Karsan 18M Repair Manual

Citymood 18 StepC C9 E6 Diesel
Repair Manual
Contents
1 Introduction........................................................................................................ 8
1.1 Important Information..............................................................................................................8
1.2 Editorial Series.........................................................................................................................8
1.3 Purpose of This Manual...........................................................................................................8
1.4 Target Audience of This Manual..............................................................................................9
1.5 How to Read This Manual........................................................................................................9
1.6 Regulations and Certifications...............................................................................................10
2 Safety.................................................................................................................. 11
2.1 General Safety Tips..................................................................................................................11
2.2 Vehicle Repair Personnel Skills..............................................................................................11
2.3 Proper Use of the Vehicle........................................................................................................11
3 Technical Data................................................................................................... 14
3.1 Tightening Torques..................................................................................................................14
3.1.1 Tightening Class.............................................................................................................14
3.1.2 Tightening Torques of Important Chassis Components..................................................14
3.2 Thermal Switches.....................................................................................................................23
3.2.1 Comprehensive Retro-Driver Control Panel...................................................................23
3.2.2 Complex Control Panel “D”............................................................................................24
3.2.3 Complex Control Panel “F”.............................................................................................25
3.3 Keys...........................................................................................................................................26
3.4 Warning and Information Labels.............................................................................................27
3.4.1 Warning and Information Labels Outside the Vehicle....................................................27
3.5 Technical Features...................................................................................................................28
3.5.1 Bus and Homologation...................................................................................................28
3.5.2 Configurations................................................................................................................28
4 Front Axle........................................................................................................... 29
3
4.1 Replace the Axle.......................................................................................................................29
4.1.1 Remove the Axle............................................................................................................29
4.1.2 Mount the Axle................................................................................................................31
4.2 Check the Brakes.....................................................................................................................33
4.2.1 Locate Brake Faults.......................................................................................................33
4.2.2 Wear Limits....................................................................................................................35
4.3 Replace the Front Brake Cylinder...........................................................................................36
4.3.1 Remove the Front Brake Cylinder..................................................................................36
4.3.2 Fit the Front Brake Cylinder...........................................................................................36
4.4 Replace the Front Pneumatic Spring.....................................................................................37
4.4.1 Remove the Front Pneumatic Spring.............................................................................37
4.4.2 Mount the Front Pneumatic Spring................................................................................39
4.5 Check the Leveling of the Vehicle..........................................................................................40
4.6 Replace Brake Discs................................................................................................................42
4.7 Replace the Shock Absorbers.................................................................................................42
5 Rear Axle............................................................................................................ 43
5.1 Replace the Complete Rear Axle............................................................................................43
5.1.1 Remove the Full Rear Axle.............................................................................................43
5.1.2 Reinstall the Complete Rear Axle..................................................................................46
5.2 Replace the Rear Brake Cylinder...........................................................................................50
5.2.1 Remove the Rear Brake Cylinder...................................................................................50
5.2.2 Install the Rear Brake Cylinder.......................................................................................51
5.3 Replace the Rear Pneumatic Spring.......................................................................................51
5.3.1 Remove the Rear Pneumatic Spring..............................................................................52
5.3.2 Fit the Rear Pneumatic Spring.......................................................................................53
5.4 Checking Wheel Hub................................................................................................................54
5.5 Checking the Rear Side Gear Reducer...................................................................................54
5.6 Replace Brake Discs................................................................................................................55
5.7 Replace the Shock Absorbers.................................................................................................55
4
6 Transmission Shaft........................................................................................... 56
6.1 Replace the Transmission Shaft.............................................................................................56
6.1.1 Remove the Drive Shaft.................................................................................................56
6.1.2 Mount the Transmission Shaft........................................................................................57
7 Automatic Speed Change................................................................................. 59

7.1 Replace the Automatic Gearbox.............................................................................................59
7.1.1 Remove the Automatic Gearbox....................................................................................59
7.1.2 Mount the Automatic Gearbox........................................................................................62
8 Engine................................................................................................................ 65
8.1 Replace the Engine..................................................................................................................65
8.1