE
ML 60E..
4 cylinders
2855.5/2855.6
875
1965 to 2065
1280
2335 to 2345
1280
2830 to 2930
1262
3090 to 3190
1637
3450 to 3550
ML 65E..
4 cylinders
2855.5/2855.6
875
1965 to 2065
1280
2335 to 2345
1280
2830 to 2930
1262
3090 to 3190
1637
3450 to 3550
ML 75E1315
4 cylinders
2855.5/2855.6
875
1965 to 2065
1280
2335 to 2345
1280
2830 to 2930
1262
3090 to 3190
1637
3450 to 3550
ML 75E17
4 cylinders
2855.5/2855.6
875
1965 to 2075
1262
2320 to 2430
1262
2815 to 2925
1262
3080 to 3190
1637
3440 to 3550
ML 75E18
6 cylinders
2855.5/2855.6
1167
2215 to 2325
1167
2710 to 2820
1167
2970 to 3080
1527
3330 to 3440
ML 80EL15
4 cylinders
2855.5/2855.6
875
1965 to 2075
1262
2320 to 2430
1262
2815 to 2925
1262
3090 to 3190
1637
3450 to 3550
ML 80EL17
4 cylinders
2855.6
1262
3080 to 3190
1637
3440 to 3550
ML 80E..
4 cylinders
2855.6
910
1980 to 2090
1317
2340 to 2450
1317
2840 to 2950
1372
3100 to 3210
1632
3460 to 3570
ML 80E..
6 cylinders
2855.6
1207
2225 to 2335
1207
2720 to 2830
1262
3000 to 3100
1622
3340 to 3450
ML 90E..
4 cylinders
2855.6
910
1980 to 2090
1317
2340 to 2450
1317
2840 to 2950
1372
3100 to 3210
1632
3460 to 3570
ML 90E..
6 cylinders
2855.6
1207
2225 to 2335
1207
2720 to 2830
1262
3000 to 3100
1622
3340 to 3450
ML 100E..
4 cylinders
2855.6
910
1980 to 2090
1317
2340 to 2450
1317
2840 to 2950
1372
3100 to 3210
1632
3460 to 3570
ML 100E..
6 cylinders
2855.6
1207
2225 to 2335
1207
2720 to 2830
1262
3000 to 3100
1622
3330 to 3440
Print 603.93.381
min
L1
mm
4815
MODEL
min
L1
mm
4185
min
max
PROPELLER SHAFTS
DIAGNOSTICS
Main propeller shaft transmission anomalies:
1 Transmission noises and vibration
Shaft distortion
NO
Unbalanced shaft.
YES
NO
NO
YES
NO
NO
TIGHTENING TORQUES
PART
TORQUE
Nm
(kgm)
63.5 6.5
(6.4 0.6)
101 10
(10.3 1)
82 8
(8.3 0.9)
Print 603.93.381
10
PROPELLER SHAFTS
Figure 7
Disengagement
Set the vehicle under safety conditions and operate
as described below:
- rotate locking rivets for dampening guard (6) under the
gearbox and remove it;
- position an hydraulic jack equipped with support
99370618 under the propeller shaft and suitably constrain
it;
- unscrew the four securing bolts (2) and detach propeller
shaft (1) from rear axle;
- unscrew the four securing bolts (5) and detach propeller
shaft from gearbox;
- unscrew the two securing bolts (3) and detach
intermediate support (4) from crossmember;
- lower the hydraulic jack and remove propeller shaft (1)
from the vehicle.
Reengagement
For the reengagement, carry out in reverse order
the operations described for the disengagement,
complying with the following warnings:
Selflocking nuts must always be replaced and
tightened at the required torque.
62249
Print 603.93.381
PROPELLER SHAFTS
505620
11
Figure 8
33700
33701
33702
Reengagement
For the reengagement, carry out in reverse order
the operations described for the disengagement,
complying with the following warnings:
Selflocking nuts must always be replaced and
tightened at the required torque.
Check that the arrows included in the sliding part and
on the shaft are aligned.
Print 603.93.381
12
PROPELLER SHAFTS
Print 603.93.381
SECTION 6
Rear axles 4517 and 4521
Page
Print 603.93.381
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
17
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
17
- Reengagement . . . . . . . . . . . . . . . . . . . . . . . .
17
18
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
18
- Reengagement . . . . . . . . . . . . . . . . . . . . . . . .
18
19
19
20
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
21
22
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
25
26
26
26
27
28
29
Page
32
34
34
34
34
38
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
Print 603.93.381
DESCRIPTION
The rear axle is of the carrier type with simple reduction and
is composed of a suitably reinforced case made of pressed
steel plate. The differential gear is characterised by a set of
helical toothed gears. The bevel pinion is supported by two
tapered roller bearings (for rear axle 4517) and two tapered
roller bearings and one pilot roller bearing (for rear axle
4521). The adjustment of the bevel pinion is carried out by
modifying the thickness between fixed differential gear and
front bearing. Moreover, it is possible to adjust the bevel
pinion position with respect to the bevel crown, modifying
the adjustment ring thickness interposed between rear axle
case and external ring for bevel pinion rear bearing.
Figure 1
33131
PARTS COMPOSING WHEEL HUBS FOR REAR AXLES 4517 AND 4521
1. Gearing inspection cover 2. Gasket 3. Halfshaft 4. Rear axle 5. Adjustment nut 6. Safety washer 7. Bearing
8. Wheel hub 9. Spacer 10. Bearing 11. Gasket resting ring 12. Sealing ring 13. Brake disk 14. Plate
Print 603.93.381
Figure 2
33132
Figure 3
33133
Print 603.93.381
4517
4521
1/3.15 (13/41)
1/3.31 (13/43)
1/3.58 (12/43)
1/3.90 (11/43)
1/4.30 (10/43)
1/4.55 (9/41)
1/5.125 (8/41)
1/5.57 (7/39)
1/3.21 (14/45)
1/3.38 (13/44)
1/3.73 (11/41)
1/4.10 (10/41)
1/4.55 (9/41)
1/4.88 (8/39)
1/5.57 (7/39)
2.2 to 3
(0.22 to 0.3)
2.6 to 3.4
(0.26 to 0.34)
mm
Nm
(kgm)
Print 603.93.381
0.15 to 0.20
0.18 to 0.23
(with 14/45 and 13/44)
0.18 to 0.23
(with 9/41; 8/41 and 7/39)
0.20 to 0.28
4517
Clearance between crown
wheels and planetary gears
4521
0.20 to 0.28
mm
WHEEL HUBS
Wheel hub bearings
max 0.16
max 4
(0.40)
max 4.5
(0.45)
through a nut
Tutela W 140/M DA
2.65 (2.4)
0.2 (0.18)
5 (4.5)
0.2 (0.18)
Print 603.93.381
DIAGNOSTICS
Main rear axle operating anomalies:
1 Wheel hubs noises;
2 Rear axle noises;
3 Noises upon release;
4 Noises when pulling;
5 Noises in a curve.
YES
YES
Sufficient lubrication.
NO
NO
YES
(continued)
Print 603.93.381
NO
NO
NO
YES
YES
YES
Sufficient lubrication.
NO
NOISES IN A CURVE
NO
Print 603.93.381
TIGHTENING TORQUES
Figure 4
77196
TORQUE
Nm
(kgm)
29 3
(2.9 0.3)
326.5 16.5
(32.6 1.7)
280 14
(28 1.4)
67.5 6.5
(6.8 0.6)
107.5 10.5
(10.8 1)
561 28
(56.1 2.8)
Before screwing the screws, apply some drops of LOCTITE TYPE 270 sealant to their threaded holes.
Print 603.93.381
10
Figure 5
61970
1
2
3
4
TORQUE
Nm
107.5 10.5
9.1 0.9
490.5 49.5
62.5 6.5
+50
400 20
61
(kgm)
(10.8 1)
(0.9 0.1)
(49 5)
(6.2 .,7)
+5
(40 2
)
(0.6 0.1)
Butter the joining surface between halfshaft and wheel hub with adhesive type B. Apply LOCTITE TYPE 222 sealant
on thread of screws (4) operating as plug
** Upon assembling the sensor support securing screws, apply some drops of LOCTITE TYPE 243 threadbraker on the
thread of holes corresponding to the bracket welded on rear axle arm.
Print 603.93.381
11
Figure 6
77197
TORQUE
Nm
(kgm)
29 3
(2.9 0.3)
326.5 16.5
(32.6 1.7)
280 14
(28 1.4)
112 11
(11.2 1.1)
167.5 8.5
(16.7 0.9)
561 28
(56.1 2.8)
267.5 26.5
(26.7 2.7)
Before screwing the screws, apply some drops of LOCTITE TYPE 270 sealant to their threaded holes.
Print 603.93.381
12
Figure 7
61972
1
2
3
4
TORQUE
Nm
163.5 13.5
463.5 46.5
9.1 0.9
103 10
+50
500 20
61
(kgm)
(16.7 1.4)
(0.9 0.1)
(49 5)
(602 0.7)
+5
(50 2
)
(0.6 0.1)
Butter the joining surface between halfshaft and wheel hub with adhesive type B. Apply LOCTITE TYPE 222 sealant
on thread of screws (4) operating as plug
** Upon assembling the sensor support securing screws, apply some drops of LOCTITE TYPE 243 threadbraker on the
thread of holes corresponding to the bracket welded on rear axle arm.
Print 603.93.381
13
TOOLS
TOOLS N.
DENOMINATION
99305121
Hotair apparatus
99306010
99321024
99322215
99345053
99345056
Print 603.93.381
14
TOOLS
TOOLS N.
DENOMINATION
99348001
99357071
Wrench for wheel hub bearing adjustment nut (for rear axle 4521)
99357080
Wrench for wheel hub bearing adjustment nut (for rear axle 4517)
99370006
99370007
99370294
Print 603.93.381
15
TOOLS
TOOLS N.
DENOMINATION
99370296
99370317
99370617
99374092
99374093
99374132
Print 603.93.381
16
TOOLS
TOOLS N.
DENOMINATION
99374201
99389819
99395026
99395684
99395728
Print 603.93.381
17
Disengagement
Place the vehicle on a plane ground, lock front
wheels and proceed as follows:
- loosen securing nuts for rear wheels, lift the vehicle from
the rear and place it on supporting stands;
- place hydraulic trolley 99321024 under rear wheels,
remove securing nuts and detach the wheels
- unscrew securing bolts (9) and disconnect propeller
shaft (8) from rear axle;
- disconnect electric connections (1) for brake wear
signals, electric connections (4) for ABS revolutions
sensors and free wiring from various check clamps;
- disconnect air supply pipings (5) next to fitting (7);
- disconnect brake oil delivery piping (2), unscrew nut (11)
and detach piping (10) from supporting bracket;
- unscrew securing bolts (19) to disconnect stabilizing bar
(13) and securing nuts (18) for disconnecting
shockabsorbers (6) from rear axle;
Reengagement
Suitable revert the operations carried out for the
disengagement and tighten at the required torque
securing screws and nuts.
Selflocking nuts must always be replaced and
tightened at the required torque.
Verify that:
- check stand (3) threading; when detecting
anomalies, adjust the threading or replace the
stands;
- carry out the brake system air drain as described
in the related section;
- check conditions of elastic pads (14); when
detecting them as worn, replace them;
- check that the lubricating oil in rear axle case is
at level; otherwise, refill it.
Print 603.93.381
62247
18
Disengagement
Place the vehicle on a plane ground, lock front
wheels and proceed as follows:
- loosen securing nuts for rear wheels, lift the vehicle from
the rear and place it on supporting stands in the marked
point ();
- place hydraulic trolley 99321024 under rear wheels,
remove securing nuts and detach the wheels
- unscrew securing bolts (9) and disconnect propeller
shaft (8) from rear axle;
- disconnect electric connections (1) for brake wear
signals, electric connections (5) for ABS revolutions
sensors and free wiring from various check clamps;
- disconnect air supply piping (25) next to fitting (26);
- disconnect brake oil delivery piping (12), unscrew nut
(11) and detach piping (10) from supporting bracket;
Reengagement
Suitable revert the operations carried out for the
disengagement and tighten at the required torque
securing screws and nuts.
Selflocking nuts must always be replaced and
tightened at the required torque.
Verify that:
- check stand (2) threading; when detecting
anomalies, adjust the threading or replace the
stands;
- carry out the brake system air drain as described
in the related section;
- check that the lubricating oil in rear axle case is
at level; otherwise, refill it.
Base October 2004
62248
Print 603.93.381
Figure 10
19
Figure 12
33049
33051
Discharge oil from plug (2). Remove oil filling plug (1).
NOTE Identification data about rear axle assembly are included in nameplate (3) secured to connection
plane to gearings inspection cover.
525010
525013
Figure 11
Figure 13
33050
Print 603.93.381
33052
Check that air vent (1) in rear axle case is not clogged, otherwise disassemble it, accurately clean it and reassemble it.
20
Figure 17
Figure 14
33053
33056
Figure 18
Figure 15
33057
Figure 19
Figure 16
33058
33055
Remove wheel hub (3), completed with brake disk (1), front
(2) and rear bearings, from sealing and spacer ring.
Print 603.93.381
21
Figure 20
33060
33061
Remove, from wheel hub (1), sealing ring (2) and rear bearing
below it.
Figure 22
33062
Print 603.93.381
22
Figure 23
18409
ground part of the barrel and, making the rear axle case rotate
around its own axis, check that it has not been subjected to
distortions.
Print 603.93.381
23
Assembly
Figure 24
Figure 27
33063
33066
Figure 25
33064
Place, in wheel hub (2) seat, the rear tapered roller bearing
and assemble it with beater 99374093 (3) and with the help
of a press (1), avoiding to abut. Turn wheel hub over and
assemble external ring of front tapered roller bearing.
Figure 26
Figure 28
33065
33068
Print 603.93.381
24
Figure 29
Figure 32
33058
33072
Figure 30
Figure 33
33057
33071
Print 603.93.381
Figure 34
25
Figure 36
33055
33076
Place the two holes (1), marked with OIL, horizontally with
respect to ground, as shown in the figure, and insert into
them 0.2 l of oil type W140 MDA, on every wheel side. Apply
on threaded part some screws whose function is plugging the
sealant type 222 LOCTITE and tighten them:
Figure 35
525010
33075
Print 603.93.381
26
Figure 40
33077
33080
Figure 38
NOTE Do not revert external races of gearing case
support bearings.
33078
Figure 41
Figure 39
33081
33079
Print 603.93.381
27
Figure 45
33082
Figure 43
33085
Figure 46
33083
33086
Figure 44
Figure 47
33084
Print 603.93.381
33087
28
Figure 48
Figure 51
33088
33091
Extract rear tapered roller bearing (2) from bevel pinion (1),
with extractor 99348001 (3).
Figure 49
Extract sealing ring (1) and front tapered roller bearing from
rear axle case (2). Extract external ring of front tapered roller
bearing with a bronze beater.
Figure 50
33090
Print 603.93.381
29
Figure 55
33092
33095
33084
33096
33094
30
Figure 60
33098
33100
Figure 61
33101
33099
Print 603.93.381
Figure 62
31
Figure 63
33102
33103
S=
A1 + A2
-(B)
3.90 + 4.10
- ( 0.05)
2
8.00
S=
- 0.05
2
S = 4.00 - 0.05
S = 3.95
The adjustment ring thickness will therefore have to be 3.95
mm.
Print 603.93.381
32
Figure 64
33104
33108
Figure 65
33110
Print 603.93.381
Figure 69
33
Figure 72
33111
33114
Tighten bevel pinion check nut, with lever 99370317 (1) and
with dynamometric wrench (2), at the torque of 561 Nm
(57.2 kgm). Settle the bearings and check, with dynamometer
99389819, the bevel pinion rolling torque.
Then carry out, through a punch, a safety notch for the check
nut.
Figure 70
Figure 73
33112
Figure 71
If the measured value does not fall within the required limits,
change the adjustment ring placed on fixed spacer till the
required value is reached.
33113
34
Figure 76
Figure 74
33117
33118
Figure 78
Figure 75
33119
Print 603.93.381
Set gearing case support bearings and check the total rolling
torque.
Such torque changes according to the applied reduction ratio
on rear axle and is computed through the following formula:
Ct = Cp + (
Cd
35
Figure 48
x 0.99)
R
Ct = total rolling torque.
Cp = rolling torque for bevel pinion bearings
Cd = 2 2.8 Nm (0.2 to 0.29 kgm) for rear axle 4517
Cd = 2.5 2.8 Nm (0.25 to 0.29 kgm) for rear axle 4521
Cd = 2 2.8 Nm (0.2 to 0.29 kgm)
33121
Example:
Ct = 3 + (
2.8
5.57
x 0.99)
Ct = 35 + 0.50
Ct = 3.50 Nm (0.36 kgm)
Figure 47
Apply, with a brush, a thin layer of lead oxide (minium) on
crown teeth. Rotate the pinion and detect the pinion teeth
contact imprint on crown teeth.
On page 37 systems are shown to obtain an exact contact
adjustment for bevel torque toothings.
33107
Print 603.93.381
36
Figure 49
Figure 50
33122
33123
Print 603.93.381
37
Figure 51
8
A
B
C
D
= Meshing depth
= Ridge
= Flank
= Clearance
Correct contact.
If the bevel torque adjustment is
correctly carried out, the
toothing surfaces contact will be
regular.
1
Excessive contact on lower
tooth flank.
Remove pinion from crown and
then approach crown to pinion to
adjust the clearance.
2
Excessive contact on tooth
heel.
Approach crown to pinion and
then remove pinion from crown
to adjust the clearance.
A
B
C
D
E
= Longer base
= Heel
= Bit
= Contact surface
= Side surface
3
Excessive contact in tooth
upper part or ridge.
Approach pinion to crown and
then remove crown from pinion
to adjust the clearance.
4
Excessive contact on tooth bit.
Remove crown from pinion and
then approach pinion to crown
to adjust the clearance.
13526
Print 603.93.381
38
10
11
7
12
14
13
33433
Figure 53
33434
Print 603.93.381
39
Disassembly
In order to disassemble the differential locking, remove halfshaft, disassemble locking control (1, Figure 53), extract gearing box
(see 525010 DIFFERENTIAL GEAR REPAIR) and afterwards remove sleeve (2, Figure 53) from rear axle case.
Checks
Insert air on operating cylinder at a pressure of about 6 bars and check that the engagement lever performs a 15mm stroke,
otherwise replace worn parts.
Assembly
In order to assemble the differential locking, insert sleeve (2, Figure 53) into rear axle case, assemble gearing case (see GEARING
CASE ASSEMBLY ON REAR AXLE CASE), assemble locking control (1, Figure 53) and afterwards insert the halfshaft.
SECT. A-A
70243
Assembly
Assemble sensor (3) on support (2) by completely pushing it into its own seat.
Secure support (2) with screws (1). Upon assembling the screws (1), dispense some drops of threadbraking LOCTITE TYPE
243 on the thread of corresponding holes of the bracket welded on rear axle arm and tighten screws (1) with a torque of
5 to 7 Nm.
Assemble the disk hub assembly with driven phonic wheel. Push the sensor into its final position in contact with phonic wheel,
through the suitable hole on brake plate.
Print 603.93.381
40
Print 603.93.381
SECTION 7
5206
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
- Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Characteristic angles . . . . . . . . . . . . . . . . . . . .
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
12
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
17
- Reengagement . . . . . . . . . . . . . . . . . . . . . . . .
17
Print 603.93.381
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
18
- Reengagement . . . . . . . . . . . . . . . . . . . . . . . .
18
19
19
20
- Wheel alignment . . . . . . . . . . . . . . . . . . . . . . .
20
21
21
21
22
23
23
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
23
24
24
Page
- Axial clearance adjustment for wheel hub
bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
25
25
26
26
- Detachment . . . . . . . . . . . . . . . . . . . . . . . . . .
26
- Reattachment . . . . . . . . . . . . . . . . . . . . . . . .
26
27
27
27
- Detachment . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Reattachment . . . . . . . . . . . . . . . . . . . . . . . .
28
30
31
32
Print 603.93.381
DESCRIPTION
Front axle
The front axle is made of a steel structure, with doubleT
section, at the end of which stub axles are articulated. The
stub axle articulation is performed through pins that are
integral with front axle body, and by means of four roller
bearings driven by interference into stub axle projection
holes.
Figure 1
77198
Print 603.93.381
Figure 2
77199
Print 603.93.381
Characteristic angles
In order to have a good vehicle roadholding, a low tire
consumption and to allow the driving wheels when steering
to spontaneously return to their straight running, certain
assembly angles are given to front wheels:
32957
Caster angle
Figure 5
Figure 3
A
A
B
32956
B
32958
The caster angle () is the angle formed by the pillar axis with
the vertical line to the ground observing the vehicle on its
side.
If the pillar axis extension falls over the wheel resting point
to the ground, along the vehicle running direction, the caster
angle is conventionally positive (A); it is negative (B) if it falls
behind the wheel resting point to the ground; it is zero if it
is perfectly vertical to the wheel resting point to the ground.
This angle allows keeping the front wheels straight when the
vehicle is in a rectilinear drive and the spontanoeus return of
the wheels, from the position assumed in a curve to the
rectilinear drive position, as soon as the steering wheel is
released by the driver.
Figure 7
32960
Vehicle toein
Figure 6
Figure 8
A
A
B
B
32959
32961
Print 603.93.381
5833/1
1
Seat diameter for stub axle roller
bearings:
upper seat
1
lower seat
2
mm
mm
mm
mm
42
52
mm
0.012 to 0.028
mm
0.014 to 0.033
mm
mm
35
43
mm
mm
41.972 to 41.988
51.967 to 51.986
2
3
6
7
34.984 to 35.000
42.984 to 43.000
Print 603.93.381
mm
0 to 0.016
mm
0 to 0.016
5833
X1
X2
5833/1
mm
0.10 to 0. 35
mm
0.25
Adjustment plates X 1 ; X 2
S
mm 0.25
mm
WHEEL HUBS
Wheel hub bearings
Axial hub bearing clearance
Bearing preload
from Nm 0.23
max 0.16
Tutela W 140/MDA
Liters (kg)
0.10 (0.09)
WHEEL ATTITUDE
mm
0.5 to 1.5
Print 603.93.381
DIAGNOSTICS
Main operating anomalies on front axle:
1 Steering wheel hardness;
2 Wobble;
3 Noises.
NO
YES
YES
YES
YES
YES
Print 603.93.381
10
WOBBLE
NO
YES
YES
YES
YES
NO
YES
Centered wheels:
- centered, not distorted rim
- correct tire assembly on rim
YES
Balanced wheels.
Print 603.93.381
11
NOISES
YES
YES
Print 603.93.381
12
TIGHTENING TORQUES
Figure 9
77200
Selflocking hexagonal head screw for securing brake calipers support to stub axle
Selfbraking hexagonal head screw for securing transverse tierod lever to stub axle
Selfbraking hexagonal head screw for securing longitudinal lever to stub axle
Flanged hexagonal head screw for securing lower fifth wheel cover to stub axle
Selflocking hexagonal head screw for securing brake calipers
Hexagonal head screw for securing brake disk to wheel hub
Hexagonal head screw for securing heat guarding cover to brake calipers support
Cylindrical head screw with embedded hexagon for locking wheel bearings
adjustment ring nut
Wheel bearings securing ring nut
Tapered threaded plug for wheel hub cover
Wheel hub cover
TORQUE
Nm
(kgm)
545 25
(54.5 2.5)
363 20
(36.3 2)
363 20
(36.3 2)
126.5 6.5 (12.6 6.7)
169.5 16.5
(17 1.6)
40 4
(4 0.4)
22.5 2.5 (2.25 0.25)
27.5 2.5
(2.75 0.25)
279.5 14.5
57.5 2.5
89 9
(2.8 1.4)
(5.9 0.25)
(8.9 0.9)
models 60 to 75
400
+50
models 80 to 100
500
+50
12
20
20
201 51.5
(40
+5
(50
+5
2
)
)
(44 54)
Print 603.93.381
13
TOOLS
TOOLS No.
DENOMINATION
99305354
99306010
99321024
99322215
99347047
99347068
Print 603.93.381
14
TOOLS
TOOLS No.
DENOMINATION
99355038
99370006
99370007
99370317
99370628
99370713
Print 603.93.381
15
TOOLS
TOOLS No.
DENOMINATION
99374092
99374172
99374370
99374401
99374528
99389819
Print 603.93.381
16
TOOLS
TOOLS No.
99395026
DENOMINATION
Print 603.93.381
17
Disengagement
Place the vehicle on a plane ground, lock front
wheels with chocks and proceed as follows:
- loosen securing nuts for front wheels, lift the vehicle and
place it on supporting stands;
- place hydraulic trolley 99321024 under the wheels,
remove securing nuts and detach the wheels;
- place an hydraulic jack equipped with support 99370628
under the front axle;
- disconnect electric connections (10) for brake wear
signals, electric connections (3) for ABS revolutions
sensors (on the right side it is necessary to remove the
heat guard) that are placed inside the longitudinal
members and free wiring from various check clamps;
- detach rigid piping (8), unscrew securing screws (9) and
detach brake pipings support bracket (7).
Reengagement
Suitable revert the operations carried out for the
disengagement and tighten at the required torque
securing screws and nuts.
Selflocking nuts must always be replaced and
tightened at the required torque.
Verify that:
- check stand (5) threading; when detecting
anomalies, adjust the threading or replace the
stands;
- carry out the brake system air drain as described
in the related section;
- check that the braking system lubricating oil is
at level; otherwise, refill it;
- check elastic pads conditions; when detecting
them as worn, replace them.
Print 603.93.381
79446
18
Disengagement
Place the vehicle on a plane ground, lock front
wheels with chocks and proceed as follows:
- loosen securing nuts for front wheels, lift the vehicle and
place it on supporting stands;
- place hydraulic trolley 99321024 under the wheels,
remove securing nuts and detach the wheels;
- place an hydraulic jack equipped with support 99370628
under the front axle;
- disconnect electric connections (16) for brake wear
signals, electric connections (6) for ABS revolutions
sensors (on the right side it is necessary to remove the
heat guard) that are placed inside the longitudinal
members and free wiring from various check clamps;
- detach rigid piping (14), unscrew securing screws (15)
and detach brake pipings support bracket (13).
Reengagement
Suitable revert the operations carried out for the
disengagement and tighten at the required torque
securing screws and nuts.
Selflocking nuts must always be replaced and
tightened at the required torque.
Verify that:
- check stand (7) threading; when detecting
anomalies, adjust the threading or replace the
stands;
- carry out the brake system air drain as described
in the related section;
- check that the braking system lubricating oil is
at level; otherwise, refill it.
Base October 2004
79447
Print 603.93.381
19
Figure 13
32974
Lift the front vehicle part and place oscillating plates (1) under
the wheels locking them with suitable stops (2).
NOTE
Figure 14
32975
Figure 12
Figure 15
32973
Print 603.93.381
32976
20
Wheel alignment
Figure 18
Figure 16
32977
32979
Level the detectors (3) through a level (1) and lock them in
position through screw (2).
Move the straightedges (4) till they are centered by the light
signal emitted from the detector and take note of the shown
values.
Figure 17
13952
32978
If the values are unequal, steer the wheels till the light signal
indexes are arranged on two equal values (A) and exactly the
mean value of the two previouslyperformed readings. In this
way a perfect wheel alignment is obtained.
Print 603.93.381
21
32980
32982
Figure 23
32981
32983
Inwardly steer the wheels by 20 and press king pin key (3)
twice; LED (2) turns on and nine horizontal lines appear on
digital display (1).
Base October 2004
22
Figure 26
32984
Outwardly steer the wheels by 20 and press king pin key (2)
again; the king pin angle value appears on digital display (1) and
must be 7.
32986
Figure 25
32985
Without moving the wheel, press caster angle key (3). LED (1)
turns on and the caster angle value appears on digital display
(2) and must be 230.
NOTE
Print 603.93.381
520610
23
Figure 27
32990
32994
520620
Figure 31
Figure 28
77201
Turn the wheel hub so that the screw plug (1) faces
downwards; release the plug and drain oil into the
appropriate container.
Figure 29
Figure 32
32993
Print 603.93.381
32995
32996
24
Figure 35
32997
Figure 34
32998
Figure 36
60875
Screw on stub axle pin tool 99370713 (3) and lubricate its
external surface with TUTELA W140/MDA oil.
Sling with a rope (1) the wheel hub (2) and support it with
the lifting device. Carefully key wheel hub (2) on stub axle pin,
in order not to damage the sealing ring.
Assemble spacer (4), internal ring (5) of the tapered roller
bearing.
Unscrew tool 99370713 (3).
Key washer (6) and screw adjustment ring nut (7) at the
required closing torque.
32999
Print 603.93.381
25
Figure 39
77202
33001
Place external bearing external ring (3) into its seat and
through keyer 99374092 (2) and beater 99370007 (1) carry
out its driving.
Figure 40
33002
77203
Turn the wheel hub until the wheel hub cover (1) reaches
the illustrated position.
Refill the prescribed oil quantity (0.10 litres) through the filling
hole (2).
Tighten the plug on the wheel hub cover (1) to the
prescribed torque.
520621
WHEEL HUB
PLACEMENT
BEARINGS
RE-
Place internal bearing external ring (3) into its seat and
through keyer 99374092 (2) and beater 99370007 (1) carry
out its driving.
Lubricate internal bearing with SAE W140/MDA oil
and place it into its own seat in wheel hub.
Assemble the sealing ring.
Carry out wheel hub reengagement.
26
520625
Figure 41
520635
33004
With generic means, undrive risers (1) from brake disk (2).
Make sure that the riser heads abutment plane is free from
burrs.
Accurately drive the risers, applying on riser head a
load that is not greater than 2300 kg.
33005
33006
Reattachment
For reattaching, carry out the detachment
operations in reverse.
Print 603.93.381
520636
TRANSVERSE TIEROD
AXLE REPLACEMENT
STUB
520632
27
Figure 46
Figure 44
33007
Lock screw (4), loosen nut (3) and unscrew stub axle (2)
from transverse tierod (1).
Screw stub axle in tierod and lock it in position by tightening
the locking nut at the required torque.
NOTE To facilitate the transverse tierod reattachment
and the following wheel toein adjustment, take
note of the necessary number of revolutions to
unscrew every single stub axle in order to screw
the new ones with the same number of
revolutions.
33009
520611
520631
Figure 45
33010
33008
28
Reattachment
Figure 48
Figure 51
33011
33014
Apply the stub axle on front axle body and insert the pin in
its own seat.
Place tool 99374401 (1) on stub axle and secure it using the
same securing screws of the lower cover locking them at an
adequate torque.
Drive the pin into the front axle tapered seat, screwing
pressure screw (2) at a torque of 7 to 8 daNm (7 to 8 kgm).
Remove tool 99374401 from stub axle.
Figure 49
33012
Figure 50
Figure 52
33013
33012
With tool 99347047 (1) and parts (2 and 3) unlock stub axle
pin.
Remove the fixture and withdraw the pin.
Place lower cover (3) completed with fifth wheel (1) and
adjustment shims (2); tighten securing screws (4) at the
required torque.
Repeat the same operation for the opposite stub axle.
Print 603.93.381
Figure 53
29
Figure 55
33011
33016
For
spare
rings
thickness,
see
table
SPECIFICATIONS AND DATA on page 8.
Figure 54
33015
Keep the stub axle lifted upward, and with a thickness meter
(1) check clearance between upper stub axle shim
adjustment and front axle that must be included between the
values of 0.10 and 0.15 mm.
Print 603.93.381
30
520615
Figure 57
Figure 56
60887
60889
Figure 58
60890
Print 603.93.381
31
520618
Figure 60
Figure 59
Apply two rods (1) completed with cones (3) into stub axle
pin holes; press the cones and lock them in position through
suitable screws on rods.
Insert two centering dowels (2) into seats of leaf springs (4)
bearing plane.
32
Figure 63
Proceed with reading the camber angle of stub axle pin holes,
on related graduated sectors (2), next to indicators (1).
Print 603.93.381
SECTION 8
5004
Suspensions
Page
Print 603.93.381
41
Print 603.93.381
5004
Print 603.93.381
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
- Models 60E..K . . . . . . . . . . . . . . . . . . . . . . . . .
- Models 75E15K . . . . . . . . . . . . . . . . . . . . . . . .
10
11
12
14
14
- Models 100E.. . . . . . . . . . . . . . . . . . . . . . . . . .
15
16
16
- Models 75E..K . . . . . . . . . . . . . . . . . . . . . . . . .
17
- Models 80E..K . . . . . . . . . . . . . . . . . . . . . . . . .
18
- Models 100E..K . . . . . . . . . . . . . . . . . . . . . . . .
19
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . .
20
- Assembly diagrams . . . . . . . . . . . . . . . . . . . . . .
20
21
21
Page
Page
- Front shock absorbers
(with halfelliptic leaf springs) . . . . . . . . . . . . .
21
22
22
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . .
23
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . .
27
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
EXPERIMENTAL TOOLS . . . . . . . . . . . . . . . . . . .
28
29
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
29
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
29
31
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
31
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
31
32
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
32
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
32
REPAIR INTERVENTIONS . . . . . . . . . . . . . . . . . .
32
32
32
32
35
36
30
36
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
30
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
30
37
31
37
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
31
38
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
31
38
31
39
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
31
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
31
Print 603.93.381
DESCRIPTION
The suspension consists of leaf springs, two doubleacting telescopic shock absorbers and a sway bar.
The leaf springs can be semielliptical or parabolic.
Semielliptical leaf springs are very stiff because all the leaves have the same thickness, from one end to the other.
Furthermore, the leaves are arranged to create high internal friction, whereby limiting the leaf spring movements.
The parabolic leaf spring thickness is higher in the middle and thinner on the edges.The leaf particular shape makes the leaf spring
ofter and therefore driving is more comfortable. riding comfort.
Doubleacting telescopic shock absorbers counteract wheel movement upwards and downwards, ensuring excellent riding
stability.
The sway bar keeps the wheel axle and chassis parallel, cancelling any load imbalance on the wheel on any one axle.
77622
77623
N 2
Leaf length
(measured at eyelet center)
1714 3
Leaf thickness
(measured in center)
29
Leaf width
70 0.5
142
8.8 7% mm/kN
45.5 0.3
45
16.5
+ 0.1
0
+ 0.2
0
Print 603.93.381
N 2
Leaf length
(measured at eyelet center)
1714 3
Leaf thickness
(measured in center)
29
Leaf width
70 0.5
142
7.9 7% mm/kN
45.5 0.3
45
16.5
Print 603.93.381
+ 0.1
0
+ 0.2
0
Half elliptic
N 2
1714 3
Leaf thickness
(1st 2nd 3rd 4th and 5th)
13
Leaf width
70 0.5
18
72.6
10.9 mm/kN
45.5
+ 0.1
0
45.5
+ 0.27
0
16.5
+ 0.2
0
Print 603.93.381
Half elliptic
N 2
Leaf lenght
(measured at eyelet center)
1714 3
12
13
Leaf width
70 0.5
15.5
71.1
9.21 mm/kN
Print 603.93.381
45.5
+ 0.1
0
45.5
+ 0.27
0
16.5
+ 0.2
0
10
Models 75E15K
mm
Half elliptic
N 2
Leaf length
(measured at eyelet center)
1714 3
12
13
Leaf width
70 0.5
16.8
74.4
8.92 mm/kN
45.5
+ 0.1
0
45.5
+ 0.27
0
16.5
+ 0.2
0
Print 603.93.381
11
Half elliptic
N 2
Leaf length
(measured at eyelet center)
1714 3
Leaf thickness (1st and 2nd 3rd 4th 5th and 6th)
(measured in center)
13
Leaf width
70 0.5
24
97
7.72 mm/kN
Print 603.93.381
45.5
+ 0.1
0
45.5
+ 0.27
0
16.5
+ 0.2
0
12
77624
77625
Print 603.93.381
13
Figure 5
77626
77627
14
N 2
1670 3
29
Leaf width
70 0.5
*
147.8
3 mm/Kn
45.5 0.3
45
33
+ 0.1
0
16.5 + 0.2
0
Print 603.93.381
15
Models 100E..
mm
Parabolic
N 2
1670 3
29
Leaf width
70 0,5
26.4 3
147.8
2.55 mm/Kn
45.5 45.6
45
16.5
36
Print 603.93.381
+ 0.1
0
+ 0.2
0
16
N 2
1670
0
6
12
Leaf width
70 0.5
22.75
63
11.78 mm/Kn
4.13 mm/Kn
45.5
+ 0.1
0
45.5
+ 0.27
0
16.5
+ 0.2
0
23
Print 603.93.381
17
Models 75E..K
mm
Halfelliptic
N 2
1670
0
6
12
Leaf width
70 0.5
22.75
71.5
11.73 mm/Kn
3.3 mm/Kn
45.5
22
Print 603.93.381
45.5
+ 0.1
0
+ 0.27
0
16.5
+ 0.2
0
18
Models 80E..K
mm
Halfelliptic
Main leaf length
(measured at eyelet center)
Auxiliary leaf length
(measured between the ends)
N 2
0
6
1670
1254
14
Leaf width
70 0.5
59
6.705 mm/Kn
2.93 mm/Kn
45.5
45.5
+ 0.1
0
+ 0.27
0
16.5
+ 0.2
0
Print 603.93.381
19
Models 100E..K
mm
Halfelliptic
Main leaf length
(measured at eyelet center)
Auxiliary leaf length
(measured between the ends)
N 2
1670
0
6
1254
14
Leaf width
70 0.5
45
5.699 mm/Kn
2.414 mm/Kn
45.5
Print 603.93.381
45.5
+ 0.1
0
+ 0.27
0
16.5
+ 0.2
0
20
SHOCK ABSORBERS
Assembly diagrams
Figure 7
72694
Figure 8
77850
Print 603.93.381
21
ARVIN MERITOR
664 3
394 3
270
662 3
396 3
266
SACHS
ARVIN MERITOR
618 3
378 3
240
618 3
378 3
240
ARVIN MERITOR
664 3
394 3
270
663 3
396 3
267
664 3
394 3
270
Print 603.93.381
22
MODELS: 60E..
65E..
75E..
80EL..
80E..
90E..
100E..
SACHS
ARVIN MERITOR
669 3
404 3
265
669 3
404 3
265
ARVIN MERITOR
692 3
422 3
270
692 3
422 3
270
SHOCK ABSORBERS
669 3
399 3
290
The check of shock absorber braking capability is carried out through an adequate equipment, comparing the values with those
included in the following tables:
Print 603.93.381
23
DIAGNOSTICS
Main suspensions operating anomalies:
1
2
3
Noisy suspension;
Irregular or excessive tire wear;
The vehicle tends to move to one part;
4
5
6
NOISY SUSPENSION
Insufficient lubrication.
NO
NO
YES
YES
YES
NO
NO
NO
Print 603.93.381
24
NO
NO
NO
Sudden accelerations.
NO
NO
YES
NO
Print 603.93.381
25
NO
NO
NO
YES
YES
NO
NO
Print 603.93.381
26
NO
YES
YES
YES
YES
NO
NO
NO
Print 603.93.381
27
TIGHTENING TORQUES
PART
TORQUE
Nm
(kgm)
166.5 16.5
(16.9 1.7)
220 20
(22.4 2)
463 46.5
(47.2 4.7)
220 20
(22.4 2)
220 20
(22.4 2)
220 20
(22.4 2)
277.5 27.5
(28.3 2.8)
220 20
(22.4 2)
220 20
(22.4 2)
300
(30.5)
FRONT SUSPENSION
Leaf spring bracket securing nut
Screw to secure leaf spring to shackle
FRONT SUSPENSION (with parabolic leaf springs)
Leaf spring bracket securing nut
TOOLS
TOOL No.
DENOMINATION
99346052
Print 603.93.381
28
EXPERIMENTAL TOOLS
In this chapter there are shown the construction technical drawings of the experimental tools (S.P.) that are used in overhauling
the leaf-springs described in this section, which can be manufactured by the repair workshops themselves.
Print 603.93.381
500410
29
Figure 9
Disengagement
Arrange the vehicle on a plane ground, lock rear
wheel with wedges and proceed as follows:
- Loosen front wheels securing nuts, lift the vehicle and
place it on supporting stands.
- Place hydraulic trolley 99321024 under the wheels,
remove securing nuts and detach the wheels.
- Unscrew nuts (1 and 3) and detach shock absorber (2).
- Unscrew securing nuts (7) for stands (6). Detach torsion
bar supports (8) and remove the stands recovering plate
(9).
- Unscrew the nut and withdraw the front pin for
anchoring leaf spring (5) to chassis support (4).
- Unscrew the nut and withdraw the rear pin for
anchoring leaf spring (5) to chassis support (10), lower
the front axle and extract the complete leaf spring.
Reengagement
Suitably reverse the operations carried out for the
disengagement and tighten at the required torque
securing screws and nuts.
Selflocking nuts must always be replaced and
tightened at the required torque.
Verify that:
- Check stand threading; when detecting
anomalies, adjust the threading or replace
them.
79448
Print 603.93.381
30
500450
Figure 10
Disengagement
Arrange the vehicle on a plane ground, lock rear
wheel with wedges and proceed as follows:
- Loosen rear wheels securing nuts, lift the vehicle from
behind and place it on supporting stands.
- Place hydraulic trolley 99321024 under rear wheels,
remove securing nuts and detach the wheels.
- Unscrew nuts (2) and extract securing Ubolts (1).
- Unscrew the nut and withdraw the rear pin (4) for
anchoring leaf spring (5) to chassis support (3).
- Unscrew the nut and withdraw the rear pin (6) for
anchoring leaf spring (5) to chassis support (7), lower the
front axle and extract the complete leaf spring.
Reengagement
Suitably reverse the operations carried out for the
disengagement and tighten at the required torque
securing screws and nuts.
Selflocking nuts must always be replaced and
tightened at the required torque.
Verify that:
- Check threading of stands (1); when detecting
anomalies, adjust the threading or replace them.
62428
Print 603.93.381
31
Reengagement
Figure 11
For the reengagement, reverse the operations
carried out for disengaging and comply with the
required tightening torques.
62429
Reengagement
For the reengagement, reverse the operations
carried out for disengaging and comply with the
required tightening torques.
62431
Reengagement
62430
32
528960
Disengagement
Figure 14
Figure 15
62432
Reengagement
For the reengagement, reverse the operations
carried out for disengaging and comply with the
required tightening torques.
REPAIR INTERVENTIONS
NOTE - The replacement of blades is not allowed if more
than one blade is broken.
- The replacement of blades is not allowed if the
number of blades composing the faulty spring is
less than threee.
99183
Lift rear axle by hydraulic jack (2) and position two stands
(1) under the chassis in the area behind rear axle, as illustrated
in figure.
By hydraulic jack (2), unload the weight of suspension from
leafsprings.
99184
Print 603.93.381
Figure 17
33
Figure 18
99186
99185
Figure 19
99187
1. Special nut
2. Thrust bearing
3. Bushing
4. Screw
5. Hexagonal section for 19 mm wrench.
Print 603.93.381
6. Washer
7. Nut
8. Bushings
9. Bushing metal shell
34
Figure 20
99188
NOTE
Next figure shows a section with the correct position of the components of tool SP 2507, that is complying with the
dismounting of bushings.
Figure 21
99189
1. Special nut
2. Thrust bearing
3. Bushing
4. Screw
5. Block
Base October 2004
35
Figure 22
Figure 23
99190
NOTE
Next figure shows a section with the correct position of the components of tool 99346052 that is complying with the
remounting of bushings.
Figure 24
99192
1. Spring bushing
2. Spacer
3. Special nut
Print 603.93.381
4. Screw
5. Washer
6. Nut
36
Figure 25
Figure 27
99195
99193
Position shackles (3), screw up securing bolts (1) and (2) and
tighten at prescribed torque.
Repeat same procedure on vehicle opposite side.
Figure 28
99194
Print 603.93.381
37
99199
99209
Figure 30
99198
Print 603.93.381
38
Figure 34
99202
99200
Figure 36
99204
99201
Print 603.93.381
Figure 37
39
Figure 39
99205
99207
Figure 38
Figure 40
99206
99208
Print 603.93.381
40
Print 603.93.381
5004
41
Print 603.93.381
PNEUMATIC SUSPENSIONS . . . . . . . . . . . . . . .
43
IN GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
44
45
46
47
48
- Remote control . . . . . . . . . . . . . . . . . . . . . . . .
48
49
- Chassis lifting/lowering . . . . . . . . . . . . . . . . . . .
49
- Chassis selfleveling . . . . . . . . . . . . . . . . . . . . .
49
- M 1 M 2 level . . . . . . . . . . . . . . . . . . . . .
49
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . .
50
TIGHTENING TORQUES . . . . . . . . . . . . . . . . .
52
52
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
54
- Pneumatic system . . . . . . . . . . . . . . . . . . . . . .
54
55
56
56
57
- Controlledpressure valve . . . . . . . . . . . . . . . .
57
- Level sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
42
Page
58
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
58
58
- Selfleveling . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
59
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
59
- Selfleveling . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
59
60
AIR SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
- Electronic unit. . . . . . . . . . . . . . . . . . . . . . . . .
60
61
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
61
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
61
62
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
62
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
62
63
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
63
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
63
63
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
63
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
63
Page
63
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
63
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
63
64
- Disengagement . . . . . . . . . . . . . . . . . . . . . . . .
64
- Reengagement . . . . . . . . . . . . . . . . . . . . . . .
64
64
64
Print 603.93.381
43
PNEUMATIC SUSPENSIONS
IN GENERAL
Pneumatic suspensions have high flexibility, high
vibrationdampening capability, and above all, independently
from vehicle load, due to system selfadjustment, the
chassisroadbed distance remains constant. Pneumatic
suspensions allow changing, through a suitable pushbutton,
the chassisroadbed distance and therefore the vehicle
working plane height.
The ECAS system, in addition to the known advantages
offered by the pneumatic suspension, allows:
- a high air consumption reduction;
- prompt response in different adjustment processes;
- system easiness;
- wide safety concepts;
- chance of a complete system diagnosis.
Print 603.93.381
44
The models equipped with mixed suspensions (mechanical front ones and pneumatic rear ones) keep the front
suspension of the models corresponding with the mechanical suspension.
Figure 1
61978
Figure 2
61979
Print 603.93.381
45
Figure 3
99002
62390
1. Air intake valve with limited return 2. Manual condensate drain valve 3. Air tank 4. Pressure control intake 5. Check
valve 6. Low pressure indicator 7. Electropneumatic distributor 8. Electronic leveling valve 9. Rear axle air spring
Print 603.93.381
46
78797
1. Air intake valve with limited return 2. Manual condensate drain valve 3. Air tank 4. Pressure control intake 5. Check
valve 6. Low pressure indicator 7. Electronic leveling valve 8. Front axle air spring 9. Front axle electropneumatic
distributor 10. Rear axle electropneumatic distributor 11. Rear axle air spring
Base October 2004
Print 603.93.381
47
78798
1. Controlledpressure valve 2. Front axle level sensor 3. Front air spring 4. Front axle electropneumatic distributor
5. Rear air spring 6. Check valve 7. Rear electropneumatic distributor 8. Tank 9. Pressure control intake 10. Rear
axle level sensor
Print 603.93.381
48
78799
49
78800
M 1 M 2 level
This operation can be activated ONLY below 20 km/h.
When such speed is exceeded, the set attitude will be kept
constant.
In order to lift/lower the chassis, operate as follows:
- Press pushbutton (1) and/or (8) to select the desired
axle; simultaneously, the related warning light A and/or
B will turn on
- Press pushbutton (3) or (4) till the desired level is
reached.
This condition and the related signal will be kept also when
disconnecting and connecting the key switch.
Print 603.93.381
50
DIAGNOSTICS
Main pneumatic suspensions operating anomalies:
1 Scarce or irregular pneumatic system recharge;
2 Irregular vehicle attitude;
3 Turnedon chassis misalignment warning light at a
speed greater than 20 km/h.
NO
NO
NO
NO
(continued)
Base October 2004
Print 603.93.381
51
NO
NO
NO
NO
NO
NO
Print 603.93.381
52
TIGHTENING TORQUES
PART
TORQUE
Nm
kgm
116.5 16.5
(11.8 1.6)
220 20
(22.4 2)
18 2
(1.8 0.2)
92 2
(9.3 0.9)
121 12
(12.3 1.2)
91499
PART
1
3
4
Nut
Screw
Nut
Screw
Nut
Screw
Nut
Screw
Nut
Screw
TORQUE
Nm
kgm
206.5 20.5
20.6 2
226.5 22.5
22.6 2.2
311 31
31 3
382 38
38 3.8
772 5 77.5
772.5
77 5
77 7.7
77
445 45
44 5 4.5
44.5
45
157 16
15.7 1.6
193.5 19.5
19 1.9
50 5
5 0.5
05
92 11
91
112.5 11.5
11 1.1
157 16
15.7 1.6
193.5 19.5
19 1.9
Print 603.93.381
53
TOOLS
TOOLS No.
DENOMINATION
99346249
Print 603.93.381
54
8.5 bar
15 liters
15 liters
8 to 16V pulse
max 90 mA
40 C to + 80 C
40 C to + 80 C
5 to 13 bars
20 bars
24 V
supply voltage
Check valve
- Type: WABCO WESTINGHOUSE 434 014 000 0 FERNA F100718
operating pressure
max 20 bar
operating temperature
Pressure control intake
- Type: RAUFOSS 623.7776 SIRT VFM 1615 WABCO 463.703.114.0
40 C to + 80 C
operating temperature
Electronic unit
- Type: WABCO
40 C to + 80 C
supply voltage
operating temperature
Low pressure manometric switch
- Type: TDS F13016
Working voltage
18 to 32 V
40 to 70 C
0,001 to 1A
Print 603.93.381
55
Parabolic
N 2
1714 3
29
21
Leaf width
70
55
13.84 mm/kN
45.5
+ 0.1
0
45.5
+ 0.27
0
16.5
+ 0.2
0
Figure 10
BB
AA
33722
Print 603.93.381
56
SHOCK ABSORBERS
650 3
430 3
220
SHOCK ABSORBERS
617.2 3
386.8 3
230.4
666 3
410.5 3
255.5
Print 603.93.381
57
Controlledpressure valve
Figure 11
20437
The valve is of the type with limited return and performs two
functions:
[counts]
200
204
180
183
160
160
140
138
120
114
100
Level sensor
-50
Figure 12
-40
-30
-20
-10
70
52
10
80
20
30
40
50
[degrees]
60
40
36
22
10
20
0
62422
62421
Print 603.93.381
58
Operation
Figure 14
Figure 16
78802
78804
Selfleveling
78803
Pneumatic connections
11 from air tank
21 from rear axle electropneumatic distributor
22 to air spring on right side
23 to air spring on left side
Electric connections
6.1 Solenoid valve supply positive
6.2 Negative
6.4
Print 603.93.381
59
Operation
Figure 17
Figure 19
78805
70117
Figure 18
4x2 FP vehicles
Duct (21) is in connection with duct (21,
Figure 16) of front axle electropneumatic
distributor for airsprings supply.
Pneumatic connections
11 from air tank
21 to front axle electropneumatic distributor
22 to air spring on right side
23 to air spring on left side
Electric connections
Pin 1 Solenoid valve A supply positive
Pin 2 Solenoid valve B supply positive
Pin 3 Solenoid valve C supply positive
Pin 4 Common negative
Print 603.93.381
Selfleveling
The unit, depending on level sensors position, will suitably
control solenoid valves A, B and/or C to perform lifting
or lowering steps till vehicle leveling or M1 or M2 stored
positions are reached.
60
Figure 20
52723
5007
AIR SPRINGS
Figure 21
NOTE All this is valid ONLY if the vehicle is moving from
at least 5 min., since the system delays every check
to allow the possible pneumatic system recharge.
30106
Print 603.93.381
500710
61
Figure 22
Disengagement
Arrange the vehicle on a plane ground, lock rear
wheel with wedges and proceed as follows:
- Loosen front wheels securing nuts, lift the vehicle and
place it on supporting stands.
- Place hydraulic trolley 99321024 under the wheels,
remove securing nuts and detach the wheels.
- Unscrew nuts (11 and 7) and detach shock absorber (8).
- On the lower vehicle side, unscrew nuts (8) and remove
stands (4) recovering plate (6).
- Unscrew the nut and withdraw rear pin (9) for anchoring
leaf spring (3) to support (10).
- Unscrew the nut and withdraw rear pin (2) for anchoring
leaf spring (3) to chassis support (1), lower the front axle
and extract the complete leaf spring.
Reengagement
Suitably reverse the operations carried out for the
disengagement and tighten at the required torque
securing screws and nuts.
Selflocking nuts must always be replaced and
tightened at the required torque.
Verify that:
- Check stand threading; when detecting
anomalies, adjust the threading or replace
them.
79449
Print 603.93.381
62
500730
Figure 23
Disengagement
Arrange the vehicle on a plane ground, lock front
wheels and proceed as follows:
- Loosen rear wheels securing nuts, lift the vehicle from
behind and place it on supporting stands in the marked
point ().
- Place hydraulic trolley 99321024 under rear wheels,
remove securing nuts and detach the wheels.
- Unscrew nut (8 and 10) and disassemble shock absorber
(7).
- Unscrew nut (12) for checking the air spring.
- Remove securing bolt (11) for stabilising bar.
- Unscrew nuts (5) and disconnect levelling valve tierod
(4).
- Unscrew securing nuts (9) recovering plates (15),
remove stands (14) and unscrew securing bolts for
spacers (13).
- Unscrew nut (2), remove the pin and disengage
suspension arm (6) from support (1).
Reengagement
Suitably reverse the operations carried out for the
disengagement and tighten at the required torque
securing screws and nuts.
Selflocking nuts must always be replaced and
tightened at the required torque.
Verify that:
- Check threading of stands (10); when
detecting anomalies, adjust the threading or
replace them.
62374
Print 603.93.381
63
Reengagement
Figure 24
For the reengagement, reverse the operations
carried out for the disengagement and comply with
the required tightening torques.
62379
Reengagement
For the reengagement, reverse the operations
carried out for the disengagement and comply with
the required tightening torques.
Reengagement
For the reengagement, reverse the operations
carried out for the disengagement and comply with
the required tightening torques.
62380
Print 603.93.381
64
528930
Figure 27
528960
62376
Reengagement
For the reengagement, reverse the operations
carried out for the disengagement and comply with
the required tightening torques.
Print 603.93.381
SECTION 9
5025
Print 603.93.381
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . .
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . .
Print 603.93.381
DESCRIPTION
The wheel rim is the rigid wheel structure and is identified by
the following dimensions:
TYRES
9.5 R 17.5
205/75 R 17.5
215/75 R 17.5
225/75 R 17.5
NOTE
Print 603.93.381
For tire pressure checking, comply with the values stated in the specific Use and Maintenance booklet.
TOOLS
TOOL No.
DENOMINATION
99305037
DIAGNOSTICS
Main tire anomalies:
1 Excessive consumption.
2 Irregular consumption.
3 The vehicle tends to one side.
EXCESSIVE CONSUMPTION
NO
NO
NO
NO
Overloaded truck.
Print 603.93.381
IRREGULAR CONSUMPTION
NO
NO
NO
NO
NO
NO
(continued)
Print 603.93.381
NO
NO
NO
Print 603.93.381
502511
Figure 1
16997
- Lift the front vehicle part and make sure that the wheels
are freely rotating.
- Arrange the unbalance detector (1) under the front axle
beside the examined wheel, placing it at such a height that
the starter roller for apparatus 99305037 (2) gets in
contact with the tire; under the opposite front axle side,
place a support stand and lower the hydraulic jack.
Print 603.93.381
- Insert switch (5) for instrument light (1) and switch (8)
for stroboscopic lamp.
- Insert starting switch (6) for apparatus 99305037 in the
first speed position in order to make the wheel rotate.
Take starting switch (6) to the second speed and push the
balancing machine against the tire.
While the wheel is dragged rotating, it is detected that the
stroboscopic effect on the wheel will make the reference
mark appear stopped; the instrument (1) pointer, starting
from the zero value, reaches a maximum value on the scale
and then goes back towards zero.
When the pointer has begun moving away, move away the
balancing machine, completely disconnect the starting switch
(6) and brake the engine through the brake lever (7).
The wheel goes on rotating by inertia and the reference mark
obtained on the tire moves; therefore, mark the point where
the reference has moved.
Read on instrument (1) the value pointed to by the pointer,
multiply it by 10, thereby obtaining the counterweight value
to be applied to the rim.
Figure 3
NOTE
502510
TIRE PRESSURE
23885
Print 603.93.381
NOTE (The value placed inside every figure shows the tire
pressure amount, while the efficiency is referred to
the life of the tire itself.)
+ 20%
90% EFFICIENCY
Figure 5
Figure 7
40%
CORRECT
40% EFFICIENCY
100% EFFICIENCY
Figure 8
Print 603.93.381
10
Print 603.93.381
STEERING SYSTEM
SECTION 10
5014
Steering system
Page
Print 603.93.381
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .
10
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
15
16
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
18
19
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
20
21
22
23
24
24
25
STEERING SYSTEM
Page
BLEEDING THE AIR FROM THE HYDRAULIC POWER STEERING CIRCUIT . . . . .
26
26
26
Print 603.93.381
STEERING SYSTEM
DESCRIPTION
Steering wheel control system on EuroCargo vehicles is made up of a ball circulation type hydraulic guide driven by a gear pump
mounted in tandem with the air compressor.
This pump is characterised in that it has its oil tank integrated into its body.
78672
1. Hydraulic guide 2. Delivery piping 3. Return piping 4. Channel fitting on return piping 5. Power steering pump with
integrated tank 6. Channel fitting on delivery piping
Steering system
ZF 8090
TRW TAS 30
130 + 13
16.6 : 1
4
140 + 10
16.5 : 1
4.6
ZF FN4 Integral
600
2700
165 (180)
16
100 C
Base October 2004
STEERING SYSTEM
78673
Print 603.93.381
STEERING SYSTEM
DIAGNOSTIC
Main hydraulic power steering failures:
1
2
3
5
6
7
8
STEERING STIFF
WHEN TURNING
RIGHT AND LEFT
YES
Check the seal of the intake pipe and the pump shaft
gasket and top up the oil. Bleed the circuit.
YES
NO
NO
NO
NO
Print 603.93.381
STEERING SYSTEM
YES
NO
NO
NO
Check the seal of the intake pipe and the pump shaft
gasket and top up the oil. Bleed the circuit.
Print 603.93.381
STEERING SYSTEM
NO
NO
NO
YES
NO
Unbalanced wheels
NO
NO
NO
Print 603.93.381
YES
STEERING SYSTEM
Unbalanced wheels
YES
YES
YES
Check the seal of the intake pipe and the pump shaft
gasket and top up the oil. Bleed the circuit.
YES
Secure mountings.
Replace ball joints.
NO
NO
NO
NO
Print 603.93.381
STEERING SYSTEM
LOSS OF FLUID
NO
In any case, it is necessary to establish where and why the fluid is being lost, eliminate the cause and with engine running, top
up fluid to the upper mark on the dipstick.
NO
NO
NO
NO
Print 603.93.381
10
STEERING SYSTEM
TIGHTENING TORQUE
COMPONENT
ZF 8090
TORQUE
Nm
Nm
400 10
(40 1)
350 10
(35 1)
325
(32,5)
45
(4.5)
55
(5.5)
12 + 3
(1 2 + 0.3)
(1.2
0 3)
72
(7.2)
TRW TAS 30
TORQUE
Nm
(kgm)
500 25
(50 2.5)
345 34
(35.6 3.5)
325
(32,5)
45
(4.5)
55
(5.5)
75 7.5
(7.5 0.75)
55 5.5
(5.5 0.55)
72
(7.2)
TOOLS
TOOL No.
DESCRIPTION
99347042
99347068
99355019
99374393
Print 603.93.381
STEERING SYSTEM
11
TOOLS
TOOL NO.
DESCRIPTION
99374398
Scaled sector and index to check steering wheel play (To be used
with 99374393).
99374399
Figure 3
78674
1. Power steering pump 2. Oil tank 3. Oil filter 4. Oil introduction plug / level sensor 5. Filter safety valve 6. Air
compressor
Print 603.93.381
12
STEERING SYSTEM
Figure 4
62596
Print 603.93.381
STEERING SYSTEM
13
Figure 5
78675
1. Cover 2. Worm screw / control box 3. Rack plunger 4. Balls 5. Torsion bar 6. Pressure limiting valve 7.
Reaspiration valve 8. Inlet shaft / rotary distribution valve 9. Hydraulic guide box 10. Outlet shaft 11. Oil tank 12.
Vane pump 13. Flow rate limiting valve
Print 603.93.381
14
STEERING SYSTEM
through the inlet ports (6) into the axial splines (1) of the
control box and after passing through worm screw ball
thread it arrives to left cylinder chamber. Hydraulic power
steering takes place, whereas inlet ports (7) closing stops oil
return to tank. Oil present into right cylinder chamber comes
out and flows through open return ports (3) to the rotary
distributor return splines (4), passing through its central hole
and then it returns to the oil tank.
When the steering wheel is turned to the left (not shown),
the operating cylinder piston moves to the left. The rotary
distributor are moved counterclockwise. Pressure oil passes
through the inlet ports (7) and goes to the axial splines (2)
and then to the right cylinder chamber.
The oil in the left cylinder chamber flows back to the tank
passing through ball thread, return ports (5), return splines
(4) and rotary distributor central hole.
Figure 6
78676
Print 603.93.381
15
STEERING SYSTEM
Figure 7
78677
78678
PISTON MOVEMENT TOWARDS THE RIGHT, STEERING CONTROL VALVES OPEN, OIL PRESSURE REDUCED
SIGNIFICANTLY
Print 603.93.381
16
STEERING SYSTEM
541430
Figure 9
Figure 11
33686
33688
Removal
Set a proper container under the hydraulic power steering
and remove the tank cover.
Use puller 99347068 (2) to remove the drag link (1) from the
lever (3).
Figure 10
Figure 12
33689
33687
Remove the split pin (1) and loosen the nut (2).
Base October 2004
STEERING SYSTEM
Refitting
17
Figure 15
Figure 16
33690
Figure 14
33693
33691
18
STEERING SYSTEM
501430
Figure 17
78679
1. Hydraulic guide pump 2. Tank 3. Delivery piping 4. Aspiration piping 5. Flow back piping 6. Hydraulic pressure
gauges 7. Axial adjustment screw C. Lock nut D. Lock nut X. Hydraulic limiting adjustment screw (rotation in
direction A) Y. Hydraulic limiting adjustment screw (rotation in direction B) f. Spacer thickness
f. Dimension (see table) for spacer to be inserted between the stoppers 7. Stop
Print 603.93.381
STEERING SYSTEM
19
77844
1. Hydraulic steering limiter screw 2. Right hydraulic steering control valve 3. Worm screw 4. Left hydraulic steering
control valve 5. Torsion bar 6. Rotary distributing valve 7. Input shaft 8. Cover 9. Balls 10. Power steering box
11. Output shaft 12. Rack piston
Description
The continuous balltype hydraulic power steering is mainly
consisting of the box that houses: hand steering mechanism,
hydraulic cylinder controlled by rotary distributing valve,
hydraulic steering control valves and safety valves.
The rotary motion imparted to the steering wheel is
transmitted from the input shaft (7) to the worm screw (3)
through the torsion bar (5).
The worm screw (3) is then connected by a set of balls (9)
to the rack piston (12) and converts the rotary motion of the
piston into an axial movement.
Piston rack tooth (12) engages the sector gear shaft tooth
and imparts it a rotary motion. The steering arm secured to
the shaft transmits motion to wheel steering rods.
Print 603.93.381
20
STEERING SYSTEM
77845
1. Capacity limiting valve 2. Oil vane pump 3. Oil tank 4. Rotary distributing valve 5. Input shaft 6. Torsion bar
7. Worm screw 8. Output shaft 9. Rack piston.
On the torsion bar (6) connecting the input shaft (5) to the
worm screw (7) is fitted the rotary distributing valve (4); in
straight running conditions the valve (4) keeps open the
communication between the oil duct coming from the vane
pump (2) and the drain one to the oil tank (3).
Print 603.93.381
21
STEERING SYSTEM
77846
1. Capacity limiting valve 2. Oil vane pump 3. Oil tank 4. Rotary distributing valve 5. Valve body 6. Input shaft
7. Torsion bar 8. Flow control valve 9. Rack piston.
Print 603.93.381
22
STEERING SYSTEM
77847
1. Capacity limiting valve 2. Oil vane pump 3. Oil tank 4. Rotary distributing valve 5. Valve body 6. Input shaft
7. Torsion bar 8. Flow control valve 9. Rack piston
Print 603.93.381
23
STEERING SYSTEM
77848
1. Steering hydraulic limiting screw A and B steering control valve 2. Piston 3. Bush 4. Valve body 5. Spring
6. Thrust sleeve 7. Spacer pin 8. Rack piston 9. Cover X. Left cylinder chamber Y. Right cylinder chamber
Rack piston end (9) houses the two steering control valves
A and B.
These valves consist of a body (5) which houses by forced
coupling, the valve operation control bush (4) which acts as
piston (3) seat. Pistons (3) are kept in closed position on
bushes (4) by the counter spring (6).
Valves A and B stay closed until piston stems (3), due to rack
piston movement, go in touch with the following:
Print 603.93.381
24
STEERING SYSTEM
Figure 24
60925
Gearbox to neutral.
Start the engine and keep it at 1500 rpm.
Turn the steering wheel to one direction with 34 Nm torque
until the setscrew (2) set on the stub axle (3) touches the
axle (1).
In this way the bush (4, Figure 17) is set backwards with
respect to the steering control valve body (5, Figure 17). The
bush position (4, Figure 17) will determine the hydraulic
pressure release inside the involved chamber before the
screw (2, Figure 17) touches the axle (1) and protecting
hydraulic system components.
Repeat the same operations in the other steering direction.
Figure 23
Print 603.93.381
STEERING SYSTEM
25
Figure 25
60926
Gearbox to neutral.
Start the engine and keep it at 1500 rpm.
Turn the steering wheel to the left (for lefthand drive
vehicles and vice versa for righthand drive vehicles) applying
34 Nm torque until reaching the steering stop and keep it
in this position.
Stop the engine.
Loosen the nut (4) and using the dynamometric wrench
tighten the screw (3) to increase the torque of 1.12 Nm.
For lefthand drive vehicles: steer the wheels to the left (vice
versa for righthand drive vehicles) applying 54 Nm torque
to the steering wheel, until the setscrew (2, Figure 23) is in
touch with the axle (1, Figure 23).
Reset the wheels in straight running conditions and check
whether the marks (2, Figure 22) showing the steering centre
are coinciding.
Loosen the nut (3) so that the gap B is 2022 mm and lock
the nut (4) to 4550 Nm torque.
Top up the tank until reaching the required oil level.
Print 603.93.381
In this condition, loosen the screw (3) by 2.5 turn and lock
the nut (4) to 4050 Nm torque.
Check automatic adjustment as described in the relevant
section.
Base October 2004
26
STEERING SYSTEM
501430
Figure 27
78681
501430
MEASURING CLEARANCE IN
STEERING BOX AT STEERING
WHEEL
Figure 26
OF
78680
Print 603.93.381
SECTION 11
Pneumatic System Brakes
Page
Print 603.93.381
12
13
14
15
17
18
19
- Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
20
20
21
22
BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
24
24
25
26
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
27
- Service braking . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Exhaust brake . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
27
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Spring cylinder . . . . . . . . . . . . . . . . . . . . . . . . .
45
45
45
46
47
50
28
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . .
50
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .
39
- Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
51
43
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
- Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
- Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
43
54
- Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
54
43
- Air tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
54
- Duplex distributor . . . . . . . . . . . . . . . . . . . . . .
43
54
43
55
44
DUPLEX DISTRIBUTOR . . . . . . . . . . . . . . . . . . .
55
44
- Brake release . . . . . . . . . . . . . . . . . . . . . . . . . .
56
44
- Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
- Air/hydraulic converters . . . . . . . . . . . . . . . . .
44
57
44
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
45
- Pressure limiting . . . . . . . . . . . . . . . . . . . . . . . .
57
45
57
- Dump valve . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
- Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
Print 603.93.381
Page
Page
- Air bleeding from the hydraulic circuit using
the deaerating device . . . . . . . . . . . . . . . . . . . .
64
65
65
58
- Predominance regulation . . . . . . . . . . . . . . . . .
58
- Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
COUPLING HEADS . . . . . . . . . . . . . . . . . . . . . .
59
- Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .
59
- Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
66
67
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
67
68
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
AIR/HYDRAULIC CONVERTERS . . . . . . . . . . . .
60
- Master cylinder . . . . . . . . . . . . . . . . . . . . . . . .
60
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60
- Repair operations . . . . . . . . . . . . . . . . . . . . . .
68
- Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
- Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68
61
REPAIRING BRAKES . . . . . . . . . . . . . . . . . . . . . .
69
- Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
- Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
ANTISKID SYSTEMS . . . . . . . . . . . . . . . . . . . . .
62
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
62
69
ELECTROPNEUMATIC VALVE . . . . . . . . . . . . .
62
70
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
62
70
63
71
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
71
RPM SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . .
63
72
PHONIC WHEELS . . . . . . . . . . . . . . . . . . . . . . .
63
72
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
72
64
73
64
73
64
- Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
Print 603.93.381
Page
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
74
74
74
74
76
77
78
Page
85
87
87
88
88
88
88
89
89
89
80
89
- Parking braking . . . . . . . . . . . . . . . . . . . . . . . . .
80
89
81
90
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
90
81
90
91
82
- For rear calliper . . . . . . . . . . . . . . . . . . . . . . . .
91
REFITTING BRAKES . . . . . . . . . . . . . . . . . . . . . .
91
91
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
83
83
93
83
94
84
95
Print 603.93.381
SYMBOL
HYDRAULIC FLOW
AIR FLOW
ELECTRIC LINE
ABLE TO ROTATE
COCK
SILENCER
COMPRESSOR
2
4
VACUUM PUMP
HYDRAULIC PUMP
32780
Print 603.93.381
SYMBOL
CONDENSATE SEPARATOR
FILTER
DRIER
DRIER
21
22
21
22
23
CONDENSATE
PRESSURE
REGULATOR
INDEPENDENT CIRCUIT
WITH
2
21 23
22 24
PRESSURE REGULATOR
21
PRESSURE REGULATOR
21
23
PRESSURE
(GOVERNOR)
REGULATOR
1
32782
32783
Print 603.93.381
SYMBOL
ADAPTER VALVE
21 23
22 24
3CIRCUIT PROTECTION VALVE
21
23
22
21
22
SAFETY VALVE
CHECK VALVE
2
2
CHECK VALVE
1
2
DOUBLE SHUTOFF VALVE
11
12
U
THROTTLE
RETURN
VALVE
WITH
QUICK
THROTTLE VALVE
32783
Print 603.93.381
32784
32785
SYMBOL
1
11
21
12
22
21
11
21
12
4
22
11
21
22
21
22
CONTROL VALVE
BRAKE VALVE
CONTROL VALVE
13
23
4
32786
Print 603.93.381
SYMBOL
41
42
2
4
41
42
43
2
41
42
43
11
12
22
11
21
12
22
12
LOAD SENSING VALVE WITH
BYPASS
21
11
2
4
4
41
42
32786
Print 603.93.381
32787
10
SYMBOL
41
42
4
SLAVE PROPORTIONAL REDUCING
VALVE
2
2
1
LEVELLING VALVE
21
LEVELLING VALVE
HANDOPERATED
SUSPENSION
RAISING CONTROL VALVE
22
12
23
11
21
23
24
21
22
32787
32788
Print 603.93.381
11
SYMBOL
2
42
41
1
13
HANDOPERATED
SUSPENSION
CONTROL VALVE WITH ELECTRICAL
MONITORING
11
21
12
22
3
1
ELECTROPNEUMATIC VALVE
ELECTROPNEUMATIC VALVE
ELECTROPNEUMATIC VALVE
21
22
VR
VL
ABS
HL
HZ2
HZ1
HR
4
AUGMENTER VALVE
1
32788
Print 603.93.381
12
SYMBOL
AIR SPRING
32789
Print 603.93.381
13
SYMBOL
VACUUM BRAKE
VACUUM BRAKE
AIR/HYDRAULIC CONVERTER
AIR/HYDRAULIC CONVERTER
OPERATING CYLINDER
BRAKE CYLINDER
SPRING CYLINDER
32790
Print 603.93.381
32791
14
SYMBOL
SERVO CLUTCH
SERVO CLUTCH
32791
Print 603.93.381
15
SYMBOL
A
ISO HALFCOUPLING
M
ISO VERSION
A
ISO HALFCOUPLING
M
VERSION WITH ISO COUPLINGS
A
CUNA HALFCOUPLING
B
ITALIAN VERSION
M
CUNA HALFCOUPLING
A
NATO HALFCOUPLING
M
NATO VERSION
32792
Print 603.93.381
32793
16
SYMBOL
4
2
V
Z
A
A
M
HALFCOUPLING
V
Z
A
HALFCOUPLING
4
2
22
M
HALFCOUPLING
4
1
32793
Print 603.93.381
17
SYMBOL
PRESSURE GAUGE
PRESSURE GAUGE
PRESSURE TRANSMITTER
LAMP
MECHANICALLY CONTROLLED
SWITCH
PRESSURE SWITCH
HORN/BUZZER
SENSOR
32794
Print 603.93.381
18
SYMBOL
32795
Print 603.93.381
799512
19
Figure 3
Overview
The pipes in the braking system of commercial vehicles are
currently of two types:
- Flexible polyamide hoses with single or twoply structure
and in the following diameters (68101216 mm)
supplied as spares by the metre.
- Rigid metal pipes of the following diameters
(4.756.3581012 mm). Pipes between 4.75 and 10
mm diameter are supplied as spares in straight lengths of
456 m, whereas those exceeding 10 mm diameter are
supplied as spares ready cut, bent and flared.
31973
Deburr the pipe (1), insert the union fitting (2) onto it and
position it between blocks (3) bearing against the pin (5). Lock
the pipe (1) with the screw (4).
Figure 1
Figure 4
31971
31974
Move pin (4) to neutral position. Tighten the screw (1) until
the die (2) comes up against the blocks (3), thus forming the
end of the pipe (5).
31972
Print 603.93.381
31975
20
Figure 9
Figure 6
31979
31976
Position pipe (1) in tool (3) and bend the pipe by pressing the
lever (2).
Figure 7
Figure 10
31980
31977
Fit union (2) and tighten so that the ring (3, fig.6) is locked onto
the pipe (1).
Figure 8
Figure 11
31978
To release the pipe (2) from the tool (3), press the catch (1).
31981
Position pipe (2) in tool (3) 99386523 and tighten screw (1).
Hold the pipe (2) and rotate the tool (3) until the pipe is
completely cut.
Print 603.93.381
21
After cutting the pipe, deburr and proceed to form the end as
described previously.
NOTE
NOTE
Replacing
couplings
flexible
hoses
with
threaded
Figure 12
mm
Double
layer
Single layer
Assembling
pressure
N/mm2
6x1
from 1 to 1.5
0.040
8x1
from 2 to 2.5
0.050
10 x 1.5
from 2 to 2.5
0.050
12 x 1.6
from 2 to 2.5
0.060
16 x 2.34
from 3 to 3.5
0.060
10397
Figure 14
- nut (3), pressure ring (2) (larger thickness towards the nut
(3)) and reinforcing bush (1);
- bush must be in perfect conditions (it must not show any
distortion or signs of hammering);
Figure 13
10399
10398
Print 603.93.381
22
Pipe diameter
mm
6x1
40
8x1
50
10 x 1.5
60
12 x 1.6
75
16 x 2.34
100
Figure 16
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.
39306
Figure 15
39307
M 10 x 1.0 mm
22
M 12 x 1.5 mm
24
M 14 x 1.5 mm
28
M 16 x 1.5 mm
35
M 22 x 1.5 mm
40
Print 603.93.381
Figure 18
23
Figure 20
39308
33977
- Insert the hose (2) by hand into the coupling (1) with a
force between 30 and 120 N according to the hose
diameter, so the reference mark L1 is inside the hose
whereas L2 remains visible.
Figure 21
Figure 19
33978
A
33976
COUPLING
SEALING RING
THREAD
DIMENSIONS
M 10 x 1.0
10.1 x 1.6
M 12 x 1.5
11.0 x 2.0
M 14 x 1.5
M 16 x 1.5
M 22 x 1.5
NOTE
15.0 x 2.0
NOTE
NOTE
0,5
L2 +1
(mm)
(mm)
(mm)
(mm)
19.8
17
22
20.5
18
23
12
25
22
28
16
27.1
24
30
Print 603.93.381
L1
0,5
+1
24
BRAKING SYSTEM
General layout for standalone vehicles
Figure 22
62625
1. Compressor 2. Air Processing Unit, 11 bar setting 3. 15 l rear axle air tank 4. 15 l axle air tank 5. Manual condensate
bleeder valve 6. Safety valve (optional) 7. Exhaust brake push button 8. Exhaust brake solenoid valve 9. Exhaust brake
valve control cylinder 10. Phonic wheel 11. Rear axle rpm sensor 12. Hydraulic control socket 13. Brake disc 14. Brake
calliper 15. Spring cylinder for parking brake 16. Dump valve for parking brake 17. Rear axle air/hydraulic converter
18. Low pressure switch indication for handbrake on 19. ABS solenoid valve 20. Autorestrictive hand distributor for parking
brake control 21. Safety hand distributor (optional) 22. Autorestrictive coaxial duplex distributor 23. Oil tank 24. Low oil
level warning light 25. ABS solenoid valves 26. Air/hydraulic converter 27. Brake disc 28. Brake calliper 29. Speed
sensor 30. Phonic wheel 31. Converter extra travel warning light 32. ABS ECU 33. Parking brake led 34. STOP light
led 35. Axle/rear axle pressure gauge 36. Stop light relay control switch 37. Switch indicating brake on for EDC
38. Air control socket A. To service circuit
Print 603.93.381
25
BRAKING SYSTEM
General layout for towing vehicles
Figure 23
62626
1. Compressor 2. Air Processing Unit, 11 bar setting 3. 15 l rear axle air tank 4. 15 l axle air tank 5. Manual condensate
bleeder valve 6. 15 l air tank for parking brake and trailer recharge 7. Pressure reducer for parking circuit and trailer
recharge 8. Exhaust brake push button 9. Safety valve (optional) 10. Exhaust brake solenoid valve 11. Trailer braking
control pressure switch 12. Exhaust brake valve control cylinder 13. Trailer control pressure reducer 14. Trailer braking
control augmenter valve 15. ABS solenoid valve 16. Phonic wheel 17. Speed sensor 18. Trailer coupling halfjoints
19. Triple control servo distributor for trailer 20. Brake disc 21. Brake calliper 22. Spring cylinder for parking brake
23. Dump valve for parking brake 24. Air/hydraulic converter 25. Low pressure switch indication for handbrake on
26. Hand distributor for parking brake control 27. Safety hand distributor (optional) 28. Parking circuit singleacting valve
29. Autorestrictive coaxial duplex distributor 30. Low oil level warning light 31. Oil tank 32. ABS solenoid valves
33. Air/hydraulic converter 34. Brake disc 35. Brake calliper 36. Speed sensor 37. Phonic wheel 38. Converter extra
travel warning light 39. ABS ECU 40. Parking brake led 41. STOP light led 42. Axle/rear axle pressure gauge
43. Stop light relay control switch 44. Switch indicating brake on for EDC 45. Air control socket A.To service circuit
Print 603.93.381
26
78620
1. Phonic wheel 2. Check valve 3. Air/hydraulic converter 4. Pressure control socket 5. Air/hydraulic converter
6. Exhaust brake solenoid valve 7. A.P.U. 8. Phonic wheel 9. Wheel speed sensor 10. Spring cylinder 11. Augmenter
valve 12. Triple control servo distributor 13. Coupling head 14. Parking brake + trailer tank 15. Hydraulic pressure
control socket 16. Wheel speed sensor 17. Phonic wheel 18. Rear disc brake assembly 19. Dump valve 20. Pressure
reducer 21. Electropneumatic valve 22. Air tanks 23. Pressure control socket 24. Pressure reducer 25. Front disc
brake assembly 26. Wheel speed sensor 27. Phonic wheel 28. Exhaust brake operating cylinder 29. Engine brake drive
pushbutton 30. Duplex distributor 31. ABS ECU 32. Singlecylinder compressor 33. Parking brake distributor
34. Trailer slowdown control distributor (optional) 35. Wheel revolution sensor
Print 603.93.381
27
Description
Service braking
Air/hydraulic pedal type with three independent circuits: one
to activate front axle braking components, the other to
activate rear axle components and, the third one for braking
the trailer.
Exhaust brake
Since the exhaust brake system is of the electric type it is
controlled by the EDC control unit. Three types of exhaust
brake control are provided that can be selected through the
proper switch set on the instrument panel, according to the
different road types/conditions.
With selector to position (o), the push button set on the left
side of the cab floor is always operating.
With selector to position 1, the exhaust brake is combined
with the accelerator pedal and operates at accelerator pedal
release.
2 x 60
2 x 60
2 x 60
Axle 5833
- Type: GIRLING 68 032 056/7
2 x 68
2 x 68
2 x 68
Rear brakes
2 x 60
2 x 60
2 x 60
Operation
Irrespectively of the set type of selection, the exhaust brake
solenoid valve is controlled by the EDC electronic control unit
through connector B pin 11.
2 x 68
2 x 68
2 x 68
Parking brake
It consists of hand distributor pneumatic control and spring
cylinder which operates on rear wheel brakes to lock them.
In case of failure this system brakes the vehicle automatically.
Brakes
Brake linings house an electrical cable connected to a warning
light set on the dashboard which indicates brake lining wear.
ABS device phonic wheels are fitted on wheel hubs.
Rear callipers are equipped with parking brake device.
Front and rear brakes are of the disc type. Discs are fitted on
wheel hubs and are equipped with cooling fins to reduce the
high temperature produced during braking.
Print 603.93.381
28
DIAGNOSTIC
7
8
9
10
11
12
13
14
The complete diagnosis of electric and electronic components must be made using Modus, E.A.SY. and IT2000.
NO
NO
A.P.U. is faulty
(continued)
Base October 2004
Print 603.93.381
29
NO
NO
NO
NO
NO
Print 603.93.381
YES
30
NO
NO
NO
NO
NO
NO
(continued)
Base October 2004
Print 603.93.381
31
NO
NO
NO
A.P.U. is faulty
NO
NO
Print 603.93.381
32
NO
NO
NO
NO
NO
YES
Print 603.93.381
33
NO
NO
NO
NO
NO
Print 603.93.381
34
NO
NO
NO
NO
Print 603.93.381
35
NO
NO
NO
NO
(continued)
Print 603.93.381
36
YES
NO
YES
NO
10
NO
A.P.U. is faulty
NO
NO
Print 603.93.381
37
11
NO
NO
NO
12
YES
NO
A.P.U. is faulty
YES
NO
Print 603.93.381
38
13
NO
NO
A.P.U. is faulty
14
NOISY BRAKES
NO
NO
Print 603.93.381
39
TIGHTENING TORQUE
COMPONENT
TORQUE
Nm
(kgm)
25 to 30
13+3
(2.5 to 3.0)
(1.3+0.3)
40 4
62 5
10
20
17.5
(4 0.4)
(6.2 0.5)
(1)
(2)
(1.8)
279.5 14.5
27.5 2.5
169.5 16.5
40 4
89 9
57.5 2.5
17.5
120
(2.8 1.4)
(2.75 0.25)
(17 1.6)
(4 0.4)
(8.9 0.9)
(5.9 0.25)
(1.8)
(12.2)
17.5
120
(1.8)
(12.2)
490.5 49.5
107.5 10.5
400 +2050
9.1 0.9
(49 5)
(10.8 1)
(42 +25 )
(0.9 0.1)
463.5 46.5
9.1 0.9
163.5 13.5
500 +2050
(46 5)
(0.9 0.1)
(16 1)
(50 +25 )
Compressor
Head fastening screws
Connecting rod cap fastening screws
Air/hydraulic converters
Screws fastening master cylinder to converter cover
Screws fastening converters to chassis
Nut for screw for fastening half bearing collar
Limit switch fastening to cover
Air inlet connection on base
Front brakes
Wheel bearing fastening ring nut
Cheeseheaded socket head screw for front wheel bearing adjusting clamp
Selflocking hexagonalhead screw for fastening brake callipers
Hexagonalhead screw for fastening brake disc to wheel hub
Front wheel hub cover
Tapered threaded plug for front wheel hub cover
Air bleeding screw on brake calliper
Hydraulic calliper guide pin screws
Rear brakes
Air bleeding screw on brake calliper
Hydraulic calliper guide pin screws
Print 603.93.381
40
TOOLS
TOOL No.
DESCRIPTION
99301001
99301005
6810
4 12
2 14
0 16
6 810
4 12
2 14
0 16
6 8 1012
4
14
2
0 16
6 8 10
4
12
2
14
0 16
810
12
14
16
99305117
99306010
99321024
99355038
Print 603.93.381
41
TOOL No.
DESCRIPTION
99357071
Wrench (85 mm) for wheel hub bearing adjusting nut (rear axle
4521)
99357080
Wrench (91.5 mm) for wheel hub bearing adjusting nut (rear axle
4521)
99374370
Tool for fitting wheel hub internal gaskets (to be used with
99370006)
99370006
99370317
99370713
Print 603.93.381
42
TOOL No.
DESCRIPTION
99372269
99374132
Tool for fitting wheel hub internal gaskets (to be used with
99370006)
99386523
99387050
99389819
99395026
Tool for checking hub rolling torque (to be used with torque
wrench)
99395684
Print 603.93.381
43
Singlecylinder
225 cm3
- Type: KNORR
Displacement
Singlecylinder
360 cm3 (*)
Drier
Disconnection pressure
Heat resistance
max + 100 C
Operating temperature
Supply voltage
Power
40 C to +80 C
24 V
100W 24V
7.5 bar
8.0 bar
6.5 bar
Air tanks
Axle
Rear axle
Parking + trailer
15 lt
15 lt
15 lt
Duplex distributor
- Type: Knorr DX 65B DX 65A
Feed pressure
Autolimiting pressure
11 0,2 bar
7.6 0,3 bar
Print 603.93.381
11 bar
8.5
+0
0.4
bar
44
DESCRIPTION
Augmenter valve (towing vehicles)
- Type: KNORR AC 575 A
Operating pressure
Increment percentage
- Type: KNORR AC 576 A
Operating pressure
Increment percentage
10 bar
48%
10 bar
29%
7.5 bar
Air/hydraulic converters
- Type: 20/31.75 (Model 80E..) 20/33,34 (Models 60E.. 65E.. 75E.. 80EL..)
Air piston diameter
20
max 50 mm
39 41.5 mm
31.75 33.34 mm
max 50 mm
24
max 50 mm
39 mm
31.75 mm
max 50 mm
13 bar
13 bar
Print 603.93.381
45
DESCRIPTION
Parking brake distributor (single vehicles)
- Type: KNORR DFR 0208 A
Supply pressure
11 bar
Operating pressure
7.5 bar
Control lever excursion (discharging) with safety braking start (resistance point)
67
Parking braking
73
8.5 bar
Control lever excursion (discharging) with safety braking start (resistance point)
67
Parking braking
73
86
Dump valve
- Type: BENDIX KY 2590/4
Max. operating pressure
10 bar
Spring cylinder
- Type: BENDIX 1186753 (Models 60E.. 65E.. 75E.. 80EL..)
Cylinder stroke
Spring load
max 40 mm
min
max
5500 N
6300 N
max 40 mm
min
max
6700 N
7500 N
22 to 26 Volt
10 bar
13 bar
Print 603.93.381
46
60
68
number
diameter
mm
mm
15.75
16.1
min. admitted
mm
1.6
1.6
mm
304.0 to 304.3
322.0 to 322.3
mm
30.00 to 30.15
min. admitted
mm
27.75
WHEEL HUBS
2 taper rollers
2 taper rollers and 1 needle
max 0.16
Nm
(kgm)
0 to 2.3
(0 to 0.23)
Nm
(kgm)
0 to 4
(0 to 0.04)
Nm
(kgm)
0 to 4.5
(0 to 0.46)
by nut
Tutela W 140/M DA
(kg)
0.10 (0.09)
Print 603.93.381
47
Always block the vehicle before starting any type of operation. Periodically check the gauges comparing them with a
master gauge.
DEVICE
DESCRIPTION
CHECKS
Compressor
A.P.U.
(Air Processing Unit)
Duplex distributor
Press the pedal to the end of its stroke, releasing the pedal it
should return immediately to its home position.
Pressure restriction: 7.6 0.3 bar
Check that the pedal gasket is not worn, that the brake control
rods are well secured and lubricated with no strain.
Check that the lever housings are not worn or oxidised.
Air/hydraulic converters
front and rear
hydraulic pumps
(continued)
Print 603.93.381
48
DEVICE
DESCRIPTION
CHECKS
Air or hydraulic
pressure control
sockets
The automatic coupling joint pipe and the gauge shall indicate
at the same time a pressure of 7.5 bar.
Dump valve
Spring cylinder
Pressure
valve
limiting
(continued)
Base October 2004
Print 603.93.381
DEVICE
Print 603.93.381
DESCRIPTION
49
CHECKS
Coupling heads
Check brake lining wear condition, brake disc scoring and wear,
piston efficiency, and dust cover wear conditions.
50
COMPRESSOR
- KNORR
Figure 25
30411
Diagnostic
FAILURE POSSIBLE CAUSE REMEDY
Oil leakage from flange
on outer side
Damaged scraper ring (this can be seen because the whole seal seat is shiny)
Scraper ring is badly fitted.
Poor efficiency
Mechanical noises
Water seepage
Deteriorated compression or
intake valve.
Piston rings are all on the same
vertical line.
Piston perforated or piston
elements broken.
Damaged gaskets.
Worn piston rings.
Air leakage between cylinder
and head.
Excessive backlash between piston and cyl.
Particles of carbonized oil between
the intake and compression valves.
Print 603.93.381
51
Figure 27
62628
Pneumatic connections
Drier
1
From compressor
3
Exhaust
24 To services
25 To pneumatic suspension
4way valve
21 To rear axle air tank
22 To front axle air tank
23 To parking plus trailer air tank
24 To services
Print 603.93.381
Electric connections
6.1 Negative for thermostatic resistance
52
Operation
Figure 28
62629
Recharge stage:
Compressed air coming from compressor through the feed
pipe fitting 11 sets on the safety valve a (at 13+4 bar) and
goes to the drier filter passing through the proper duct.
Compressed air flowing through the filter releases its
humidity and feeds timer chamber b through the calibrated
hole. At the same time, it opens hold singleacting valve c
and, in this way, it feeds outlet pressure intake 24, pressure
regulator d, outlet 25 for pneumatic suspension circuit feed
and forway protection valve through outlet 21. This valve
adjusts air below the controlled pressure valves of brake
system outlets 21 and 22.
Print 603.93.381
53
Diagnostics
INCONVENIENCE
POSSIBLE REASON
REMEDY
Excessive amount of
condensate in the circuit
Print 603.93.381
54
543730
Figure 31
62372
72658
793336
Figure 32
Figure 30
62382
71957
Print 603.93.381
55
Electric connections
1 Not used
2 Positive STOP lights/Body Controller
3 Input positive
4 EDC positive
Figure 35
71959
793110
DUPLEX DISTRIBUTOR
Figure 34
62579
71951
Print 603.93.381
56
Piston (4) push rod seat first closes the bleeder and then
opens the upper valve (6). The compressed air coming from
fitting 11 feeds the fitting 21 and chamber A.
Figure 36
Brake release
62580
When releasing the brake pedal, the control push rod (2) and
the piston unit (1 and 4) return upwards together with piston
(7).
Continuing to release the brake pedal the valves remain on
the relevant inlet seats and then piston bleeding seats (4 and
7) disconnect from valves and air flows to atmosphere
through bleeder 3.
When brake release is ended, microswitches (3) return to
running position.
Diagnostic
FAILURE POSSIBLE CAUSE REMEDY
Air escapes from the
discharge hole
Irregular autorestrictive
distributor
Worn springs.
Irregular operation of
stop light control switch
Print 603.93.381
793321
57
Pressure limiting
Figure 39
Figure 37
34953
Cuts off the compressed air flow to the user when the
pressure in the latter reaches a determined value (set point).
20046
When the air contained in chamber (A) reaches the set value
it overcomes the spring force (2) and pushes downwards
pistons (1 and 3) thus stopping feeding.
Should set pressure on fitting 2 be accidentally exceeded, the
piston shall continue its downstroke and the valve (2) shall
open for the time required for releasing the excessive
pressure through hole 3.
Operation
- System feed
Figure 38
70118
Diagnostic
FAILURE
POSSIBLE CAUSE
REMEDY
Pressure at fitting 2
is different from
set value
Valve misadjusted.
Leaks from the sealing rings.
58
793332
Figure 40
Predominance regulation
Unit is equipped with a predominance regulating device.
Figure 41
bar
62373
60255
Diagnostic
FAILURE
POSSIBLE CAUSE
Outlet pressures
different from
established values
REMEDY
Print 603.93.381
798510
COUPLING HEADS
793319
- Moderate
59
CHECK VALVE
- WABCO
- Automatic
Figure 44
Figure 42
33987
52871
Operation
Operation
Figure 43
Figure 45
25958
72657
60
794101
Checks
AIR/HYDRAULIC
CONVERTERS
(diaphragm)
Figure 46
62369
Master cylinder
Refitting
- BENDITALIA ( 31,75)
Figure 47
25966
Print 603.93.381
61
Diagnostic
PNEUMATIC CYLINDER
FAILURE
POSSIBLE CAUSE
REMEDY
Insufficient brake
shoes control master
cylinder activation
force
Hardened push rod when sliding into Overhaul the unit and replace the faulty components.
guide bush
MASTER CYLINDER
Missing axle braking
discontinue axle
braking
Locked master cylinder. Leaks due to Remove master cylinder form converter cover, replace
sealing ring wear (4 and 7, Figure 47) the assembly.
Faulty
pistoncylinder
strained return spring
793325
AUGMENTER VALVE
(towing vehicles)
Figure 48
Diagnostic
78616
FAILURE
POSSIBLE CAUSE
REMEDY
Outlet
pressure
lower than preset
pressure
Print 603.93.381
62
Operation
ANTISKID SYSTEMS
Antilock braking system (ABS)
This system is able to prevent wheel locking which could
occur when braking, under any vehicle load conditions and
wheelroad surface friction coefficient, to ensure better
braking performance and better vehicle stability.
The system is activated at ignition and automatically operates
for speeds over 5 km/h if, after braking, one or more wheels
tend to lock.
The ABS system can control the cutting out of the exhaust
brake and the reduction gear locking (if any).
These are deactivated if it is detected that one or more
driving wheels tend to lock.
The reactivation is automatic when the ABS system
operation terminates.
35380
526714
ELECTROPNEUMATIC VALVE
Figure 49
35381
3 Discharge
Base October 2004
Print 603.93.381
63
- Pressure keeping
Figure 52
The fourth and last circuit is the safety circuit that checks the
efficiency of the various system components.
In case of failure, it not only informs the driver by switching
on the relevant warning light on the dashboard, but it also
automatically disconnects the entire ABS system, leaving the
conventional braking system fully efficient.
35382
526711
526713
526712
- KNORR BREMSE
RPM SENSORS
PHONIC WHEELS
Figure 54
Figure 53
35383
62609
Operation
Each channel features four function circuits; the first is the
input circuit that receives the analog signals from the sensor
on the relevant wheel, signals are debugged and converted
to digital data through the measurement of the cycle
duration. There is also a main circuit which has a
microprocessor to process the information received from the
input circuit. The microprocessor contains a sophisticated
Print 603.93.381
Operation
The phonic wheel is housed on the wheel hub and turns at
the same speed as the wheel. It generates in the sensors, by
induction, alternate voltages having a frequency that is
proportional to the rotation speed of the wheel. These
voltage signals are transmitted to the ECU for processing.
Each wheel has a sensor and a phonic wheel installed. This
enables individual adjustment of the braking pressure for each
wheel, thus optimising driving stability and braking distance.
64
Figure 55
33898
68383
62384
- fill the tank (3, Figure 57) with Tutela TRUCK DOT
SPECIAL;
Print 603.93.381
794310
- open cock (4) until the gauge (5) indicates 1 to 1.2 bar
pressure.
65
Figure 59
78619
Diagnostic
FAILURE
POSSIBLE CAUSE
REMEDY
Distributor control
lever is difficult to
turn
Overhaul the
components.
device
and
replace
the
faulty
Print 603.93.381
66
794310
Figure 60
Device connections:
1 From fourway safety valve
21 To spring cylinders
22 To trailer braking triple control servo distributor.
78618
Diagnostic
FAILURE
POSSIBLE CAUSE
REMEDY
seat or
faulty
In braking position
faulty
Print 603.93.381
794922
67
- Braking position
Figure 63
Figure 61
34009
34007
This device brakes the vehicle during the parking braking and
when the pneumatic system is discharged.
Operation
Spring cylinder emergency brake release
device
34008
Print 603.93.381
34010
68
- reset the boot to initial conditions; lift the rear part of the
vehicle using hydraulic jack, set it on suitable stands,
remove wheels, remove brake linings, and tighten the
screw of the automatic backlash adjusting device to reset
the proper backlash between brake linings and brake disc,
during towing backlash may be varied.
Figure 65
Repair operations
- Removal
Figure 67
35362
Remove the boot (2), remove the sleeve (1), remove the
nuts (3 and 5) with the relevant clamp and remove the cover
(4). Overhaul the device and replace the worn components.
34012
- Refitting
For refitting reverse the removal operations.
Diagnostic
FAILURE
POSSIBLE CAUSE
REMEDY
5274
REPAIRING BRAKES
5274
69
Figure 69
Front brakes
Description
The supporting plate of the brake calliper assembly is secured
to the stub axle by means of a support.
The hydraulic brake calliper body is connected to the plate
by guide pins fitted with sliding sleeves which are lubricated
and fitted with dust boots.
The hydraulic brake calliper body, performing floating
operation on the plate, consists of two pistons.
32963
Operation
Set the vehicle on flat ground and lock the front wheels.
Loosen front wheel fastening nuts (1). Lift the front part of
the vehicle using a hydraulic jack and rest it on two stands (2).
Figure 68
Figure 70
32964
27296
Loosen the fastening nuts and remove the wheels using the
hydraulic trolley 99321024 (1).
Figure 71
33856
Remove the safety clips (1 and 2) from the retaining pins (3).
Print 603.93.381
70
Figure 72
Figure 75
33861
33857
Loosen screw (3) and nut (4), remove the spring (2) and then
remove the brake lining (1).
33860
Print 603.93.381
71
Figure 76
Figure 78
27297
33862
Connect wear indicator cable pin (1). Apply clamp (3) and
then (2 and 4) and fasten the cables to the brake fluid pipe.
Fit the retaining pins (6) into brake calliper (5) seats and refit
the safety clips (7).
Proceed as described on the opposite side.
Figure 77
33862
33864
Print 603.93.381
Connect wear indicator cable pin (1). Secure the cable (2)
to pipe (3). Apply the spring (4) to the brake calliper and lock
it by screw (5) and nut (6).
Proceed as described on the opposite side.
Fit wheels using the hydraulic trolley 99321024.
Lower the vehicle.
Tighten wheel fastening nuts to the specified torque.
Fit the protection cap on the wheel hubs.
Once repair operations are completed, depress the brake
pedal repeatedly with the vehicle running in both directions
to set the brake linings.
72
527413
Figure 83
Figure 80
33868
33865
520620
Figure 84
Figure 81
33866
77201
Turn the wheel hub so that the screw plug (1) faces
downwards; release the plug and drain oil into the
appropriate container.
Figure 85
33867
Use the proper wrench (2) to release and loosen the two
guide pin screws (8, SENZA CODICE) fastening the
hydraulic calliper body (3) and remove it from the supporting
plate.
32995
Print 603.93.381
527411
Figure 86
73
Figure 88
34046
Loosen the screw (3), the adjusting ring nut (2), withdraw the
washer (4), the outer bearing (1) and remove the brake disc
with the wheel hub.
Remove the opposite brake assembly and keep separate the
components.
33901
- fit the brake disc (1) including the hub on lathe shaft
99301002 (2);
- fit a set of spacers on the shaft to remove unit end play,
tighten the lock nut and place the lathe support.
Align the tool holder (3) and the brake disc (1), adjust tool
depth to remove the same amount of brake disc working
surface.
Turn the brake disc (1) with one or more removal runs
according to the scoring found.
Figure 89
Figure 87
33902
33900
74
Rear brakes
Operation
The operation of the rear brake calliper is similar to that of
the front one.
62586
Screw (5) thread couples with ring nut thread (7, detail B).
Ring nut (7) engagement surface is forced against the
secondary piston (10). Since neither the ring nut nor the
screw can rotate, the primary piston (11) is forced towards
the outside thus activating the parking brake.
Print 603.93.381
75
TECHNICAL DATA
The parking device with automatic backlash take up (pad and
disc) is fitted to keep constant the parking brake stroke.
The take up device enables, by a certain pressure value, to
cut out the influence of the temporary distortions due to
pressure increase in order to avoid excessive backlash take
up with subsequent residual torque or brake locking.
The take up device operates during the service braking.
It is built so as to take up automatically the calliper body
backward movement due to external pad and disc wear, with
control lever rotation to obtain a constant gap between the
actuator cylinder and its application point on the control
lever.
Print 603.93.381
76
49115
Print 603.93.381
77
49116
78
49117
A = Bush
B = Pin
F1 = S1 x p
S1 = surface corresponding to d 1
p = hydraulic pressure
F1 = Force generated by the spring
F3 = Thrust on floating element due to pressure p
Print 603.93.381
79
49118
A = Bush
B = Pin
F1 = S1 x p
S1 = surface corresponding to d 1
p = hydraulic pressure
F1 = Force generated by the spring
F3 = Thrust on floating element due to pressure p
80
Parking braking
Figure 95
69119
A = Bush
B = Pin
Parking brake
operation
The tightening force is transmitted through the following
components: control lever (9), cam (10), cap (8), piston (7),
threaded pin (3), threaded bush (4) and piston (1).
Lever (9) rotary motion is converted into linear motion along
the piston axis by cam (10).
To obtain constant tightening force the gap between the
actuator cylinder set on vehicle and its application point on
the control lever shall be constant.
Print 603.93.381
527417
81
Figure 99
Figure 96
33037
33871
Set the vehicle on flat ground. Set the parking brake lever to
running position, loosen rear wheel fastening nuts. Use the
hydraulic jack (2) to lift the rear part of the vehicle and rest
it on two stands (1).
Remove the split pin (4), withdraw the pin (3), lock the
parking brake device lever (2) by split pin (1) or proper pin.
Set parking brake lever in braking position and disconnect the
lever (2) from the sleeve (5).
Figure 100
Figure 97
33872
33038
Remove the safety clips (1), remove the retaining pins (2) and
remove the brake linings (3).
Removal
Figure 98
33870
Print 603.93.381
33873
82
Clean the brake calliper using a wire brush taking care not to
damage the dust boots.
33874
Figure 104
Figure 103
49120
Print 603.93.381
Refitting
For rear axle 4521
83
Figure 108
Figure 105
33872
33870
Figure 106
527413
33873
Figure 109
Figure 107
33880
33871
Print 603.93.381
84
525030
Figure 113
Figure 110
33881
Turn brake disc (1) until one of the two OIL inscriptions is
set upwards. Remove screws (2 and 3) and drain out oil. Then
loosen in sequence all the other axle shaft fastening screws.
33879
NOTE Use wrench 99377080 (1) for rear axle 4517 and
wrench 99357071 (1) for rear axle 4521.
Figure 114
Figure 111
33898
34106
Remove the axle shaft (2) from the wheel hub (1).
Figure 115
Figure 112
34108
Remove the taper roller bearing (2). Remove the brake disc
(3) including the wheel hub (1).
34107
Print 603.93.381
527413
85
Figure 116
33884
Figure 117
34051
Print 603.93.381
86
Figure 118
49121
Print 603.93.381
87
Figure 121
33886
33882
Set the brake calliper (1) on the bench and clamp it in a vice.
Remove plugs (2 and 3) using a setscrew wrench (4).
Figure 122
Figure 120
27298
88
Figure 126
Figure 123
33890
Clamp the calliper (1) in a vice and using the proper pliers
remove the seeger ring (2).
When removing the seeger ring, cover partly the
hole using the proper tool to prevent sudden
removals of the components pushed by the spring.
33887
Figure 124
33888
33891
Remove from the brake calliper: the seeger ring (1), the spring
retaining cover (2), the spring (4) and the screw (3).
Figure 125
33891
33889
Remove dust covers (1) from the seats on the brake calliper
(2) with a slight pressure.
Base October 2004
Remove from the brake calliper: the seeger ring (5), the spring
ring nut (4), the spring (3), the screw (2) and the safety block
(1).
Print 603.93.381
89
33892
Refit in the brake calliper (5) the parts composing the device
for taking up the backlash automatically and the parking brake
after lubricating them with brake fluid in the following
sequence.
Refit the screw (4), the spring (3), the spring retaining cover
(2) and the seeger ring (1).
49123
Refit in the brake calliper (6) the parts composing the device
for taking up the backlash automatically and the parking brake
after lubricating them with brake fluid in the following
sequence: refit the safety block (5), the screw (4), the spring
(3), the spring ring nut (2) and the seeger ring (1).
Print 603.93.381
90
Figure 133
33895
33893
Set the hydraulic brake calliper body in a vice fitted with caps.
Lubricate the pistons by immersing them partly into brake
fluid.
Insert the piston (1) in the upper edge of the dust boot (2),
rotate slightly to enable fitting then, keeping it perfectly
perpendicular to its seat, insert it into brake calliper body
cylinder (3). Use a wooden board resting on the piston (1)
and press to fit it partially. Insert dust boot edge (2) into
piston grooved seat (1).
Fit pistons (1 and 4) into their seats.
Fit the sleeves (5) into brake calliper seats (3) and position
properly the sealing edge of the dust cover into the sleeve
seat.
Immerse the sealing rings in brake fluid. Fit sealing rings (4)
into cylinder seats (3).
Figure 132
33896
Apply dust boots (1) on brake calliper body seats (2) and
push slightly to check their correct positioning, they shall not
be removed from their seats.
Lubricate cylinder surfaces (3) with brake fluid without
fouling the upper boot edge.
Fit dust covers (3). Fit the sliding sleeves (4) and the pins (5).
Position properly the dust cover sealing edge into sleeve
seats.
Print 603.93.381
91
REFITTING BRAKES
520620 REFITTING THE FRONT WHEEL
HUBS
Figure 138
33897
33975
NOTE Make sure that the surfaces of all parts inside the
hub are accurately clean, free from slags and burrs.
Figure 139
33885
Fit the supporting plate (1) to the brake calliper (2). Use
wrench (3) to lock the guide pins (4).
Figure 137
60875
33882
Fit in the brake calliper (1): plugs (2 and 3) and tighten using
wrench (4).
Print 603.93.381
Screw on stub axle pin tool 99370713 (3) and lubricate its
external surface with TUTELA W140/MDA oil.
Sling with a rope (1) the wheel hub (2) and support it with
the lifting device. Carefully key wheel hub (2) on stub axle pin,
in order not to damage the sealing ring.
Assemble spacer (4), internal ring (5) of the tapered roller
bearing.
Unscrew tool 99370713 (3).
Key washer (6) and screw adjustment ring nut (7) at the
required closing torque.
92
Figure 140
Figure 142
77202
32998
Figure 143
Figure 141
77203
32999
Turn the wheel hub until the wheel hub cover (1) reaches
the illustrated position.
Refill the prescribed oil quantity (0,10 litres) through the filling
hole (2).
Tighten the plug on the wheel hub cover (1) to the
prescribed torque.
Print 603.93.381
520620
93
Figure 147
Figure 144
34047
33903
Figure 148
Figure 145
34108
Set the magnetic base gauge 99395684 (3) on the wheel hub
(1) and rest the rod on the sleeve (2). Check that wheel hub
end play is falling between 0 and 0.16 mm.
34108
Figure 149
Wet and fit the spacer and the wheel hub (3) including the
brake disc (1) on the axle casing sleeve.
Lubricate the front taper roller bearing (2) with SAE W 140
MDA and remove it from its seat on the wheel hub (3).
Figure 146
34048
33898
Fit the safety washer (1) so that the clip is properly guided
into axle casing sleeve slotted space.
Print 603.93.381
94
527413
Figure 150
34107
Once the required rolling torque and wheel hub end play
have been obtained, check that one of the holes on the
adjusting nut (2) is coinciding with one of the holes on the
safety washer. Otherwise loosen gradually the adjusting nut
(2) until the safety screw (1) can be inserted. Tighten the
adjusting nut safety screw (1) to 9.1 Nm (0.9 kgm).
33868
Apply the supporting plate (2) to the support (1) and tighten
to contact the selflocking screws (3).
Use the proper dynamometric wrench fitted with box
wrench to tighten screws to the specified torque.
Figure 151
34049
Figure 154
Figure 152
33905
34050
527413
Figure 155
95
Figure 157
33906
33880
Figure 156
Fit the brake calliper assembly on the stub axle. Tighten the
screws to the specified torque using wrench (3). Secure the
bracket (1) to the supporting plate (2) using the proper
screws. Connect brake fluid hose fitting (4) to the calliper.
Apply the brake fluid hose (4) to the brake calliper (6) and
tighten fitting (5) to contact; set the bracket (1) and insert the
fastening screw (3) and then lock it.
Tighten fitting (5) to the specified torque.
NOTE Should hose (2) be replaced, lock the fittings
without causing torsion to piping and complying
with procedure described in chapter pipes and
fittings.
For refitting the brake linings, comply with the procedure
previously described in the chapter dealing with brake lining
replacement.
NOTE After refitting the brake callipers, bleed air from the
hydraulic circuit as described in the relevant
chapter.
Print 603.93.381
96
Print 603.93.381
BODY CHASSIS
SECTION 12
5501 Body
5001 Chassis
Page
Print 603.93.381
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- General information . . . . . . . . . . . . . . . . . . . . .
- Protective treatment . . . . . . . . . . . . . . . . . . . .
- Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . .
10
- Welding instructions . . . . . . . . . . . . . . . . . . . .
10
10
10
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
CHASSIS FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
14
14
14
15
16
BODY CHASSIS
Page
CAB GEOMETRY . . . . . . . . . . . . . . . . . . . . . . . .
21
22
25
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
- Cab anchoring . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
31
32
33
33
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
- Vibration knife . . . . . . . . . . . . . . . . . . . . . . . . .
33
- Harmonic wire . . . . . . . . . . . . . . . . . . . . . . . . .
34
34
34
35
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
37
38
38
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . .
40
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
40
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
Page
41
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
46
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
Print 603.93.381
5501
BODY - CHASSIS
CAB
General information
The cab is an advanced one, it can be tipped up hydraulically with a mechanical control.
Tilting angle 57.
Pressed and welded steel framework, parts made of electro-galvanized sheet steel.
Sound deadening on the underbody and anticorrosion protection in the boxed compartments.
The cab suspension is mechanical.
Figure 1
78688
Print 603.93.381
BODY CHASSIS
ML 60E.. 60E../P
ML 65E.. 65E../P
ML 75E.. 75E../P
ML 80EL.. 60EL../P
Figure 2
78689
Dimensions (mm)
X Wheel base
K
B
C1
C2
Maximum length
Maximum width (*)
Front track
Rear track
Noload
No load chassis height (mechanical
suspension)
Noload
No load chassis height (pneumatic
suspension)
Y Rear overhang
Z Front overhang
H Noload maximum height
Steering minimum diameter
D Front axle body edge distance
W Practicable maximum length
Practicable maximum width
(...)
(*)
(**)
Models
abcd
abcd
abcd
abcd
abc
d
abc
d
abcd
abcd
abcd
abcd
abcd
abcd
4455
2700
3105
3330
3690
4185
5290
5718
6460
6820
2170
1810
1660
902
916
7630
(**)
8035
2145
2280
2505
14400 15200
475 (1055)
6220
6650
16300
(5640)
(6645)
1290
990
3845
abcd
4815
8620
740
750
1313
1830
11100
475
4420
11800
4850
1830
2545
12900
5425
(4845)
2550
(6070)
7225
Print 603.93.381
Models: a)
b)
c)
BODY CHASSIS
ML 80E.. 80E../P
ML 90E.. 90E../P 90E../FP
ML 100E.. 100E../P 100E../FP
Figure 3
78689
Dimensions (mm)
X Wheel base
Models
K
B
C1
C2
Maximum length
Maximum width (*)
Front track
Rear track
Noload
No load chassis height (mechanical
suspension)
Noload
No load chassis height (pneumatic
suspension)
Y Rear overhang
Z Front overhang
H Noload maximum height
Steering minimum diameter
D Front axle body edge distance
W Practicable maximum length
abc
abc
abc
abc
ab
c
ab
c
abc
abc
abc
abc
abc
abc
abc
(...)
(*)
(**)
2700
3105
3330
3690
5313
(**)
5718
(**)
6460
(**)
6820
2200
1835
1680
915
930
1313
9900
3845
4185
4455
4815
7630
8035
8620
2145
2280
2505
14400 15200
475 (1055)
6220
6650
16300
(5640)
(6645)
750
790
1313
1830
11100
475
4420
11800
1830
2555
12900
4850
5425
(4845)
2550
(6070)
7225
Print 603.93.381
BODY CHASSIS
Models: a)
b)
c)
ML 80 90 100E17D D/P
ML 80 90 100E18D D/P
ML 80 90 100E21D D/P
Figure 4
78690
Dimensions (mm)
X Wheel base
K Maximum length
B Maximum width (*)
C1 Front track
C2 Rear track
t
t
Y
Z
H
abc
abc
abc
abc
ac
b
abc
abc
abc
abc
abc
abc
abc
abc
3105
5718
1313
11100
3290
3690
6820
4185
4455
7630
8035
2200
1835
1680
915
900
795
1830
2145
2280
4815
8620
2505
11630
6190
Print 603.93.381
Models:
a)
b)
BODY CHASSIS
ML 60 65 75E..K
ML 80 90 100E..K
Figure 5
78691
Dimensions (mm)
X Wheel base
K
Maximum length
C1 Front track
C2 Rear track
t
Rear overhang
Front overhang
H Noload
No load maximum height
Steering minimum diameter
D Front axle body edge distance
W Practicable maximum length
Practicable maximum width
(*)
Models
a
b
a
b
a
b
a
b
a
b
a
b
ab
a
b
ab
ab
ab
ab
2700
5290
5313
3105
5718
5718
3330
6460
6460
3690
6820
6820
1830
1830
1830
1830
11800
12900
4850
5425
2170
2200
1810
1835
1660
1680
900
930
1290
1313
1313
1313
2545
2590
9900
11100
475
3845
4420
2550
Print 603.93.381
BODY CHASSIS
78692
BODY CHASSIS
Print 603.93.381
10
BODY CHASSIS
Spot welding
This must be workmanlike. Take special care over the setting of the device so as to make spot welds that ensure a fully efficient
join. Avoid positioning spots near the edge of the parts to weld.
NOTE
The areas of the chassis frame involved in welding must be thoroughly cleaned and, after welding, protected with
twocomponent epoxy rustproofing or another similar product, and with another coat of single or twocomponent
paint.
The earth cable of the welding system must be connected on the chassis frame as close as possible to the welding zone, and never
near a rotating part (transmission, wheel hubs, etc.) nor above or under an assembly with moving parts (compressor, bearings, etc.).
Welding instructions
Before welding, which must be done so as to minimize the tension and deformation that may be created, remove the paint and
carefully deoxidize the surfaces involved.
Classification of corresponding steels in the EU:
French standards
A 35 501
German standards
DIN 17 100
British standards
BS 4360
American standards
ASTM
E 24.2
E 26.3
E 36.4
Italian standards
UNI 7070
RSt. 37.2
St. 42.3
St. 52.3
Swedish standards
MNC 810
40 B
43 C
50 D
Spanish standards
UNE 36 080
A 283 gr. D
A 284 gr. C
Belgian standards
NBN 631
Fe 37.B
Fe 42.C
Fe 52.D
13.12.00
14.13.00
21.34.01
A 360.B
A 410.C
A 510.D
AE 22B or AE24B
AE 26 C
AE 36 D
Print 603.93.381
BODY CHASSIS
11
PRECAUTIONS
Figure 7
Figure 9
17360
17358
Figure 8
Figure 10
17359
17361
Print 603.93.381
12
BODY CHASSIS
Figure 12
17364
17362
A 0,3 H
b H (min. 175 mm)
S (0,8 1) S1
17365
17363
Print 603.93.381
BODY CHASSIS
5001
CHASSIS FRAME
REPAIRS AND CHECKS
13
Figure 15
17347
Figure 13
Figure 16
17344
Figure 14
Figure 17
17345
Carefully check for any peeling or cracking all over the chassis
frame, paying special attention to joints under great strain,
such as: chassis frame cross members, brackets, mounts of
leaf springs and chassis frame structural members.
Mark any peeled or cracked points straight away.
17349
Print 603.93.381
14
BODY CHASSIS
Figure 18
Figure 21
17350
17353
17351
Figure 20
17352
17354
Print 603.93.381
BODY CHASSIS
15
Figure 23
17355
Figure 24
17356
17357
16
BODY CHASSIS
78281
II
Dimension
(mm)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
4455
1001.25
180
720
1080
2182.5
3262.5
405
405
840
967.5
1440
840
967.5
2272.5
1755
840
967.5
2272.5
1890
840
967.5
2272.5
832.5
202.5
787.5
832.5
202.5
787.5
832.5
202.5
787.5
1192,5
1080
3105
1313
5498
1710
1080
3330
1830
6240
1710
1080
3690
1830
6600
832.5
202.5
787.5
1665
2025
1080
4185
2145
7410
832.5
202.5
787.5
1800
2160
1080
4455
2280
7815
3105
1001.25
180
720
1080
1912.5
3330
1001.25
180
720
1080
1912.5
405
405
405
405
990
840
967.5
4815
1001.25
180
720
1080
2182.5
3217.5
405
405
1260
2115
840
967.5
2272.5
3127.5
832.5
202.5
787.5
2025
2390
1080
4815
2505
8400
Print 603.93.381
Models:
17
BODY CHASSIS
60 to 75 (mechanic suspensions)
Figure 27
78280
II
Dimension
(mm)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
Print 603.93.381
2700
1001.25
180
720
1080
3105
1001.25
180
720
1080
1912.5
3330
1001.25
180
720
1080
1912.5
405
405
405
405
405
405
990
840
967.5
990
840
967.5
832.5
135
787.5
1175
1080
2700
1290
5070
405
405
4185
1001.25
180
720
1080
2182.5
2992.5
405
405
4455
1001.25
180
720
1080
2182.5
3262.5
405
405
840
967.5
1440
840
967.5
2272.5
1755
840
967.5
2272.5
1890
840
967.5
2272.5
832.5
135
787.5
832.5
135
787.5
832.5
135
787.5
1192.5
1080
3105
1313
5498
1710
1080
3330
1830
6240
1710
1080
3690
1830
6600
832.5
135
787.5
1665
2025
1080
4185
2145
7410
832.5
135
787.5
1800
2160
1080
4455
2280
7815
4815
1001.25
180
720
1080
2182.5
3217.5
405
405
1260
2115
840
967.5
2272.5
3127,5
832.5
135
787.5
2025
2390
1080
4815
2505
8400
18
BODY CHASSIS
78283
II
Dimension
(mm)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
3105
1001.25
720
1080
1912.5
3330
1001.25
720
1080
1912.5
405
405
405
405
990
840
967.5
840
967.5
832.5
202.5
787.5
1147.5
1080
3105
1313
5498
832.5
202.5
787.5
1080
3330
1830
6240
4455
1001.25
720
1080
2182.5
3262.5
405
405
1440
840
967.5
2272.5
1755
840
967.5
2272.5
1890
840
967.5
2272.5
832.5
202.5
787.5
1665
1080
3690
1830
6600
832.5
202.5
787.5
1980
1080
4185
2145
7410
832.5
202.5
787.5
2115
1080
4455
2280
7815
4815
1001.25
720
1080
2182.5
3217.5
405
405
1260
2115
840
967.5
2272.5
3127.5
832.5
202.5
787.5
2340
1080
4815
2505
8400
Print 603.93.381
19
BODY CHASSIS
78282
II
Dimension
(mm)
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
Print 603.93.381
2700
1001.25
720
1080
3105
1001.25
720
1080
1912.5
3330
1001.25
720
1080
1912.5
405
405
405
405
405
405
990
840
967.5
990
840
967.5
840
967.5
832.5
135
787.5
1147.5
1080
2700
1313
5093
832.5
135
787.5
1147.5
1080
3105
1313
5498
832.5
135
787.5
1080
3330
1830
6240
405
405
4185
1001.25
720
1080
2182.5
2992.5
405
405
4455
1001.25
720
1080
2182.5
3262.5
405
405
1440
840
967.5
2272.5
1755
840
967.5
2272.5
1890
840
967.5
2272.5
832.5
135
787.5
1665
1080
3690
1830
6600
832.5
135
787.5
1980
1080
4185
2145
7410
832.5
135
787.5
2115
1080
4455
2280
7815
4815
1001.25
720
1080
2182.5
3217.5
405
405
1260
2115
840
967.5
2272.5
3127.5
832.5
135
787.5
2340
1080
4815
2505
8400
20
BODY CHASSIS
Print 603.93.381
BODY CHASSIS
21
CAB GEOMETRY
Figure 30
A
B
C
D
E
DRIVERS
PASSENGERS
SEAT
SEAT
440 455
440 465
1145 1160
1135 1160
LOWER BED
UPPER BED
CHASSIS INSIDE UPPER EDGE
78693
Print 603.93.381
22
BODY CHASSIS
SEC. A A
SEC. D D
SEC. E E
SEC. N N
SEC. P P
SEC. F F
78694
Print 603.93.381
BODY CHASSIS
23
Figure 32
78695
Print 603.93.381
24
BODY CHASSIS
Print 603.93.381
5542
BODY - CHASSIS
25
Figure 33
78696
78697
TORQUE
Hexagonal nut with flange for shock absorber upper fastening
Hexagonal nut for shock absorber lower fastening
Hexagonal screw with flange to secure bracket to cab on chassis side
Print 603.93.381
Nm
122.5 12.5
122.5 12.5
296 29
(Kgm)
(12.2 1.2)
(12.2 1.2)
(29.6 2.9)
26
BODY CHASSIS
Figure 34
78698
78699
TORQUE
Hexagonal screw with flange for block fastening
Hexagonal screw with flange to secure bracket to block
Nm
187 37
296 29
(Kgm)
(18.7 3.7)
(29.6 2.9)
Print 603.93.381
27
BODY CHASSIS
Figure 35
78704
TORQUE
Bumper securing screw
Upper shock absorber securing screw
Lower shock absorber securing screw
Screw to secure bracket to chassis
Print 603.93.381
Nm
120 24
120 24
120 24
75 15
(Kgm)
(12 2.4)
(12 2.4)
(12 2.4)
(7.5 1.5)
28
BODY CHASSIS
Figure 36
78700
78701
TORQUE
Selflocking hexagonal nut with flange and hexagonal screw with flange to secure
bracket to chassis
Selflocking hexagonal nut to secure shock absorber and elastic bumper to cross
member on upper side
Selflocking nut and hexagonal screw for shock absorber fastening on lower side
Nm
179 18
(Kgm)
(17.9 1.8)
216.5 21.5
(21.6 2.1)
189 19
(18.9 1.9)
Print 603.93.381
BODY CHASSIS
29
Figure 37
78702
TORQUE
Bumper securing screw
Screw to secure bracket to chassis
Screw to secure cross member connecting pipe
Screw to secure shock absorber
Print 603.93.381
Nm
128 52
105 21
263 53
128 52
(Kgm)
(12,8 5,2)
(10,5 2,1)
(26,3 5,3)
(12,8 5,2)
30
BODY CHASSIS
TOOLS
TOOL No.
DENOMINATION
99370147
99378031
Print 603.93.381
BODY CHASSIS
REPAIRS
5542
Cab anchoring
554215
554243
31
Figure 40
Figure 38
38600
41851
Figure 39
33911
32
BODY CHASSIS
78707
Print 603.93.381
554255
BODY CHASSIS
33
Vibration knife
Figure 44
Figure 43
60967
99379
Unscrew the oil fittings (4); unscrew the nuts (1 and 2) for the
connecting pins and extract the cylinder (3).
NOTE
NOTE
60968
34
BODY CHASSIS
Harmonic wire
For cutting the sealant bead with the harmonic wire, it is
necessary to use a tool as illustrated in Figure 47.
Figure 48
Figure 46
78708
The other operator, who is outside the vehicle, has to pull the
draw handle (1) while following the windscreen profile, and
cut the sealant bead.
60969
Figure 47
78709
60970
Cut a wire section about 500 mm long and, using a check tool
(3), put in a wire end (1) through sealant bead (2), starting
from windscreen window lower centre (see Figure 48).
Fix the wire end to check tool (3), operating inside the vehicle,
and the other end to the draw handle outside the vehicle.
The inside operator has to point the check tool at sealant bead
(2), about 300 mm from where wire (1) runs through.
Print 603.93.381
BODY CHASSIS
35
Figure 52
78713
78710
Refitting
Figure 53
Figure 51
78711
78712
36
BODY CHASSIS
Figure 54
Figure 56
78714
78716
NOTE
Figure 55
78715
Print 603.93.381
550740
BODY CHASSIS
37
Figure 57
33919
Take off the screw caps (arrows), unscrew the screws and
extract the armrest (2). Remove the pushbutton (1).
33922
Figure 58
33922
Unhook the safety clip (1) from the lifting device (2).
33920
Using proper tool (2), take off the safety ring and dismount
handle (3). Using the pliers, dismount handles (1). Remove the
whole panel.
Figure 62
Figure 59
33924
Lift the window (1) and extract it from the top (arrow).
33921
Lower the window, extract the internal and external seals (1).
Print 603.93.381
38
BODY CHASSIS
550730
Figure 63
33927
Extract the outside seal (1), apply the suction cup 99378031
(2).
33925
Unhook the clips (1), unscrew the screws (2), unhook the
window from its lifting device (4) and extract the window
winder (3).
To fit it, carry out the steps described for removal in reverse
order.
550478
Figure 64
Position the window in its seat correctly, register its position
and mark it with adhesive tape. Cut the tape and take out the
window.
33926
Lift the shields (1), unscrew the screws and remove the
rearview mirror (2). Take off the shield (3).
Remove the inside door trim.
Base October 2004
Print 603.93.381
BODY CHASSIS
Figure 66
39
Figure 68
33921
33928
Place the windscreen in its seat with the suction cup handle
(2).
- Align the window with its housing bay, using the adhesive
tape applied beforehand as a reference.
NOTE
Figure 69
Figure 67
33930
33929
Print 603.93.381
40
BODY CHASSIS
553710
INSTRUMENT PANEL
Figure 72
Removal
Before performing repair interventions, disconnect
batteries and observe safety rules.
Figure 70
79612
Refitting
Perform reattaching operations inverting described
detaching operations.
79610
553710
Removal
Figure 71
Figure 73
79611
79613
Print 603.93.381
41
BODY CHASSIS
Figure 74
NOTE Mark electric wiring harness to make reattaching
operations easier.
Figure 77
79614
Refitting
Perform reattaching operations inverting described
detaching operations.
552211
79615
Removal
Figure 78
79618
42
BODY CHASSIS
Figure 79
Figure 82
79619
79620
79621
79624
BODY CHASSIS
Figure 85
43
Figure 88
79625
78628
Figure 89
Figure 86
79629
79626
Figure 87
79630
79627
Print 603.93.381
44
BODY CHASSIS
Figure 91
Figure 93
79631
Figure 92
Figure 94
79632
79634
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BODY CHASSIS
Figure 95
45
Figure 98
79635
79638
Figure 96
79636
Figure 99
79639
46
BODY CHASSIS
Figure 100
Figure 103
79640
79643
Figure 101
Figure 104
79641
Refitting
Perform instrument panel (1) covering reattaching
operations properly inverting described detaching operations.
533210
Removal
79645
Refitting
Figure 102
79642
Print 603.93.381
PROGRAMMED MAINTENANCE
SECTION 13
Programmed maintenance
Page
Print 603.93.381
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Service plan . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE FREQUENCY . . . . . . . . . . . . . . . . . . . . . .
M1 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M2 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M3 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
M4 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
EP1 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
EP2 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
EP3 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
EP4 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
14
14
14
14
EP5 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
PROGRAMMED MAINTENANCE
Print 603.93.381
PROGRAMMED MAINTENANCE
SERVICING
Service plan
The checks, maintenance interventions and adjustments required at regular frequency on vehicle parts to ensure optimal working
conditions are illustrated on the following pages.
NOTE
The engine lubricant frequency in kilometres refers to a percentage of sulphur in fuel lower than 0.5%.
Halve the oil replacement frequency if fuel with a percentage of sulphur higher than 0.5% is used.
- In the case lower class lubricant is used, for example ACEA E2 (Urania Turbo), halve the oil replacement
frequency.
- Change the engine lubricant oil in any case every 12 months in the event of very low distance, less than 800
hours/80.000 kilometres per year.
- Change the transmission and axle oil at least once every two years in the event of very low yearly distances.
- Carry out the general greasing procedure at least once a year in the event of very low yearly distances.
SERVICE FREQUENCY
Type of use
Long distance hauls: national
or international, mainly
motorway
Shorttomedium distance
hauls: regional or
interregional
Demanding use, mainly in city
traffic: tippers, compactors,
road cleaning services,
distribution, offroad.
M1
80,000
km/
3200
hours
60,000
km/
2400
hours
40,000
km/
1600
hours/
1 year
M2
160,000
km/
6400
hours
120,000
km/
4800
hours
80,000
km/
3200
hours/
2 years
M3
240,000
km/
9600
hours
M4
480,000
km/
19200
hours
240,000
km/
9600
hours
160,000
km/
6400
hours/
4 years
EP1
EP2
EP3
EP4
EP5
6
months
1
months
2
months
3
months
40,000
km
800
hours
Extra plan operation (to be carried out possibly at the same time as a planned service operation)
EPI
EVERY 20,000 km or 800 hours for urban or offroad use.
EVERY 40,000 km for long, medium or short distance hauls.
G Change automatic transmission filter and oil.
G Removerefit and clean automatic transmission oil breather.
EP2
EVERY 6 MONTHS particularly at the beginning of spring
G Clean radiator curtain.
Print 603.93.381
PROGRAMMED MAINTENANCE
EP3
EVERY YEAR
G Replace pneumatic system drier filter.
EVERY YEAR before winter
G Check coolant density
G Replace supplementary heater fuel filter.
EVERY YEAR before summer
G Check conditioner coolant conditions through the gauge.
EP4
EVERY TWO YEARS
G Replace air cleaner cartridge and clean container.
G Change engine coolant.
EP5
EVERY THREE YEARS
G Oil change and clutch hydraulic system bleeding.
G Oil change and brake hydraulic system bleeding.
1
13
5/11
14
12
6
10
4
7
3
M1
D
D
D
D
D
D
D
D
M2
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
M3
D
D
D
D
D
D
D
D
M4
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
15
2
16
9
16
8
13
Print 603.93.381
PROGRAMMED MAINTENANCE
Figure 1
84409
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PROGRAMMED MAINTENANCE
Figure 2
78294
Print 603.93.381
PROGRAMMED MAINTENANCE
M2
M3
M4
18
20
22
23
21
17
22
25
24
Print 603.93.381
PROGRAMMED MAINTENANCE
M1 SERVICE
S Handling operations
S Functional testing on road
S General chassis greasing
S Checking cooling system and hydraulic
brake pipe seal
1 - Blowby filter replacement
Figure 3
84410
77836
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PROGRAMMED MAINTENANCE
M2 SERVICE
20 Changing engine oil filters
Figure 6
75338
Screw the plug back on under the sump and tighten it to the
required torque.
Pour oil into the engine through the fillingpipe (2) of the required grade and quantity (see fluids table in the GENERAL
section).
See that the belts are not worn or deteriorated; if they are,
replace them as described under the relevant headings.
78148
- With the axle warm, drain off the oil into a specific
container by taking out the plug (2).
- Replenish with fresh oil through the hole closed by the
plug (1) (see the FLUIDS section under the heading
GENERAL INFORMATION).
- Clean the rear axle oil vapour breather.
- Tighten the plugs to the prescribed torque.
Print 603.93.381
10
PROGRAMMED MAINTENANCE
77837
- Turn the wheel hub until the hub cover (1) reaches the
position illustrated in Figure 11;
- unloose the plug (2) and drain oil in the appropriate
container;
- suck the remaining oil with the suitable syringe.
Figure 12
77203
- Turn the wheel hub until the hub cover (1) reaches the
position illustrated in Figure 12;
- refill with the prescribed quantity of new oil (see
SPECIFICATIONS AND DATA) through the hole (2);
- refit and tighten the plug (2) illustrated in Figure 11 and
the hub cover (1) to the prescribed torque.
PROGRAMMED MAINTENANCE
Ball joints
- Clean the ball joints of the tie rods.
- This must be done with dry rags or raw cotton; use no
solvents.
- Check that the ball joints, in their components, have no
points of corrosion with sections of depth greater than
1 mm. In particular, check the sheet metal cover close to
the rolled section.
- Check the protective casing: it has to be secured to the
body and to the pin of the articulation with the split ring
and it must not turn.
- The casing must be neither deteriorated nor damaged.
- Manually crush the protective casings and check that
lubricating grease comes out.
- Check that the nuts and split pins are not deteriorated.
11
74341
84411
Print 603.93.381
12
PROGRAMMED MAINTENANCE
M3 SERVICE
EP2 SERVICE
15 Cleaning the radiator shade
Figure 17
84412
Remove any dirt from the radiator shade (1) to let air flow
towards the radiator.
77839
To remove and fit the belt (1) back on, you need to use an
appropriate tool on the tightener (2) in the direction shown
by the arrow.
NOTE The tighteners are automatic, so they are not to be
adjusted after assembly.
EP3 SERVICE
2 Changing pneumatic system drier filter
Figure 18
M4 SERVICE
NOTE Service M4 includes all operations.
77841
PROGRAMMED MAINTENANCE
13
EP4 SERVICE
9 Changing the cartridge of the dry air filter
and cleaning its container (even if no clogging
signalled)
Once a year (servicing with frequency in hours)
Once every two years (servicing with frequency in km)
Figure 20
84413
77843
The plug (1) must never be taken out for any reason
whatsoever.
With the engine warm, the cooling system is in
overpressure, therefore take care when taking off
the cap (2).
Take off the cap (2) and draw off a sample of the coolant from
the expansion tank (3) with the densimeter 99395858.
Depending on the temperature of the liquid, check the
percentage of antifreeze in the liquid on the scale of the
instrument. The percentage has to be higher than 40% and
must not exceed 50%.
Supplementary
replacement
Print 603.93.381
heater
fuel
filter
14
PROGRAMMED MAINTENANCE
OIL
REPLACEMENT
AND
HYDRAULIC SYSTEM BLEEDING
Front brake circuit
BRAKE
NOTE
Figure 21
33898
68383
62384
Print 603.93.381
PROGRAMMED MAINTENANCE
15
EP5 SERVICE
13 - Oil replacement and clutch hydraulic
system bleeding
Figure 25
84410
Drain off the clutch control fluid and change it (see Fluids
table in GENERAL section).
The clutch fluid is poisonous and corrosive: if you
accidentally come into contact with it, wash
immediately with water and a neutral soap.
Bleed air from the clutch hydraulic system through the
bleeding valve on the deaerator operator cylinder 99306010.
Print 603.93.381
16
PROGRAMMED MAINTENANCE
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
SECTION 14
Electric/Electronic system
Page
Print 603.93.381
PRELIMINARY REMARKS . . . . . . . . . . . . . . . . . .
SYMBOLS WARNINGS . . . . . . . . . . . . . . . . . .
PRODUCT CODE . . . . . . . . . . . . . . . . . . . . . . .
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . .
- Practical tips . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
CAN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
13
ELECTRICAL CHARACTERISTICS . . . . . . . . . . .
13
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . .
14
- Engine F4AE0481 . . . . . . . . . . . . . . . . . . . . . .
14
POWER NETWORK . . . . . . . . . . . . . . . . . . . . .
15
- Positive network . . . . . . . . . . . . . . . . . . . . . . .
15
15
- Negative network . . . . . . . . . . . . . . . . . . . . . .
16
17
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
- General remarks . . . . . . . . . . . . . . . . . . . . . . .
24
24
25
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . .
26
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . .
27
COMPONENT CODE . . . . . . . . . . . . . . . . . . . .
28
JUNCTION CONNECTOR . . . . . . . . . . . . . . . .
33
ELECTRIC/ELECTRONIC SYSTEM
Page
Page
BULKHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
78
125
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . .
94
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
149
CENTRAL DASHBOARD . . . . . . . . . . . . . . . . . .
95
ECAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
156
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . .
97
ENGINE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . .
169
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .
97
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . . . . .
171
- Models available . . . . . . . . . . . . . . . . . . . . . . . .
99
100
101
POPUP EVENTS . . . . . . . . . . . . . . . . . . . . . . .
103
CLUSTER (PINOUT) . . . . . . . . . . . . . . . . . . . . .
104
105
184
DIAGNOSTIC INSTRUMENTS . . . . . . . . . . . . . .
197
- Diagnosis instruments . . . . . . . . . . . . . . . . . . . .
197
198
106
- DIAGNOSTIC screen
(oly for Highline versions) . . . . . . . . . . . . . . . .
199
FUSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
107
199
CONNECTOR ASSEMBLY . . . . . . . . . . . . . . . . .
109
200
116
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .
201
117
201
BODY CONTROLLER . . . . . . . . . . . . . . . . . . . .
118
216
- Linking connectors . . . . . . . . . . . . . . . . . . . . . .
118
221
CONNECTOR PINOUT . . . . . . . . . . . . . . . . . .
123
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . .
489
TACHOGRAPH . . . . . . . . . . . . . . . . . . . . . . . . .
124
CIRCUIT CARDS . . . . . . . . . . . . . . . . . . . . . . . . .
491
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
PRELIMINARY REMARKS
Manuals for repairs are split into Sections, each one of which is marked by a numeral; the contents of these sections are indicated
in the general table of contents.
Each section is generally dedicated to a main Unit (e.g.: engine, gearbox, electric system, etc.).
Sections with mechanical contents include technical data, tightening torque collections, tool lists, connections disconnections
of units to/from the vehicle, overhauls at the bench and relating troubleshooting.
On the electric/electronic system section there are the descriptions of the electric network and vehicle electronic systems, electric
schemes, components electric characteristics, components codes and troubleshooting relating to the central units specific of the
electric system.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular,
there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS WARNINGS
Danger for persons
Missing or incomplete observance of these prescriptions can cause serious danger for persons safety.
General danger
It includes the dangers of above described signals.
Environment protection
It indicates correct behaviour in order that vehicle use is environmentally friendly as much as possible.
NOTE
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
Intake
Refitting
Connection
Exhaust
Removal
Disassembly
Operation
Fitting in place
Assembly
Compression ratio
Tighten to torque
Tolerance
Weight difference
Rolling torque
Press or caulk
Rotation
Regulation
Adjustment
Angle
Angular value
Visual inspection
Fitting position check
Preload
Measurement
Value to find
Check
Number of revolutions
Equipment
Temperature
bar
Pressure
Oversized
Higher than.
Maximum, peak
Undersized
Less than.
Minimum
Selection
Classes
Oversizing
Temperature < 0 C
Cold
Winter
Temperature > 0 C
Hot
Summer
Replacement
Original spare parts
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
PRODUCT CODE
Each title or subtitle concerning operations being performed is preceded by a sixfigure number named PRODUCT CODE.
This number represents the PRODUCT CODE referred to by the repair operation contained in both REPAIR TIMES and
TROUBLE CODE document.
As a quick reference there are shown below the guide lines to read this code (see Repair Timing, too).
5 0
Product Code:
PRODUCT
7 6
UNIT
SUBASSEMBLY
COMPONENT
PRODUCT
UNIT
SUBASSEMBLY
COMPONENT
The first and second figures identify the PRODUCT within motor vehicle.
Example :
Product
Product
Product
Product
50
52
53
76
=
=
=
=
Vehicle chassis;
Axles;
Transmission;
Electric ssystem.
0 1
Unit Code:
PRODUCT
UNIT
0 3
SUBASSEMBLY
COMPONENT
PRODUCT
UNIT
SUBASSEMBLY
COMPONENT
The third and fourth figures identify the UNIT within the PRODUCT.
Example :
Product
Unit
Unit
Unit
50
01
02
03
=
=
=
=
Vehicle chassis;
Chassis;
Bumpers;
Alternator.
4 0
Subassembly Code:
PRODUCT
UNIT
SUBASSEMBLY
COMPONENT
1 3
PRODUCT
UNIT
SUBASSEMBLY
COMPONENT
The fifth and sixth figures exactly identify the SUBASSEMBLY and Component of a Unit within a PRODUCT.
Example :
Product
50
Unit
01
Subassembly 40
Subassembly 13
Print 603.93.381
=
=
=
=
Vehicle chassis;
Chassis;
Chassis cross members;
Rotor.
ELECTRIC/ELECTRONIC SYSTEM
GENERAL WARNINGS
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to
contact immediate superiors where a danger situation occurs which is not described.
Use both specific and generalpurpose toolings according to the prescriptions contained in respective use and
maintenance handbooks. Check use state and suitability of tools not subjected to regular check.
The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and
on the path.
Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters,
ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means
is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it.
In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from
accidentally striking workshop personnel.
Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be
dangerous for the cooperator because of lack of visibility or of his/her not correct position.
Keep personnel not authorised to operations clear of working area.
Learn operation and safety knowledge necessary relating to the vehicle prior to each intervention on it. Scrupulously
observe all safety warnings on the vehicle. Apply suitable signals for the vehicles being repaired. Once the repair
intervention has been completed, before starting up the vehicle, perform all checks indicated on paragraph Controls
care of user of Use and Maintenance handbook.
In lack of visibility in operating from the vehicle, charge a person on the ground with assistance. Do not leave
unmanned a vehicle in motion during repair interventions.
Keep the vehicle stationary by proper chocks.
In the case of an intervention on a vehicle lifted from the ground, check the vehicle to be quite steady on special
support stands and, in the case of lifting by means of a lift, check manual/automatic safeties to be activated.
When it is necessary to perform an intervention on methanefed vehicles, observe the indications contained inside
the document, as well as all specific safety regulations provided.
Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure
out.
Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on
harmful materials 12point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes,
free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting
fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to
store harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable
substances into suitable containers.
Worn out, damaged or consumable parts must be replaced by Iveco original spares.
During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil
spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
For every intervention on vehicle hydraulic, pneumatic, conditioning and AIR BAG systems, scrupulously observe
indications specified in relating manual sections.
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
GENERAL WARNINGS
Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact
with moving parts can cause serious injuries. Use suitable, preferably tightfitted garments, and avoid to use jewels,
scarves, etc.
Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside.
Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health;
operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present.
Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious
burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has
occurred, refer to 12point cards for provisions to make.
Clean units or assemblies detached from the vehicle and carefully check their integrity before overhaul. Tidy up
detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers.
Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc.
Selflocking nuts with an insert made of nylon must always be replaced.
Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances.
Before washing under pressure mechanical parts, protect electric connectors, and central units, if present.
Tightening screws and nuts must always be according to prescriptions; IVECO commercial and assistance network
is available to give all clarifications necessary to perform repair interventions not provided in this document.
Before welding:
- Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding)
and detach connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water.
- Await about 15 minutes before welding.
- Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials
flow which may catch fire easily on welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), disassemble drive electronic central
units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
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ELECTRIC/ELECTRONIC SYSTEM
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case,
always disconnect, as a first one, the chassis bonding cable from batteries negative terminal.
Before connecting the batteries to the system, make sure that the system is well isolated.
Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery
terminals.
Do not cause sparks to be generated in checking if the circuit is energised.
Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses.
Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening
braiding, bonding, etc.) comply with IVECO system and are carefully recovered after repair or maintenance
interventions.
Measurements in drive electronic central units, plugged connections and electric connections to components can only
be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers,
clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which
would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special
truck.
A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries)
can cause them to be destroyed.
Disconnect the batteries from the system during their recharging with an external apparatus.
On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening
torque.
Before disconnecting the junction connector from an electronic central unit, isolate the system.
Do not directly supply electronic central units servo components at nominal vehicle voltage.
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body
structure.
Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according
to original arrangement.
Key memorisation procedures are influenced by electromagnetic jamming (mobile phones, etc.). Therefore, during key
memorisation:
1 Pay attention that jamming sources are not present in the cab or near the keys.
2. Keys not insered in the panel must be at least 1 meter away.
NOTE
Connectors present must be seen from cable side. Connectors views contained in the manual are representative of cable
side.
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ELECTRIC/ELECTRONIC SYSTEM
Figure 1
6616
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10
ELECTRIC/ELECTRONIC SYSTEM
Practical tips
The negative leads connected to a system grounding point must be as short as possible and connected to one another in star
configuration; make sure that they are tightened in an orderly and adequate manner (Figure 2, ref. M).
Furthermore, for electronic components, the instructions to be followed very carefully are:
- ECUs must be connected to the system ground if they are provided with a case.
- ECU negative cables must be connected both to a system grounding point, such as for instance the dash compartment ground
(with no serial or chain connections) and to the negative terminal(s) of the battery/batteries.
- Even though they are not connected to the system ground/battery negative terminals, analogue ground elements (sensors)
must have excellent insulation. As a result, special care must be devoted to the eddy resistances of the cable terminals: oxidation,
seamfolding defects, etc.
- The metal braid of shielded circuits must be in electrical contact at either end with system components.
- Only one end of the shielding braid must be connected to the system ground.
- In the presence of jointing connectors, the nonshielded portion, d, must be as short as possible in the proximity of the
connectors (Figure 2).
- The cables must be arranged so as to run parallel to the reference plane, i.e., as close as possible to the frame/body structure.
- Additional electromechanical systems must be connected with the greatest care to the system ground and must not be placed
alongside the cables of electronic components.
Figure 2
88039
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ELECTRIC/ELECTRONIC SYSTEM
11
CAN LINE
The term CAN stands for Controller Area Network. It is a dedicated cable linking together the (ECU)s of a vehicle so as to create
a structure resembling the nervous system.
This system makes it possible to exchange large quantities of data between the various onboard electronic systems instantaneously.
It represents a TWODIRECTIONAL communication mode which is gaining ground in the automotive field, thanks to the reduction
in the number of conductors and reduced noise.
The data travel in keeping with a protocol that defines the communication mode:
- Data synchronisation
- Call and reply modes between the various systems
- Identification and correction of possible transmission errors
Instrument Cluster
Figure 3
A8
Tachograph
H
A4
B1
OK
120 W
Cancel
Immobilizer
H
B4
X1_1
X1_3
Menu UP
Menu DOWN
ABS
Retarder
Allison
transmission
L
X1_1
X1_3
ECAS
19
20
C11
Mirror
control
Sensors
Sensors
Sensors
Sensors
IBC
H
B52
B53
C12
Actuators
EDC7
120 W
79487
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12
ELECTRIC/ELECTRONIC SYSTEM
Figure 4
B
73652
60
120
0.L.
CAN line OK
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ELECTRIC/ELECTRONIC SYSTEM
13
2. Rated power supply voltage of 24 Vdc, with two 12 V / 110 Ah batteries connected in series
3. Power supply of electrical system and battery recharging with alternator 28V / 70A (BOSCH) (90A OPT).
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14
ELECTRIC/ELECTRONIC SYSTEM
ENGINE COMPONENTS
Engine F4AE0481
B C D
Figure 5
101585
Figure 6
50277
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ELECTRIC/ELECTRONIC SYSTEM
POWER NETWORK
15
Figure 7
Positive network
50358
16 mm2
10 mm2
= 1/2,5/4mm2
- alternator cable
16 mm2
70 mm2
101519
101510
16
ELECTRIC/ELECTRONIC SYSTEM
Negative network
The batteries are connected to the chassis ground by means
of a brown, 70 mm2 cable, at earth point (M6) on the right side
member.
Figure 10
M6
50358
M8
50354
101511
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ELECTRIC/ELECTRONIC SYSTEM
17
S M2
T1T2
M3M4
M1
M7
M6
M5
M9
M8
84596
M1/M3. Left side cab internal ground M2. Right side cab internal ground M4. Roof panel ground M5. Rear chassis
ground M6. Battery ground M7. Front part left sidemember ground M8. Starting motor ground M9. Front part
left sidemember ground S. Cab interior ground (signal ground) T1/T2. Negative electric unipotential plait
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18
ELECTRIC/ELECTRONIC SYSTEM
MS
M2
85559
Figure 15
101512
Earth point
Description
M2
Body builder light remotecontrol switch. Power supply (+15) remotecontrol switches for diagnosis connector. Roof panel cable earth. Slow gear engagement switch. ABS resistor. Switch on
the righthand pillar. Ashtray compartment lighting. Interconnecting control unit (I) (F). Body
builder connector. Fog light remotecontrol switch. ABS control unit (I). Exhaust brake switch.
Electric heater.
Body Controller
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19
ELECTRIC/ELECTRONIC SYSTEM
Figure 16
M4
101513
Figure 17
ELECTRIC CONNECTIONS M4
Ground point
M4
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101514
Description
Tachograph, step lighting ceiling light, car radio, internal lighting ceiling light, voltage reducer, CB.
20
ELECTRIC/ELECTRONIC SYSTEM
M1
M3
85558
Figure 19
101515
Earth point
Description
M1
Internal ceiling light. MENU UP button. MENU DOWN button. MENU G button. MENU
OK button. Rear fog light switch. Headlamp trim control. Fog light switch. Internal light switch.
Emergency light switch. Cluster (A19).
M3
Switch on the leftside pillar. Floor cable earth. Steering column stalk (B)/(A)/(C). Cruise Control
(control). Clutch ON signalling switch.
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21
ELECTRIC/ELECTRONIC SYSTEM
Figure 20
Figure 21
M6
T1
50358
M8
50354
T2
50361
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22
ELECTRIC/ELECTRONIC SYSTEM
M5
50362
Earth point
M5
Description
Rear lights ground
M9
50360
Figure 25
ELECTRIC CONNECTIONS M9
Earth point
M9
101516
Description
Headlamp washer pump, windscreen wiper unit, windscreen washer electric pump, radiator
water low level sensor, windscreen washer fluid low level sensor, power steering fluid low level
sensor, air filter clogging sensor, geareddown speed ON switch, sensor for signalling the
presence of water in the fuel filter, front and rear wheel shoe wear sensor, horn, bodybuilder
connector
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23
ELECTRIC/ELECTRONIC SYSTEM
M7
50360
Figure 27
101517
ELECTRIC CONNECTIONS M7
Earth point
M7
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Description
EDC control unit, fog headlamps, side indicator lamp (right/left), front indicator lamp (right/left),
front clearance lamp (right/left), low/highbeam headlamp (right/left), headlamp trim corrector
actuator, transverse lock switch ON, TGC, power takeoff ON switch, rotary lamp, brake air
drier resistor, diesel fuel prefilter heating resistor
Base October 2004
24
ELECTRIC/ELECTRONIC SYSTEM
STARTING
General remarks
Figure 28
+30
53508
30
52502
50
B20
53006
53512
53511
85150
+15
B27
30
50
08000
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25
ELECTRIC/ELECTRONIC SYSTEM
Figure 29
84595
- the switch for signalling the unhooked cab 53511 with the
cab tilted is closed towards the ground;
- key switch set to running position (+15).
2363
26
ELECTRIC/ELECTRONIC SYSTEM
ALTERNATOR
Supplier
Rated voltage
Current
BOSCH
28V
70A 1800 RPM
Figure 32
B
+
W
L
1
S
5
TECHNICAL VIEW
7998
Figure 35
Figure 33
A
80
70
60
B
50
40
A
8003
30
20
WIRING DIAGRAM
A. Alternator B. Voltage regulator
10
Figure 34
2 4 6 8 10 12 14 16
rpm
8002
8000
Rated voltage
28 V
Rated power
70 A
Current at environment temperature 1800 RPM/35 A
At 25 C and rated voltage
6000 RPM/70 A
Direction of rotation
clockwise, seen from pulley
Weight
6.4 kg
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27
ELECTRIC/ELECTRONIC SYSTEM
STARTER MOTOR
Supplier
Rated voltage
Rated power
BOSCH
24V
4kw
Figure 36
50275
WIRING DIAGRAM
50
30
POWER RELAY
STARTER
50354
Starting
EDC7 system features a peculiar characteristic that distinguish it from previous electronic injection systems.
ECU can control engine starting function.
When turning key 52502 to starting position 50, positive voltage is provided to EDC7 PIN 20.
EDC7 PIN 37 controls a power relay providing power to starter remote switch coil thus enabling, through terminal 30, the positive
voltage required for its operation. In case of SR remote switch coil cutoff or wiring cutoff to terminal 50, the vehicle cannot be
started since EDC control unit detects on pin 37, the presence of remote switch coil resistance.
The vehicle cannot be started even if disconnecting terminal 50 and connecting it directly to +24V, for the above mentioned
reason (SR remote switch resistance not recognised).
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28
ELECTRIC/ELECTRONIC SYSTEM
COMPONENT CODE
03000
08000
Starter motor
12011
12012
12010
12019
Motor,cab tilting
19005
Thermostarter
20000
Starting battery
22000
Horn
25003
25007
25013
Relay for switching off low beam lights with high beams on
25035
25104
Relay for switching off retarder and/or exhaust brake with ABS on
25202
25207
25213
Relay for supply of users connected to ignition switch through battery positive
25222
25307
25348
25546
Remotecontrol switch for ECAS control from the box (power supply)
25547
25548
25549
25551
25704
25709
25805
Relay, horns
25810
25813
25818
25847
25893
25900
25xx1
25xx2
25xx3
25xx4
25xx5
30001
30011
Fog headlight
30100
32002
32005
32010
Rotary beacon
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33006
34000
35000
37002
39000
39003
39020
39027
39xx1
40011
Electronic tachograph
40032
40047
42031
42032
42200
42351
42379
42393
42608
44031
44032
ELECTRIC/ELECTRONIC SYSTEM
44035
44036
44037
44039
47033
47041
48037
48040
50003
Electronic dashboard with microprocessor for instrument and warning light displaying
52007
52019
52021
52035
52306
52048
52075
52219
52302
52307
52312
52321
Switch with builtin w/lamp for fog lights and rear fog lights enablement
52324
52502
52522
52600
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29
30
ELECTRIC/ELECTRONIC SYSTEM
53003
53006
53007
53008
53040
53300
53302
53306
53309
53310
53312
53400
53401
53402
53403
53507
53508
Switch for preventing engine starting with gear engaged and reversing light on
53511
53512
53514
53515
53517
53521
53536
53541
53592
535xx
53800
53801
53xxx
54031
54033
61000
61005
61069
61070
61071
61101
61104
61106
61108
61110
61129
61130
Resistor holder container for brake pedal pressure switch for retarder
64000
65000
66005
66010
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68001
Loudspeaker
68007
City Band
6xxxx
70000
6fuse holder
70xx1
72000
72001
72006
72021
72054
6A current outlet
75000
78052
78054
78055
78174
78175
78208
78242
78243
Electropneumatic distributor
78245
7xxxx
80000
80001
82000
82005
84013
Ambient thermostat
84014
84017
Electronic timer
85000
Cigar lighter
85006
85007
85008
85010
85031
85036
85038
85040
85100
85130
85150
85160
86002
86003
86004
86013
86023
86024
86029
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ELECTRIC/ELECTRONIC SYSTEM
31
32
ELECTRIC/ELECTRONIC SYSTEM
860xx
86116
86127
88000
88001
89000
Food heater
Xxxx5
Xxxx6
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ELECTRIC/ELECTRONIC SYSTEM
33
JUNCTION CONNECTOR
Location of junction connectors cab
STX2
ST21
ST22
ST19
ST23
JC1
JC2
JC3
XXXX4
STY12
STX3
STX4
72021
STZ1
STY16
STY17
STZ5
ST11
ST12
STY11
STV
STY18
ST04
ST13
STA
ST0
ST01
ST02
ST03
ST05
ST06
ST20
ST24
ST25
STX
STY05
STY07
STY09
STY10
STY15
STY20
STY25
STY33
STZ2
STZ3
STZ4
JC4
JC5
JC6
61071
Figure 37
101518
The location of the connectors available (cab chassis) may be changed due to wiring requirements.
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34
ELECTRIC/ELECTRONIC SYSTEM
List of connectors
Name
61069
XXXX4
JC1
JC2
JC3
JC4
JC5
JC6
ST0
ST01
ST02
ST03
ST04
ST05
ST06
ST11
ST12
ST13
ST19
ST21
ST22
ST23
ST24
ST25
STA
STV
STX
STX2
STX3
STX4
STY05
STY07
STY09
STY10
STY11
STY12
STY15
STY16
STY17
STY18
STY20
STY25
STY33
STZ1
STZ2
STZ3
STZ4
STZ5
Description
Body builder connector (cab)
Branching from the cluster for optional items
Ideograph power supply positive
Ideograph power supply positive
Cigar lighter power supply positive
Positive (+15/D+alternator) / ceiling light ground
Positive (+15/+30) / start lock signal
Positive (windscreen washer / +30)
Cruise Control cutout signal
Power supply (+50)
ABS power supply
Power supply (+15)
Auxiliary heater remotecontrol switch power supply
Alternator excitation
Auxiliary heater remotecontrol switch power supply
Sunroof power supply
Sunroof power supply
Auxiliary heater ground
Geareddown speed ON signal
Engine stop signal
Speed limiter signal
Power supply (+30)
PTO1 ON signal
PTO1 ON signal
Insulated ground for auxiliary heater
Cab rear part / dashboard cable junction
Dashboard cable / roof panel cable junction
Remote control (ECAS)
Ceiling light cable / roof panel cable junction
Radio power supply
Manual conditioner
Remotecontrol switch control / diesel fuel preheating signal
Central locking and loudspeaker (drivers side)
Central locking and loudspeaker (passengers side)
Right rotary lamp power supply
Left rotary lamp power supply
Central locking arrangement
Heated mirror control (drivers side)
Heated mirror control (passengers side)
Auxiliary heater control unit cable / cab cable junction
Power takeoff
ADR
Body builders (optional DMI control unit)
Diagnosis connector (CAN line)
ECAS control unit (CAN line)
Electric mirror control unit (CAN line)
DMI control unit (option) (CAN line)
Telma/Allison (CAN line)
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ELECTRIC/ELECTRONIC SYSTEM
35
STY2
Figure 38
101519
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36
ELECTRIC/ELECTRONIC SYSTEM
List of connectors
Name
61070
61071
75010/1
75010/2
ST16
ST20
STF1
STY01
STY02
STY03
STY04
STY06
STY08
STY13
STY14
STY19
STY21
STY22
STY23
STY24
STY26
STY32
Description
Connector for body builders (chassis) EDC signals
Connector for body builders (chassis) lights
Rear lights
Trailer rear lights
Front parking brake arrangement
Insulated ground
Front axle arrangement (ECAS)
Right lights (front)
Left lights (front)
Bulkhead C/B3 (EDC)
Conditioner arrangement
Brake air drier
Cab tilting remotecontrol switch ground
Front right clearance lamp
Front left clearance lamp
Differential lock (transverse longitudinal)
Exhaust brake with automatic transmission
Reversing light ignition
Stop signalling (Telma)
Insertion of power takeoff on the gearbox
Geareddown speed ON signalling switch
TGC ground
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ELECTRIC/ELECTRONIC SYSTEM
37
Perspective view
Pin
Name
STY8
STY15
61070 STY20
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Connector view
38
ELECTRIC/ELECTRONIC SYSTEM
Pin
Name
STY5
STX2
STY1 STY2
11
75010/2
12
13
75010/1
20
Connector view
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ELECTRIC/ELECTRONIC SYSTEM
39
101520
101521
ST0
Pin
1
Function
Signal from the switch for Cruise Control cutout for EDC
Cable
colour code
8154
ST01
Pin
1
Function
Cable
colour code
8037
ST02
Pin
1
Function
Cable
colour code
8847
ST03
Pin
1
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Function
+15 alternator
Cable
colour code
8876
Base October 2004
40
ELECTRIC/ELECTRONIC SYSTEM
101520
101522
101523
101524
Figure 44
ST19
Pin
1
Function
Geareddown speed ON warning light signal
Cable
colour code
9976
ST22
Pin
1
Function
Cable
colour code
9968
ST23
Pin
1
Function
Cable
colour code
7777
Battery positive
STY8
Pin
1
Function
Hydraulic cab tilting relay control ground after grill opening signalling switch
Cable
colour code
0029
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ELECTRIC/ELECTRONIC SYSTEM
41
101525
101526
ST04 (black)
Pin
Function
Cable
colour code
Auxiliary heater remotecontrol switch power supply throughthe safety control unit
7779
Auxiliary heater remotecontrol switch power supply throughthe safety control unit
7779
ST05
Pin
Function
Cable
colour code
Alternator excitation
7773
Alternator excitation
7773
ST11
Pin
Function
Cable
colour code
7010
7011
ST12
Pin
Function
Cable
colour code
7010
7011
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42
ELECTRIC/ELECTRONIC SYSTEM
101525
101527
ST13 (black)
Pin
Function
Cable
colour code
0022
ST20
Pin
Function
ABS disconnection
Cable
colour code
0049
ST21
Pin
Function
Cable
colour code
9906
ST24 (white)
Pin
Function
Cable
colour code
6131
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ELECTRIC/ELECTRONIC SYSTEM
43
101525
101528
ST25 (white)
Pin
Function
Cable
colour code
6132
STA
Pin
Function
Cable
colour code
0022
0022
STX4
Pin
Function
Cable
colour code
8899
Ground
0001
STY7
Pin
Function
Cable
colour code
8837
0087
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44
ELECTRIC/ELECTRONIC SYSTEM
101529
101530
Pin
Function
Cable
colour code
9964
9965
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ELECTRIC/ELECTRONIC SYSTEM
45
101531
101532
Function
Cable
colour code
1117
Ground
0000
Function
Cable
colour code
Ground
0000
8840
Function
Cable
colour code
1115
Ground
0000
Function
Cable
colour code
1115
Ground
0000
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46
ELECTRIC/ELECTRONIC SYSTEM
101531
101533
Function
Cable
colour code
3390
Ground
0000
Function
Cable
colour code
3380
Ground
0000
Function
Cable
colour code
8159
7151
Function
Cable
colour code
7773
9954
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ELECTRIC/ELECTRONIC SYSTEM
47
101531
101534
Function
Cable
colour code
Ground
0000
Pressure switch actuated when shifting between normal and geareddown speeds
9976
Function
Cable
colour code
CAN line H
6108
CAN line L
6109
Function
Cable
colour code
CAN line H
6108
CAN line L
6109
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48
ELECTRIC/ELECTRONIC SYSTEM
101531
101535
Function
Cable
colour code
CAN line H
6108
CAN line L
6109
Function
Cable
colour code
CAN line H
6108
CAN line L
6109
Function
Cable
colour code
CAN line H
6108
CAN line L
6109
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ELECTRIC/ELECTRONIC SYSTEM
49
101536
101537
Function
Cable
colour code
0150
8892
2226
Function
Cable
colour code
9066
9065
9071
STY32 TGC
Pin
Function
Cable
colour code
Print 603.93.381
0012
50
ELECTRIC/ELECTRONIC SYSTEM
101538
101539
Function
Cable
colour code
Ground
0000
3332
3331
8869
Function
Cable
colour code
9413
5410
0400
9426
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ELECTRIC/ELECTRONIC SYSTEM
51
101538
101540
Function
Cable
colour code
6620
Ground
0000
Signal from Iveco and Rockwell rear axle transverse locking signalling switch
6621
0055
Function
Cable
colour code
0150
2226
2268
0147
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52
ELECTRIC/ELECTRONIC SYSTEM
101538
101541
Function
Cable
colour code
1177
1176
7151
8158
STY25 - ADR
Pin
Function
Cable
colour code
8045
0077
Ground
0000
0078
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
53
101542
101543
Function
Cable
colour code
7151
5502
5584
8050
2226
Function
Cable
colour code
Ground
0000
6132
6131
5877
0058
Print 603.93.381
54
ELECTRIC/ELECTRONIC SYSTEM
101545
101546
Pin
1
2
3
4
5
6
Function
Manual conditioner relay control
Compressor relay power supply
Maximum speed relay power supply
Compressor actuation warning light power supply
Cable
colour code
9066
9067
9068
9065
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
55
101547
101548
Pin
1
2
3
4
5
6
Print 603.93.381
Function
Levelling control system power supply after the fuse
Ground
Clock line on the ECAS suspension control pushbutton panel
Data line on the ECAS suspension control pushbutton panel
Cable
colour code
8810
0000
6402
6403
56
ELECTRIC/ELECTRONIC SYSTEM
101551
101552
Pin
1
2
3
4
5
6
7
Function
Clearance light and sidelight general power supply
Right lowbeam headlamp power supply
Right highbeam headlamp power supply
Headlamp trim corrector (position B)
Front right indicator bulb
Ground
Cable
colour code
3390
2223
2221
9936
1123
0000
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ELECTRIC/ELECTRONIC SYSTEM
57
101551
101553
Pin
1
2
3
4
5
6
7
Print 603.93.381
Function
Clearance light and sidelight general power supply
Left lowbeam headlamp power supply
Left highbeam headlamp power supply
Headlamp trim corrector (position B)
Front left indicator bulb
Ground
Cable
colour code
3380
2231
2219
9936
1129
0000
58
ELECTRIC/ELECTRONIC SYSTEM
101554
101555
Pin
1
2
3
4
5
6
7
8
9
10
11
12
Function
Pneumatic suspension low air pressure warning light (ECAS)
Rear axle right chassis level control sensor signal (ECAS)
Chassis level control sensor ground (ECAS)
Rear axle left chassis level control sensor signal (ECAS)
Chassis level control sensor ground (ECAS)
Front axle chassis level control sensor signal (ECAS)
Chassis level control sensor ground (ECAS)
Front axle solenoid valve power supply (ECAS)
Rear axle solenoid valve cluster power supply (ECAS)
Rear axle solenoid valve cluster power supply (right valve)
Rear axle solenoid valve cluster power supply (left valve)
Solenoid valve power supply after the control unit (ECAS)
Cable
colour code
6401
5421
0400
5422
0400
5410
0400
9413
9423
9424
9425
9400
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
59
101554
101556
Function
Handbrake ON signalling optical indicator
Cab unhooked signalling optical indicator
General interlocking power supply after the fuse
Ground
Cable
colour code
6662
6666
8879
0000
7780
0150
9907
7770
Base October 2004
60
ELECTRIC/ELECTRONIC SYSTEM
101554
101557
Pin
1
2
3
4
5
6
7
8
9
10
11
12
Function
Ceiling light ignition ground (switch on the door)
Radio power supply (12v)
Ground
Radio power supply (12v)
Radio amplifier power supply
Ceiling light ignition with separate switch (trucks)
Cable
colour code
0003
7770
0000
7770
7704
4441
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
61
Junction connector STY09 (gray) drivers side door electric lock and loudspeaker
Figure 85
101554
101558
Pin
Function
1
2
3
4
5
6
7
8
9
10
11
12
Cable
colour code
8863
8863
0066
0065
0064
9965
9964
1186
1188
3
Print 603.93.381
62
ELECTRIC/ELECTRONIC SYSTEM
Junction connector STY10 (gray) passengers side door electric lock and loudspeaker
Figure 87
101554
Pin
Function
1
2
3
4
5
6
7
8
9
10
11
12
101559
Cable
colour code
8863
8863
0066
0065
0064
9965
9964
1183
1184
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
63
101554
Pin
1
2
3
4
5
6
7
8
9
10
11
12
Print 603.93.381
Function
Motor power supply for vertical orientation of main left rearview mirror
Motor power supply for horizontal orientation of main left rearview mirror
Motor power supply for orientation of main left rearview mirror
Heated rearview mirror resistor power supply
Ground
101560
Cable
colour code
8808
8809
8806
8830
0000
64
ELECTRIC/ELECTRONIC SYSTEM
101554
101561
Function
Cable
colour code
1
2
3
4
5
6
7
8
9
10
11
12
Motor power supply for vertical orientation of main right rearview mirror
Motor power supply for horizontal orientation of main right rearview mirror
Motor power supply for orientation of main right rearview mirror
Heated rearview mirror resistor power supply
Ground
Motor power supply for vertical orientation of passengers side wideangle rearview mirror
Motor power supply for horizontal orientation of passengers side wideangle rearview mirror
Motor power supply for vertical orientation of passengers side approach rearview mirror
Motor power supply for horizontal orientation of passengers side approach rearview mirror
8858
8859
8857
8830
0000
8852
8853
8838
8839
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
65
Junction connector STY18 (gray) cab cable / auxiliary heater control unit cable
Figure 93
101554
Pin
1
2
3
4
5
6
7
8
9
10
11
12
Print 603.93.381
Function
Auxiliary heater air temperature control thermostat power supply
Positive after the fuse
Auxiliary heater fuel intercept solenoid valve and auxiliary fuel pump power supply
Auxiliary heater cab heating air motor power supply
Auxiliary heater fuel intercept solenoid valve and auxiliary fuel pump power supply
Auxiliary heater ignition spark power supply
Insulated ground for auxiliary heater
Alternator excitation
Insulated ground for auxiliary heater
Diagnostic K line for Instrument Cluster
Auxiliary heater remotecontrol switch power supply throughthe safety control unit
101562
Cable
colour code
7736
7772
7725
7783
7722
7783
7705
0022
7773
0022
2295
7779
Base October 2004
66
ELECTRIC/ELECTRONIC SYSTEM
Junction connector XXXX4 (gray) branchingoff from Cluster for optional provision
Figure 95
101554
101563
Pin
1
2
3
4
5
6
7
8
9
10
11
12
Function
External temperature sensor
External temperature sensor
Cable
colour code
4710
0512
2200
6607
6671
7778
6401
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ELECTRIC/ELECTRONIC SYSTEM
67
101564
101565
68
ELECTRIC/ELECTRONIC SYSTEM
Pinout
Pin
Function
Cable colour
code
5542
7780
8000
9907
2286
7772
8050
9906
Ground
0000
10
8154
11
8154
12
8155
13
8156
14
8157
15
0150
16
0169
17
0166
18
0167
19
0168
20
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ELECTRIC/ELECTRONIC SYSTEM
69
101564
101566
70
ELECTRIC/ELECTRONIC SYSTEM
Pinout
Pin
Function
Cable colour
code
6108
6109
4442
5514
0058
5517
5516
8879
7768
10
1186
11
5155
12
13
4408
14
7704
15
1191
16
7770
17
4441
18
1188
19
1183
20
1184
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
71
Junction connector STY33 (black) for body builders (DMI control unit option 5626)
Figure 101
101564
101567
72
ELECTRIC/ELECTRONIC SYSTEM
Pinout
Pin
Function
Cable colour
code
CAN line L
6109
CAN line H
6108
5011
5001
5002
5022
1011
10
11
12
13
14
5003
15
8100
16
2226
17
1000
18
19
3310
20
3311
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ELECTRIC/ELECTRONIC SYSTEM
73
75010/1
75010/2
101568
101569
74
ELECTRIC/ELECTRONIC SYSTEM
Function
Cable colour
code
2286
2226
1125
1120
1172
1177
3330
Right sidelights
3335
Left sidelights
3334
10
3339
11
3330
12
3339
13
Function
Cable colour
code
2282
1185
1180
1179
3331
3332
2226
8869
10
11
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
75
101570
Figure 106
101571
Function
Cable colour
code
4442
Function
Cable colour
code
4442
Function
Cigar lighter power supply positive
Cable colour
code
7721
Base October 2004
76
ELECTRIC/ELECTRONIC SYSTEM
101572
Function
Cable colour
code
13
Positive +15 for general interlocking power supply after the fuse
8879
46
D+ alternator
7780
79
0010
Function
Cable colour
code
13
Positive +15 for power supply provided for external body builders (max. = 10 A)
8710
46
7704
79
0029
Function
Cable colour
code
13
8886
46
7772
79
Free
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
77
101573
Branch
point
Function
101574
BC
4442
4442
Positive +15 for general interlocking power supply after the fuse (cab section)
8879
Positive +15 for general service power supply before the fuse (cab section)
8887
V2
Positive for EDC system power supply after the fuse (chassis section)
7151
W1
0094
W2/1
0150
W2/2
0150
Print 603.93.381
78
ELECTRIC/ELECTRONIC SYSTEM
BULKHEAD
Figure 110
F
101575
Ref.
A
B
C
D
E
F
Description
Option
EDC
Services / Lights
Automatic transmission
Services / Lights
d
ABS / ECAS
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
79
d
101576
80
ELECTRIC/ELECTRONIC SYSTEM
Description
Front parking brake ON switch signal
PTO1 ON signal
PTO2 ON signal
PTO actuation solenoid valve power supply
PTO actuation solenoid valve ground
Auxiliary heater fuel intercept solenoid valve and auxiliary fuel pump power supply
Auxiliary heater fuel intercept solenoid valve and auxiliary fuel pump power supply
TGC ground
Brake light signal from brake value transmitter with EBS
TGC excitation through key switch
Alternator D+ after the power diode
Cable
1117
6131
6132
5877
0058
7773
9954
0029
8840
7783
7783
0012
0077
8045
0078
1115
7753
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
81
d
101577
82
ELECTRIC/ELECTRONIC SYSTEM
Connector B pinout
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Description
Negative for starting sensors
Signal +50
Engine stop signal
Cab unhooked signal
Clutch release signal
EDC diagnosis K line
EDC diagnosis L line
30pole diagnosis pin 23 (engine phase)
Engine starting signal
30pole diagnosis pin 28 (rate gyroscope)
Handbrake ON signal
EDC diagnosis request button
EDC failure warning light positive
EDC failure warning light negative
Power supply +15
Diesel fuel heating remotecontrol switch
Diesel fuel heating remotecontrol switch
Exhaust brake cutout with ABS
L warning light alternator
+15 alternator
EDC7 pin 32 (PTO 1, 2, 3)
EDC7 pin 87 (PTO 1, 2, 3)
Conditioner control
Conditioner compressor remotecontrol switch
Conditioner compressor actuation signal
Conditioner
Cable
0150
8037
9906
6666
5602
2298
1198
5198
9905
5584
9907
0156
5535
0535
8051
0087
8837
0027
7780
8876
0169
5120
9066
9067
9068
9065
7151
8153/1117
0159
0158
0157
5158
5157
6108
6109
8150
7777
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
83
d
101578
84
ELECTRIC/ELECTRONIC SYSTEM
Connector C pinout
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Description
Trailer rear fog light
Reversing lights
Rear right indicator light
Rear left indicator light
Trailer right indicator light
Trailer left indicator light
Trailer right & left brake lights
Trailer right sidelights
Trailer left sidelights
External temperature sensor
Tractor right & left rear fog lights
Tractor right brake light
Tractor left brake light
Tractor right & left license plate lights
Rear right sidelights
Rear left sidelights
Rear right & left clearance lights
Front wheel brake wear
Rear wheel brake wear
Windscreen washer tank low water level warning light
Cooling water minimum level warning light
Power steering fluid low level warning light
Signalling the presence of water in the diesel fuel filter
Signalling the presence of water in the diesel fuel filter
Air filter clogged signalling
Geareddown speeds ON warning light
Horn
+15 for body builders
Windscreen washer water pump
Windscreen wiper motor 53/B
Windscreen wiper motor 53
Windscreen wiper motor 31/B
Headlamp wiper power supply
Engine oil level
Engine oil level
External temperature sensor
Cable
2282
2268
1125
1120
1185
1180
1179
3331
3332
4710
2286
1172
1177
3330
3334
3335
3339
6012
6013
5521
5525
5520
5530
8879
6663
9976
1116
8869/8869
8886
8881
8882
8873
8821
5506
5505
0512
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
85
d
101579
86
ELECTRIC/ELECTRONIC SYSTEM
Connector D pinout
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Description
Automatic neutral position signal for body builders (Allison automatic transmission)
Resistor cluster ground for retarder pressure switches (Allison automatic transmission)
Retarder request signal from the resistor cluster for retarder pressure switches (Allison
automatic transmission)
Resistor cluster power supply for retarder pressure switches (Allison automatic transmission)
Cable
0000
2268
2226
6132
8133
8159
0147
8135
6164
7124
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
87
d
101580
88
ELECTRIC/ELECTRONIC SYSTEM
Connector E pinout
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Cable
1124
1126
2223
2221
1123
2231
2219
1129
2228
9936
3390
3380
0616
5557
6684
6613
5514
25
Tachograph (B1)
Brake failure indicator for ABS
0058
26
Tachograph (B2)
L alternator (telltale)
5517
27
Tachograph (B3)
Alternator 15 terminal
5516
28
Tachograph (B4)
+ battery for tachograph
6680
29
30
31
32
33
34
35
36
37
5562
5560
5561
0000
0055
6621
6620
38
39
40
7733
Description
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
89
d
101581
90
ELECTRIC/ELECTRONIC SYSTEM
Connector F pinout
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Description
Cable
6401
5421
0400
5422
0400
5410
0400
9413
9423
9424
9425
0000
0000
0000
0000
9931
9921
9919
9918
9920
9930
9928
5570
5570
5571
5571
5572
5572
5573
5573
9929
9400
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
91
16 1 2
15 26 17 3
18 4
14
25 27 28 19
13 30 29
5
24
20
12 23 21 6
11 22 7
10 9 8
101582
101583
92
ELECTRIC/ELECTRONIC SYSTEM
Pinout
Function
Cable colour
code
1198
2298
1199
2299
1191
2295
+15
8876
Ref.
1
Function
EDC
2
3
ABS
4
5
Retarder arrangement
Cluster / Tachograph
9
10
11
12
Immobilizer
2292
13
1196
14
2296
15
2294
16
ECAS suspensions
17
18
2297
19
8119
20
21
6108
22
6109
Phase
5198
Braided wire
8050
8892
+30
7772
23
24
Screen
25
26
27
Positive
28
Engine revs
5584
29
Vehicle speed
5542
31
0050
30
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
93
Figure 119
101584
Print 603.93.381
94
ELECTRIC/ELECTRONIC SYSTEM
INSTRUMENT PANEL
Figure 120
91324
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Description
Rev counter
Engine coolant temperature gauge
Fuel level gauge
Tachograph display
Headlamp trim control
External light switch
Cap
Fog light actuation switch
Rear fog light actuation switch
Optical indicator cluster
Optical indicator cluster
Display
Optical indicator cluster
Display menu output switch
Display menu actuation switch
Menu switch
Menu switch +
Emergency light actuation switch
Speed limiter switch
Internal light switch (located in the central dashboard if the retarder hand lever is available)
Internal illumination ceiling light switch (available on long cabs only)
TGC actuation (where provided)
Print 603.93.381
95
ELECTRIC/ELECTRONIC SYSTEM
CENTRAL DASHBOARD
Figure 121
3 4 5
8 9 10 11
17
1
16
3
4
12
13
15
14
87154
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Print 603.93.381
Description
Arrangement for exhaust brake
Rotating lamp actuation switch
Heated windscreen actuation switch
Passengers side window regulator button
TGC deactivation in an emergency (ADR)
Sunroof control
Overall power takeoff control
Cab interior light switch (only if the retarder hand lever is available)
Retarder cutout from the brake pedal
Loading gate
Auxiliary highbeam headlamps
WEBASTO heater control
Glove compartment
30pole diagnosis takeoff
Cigar lighter
Cab interior heater controls (conditioner OPTION)
Drivers side window regulator button
96
ELECTRIC/ELECTRONIC SYSTEM
4x4
1
21
11
20
79483
Figure 123
EuroMidi
1
20
79484
Figure 124
Fire Fighting
1
11
20
79485
Ref.
1
2
3
5
6
8
9
11
20
21
Description
Arrangement for exhaust brake
Rotating lamp actuation switch
Heated windscreen actuation switch
TGC deactivation in an emergency (ADR)
Sunroof control
Cab interior light switch (only if the retarder hand lever is available)
Retarder cutout from the brake pedal
Auxiliary highbeam headlamps
Upper part of central dashboard (different according to the models)
ABS cutout (only 4x4)
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
97
INSTRUMENT CLUSTER
Description
Figure 125
79486
The vehicles electric system has been modified by introducing a new instrument board called Instrument Cluster, similar to the
model available on higher range STRALIS vehicles.
This system has the following characteristics and is made up of:
- one instrument indicating the vehicle speed (both in km/h and mph);
- one instrument indicating engine speed
- one fuel level gauge;
- one coolant temperature gauge;
- one display showing faults and user messages;
- three optical indicator clusters;
- four buttons to scroll the various menus (model Highline only);
- one background lighting control button;
- one trip meter reset button (page shift on Baseline).
In addition to being connected to the vehicles CAN line, the Instrument Cluster receives a set of signals directly from a few sensors
or switches available in the vehicles electric system.
The Instrument Cluster also receives the signals from the four buttons for display menu control. The button operating logic is of
the standard type: the arrows allow you to shift the pages; if a page with various lines to be displayed is chosen, the display allows
you to view only 3 lines at a time or a page with a submenu. Pressing OK allows you to access the page and the arrows can be
used. Button C allows you to return to the previous page.
Print 603.93.381
98
ELECTRIC/ELECTRONIC SYSTEM
A blackandwhite display is available. The lack of a colour display has been made up for by a logic associating a yellow or red warning
light to the icon indicating the information to be signalled to the driver. Direct signals are sent out to the Instrument Cluster (no
CAN line is provided) from:
- Engine oil level
- Fuel level
- Presence of water in the diesel fuel filter
- Air filter clogged signalling
- Rear converter limit switch signalling
- Rear brake oil level
- Immobilizer optical indicator
- Battery recharge indicator
- Trailer ABS failure indicator.
All the other signals are received, through the CAN line, in order to allow the relevant message to be displayed.
The Cluster does not store failures; it only displays them.
At present, the vehicle systems on which diagnosis can be made are EDC, IMMOBILIZER, ELECTRIC MIRRORS, and BODY
CONTROLLER.
With these systems, if the HIGHLINE model Cluster is available, a diagnosis screen can be shown on the display, which allows
you to refer to the failure codes of the concerned system.
These codes can be referred to by means of the MENU buttons provided on the dashboard.
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
99
Models available
Two models of the IC system are available: BASELINE and HIGHLINE.
They differ from each other in that they have (or have not) control buttons, and the screens on the IC display.
Baseline
No menu control button is provided.
Trip meter reset button (this is also used to change IC screen).
Highline
Four menu/IC screen control buttons are available.
Trip meter reset button (this is also used for trip 1 function).
Screens available with vehicle running
Baseline
time/km/partial km
time/km/partial time
time/miles/partial miles (UK customer market)
brake air pressure / engine oil pressure
Highline
time/km/partial km/C/gear engaged (automatic transmission)
time/km/partial time/C/gear engaged (automatic transmission)
engine oil pressure / brake air pressure
trip 1
trip 2
time/km/partial km
time/km/partial time
time/miles/partial miles (UK customer market)
engine oil level
brake air pressure / engine oil pressure
Highline
time/km/partial km/C/gear engaged (automatic transmission)
time/km/partial time/C/gear engaged (automatic transmission)
engine oil level / brake pad wear percentage (%)
engine oil pressure / brake air pressure
trip 1
trip 2
fuel litre meter index / fuel consumption indicator
engine oil level / brake pad wear percentage (%)
light check
diagnostics
vehicle maintenance
language setting / measurement unit
Print 603.93.381
100
ELECTRIC/ELECTRONIC SYSTEM
79486
Description
External lights
Colour
Green
Ideograph
Description
Colour
Yellow
Highbeam headlamps
Blue
Yellow
Emergency lights
Red
Green
Red
Decelerator ON
Yellow
Yellow
Fog lights
Green
Exhaust brake ON
Yellow
Red
Yellow
Emergency brake ON
Red
Engine preheating
Yellow
Yellow
Yellow
Yellow
Heated mirrors
Yellow
Red
Yellow
Red
Yellow
Yellow
Ideograph
Green
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
101
Figure 127
Description
Minor anomaly and failure
warning light
Serious failure warning light
(stop)
Colour
Ideograph
79489
Yellow
Red
Description
Colour
Red
Red
Red
EDC
Red
Red
Gearbox failure
Red
Red
Yellow
Red
Yellow
Red
Decelerator failure
Yellow
Red
Red
Red
IBC failure
Red
Red
Generator charge
Red
Red
Red
Print 603.93.381
Ideograph
Description
Colour
Ideograph
102
ELECTRIC/ELECTRONIC SYSTEM
Description
Colour
Ideograph
Description
Colour
Red
External lighting
Yellow
Cab uncoupled
Red
Box tipped
Yellow
Loading gate
Red
Yellow
Airbag failure
Red
Yellow
Doors open
Red
Yellow
Yellow
Yellow
Yellow
Trailer linked
EDC failure
Yellow
Immobilizer actuation/failure
Yellow
Immobilizer actuation/failure
Yellow
Yellow
Gearbox failure
Yellow
Yellow
Yellow
Yellow
Yellow
Red
Ideograph
Yellow
Yellow
Red
Yellow
Red
Yellow
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
103
POPUP EVENTS
Both current models allow you to display a few vehicle conditions (called POPUP events) in the base page structure, for a
preestablished time. After this screen is shown, the display will automatically go back to the latest screen available.
Below is a list of the conditions that can be displayed:
Headlamp setting
Mirror adjustment
Speed limiter
Cruise control
PTO (revs)
Engine idling speed
Figure 128
Headlamp aiming
Mirror orientation
Speed limiter
Cruise Control
PTO
Engine idling speed
85589
Print 603.93.381
104
ELECTRIC/ELECTRONIC SYSTEM
CLUSTER (PINOUT)
Figure 129
49837/a
Ref.
A Black
Cable
colour
6092
6108
6109
1
2
3
4
5
6
7
8
9
10
11
12
4710
0152
5557
0616
13
14
15
16
17
18
19
20
+15
Earth
+30
5505
5506
8879
0000
8871
B Blue
Diagnosis connector pin 8
ABS (connector X118)
Trailer ABS failure warning light signal
Menu C button
Cable
colour
1191
6670
6671
6662
6401
6680
6613
6607
6663
5530
5900
5901
5902
7780
7778
5903
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
105
2
3
Ref.
1
2
3
4
5
Print 603.93.381
79370/1
Description
Fuse holder (70000/3 /1 /2)
Remotecontrol switches
LED (see Immobilizer)
Body Controller
Control unit / Remotecontrol switches
106
ELECTRIC/ELECTRONIC SYSTEM
E1 E2 E3
E4
E5
E6
E7
E8
79370/3
Ref.
Code
E1
E2
E3
E4
E5
E6
E7
E8
25213
25879
25805
25035
25810
25003
25813
Description
Keycontrolled power supply remotecontrol switch
PTO remotecontrol switch
Horn control remotecontrol switch
External light (body builders) remotecontrol switches
Diesel fuel heating remotecontrol switch
Fog light remotecontrol switch
Heated rearview mirror remotecontrol switch
Remotecontrol switch for +15 power supply from diagnosis connector
Print 603.93.381
107
ELECTRIC/ELECTRONIC SYSTEM
FUSE ASSEMBLY
Figure 132
70000/1
70000/2
70000/3
79370/2
70000/1 (YELLOW)
70000/3 (GREEN)
70000/2 (RED)
50340
Position
70000/3
70000/1
70000/2
Print 603.93.381
1
2
3
4
5
6
1
2
3
4
5
6
1
Rating
30A
30A
10A
10A
10A
10A
10A
10A
20A
2
3
4
5
6
20A
20A
20A
5A
5A
Function
Heated windscreen
Heated windscreen
Auxiliary heater
Cigar lighter / Headlamp washer / Ceiling light
Fog light / Rotating lamps
Conditioner / Adjustable heated mirrors
Heated seat
Reversing lights
Diesel fuel heating / Loading gate / Diesel fuel prefilter heating / Window regulator
Sunroof
Trailer ABS
ABS
ABS ECAS
ABS
Power supply
+30
+30
+30
+30
+30
+30
+15/1
+15/1
+30
+30
+30
+30
+15/1
+30
108
ELECTRIC/ELECTRONIC SYSTEM
Figure 133
10
11
12
13
14
15
16
17
18
19
20
50364
Fuse
Rating
1
2
5A
5A
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
10A
10A
5A
5A
10A
10A
5A
10A
10A
10A
20A
20A
10A
5A
5A
5A
20A
10A
Description
Body Control (15) / MICO tachograph / Instruments Cluster
Cab uncoupled / Immobilizer / Sensor for presence of water in the diesel fuel filter / Headlamp trim
corrector / Bed lights
MICO tachograph / Body Control (Left lowbeam lamp Right highbeam lamp)
Body builders
EDC7
Trailer takeoff (+15) / Chassis body builder takeoff (+15)
Central locking / Auxiliary heater / Fridge / Radio
Body Control (Right lowbeam lamp Left highbeam lamp)
Cab body builders (+15)
Body Control (left sidelights and stop lights)
Body Control (indicators emergency lights)
Horn
Window regulators / Heated windscreen
Windscreen defrosting electric heater / Conditioner
Body Control (windscreen wiper windscreen washer)
Brake air drier / Adjustable heated rearview mirrors / Control unit
External light body builders (+58)
Instruments Cluster
EDC7
Body Control (right sidelights and rear fog light)
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
109
CONNECTOR ASSEMBLY
Figure 134
84599
Print 603.93.381
110
ELECTRIC/ELECTRONIC SYSTEM
Connector A B C
Figure 135
A
7
B
2
50365
Ref.
1
2
3
4
5
6
7
1
2
1
2
3
4
5
6
Function
Positive after TGC for body builders connector / connector IWT2 (1)
2197
8879
1117
8150
8869
8887
7768
0053
9954
7704
8861
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
111
Connector E
Figure 136
E
1
14
50365
Ref.
1
2
3
4
5
6 (OPT)
7
8
9
10
11
12
13
14
Print 603.93.381
Description
Cable colour
code
8879
7777
8879
112
ELECTRIC/ELECTRONIC SYSTEM
Connector F
Figure 137
F
1
10
20
50365
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Description
Positive
15/1 positive
Signal ground
Positive
Positive
Cable colour
code
8887
8051
8807
0000
7772
8871
2283
1116
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
113
Connector G H
Figure 138
G
B
A
H
1
50365
Ref.
A
B
1
2
H 3
4
5
6
7
8
Print 603.93.381
Description
Battery positive after TGC
Battery positive after TGC
Connector IWT2 (3) / Body builders light remotecontrol switch (30) positive
Positive for Body Controller (E4) / Roof panel cable junction / Cluster (A18) +15
Connector IWT1 (7) +15
Connector IWT1 (6) +30
Cable colour
code
7777
7701
8830/7777
8886/8879
8840
7772
Base October 2004
114
ELECTRIC/ELECTRONIC SYSTEM
Connector I
Figure 139
I
1
12
50365
Description
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
Ground
Cable colour
code
0000
8880
1116
7777
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
115
84590
Print 603.93.381
116
ELECTRIC/ELECTRONIC SYSTEM
TECHNICAL VIEW
Ref.
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
6
7
1
2
3
4
5
6
7
Cable
colour code
1103
0000
1109
1116
1116
2201
0000
2204
0000
8881
8882
0000
8822
8886
0000
8157
8155
0000
8156
8154
Function
Right indicator
Earth
Left indicator
Horn control
Horn positive (+30)
Earth
Windscreen wiper (intermittent wipe)
Windscreen wiper (electric pump control)
Earth
To Body Controller terminal A38 (SET+)
To Body Controller terminal A37 (RESUME)
Earth
To Body Controller terminal A27 (SET)
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
117
Figure 142
9 8
7 6 5
84591
Ref.
1
2
3
4
57
8
9
Print 603.93.381
Description
ABS
Rearview mirror control
Remotecontrol switch
Central locking control unit
Auxiliary remotecontrol switches (OPT.)
Diode cluster
Resistor cluster
118
ELECTRIC/ELECTRONIC SYSTEM
BODY CONTROLLER
Linking connectors
Figure 143
A
1
D
C
E
84592
Ref.
A
B
C
D
E
Description
External lights / Rear fog lights / Startprevent switch with hand brake OFF / Highbeam headlamps / Low
beam headlamps / Flashing the lights / Headlamp trim / Emergency lights / Indicators / Braking gasket wear /
Speed limiter / Exhaust brake selector / Door lights / Slow gear switch / Front and rear brake air pressure
sensors / Stop signal (from brake pedal switch on the duplex) / Windscreen wiper
Power takeoff / Levels: radiator water, power steering oil, windscreen washer, TGC
Power supply +30 (after TGC) / +30 / CAN line / Windscreen wiper motor / Windscreen washer electric
pump / Ceiling light / Step lights / Earth / Indicators / Left lowbeam lamp / Right highbeam lamp / Trailer
junction (rightleft indicators) / CAN line
Left highbeam lamp / Right highbeam lamp / rear fog lights, stop lights, sidelights, clearance lights, number
plate lights
(Highlow) gear engagement solenoid valve control
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
119
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Print 603.93.381
Cable
colour code
3302
5560
0000
6662
9024
9976
2237
2282
8886
9934
9936
5561
9025
2205
9968
2228
6620
6621
5562
7728
0003
8882
1103
2204
8156
8154
8822
8881
0010
3333
0003
1117
1109
2201
8155
8157
6012
6013
Function
Positive for fog light remotecontrol switch
Positive for brake air sensors
Brake air sensor earth
Signal from startprevent switch with hand brake ON
Signal from exhaust brake selector (PIN1)
Geareddown speed ON warning light (signal)
External light switch (PIN 4)
Rear fog light switch (PIN 2)
Steering column stalk (windscreen wiper control (PIN 7C))
IVECO rear axle differential lock signal
Signal from headlamp trim corrector (PIN 3)
Headlamp adjustment unit control (PIN 2)
Rear brake air pressure sensor signal
120
ELECTRIC/ELECTRONIC SYSTEM
Connector B (white)
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Cable colour
code
6131
6132
0055
6659
5520
5525
5521
Function
Rear power takeoff ON signal
Side power takeoff ON signal
Free
Longitudinal lock ON signal
Free
Front differential lock ON signal
Radiator water level signal
Power steering oil level signal
Windscreen washer fluid level signal
Free
Free
Free
Free
Free
Control from TGC closing button
Free
Free
Positive for TGC closing remotecontrol switch excitation
Free
Free
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
121
Connector C (black)
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Print 603.93.381
Cable colour
code
7768
4441
2221
2231
8861
8882
8886
8873
0000
6108
6109
2197
4408
1117
1180
1120
1185
1125
Function
Free
Positive +30 (prima TGC)
Positive for internal ceiling light
Right highbeam headlamp
Left lowbeam headlamp
Windscreen wiper motor (53B)
Windscreen wiper motor (53)
Positive for windscreen washer electric pump
Windscreen wiper motor (31B)
Earth
CAN H line
CAN L line
Free
Positive after TGC
Positive for step light
Positive after TGC
Positive for trailer left indicators
Positive for left indicators
Positive for trailer right indicators
Positive for right indicators
122
ELECTRIC/ELECTRONIC SYSTEM
Connector D (blue)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Cable colour
code
4442
2282
2286
3334
3380
3339
3332
8807
2223
2219
8879
8887
3330
3335
3390
3331
18
19
20
1177
1172
1179
Ref.
Function
Positive for ideograph illumination
Free
Positive for trailer reverse fog light
Positive for reverse fog light
Positive for rear left sidelights
Positive for front left sidelight / Positive for front right clearance light
Positive for rear clearance lights
Positive for trailer left sidelight
Positive after TGC
Right lowbeam headlamp / Headlamp trim consent
Left lowbeam headlamp
Positive after TGC
Positive after TGC
Numberplate lights
Positive for rear right sidelights
Positive for front right sidelights / Positive for front left clearance light
Positive for trailer front sidelights / Positive for body builders connector external light remote
control switch
Positive for left stop light
Positive for right stop light
Positive for trailer stop light
Connector E (white)
Ref.
1
2
3
4
5
6
7
8
Cable colour
code
9973
8886
9110
Function
Free
Free
Positive for high gear engagement solenoid valve control (9speed gearbox)
Positive +15
Free
Free
Positive for geareddown speed engagement solenoid valve control (9speed gearbox)
Free
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
123
CONNECTOR PINOUT
Figure 144
85561
85562
CONNECTOR B
CONNECTOR A
85563
CONNECTOR C/D
85564
CONNECTOR E
Print 603.93.381
124
ELECTRIC/ELECTRONIC SYSTEM
TACHOGRAPH
Figure 145
79369
1. Tachograph
Ref.
7768
4444
8879
6108
0066
0066
6108
5514
0058
5517
5516
5515
1191
Function
Positive +30 direct to the battery
Ideograph illumination
Positive +15
CAN H line
Earth
Earth
CAN L line
Sensor (A) signal
Sensor (B) signal
Sensor (C) signal
Sensor (D) signal
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
125
Injection control
Based on the information coming from the sensors, the control unit manages the pressure regulator, changes the preinjection and
the main injection operating modes. On Tector motors preinjection is active at any rotation speed rate of the motor.
Cut Off
Fuel cut off at release stage is managed by the control unit which implements the following logics:
- cuts off the power to the electroinjectors
- reactivates the electroinjectors immediately before idling speed is reached
- controls the fuel pressure regulator.
Print 603.93.381
126
ELECTRIC/ELECTRONIC SYSTEM
After Run
The control unit microprocessor makes it possible to memorize some data in the EEPROM, including the failure memory and the
Immobilizer information, so as to make them available for the subsequent starting.
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
127
EDC
PRES OLIO
IVECO
CAN LINE
84593
Print 603.93.381
128
ELECTRIC/ELECTRONIC SYSTEM
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Description
Position sensor on accelerator pedal
Primary and secondary brake switch
Sensor on clutch pedal
Exhaust brake switch
Immobilizer ECU
Ignition key
Lever mounted switches
Cab unhooked switch
Handbrake engaged
Neutral switch
(20 A) protective fuse
Tester connector
BlinkCode button
Exhaust brake selector
Starter motor
Crankshaft sensor
Engine stop/start buttons
Preheating remote control switch
Fuel temperature sensor
Fuel heating resistor
Timing system sensor
Pressure regulator
Coolant temperature sensor
Preheating resistor
Electroinjectors
Air temperature/pressure sensor
Fuel temperature/pressure sensor
Exhaust brake solenoid valve
Oil temperature/pressure sensor
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
129
50367
Print 603.93.381
130
ELECTRIC/ELECTRONIC SYSTEM
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
Component
code
85153
78247
85157
85156
44037
48042
47042
85150
48035
44043
42030
61121
Description
Coolant temperature sensor
Electroinjector
RAIL pressure sensor
Air temperature/pressure sensor
Power steering level sensor
Timing sensor
Fuel temperature sensor
EDC7 control unit
Crankshaft sensor
Engine oil level transmitter
Engine oil pressure/temperature sensor
Prepost hearing resistance
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
131
50351
Print 603.93.381
132
ELECTRIC/ELECTRONIC SYSTEM
Sensors connector C
Figure 149
Colour legend
B
black
R
red
U
blue
W
white
P
purple
G
green
N
brown
Y
yellow
O
orange
16
15
22
23 30
36
29
4
5
50350
ECU
Pin
14
5
6
7
8
9
10
11
12
1316
17
18
19
20
21
22
23
24
25
26
27
28
29
30
3132
33
34
35
36
Cable
Colour
NW
NP
PY
NY
GY
YR
YN
PN
GN
N
U
U
R
GO
NG
UO
R
PO
YU
PG
YO
Function
Timing sensor
Crankshaft sensor
Crankshaft sensor
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
133
B frame connector
Figure 150
71
89
72
54
11
1
7
12
53
35
18
36
17
50350
ECU
Pin
1
2
3
4
5
6
7
8
Cable
Function
8150
0087
0000
0094
9068
8150
7777
9
10
11
12
13
14
15
16
1718
19
0000
9067
9966
8150
8150
0000
0000
8885
0150
20
21
22
2325
26
27
28
29
30
31
32
3335
36
37
38
8037
8159
5162
5535
1198
2298
0169
8837
8888
Print 603.93.381
134
ELECTRIC/ELECTRONIC SYSTEM
B frame connector
ECU
Pin
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
5758
59
60
61
62
63
64
65
66
6771
72
73
74
75
76
77
78
79
80
81
82
83
87
Cable
8051
0027
9907
6666
0115
9905
9906
5198
5584
0158
6109
6108
5158
5602
0535
0159
0159
5155
8158
5502
9071
8153
0157
5157
5120
Function
Positive from keyoperated switch, +15
Cutting off engine brake with ABS in
Signal from handbrake engaged switch
Signal from cab unhooked switch
Gearbox in neutral position (signal)
Positive from start button from engine compartment
Positive from stop button from engine compartment
Clutch sensor
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
135
Electroinjectors connector A
Figure 151
12
16
11
5
50350
ECU
Pin
Cable
Colour
(4 cylinders)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
WP
RG
UN
UG
WR
RY
UO
UY
Function (4 cylinders)
Cylinder 4 injector
Cylinder 1 injector
Cylinder 2 injector
Cylinder 3 injector
Cylinder 4 injector
Cylinder 1 injector
Cylinder 2 injector
Cylinder 3 injector
Colour legend
B
black
R
red
U
blue
W
white
P
purple
G
green
N
brown
Y
yellow
O
orange
Print 603.93.381
136
ELECTRIC/ELECTRONIC SYSTEM
Figure 152
50324
CONNECTION CONNECTOR
Ref
Ref.
Description
Air
Ground
19C
21C
Temp. signal
35C
29C
+5
9C
10C
Press. signal
33C
28C
Figure 154
50344
WIRING DIAGRAM
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
137
Figure 156
180 15
8518
TECHNICAL VIEW
8519
WIRING DIAGRAM
Figure 157
8520
PERSPECTIVE VIEW
Ref
Ref.
1
2
3
Print 603.93.381
Description
Signal
Signal
Shielding
23C
30C
138
ELECTRIC/ELECTRONIC SYSTEM
Figure 158
A Distribution manifold
Ref.
1
2
3
Description
Ground
Signal
Power
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
139
Figure 159
A
1
B
C
3
D
E
000912t
Print 603.93.381
140
ELECTRIC/ELECTRONIC SYSTEM
Electroinjector
The injector features a traditional construction, save for the fact
that it has no needle return springs.
Figure 160
Injection starts
Upon being energised, coil 4 moves up the shutter 6.
50336
Figure 161
Injection ends
When coil 4 is deenergised, the shutter 6 closes again so as
to recreate a balance of forces which moves the needle back
into its closed position and stops the injection process.
000933t
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
141
Connecting connectors
Figure 162
50343
2
FAN SIDE
50349
Ref.
CONNECTOR 1
CONNECTOR 2
CONNECTOR 3
Print 603.93.381
Description
1
2
3
4
1
2
3
4
1
2
3
4
Cylinder 2 injector
Cylinder 2 injector
Cylinder 1 injector
Cylinder 1 injector
Cylinder 4 injector
Cylinder 4 injector
Cylinder 3 injector
Cylinder 3 injector
Cylinder 6 injector
Cylinder 6 injector
Cylinder 5 injector
Cylinder 5 injector
142
ELECTRIC/ELECTRONIC SYSTEM
Figure 164
50321
Figure 165
50322
Figure 166
Ref
Ref.
Description
1
2
ECU pin
47035
47042
Ground
18C
17C
Signal
36C
34C
A
B
50348
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ELECTRIC/ELECTRONIC SYSTEM
Fuel prefilter
The water separation type fuel filter is mounted on the right
hand side of the vehicle frame and has, on the cartridge base
3, a sensor 4 detecting the presence of water in the fuel.
143
Figure 167
000910t
Tightening torque
Bleed screw 2
Filtering cartridge 3
Sensor 4
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6 to 8 Nm
18 0.1 Nm
0.8 0.1 Nm
144
ELECTRIC/ELECTRONIC SYSTEM
Figure 168
50332
Figure 169
50326
A. Clutch sensor
Figure 170
PEDAL BODY
Ref.
Cable
colour
Description
Control unit
pin
0000
Ground
7151
Power supply
8B
0160
Signal
62B
SENSOR PART
50333
D. Triggering distance
Base October 2004
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ELECTRIC/ELECTRONIC SYSTEM
Figure 171
145
A. B. Connecting terminals
Figure 172
C
50325
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146
ELECTRIC/ELECTRONIC SYSTEM
Figure 173
50334
WIRING DIAGRAM
Figure 174
000600t
Figure 175
50328
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ELECTRIC/ELECTRONIC SYSTEM
147
Figure 176
001662t
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148
ELECTRIC/ELECTRONIC SYSTEM
Testing methods
Two warning lights (yellow or red) will be displayed according to the gravity of the failure.
HIGHLINE model clusters will show a DIAGNOSTIC screen, in the middle part of the display, which will indicate failure codes.
Figure 177
84589A
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ELECTRIC/ELECTRONIC SYSTEM
149
ABS
Electronic control unit location on vehicle
Print 603.43.691
Figure 178
84591
The system is able to prevent wheel locking, that could occur when braking, under any vehicle load condition and under any
wheelroadbed friction coefficient condition, in order to guarantee better braking performances and a better vehicle stability.
The system is activated upon startup and automatically operates for speeds greater than 5 km/h if, after a braking, one or more
wheels tend to lock.
The ABS system is able to control engine brake exclusion and distributor locking (if it exists).
They are disconnected when it is detected that one or more driving wheels tend to lock.
Reconnection is automatic when the ABS system ceases to operate.
On all vehicles of the range, the system has three channels, two on front wheels and one on rear axle, apart from 3axle vehicles
in which the system has four channels.
Purpose of the unit is processing signals coming from wheel revolution sensors and suitably driving the system solenoid valves
in order to avoid locking the wheels when braking.
Signal processing is carried out by a microprocessor that computes acceleration and deceleration values of the different wheels
and carries out the logic combination of the various adjustment signals.
If an anomaly is detected, the unit takes care of automatically excluding the whole ABS system, leaving however the traditional
braking system efficient, and of informing the driver by lighting the suitable warning light on the dashboard.
Print 603.93.381
150
ELECTRIC/ELECTRONIC SYSTEM
Figure 179
101587
Components
code
78052
88000
88001
Description
Solenoid valve for ABS
Electronic control unit for ABS system
Sensor for ABS system
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ELECTRIC/ELECTRONIC SYSTEM
151
ABS
Component location on a vehicle (Pneumatic system)
Figure 180
78620
1. Phonic wheel 2. Check valve 3. Hydropneumatic converter 4. Pressure control takeoff 5. Hydropneumatic converter
6. Exhaust brake solenoid valve 7. A.P.U. 8. Phonic wheel 9. Wheel revs sensor 10. Springoperated cylinder
1. Power valve 12. Triplecontrol servodistributor 13. Coupling head 14. Emergency braking tank + trailer 15. Hydraulic
pressure control takeoff 16. Wheel revs sensor 17. Phonic wheel 18. Rear disc brake assembly 19. Quickrelease valve
20. Pressure reducer 21. Electropneumatic valve 22. Air tank 23. Pressure control takeoff 24. Pressure reducer 25.
Front disc brake assembly 26. Wheel revs sensor 27. Phonic wheel 28. Exhaust brake cylinder 29. Exhaust brake control
button 30. Duplex distributor 31. ABS electronic control unit 32. Singlecylinder compressor 33. Emergency brake
distributor 34. Trailer deceleration control distributor (option) 35. Wheel revs sensor.
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152
ELECTRIC/ELECTRONIC SYSTEM
Connector
II
III
IV
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1 4
18
3 II
Cable colour
6684
8847
7710
0050
0000
2299
1199
6670
9921
9919
0000
5570
5570
5571
5571
9918
9920
0000
9930
0000
5572
5572
5573
5573
9924
3 III 9
13
IV
15
62608
Description
CAN L line
CAN H line
Signal from front br. converter cylinder limit switches(only vehicles 60100)
Positive (+15)
Ground
Ground
To tester connector (pin 4) line K
To tester connector (pin 3) Line L
Negative for rear axle ABS (left Mod. 260) solenoid valve
Positive for rear axle ABS (right Mod. 260) solenoid valve
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ELECTRIC/ELECTRONIC SYSTEM
153
Duplex distributor
Figure 182
62579
000607t
Brake switch
This is a microswitch mounted directly on the duplex distributor (SWITCH).
The N.C. contact provides the control unit (pin B76) with a positive signal (with the pedal released) and is used to detect service
brake actuation so as to deactivate the Cruise Control function and cut off fuel delivery.
The N.A. contact provides the BODY CONTROLLER control unit (pin A34) with a positive signal, so that the control unit itself
can control stop light actuation.
Electric connections
Ref.
1
2
3
4
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Cable colour
1176
7151
8158
Description
Power supply positive signal
Positive signal to turn on the stop lights (Body Controller, pin E11)
Power supply positive signal
Positive signal with brake released for EDC control unit (pin B76)
154
ELECTRIC/ELECTRONIC SYSTEM
Figure 183
B
A
B
000840t
000841t
AIR GAP
000842t
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ELECTRIC/ELECTRONIC SYSTEM
155
Diagnostics
Warning lights operation
Figure 184
1
2
79486
Figure 185
Wear indicator
84598
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156
ELECTRIC/ELECTRONIC SYSTEM
Print 603.43.691
ECAS
General
The air suspension features great flexibility, vibration damping capacity and above all, thanks to the systems selfadjusting functions,
it maintains the frameroad surface distance constant, regardless of vehicle load. By means of a special button, the air suspension
makes it possible, among other things, to vary the frameroad surface distance and hence the height of the vehicles loading floor.
In addition to the well known advantages of air suspension, the ECAS suspension offers:
- an appreciable reduction in air consumption;
- prompt action of the different adjustment processes;
- simple system construction;
- full safety;
- the possibility of total system diagnosis.
The ECAS (Electronically Controlled Air Suspension) system automatically controls the nominal level of the vehicles air
suspension, with the possibility, for the vehicles that adopt it, of lifting the rear added axle, when required by the vehicles operating
conditions, and transferring the load onto the drive axle at takeoff, if adherence conditions are poor (aid at takeoff).
However, all the foregoing operations can take place only in specific operating conditions under the surveillance of the safety devices
equipping the systems connected to the units involved.
The ECAS automatically controls the height of the frame (the distance between the frame and the road surface) based on the actual
values sent in by the sensors, by comparing these actual values with the nominal ones stores in its memory.
If the actual level changes or departs from the nominal value or the value set previously by the driver, the control unit corrects it
by means of the electropneumatic devices.
The system is equipped with a remote control for frame lifting/lowering and levelling operations, which can be operated with the
vehicle standing or moving.
In addition to the lifting, lowering and selflevelling operations, the remote control makes it possible to save other frame levels, which
can be recalled as necessary.
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ELECTRIC/ELECTRONIC SYSTEM
157
001716t
WABCO
18 to 32V
40 to +70
The electronic control unit makes it possible to manage the different positions of the frame as a function of the commands imparted
by the driver by means of the remote control unit. When you turn on the keyoperated switch, the electronic control unit performs
a system test by powering for ca 2 sec. the yellow and red telltales located on the dash.
If a fault is detected, the red warning light will either stay permanently lit or blink, depending on its severity, while the yellow light
can stay lit only if the vehicle level is not normal or a plausibility error is detected.
Since it has to keep the running level requested by the driver constant and, at the same time, it has to reduce the consumption
of air, the control unit checks cyclically the signals coming from the level sensors and steps in ONLY if it detects a deviation for more
than five counts.
The correction is applied with a time lag, as follows:
~1 sec. if the vehicle is standing
~ 60 sec. if the vehicle is moving
If the level is not reset within a max. time interval of 30 sec. of the start of the correction, the control unit will memorise a plausibility
error.
At the braking stage, upon receiving a signal from the stop light switch, the electronic control unit stops all automatic level adjustment
operations. Though it has a Blink Code, displayed through the red warning light, for a preliminary diagnosis, the control unit has a
highly advance selftesting system that can recognise and memorise, as a function of environmental conditions, any failure, including
those of intermittent types, which may occur during system operation, so as to ensure effective and reliable repair interventions.
All tests and failure memory programming/deletion interventions, etc. can be performed by means of the computerised testing
station MODUS. All system components, save for the steering system, are connected to the electronic control unit via a comb
type connector. The number of the pins, and hence the type of ECU, vary depending on the version.
Print 603.93.381
158
ELECTRIC/ELECTRONIC SYSTEM
78798
1. Controlledpressure valve 2. Front axle level sensor 3. Front airoperated spring 4. Front axle electropneumatic
distributor 5. Rear airoperated spring 6. Check valve 7. Rear axle electropneumatic distributor 8. Tank 9. Pressure
control takeoff 10. Rear axle level sensor.
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ELECTRIC/ELECTRONIC SYSTEM
159
X1
X2
001717t
Connector X1
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Cable
GN/VE
WS/BI
8445
7440
6402
2294
8810
6403
0000
8810
0402
Function
CAN L line
CAN H line
Connector X2
Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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Cable
9400
5422
0400
5421
5410
9425
9423
9424
Function
Negative for front axle (pin 2) and rear axle (pin 4) solenoid valve (front / rear distributor)
Positive for left rear axle level sensor (pin 1)
Negative for rear right chassis control solenoid valve (pin 2) (rear distributor)
Negative for front chassis control solenoid valve (pin 1) (front distributor)
160
ELECTRIC/ELECTRONIC SYSTEM
Level sensor
Figure 189
Technical data
Power supply voltage
Pulse 5 to 15V
Measuring principle
Inductive
Current drained
Max 100mA
Max 100
62421
Figure 190
Figure 191
(counts)
200
204
180
183
160
160
140
138
120
114
100
--50
--40
--30
--20
--10
70
52
10
20
80
30
40
50
(degrees)
60
40
36
22
10
20
0
62422
WORKING CURVE
Base October 2004
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ELECTRIC/ELECTRONIC SYSTEM
161
Pin 2
Negative
Pin 4
Figure 192
78803
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162
ELECTRIC/ELECTRONIC SYSTEM
Pin 2
Pin 3
Pin 4
Common negative
Figure 193
78806
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ELECTRIC/ELECTRONIC SYSTEM
163
Figure 194
78799
1)
2)
3)
4)
5)
6)
7)
8)
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164
ELECTRIC/ELECTRONIC SYSTEM
F Throughwall joint
Figure 195
50355
50341
Pin
1
2
3
4
5
6
7
8
9
10
11
12
Base October 2004
Function
Air/ECAS suspension
Right rear ECAS sensor
Right rear ECAS sensor
Left rear ECAS sensor
Left rear ECAS sensor
Front ECAS sensor
Front ECAS sensor
Front ECAS solenoid valve
Rear ECAS solenoid valve
Rear ECAS solenoid valve
Rear ECAS solenoid valve
Cable colour
code
6401
5421
0400
5422
0400
5410
0400
9413
9423
9424
9425
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ELECTRIC/ELECTRONIC SYSTEM
165
Figure 196
7
62390
1. Air intake valve with limited return 2. Manual condensate bleed valve 3. Air tank 4. Pressure testing tap
5. Check valve 6. Low pressure indicator 7. Electropneumatic distributor 8. Electronic levelling valve
9. Rear axle air spring
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166
ELECTRIC/ELECTRONIC SYSTEM
Figure 197
10
11
12
22
21
14
23
11
22
23
62391
1. Air intake valve with limited return 2. Manual condensate bleed valve 3. Air tank 4. Pressure testing tap
5. Check valve 6. Low pressure indicator 7. Electronic levelling valve 8. Axle air spring 9. Axle electropneumatic
distributor 10. Rear axle electropneumatic distributor 11. Rear axle air spring.
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ELECTRIC/ELECTRONIC SYSTEM
167
Diagnosis
If an anomaly is found, the CLUSTER display will show an error message which can be yellow (minor anomaly) or red (serious
anomaly).
If yellow symbol 2 (minor anomaly) appears, it will be shown on the left side of the display. If red symbol 3 (serious anomaly) appears,
it will be shown on the right side of the display.
The engine must not be stopped if warning light 1 comes on.
If warning light 3 comes on when the vehicle is running, stop the vehicle and turn the ignition key to STOP. Turn the key to MAR
again after approximately 7 seconds: if warning light 3 does not go out after approximately 2 seconds, contact your Dealership
immediately.
Figure 198
3
2
79489
1. Low pressure warning light 2. System failure (YELLOW) 3. System failure (RED)
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168
ELECTRIC/ELECTRONIC SYSTEM
As far as electronic systems are concerned, the respective failure messages can be shown in the display (if the CLUSTER is available
in HIGHLINE models).
Figure 199
84589A
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ELECTRIC/ELECTRONIC SYSTEM
169
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ENGINE BRAKE
Simplified system operation
The engine brake system is controlled by the EDC control unit.
There are three engine brake control modes which can be selected using the special switch on the centre dashboard, to be used
in the different types of situations/routes.
With the selector in the rest position, the button on the cab floor is always operational, (for intermittent use on hills and on snow
or ice).
With the selector in position 1 the engine brake is combined with the accelerator pedal, coming into action when the pedal is
released (to be used on long downhill roads with steady gradient).
With the selector in position 2 the engine brake is combined with the service brake, functioning starting from the first section of
pedal stroke and maintaining the position (essentially to be used to reduce service brake wear for routes where much use of it is
needed).
Every time the engine brake is engaged a warning lamp on the cluster turns on.
Engagement of the engine brake in combination with the accelerator pedal disables all the adjustment operations
connected with the Cruise Control.
ENGINE
BRAKE
EDC
The lighting of the respective warning light (located on the CLUSTER) occurs through the CAN line.
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170
ELECTRIC/ELECTRONIC SYSTEM
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System components
Figure 200
001521t
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ELECTRIC/ELECTRONIC SYSTEM
171
IMMOBILIZER
Description and operation
For better protection against theft, the vehicles have been equipped with an engine blocking system called Immobilizer which
is automatically activated when the ignition key is removed. The key, in fact, contains an electronic device, known as Transponder,
which transmits a coded signal to a special control unit ICU that enables the engine to be started only if it recognises the code.
General characteristics
System composition
The main components of the system can be summarised as follows:
Immobilizer control unit (ICU)
Antitheft device + No. 2 keys with electronic Transponder (non separable)
Aerial (on ignition switch)
EDC type fuel flow actuator (ACT)
Code_card (specific card with PIN electronic code and mechanical code)
Installation
For its correct operation, the system requires an installation process consisting of the following stages:
Key training
Actuator training
At the end of the process, the Immobiliser control unit is able to detect tampering attempts by recognising the components
connected to it in a univocal manner (non separable)
Operating principle
With the key set on ON, the Transponder contained in the key generates a code which is received by the Immobiliser control
unit through the aerial.
The control unit transmits to the actuator a request for a validation process by communicating the code received.
The actuator deciphers the code and compares it with the data saved during the installation process.
If the comparison is successful the actuator transmits to the control unit a request to enable fuel flow.
The control unit processes the request and, if everything is correct, sends out the fuel release command to the actuator.
The vehicle can be started.
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172
ELECTRIC/ELECTRONIC SYSTEM
Components
7
Figure 201
EDC
8
6
11
EDC
3
2
49523
Ref.
Description
Codecard
Electronic key
Antenna
Electroinjectors
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ELECTRIC/ELECTRONIC SYSTEM
173
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174
ELECTRIC/ELECTRONIC SYSTEM
Figure 203
8
4
3
1
B
A
Ref.
A
Description
Cable colour
Aerial
Aerial
6109
2292
6092
0108
Ground
0050
8092
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ELECTRIC/ELECTRONIC SYSTEM
175
Figure 204
The handle of the key contains an electronic device called a Transponder that is NOT powered by any battery, this device
contains and transmits the secret code.
By inserting the key, the Transponder is activated and therefore energized by the radio waves emitted by the antenna
(assembled on the lock of the key switch) and automatically replies by emitting the secret code. If the two codes match, the control
unit enables the vehicle to be started, if they dont match it blocks the flow of fuel and therefore the vehicle cannot be started.
- Two keys are supplied.
- Each key contains a Transponder with the relative secret code.
- IT IS VERY IMPORTANT to follow the correct procedure for key learning.
The Transponders in the keys cannot be removed.
There is no master key.
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176
ELECTRIC/ELECTRONIC SYSTEM
Aerial
Figure 205
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ELECTRIC/ELECTRONIC SYSTEM
177
Code Card
Figure 206
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178
ELECTRIC/ELECTRONIC SYSTEM
6.
7.
8.
To perform the emergency procedure in case the CAN line is affected by a SERIOUS FAULT, it will be necessary to refer to the
lighting messages of LED (1) available in the U.C.I. in front of the passengers seat. Under normal conditions, displaying will occur
by means of the EDC warning light available on the Cluster display.
Figure 207
79370A
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ELECTRIC/ELECTRONIC SYSTEM
179
Figure 208
KEY
1
KEY
2
In the event that the key is lost or for its replacement, a specific procedure must be followed using only the specific diagnostic
devices.
This procedure can only be carried out with the assistance of the Modus, IWT
The key memorization procedure can be carried out even if the EDC control unit is not connected.
The keys have already undergone a learning procedure, and therefore belong to that ICU.
It is possible to teach new and old keys.
In each case the keys used (enabled on ignition) can never be more than three in number and can only be those used during
the last learning process.
A key that has been previously memorized but not inserted in the last learning process will not be able to start the vehicle.
The memorization procedure can only be carried out after having correctly inserted the Electronic Code shown on the Code
Card supplied.
There are two different procedures, depending on the following situations:
- Replacement or addition of one or more keys.
- Installation of a new Immobilizer control unit.
For further clarifications on this matter see manual no. 603.43.613.
Print 603.93.381
180
ELECTRIC/ELECTRONIC SYSTEM
System selftesting
After the initial test, the behaviour of the code light informs the operator about system faults, such as:
Light always blinking at a frequency of 0.3 sec. ON and 3 sec OFF reveals that an error is present or that the starting
procedure in an emergency has not been performed correctly.
Light always blinking at a frequency of 0.3 sec. ON and 3 sec OFF reveals that no key training process has been performed.
Light permanently lit means that the key training procedure has not been performed correctly.
o As a preliminary step you can display the faults, if any, on the telltale module of the onboard panel by activating the Blink code.
For a more exhaustive diagnosis, however, it is indispensable to use the tools, such as MODUS, available to the service network.
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
181
If after accurate diagnosis it is necessary to replace one or more components, proceed as described below
ALL ENGINES
PART TO BE
REPLACED
One or two keys
(with one still
available)
Addition of a
key
Steering lock
and/or ratchets
ALL the keys
PARTS TO BE
ORDERED
Parts Keys
ECU Immobilizer
Key memorising
).
Perform Key
memorising in Immobilizer diagnostics ((*).
Aerial
Aerial
KIT ECU
Including:
Immobilizer ECU
2 keys to be cut
New Code Card
(*) With MODUS 2.0 (Windows), 1.6C (DOS) or IWT 1.4 release before performing New key memorising, it is
absolutely necessary to disconnect the EDC . Once the operation has been completed, clear the fault memory to prevent
the error from staying memorised on the actuator.
For subsequent releases keep to any new instructions given on the screen.
Print 603.93.381
182
ELECTRIC/ELECTRONIC SYSTEM
Figure 209
91236
X1
X2
X3
91237
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Connector
X1
X2
X3
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ELECTRIC/ELECTRONIC SYSTEM
Pin
1
Cable colour
7777
8887
0000
Earth
5001
5002
6
7
9
10
6108
2290
CAN line H
K line PDA connector (Palmar connection)
11
12
6109
13
14
5511
15
16
17
1000
2226
18
8100
3311
1012
6108
4
5
5522
1012
6109
1011
8
9
10
11
12
13
14
15
3310
5
6
5003
5004
9906
9907
183
Description
184
ELECTRIC/ELECTRONIC SYSTEM
Turn off the heater to avoid risks of explosions in proximity of fuel depots, filling stations, storerooms where dusts
or fumes could be set on fire (coal depots, wood dust or cereals storerooms etc.).
To avoid the risk of intoxication do not start the heater in a closed or poorly aerated environment even by means of
a time preselector.
Figure 210
A
85557
A. Auxiliary heater
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ELECTRIC/ELECTRONIC SYSTEM
185
GENERAL DESCRIPTION
The airoperated AIR TOP 2000 auxiliary heater, whose working principle is based on the evaporator, is thoroughly separated
from that of vehicles engine.
The heater consists essentially of the following components:
- comburent air fan
- heated air fan
- heat exchanger
- burner union and combustion pipe
The heater is controlled and monitored by means of the following units:
- electronic control unit
- flame test
- bulb
- heat lmiting device
- heat sensor
The vehicles fuel tank supplies the heater with fuel through a metering pump.
The AIR TOP 2000 heater is started and set in operation by a control unit and a timer device. The latter can be of different types
depending on the vehicle model on which it is assembled.
Control voltage
Heat power output
Fuel consumption
Electric power output
Output temperature
Air delivery
Weight
max
regulation
max
regulation
max
regulation
max
regulation
max
24V
2Kw
0.9 to 1.8Kw
0,240L/h
0.12 to 0.22L/h
22W
10 to 18W
+40C
+10C to +35C
70m3/h
2,6Kg
Figure 211
186
ELECTRIC/ELECTRONIC SYSTEM
Exploded view
Figure 212
51747
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ELECTRIC/ELECTRONIC SYSTEM
187
The following procedure deletes all presetting regulation data set by the Manufacturer.
Figure 213
188
ELECTRIC/ELECTRONIC SYSTEM
OPERATION
Beginning of the combustion phase
Once the desired temperature (ranging between 10 and 45C) is preset, the heater can be switched on by means of the
hand/automatic device. The pilot lamp illuminates and the bulb is activated via a pulse regulation system.
The heating and comburent air motor starts to turn at high speed for about 1 sec and then gradually reduces its speed to 30%
of its potential.
If the temperature of the air entering the system is higher than the desired temperature only the heating and comburent air motor
is activated.
On the contrary, if the temperature of the air entering the system is lower than the desired temperature the combustion process
is set in operation.
After 20 seconds approximately the fuel metering pump is started by the electronic control unit or control board.
25 seconds later the fan speed is increased and kept steady for about 20 seconds, i.e. until the beginning of the combustion phase.
From the moment the flame is turned on (indicated by the flame sensor) the combustion process remains steady for the next
20 seconds, that is to say the fan speed is subjected to continuous increasing adjustments until it reaches its maximum figure (this
phase lasts 20 seconds approximately).
Should the flame go out during this phase, the starting procedure is automatically repeated.
If combustion is irregular, after two minutes the fan increases its speed for about 30 seconds with the bulb activated and the fuel
metering pump closed; the starting procedure is then repeated.
If a second attempt at starting the combustion process also proves unsuccessful, the heater is probably defective. It will go off
on its own after 80 seconds approximately.
The heating and comburent air fan is brought to peak speed for about two minutes.
The overall combustion phase lasts for about three minutes.
The control device is fitted with a green led which illuminates and remains on (fixed light) throughout normal operation of the
system. A flashing light by the same led indicates overheating.
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ELECTRIC/ELECTRONIC SYSTEM
189
Cab heating
While the heater is in operation exhaust gases flow to the heat exchanger. The heat developed by the combustion process is passed
on to the heat exchanger faces, absorbed by the air fed by the fan and then spread into the cab.
The temperature of the air entering the system is measured by a sensor fitted to the heater inlet side.
If the temperature of the outgoing air is lower than the preset value, the heater increases its heating power until it reaches the
specified figure.
When the system is required to work for a long time without stopping, the delivery of the metering pump is reduced every 15
minutes for 20 seconds in order to increase its heating output to 1.1 Kw.
The pump delivery is instead reduced every 30 minutes for 4 seconds if the desired heating output is less than 1.1 Kw.
Once the preset temperature is attained, the system will reduce the speed of the heating and comburent air fan and the delivery
of the fuel metering pump.
- If the temperature of the air entering the heater is higher than the figure selected beforehand, the system will function at
idling speed for about 5 seconds and then switch off the metering pump and terminate the combustion process. The fan
speed will remain steady for about 35 seconds after which it will increase (for at least 120 seconds) to 60% of its maximum
power thus allowing the heater to cool down.
- If the temperature of the air entering the heater is lower than the figure selected beforehand, the fan will function at 30%
of its maximum power.
The heater will remain on even in case a signal from the temperature sensor informs the control unit that the running temperature
is lower than the preselected figure.
Print 603.93.381
190
ELECTRIC/ELECTRONIC SYSTEM
Figure 214
Figure 215
Figure 216
Heat exchanger
The heat developed by the combustion process inside the
heat exchanger is sent to the heating and comburent air fan.
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
191
Figure 217
Flame test
The flame test is performed by a PTC type low value
resistor which adjusts its resistance depending on flame and
heating degree.
Figure 218
Figure 219
Bulb
The bulb enables ignition of the air and fuel mix during the
heater starting phase.
The bulb functions as an electric resistor. It is assembled
into the burner union on the flames opposite side.
TEST VALUES
- 25C resistance
test current
Print 603.93.381
192
ELECTRIC/ELECTRONIC SYSTEM
Figure 220
Figure 221
2
Fuel metering pump
This pump is made up of fuel feed, metering and cutoff
components.
Fuel supply to the heater is from the vehicles fuel reservoir.
Assembly of the pump should be carried out according to
specified installation standards.
The metering pump should be secured by means of a
shock absorber suspension system.
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
193
Assembly drawing
Figure 222
Print 603.93.381
194
ELECTRIC/ELECTRONIC SYSTEM
ST X1 connection connector
Figure 223
13
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
Description
Air temperature adjustment thermostat supply
Supplementary heater supply
Timer supply
Supplementary pump supply
Supplementary heater blower engine supply
Supplementary pump supply
Supplementary heater turningon spark plug supply
Supplementary heater ground
Diagnostic K Line
Remote control switch supply (control) for TGC
Cable
colour
7736
7708
7725
7783
7722
7783
7705
0022
2295
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
195
Fault diagnosis
Fault symptoms general
Fault
Possible cause
Remedy
Washing performed
Remedy
Faulty wiring, fuse cut off
immediately
immediately
1 second
5 seconds
1 second
20 seconds
120 seconds
40 to 120 sec.
230 seconds
while
heater
running
Motor off, no washing
while
heater
running
Metering pump cycle discontinued; 30 while
heater
seconds max speed after starting running
procedure is repeated
Print 603.93.381
196
ELECTRIC/ELECTRONIC SYSTEM
Repair operations
Repair and maintenance operations should be carried out only by skilled personnel.
Isolate system batteries before carrying out any repair operation on the auxiliary heater.
Especially before the cold season operate the heater at regular intervals for at least ten minutes approximately every
four weeks to prevent mechanical parts from locking with time. Overhaul the entire system before the winter season.
Carry out the following operations to obtain maximum performance from your heater:
- Ensure the heating air input and output ports are not restricted by dirt or foreign bodies; this could result in heater
overheating and consequent release of the heat limiting device.
- Clean the auxiliary heater from the outside.
- Check efficiency of electrical connections.
- Check the condition of exhaust gas and comburent air lines. Ensure they are not damaged or restricted.
- Check fuel line for tightness and filter efficiency. Replace the latter, if necessary.
Description
No starting (after performing the starting procedure twice)
Flame cutoff
Low voltage or overvoltage
Immediate flame recognition failure
Flame test cutoff or shortcircuit
Temperature sensor cutoff or shortcircuit
Fuel metering pump cutoff or shortcircuit
Fan motor cutoff or shortcircuit or defective fan motor running speed
Bulb cutoff or shortcircuit
Overheating
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
197
DIAGNOSTIC INSTRUMENTS
Electronic system troubleshooting can be performed either by means of the Cluster of the Modus, IT 2000, and E.A.S.Y. diagnostic
instruments.
Diagnosis by means of the Cluster allows you to evaluate in advance the situation of the faults found in the system, whereas the
diagnostic instruments are essential to carry out thorough diagnosis and take appropriate measures with regard to the individual faults.
Every single instrument displays a guide to diagnosis and repair work, and is connected to the diagnosis connector available on the
vehicle (30 pole).
Diagnosis instruments
MODUS (Maintenance and diagnostic system)
Computerized diagnosis station used to diagnose braking systems, pneumatic suspensions, engine and electronicallycontrolled
systems.
The station is equipped with auxiliary functions such as electronic control unit programming, spare part catalog referencing, time
schedules, etc.
The vehicle is equipped with a 30pole diagnosis takeoff for interfacing with the instrument.
IT 2000 (IVECO Electronic Tester)
It makes it possible to immediately act on the vehicle, by recognizing the latter by means of the chassis number.
It stores the results of the diagnosis work carried out.
It can also be used as a portable PC and is set for remote diagnosis.
By using the MODUS as a mother station, you can update and configure the IT 2000.
IT 2000 is interfaced with the vehicle through a 30pole diagnosis takeoff.
E.A.SY.
The E.A.SY. system allows you to easily diagnose and program the various electronic control units available on the vehicle. The system
is made up of the ECI module for communication with the electronic control units, and a PC made by Panasonic.
The ECI module makes it possible, by taking advantage of the Panasonic PC, to take the proper actions on the vehicle on the road.
In particular, diagnosis may, thanks to the Panasonic PC wireless technology (e.g. GPRS), be assisted by an expert remote center.
Figure 224
101586
Print 603.93.381
198
ELECTRIC/ELECTRONIC SYSTEM
Figure 225
85156
If an anomaly is found, the display shows the symbol of the electronic system involved.
For Highline versions, the error code can be displayed by entering menu DIAGNOSTIC by means of the dedicated controls available
on the dashboard righthand frame (see figure below).
Figure 226
86157
1. Previous page (ESCAPE) 2. Submenu display/display actuation (OK) 3. Upper line displaying button
4. Lower line displaying button
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
199
Figure 227
85158
These screens show the faults found in the various electronic systems (EDC, ABS, ECAS, etc.).
86159
1.
2.
3.
4.
Print 603.93.381
200
ELECTRIC/ELECTRONIC SYSTEM
XX
YY
Fault code (DTC)
EuroCargo code
Control unit code (e.g. 21 = 1B)
Print 603.93.381
EEPROM
DTC
FMI
Visible anomaly
Possible cause
12
22102
12
IBC
22103
IBC
22103
IBC
22103
Values to
be found
Notes
ELECTRIC/ELECTRONIC SYSTEM
201
22101
Measuring
conditions
Component failure
TROUBLESHOOTING
Instrument Body Controller (IBC)
Print 603.93.381
Text
on
Cluster
Component failure
DTC
FMI
Visible anomaly
Possible cause
On left Cluster part, IBC words Supply voltage on line 1 lower than
remain turned on.
8 Volts.
The affected voltage value is lower
than the threshold.
The error could be denounced and
not monitored when starting the
engine.
IBC
22104
IBC
22104
IBC
22104
On left Cluster part, IBC words Supply voltage k30 on line 2 greater
remain turned on.
than 36 Volts.
The affected voltage value is
greater than the threshold.
The error could be denounced and
not monitored when starting the
engine.
Values to
be found
Notes
Print 603.93.381
22103
Measuring
conditions
ELECTRIC/ELECTRONIC SYSTEM
IBC
202
Text
on
Cluster
Component failure
DTC
FMI
Visible anomaly
Possible cause
22104
On left Cluster part, IBC words Supply voltage K30 on line 2 lower
remain turned on.
than 8 Volts.
The affected voltage value is lower
than the threshold.
The error could be denounced and
not monitored when starting the
engine.
IBC
22105
IBC
22105
IBC
22105
Measuring
conditions
Values to
be found
Notes
ELECTRIC/ELECTRONIC SYSTEM
203
IBC
Print 603.93.381
Text
on
Cluster
Component failure
DTC
FMI
Visible anomaly
Possible cause
On left Cluster part, IBC words Supply voltage K30 on line 3 lower
remain turned on.
than 8 Volts.
The affected voltage value is lower
than the threshold.
The error could be denounced and
not monitored when starting the
engine.
IBC
22106
IBC
22106
IBC
22106
Print 603.93.381
Values to
be found
Notes
22105
Measuring
conditions
ELECTRIC/ELECTRONIC SYSTEM
IBC
204
Text
on
Cluster
Component failure
DTC
FMI
Visible anomaly
Possible cause
IBC
22106
On left Cluster part, IBC words Supply voltage K30 on line 4 lower
remain turned on.
than 8 Volts.
The affected voltage value is lower
than the threshold.
The error could be denounced and
not monitored when starting the
engine (EEC1 message Engine
Starter Mode = 0001 or 0010).
IBC
22107
IBC
22107
Measuring
conditions
Values to
be found
Notes
Print 603.93.381
Text
on
Cluster
ELECTRIC/ELECTRONIC SYSTEM
205
Component failure
DTC
FMI
Visible anomaly
Possible cause
22107
IBC
22107
On left Cluster part, IBC words Supply voltage K30 on line 5 lower
remain turned on.
than 8 Volts.
The affected voltage value is lower
than the threshold.
The error could be denounced and
not monitored when starting the
engine.
22108
On the left Cluster part a lamp is The current value acquired from
displayed; a right indicator light is the unit is below the current
not turned on.
threshold (I< Is) (Is=2.7A).
One of the 3 lamps (21W) is burnt.
The error is detected only when
the supply voltage is included
between 18V and 24V.
Right direction
lights
Measuring
conditions
Values to
be found
Notes
ELECTRIC/ELECTRONIC SYSTEM
IBC
206
Text
on
Cluster
Print 603.93.381
Component failure
DTC
FMI
Visible anomaly
Possible cause
22109
Right
vehicle/trailer
direction lights
2210A
Left direction
lights
2210B
Left trailer
direction lights
2210C 5
Notes
207
Values to
be found
ELECTRIC/ELECTRONIC SYSTEM
Right trailer
direction lights
Measuring
conditions
Print 603.93.381
Text
on
Cluster
Component failure
DTC
FMI
2210D 6
Front right
parking and
clearance lights
2210E
Rear left
parking lights
2210F
22110
Possible cause
Measuring
conditions
Values to
be found
Notes
ELECTRIC/ELECTRONIC SYSTEM
Left
vehicle/trailer
direction lights
Visible anomaly
208
Text
on
Cluster
Print 603.93.381
Component failure
DTC
Front right
parking and
clearance lights
or Rear left
parking light or
Right/left
number plate
lights or Right
trailer parking
and clearance
lights
Front left
parking and
clearance lights
22111
FMI
Visible anomaly
Possible cause
22112
Rear right
parking lights
22113
22114
Internal
IBC
unit
driver
shortcircuited to ground or
overloaded
or
with
overtemperature.
One of the Body Controller
outputs (pin D16 or D15 or D14 or
D17) shortcircuited to ground or
current overloaded.
The error is detected only when
the voltage is included between
18V and 32V.
The current value acquired from
the unit is below the current
threshold (I< Is) (Is=2.7A).
One of the 2 lamps (5W) is burnt.
The error is detected only when
the supply voltage is included
between 18V and 32V.
Opencircuited IBC output D5.
The current value acquired from
the unit is below the current
threshold (I< Is) (Is=1.8A).
One of the 2 lamps (5W) is burnt.
The error is detected only when
the supply voltage is included
between 18V and 32V.
Opencircuited IBC output D7.
The current value acquired from
the unit is below the current
threshold (I< Is) (Is=1.8A).
One of the 2 lamps (5W) is burnt.
The error is detected only when
the supply voltage is included
between 18V and 32V.
Measuring
conditions
Values to
be found
Notes
Print 603.93.381
Text
on
Cluster
209
ELECTRIC/ELECTRONIC SYSTEM
IBC
DTC
Front left
parking and
clarance lights
or Rear right
parking light or
Right/left
clearance lights
or Left trailer
parking and
clearance lights
22115
Right/left
vehicle fog
lights or
right/left trailer
fog lights
FMI
Visible anomaly
Possible cause
22116
22117
Internal
IBC
unit
driver
shortcircuited to ground or
overloaded
or
with
overtemperature.
One of the Body Controller
outputs (pin D6 or D5 or D7 or
D8) shortcircuited to ground or
current overloaded.
The error is detected only when
the voltage is included between
18V and 32V.
Opencircuited IBC output pin D4.
The current value acquired by the
unit is below the current threshold
(I < Is) (Is=1.8A).
One of the 2 lamps (5W) is burnt.
The error is detected only if supply
voltage is included between 18V
and 32V.
Shortcircuited IBC outputs pins
D4 and/or D3.
The current value acquired by the
unit on pin D4 or D3 is above the
current threshold (I > Is) (Is=1.8A).
The error is detected only if supply
voltage is included between 18V
and 32V.
Measuring
conditions
Values to
be found
Notes
ELECTRIC/ELECTRONIC SYSTEM
IBC
Component failure
210
Text
on
Cluster
Print 603.93.381
Component failure
DTC
FMI
Visible anomaly
Possible cause
Opencircuited
or
positive
shortcircuited IBC output pin
D18.
The current value acquired by the
unit is below the current threshold
(I < Is) (Is=0.9A).
The lamp (5W) is burnt.
The error is detected only if supply
voltage is included between 18V
and 32V.
Opencircuited
or
positive
shortcircuited IBC output pin
D19.
The current value acquired by the
unit is below the current threshold
(I < Is) (Is=0.9A).
The lamp (5W) is burnt.
The error is detected only if supply
voltage is included between 18V
and 32V.
Ground
shortcircuited
IBC
outputs pins D18 and/or D19
and/or D20.
The current value acquired by the
unit on pin D18 or D19 is above
the current threshold (I > Is)
(Is=0.9A) or the current value
acquired by IBC on pin D10 is >
1.8A. The error is detected only if
supply voltage is included between
18V and 32V.
IBC inputs pin A35 and pin A25
both ground shortcircuited.
22118
22119
IBC
IBC
Right/left arrow
control switch
(shunt).
2211B
Values to
be found
Notes
211
ELECTRIC/ELECTRONIC SYSTEM
Measuring
conditions
Print 603.93.381
Text
on
Cluster
Component failure
DTC
FMI
Possible cause
IBC
Windscreen
wiper switches
2211C 2
IBC
Engine brake
mode selector
2211D 2
Rear transverse
differential
locking selector
2211E
IBC
Values to
be found
Notes
Print 603.93.381
Measuring
conditions
ELECTRIC/ELECTRONIC SYSTEM
Visible anomaly
212
Text
on
Cluster
Component failure
DTC
FMI
Possible cause
Measuring
conditions
Values to
be found
Notes
213
ELECTRIC/ELECTRONIC SYSTEM
Visible anomaly
Print 603.93.381
Text
on
Cluster
Component failure
DTC
FMI
Possible cause
IBC
Brake air
2212B
pressure sensor
supply
IBC
Brake air
2212B
pressure sensor
supply
Measuring
conditions
Values to
be found
Notes
ELECTRIC/ELECTRONIC SYSTEM
Visible anomaly
214
Text
on
Cluster
Print 603.93.381
Component failure
DTC
FMI
Visible anomaly
Possible cause
IBC
Brake air
2212B
pressure sensor
supply
IBC
Brake air
2212B
pressure sensor
supply
CAN
2212D 31
Measuring
conditions
Values to
be found
Notes
Print 603.93.381
Text
on
Cluster
215
ELECTRIC/ELECTRONIC SYSTEM
IC
21704
FMI
12
21706
21706
21706
21706
Visible anomaly
Possible cause
Values to
be found
Notes
Print 603.93.381
Blocked speed and level Failure or anomaly of stepper Try carrying out an after run by
indicator pointers on Cluster.
motor adjusting the pointers disconnecting Cluster 5A supply
movement.
fuses (18 and 1) for 10 seconds.
If pointers are still blocked, replace
the Cluster.
The Cluster displays an ideogram Open circuit or short circuit on fuel Verify wiring between Instrument
for level indicator.
level sensor, the error is detected Cluster and fuel level sensor.
The fuel level indicating pointer only if it is active for more than 4 Verify continuity between pin 11
on Cluster is always fixed on seconds.
(fuel level indicator signal) and
reserve or maximum.
sensor, and between pin 12 (fuel
level indicator ground) and sensor
ground. Measuring directly only on
sensor, a 210 Ohm resistance must
be detected.
Wrong oil level measure.
Voltage delta acquired as input to Verify sensor resistance: at the
Cluster (pin A14) of oil level sensor, temperature of 20C, the resistance
between first and second must be equal to 13 Ohm. Check
measures, is above the established wiring integrity between sensor
range.
and Instrument Cluster (pins A14,
A15).
Wrong oil level measure.
Voltage delta acquired as input to Verify sensor resistance: at the
Cluster (pin A14) of oil level sensor, temperature of 20C, the resistance
between first and second must be equal to 13 Ohm. Check
measures, is above the established wiring integrity between sensor
range.
and Instrument Cluster (pins A14,
A15).
Wrong oil level measure.
Voltage provided as output from Verify sensor resistance: at the
Cluster (pin A15) to oil level sensor temperature of 20C, the resistance
is above the established range.
must be equal to 13 Ohm.
Cluster
output
pin
A15 Check wiring integrity between
shortcircuited to positive or sensor and Instrument Cluster
opencircuited.
(pins A14, A15).
Wrong oil level measure.
Voltage provided as output from Verify sensor resistance: at the
Cluster (pin A15) to oil level sensor temperature of 20C, the resistance
is below the established range. must be equal to 13 Ohm.
Cluster
output
pin
A15 Check wiring integrity between
shortcircuited to ground.
sensor and Instrument Cluster
(pins A14, A15).
Measuring
conditions
ELECTRIC/ELECTRONIC SYSTEM
Stepper motor
DTC
216
Component failure
Text
on
Cluster
CAN
CAN
Component failure
DTC
FMI
Visible anomaly
Possible cause
Ambient
temperature
sensor
21707
Ambient
temperature
sensor
21707
CAN line
2170C 2
2170D 2
On Cluster the CAN text The Cluster does not receive the
remains on.
CAN message from Iveco Body
Controller 2 ECU (IBC), possible
problem on VDB CAN line,
information on IBC unit are not
transmitted to Cluster.
Values to
be found
Notes
ELECTRIC/ELECTRONIC SYSTEM
217
Measuring
conditions
Print 603.93.381
Text
on
Cluster
Component failure
DTC
FMI
CAN
2170E
CAN
2170F
Measuring
conditions
Values to
be found
Notes
Possible cause
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Visible anomaly
218
Text
on
Cluster
Component failure
DTC
FMI
CAN
ETC
(Allison
Gearbox)
21710
CAN
EBC
(Braking
System)
ABS/EBS
21711
CAN
ECAS
21712
DRIVELINE
RETARDER
21713
Visible anomaly
Possible cause
Measuring
conditions
Values to
be found
Notes
Print 603.93.381
Text
on
Cluster
ELECTRIC/ELECTRONIC SYSTEM
219
DTC
FMI
MIRROR
21714
CONTROLLER
EEPROM
12
21701
Visible anomaly
Possible cause
Measuring
conditions
Values to
be found
Notes
ELECTRIC/ELECTRONIC SYSTEM
CAN
Component failure
220
Text
on
Cluster
Print 603.93.381
FMI
Error type
Visible anomaly
Possible cause
Recommended repairs
00
00
00
00
00
00
00
00
Notes
221
ELECTRIC/ELECTRONIC SYSTEM
DTC
Print 603.93.381
Component
failure
FMI
Error type
Visible anomaly
Possible cause
Recommended repairs
00
00
00
00
00
00
00
00
00
00
00
00
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
222
Component
failure
Print 603.93.381
DTC
FMI
00
00
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Generally, in presence of
these symptoms, it is
instinctive to give up starting
the engine. By keeping on
trying, however, it is possible
to start the vehicle in order
to reach an Iveco workshop.
Print 603.93.381
Component
failure
00
00
00
223
ELECTRIC/ELECTRONIC SYSTEM
FMI
00
00
01
00
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ATMOSPHERIC
PRESSURE
DTC
224
Component
failure
Print 603.93.381
SENSORS
ATMOSPHERIC
PRESSURE
DTC
FMI
01
01
Error type
Visible anomaly
Possible cause
Recommended repairs
01
02
SENSORS
ATMOSPHERIC
PRESSURE
01
03
NO SIGNAL
SENSORS
ATMOSPHERIC
PRESSURE
01
04
SIGNAL
PLAUSIBLE
225
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ATMOSPHERIC
PRESSURE
Notes
Print 603.93.381
Component
failure
FMI
01
05
Error type
Visible anomaly
Possible cause
Recommended repairs
SENSORS
ATMOSPHERIC
PRESSURE
01
06
SENSORS
ATMOSPHERIC
PRESSURE
01
07
VALUE OVER
NORMAL LIMIT
SENSORS
ATMOSPHERIC
PRESSURE
01
08
VALUE
LIMIT
BELOW
Notes
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ATMOSPHERIC
PRESSURE
DTC
226
Component
failure
SENSORS
COOLANT
TEMPERATURE
DTC
FMI
02
00
Error type
Visible anomaly
NO
AVAILABLE Indication on the water
SYMPTOM
temperature instrument
fixed at limit stop and pilot
light lighted up.
Possible cause
Positively shortcircuited,
groundshortcircuited or
opencircuited
water
tem?perature sensor
Recommended repairs
Notes
Reading
of
measurable EDC pilot light on.
parameters: in presence of this
error, the water temperature
read on the gearcase will be
the same of the engine oil one.
Check by means of a
multimeter that the sensor is
all right (R = approx. 2,5
kOhm at 20 C) between pins
1 and 2 of sensor itself.
SENSORS
COOLANT
TEMPERATURE
02
01
Print 603.93.381
Component
failure
227
ELECTRIC/ELECTRONIC SYSTEM
FMI
02
02
Error type
Visible anomaly
Possible cause
Positively shortcircuited,
groundshortcircuited or
opencircuited
water
tem?perature sensor
Recommended repairs
Notes
Reading
of
measurable EDC pilot light on.
parameters: in presence of this
error, the water temperature
read on the gearcase will be
the same of the engine oil one.
Check by means of a
multimeter that the sensor is
all right (R = approx. 2,5
kOhm at 20 C) between pins
1 and 2 of sensor itself.
SENSORS
COOLANT
TEMPERATURE
02
03
NO SIGNAL
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
COOLANT
TEMPERATURE
DTC
228
Component
failure
Print 603.93.381
SENSORS
COOLANT
TEMPERATURE
DTC
FMI
02
04
Error type
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Positively shortcircuited,
groundshortcircuited or
opencircuited
water
tem?perature sensor
Recommended repairs
Notes
Reading
of
measurable EDC pilot light on.
parameters: in presence of this
error, the water temperature
read on the gearcase will be
the same of the engine oil one.
Check by means of a
multimeter that the sensor is
all right (R = approx. 2,5
kOhm at 20 C) between pins
1 and 2 of sensor itself.
SENSORS
COOLANT
TEMPERATURE
02
05
Print 603.93.381
Component
failure
229
ELECTRIC/ELECTRONIC SYSTEM
FMI
02
06
Error type
Visible anomaly
Possible cause
Positively shortcircuited,
groundshortcircuited or
opencircuited
water
tem?perature sensor
Recommended repairs
Notes
Reading
of
measurable EDC pilot light on.
parameters: in presence of this
error, the water temperature
read on the gearcase will be
the same of the engine oil one.
Check by means of a
multimeter that the sensor is
all right (R = approx. 2,5
kOhm at 20 C) between pins
1 and 2 of sensor itself.
SENSORS
COOLANT
TEMPERATURE
02
07
VALUE OVER
NORMAL LIMIT
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
COOLANT
TEMPERATURE
DTC
230
Component
failure
Print 603.93.381
SENSORS
ACCELERATOR
PEDAL
DTC
FMI
03
00
Error type
Visible anomaly
Possible cause
NO
AVAILABLE Power reduction
Accelerator
SYMPTOM
potentiometer
With the accelerator
shortcircuited.
pedal at rest, the engine
runs at accelerated idling
(approx. 1100 rpm.)
Pressing the pedal, the
engine progressively and
uncontrollably increases
the rpm up to approx
2600 rpm.
Recommended repairs
Notes
pedal Reading
of
measurable EDC pilot light on.
parameters
using
the
diagnostic instrument to verify
the
potentiometer
malfunctioning (the signal
doesnt vary from 0% to
100%).
Print 603.93.381
Component
failure
Check by means of a
multimeter
that
the
potentiometer is all right
(Total R. = approx. 1 kOhm)
between pins 2 and 3 of pedal
connector (component side),
check the linear resistance
variance of the potentiometer
between pins 13 and 23
between the idling and the
peak
231
ELECTRIC/ELECTRONIC SYSTEM
FMI
03
00
Error type
Visible anomaly
NO
AVAILABLE a)idling accelerated at
SYMPTOM
approx. 1100 rpm in idling
position and standard
acceleration when the
pedal is pressed.
b)standard idling but
revolution and power
reduction
when
accelerating.
Possible cause
Recommended repairs
Reading of parameters by
means of the diagnostic
instrument to determine the
faulty part of the accelerator
(potentiometer
or
idling
switch).
a)check on the component that
the idling switch is not damaged
by means of the multimeter
(ONOFF
switchover
between pins 4 and 5 of pedal
connector, component side).
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL
DTC
232
Component
failure
SENSORS
ACCELERATOR
PEDAL
03
00
Print 603.93.381
SENSORS FUEL
TEMPERATURE
DTC
FMI
03
00
Error type
Visible anomaly
Possible cause
Recommended repairs
NO
AVAILABLE No reaction noticeable on Positively shortcircuited,
SYMPTOM
behalf of the driver.
groundshortcircuited or
opencircuited
fuel
temperature sensor
Notes
Reading
of
measurable EDC pilot light off
parameters: in presence of this
error, the fuel temperature will
be fixed at 20 C
Check the sensor is all right (R
= approx. 2,5 kOhm at 20 C)
SENSORS
ACCELERATOR
PEDAL
03
01
Print 603.93.381
Component
failure
ELECTRIC/ELECTRONIC SYSTEM
233
FMI
03
01
Error type
Visible anomaly
Possible cause
Recommended repairs
Reading of parameters by
means of the diagnostic
instrument to determine the
faulty part of the accelerator
(potentiometer
or
idling
switch).
a)check on the component that
the idling switch is not damaged
by means of the multimeter
(ONOFF
switchover
between pins 4 and 5 of pedal
connector, component side).
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL
DTC
234
Component
failure
SENSORS
ACCELERATOR
PEDAL
03
01
Print 603.93.381
SENSORS FUEL
TEMPERATURE
DTC
FMI
03
01
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Reading
of
measurable EDC pilot light off
parameters: in presence of this
error, the fuel temperature will
be fixed at 20 5C
Check the sensor is all right (R =
approx. 2,5 kOhm at 20 5C)
SENSORS
ACCELERATOR
PEDAL
03
02
Print 603.93.381
Component
failure
ELECTRIC/ELECTRONIC SYSTEM
235
FMI
03
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Reading of parameters by
means of the diagnostic
instrument to determine the
faulty part of the accelerator
(potentiometer
or
idling
switch).
a)check on the component that
the idling switch is not damaged
by means of the multimeter
(ONOFF
switchover
between pins 4 and 5 of pedal
connector, component side).
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL
DTC
236
Component
failure
SENSORS
ACCELERATOR
PEDAL
03
02
Print 603.93.381
SENSORS FUEL
TEMPERATURE
DTC
FMI
03
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Reading
of
measurable EDC pilot light off
parameters: in presence of this
error, the fuel temperature will
be fixed at 20 C
Check the sensor is all right (R =
approx. 2,5 kOhm at 20 C)
SENSORS
ACCELERATOR
PEDAL
03
03
NO SIGNAL
a)idling accelerated at
approx. 1100 rpm in idling
position and standard
acceleration when the
pedal is pressed.
b)standard idling but
revolution and power
reduction
when
accelerating.
237
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
SENSORS
ACCELERATOR
PEDAL
FMI
03
03
03
03
Error type
NO SIGNAL
NO SIGNAL
Visible anomaly
Possible cause
Recommended repairs
Notes
Power reduction
No
accelerator Check by means of a EDC pilot light on.
potentiometer
signal multimeter directly on the
Accelerated idling at
(possible open circuit).
component
that
the
approx. 1100 rpm in any
potentiometer is all right
pedal position.
(Total R. = approx. 1 kOhm)
between pins 2 and 3 of
connector (component side).
Power reduction
Accelerator
potentiometer
With the accelerator
shortcircuited.
pedal at rest, the engine
runs at accelerated idling
(approx. 1100 rpm.)
Pressing the pedal, the
engine progressively and
uncontrollably increases
the rpm up to approx
2600 rpm.
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL
DTC
238
Component
failure
Check by means of a
multimeter
that
the
potentiometer is all right
(Total R. = approx. 1 kOhm)
between pins 2 and 3 of pedal
connector (component side),
check the linear resistance
variance of the potentiometer
between pins 13 and 23
between the idling and the
peak
Print 603.93.381
SENSORS FUEL
TEMPERATURE
DTC
FMI
03
03
Error type
NO SIGNAL
Visible anomaly
Possible cause
Recommended repairs
Notes
Reading
of
measurable EDC pilot light off
parameters: in presence of this
error, the fuel temperature will
be fixed at 20 C
Check the sensor is all right (R =
approx. 2,5 kOhm at 20 C)
SENSORS
ACCELERATOR
PEDAL
03
04
SIGNAL
PLAUSIBLE
239
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
SENSORS
ACCELERATOR
PEDAL
FMI
03
04
03
04
Error type
SIGNAL
PLAUSIBLE
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
No
accelerator Check by means of a EDC pilot light on.
potentiometer
signal multimeter directly on the
Accelerated idling at
(possible open circuit).
component
that
the
approx. 1100 rpm in any
potentiometer is all right
pedal position.
(Total R. = approx. 1 kOhm)
between pins 2 and 3 of
connector (component side).
Accelerator
potentiometer
With the accelerator
shortcircuited.
pedal at rest, the engine
runs at accelerated idling
(approx. 1100 rpm.)
Pressing the pedal, the
engine progressively and
uncontrollably increases
the rpm up to approx
2600 rpm.
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL
DTC
240
Component
failure
Check by means of a
multimeter
that
the
potentiometer is all right
(Total R. = approx. 1 kOhm)
between pins 2 and 3 of pedal
connector (component side),
check the linear resistance
variance of the potentiometer
between pins 13 and 23
between the idling and the
peak
Print 603.93.381
SENSORS
ACCELERATOR
PEDAL
DTC
FMI
03
05
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
pedal Reading
of
measurable EDC pilot light on.
parameters
using
the
diagnostic instrument to verify
the
potentiometer
malfunctioning (the signal
doesnt vary from 0% to
100%).
Print 603.93.381
Component
failure
Check by means of a
multimeter
that
the
potentiometer is all right
(Total R. = approx. 1 kOhm)
between pins 2 and 3 of pedal
connector (component side),
check the linear resistance
variance of the potentiometer
between pins 13 and 23
between the idling and the
peak
241
ELECTRIC/ELECTRONIC SYSTEM
FMI
03
05
Error type
Visible anomaly
Possible cause
Recommended repairs
Reading of parameters by
means of the diagnostic
instrument to determine the
faulty part of the accelerator
(potentiometer
or
idling
switch).
a)check on the component that
the idling switch is not damaged
by means of the multimeter
(ONOFF
switchover
between pins 4 and 5 of pedal
connector, component side).
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL
DTC
242
Component
failure
SENSORS
ACCELERATOR
PEDAL
03
05
Print 603.93.381
SENSORS
ACCELERATOR
PEDAL
DTC
FMI
03
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
pedal Reading
of
measurable EDC pilot light on.
parameters
using
the
diagnostic instrument to verify
the
potentiometer
malfunctioning (the signal
doesnt vary from 0% to
100%).
Print 603.93.381
Component
failure
Check by means of a
multimeter
that
the
potentiometer is all right
(Total R. = approx. 1 kOhm)
between pins 2 and 3 of pedal
connector (component side),
check the linear resistance
variance of the potentiometer
between pins 13 and 23
between the idling and the
peak
243
ELECTRIC/ELECTRONIC SYSTEM
FMI
03
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Reading of parameters by
means of the diagnostic
instrument to determine the
faulty part of the accelerator
(potentiometer
or
idling
switch).
a)check on the component that
the idling switch is not damaged
by means of the multimeter
(ONOFF
switchover
between pins 4 and 5 of pedal
connector, component side).
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL
DTC
244
Component
failure
SENSORS
ACCELERATOR
PEDAL
03
06
Print 603.93.381
SENSORS
ACCELERATOR
PEDAL
DTC
FMI
Error type
03
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Possible cause
Accelerator
potentiometer
With the accelerator
shortcircuited.
pedal at rest, the engine
runs at accelerated idling
(approx. 1100 rpm.)
Pressing the pedal, the
engine progressively and
uncontrollably increases
the rpm up to approx
2600 rpm.
Recommended repairs
Notes
pedal Reading
of
measurable EDC pilot light on.
parameters
using
the
diagnostic instrument to verify
the
potentiometer
malfunctioning (the signal
doesnt vary from 0% to
100%).
Print 603.93.381
Component
failure
Check by means of a
multimeter
that
the
potentiometer is all right
(Total R. = approx. 1 kOhm)
between pins 2 and 3 of pedal
connector (component side),
check the linear resistance
variance of the potentiometer
between pins 13 and 23
between the idling and the
peak
245
ELECTRIC/ELECTRONIC SYSTEM
FMI
Error type
03
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL
DTC
246
Component
failure
SENSORS
ACCELERATOR
PEDAL
03
07
VALUE OVER
NORMAL LIMIT
Print 603.93.381
SENSORS
COOLANT
TEMPERATURE
DTC
FMI
03
08
Error type
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Positively shortcircuited,
groundshortcircuited or
opencircuited
water
tem?perature sensor
Recommended repairs
Notes
Reading
of
measurable EDC pilot light on.
parameters: in presence of this
error, the water temperature
read on the gearcase will be
the same of the engine oil one.
Check by means of a
multimeter that the sensor is
all right (R = approx. 2,5
kOhm at 20 C) between pins
1 and 2 of sensor itself.
SENSORS
ACCELERATOR
PEDAL
03
08
VALUE
LIMIT
BELOW
Print 603.93.381
Component
failure
247
FMI
03
08
Error type
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Accelerator
potentiometer
With the accelerator
shortcircuited.
pedal at rest, the engine
runs at accelerated idling
(approx. 1100 rpm.)
Pressing the pedal, the
engine progressively and
uncontrollably increases
the rpm up to approx
2600 rpm.
Recommended repairs
Notes
pedal Reading
of
measurable EDC pilot light on.
parameters
using
the
diagnostic instrument to verify
the
potentiometer
malfunctioning (the signal
doesnt vary from 0% to
100%).
Check by means of a
multimeter
that
the
potentiometer is all right
(Total R. = approx. 1 kOhm)
between pins 2 and 3 of pedal
connector (component side),
check the linear resistance
variance of the potentiometer
between pins 13 and 23
between the idling and the
peak
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL
DTC
248
Component
failure
Print 603.93.381
SENSORS
ACCELERATOR
PEDAL
DTC
FMI
03
08
Error type
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
04
00
NO
AVAILABLE Significant
SYMPTOM
reduction
249
ELECTRIC/ELECTRONIC SYSTEM
SENSORS FUEL
PRESSURE
SENSORS FUEL
PRESSURE
SENSORS FUEL
PRESSURE
FMI
04
01
04
04
02
03
Error type
Visible anomaly
NO SIGNAL
Significant
reduction
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS FUEL
PRESSURE
DTC
250
Component
failure
Print 603.93.381
SENSORS FUEL
TEMPERATURE
DTC
FMI
04
04
Error type
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
Reading
of
measurable EDC pilot light off
parameters: in presence of this
error, the fuel temperature
will be fixed at 20 C
Check the sensor is all right (R
= approx. 2,5 kOhm at 20 C)
SENSORS FUEL
PRESSURE
SENSORS FUEL
TEMPERATURE
04
04
04
05
SIGNAL
PLAUSIBLE
NOT Significant
reduction
Print 603.93.381
Component
failure
251
ELECTRIC/ELECTRONIC SYSTEM
SENSORS FUEL
TEMPERATURE
FMI
04
05
04
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS FUEL
PRESSURE
DTC
252
Component
failure
SENSORS FUEL
PRESSURE
04
06
SENSORS FUEL
TEMPERATURE
DTC
FMI
Error type
04
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Possible cause
Recommended repairs
Notes
Reading
of
measurable EDC pilot light off
parameters: in presence of this
error, the fuel temperature
will be fixed at 20 C
Check the sensor is all right (R
= approx. 2,5 kOhm at 20 C)
SENSORS FUEL
PRESSURE
SENSORS FUEL
TEMPERATURE
04
04
07
08
VALUE OVER
NORMAL LIMIT
VALUE
LIMIT
BELOW
THE Significant
reduction
Print 603.93.381
Component
failure
253
ELECTRIC/ELECTRONIC SYSTEM
SENSORS OIL
TEMPERATURE
SIGNAL
FMI
04
08
05
00
Error type
VALUE
LIMIT
BELOW
Visible anomaly
THE Significant
reduction
Possible cause
Recommended repairs
NO
AVAILABLE No reaction noticeable on Oil temperature
SYMPTOM
behalf of the driver.
shortcircuited
opencircuited
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS FUEL
PRESSURE
DTC
254
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 1
SENSORS OIL
TEMPERATURE
SIGNAL
DTC
FMI
05
00
05
01
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
NO
AVAILABLE The engine runs at 3 (5) Electrical part of cylinder n1 Check that the nuts fixing the EDC pilot light on.
SYMPTOM
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also the error 5.7 can be
If the solenoid valve is all right,
stored.
check the wiring on the
cylinder
head
between
connector 1 pins 3 and 4 and
electroinjector.
Print 603.93.381
Component
failure
255
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 1
FMI
05
01
05
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SHORT CIRCUIT TO The engine runs at 3 (5) Electrical part of cylinder n1 Check that the nuts fixing the EDC pilot light on.
POSITIVE
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also the error 5.7 can be
If the solenoid valve is all right,
stored.
check the wiring on the
cylinder
head
between
connector 1 pins 3 and 4 and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 1
DTC
256
Component
failure
Print 603.93.381
SENSORS OIL
TEMPERATURE
SIGNAL
ENGINE
INJECTOR
CYLINDER 1
DTC
FMI
05
02
05
03
Error type
Visible anomaly
Possible cause
NO SIGNAL
Recommended repairs
sensor Reading
of
measurable
or parameters: in presence of this
error,
the
engine
oil
temperature will be fixed at
120 C.
Notes
Print 603.93.381
Component
failure
257
ELECTRIC/ELECTRONIC SYSTEM
SENSORS OIL
TEMPERATURE
SIGNAL
FMI
05
03
05
04
Error type
NO SIGNAL
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
sensor Reading
of
measurable
or parameters: in presence of this
error,
the
engine
oil
temperature will be fixed at
120 C.
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS OIL
TEMPERATURE
SIGNAL
DTC
258
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 1
SENSORS OIL
TEMPERATURE
SIGNAL
DTC
FMI
05
04
05
05
Error type
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
NOT The engine runs at 3 (5) Electrical part of cylinder n1 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also the error 5.7 can be
If the solenoid valve is all right,
stored.
check the wiring on the
cylinder
head
between
connector 1 pins 3 and 4 and
electroinjector.
Print 603.93.381
Component
failure
259
ELECTRIC/ELECTRONIC SYSTEM
SENSORS OIL
TEMPERATURE
SIGNAL
FMI
05
05
05
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SUPPLY OVER THE The engine runs at 3 (5) Electrical part of cylinder n1 Check that the nuts fixing the EDC pilot light on.
NORMAL RANGE
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also the error 5.7 can be
If the solenoid valve is all right,
stored.
check the wiring on the
cylinder
head
between
connector 1 pins 3 and 4 and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 1
DTC
260
Component
failure
Print 603.93.381
SENSORS OIL
TEMPERATURE
SIGNAL
SENSORS OIL
TEMPERATURE
SIGNAL
DTC
FMI
Error type
05
07
VALUE OVER
NORMAL LIMIT
05
08
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
sensor Reading
of
measurable
or parameters: in presence of this
error,
the
engine
oil
temperature will be fixed at
120 C.
Notes
Print 603.93.381
Component
failure
261
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 3
FMI
06
00
06
00
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
NO
AVAILABLE The engine runs at 5 Electrical part of cylinder n5 Check that the nuts fixing the EDC pilot light on.
SYMPTOM
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 3
Check the injector solenoid cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.8 can be stored
If the solenoid valve is all right,
.
check the wiring on cylinder
head between connector 3
pins
1
and
2
and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 5
DTC
262
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 5
ENGINE
INJECTOR
CYLINDER 3
DTC
FMI
06
01
06
01
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SHORT CIRCUIT TO The engine runs at 5 Electrical part of cylinder n5 Check that the nuts fixing the EDC pilot light on.
POSITIVE
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 3
Check the injector solenoid cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.8 can be stored
If the solenoid valve is all right,
.
check the wiring on cylinder
head between connector 3
pins
1
and
2
and
electroinjector.
263
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 5
FMI
06
02
06
03
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
OPEN CIRCUIT OR The engine runs at 5 Electrical part of cylinder n5 Check that the nuts fixing the EDC pilot light on.
SHORT CIRCUIT TO cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
GROUND
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 3
Check the injector solenoid cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.8 can be stored
If the solenoid valve is all right,
.
check the wiring on cylinder
head between connector 3
pins
1
and
2
and
electroinjector.
NO SIGNAL
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 5
DTC
264
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 5
ENGINE
INJECTOR
CYLINDER 5
DTC
FMI
06
04
06
05
Error type
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
NOT The engine runs at 5 Electrical part of cylinder n5 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 3
Check the injector solenoid cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.8 can be stored
If the solenoid valve is all right,
.
check the wiring on cylinder
head between connector 3
pins
1
and
2
and
electroinjector.
265
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 5
FMI
06
06
06
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SUPPLY BELOW THE The engine runs at 3 (5) Electrical part of cylinder n1 Check that the nuts fixing the EDC pilot light on.
RANGE
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also the error 5.7 can be
If the solenoid valve is all right,
stored.
check the wiring on the
cylinder
head
between
connector 1 pins 3 and 4 and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 1
DTC
266
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 1
ENGINE
INJECTOR
CYLINDER 5
DTC
FMI
Error type
06
07
VALUE OVER
NORMAL LIMIT
06
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Possible cause
Recommended repairs
Notes
THE The engine runs at 3 (5) Electrical part of cylinder n1 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also the error 5.7 can be
If the solenoid valve is all right,
stored.
check the wiring on the
cylinder
head
between
connector 1 pins 3 and 4 and
electroinjector.
267
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 5
FMI
06
08
06
08
Error type
VALUE
LIMIT
VALUE
LIMIT
BELOW
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
THE The engine runs at 3 (5) Electrical part of cylinder n1 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also the error 5.7 can be
If the solenoid valve is all right,
stored.
check the wiring on the
cylinder
head
between
connector 1 pins 3 and 4 and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 1
DTC
268
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 6
ENGINE
INJECTOR
CYLINDER 6
DTC
FMI
07
00
07
01
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
NO
AVAILABLE The engine runs at 5 Electrical part of cylinder n6 Check that the nuts fixing the EDC pilot light on.
SYMPTOM
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 3
Check the injector solenoid cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.8 can be stored
If the solenoid valve is all right,
.
check the wiring on cylinder
head between connector 3
pins
1
and
2
and
electroinjector.
269
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 6
FMI
07
02
07
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
OPEN CIRCUIT OR The engine runs at 3 (5) Electrical part of cylinder n3 Check that the nuts fixing the EDC pilot light on.
SHORT CIRCUIT TO cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
GROUND
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (6 cylinders)
If the solenoid valve is all right,
or 5.8 (4 cylinders) can be
check the wiring on cylinder
stored .
head between connector 2
pins
3
and
4
and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 3
DTC
270
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 3
ENGINE
INJECTOR
CYLINDER 6
DTC
FMI
07
03
07
03
Error type
NO SIGNAL
NO SIGNAL
Visible anomaly
Possible cause
Recommended repairs
Notes
The engine runs at 3 (5) Electrical part of cylinder n3 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (6 cylinders)
If the solenoid valve is all right,
or 5.8 (4 cylinders) can be
check the wiring on cylinder
stored .
head between connector 2
pins
3
and
4
and
electroinjector.
271
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 6
FMI
07
04
07
04
Error type
SIGNAL
PLAUSIBLE
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
NOT The engine runs at 3 (5) Electrical part of cylinder n3 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (6 cylinders)
If the solenoid valve is all right,
or 5.8 (4 cylinders) can be
check the wiring on cylinder
stored .
head between connector 2
pins
3
and
4
and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 3
DTC
272
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 3
ENGINE
INJECTOR
CYLINDER 6
DTC
FMI
07
05
07
05
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SUPPLY OVER THE The engine runs at 3 (5) Electrical part of cylinder n3 Check that the nuts fixing the EDC pilot light on.
NORMAL RANGE
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (6 cylinders)
If the solenoid valve is all right,
or 5.8 (4 cylinders) can be
check the wiring on cylinder
stored .
head between connector 2
pins
3
and
4
and
electroinjector.
273
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 6
FMI
07
06
07
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SUPPLY BELOW THE The engine runs at 3 (5) Electrical part of cylinder n3 Check that the nuts fixing the EDC pilot light on.
RANGE
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (6 cylinders)
If the solenoid valve is all right,
or 5.8 (4 cylinders) can be
check the wiring on cylinder
stored .
head between connector 2
pins
3
and
4
and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 3
DTC
274
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 3
ENGINE
INJECTOR
CYLINDER 6
DTC
FMI
Error type
07
07
VALUE OVER
NORMAL LIMIT
07
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Possible cause
Recommended repairs
Notes
THE The engine runs at 3 (5) Electrical part of cylinder n3 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (6 cylinders)
If the solenoid valve is all right,
or 5.8 (4 cylinders) can be
check the wiring on cylinder
stored .
head between connector 2
pins
3
and
4
and
electroinjector.
275
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 4
FMI
07
08
08
00
Error type
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
THE The engine runs at 3 (5) Electrical part of cylinder n3 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (6 cylinders)
If the solenoid valve is all right,
or 5.8 (4 cylinders) can be
check the wiring on cylinder
stored .
head between connector 2
pins
3
and
4
and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 3
DTC
276
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 2
ENGINE
INJECTOR
CYLINDER 4
DTC
FMI
08
00
08
01
Error type
Visible anomaly
Possible cause
NO
AVAILABLE The engine runs at 3 (5) Cylinder
n2
SYMPTOM
cylinders.
electrical
shortcircuited
opencircuited.
Recommended repairs
Notes
injector Check that the nuts fixing the EDC pilot light on.
part cables on the injector solenoid
It
is
possible
that
or valve are properly tightened to
immediately afterwards the
the torque of 1,5 Nm
engine keeps on running at 2
Check the continuity and (3) cylinders, because the
resistance of the injector injectors are driven by two
solenoid valve (R = approx. power stages. In this case
0,5 Ohm)
also error 5.7 (6 cylinders)
or 5.8 (4 cylinders) can be
If the solenoid valve is all right,
stored.
check the wiring on cylinder
head between connector 1
pins
1
and
2
and
electroinjector
277
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 2
FMI
08
01
08
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
injector Check that the nuts fixing the EDC pilot light on.
part cables on the injector solenoid
It
is
possible
that
or valve are properly tightened to
immediately afterwards the
the torque of 1,5 Nm
engine keeps on running at 2
Check the continuity and (3) cylinders, because the
resistance of the injector injectors are driven by two
solenoid valve (R = approx. 0,5 power stages. In this case
Ohm)
also error 5.7 (6 cylinders)
or 5.8 (4 cylinders) can be
If the solenoid valve is all right,
stored.
check the wiring on cylinder
head between connector 1 pins
1 and 2 and electroinjector
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 2
DTC
278
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 4
ENGINE
INJECTOR
CYLINDER 2
DTC
FMI
08
02
08
03
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
OPEN CIRCUIT OR The engine runs at 3 (5) Electrical part of cylinder n4 Check that the nuts fixing the EDC pilot light on.
SHORT CIRCUIT TO cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
GROUND
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (4 cylinders)
If the solenoid valve is all right,
or 5.8 (6 cylinders) can be
check the wiring on cylinder
stored .
head between connector 3
pins
1
and
2
and
electroinjector.
NO SIGNAL
279
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 2
FMI
08
03
08
04
Error type
NO SIGNAL
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
The engine runs at 3 (5) Electrical part of cylinder n4 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
If the solenoid valve is all right, also error 5.7 (4 cylinders)
check the wiring on cylinder or 5.8 (6 cylinders) can be
head between connector 3 pins stored .
1 and 2 and electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 4
DTC
280
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 2
ENGINE
INJECTOR
CYLINDER 2
DTC
FMI
08
05
08
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
injector Check that the nuts fixing the EDC pilot light on.
part cables on the injector solenoid
It
is
possible
that
or valve are properly tightened to
immediately afterwards the
the torque of 1,5 Nm
engine keeps on running at 2
Check the continuity and (3) cylinders, because the
resistance of the injector injectors are driven by two
solenoid valve (R = approx. 0,5 power stages. In this case
Ohm)
also error 5.7 (6 cylinders)
or 5.8 (4 cylinders) can be
If the solenoid valve is all right,
stored.
check the wiring on cylinder
head between connector 1 pins
1 and 2 and electroinjector
281
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 6
FMI
Error type
08
07
VALUE OVER
NORMAL LIMIT
08
08
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
injector Check that the nuts fixing the EDC pilot light on.
part cables on the injector solenoid
It
is
possible
that
or valve are properly tightened to
immediately afterwards the
the torque of 1,5 Nm
engine keeps on running at 2
Check the continuity and (3) cylinders, because the
resistance of the injector injectors are driven by two
solenoid valve (R = approx. 0,5 power stages. In this case
Ohm)
also error 5.7 (6 cylinders)
or 5.8 (4 cylinders) can be
If the solenoid valve is all right,
stored.
check the wiring on cylinder
head between connector 1 pins
1 and 2 and electroinjector
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 2
DTC
282
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 2
DTC
FMI
08
08
ENGINE
ENGINE
OVERSPEED
09
00
ENGINE
ENGINE
OVERSPEED
09
01
Error type
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
injector Check that the nuts fixing the EDC pilot light on.
part cables on the injector solenoid
It
is
possible
that
or valve are properly tightened to
immediately afterwards the
the torque of 1,5 Nm
engine keeps on running at 2
Check the continuity and (3) cylinders, because the
resistance of the injector injectors are driven by two
solenoid valve (R = approx. power stages. In this case
0,5 Ohm)
also error 5.7 (6 cylinders)
or 5.8 (4 cylinders) can be
If the solenoid valve is all right,
stored.
check the wiring on cylinder
head between connector 1
pins
1
and
2
and
electroinjector
283
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
ENGINE
INJECTOR
CYLINDER 4
FMI
09
04
09
05
Error type
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
NOT The engine runs at 3 (5) Electrical part of cylinder n4 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (4 cylinders)
If the solenoid valve is all right,
or 5.8 (6 cylinders) can be
check the wiring on cylinder
stored .
head between connector 3
pins
1
and
2
and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 4
DTC
284
Component
failure
Print 603.93.381
ENGINE
INJECTOR
CYLINDER 4
ENGINE
INJECTOR
CYLINDER 4
DTC
FMI
09
06
09
07
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SUPPLY BELOW THE The engine runs at 3 (5) Electrical part of cylinder n4 Check that the nuts fixing the EDC pilot light on.
RANGE
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (4 cylinders)
If the solenoid valve is all right,
or 5.8 (6 cylinders) can be
check the wiring on cylinder
stored .
head between connector 3
pins
1
and
2
and
electroinjector.
VALUE OVER
NORMAL LIMIT
285
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
SENSORS
ACCELERATOR
PEDAL/BRAKE
PEDAL SUSPECT
FMI
09
08
0A
00
Error type
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
THE The engine runs at 3 (5) Electrical part of cylinder n4 Check that the nuts fixing the EDC pilot light on.
cylinders.
injector shortcircuited or cables on the injector solenoid
It
is
possible
that
valve are properly tightened to
opencircuited.
immediately afterwards the
the torque of 1,5 Nm.
engine keeps on running at 2
Check the injector solenoid (3) cylinders, because the
valve continuity and resistance injectors are driven by two
(R = approx. 0,5 Ohm).
power stages. In this case
also error 5.7 (4 cylinders)
If the solenoid valve is all right,
or 5.8 (6 cylinders) can be
check the wiring on cylinder
stored .
head between connector 3
pins
1
and
2
and
electroinjector.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
INJECTOR
CYLINDER 4
DTC
286
Component
failure
Print 603.93.381
SENSORS
ACCELERATOR
PEDAL/BRAKE
PEDAL SUSPECT
SENSORS
ACCELERATOR
PEDAL/BRAKE
PEDAL SUSPECT
DTC
FMI
0A
01
0A
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
287
Print 603.93.381
Component
failure
SENSORS
ACCELERATOR
PEDAL/BRAKE
PEDAL SUSPECT
FMI
0A
03
0A
04
Error type
NO SIGNAL
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL/BRAKE
PEDAL SUSPECT
DTC
288
Component
failure
SENSORS
ACCELERATOR
PEDAL/BRAKE
PEDAL SUSPECT
SENSORS
ACCELERATOR
PEDAL/BRAKE
PEDAL SUSPECT
DTC
FMI
0A
05
0A
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
289
Print 603.93.381
Component
failure
SENSORS
ACCELERATOR
PEDAL/BRAKE
PEDAL SUSPECT
FMI
Error type
0A
07
VALUE OVER
NORMAL LIMIT
0A
08
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
ACCELERATOR
PEDAL/BRAKE
PEDAL SUSPECT
DTC
290
Component
failure
SENSORS
BOOST
PRESSURE
SENSORS
BOOST
PRESSURE
SENSORS
BOOST
PRESSURE
DTC
FMI
0B
00
0B
0B
01
02
Error type
Visible anomaly
Possible cause
NO
AVAILABLE No reaction noticeable on Positively shortcircuited,
SYMPTOM
behalf of the driver.
groundshortcircuited or
opencircuited air pressure
Power reduction (only in
sensor on suction manifold,
the software version for
or sensor supplied by a
engine with singlestage
current that exceeds the
overpressure valve).
minimum or maximum limit
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
overcharging pressure will be
fixed at 1600 mbar. Check the
wiring between the sensor
connector (wiring side) pin 3
and connector EDC pin C10,
between sensor connector
(wiring side) pin 4 and
connector EDC pin C28.
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
overcharging pressure will be
fixed at 1600 mbar. Check the
wiring between the sensor
connector (wiring side) pin 3
and connector EDC pin C10,
between sensor connector
(wiring side) pin 4 and
connector EDC pin C28.
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
overcharging pressure will be
fixed at 1600 mbar. Check the
wiring between the sensor
connector (wiring side) pin 3
and connector EDC pin C10,
between sensor connector
(wiring side) pin 4 and
connector EDC pin C28.
Notes
291
ELECTRIC/ELECTRONIC SYSTEM
Positively shortcircuited,
groundshortcircuited or
opencircuited air pressure
sensor on suction manifold,
or sensor supplied by a
current that exceeds the
minimum or maximum limit
Recommended repairs
Print 603.93.381
Component
failure
SENSORS
BOOST
PRESSURE
SENSORS
BOOST
PRESSURE
FMI
0B
03
0B
0B
04
05
Error type
NO SIGNAL
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Print 603.93.381
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
overcharging pressure will be
fixed at 1600 mbar. Check the
wiring between the sensor
connector (wiring side) pin 3
and connector EDC pin C10,
between sensor connector
(wiring side) pin 4 and
connector EDC pin C28.
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
overcharging pressure will be
fixed at 1600 mbar. Check the
wiring between the sensor
connector (wiring side) pin 3
and connector EDC pin C10,
between sensor connector
(wiring side) pin 4 and
connector EDC pin C28.
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
overcharging pressure will be
fixed at 1600 mbar. Check the
wiring between the sensor
connector (wiring side) pin 3
and connector EDC pin C10,
between sensor connector
(wiring side) pin 4 and
connector EDC pin C28.
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
BOOST
PRESSURE
DTC
292
Component
failure
SENSORS
BOOST
PRESSURE
SENSORS
BOOST
PRESSURE
SENSORS
BOOST
PRESSURE
DTC
FMI
0B
06
0B
0B
07
08
Error type
Visible anomaly
Possible cause
VALUE
LIMIT
BELOW
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
overcharging pressure will be
fixed at 1600 mbar. Check the
wiring between the sensor
connector (wiring side) pin 3
and connector EDC pin C10,
between sensor connector
(wiring side) pin 4 and
connector EDC pin C28.
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
overcharging pressure will be
fixed at 1600 mbar. Check the
wiring between the sensor
connector (wiring side) pin 3
and connector EDC pin C10,
between sensor connector
(wiring side) pin 4 and
connector EDC pin C28.
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
overcharging pressure will be
fixed at 1600 mbar. Check the
wiring between the sensor
connector (wiring side) pin 3
and connector EDC pin C10,
between sensor connector
(wiring side) pin 4 and
connector EDC pin C28.
Notes
293
ELECTRIC/ELECTRONIC SYSTEM
VALUE OVER
NORMAL LIMIT
Recommended repairs
Print 603.93.381
Component
failure
FMI
SENSORS
CRANKSHAFT
0F
00
SENSORS
CRANKSHAFT
0F
03
SENSORS
CRANKSHAFT
0F
04
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
NO
AVAILABLE The engine doesnt start. Drive shaft sensor: lack of Check the cleaning and the EDC pilot light on.
SYMPTOM
Light power reduction.
signal or unfeasible signal
proper fastening of the sensor.
Error
6.1 is always
Check the phonic wheel is not combined with 6.3
damaged and verify its cleaning.
The engine doesnt start
Check the sensor is all right (R = because after a few
approx. 920 Ohm).
revolutions the gearcase
disables the starter.
If the sensor is not damaged,
check the wiring between the
sensor connector (wiring side)
pin 1 and connector EDC pin
C25, between sensor connector
(wiring side) pin 2 and
connector EDC pin C24.
NO SIGNAL
The engine doesnt start. Drive shaft sensor: lack of Check the cleaning and the EDC pilot light on.
proper fastening of the sensor.
Light power reduction.
signal or unfeasible signal
Error
6.1 is always
Check the phonic wheel is not combined with 6.3
damaged and verify its cleaning.
The engine doesnt start
Check the sensor is all right (R = because after a few
approx. 920 Ohm).
revolutions the gearcase
If the sensor is not damaged, disables the starter.
check the wiring between the
sensor connector (wiring side)
pin 1 and connector EDC pin
C25, between sensor connector
(wiring side) pin 2 and
connector EDC pin C24.
SIGNAL
NOT The engine doesnt start. Drive shaft sensor: lack of Check the cleaning and the EDC pilot light on.
proper fastening of the sensor.
PLAUSIBLE
Light power reduction.
signal or unfeasible signal
Error
6.1 is always
Check the phonic wheel is not combined with 6.3
damaged and verify its cleaning.
The engine doesnt start
Check the sensor is all right (R = because after a few
approx. 920 Ohm).
revolutions the gearcase
If the sensor is not damaged, disables the starter.
check the wiring between the
sensor connector (wiring side)
pin 1 and connector EDC pin
C25, between sensor connector
(wiring side) pin 2 and
connector EDC pin C24.
ELECTRIC/ELECTRONIC SYSTEM
DTC
294
Component
failure
DTC
FMI
SENSORS
CRANKSHAFT
0F
05
SENSORS
CAMSHAFT
10
00
SENSORS
CAMSHAFT
10
03
Error type
NOISY
WUP 1
Visible anomaly
Possible cause
Recommended repairs
Notes
SIGNAL
ON The engine doesnt start. Drive shaft sensor: lack of Check the cleaning and the EDC pilot light on.
Light power reduction.
signal or unfeasible signal
proper fastening of the sensor.
Error
6.1 is always
Check the phonic wheel is not combined with 6.3
damaged and verify its cleaning.
The engine doesnt start
Check the sensor is all right (R = because after a few
approx. 920 Ohm).
revolutions the gearcase
disables the starter.
If the sensor is not damaged,
check the wiring between the
sensor connector (wiring side)
pin 1 and connector EDC pin
C25, between sensor connector
(wiring side) pin 2 and
connector EDC pin C24.
NO
AVAILABLE Difficult starting in every Distribution shaft sensor: Check the correct sensor EDC pilot light on.
SYMPTOM
condition.
lack of signal or unfeasible fastening and its cleaning.
This error is always
signal
False injections and grade
Check that the sensor is not combined with 6.3.
of smoke at the exhaust
damaged (R = approx. 890
during starting.
Ohm).
NO SIGNAL
295
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
Component
failure
SENSORS
CRANKSHAFT
SENSORS
VEHICLE SPEED
FMI
10
04
10
11
06
00
Error type
SIGNAL
PLAUSIBLE
NOISY
WUP 2
SIGNAL
Visible anomaly
Possible cause
NO
AVAILABLE The speedometer doesnt
SYMPTOM
work (if the failure is
between the sensor and
the speedometer)
Cruise Control doesnt
work.
Recommended repairs
Notes
always
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
CAMSHAFT
DTC
296
Component
failure
SENSORS
VEHICLE SPEED
DTC
FMI
11
01
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
297
FMI
11
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
VEHICLE SPEED
DTC
298
Component
failure
Print 603.93.381
SENSORS
VEHICLE SPEED
DTC
FMI
11
03
Error type
NO SIGNAL
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
299
FMI
11
04
Error type
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
VEHICLE SPEED
DTC
300
Component
failure
Print 603.93.381
SENSORS
VEHICLE SPEED
DTC
FMI
11
05
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
301
FMI
11
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
VEHICLE SPEED
DTC
302
Component
failure
Print 603.93.381
SENSORS
VEHICLE SPEED
DTC
FMI
Error type
11
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
VOLTAGE
12
00
VOLTAGE
12
01
12
02
303
ELECTRIC/ELECTRONIC SYSTEM
VOLTAGE
Idling
accelerated
(depending upon the
detected voltage), up to a
maximum of 200 rpm
over the standard idling
speed.
Idling
accelerated
(depending upon the
detected voltage), up to a
maximum of 200 rpm
over the standard idling
speed.
FMI
12
08
Error type
VALUE
LIMIT
BELOW
Visible anomaly
13
ELECTRONIC
CONTROL
UNIT SENSOR
POWER SUPPLY
13
ELECTRONIC
CONTROL
UNIT SENSOR
POWER SUPPLY
13
00
01
02
NO
AVAILABLE Anomalous
engine
SYMPTOM
operation
due
to
incorrectly
powered
sensors. Reduced power.
SHORT CIRCUIT TO Anomalous
engine
POSITIVE
operation
due
to
incorrectly
powered
sensors. Reduced power.
Recommended repairs
Notes
Print 603.93.381
ELECTRONIC
CONTROL
UNIT SENSOR
POWER SUPPLY
Possible cause
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
VEHICLE SPEED
DTC
304
Component
failure
DTC
FMI
ELECTRONIC
CONTROL
UNIT SENSOR
POWER SUPPLY
13
03
NO SIGNAL
ELECTRONIC
CONTROL
UNIT SENSOR
POWER SUPPLY
13
04
SIGNAL
PLAUSIBLE
ELECTRONIC
CONTROL
UNIT SENSOR
POWER SUPPLY
13
05
ELECTRONIC
CONTROL
UNIT SENSOR
POWER SUPPLY
13
06
VOLTAGE
13
07
VOLTAGE HIGH
13
VOLTAGE
13
07
08
VALUE OVER
NORMAL LIMIT
VOLTAGE LOW
Visible anomaly
Possible cause
Anomalous
engine Sensor power circuit fault in
operation
due
to ECU.
incorrectly
powered
sensors. Reduced power.
NOT Anomalous
engine Sensor power circuit fault in
operation
due
to ECU.
incorrectly
powered
sensors. Reduced power.
Idling
accelerated
(depending upon the
detected voltage), up to a
maximum of 200 rpm
over the standard idling
speed.
THE Anomalous
engine
operation
due
to
incorrectly
powered
sensors. Reduced power.
Notes
305
Idling
accelerated
(depending upon the
detected voltage), up to a
maximum of 200 rpm
over the standard idling
speed.
Recommended repairs
ELECTRIC/ELECTRONIC SYSTEM
ELECTRONIC
CONTROL
UNIT SENSOR
POWER SUPPLY
Error type
Print 603.93.381
Component
failure
FMI
ELECTRONIC
CONTROL
UNIT SENSOR
POWER SUPPLY
13
08
SWITCH
BRAKE PEDAL
14
SWITCH
BRAKE PEDAL
14
00
01
Error type
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
THE Anomalous
engine Sensor power circuit fault in
operation
due
to ECU.
incorrectly
powered
sensors. Reduced power.
NO
AVAILABLE Possible lack of stop lights Unfeasible brake switches
SYMPTOM
operationPossible lack of signals between primary and
cruise
con?trol/power secondary
takeoff operation
Recommended repairs
Print 603.93.381
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
306
Component
failure
SWITCH
BRAKE PEDAL
DTC
FMI
14
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
SWITCH
BRAKE PEDAL
14
03
NO SIGNAL
307
FMI
14
04
Error type
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
SWITCH
BRAKE PEDAL
14
05
ELECTRIC/ELECTRONIC SYSTEM
SWITCH
BRAKE PEDAL
DTC
308
Component
failure
Print 603.93.381
DTC
FMI
Error type
Visible anomaly
Possible cause
SWITCH
CRUISE
CONTROL
15
00
NO
AVAILABLE Cruise
control/power Unfeasibility
of
SYMPTOM
takeoffare not operating control/power
control keys
SWITCH
CRUISE
CONTROL
15
01
SWITCH
CRUISE
CONTROL
15
02
Recommended repairs
ELECTRIC/ELECTRONIC SYSTEM
309
Notes
Print 603.93.381
Component
failure
DTC
FMI
Error type
Visible anomaly
Possible cause
15
03
NO SIGNAL
Cruise
control/power Unfeasibility
of
takeoffare not operating control/power
control keys
SWITCH
CRUISE
CONTROL
15
04
SIGNAL
PLAUSIBLE
SWITCH
CRUISE
CONTROL
15
05
NOT Cruise
control/power Unfeasibility
of
takeoffare not operating control/power
control keys
Print 603.93.381
Notes
ELECTRIC/ELECTRONIC SYSTEM
SWITCH
CRUISE
CONTROL
Recommended repairs
310
Component
failure
SWITCH
BRAKE PEDAL
DTC
FMI
15
06
Error type
Visible anomaly
Possible cause
Recommended repairs
SUPPLY BELOW THE Possible lack of stop lights Unfeasible brake switches
RANGE
operationPossible lack of signals between primary and
cruise
con?trol/power secondary
takeoff operation
Notes
Print 603.93.381
Component
failure
SWITCH
CRUISE
CONTROL
15
06
311
ELECTRIC/ELECTRONIC SYSTEM
FMI
Error type
15
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Possible cause
Recommended repairs
SWITCH
CRUISE
CONTROL
15
07
VALUE OVER
NORMAL LIMIT
THE Cruise
control/power Unfeasibility
of
takeoffare not operating control/power
control keys
Print 603.93.381
Notes
ELECTRIC/ELECTRONIC SYSTEM
SWITCH
BRAKE PEDAL
DTC
312
Component
failure
SWITCH
BRAKE PEDAL
DTC
FMI
15
08
Error type
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
SWITCH
CRUISE
CONTROL
15
08
VALUE
LIMIT
BELOW
THE Cruise
control/power Unfeasibility
of
takeoffare not operating control/power
control keys
cruise
takeoff
SWITCH PTO
SELECTOR
17
00
NO
AVAILABLE The PTO Selector does Open circuit or short circuit
SYMPTOM
not work
on the wiring between EDC
and switch.
313
ELECTRIC/ELECTRONIC SYSTEM
SWITCH PTO
SELECTOR
FMI
17
00
17
01
Error type
Visible anomaly
Possible cause
NO
AVAILABLE Not operating cruise Clutch switch: unfeasible
SYMPTOM
control/power takeoff
signal (signals the unit that
the clutch is pressed while it
is not)
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
SWITCH
CLUTCH
DTC
314
Component
failure
Cruise
Control/Power
takeoff do not work because
according to the gearcase
the clutch pedal is always
pressed.
Print 603.93.381
SWITCH
CLUTCH
SWITCH PTO
SELECTOR
DTC
FMI
17
01
17
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
315
ELECTRIC/ELECTRONIC SYSTEM
SWITCH PTO
SELECTOR
FMI
17
02
17
03
Error type
Visible anomaly
Possible cause
NO SIGNAL
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
SWITCH
CLUTCH
DTC
316
Component
failure
Cruise
Control/Power
takeoff do not work because
according to the gearcase
the clutch pedal is always
pressed.
Print 603.93.381
SWITCH
CLUTCH
DTC
FMI
17
03
Error type
NO SIGNAL
Visible anomaly
Possible cause
17
04
SIGNAL
PLAUSIBLE
SWITCH PTO
SELECTOR
17
05
SUPPLY OVER THE The PTO Selector does Open circuit or short circuit
NORMAL RANGE
not work
on the wiring between EDC
and switch.
Notes
317
ELECTRIC/ELECTRONIC SYSTEM
SWITCH PTO
SELECTOR
Recommended repairs
Print 603.93.381
Component
failure
SWITCH PTO
SELECTOR
SWITCH PTO
SELECTOR
FMI
17
06
17
17
07
08
Error type
Visible anomaly
Possible cause
Recommended repairs
SUPPLY BELOW THE The PTO Selector does Open circuit or short circuit Disconnect the Italamec
RANGE
not work
on the wiring between EDC 732.24
component
and switch.
(resistances group) from the
UCI and check that the
resistance between pin 1 and
2 (UCI side) is of 5,6 Kohm.
Check that reading between
pin 32 and 87 of the connector
89 pin (EDC) are those
indicated in the Notes.
VALUE OVER THE The PTO Selector does Open circuit or short circuit Disconnect the Italamec
NORMAL LIMIT
not work
on the wiring between EDC 732.24
component
and switch.
(resistances group) from the
UCI and check that the
resistance between pin 1 and
2 (UCI side) is of 5,6 Kohm.
Check that reading between
pin 32 and 87 of the connector
89 pin (EDC) are those
indicated in the Notes.
VALUE BELOW THE The PTO Selector does Open circuit or short circuit Disconnect the Italamec
LIMIT
not work
on the wiring between EDC 732.24
component
and switch.
(resistances group) from the
UCI and check that the
resistance between pin 1 and
2 (UCI side) is of 5,6 Kohm.
Check that reading between
pin 32 and 87 of the connector
89 pin (EDC) are those
indicated in the Notes.
Notes
ELECTRIC/ELECTRONIC SYSTEM
SWITCH PTO
SELECTOR
DTC
318
Component
failure
Print 603.93.381
SWITCH
CLUTCH
SWITCH
CLUTCH
DTC
FMI
18
04
18
05
Error type
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
319
ELECTRIC/ELECTRONIC SYSTEM
SWITCH
CLUTCH
FMI
18
06
18
07
Error type
Visible anomaly
Possible cause
VALUE OVER
NORMAL LIMIT
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
SWITCH
CLUTCH
DTC
320
Component
failure
Cruise
Control/Power
takeoff do not work because
according to the gearcase
the clutch pedal is always
pressed.
Print 603.93.381
SWITCH
CLUTCH
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
AFTERRUN
DTC
FMI
18
08
1A
00
Error type
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
NO
AVAILABLE Significant
SYMPTOM
reduction.
Recommended repairs
Notes
Print 603.93.381
Component
failure
321
ELECTRIC/ELECTRONIC SYSTEM
FMI
1A
01
Error type
Visible anomaly
COMMUNICATI
ON LINES
IMMOBILISER
1B
00
NO
AVAILABLE
SYMPTOM
COMMUNICATI
ON LINES
IMMOBILISER
1B
01
SHORT CIRCUIT TO
POSITIVE
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
AFTERRUN
1B
02
OPEN CIRCUIT OR
SHORT CIRCUIT TO
GROUND
Possible cause
Recommended repairs
Notes
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
AFTERRUN
DTC
322
Component
failure
DTC
FMI
COMMUNICATI
ON LINES
IMMOBILISER
1B
02
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
AFTERRUN
1B
03
Error type
Visible anomaly
Possible cause
OPEN CIRCUIT OR The engine doesnt start. The engine does not
SHORT CIRCUIT TO Possible 7.2.
start.Communication
GROUND
problems
with
shortcircuited
or
opencircuited Immobilizer
on CAN line
NO SIGNAL
Significant
power Failure of the internal test
reduction.
procedure that takes place
in the control unit each time
the engine stops.
1B
03
NO SIGNAL
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
AFTERRUN
1B
04
SIGNAL
PLAUSIBLE
Notes
323
ELECTRIC/ELECTRONIC SYSTEM
COMMUNICATI
ON LINES
IMMOBILISER
Recommended repairs
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
IMMOBILISER
1B
04
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
AFTERRUN
1B
05
COMMUNICATI
ON LINES
IMMOBILISER
1B
05
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
AFTERRUN
1B
06
Error type
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
DTC
324
Component
failure
DTC
FMI
COMMUNICATI
ON LINES
IMMOBILISER
1B
06
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
AFTERRUN
1B
07
Error type
Visible anomaly
Possible cause
SUPPLY BELOW THE The engine doesnt start. The engine does not
RANGE
Possible 7.2.
start.Communication
problems
with
shortcircuited
or
opencircuited Immobilizer
on CAN line
VALUE OVER THE Significant
power Failure of the internal test
NORMAL LIMIT
reduction.
procedure that takes place
in the control unit each time
the engine stops.
1B
07
VALUE OVER
NORMAL LIMIT
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
AFTERRUN
1B
08
VALUE
LIMIT
BELOW
Notes
325
ELECTRIC/ELECTRONIC SYSTEM
COMMUNICATI
ON LINES
IMMOBILISER
Recommended repairs
Print 603.93.381
Component
failure
Error type
COMMUNICATI
ON LINES
IMMOBILISER
1C
08
ELECTRONIC
CONTROL
UNIT
BOOSTER 1
1D
00
ELECTRONIC
CONTROL
UNIT
BOOSTER 1
1D
01
ELECTRONIC
CONTROL
UNIT
BOOSTER 1
1D
02
ELECTRONIC
CONTROL
UNIT
BOOSTER 2
1E
00
NO
AVAILABLE The engine runs at 2 (3) Power stage for the
SYMPTOM
cylinders.
electroinjectors
of
cylinders 23 (fourcylinder
engine)
or
456
(sixcylinder engine) faulty.
ELECTRONIC
CONTROL
UNIT
BOOSTER 2
1E
01
VALUE
LIMIT
Visible anomaly
Possible cause
BELOW
Print 603.93.381
Recommended repairs
Notes
FMI
ELECTRIC/ELECTRONIC SYSTEM
DTC
326
Component
failure
DTC
FMI
ELECTRONIC
CONTROL
UNIT
BOOSTER 2
1E
02
COMMUNICATI
ON LINES Can
A Module
1F
00
Error type
Visible anomaly
Possible cause
NO
AVAILABLE
SYMPTOM
CAN line.
Recommended repairs
Notes
Print 603.93.381
Component
failure
1F
00
327
ELECTRIC/ELECTRONIC SYSTEM
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
FMI
Error type
Visible anomaly
Possible cause
COMMUNICATI
ON LINES
PTO: Power Take
Off Information
1F
00
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
COMMUNICATI
ON LINES Can
A Module
1F
01
SHORT CIRCUIT TO
POSITIVE
CAN line.
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
328
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES Can
A Module
1F
01
COMMUNICATI
ON LINES
PTO: Power Take
Off Information
1F
01
Error type
Visible anomaly
Recommended repairs
Notes
329
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
1F
02
OPEN CIRCUIT OR
SHORT CIRCUIT TO
GROUND
Visible anomaly
Possible cause
CAN line.
Recommended repairs
Notes
COMMUNICATI
ON LINES Can
A Module
1F
02
COMMUNICATI
ON LINES Can
A Module
1F
03
NO SIGNAL
CAN line.
ELECTRIC/ELECTRONIC SYSTEM
COMMUNICATI
ON LINES Can
A Module
DTC
330
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES Can
A Module
1F
03
NO SIGNAL
COMMUNICATI
ON LINES Can
A Module
1F
04
SIGNAL
PLAUSIBLE
NOT
Visible anomaly
Possible cause
CAN line.
Recommended repairs
Notes
Print 603.93.381
Component
failure
ELECTRIC/ELECTRONIC SYSTEM
331
FMI
Error type
Visible anomaly
COMMUNICATI
ON LINES Can
A Module
1F
04
SIGNAL
PLAUSIBLE
COMMUNICATI
ON LINES Can
A Module
1F
05
Possible cause
CAN line.
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
332
Component
failure
Print 603.93.381
DTC
FMI
Error type
Visible anomaly
Possible cause
COMMUNICATI
ON LINES Can
A Module
1F
05
COMMUNICATI
ON LINES Can
A Module
1F
06
CAN line.
Recommended repairs
Notes
Print 603.93.381
Component
failure
ELECTRIC/ELECTRONIC SYSTEM
333
FMI
Error type
Visible anomaly
COMMUNICATI
ON LINES Can
A Module
1F
06
COMMUNICATI
ON LINES Can
A Module
1F
07
VALUE OVER
NORMAL LIMIT
CAN line.
THE
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
334
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES Can
A Module
1F
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES Can
A Module
1F
08
VALUE
LIMIT
THE
CAN line.
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
ELECTRIC/ELECTRONIC SYSTEM
335
FMI
Error type
COMMUNICATI
ON LINES Can
A Module
1F
08
VALUE
LIMIT
Possible cause
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
COMMUNICATI
ON LINES
TCO1:
Tachograph
Output
20
00
BELOW
Visible anomaly
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
336
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES
TCO1:
Tachograph
Output
20
01
COMMUNICATI
ON LINES
PTO: Power Take
Off Information
20
02
Error type
Visible anomaly
Recommended repairs
Notes
337
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
TCO1:
Tachograph
Output
20
02
COMMUNICATI
ON LINES
PTO: Power Take
Off Information
20
03
Error type
Visible anomaly
Possible cause
Recommended repairs
NO SIGNAL
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
338
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES
TCO1:
Tachograph
Output
20
03
NO SIGNAL
COMMUNICATI
ON LINES
PTO: Power Take
Off Information
20
04
SIGNAL
PLAUSIBLE
Possible cause
Recommended repairs
Notes
339
ELECTRIC/ELECTRONIC SYSTEM
Visible anomaly
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES
TCO1:
Tachograph
Output
20
04
SIGNAL
PLAUSIBLE
COMMUNICATI
ON LINES
PTO: Power Take
Off Information
20
05
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
340
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES
TCO1:
Tachograph
Output
20
05
COMMUNICATI
ON LINES
PTO: Power Take
Off Information
20
06
Error type
Visible anomaly
Recommended repairs
Notes
341
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
TCO1:
Tachograph
Output
20
06
COMMUNICATI
ON LINES
PTO: Power Take
Off Information
20
07
Error type
Visible anomaly
Possible cause
Recommended repairs
VALUE OVER
NORMAL LIMIT
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
342
Component
failure
Print 603.93.381
FMI
Error type
COMMUNICATI
ON LINES
TCO1:
Tachograph
Output
20
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES
PTO: Power Take
Off Information
20
08
VALUE
LIMIT
RELAY MAIN
21
00
NO
AVAILABLE The unit remains always Main
relay
SYMPTOM
supplied and the EDC disconnected
warning light remains on
also with an Off keyThe
battery discharges.
BELOW
Visible anomaly
Recommended repairs
is
not
Notes
343
Possible cause
ELECTRIC/ELECTRONIC SYSTEM
DTC
Print 603.93.381
Component
failure
RELAY MAIN
RELAY MAIN
FMI
21
01
21
21
02
03
Error type
Visible anomaly
Possible cause
NO SIGNAL
COMMUNICATI
ON LINES
TCO1:
Tachograph
Output
21
08
VALUE
LIMIT
BELOW
RELAY MAIN
22
04
SIGNAL
PLAUSIBLE
is
Notes
Print 603.93.381
wiring
and
not Check
connections(note: the main
relay is embedded into the EDC
unit).Try and remove the fuse
and put it again in place. If the
inconvenience remains, contact
the Help Desk for possible unit
replacement.
wiring
and
Main
relay
is
not Check
connections(note: the main
disconnected
relay is embedded into the EDC
unit).Try and remove the fuse
and put it again in place. If the
inconvenience remains, contact
the Help Desk for possible unit
replacement.
wiring
and
Main
relay
is
not Check
connections(note: the main
disconnected
relay is embedded into the EDC
unit).Try and remove the fuse
and put it again in place. If the
inconvenience remains, contact
the Help Desk for possible unit
replacement.
Possible CAN line problem: Check CAN VDB line: 1)
CAN line shortcircuit to Resistance measured with key
earth or CAN H and CAN off directly on EDC ECU
L
lines
reciprocally between pin B52 (CAN L) and
shortcircuiting. Check that pin B53 (CAN H) must be equal
to 120 ohm. 2) Resistance
all vehicle ECUs are measured with key off on wiring
connected.
between pin B52 and pin B53
must be equal to 120 ohm. 3)
Impedance measured between
30pin connector pin 21 (CAN
H) and pin 22 (CAN L) must be
equal to 60 ohm +/3%
(measured with key off and
ECUs connected).
wiring
and
Main
relay
is
not Check
connections(note: the main relay
disconnected
is embedded into the EDC
unit).Try and remove the fuse and
put it again in place. If the
inconvenience remains, contact
the Help Desk for possible unit
replacement.
Recommended repairs
ELECTRIC/ELECTRONIC SYSTEM
RELAY MAIN
DTC
344
Component
failure
RELAY MAIN
RELAY MAIN
RELAY MAIN
RELAY MAIN
DTC
FMI
22
05
22
22
22
24
SWITCH
SECOND SPEED
LIMITER
SWITCH
24
07
08
00
Visible anomaly
is
is
VALUE OVER
NORMAL LIMIT
is
VALUE
LIMIT
is
BELOW
NO
AVAILABLE a)Preheating pilot light
SYMPTOM
always on
b)Preheating pilot light
always off.
00
Possible cause
NO
AVAILABLE The
programmable
SYMPTOM
overspeed
governor
either doesnt start or it
remains always engaged.
Recommended repairs
wiring
and
not Check
connections(note: the main relay
is embedded into the EDC
unit).Try and remove the fuse and
put it again in place. If the
inconvenience remains, contact
the Help Desk for possible unit
replacement.
wiring
and
not Check
connections(note: the main relay
is embedded into the EDC
unit).Try and remove the fuse and
put it again in place. If the
inconvenience remains, contact
the Help Desk for possible unit
replacement.
wiring
and
not Check
connections(note: the main relay
is embedded into the EDC
unit).Try and remove the fuse and
put it again in place. If the
inconvenience remains, contact
the Help Desk for possible unit
replacement.
wiring
and
not Check
connections(note: the main relay
is embedded into the EDC
unit).Try and remove the fuse and
put it again in place. If the
inconvenience remains, contact
the Help Desk for possible unit
replacement.
1) The preheater warning light
should come on for a few seconds
at keyon (lamp test). 2) Run
Cluster
active
diagnostic
procedure (preheater warning
light) with a diagnostic tool.
345
Notes
ELECTRIC/ELECTRONIC SYSTEM
WARNING
LIGHTS
PREPOSTHEAT
ING
06
Error type
Print 603.93.381
Component
failure
Error type
Visible anomaly
WARNING
LIGHTS
PREPOSTHEAT
ING
24
01
SWITCH
SECOND SPEED
LIMITER
SWITCH
24
01
WARNING
LIGHTS
PREPOSTHEAT
ING
24
02
WARNING
LIGHTS
PREPOSTHEAT
ING
24
WARNING
LIGHTS
PREPOSTHEAT
ING
24
03
NO SIGNAL
04
SIGNAL
PLAUSIBLE
Possible cause
Recommended repairs
Notes
Print 603.93.381
FMI
ELECTRIC/ELECTRONIC SYSTEM
DTC
346
Component
failure
FMI
WARNING
LIGHTS
PREPOSTHEAT
ING
24
05
WARNING
LIGHTS
PREPOSTHEAT
ING
24
WARNING
LIGHTS
PREPOSTHEAT
ING
24
WARNING
LIGHTS
PREPOSTHEAT
ING
24
WARNING
LIGHTS
ENGINE BRAKE
25
Error type
Visible anomaly
Possible cause
06
07
VALUE OVER
NORMAL LIMIT
08
VALUE
LIMIT
BELOW
00
NO
AVAILABLE The pilot light either CAN line failure.
SYMPTOM
doesnt work or it remains
always lighted up.
Recommended repairs
347
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
Print 603.93.381
Component
failure
FMI
Error type
Visible anomaly
WARNING
LIGHTS
ENGINE BRAKE
25
01
SWITCH
SECOND SPEED
LIMITER
SWITCH
25
02
WARNING
LIGHTS
ENGINE BRAKE
25
02
SWITCH
SECOND SPEED
LIMITER
SWITCH
25
03
NO SIGNAL
The
programmable
overspeed
governor
either doesnt start or it
remains always engaged.
Possible cause
Recommended repairs
Print 603.93.381
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
348
Component
failure
FMI
Error type
Visible anomaly
Possible cause
WARNING
LIGHTS
ENGINE BRAKE
25
03
NO SIGNAL
SWITCH
SECOND SPEED
LIMITER
SWITCH
25
04
SIGNAL
PLAUSIBLE
SWITCH
SECOND SPEED
LIMITER
SWITCH
25
05
WARNING
LIGHTS
ENGINE BRAKE
25
05
SUPPLY OVER THE The pilot light either CAN line failure.
NORMAL RANGE
doesnt work or it remains
always lighted up.
NOT The
programmable
overspeed
governor
either doesnt start or it
remains always engaged.
Recommended repairs
349
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
Print 603.93.381
Component
failure
FMI
Error type
Visible anomaly
Possible cause
SWITCH
SECOND SPEED
LIMITER
SWITCH
25
06
WARNING
LIGHTS
ENGINE BRAKE
25
06
SUPPLY BELOW THE The pilot light either CAN line failure.
RANGE
doesnt work or it remains
always lighted up.
SWITCH
SECOND SPEED
LIMITER
SWITCH
25
07
VALUE OVER
NORMAL LIMIT
THE The
programmable
overspeed
governor
either doesnt start or it
remains always engaged.
WARNING
LIGHTS
ENGINE BRAKE
25
07
VALUE OVER
NORMAL LIMIT
Recommended repairs
Print 603.93.381
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
350
Component
failure
DTC
FMI
SWITCH
SECOND SPEED
LIMITER
SWITCH
25
08
VALUE
LIMIT
WARNING
LIGHTS OIL
LOW PRESSURE
26
00
NO
AVAILABLE The pilot light either
SYMPTOM
doesnt work or it remains
always lighted up.
RELAY GLOW
PLUG
26
00
NO
AVAILABLE A) the prepost heating
SYMPTOM
resistance is not powered,
possible cold start difficult
and grade of smoke when
starting
26
01
BELOW
Visible anomaly
THE The
programmable
overspeed
governor
either doesnt start or it
remains always engaged.
Possible cause
Recommended repairs
Notes
351
ELECTRIC/ELECTRONIC SYSTEM
WARNING
LIGHTS OIL
LOW PRESSURE
Error type
Print 603.93.381
Component
failure
FMI
26
01
WARNING
LIGHTS OIL
LOW PRESSURE
26
02
RELAY GLOW
PLUG
26
02
26
03
Visible anomaly
Possible cause
NO SIGNAL
Recommended repairs
Active diagnosis.
Notes
Print 603.93.381
WARNING
LIGHTS OIL
LOW PRESSURE
Error type
ELECTRIC/ELECTRONIC SYSTEM
RELAY GLOW
PLUG
DTC
352
Component
failure
RELAY GLOW
PLUG
DTC
FMI
26
03
Error type
NO SIGNAL
Visible anomaly
Possible cause
26
04
SIGNAL
PLAUSIBLE
WARNING
LIGHTS OIL
LOW PRESSURE
26
05
SUPPLY OVER THE The pilot light either CAN line failure.
NORMAL RANGE
doesnt work or it remains
always lighted up.
WARNING
LIGHTS OIL
LOW PRESSURE
26
06
SUPPLY BELOW THE The pilot light either CAN line failure.
RANGE
doesnt work or it remains
always lighted up.
Active diagnosis.
Check the wiring between
relay pin 85 and connector
EDC pin B4, between relay pin
86 and connector EDC pin
B16.
353
Notes
ELECTRIC/ELECTRONIC SYSTEM
WARNING
LIGHTS OIL
LOW PRESSURE
Recommended repairs
Print 603.93.381
Component
failure
FMI
Error type
Visible anomaly
WARNING
LIGHTS OIL
LOW PRESSURE
26
07
VALUE OVER
NORMAL LIMIT
WARNING
LIGHTS
ENGINE BRAKE
26
08
VALUE
LIMIT
BELOW
WARNING
LIGHTS OIL
LOW PRESSURE
26
08
VALUE
LIMIT
BELOW
RELAY GLOW
PLUG
27
04
SIGNAL
PLAUSIBLE
Print 603.93.381
Recommended repairs
Notes
Possible cause
ELECTRIC/ELECTRONIC SYSTEM
DTC
354
Component
failure
RELAY GLOW
PLUG
RELAY GLOW
PLUG
RELAY GLOW
PLUG
FMI
27
05
27
27
27
06
07
08
Error type
Visible anomaly
Possible cause
VALUE OVER
NORMAL LIMIT
VALUE
LIMIT
BELOW
Active diagnosis.
Notes
Active diagnosis.
Active diagnosis.
Active diagnosis.
Check the wiring between
relay pin 85 and connector
EDC pin B4, between relay pin
86 and connector EDC pin
B16.
355
Recommended repairs
ELECTRIC/ELECTRONIC SYSTEM
RELAY GLOW
PLUG
DTC
Print 603.93.381
Component
failure
FMI
Error type
Visible anomaly
Possible cause
ELECTROVALVE
S ENGINE
BRAKE
28
00
NO
AVAILABLE The engine brake is not Positively shortcircuited,
SYMPTOM
operating or is always groundshortcircuited or
activated above 1000 rpm opencircuited engine brake
solenoid valve
ELECTROVALVE
S ENGINE
BRAKE
28
01
ELECTROVALVE
S ENGINE
BRAKE
28
02
Recommended repairs
Notes
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
DTC
356
Component
failure
Error type
Visible anomaly
Possible cause
ELECTROVALVE
S ENGINE
BRAKE
28
03
NO SIGNAL
ELECTROVALVE
S ENGINE
BRAKE
28
04
SIGNAL
PLAUSIBLE
ELECTROVALVE
S ENGINE
BRAKE
28
05
RELAY
AIRCONDITIO
NER
COMPRESSOR
RELAY
AIRCONDITIO
NER
COMPRESSOR
29
00
NO
AVAILABLE A/C compressor always
SYMPTOM
on or not working.
29
01
Recommended repairs
Notes
357
FMI
ELECTRIC/ELECTRONIC SYSTEM
DTC
Print 603.93.381
Component
failure
FMI
ELECTROVALVE
S ENGINE
BRAKE
29
06
ELECTROVALVE
S ENGINE
BRAKE
29
07
VALUE OVER
NORMAL LIMIT
ELECTROVALVE
S ENGINE
BRAKE
29
08
VALUE
LIMIT
RELAY
HEATED
FILTER
2A
00
NO
AVAILABLE a) Heater always engaged. Fuel filter heater relay faulty.
SYMPTOM
The battery becomes
discharged.
FUEL
Error type
BELOW
Visible anomaly
Recommended repairs
Notes
Print 603.93.381
Possible cause
ELECTRIC/ELECTRONIC SYSTEM
DTC
358
Component
failure
FMI
FUEL
2A
01
RELAY
AIRCONDITIO
NER
COMPRESSOR
RELAY
HEATED FUEL
FILTER
2A
02
2A
02
RELAY
AIRCONDITIO
NER
COMPRESSOR
RELAY
HEATED FUEL
FILTER
2A
03
2A
03
NO SIGNAL
RELAY
AIRCONDITIO
NER
COMPRESSOR
2A
04
SIGNAL
PLAUSIBLE
RELAY
HEATED
FILTER
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SHORT CIRCUIT TO a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis.
EDC pilot light off.
POSITIVE
The battery becomes
Check the wiring between a)Possible storage of 2.3
discharged.
relay pin 85 and connector because the fuel overheats.
b)Heater never engaged.
EDC pin B2 passing through
Possible filter clogging due
sleeve E pin 38, between relay
to paraffin traces in the
pin 86 and connector EDC pin
fuel in presence of too low
B36 passing through sleeve E
external temperatures (<
pin 29.
15 C).
OPEN CIRCUIT OR A/C compressor always
Check wiring and connections.
SHORT CIRCUIT TO on or not working.
Replace relay if required.
GROUND
OPEN CIRCUIT OR a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis.
EDC pilot light off.
SHORT CIRCUIT TO The battery becomes
Check the wiring between a)Possible storage of 2.3
GROUND
discharged.
relay pin 85 and connector because the fuel overheats.
b)Heater never engaged.
EDC pin B2 passing through
Possible filter clogging due
sleeve E pin 38, between relay
to paraffin traces in the
pin 86 and connector EDC pin
fuel in presence of too low
B36 passing through sleeve E
external temperatures (<
pin 29.
15 C).
NO SIGNAL
A/C compressor always
Check wiring and connections.
on or not working.
Replace relay if required.
a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis.
EDC pilot light off.
The battery becomes
Check the wiring between a)Possible storage of 2.3
discharged.
relay pin 85 and connector because the fuel overheats.
b)Heater never engaged.
EDC pin B2 passing through
Possible filter clogging due
sleeve E pin 38, between relay
to paraffin traces in the
pin 86 and connector EDC pin
fuel in presence of too low
B36 passing through sleeve E
external temperatures (<
pin 29.
15 C).
NOT A/C compressor always
Check wiring and connections.
on or not working.
Replace relay if required.
ELECTRIC/ELECTRONIC SYSTEM
359
DTC
Print 603.93.381
Component
failure
FUEL
2A
04
RELAY
AIRCONDITIO
NER
COMPRESSOR
RELAY
HEATED FUEL
FILTER
2A
05
2A
05
RELAY
AIRCONDITIO
NER
COMPRESSOR
RELAY
HEATED FUEL
FILTER
2A
06
2A
06
RELAY
AIRCONDITIO
NER
COMPRESSOR
2A
07
RELAY
HEATED
FILTER
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SIGNAL
PLAUSIBLE
NOT a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis.
EDC pilot light off.
The battery becomes
Check the wiring between a)Possible storage of 2.3
discharged.
relay pin 85 and connector because the fuel overheats.
b)Heater never engaged.
EDC pin B2 passing through
Possible filter clogging due
sleeve E pin 38, between relay
to paraffin traces in the
pin 86 and connector EDC pin
fuel in presence of too low
B36 passing through sleeve E
external temperatures (<
pin 29.
15 C).
SUPPLY OVER THE A/C compressor always
Check wiring and connections.
NORMAL RANGE
on or not working.
Replace relay if required.
SUPPLY OVER THE a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis.
EDC pilot light off.
NORMAL RANGE
The battery becomes
Check the wiring between a)Possible storage of 2.3
discharged.
relay pin 85 and connector because the fuel overheats.
b)Heater never engaged.
EDC pin B2 passing through
Possible filter clogging due
sleeve E pin 38, between relay
to paraffin traces in the
pin 86 and connector EDC pin
fuel in presence of too low
B36 passing through sleeve E
external temperatures (<
pin 29.
15 C).
SUPPLY BELOW THE A/C compressor always
Check wiring and connections.
RANGE
on or not working.
Replace relay if required.
SUPPLY BELOW THE a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis.
EDC pilot light off.
RANGE
The battery becomes
Check the wiring between a)Possible storage of 2.3
discharged.
relay pin 85 and connector because the fuel overheats.
b)Heater never engaged.
EDC pin B2 passing through
Possible filter clogging due
sleeve E pin 38, between relay
to paraffin traces in the
pin 86 and connector EDC pin
fuel in presence of too low
B36 passing through sleeve E
external temperatures (<
pin 29.
15 C).
VALUE OVER THE A/C compressor always
Check wiring and connections.
NORMAL LIMIT
on or not working.
Replace relay if required.
FMI
ELECTRIC/ELECTRONIC SYSTEM
Print 603.93.381
DTC
360
Component
failure
DTC
FMI
Error type
FUEL
2A
07
VALUE OVER
NORMAL LIMIT
RELAY
AIRCONDITIO
NER
COMPRESSOR
RELAY START
2A
08
VALUE
LIMIT
2B
00
ENGINE
CONTROL
SYSTEM
PREPOSTHEAT
ING
2B
00
NO
AVAILABLE The engine doesnt start. Starter relay shortcircuited Check the component is all
SYMPTOM
or opencircuited.
right.
In case it is already running,
it stops.
Check the wiring between
relay and connector EDC pin
B37.
NO
AVAILABLE Possible grade of smoke Prepost heating procedure Check that the cables are
SYMPTOM
after starting.
monitoring.
properly connected to the
prepost heating resistance
terminals.
RELAY
HEATED
FILTER
Possible cause
Recommended repairs
Notes
THE a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis.
EDC pilot light off.
The battery becomes
Check the wiring between a)Possible storage of 2.3
discharged.
relay pin 85 and connector because the fuel overheats.
b)Heater never engaged.
EDC pin B2 passing through
Possible filter clogging due
sleeve E pin 38, between relay
to paraffin traces in the
pin 86 and connector EDC pin
fuel in presence of too low
B36 passing through sleeve E
external temperatures (<
pin 29.
15 C).
THE A/C compressor always
Check wiring and connections.
on or not working.
Replace relay if required.
2B
01
361
ELECTRIC/ELECTRONIC SYSTEM
RELAY START
BELOW
Visible anomaly
Print 603.93.381
Component
failure
FMI
2B
01
RELAY START
2B
02
ENGINE
CONTROL
SYSTEM
PREPOSTHEAT
ING
2B
02
2B
03
Visible anomaly
Possible cause
Recommended repairs
Notes
SHORT CIRCUIT TO Possible grade of smoke Prepost heating procedure Check that the cables are EDC pilot light on.
properly connected to the
POSITIVE
after starting.
monitoring.
prepost heating resistance The gearcase doesnt detect,
by means of the air
terminals.
temperature sensor in the
Check that the prepost heating suction
manifold,
the
resistance is all right (R = approx. increase in the temperature
0,5 Ohm)
due to the operation of the
Check wiring and connections resistance.
between the prepost heating
resistance remote control switch
pin 87 and the terminal (+) of
the resistance, passing through
sleeve E pin 40.
Check wiring and connections
between terminal () of the
resistance and earth.
OPEN CIRCUIT OR The engine doesnt start. Starter relay shortcircuited Check the component is all right. EDC pilot light on.
SHORT CIRCUIT TO
or opencircuited.
Check the wiring between relay
In case it is already running,
GROUND
and connector EDC pin B37.
it stops.
OPEN CIRCUIT OR Possible grade of smoke Prepost heating procedure Check that the cables are EDC pilot light on.
properly connected to the
SHORT CIRCUIT TO after starting.
monitoring.
prepost heating resistance The gearcase doesnt detect,
GROUND
by means of the air
terminals.
temperature sensor in the
Check that the prepost heating suction
manifold,
the
resistance is all right (R = approx. increase in the temperature
0,5 Ohm)
due to the operation of the
Check wiring and connections resistance.
between the prepost heating
resistance remote control switch
pin 87 and the terminal (+) of
the resistance, passing through
sleeve E pin 40.
NO SIGNAL
Print 603.93.381
RELAY START
Error type
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
CONTROL
SYSTEM
PREPOSTHEAT
ING
DTC
362
Component
failure
FMI
ENGINE
CONTROL
SYSTEM
PREPOSTHEAT
ING
2B
03
RELAY START
2B
04
SIGNAL
PLAUSIBLE
RELAY START
2B
05
RELAY START
2B
06
RELAY START
2B
07
VALUE OVER
NORMAL LIMIT
THE
RELAY
HEATED
FILTER
2B
08
VALUE
LIMIT
BELOW
THE
VALUE
LIMIT
BELOW
FUEL
RELAY START
2B
08
Error type
Visible anomaly
NO SIGNAL
NOT
THE
Possible cause
Recommended repairs
Possible grade of smoke Prepost heating procedure Check that the cables are
properly connected to the
after starting.
monitoring.
prepost heating resistance
terminals.
Check that the prepost heating
resistance is all right (R = approx.
0,5 Ohm)
Check wiring and connections
between the prepost heating
resistance remote control switch
pin 87 and the terminal (+) of
the resistance, passing through
sleeve E pin 40.
Check wiring and connections
between terminal () of the
resistance and earth.
The engine doesnt start. Starter relay shortcircuited Check the component is all right.
Check the wiring between relay
or opencircuited.
In case it is already running,
and connector EDC pin B37.
it stops.
The engine doesnt start. Starter relay shortcircuited Check the component is all right.
Check the wiring between relay
In case it is already running, or opencircuited.
and connector EDC pin B37.
it stops.
The engine doesnt start. Starter relay shortcircuited Check the component is all right.
Check the wiring between relay
or opencircuited.
In case it is already running,
and connector EDC pin B37.
it stops.
The engine doesnt start. Starter relay shortcircuited Check the component is all right.
Check the wiring between relay
or opencircuited.
In case it is already running,
and connector EDC pin B37.
it stops.
a) Heater always engaged. Fuel filter heater relay faulty. Active diagnosis.
Check the wiring between relay
The battery becomes
pin 85 and connector EDC pin
discharged.
B2 passing through sleeve E pin
b)Heater never engaged.
38, between relay pin 86 and
Possible filter clogging due
connector EDC pin B36 passing
to paraffin traces in the fuel
through sleeve E pin 29.
in presence of too low
external temperatures (<
15 C).
The engine doesnt start. Starter relay shortcircuited Check the component is all right.
Check the wiring between relay
In case it is already running, or opencircuited.
and connector EDC pin B37.
it stops.
Notes
ELECTRIC/ELECTRONIC SYSTEM
363
DTC
Print 603.93.381
Component
failure
FMI
2C
00
Error type
Visible anomaly
NO
AVAILABLE Slight power reduction
SYMPTOM
Possible cause
Recommended repairs
Positively shortcircuited,
groundshortcircuited or
opencircuited
air
tempe?rature sensor on
suction manifold
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
supercharging air temperature
will be fixed at 30 C.
Notes
SENSORS
BOOST
AIR
TEMPERATURE
2C
01
Positively shortcircuited,
groundshortcircuited or
opencircuited
air
tempe?rature sensor on
suction manifold
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
BOOST
AIR
TEMPERATURE
DTC
364
Component
failure
Print 603.93.381
SENSORS
BOOST
AIR
TEMPERATURE
DTC
FMI
2C
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Positively shortcircuited,
groundshortcircuited or
opencircuited
air
tempe?rature sensor on
suction manifold
Reading
of
measurable
parameters by means of the
diagnostic instrument: in
presence of this error, the
supercharging air temperature
will be fixed at 30 C.
Notes
Print 603.93.381
Component
failure
SENSORS
BOOST
AIR
TEMPERATURE
2C
03
NO SIGNAL
Positively shortcircuited,
groundshortcircuited or
opencircuited
air
tempe?rature sensor on
suction manifold
365
ELECTRIC/ELECTRONIC SYSTEM
SENSORS
BOOST
AIR
TEMPERATURE
FMI
2C
04
2C
04
Error type
SIGNAL
PLAUSIBLE
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
NOT Possible grade of smoke Prepost heating procedure Check that the cables are EDC pilot light on.
after starting.
monitoring.
properly connected to the
The gearcase doesnt detect,
prepost heating resistance
by means of the air
terminals.
temperature sensor in the
Check that the prepost suction
manifold,
the
heating resistance is all right (R increase in the temperature
= approx. 0,5 Ohm)
due to the operation of the
resistance.
Check wiring and connections
between the prepost heating
resistance remote control
switch pin 87 and the terminal
(+) of the resistance, passing
through sleeve E pin 40.
Positively shortcircuited,
groundshortcircuited or
opencircuited
air
tempe?rature sensor on
suction manifold
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
CONTROL
SYSTEM
PREPOSTHEAT
ING
DTC
366
Component
failure
Print 603.93.381
ENGINE
CONTROL
SYSTEM
PREPOSTHEAT
ING
SENSORS
BOOST
AIR
TEMPERATURE
DTC
FMI
2C
05
2C
05
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SUPPLY OVER THE Possible grade of smoke Prepost heating procedure Check that the cables are EDC pilot light on.
NORMAL RANGE
after starting.
monitoring.
properly connected to the
The gearcase doesnt detect,
prepost heating resistance
by means of the air
terminals.
temperature sensor in the
Check that the prepost suction
manifold,
the
heating resistance is all right (R increase in the temperature
= approx. 0,5 Ohm)
due to the operation of the
resistance.
Check wiring and connections
between the prepost heating
resistance remote control
switch pin 87 and the terminal
(+) of the resistance, passing
through sleeve E pin 40.
Positively shortcircuited,
groundshortcircuited or
opencircuited
air
tempe?rature sensor on
suction manifold
Print 603.93.381
Component
failure
367
SENSORS
BOOST
AIR
TEMPERATURE
FMI
2C
06
2C
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
SUPPLY BELOW THE Possible grade of smoke Prepost heating procedure Check that the cables are EDC pilot light on.
RANGE
after starting.
monitoring.
properly connected to the
The gearcase doesnt detect,
prepost heating resistance
by means of the air
terminals.
temperature sensor in the
Check that the prepost suction
manifold,
the
heating resistance is all right (R increase in the temperature
= approx. 0,5 Ohm)
due to the operation of the
resistance.
Check wiring and connections
between the prepost heating
resistance remote control
switch pin 87 and the terminal
(+) of the resistance, passing
through sleeve E pin 40.
Positively shortcircuited,
groundshortcircuited or
opencircuited
air
tempe?rature sensor on
suction manifold
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
CONTROL
SYSTEM
PREPOSTHEAT
ING
DTC
368
Component
failure
Print 603.93.381
ENGINE
CONTROL
SYSTEM
PREPOSTHEAT
ING
SENSORS
BOOST
AIR
TEMPERATURE
DTC
FMI
Error type
2C
07
VALUE OVER
NORMAL LIMIT
2C
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Possible cause
Recommended repairs
Notes
THE Possible grade of smoke Prepost heating procedure Check that the cables are EDC pilot light on.
after starting.
monitoring.
properly connected to the
The gearcase doesnt detect,
prepost heating resistance
by means of the air
terminals.
temperature sensor in the
Check that the prepost suction
manifold,
the
heating resistance is all right (R increase in the temperature
= approx. 0,5 Ohm)
due to the operation of the
resistance.
Check wiring and connections
between the prepost heating
resistance remote control
switch pin 87 and the terminal
(+) of the resistance, passing
through sleeve E pin 40.
Positively shortcircuited,
groundshortcircuited or
opencircuited
air
tempe?rature sensor on
suction manifold
Print 603.93.381
Component
failure
369
SENSORS
BOOST
AIR
TEMPERATURE
FMI
2C
08
2C
08
Error type
VALUE
LIMIT
VALUE
LIMIT
BELOW
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
THE Possible grade of smoke Prepost heating procedure Check that the cables are EDC pilot light on.
after starting.
monitoring.
properly connected to the
The gearcase doesnt detect,
prepost heating resistance
by means of the air
terminals.
temperature sensor in the
Check that the prepost suction
manifold,
the
heating resistance is all right (R increase in the temperature
= approx. 0,5 Ohm)
due to the operation of the
resistance.
Check wiring and connections
between the prepost heating
resistance remote control
switch pin 87 and the terminal
(+) of the resistance, passing
through sleeve E pin 40.
Positively shortcircuited,
groundshortcircuited or
opencircuited
air
tempe?rature sensor on
suction manifold
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
CONTROL
SYSTEM
PREPOSTHEAT
ING
DTC
370
Component
failure
Print 603.93.381
ENGINE
ENGINE SPEED
SENSING
DTC
FMI
2D
00
Error type
Visible anomaly
NO
AVAILABLE Light power reduction.
SYMPTOM
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
2D
00
NO
AVAILABLE The pilot light either CAN line failure.
SYMPTOM
doesnt work or it remains
always lighted up.
371
ELECTRIC/ELECTRONIC SYSTEM
WARNING
LIGHTS
COOLANT
TEMPERATURE
FMI
2D
01
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
ENGINE SPEED
SENSING
DTC
372
Component
failure
WARNING
LIGHTS
COOLANT
TEMPERATURE
2D
01
Print 603.93.381
ENGINE
ENGINE SPEED
SENSING
DTC
FMI
2D
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
2D
02
WARNING
LIGHTS
COOLANT
TEMPERATURE
2D
03
NO SIGNAL
373
ELECTRIC/ELECTRONIC SYSTEM
WARNING
LIGHTS
COOLANT
TEMPERATURE
FMI
2D
03
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
ENGINE SPEED
SENSING
DTC
374
Component
failure
WARNING
LIGHTS
COOLANT
TEMPERATURE
2D
04
SIGNAL
PLAUSIBLE
Print 603.93.381
ENGINE
ENGINE SPEED
SENSING
DTC
FMI
2D
04
Error type
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
2D
05
SUPPLY OVER THE The pilot light either CAN line failure.
NORMAL RANGE
doesnt work or it remains
always lighted up.
375
ELECTRIC/ELECTRONIC SYSTEM
WARNING
LIGHTS
COOLANT
TEMPERATURE
FMI
2D
05
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
ENGINE SPEED
SENSING
DTC
376
Component
failure
Print 603.93.381
ENGINE
ENGINE SPEED
SENSING
DTC
FMI
2D
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
ELECTRIC/ELECTRONIC SYSTEM
377
FMI
Error type
2D
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
ENGINE
ENGINE SPEED
SENSING
DTC
378
Component
failure
Print 603.93.381
ENGINE
ENGINE SPEED
SENSING
DTC
FMI
2D
08
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
WARNING
LIGHTS EDC
2E
00
NO
AVAILABLE The pilot light either CAN line failure.
SYMPTOM
doesnt work or it remains
always lighted up.
379
ELECTRIC/ELECTRONIC SYSTEM
FMI
2E
00
WARNING
LIGHTS EDC
2E
01
ELECTROVALVE
S
FUEL
PRESSURE
REGULATION
2E
01
WARNING
LIGHTS EDC
2E
02
Error type
Visible anomaly
NO
AVAILABLE Significant
SYMPTOM
reduction.
Possible cause
Recommended repairs
Print 603.93.381
Notes
ELECTRIC/ELECTRONIC SYSTEM
ELECTROVALVE
S
FUEL
PRESSURE
REGULATION
DTC
380
Component
failure
FMI
Error type
Visible anomaly
Possible cause
WARNING
LIGHTS EDC
2E
03
NO SIGNAL
WARNING
LIGHTS EDC
2E
04
SIGNAL
PLAUSIBLE
WARNING
LIGHTS EDC
2E
05
SUPPLY OVER THE The pilot light either CAN line failure.
NORMAL RANGE
doesnt work or it remains
always lighted up.
WARNING
LIGHTS
COOLANT
TEMPERATURE
2E
06
SUPPLY BELOW THE The pilot light either CAN line failure.
RANGE
doesnt work or it remains
always lighted up.
WARNING
LIGHTS EDC
2E
06
SUPPLY BELOW THE The pilot light either CAN line failure.
RANGE
doesnt work or it remains
always lighted up.
Recommended repairs
381
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
Print 603.93.381
Component
failure
FMI
Error type
Visible anomaly
Possible cause
WARNING
LIGHTS
COOLANT
TEMPERATURE
2E
07
VALUE OVER
NORMAL LIMIT
WARNING
LIGHTS EDC
2E
07
VALUE OVER
NORMAL LIMIT
WARNING
LIGHTS
COOLANT
TEMPERATURE
2E
08
VALUE
LIMIT
BELOW
WARNING
LIGHTS EDC
2E
08
VALUE
LIMIT
BELOW
Recommended repairs
Print 603.93.381
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
382
Component
failure
ELECTROVALVE
S
FUEL
PRESSURE
REGULATION
ELECTROVALVE
S
FUEL
PRESSURE
REGULATION
ELECTROVALVE
S
FUEL
PRESSURE
REGULATION
DTC
FMI
2F
02
2F
2F
03
04
Error type
Visible anomaly
NO SIGNAL
SIGNAL
PLAUSIBLE
Possible cause
Recommended repairs
NOT Significant
reduction.
383
ELECTRIC/ELECTRONIC SYSTEM
Significant
reduction.
Notes
Print 603.93.381
Component
failure
ELECTROVALVE
S
FUEL
PRESSURE
REGULATION
ELECTROVALVE
S
FUEL
PRESSURE
REGULATION
FMI
2F
05
2F
2F
06
07
Error type
Visible anomaly
Possible cause
Recommended repairs
VALUE OVER
NORMAL LIMIT
THE Significant
reduction.
Print 603.93.381
Notes
ELECTRIC/ELECTRONIC SYSTEM
ELECTROVALVE
S
FUEL
PRESSURE
REGULATION
DTC
384
Component
failure
ELECTROVALVE
S
FUEL
PRESSURE
REGULATION
ENGINE
POWER STAGE
FOR TD SIGNAL
DTC
FMI
2F
08
30
00
Error type
VALUE
LIMIT
BELOW
Visible anomaly
THE Significant
reduction.
NO
AVAILABLE The speed
SYMPTOM
doesnt work.
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
385
FMI
Error type
Visible anomaly
Possible cause
ENGINE
POWER STAGE
FOR TD SIGNAL
30
01
ENGINE
POWER STAGE
FOR TD SIGNAL
30
02
Recommended repairs
Notes
signal Check the wiring between pin Check CAN VDB line: 1)
or 3 of the instrument and Resistance measured with
connector EDC pin B49.
key off directly on EDC ECU
between pin B52 (CAN L)
and pin B53 (CAN H) must
be equal to 120 ohm. 2)
Resistance measured with
key off on wiring between
pin B52 and pin B53 must be
equal to 120 ohm. 3)
Impedance
measured
between 30pin connector
pin 21 (CAN H) and pin 22
(CAN L) must be equal to
60 ohm +/3% (measured
with key off and ECUs
connected).
signal Check the wiring between pin Check CAN VDB line: 1)
or 3 of the instrument and Resistance measured with
connector EDC pin B49.
key off directly on EDC ECU
between pin B52 (CAN L)
and pin B53 (CAN H) must
be equal to 120 ohm. 2)
Resistance measured with
key off on wiring between
pin B52 and pin B53 must be
equal to 120 ohm. 3)
Impedance
measured
between 30pin connector
pin 21 (CAN H) and pin 22
(CAN L) must be equal to
60 ohm +/3% (measured
with key off and ECUs
connected).
ELECTRIC/ELECTRONIC SYSTEM
DTC
386
Component
failure
Print 603.93.381
FMI
Error type
ENGINE
POWER STAGE
FOR TD SIGNAL
30
03
NO SIGNAL
ENGINE
POWER STAGE
FOR
SYNC.
SIGNAL
(MODUS)
ENGINE
POWER STAGE
FOR
SYNC.
SIGNAL
(MODUS)
ENGINE
POWER STAGE
FOR
SYNC.
SIGNAL
(MODUS)
ENGINE
POWER STAGE
FOR
SYNC.
SIGNAL
(MODUS)
31
00
NO
AVAILABLE
SYMPTOM
31
01
SHORT CIRCUIT TO
POSITIVE
31
02
OPEN CIRCUIT OR
SHORT CIRCUIT TO
GROUND
31
03
NO SIGNAL
Visible anomaly
The speed
doesnt work.
Possible cause
Recommended repairs
Notes
signal Check the wiring between pin Check CAN VDB line: 1)
or 3 of the instrument and Resistance measured with
connector EDC pin B49.
key off directly on EDC ECU
between pin B52 (CAN L)
and pin B53 (CAN H) must
be equal to 120 ohm. 2)
Resistance measured with
key off on wiring between
pin B52 and pin B53 must be
equal to 120 ohm. 3)
Impedance
measured
between 30pin connector
pin 21 (CAN H) and pin 22
(CAN L) must be equal to
60 ohm +/3% (measured
with key off and ECUs
connected).
EDC
to
diagnostic Check that the wiring EDC pilot light off
instrument synchronization between connector EDC pin
signal shortcircuited or B48 and diagnosis plug pin 23,
opencircuited.
passing through the brown
sleeve B pin 11, is all right.
EDC
to
diagnostic Check that the wiring EDC pilot light off
instrument synchronization between connector EDC pin
signal shortcircuited or B48 and diagnosis plug pin 23,
opencircuited.
passing through the brown
sleeve B pin 11, is all right.
EDC
to
diagnostic Check that the wiring EDC pilot light off
instrument synchronization between connector EDC pin
signal shortcircuited or B48 and diagnosis plug pin 23,
opencircuited.
passing through the brown
sleeve B pin 11, is all right.
EDC
to
diagnostic Check that the wiring EDC pilot light off
instrument synchronization between connector EDC pin
signal shortcircuited or B48 and diagnosis plug pin 23,
opencircuited.
passing through the brown
sleeve B pin 11, is all right.
387
ELECTRIC/ELECTRONIC SYSTEM
DTC
Print 603.93.381
Component
failure
FMI
Error type
Visible anomaly
ENGINE
POWER STAGE
FOR TD SIGNAL
31
04
SIGNAL
PLAUSIBLE
ENGINE
POWER STAGE
FOR
SYNC.
SIGNAL
(MODUS)
ENGINE
POWER STAGE
FOR TD SIGNAL
31
04
SIGNAL
PLAUSIBLE
NOT
31
05
Possible cause
Recommended repairs
Notes
Print 603.93.381
signal Check the wiring between pin Check CAN VDB line: 1)
or 3 of the instrument and Resistance measured with
connector EDC pin B49.
key off directly on EDC ECU
between pin B52 (CAN L)
and pin B53 (CAN H) must
be equal to 120 ohm. 2)
Resistance measured with
key off on wiring between
pin B52 and pin B53 must be
equal to 120 ohm. 3)
Impedance
measured
between 30pin connector
pin 21 (CAN H) and pin 22
(CAN L) must be equal to
60 ohm +/3% (measured
with key off and ECUs
connected).
EDC
to
diagnostic Check that the wiring EDC pilot light off
instrument synchronization between connector EDC pin
signal shortcircuited or B48 and diagnosis plug pin 23,
opencircuited.
passing through the brown
sleeve B pin 11, is all right.
indicator Speed indicator signal Check the wiring between pin Check CAN VDB line: 1)
shortcircuited
or 3 of the instrument and Resistance measured with
opencircuited.
connector EDC pin B49.
key off directly on EDC ECU
between pin B52 (CAN L)
and pin B53 (CAN H) must
be equal to 120 ohm. 2)
Resistance measured with
key off on wiring between
pin B52 and pin B53 must be
equal to 120 ohm. 3)
Impedance
measured
between 30pin connector
pin 21 (CAN H) and pin 22
(CAN L) must be equal to
60 ohm +/3% (measured
with key off and ECUs
connected).
ELECTRIC/ELECTRONIC SYSTEM
DTC
388
Component
failure
DTC
FMI
Error type
Visible anomaly
ENGINE
POWER STAGE
FOR
SYNC.
SIGNAL
(MODUS)
ENGINE
POWER STAGE
FOR TD SIGNAL
31
05
31
06
ENGINE
POWER STAGE
FOR
SYNC.
SIGNAL
(MODUS)
31
06
Possible cause
Recommended repairs
EDC
to
diagnostic
instrument synchronization
signal shortcircuited or
opencircuited.
indicator Speed indicator
shortcircuited
opencircuited.
Notes
Print 603.93.381
Component
failure
ELECTRIC/ELECTRONIC SYSTEM
389
FMI
Error type
ENGINE
POWER STAGE
FOR TD SIGNAL
31
07
VALUE OVER
NORMAL LIMIT
ENGINE
POWER STAGE
FOR
SYNC.
SIGNAL
(MODUS)
ENGINE
POWER STAGE
FOR TD SIGNAL
31
07
VALUE OVER
NORMAL LIMIT
THE
31
08
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
signal Check the wiring between pin Check CAN VDB line: 1)
or 3 of the instrument and Resistance measured with
connector EDC pin B49.
key off directly on EDC ECU
between pin B52 (CAN L)
and pin B53 (CAN H) must
be equal to 120 ohm. 2)
Resistance measured with
key off on wiring between
pin B52 and pin B53 must be
equal to 120 ohm. 3)
Impedance
measured
between 30pin connector
pin 21 (CAN H) and pin 22
(CAN L) must be equal to
60 ohm +/3% (measured
with key off and ECUs
connected).
EDC
to
diagnostic Check that the wiring EDC pilot light off
instrument synchronization between connector EDC pin
signal shortcircuited or B48 and diagnosis plug pin 23,
opencircuited.
passing through the brown
sleeve B pin 11, is all right.
indicator Speed indicator signal Check the wiring between pin Check CAN VDB line: 1)
shortcircuited
or 3 of the instrument and Resistance measured with
opencircuited.
connector EDC pin B49.
key off directly on EDC ECU
between pin B52 (CAN L)
and pin B53 (CAN H) must
be equal to 120 ohm. 2)
Resistance measured with
key off on wiring between
pin B52 and pin B53 must be
equal to 120 ohm. 3)
Impedance
measured
between 30pin connector
pin 21 (CAN H) and pin 22
(CAN L) must be equal to
60 ohm +/3% (measured
with key off and ECUs
connected).
ELECTRIC/ELECTRONIC SYSTEM
DTC
390
Component
failure
DTC
FMI
Error type
ENGINE
POWER STAGE
FOR
SYNC.
SIGNAL
(MODUS)
WARNING
LIGHTS OIL
PRESSURE
GAUGE
31
08
VALUE
LIMIT
32
00
NO
AVAILABLE The pilot light either CAN line failure.
SYMPTOM
doesnt work or it remains
always lighted up.
WARNING
LIGHTS
COOLANT
TEMPERATUR
GAUGE
32
00
NO
AVAILABLE Incorrect display of the CAN line failure.
SYMPTOM
engine
coolant
temperature.
BELOW
Visible anomaly
THE
Possible cause
EDC
to
diagnostic
instrument synchronization
signal shortcircuited or
opencircuited.
Recommended repairs
Notes
Print 603.93.381
Component
failure
ELECTRIC/ELECTRONIC SYSTEM
391
FMI
Error type
Visible anomaly
Possible cause
WARNING
LIGHTS OIL
PRESSURE
GAUGE
32
01
WARNING
LIGHTS
COOLANT
TEMPERATUR
GAUGE
32
01
WARNING
LIGHTS OIL
PRESSURE
GAUGE
32
02
WARNING
LIGHTS
COOLANT
TEMPERATUR
GAUGE
32
02
Recommended repairs
Print 603.93.381
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
392
Component
failure
DTC
FMI
Error type
Visible anomaly
Possible cause
WARNING
LIGHTS OIL
PRESSURE
GAUGE
32
03
NO SIGNAL
WARNING
LIGHTS
COOLANT
TEMPERATUR
GAUGE
32
03
NO SIGNAL
WARNING
LIGHTS OIL
PRESSURE
GAUGE
32
04
SIGNAL
PLAUSIBLE
WARNING
LIGHTS
COOLANT
TEMPERATUR
GAUGE
32
04
SIGNAL
PLAUSIBLE
Recommended repairs
393
ELECTRIC/ELECTRONIC SYSTEM
Notes
Print 603.93.381
Component
failure
Error type
WARNING
LIGHTS OIL
PRESSURE
GAUGE
32
05
SUPPLY OVER THE The pilot light either CAN line failure.
NORMAL RANGE
doesnt work or it remains
always lighted up.
WARNING
LIGHTS
COOLANT
TEMPERATUR
GAUGE
32
05
WARNING
LIGHTS OIL
PRESSURE
GAUGE
32
06
SUPPLY BELOW THE The pilot light either CAN line failure.
RANGE
doesnt work or it remains
always lighted up.
WARNING
LIGHTS OIL
PRESSURE
GAUGE
32
07
VALUE OVER
NORMAL LIMIT
WARNING
LIGHTS OIL
PRESSURE
GAUGE
32
08
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Print 603.93.381
Notes
FMI
ELECTRIC/ELECTRONIC SYSTEM
DTC
394
Component
failure
FMI
SWITCH
ENGINE BRAKE
PRESELECTION
BUTTON
33
00
ENGINE
MONITORING
OF PRESSURE
RELIEF VALVE
SWITCH
ENGINE BRAKE
PRESELECTION
BUTTON
33
00
33
01
ENGINE
MONITORING
OF PRESSURE
RELIEF VALVE
SWITCH
ENGINE BRAKE
PRESELECTION
BUTTON
33
01
33
02
SWITCH
ENGINE BRAKE
PRESELECTION
BUTTON
33
03
Error type
Visible anomaly
Recommended repairs
NO
AVAILABLE The exhaust brake engages
only if operated by means of
SYMPTOM
the pushbutton on the
floor, or if operated by the
pushbutton on the floor
and only by means of one of
the other two ways, even if
a different selection has
been chosen.
NO
AVAILABLE Significant power reduction.
SYMPTOM
Notes
Intervention
of
the Carry out the checks foreseen EDC pilot light winking.
doublestage overpressure for 8.2 and 8.3.
valve.
Read Body Controller state
parameters with diagnostic
tool (engine brake switch not
managed by EDC).
Intervention
of
the Carry out the checks foreseen EDC pilot light winking.
doublestage overpressure for 8.2 and 8.3.
valve.
395
Possible cause
ELECTRIC/ELECTRONIC SYSTEM
DTC
Print 603.93.381
Component
failure
FMI
SWITCH
ENGINE BRAKE
PRESELECTION
BUTTON
33
04
SWITCH
ENGINE BRAKE
PRESELECTION
BUTTON
33
05
WARNING
LIGHTS
COOLANT
TEMPERATUR
GAUGE
33
06
SWITCH
ENGINE BRAKE
PRESELECTION
BUTTON
33
06
Error type
Visible anomaly
SIGNAL
PLAUSIBLE
NOT The
exhaust
brake
engages only if operated
by
means
of
the
pushbutton on the floor,
or if operated by the
pushbutton on the floor
and only by means of one
of the other two ways,
even if a different selection
has been chosen.
SUPPLY OVER THE The
exhaust
brake
NORMAL RANGE
engages only if operated
by
means
of
the
pushbutton on the floor,
or if operated by the
pushbutton on the floor
and only by means of one
of the other two ways,
even if a different selection
has been chosen.
SUPPLY BELOW THE Incorrect display of the
RANGE
engine
coolant
temperature.
Recommended repairs
Notes
Print 603.93.381
Possible cause
ELECTRIC/ELECTRONIC SYSTEM
DTC
396
Component
failure
FMI
Error type
Visible anomaly
Possible cause
WARNING
LIGHTS
COOLANT
TEMPERATUR
GAUGE
33
07
VALUE OVER
NORMAL LIMIT
SWITCH
ENGINE BRAKE
PRESELECTION
BUTTON
33
07
VALUE OVER
NORMAL LIMIT
WARNING
LIGHTS
COOLANT
TEMPERATUR
GAUGE
33
08
VALUE
LIMIT
BELOW
SWITCH
ENGINE BRAKE
PRESELECTION
BUTTON
33
08
VALUE
LIMIT
BELOW
ENGINE FUEL
PRESSURE
MONITORING
34
00
Recommended repairs
Notes
397
ELECTRIC/ELECTRONIC SYSTEM
DTC
Print 603.93.381
Component
failure
ENGINE FUEL
PRESSURE
MONITORING
ENGINE FUEL
PRESSURE
MONITORING
ENGINE FUEL
PRESSURE
MONITORING
Error type
34
00
NO
AVAILABLE
SYMPTOM
34
00
Visible anomaly
NO
AVAILABLE
SYMPTOM
34
00
NO
AVAILABLE
SYMPTOM
34
00
NO
AVAILABLE Significant
SYMPTOM
reduction.
34
01
TOO
HIGH
PRESSURE
Possible cause
Recommended repairs
Notes
Print 603.93.381
ENGINE FUEL
PRESSURE
MONITORING
FMI
ELECTRIC/ELECTRONIC SYSTEM
ENGINE FUEL
PRESSURE
MONITORING
DTC
398
Component
failure
ENGINE FUEL
PRESSURE
MONITORING
DTC
FMI
34
02
Error type
Visible anomaly
ENGINE FUEL
PRESSURE
MONITORING
34
02
OPEN CIRCUIT OR
SHORT CIRCUIT TO
GROUND
ENGINE
MONITORING
OF PRESSURE
RELIEF VALVE
ENGINE FUEL
PRESSURE
MONITORING
34
02
34
02
OPEN CIRCUIT OR
SHORT CIRCUIT TO
GROUND
ENGINE FUEL
PRESSURE
MONITORING
34
02
02
OPEN CIRCUIT OR
SHORT CIRCUIT TO
GROUND
OPEN CIRCUIT OR
SHORT CIRCUIT TO
GROUND
Recommended repairs
Notes
Reading
of
measurable EDC pilot light winking.
parameters: ?Duty Cycle rail
pressure solenoid valve?
(with release 22001
subsequent ones):
and
ELECTRIC/ELECTRONIC SYSTEM
399
ENGINE FUEL
PRESSURE
MONITORING
34
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
Visible anomaly
ENGINE
MONITORING
OF PRESSURE
RELIEF VALVE
ENGINE FUEL
PRESSURE
MONITORING
34
03
NO SIGNAL
34
03
TOO
LOW
PRESSURE
ENGINE
MONITORING
OF PRESSURE
RELIEF VALVE
ENGINE FUEL
PRESSURE
MONITORING
34
04
SIGNAL
PLAUSIBLE
NOT Significant
reduction.
34
04
NEGATIVE
FUEL Significant
PRESSURE DEVIATION reduction.
Significant
reduction.
34
04
NEGATIVE
FUEL
PRESSURE DEVIATION
34
04
NEGATIVE
FUEL
PRESSURE DEVIATION
ENGINE FUEL
PRESSURE
MONITORING
34
04
NEGATIVE
FUEL
PRESSURE DEVIATION
Recommended repairs
Notes
power Intervention
of
the Carry out the checks foreseen EDC pilot light winking.
doublestage overpressure for 8.2 and 8.3.
valve.
Maxmin pressure error in Replace the overpressure valve EDC pilot light winking.
the rail
If the problem persists, carry out
Check that suction and the checks foreseen for 8.2 and
return lines of gasoil are not 8.3.
inverted (tank sensor)
power Intervention
of
the Carry out the checks foreseen EDC pilot light winking.
doublestage overpressure for 8.2 and 8.3.
valve.
power Fuel pressure adjustment:
pressure in the rail is lower
or higher than the one
evaluated by the gearcase.
Reading
of
measurable EDC pilot light winking.
parameters: ?Duty Cycle rail
pressure solenoid valve?
(with release 22001
subsequent ones):
and
Print 603.93.381
ENGINE FUEL
PRESSURE
MONITORING
ENGINE FUEL
PRESSURE
MONITORING
Possible cause
ELECTRIC/ELECTRONIC SYSTEM
DTC
400
Component
failure
ENGINE FUEL
PRESSURE
MONITORING
DTC
FMI
Error type
34
04
NEGATIVE
FUEL
PRESSURE DEVIATION
Visible anomaly
ENGINE
MONITORING
OF PRESSURE
RELIEF VALVE
ENGINE FUEL
PRESSURE
MONITORING
34
05
34
05
POSITIVE
FUEL
PRESSURE DEVIATION
ENGINE FUEL
PRESSURE
MONITORING
34
05
POSITIVE
FUEL Significant
PRESSURE DEVIATION reduction.
34
05
POSITIVE
FUEL
PRESSURE DEVIATION
ENGINE FUEL
PRESSURE
MONITORING
34
05
POSITIVE
FUEL
PRESSURE DEVIATION
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
401
ENGINE FUEL
PRESSURE
MONITORING
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
Visible anomaly
ENGINE FUEL
PRESSURE
MONITORING
34
05
POSITIVE
FUEL
PRESSURE DEVIATION
ENGINE
MONITORING
OF PRESSURE
RELIEF VALVE
ENGINE FUEL
PRESSURE
MONITORING
34
06
34
06
LEAKAGE IN OVERRUN
ENGINE FUEL
PRESSURE
MONITORING
34
06
LEAKAGE IN OVERRUN
ENGINE FUEL
PRESSURE
MONITORING
34
06
LEAKAGE IN OVERRUN
Possible cause
Recommended repairs
Notes
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
DTC
402
Component
failure
FMI
Error type
Visible anomaly
Possible cause
ENGINE FUEL
PRESSURE
MONITORING
ENGINE FUEL
PRESSURE
MONITORING
34
06
LEAKAGE IN OVERRUN
34
06
ENGINE FUEL
PRESSURE
MONITORING
34
07
LEAKAGE QBAL
ENGINE FUEL
PRESSURE
MONITORING
ENGINE
MONITORING
OF
PRESSURE
RELIEF VALVE
ENGINE FUEL
PRESSURE
MONITORING
34
07
LEAKAGE QBAL
34
07
VALUE OVER
NORMAL LIMIT
34
07
LEAKAGE QBAL
ENGINE FUEL
PRESSURE
MONITORING
34
07
LEAKAGE QBAL
Recommended repairs
THE Significant
reduction.
Significant
reduction.
Reading
of
measurable
parameters: ?Duty Cycle rail
pressure solenoid valve?
(with release 22001 and
subsequent ones):
in normal conditions, at idling
speed, loadless, and steady state
engine, the value must be lower
than 5%.
Check whether the priming
pump on the prefilter works
properly.
If the pump knob remains
sucked downwards because of
the
suction
pressure,
disassemble and check the tank
suction pipe.
If the suction pipe is all right,
replace the filter.
Check fuel level.
Notes
power Intervention
of
the Carry out the checks foreseen EDC pilot light winking.
doublestage overpressure for 8.2 and 8.3.
valve.
power Fuel pressure adjustment:
pressure in the rail is lower
or higher than the one
evaluated by the gearcase.
Reading
of
measurable EDC pilot light winking.
parameters: ?Duty Cycle rail
pressure solenoid valve?
(with release 22001 and
subsequent ones):
in normal conditions, at idling
speed, loadless, and steady state
engine, the value must be lower
than 5%.
Air intake upstream of the Check the ORings and the EDC pilot light winking.
proper connection of the pipe
fuel gear pump.
unions between the tank and
the fuel pump (fasteners must
be out and unions well
hooked).
ELECTRIC/ELECTRONIC SYSTEM
403
DTC
Print 603.93.381
Component
failure
ENGINE
MONITORING
OF PRESSURE
RELIEF VALVE
SENSORS OIL
PRESSURE
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
STARTUP
FMI
34
07
Error type
Visible anomaly
LEAKAGE QBAL
08
VALUE
LIMIT
35
00
NO
AVAILABLE Power reduction
SYMPTOM
00
Recommended repairs
34
35
BELOW
Possible cause
THE Significant
reduction.
NO
AVAILABLE Significant
SYMPTOM
reduction.
Notes
sensor Reading
of
measurable
or parameters by means of the
diagnostic instrument: in
presence of this error, the oil
pressure will be fixed at 60
mbar.
ELECTRIC/ELECTRONIC SYSTEM
ENGINE FUEL
PRESSURE
MONITORING
DTC
404
Component
failure
Print 603.93.381
SENSORS OIL
PRESSURE
DTC
FMI
35
01
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
STARTUP
35
SENSORS OIL
PRESSURE
35
35
02
02
Visible anomaly
Possible cause
Oil
pressure
shortcircuited
opencircuited.
Recommended repairs
sensor Reading
of
measurable
or parameters by means of the
diagnostic instrument: in
presence of this error, the oil
pressure will be fixed at 60
mbar.
Oil
pressure
shortcircuited
opencircuited.
sensor
or
Notes
ELECTRIC/ELECTRONIC SYSTEM
405
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
STARTUP
01
Error type
Print 603.93.381
Component
failure
FMI
35
03
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
STARTUP
35
SENSORS OIL
PRESSURE
35
SENSORS OIL
PRESSURE
35
03
04
05
Error type
NO SIGNAL
NO SIGNAL
SIGNAL
PLAUSIBLE
Visible anomaly
Power reduction
Significant
reduction.
Possible cause
Oil
pressure
shortcircuited
opencircuited.
Recommended repairs
sensor Reading
of
measurable
or parameters by means of the
diagnostic
instrument:
in
presence of this error, the oil
pressure will be fixed at 60
mbar.
Oil
pressure
shortcircuited
opencircuited.
Oil
pressure
shortcircuited
opencircuited.
sensor
or
Print 603.93.381
Notes
ELECTRIC/ELECTRONIC SYSTEM
SENSORS OIL
PRESSURE
DTC
406
Component
failure
SENSORS OIL
PRESSURE
SENSORS OIL
PRESSURE
DTC
FMI
35
06
35
07
Error type
Visible anomaly
VALUE OVER
NORMAL LIMIT
35
08
LEAKAGE IN LOWIDLE
ENGINE FUEL
PRESSURE
MONITORING
35
08
LEAKAGE IN LOWIDLE
Significant
reduction.
Oil
pressure
shortcircuited
opencircuited.
Oil
pressure
shortcircuited
opencircuited.
Recommended repairs
sensor Reading
of
measurable
or parameters by means of the
diagnostic
instrument:
in
presence of this error, the oil
pressure will be fixed at 60
mbar.
Verify the wiring between the
sensor connector (wiring side)
pin 3 and connector EDC pin
C9, between sensor connector
(wiring side) pin 4 and
connector EDC pin C35.
sensor Reading
of
measurable
or parameters by means of the
diagnostic
instrument:
in
presence of this error, the oil
pressure will be fixed at 60
mbar.
Notes
407
ELECTRIC/ELECTRONIC SYSTEM
ENGINE FUEL
PRESSURE
MONITORING
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
ENGINE FUEL
PRESSURE
MONITORING
35
08
LEAKAGE IN LOWIDLE
ENGINE FUEL
PRESSURE
MONITORING
35
08
LEAKAGE IN LOWIDLE
ENGINE FUEL
PRESSURE
MONITORING
SENSORS OIL
PRESSURE
35
08
LEAKAGE IN LOWIDLE
35
08
VALUE
LIMIT
COMMUNICATI
ON LINES Can
B Module
36
00
BELOW
Visible anomaly
NO
AVAILABLE
SYMPTOM
Possible cause
Recommended repairs
Notes
CAN line.
sensor Reading
of
measurable
or parameters by means of the
diagnostic
instrument:
in
presence of this error, the oil
pressure will be fixed at 60
mbar.
ELECTRIC/ELECTRONIC SYSTEM
DTC
408
Component
failure
Print 603.93.381
DTC
FMI
Error type
Visible anomaly
Possible cause
COMMUNICATI
ON LINES Can
B Module
36
00
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
COMMUNICATI
ON LINES Can
B Module
36
01
SHORT CIRCUIT TO
POSITIVE
CAN line.
Recommended repairs
Notes
Print 603.93.381
Component
failure
36
01
409
ELECTRIC/ELECTRONIC SYSTEM
FMI
Error type
36
02
OPEN CIRCUIT OR
SHORT CIRCUIT TO
GROUND
Visible anomaly
Possible cause
CAN line.
Recommended repairs
Notes
COMMUNICATI
ON LINES Can
B Module
36
02
COMMUNICATI
ON LINES Can
B Module
36
03
NO SIGNAL
CAN line.
ELECTRIC/ELECTRONIC SYSTEM
COMMUNICATI
ON LINES Can
B Module
DTC
410
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES Can
B Module
36
03
NO SIGNAL
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
STARTUP
36
04
SIGNAL
PLAUSIBLE
NOT Significant
reduction.
COMMUNICATI
ON LINES Can
B Module
36
SIGNAL
PLAUSIBLE
NOT
04
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
411
ELECTRIC/ELECTRONIC SYSTEM
FMI
COMMUNICATI
ON LINES Can
B Module
36
04
SIGNAL
PLAUSIBLE
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
STARTUP
36
05
COMMUNICATI
ON LINES Can
B Module
36
05
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
412
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES Can
B Module
36
05
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
STARTUP
36
06
COMMUNICATI
ON LINES Can
B Module
36
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
413
ELECTRIC/ELECTRONIC SYSTEM
FMI
COMMUNICATI
ON LINES Can
B Module
36
06
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
STARTUP
36
07
VALUE OVER
NORMAL LIMIT
THE Significant
reduction.
COMMUNICATI
ON LINES Can
B Module
36
VALUE OVER
NORMAL LIMIT
THE
07
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
414
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES Can
B Module
36
07
VALUE OVER
NORMAL LIMIT
ELECTRONIC
CONTROL
UNIT SELF
TEST SHUTOFF
PATHS
STARTUP
36
08
VALUE
LIMIT
BELOW
THE Significant
reduction.
COMMUNICATI
ON LINES Can
B Module
36
VALUE
LIMIT
BELOW
08
Visible anomaly
THE
Possible cause
Recommended repairs
Notes
Print 603.93.381
Component
failure
415
ELECTRIC/ELECTRONIC SYSTEM
FMI
Error type
COMMUNICATI
ON LINES Can
B Module
36
08
VALUE
LIMIT
Possible cause
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
COMMUNICATI
ON LINES
BC2EDC1: Body
Computer
to
EDC #1
37
00
BELOW
Visible anomaly
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
416
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES
BC2EDC2: Body
Computer
to
EDC #2
37
00
COMMUNICATI
ON LINES
BC2EDC1: Body
Computer
to
EDC #1
37
01
Error type
Visible anomaly
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
Notes
417
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
BC2EDC2: Body
Computer
to
EDC #2
37
01
COMMUNICATI
ON LINES
BC2EDC1: Body
Computer
to
EDC #1
37
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
418
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES
BC2EDC2: Body
Computer
to
EDC #2
37
02
COMMUNICATI
ON LINES
BC2EDC2: Body
Computer
to
EDC #2
37
03
Error type
Visible anomaly
Recommended repairs
NO SIGNAL
Notes
419
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES
BC2EDC1: Body
Computer
to
EDC #1
37
03
NO SIGNAL
COMMUNICATI
ON LINES
BC2EDC2: Body
Computer
to
EDC #2
37
04
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
420
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES
BC2EDC1: Body
Computer
to
EDC #1
37
04
SIGNAL
PLAUSIBLE
COMMUNICATI
ON LINES
BC2EDC2: Body
Computer
to
EDC #2
37
05
Visible anomaly
Recommended repairs
Notes
421
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
BC2EDC1: Body
Computer
to
EDC #1
37
05
COMMUNICATI
ON LINES
BC2EDC1: Body
Computer
to
EDC #1
37
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
422
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES
BC2EDC1: Body
Computer
to
EDC #1
37
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES
BC2EDC1: Body
Computer
to
EDC #1
37
08
VALUE
LIMIT
BELOW
Visible anomaly
Recommended repairs
Notes
423
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
EBC1: Electronic
Brake Controller
38
00
COMMUNICATI
ON LINES
CCVSV: Cruise
Control
from
Vehicle
Controller
38
00
Error type
Visible anomaly
Possible cause
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
424
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES
CCVSV: Cruise
Control
from
Vehicle
Controller
38
01
COMMUNICATI
ON LINES
EBC1: Electronic
Brake Controller
38
01
Error type
Visible anomaly
Recommended repairs
Notes
425
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
CCVSV: Cruise
Control
from
Vehicle
Controller
38
02
COMMUNICATI
ON LINES
CCVSV: Cruise
Control
from
Vehicle
Controller
38
03
Error type
Visible anomaly
Possible cause
Recommended repairs
NO SIGNAL
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
426
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES
CCVSV: Cruise
Control
from
Vehicle
Controller
38
04
SIGNAL
PLAUSIBLE
COMMUNICATI
ON LINES
CCVSV: Cruise
Control
from
Vehicle
Controller
38
05
Visible anomaly
Recommended repairs
Notes
427
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
BC2EDC2: Body
Computer
to
EDC #2
38
06
COMMUNICATI
ON LINES
CCVSV: Cruise
Control
from
Vehicle
Controller
38
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
428
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES
BC2EDC2: Body
Computer
to
EDC #2
38
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES
CCVSV: Cruise
Control
from
Vehicle
Controller
38
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Recommended repairs
Notes
429
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES
CCVSV: Cruise
Control
from
Vehicle
Controller
38
08
VALUE
LIMIT
BELOW
COMMUNICATI
ON LINES
BC2EDC2: Body
Computer
to
EDC #2
38
08
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
430
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES
ETC1: Electronic
Trasmission
Controller
39
00
COMMUNICATI
ON LINES
ETC1: Electronic
Trasmission
Controller
39
01
Error type
Visible anomaly
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
Notes
431
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
EBC1: Electronic
Brake Controller
39
02
COMMUNICATI
ON LINES
ETC1: Electronic
Trasmission
Controller
39
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
432
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES
EBC1: Electronic
Brake Controller
39
03
COMMUNICATI
ON LINES
ETC1: Electronic
Trasmission
Controller
39
03
Error type
Possible cause
Recommended repairs
NO SIGNAL
NO SIGNAL
Notes
433
ELECTRIC/ELECTRONIC SYSTEM
Visible anomaly
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES
EBC1: Electronic
Brake Controller
39
04
SIGNAL
PLAUSIBLE
COMMUNICATI
ON LINES
ETC1: Electronic
Trasmission
Controller
39
04
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
434
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES
EBC1: Electronic
Brake Controller
39
05
COMMUNICATI
ON LINES
ETC1: Electronic
Trasmission
Controller
39
05
Error type
Visible anomaly
Recommended repairs
Notes
435
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
EBC1: Electronic
Brake Controller
39
06
COMMUNICATI
ON LINES
ETC1: Electronic
Trasmission
Controller
39
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
436
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES
EBC1: Electronic
Brake Controller
39
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES
ETC1: Electronic
Trasmission
Controller
39
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Recommended repairs
Notes
437
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES
EBC1: Electronic
Brake Controller
39
08
VALUE
LIMIT
Possible cause
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
COMMUNICATI
ON LINES AE:
Torque/Speed
Control
from
ATC (Asr)
to
EDC
3A
00
BELOW
Visible anomaly
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
438
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES DE:
Torque/Speed
Control
from
Driveline
Retarder to EDC
3A
00
COMMUNICATI
ON LINES DE:
Torque/Speed
Control
from
Driveline
Retarder to EDC
3A
01
Error type
Visible anomaly
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
Notes
439
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES AE:
Torque/Speed
Control
from
ATC (Asr)
to
EDC
3A
01
COMMUNICATI
ON LINES DE:
Torque/Speed
Control
from
Driveline
Retarder to EDC
3A
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
440
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES AE:
Torque/Speed
Control
from
ATC (Asr)
to
EDC
3A
02
COMMUNICATI
ON LINES AE:
Torque/Speed
Control
from
ATC (Asr)
to
EDC
3A
03
Error type
Visible anomaly
Recommended repairs
NO SIGNAL
Notes
441
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES DE:
Torque/Speed
Control
from
Driveline
Retarder to EDC
3A
03
NO SIGNAL
COMMUNICATI
ON LINES AE:
Torque/Speed
Control
from
ATC (Asr)
to
EDC
3A
04
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
442
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES AE:
Torque/Speed
Control
from
ATC (Asr)
to
EDC
3A
05
COMMUNICATI
ON LINES AE:
Torque/Speed
Control
from
ATC (Asr)
to
EDC
3A
06
Error type
Visible anomaly
Recommended repairs
Notes
443
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES AE:
Torque/Speed
Control
from
ATC (Asr)
to
EDC
3A
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES
ETC1: Electronic
Trasmission
Controller
3A
08
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
444
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES AE:
Torque/Speed
Control
from
ATC (Asr)
to
EDC
3A
08
VALUE
LIMIT
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
COMMUNICATI
ON LINES PE:
Torque/Speed
Control
from
PTO to EDC
3B
00
Notes
445
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
BELOW
Visible anomaly
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES PE:
Torque/Speed
Control
from
PTO to EDC
3B
01
COMMUNICATI
ON LINES PE:
Torque/Speed
Control
from
PTO to EDC
3B
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
446
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES PE:
Torque/Speed
Control
from
PTO to EDC
3B
03
NO SIGNAL
COMMUNICATI
ON LINES DE:
Torque/Speed
Control
from
Driveline
Retarder to EDC
3B
04
SIGNAL
PLAUSIBLE
Possible cause
Recommended repairs
Notes
447
ELECTRIC/ELECTRONIC SYSTEM
Visible anomaly
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES PE:
Torque/Speed
Control
from
PTO to EDC
3B
04
SIGNAL
PLAUSIBLE
COMMUNICATI
ON LINES DE:
Torque/Speed
Control
from
Driveline
Retarder to EDC
3B
05
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
448
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES PE:
Torque/Speed
Control
from
PTO to EDC
3B
05
COMMUNICATI
ON LINES DE:
Torque/Speed
Control
from
Driveline
Retarder to EDC
3B
06
Error type
Visible anomaly
Recommended repairs
Notes
449
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES PE:
Torque/Speed
Control
from
PTO to EDC
3B
06
COMMUNICATI
ON LINES DE:
Torque/Speed
Control
from
Driveline
Retarder to EDC
3B
07
Error type
Visible anomaly
Possible cause
Recommended repairs
VALUE OVER
NORMAL LIMIT
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
450
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES PE:
Torque/Speed
Control
from
PTO to EDC
3B
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES DE:
Torque/Speed
Control
from
Driveline
Retarder to EDC
3B
08
VALUE
LIMIT
BELOW
Visible anomaly
Recommended repairs
Notes
451
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES PE:
Torque/Speed
Control
from
PTO to EDC
3B
08
VALUE
LIMIT
Possible cause
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
COMMUNICATI
ON LINES TE:
Torque/Speed
Control from ETC
to EDC
3C
00
BELOW
Visible anomaly
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
452
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES VE:
Torque/Speed
Control
from
Vehicle
Management to
EDC
3C
00
COMMUNICATI
ON LINES TE:
Torque/Speed
Control from ETC
to EDC
3C
01
Error type
Visible anomaly
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
Notes
453
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES VE:
Torque/Speed
Control
from
Vehicle
Management to
EDC
3C
01
COMMUNICATI
ON LINES TE:
Torque/Speed
Control from ETC
to EDC
3C
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
454
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES VE:
Torque/Speed
Control
from
Vehicle
Management to
EDC
3C
02
COMMUNICATI
ON LINES TE:
Torque/Speed
Control from ETC
to EDC
3C
03
Error type
Visible anomaly
Recommended repairs
NO SIGNAL
Notes
455
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES VE:
Torque/Speed
Control
from
Vehicle
Management to
EDC
3C
03
NO SIGNAL
COMMUNICATI
ON LINES TE:
Torque/Speed
Control from ETC
to EDC
3C
04
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
456
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES VE:
Torque/Speed
Control
from
Vehicle
Management to
EDC
3C
04
SIGNAL
PLAUSIBLE
COMMUNICATI
ON LINES TE:
Torque/Speed
Control from ETC
to EDC
3C
05
Visible anomaly
Recommended repairs
Notes
457
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES VE:
Torque/Speed
Control
from
Vehicle
Management to
EDC
3C
05
COMMUNICATI
ON LINES TE:
Torque/Speed
Control from ETC
to EDC
3C
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
458
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES TE:
Torque/Speed
Control from ETC
to EDC
3C
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES TE:
Torque/Speed
Control from ETC
to EDC
3C
08
VALUE
LIMIT
BELOW
Visible anomaly
Recommended repairs
Notes
459
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES AR:
Torque/Speed
Control
from
ATC (Asr) to
Engine Brake
3D
00
COMMUNICATI
ON LINES DR:
Torque/Speed
Control
from
Driveline
Retarder
to
Engine Brake
3D
00
Error type
Visible anomaly
Possible cause
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
460
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES AR:
Torque/Speed
Control
from
ATC (Asr) to
Engine Brake
3D
01
COMMUNICATI
ON LINES DR:
Torque/Speed
Control
from
Driveline
Retarder
to
Engine Brake
3D
01
Error type
Visible anomaly
Recommended repairs
Notes
461
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES AR:
Torque/Speed
Control
from
ATC (Asr) to
Engine Brake
3D
02
COMMUNICATI
ON LINES AR:
Torque/Speed
Control
from
ATC (Asr) to
Engine Brake
3D
03
Error type
Visible anomaly
Possible cause
Recommended repairs
NO SIGNAL
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
462
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES AR:
Torque/Speed
Control
from
ATC (Asr) to
Engine Brake
3D
04
SIGNAL
PLAUSIBLE
COMMUNICATI
ON LINES AR:
Torque/Speed
Control
from
ATC (Asr) to
Engine Brake
3D
05
Visible anomaly
Recommended repairs
Notes
463
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES AR:
Torque/Speed
Control
from
ATC (Asr) to
Engine Brake
3D
06
COMMUNICATI
ON LINES VE:
Torque/Speed
Control
from
Vehicle
Management to
EDC
3D
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
464
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES AR:
Torque/Speed
Control
from
ATC (Asr) to
Engine Brake
3D
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES VE:
Torque/Speed
Control
from
Vehicle
Management to
EDC
3D
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Recommended repairs
Notes
465
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES VE:
Torque/Speed
Control
from
Vehicle
Management to
EDC
3D
08
VALUE
LIMIT
BELOW
COMMUNICATI
ON LINES AR:
Torque/Speed
Control
from
ATC (Asr) to
Engine Brake
3D
08
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
466
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES TR:
Torque/Speed
Control from ETC
to Engine Brake
3E
00
COMMUNICATI
ON LINES TR:
Torque/Speed
Control from ETC
to Engine Brake
3E
01
Error type
Visible anomaly
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
Notes
467
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES DR:
Torque/Speed
Control
from
Driveline
Retarder
to
Engine Brake
3E
02
COMMUNICATI
ON LINES TR:
Torque/Speed
Control from ETC
to Engine Brake
3E
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
468
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES DR:
Torque/Speed
Control
from
Driveline
Retarder
to
Engine Brake
3E
03
COMMUNICATI
ON LINES TR:
Torque/Speed
Control from ETC
to Engine Brake
3E
03
Error type
Possible cause
Recommended repairs
NO SIGNAL
NO SIGNAL
Notes
469
ELECTRIC/ELECTRONIC SYSTEM
Visible anomaly
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES DR:
Torque/Speed
Control
from
Driveline
Retarder
to
Engine Brake
3E
04
SIGNAL
PLAUSIBLE
COMMUNICATI
ON LINES TR:
Torque/Speed
Control from ETC
to Engine Brake
3E
04
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
470
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES DR:
Torque/Speed
Control
from
Driveline
Retarder
to
Engine Brake
3E
05
COMMUNICATI
ON LINES TR:
Torque/Speed
Control from ETC
to Engine Brake
3E
05
Error type
Visible anomaly
Recommended repairs
Notes
471
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES DR:
Torque/Speed
Control
from
Driveline
Retarder
to
Engine Brake
3E
06
COMMUNICATI
ON LINES TR:
Torque/Speed
Control from ETC
to Engine Brake
3E
06
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
472
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES DR:
Torque/Speed
Control
from
Driveline
Retarder
to
Engine Brake
3E
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES TR:
Torque/Speed
Control from ETC
to Engine Brake
3E
07
VALUE OVER
NORMAL LIMIT
Visible anomaly
Recommended repairs
Notes
473
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES DR:
Torque/Speed
Control
from
Driveline
Retarder
to
Engine Brake
3E
08
VALUE
LIMIT
Possible cause
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
COMMUNICATI
ON LINES VR:
Torque/Speed
Control
from
Vehicle
Management to
Engine Brake
3F
00
BELOW
Visible anomaly
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
474
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES
VM2EDC2:
Vehicle
Management to
EDC #2
3F
00
COMMUNICATI
ON LINES VR:
Torque/Speed
Control
from
Vehicle
Management to
Engine Brake
3F
01
Error type
Visible anomaly
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
Notes
475
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES
VM2EDC2:
Vehicle
Management to
EDC #2
3F
01
COMMUNICATI
ON LINES VR:
Torque/Speed
Control
from
Vehicle
Management to
Engine Brake
3F
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
476
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES
VM2EDC2:
Vehicle
Management to
EDC #2
3F
02
COMMUNICATI
ON LINES VR:
Torque/Speed
Control
from
Vehicle
Management to
Engine Brake
3F
03
Error type
Visible anomaly
Recommended repairs
NO SIGNAL
Notes
477
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES
VM2EDC2:
Vehicle
Management to
EDC #2
3F
03
NO SIGNAL
COMMUNICATI
ON LINES VR:
Torque/Speed
Control
from
Vehicle
Management to
Engine Brake
3F
04
SIGNAL
PLAUSIBLE
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
478
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES VR:
Torque/Speed
Control
from
Vehicle
Management to
Engine Brake
3F
05
COMMUNICATI
ON LINES VR:
Torque/Speed
Control
from
Vehicle
Management to
Engine Brake
3F
06
Error type
Visible anomaly
Recommended repairs
Notes
479
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES VR:
Torque/Speed
Control
from
Vehicle
Management to
Engine Brake
3F
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES TR:
Torque/Speed
Control from ETC
to Engine Brake
3F
08
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
480
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES VR:
Torque/Speed
Control
from
Vehicle
Management to
Engine Brake
3F
08
VALUE
LIMIT
Recommended repairs
NO
AVAILABLE CAN message appears on
SYMPTOM
Cluster.CAN messages
cannot be viewed on
Cluster.
Possible
communication problem
with IMMOBILIZER for
cranking. Possible ECAS
suspension
levelling
operation problem via
remote control in cab.
Speedometer may stay
off.
COMMUNICATI
ON LINES WSI:
Wheel
Speed
Information
40
00
Notes
481
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
BELOW
Visible anomaly
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES WSI:
Wheel
Speed
Information
40
01
COMMUNICATI
ON LINES WSI:
Wheel
Speed
Information
40
02
Error type
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
482
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES WSI:
Wheel
Speed
Information
40
03
NO SIGNAL
COMMUNICATI
ON LINES
VM2EDC2:
Vehicle
Management to
EDC #2
40
04
SIGNAL
PLAUSIBLE
Possible cause
Recommended repairs
Notes
483
ELECTRIC/ELECTRONIC SYSTEM
Visible anomaly
Print 603.93.381
Component
failure
FMI
Error type
COMMUNICATI
ON LINES WSI:
Wheel
Speed
Information
40
04
SIGNAL
PLAUSIBLE
COMMUNICATI
ON LINES
VM2EDC2:
Vehicle
Management to
EDC #2
40
05
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
484
Component
failure
Print 603.93.381
DTC
FMI
COMMUNICATI
ON LINES WSI:
Wheel
Speed
Information
40
05
COMMUNICATI
ON LINES
VM2EDC2:
Vehicle
Management to
EDC #2
40
06
Error type
Visible anomaly
Recommended repairs
Notes
485
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
COMMUNICATI
ON LINES WSI:
Wheel
Speed
Information
40
06
COMMUNICATI
ON LINES
VM2EDC2:
Vehicle
Management to
EDC #2
40
07
Error type
Visible anomaly
Possible cause
Recommended repairs
VALUE OVER
NORMAL LIMIT
Notes
ELECTRIC/ELECTRONIC SYSTEM
DTC
486
Component
failure
Print 603.93.381
DTC
FMI
Error type
COMMUNICATI
ON LINES WSI:
Wheel
Speed
Information
40
07
VALUE OVER
NORMAL LIMIT
COMMUNICATI
ON LINES
VM2EDC2:
Vehicle
Management to
EDC #2
40
08
VALUE
LIMIT
BELOW
Visible anomaly
Recommended repairs
Notes
487
ELECTRIC/ELECTRONIC SYSTEM
Possible cause
Print 603.93.381
Component
failure
FMI
40
08
Error type
VALUE
LIMIT
BELOW
Visible anomaly
Possible cause
Recommended repairs
Notes
ELECTRIC/ELECTRONIC SYSTEM
COMMUNICATI
ON LINES WSI:
Wheel
Speed
Information
DTC
488
Component
failure
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
489
MAINTENANCE SCHEDULE
One important functional character is the ELECTRONIC MAINTENANCE SCHEDULE which can, with the latest Modus and
IT2000 release, be managed and programmed very easily.
The workshop service slip will be quickly registered directly on the vehicle, and the recorded maintenance history will be able to
be displayed.
The Dealerhsip Workshop shall, prior to delivering the vehicle, program the maintenance schedule (from among those established
by Iveco) into the onboard panel control unit by means of the diagnosis station.
According to the vehicles mission, a km or hourbased maintenance schedule can be chosen.
The single workshop can subsequently modify the maintenance schedule according to the vehicle requirements.
After the vehicle has been delivered, the driver will be able to refer to their own maintenance schedule through the owner handbook
and also by means of their own Cluster, where a screen dedicated to this function will be available.
The customer can neither cancel or modify the program; they will have to contact an authorized Iveco service center.
Figure 224
004909t
Print 603.93.381
490
ELECTRIC/ELECTRONIC SYSTEM
Shortly before the vehicle has reached the distance in kilometres at which the service slip is to be made, an alarm warning light will
illuminate on the Cluster, to inform the driver that the vehicle has to be serviced at an authorized workshop.
Figure 225
004909t
If the vehicle is serviced at a workshop where a diagnosis instrument is available, the instrument will, after maintenance has been
completed, have to be connected: it will store both the date and the type of slip into the Cluster memory, and then will cause the
alarm warning light to go out.
In the event that operational maintenance is not carried out at a service centre where a diagnosis instrument is available, the warning
light on the dashboard cannot be turned off.
At the root of this choice is a strategy aimed at making the customer more and more loyal to the brandname through the
competence of our Dealerships, so as to induce the customer to go to an authorized workshop and have any type of maintenance
work (including operational maintenance) performed on the vehicle by qualified engineers.
This system, introduced into the latest EuroCargo, obviously gives new advantages to the customer too, who will therefore be able
to better plan their vehicles maintenance schedule (and will always remember to have it done). Thus, they will always be able to
rely on vehicles in perfect working order and ensuring top performance levels.
This functional character is possible provided that the vehicle is equipped with a HighLinetype Cluster. It is not available on
BaseLinetype Clusters.
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
491
Circuit cards
Page
Print 603.93.381
Card 1:
Card 2:
Card 3:
Card 4:
Card 5:
Card 6:
Card 7:
Card 8:
Card 9:
Card 10:
Card 11:
Card 12:
Card 13:
Card 14:
Immobilizer . . . . . . . . . . . . . . . . . . . . . . 506
Card 15:
ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
Card 16:
ECAS P . . . . . . . . . . . . . . . . . . . . . . . . . 508
Card 17:
ECAS FP . . . . . . . . . . . . . . . . . . . . . . . . 509
Card 18:
Card 19:
Card 20:
Card 21:
Card 22:
Card 23:
Card 24:
492
ELECTRIC/ELECTRONIC SYSTEM
Page
Card 25:
Card 26:
Card 27:
Card 28:
Card 29:
Card 30:
Card 31::
Card 32:
Card 33:
Card 34:
Print 603.93.381
Card 1:
ELECTRIC/ELECTRONIC SYSTEM
493
101640
Print 603.93.381
494
ELECTRIC/ELECTRONIC SYSTEM
Card 2:
101641
Print 603.93.381
Card 3:
ELECTRIC/ELECTRONIC SYSTEM
495
101642
Print 603.93.381
496
ELECTRIC/ELECTRONIC SYSTEM
Card 4:
101643
Print 603.93.381
Card 5:
ELECTRIC/ELECTRONIC SYSTEM
497
101644
Print 603.93.381
498
ELECTRIC/ELECTRONIC SYSTEM
Card 6:
101645
Print 603.93.381
Card 7:
ELECTRIC/ELECTRONIC SYSTEM
499
Body Controller
101646
Print 603.93.381
500
ELECTRIC/ELECTRONIC SYSTEM
Card 8:
Body Controller
101647
Print 603.93.381
Card 9:
ELECTRIC/ELECTRONIC SYSTEM
501
Body Controller
101648
Print 603.93.381
502
ELECTRIC/ELECTRONIC SYSTEM
101649
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
503
101650
Print 603.93.381
504
ELECTRIC/ELECTRONIC SYSTEM
101652
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
505
101653
Print 603.93.381
506
ELECTRIC/ELECTRONIC SYSTEM
101654
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
507
101655
Print 603.93.381
508
ELECTRIC/ELECTRONIC SYSTEM
101659
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
509
101660
Print 603.93.381
510
ELECTRIC/ELECTRONIC SYSTEM
101661
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
511
101662
Print 603.93.381
512
ELECTRIC/ELECTRONIC SYSTEM
101663
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
513
101664
Print 603.93.381
514
ELECTRIC/ELECTRONIC SYSTEM
101665
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
515
101666
Print 603.93.381
516
ELECTRIC/ELECTRONIC SYSTEM
Card 24: Electric window regulator/Sunroof (with and without the Bed Module)
101667
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
517
101668
Print 603.93.381
518
ELECTRIC/ELECTRONIC SYSTEM
101669
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
519
101670
Print 603.93.381
520
ELECTRIC/ELECTRONIC SYSTEM
Card 28: Current Main Remote Control Switch (TGC) prearrangement (TGC)/
Compliance to rules ADR (TMP)
101671
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
521
101672
Print 603.93.381
522
ELECTRIC/ELECTRONIC SYSTEM
101673
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
523
101674
Print 603.93.381
524
ELECTRIC/ELECTRONIC SYSTEM
101675
Print 603.93.381
ELECTRIC/ELECTRONIC SYSTEM
525
Card 33: PTO lateral trasero total /Bloqueo diferencial transversal y longitudinal
101676
Print 603.93.381
526
ELECTRIC/ELECTRONIC SYSTEM
101681
Print 603.93.381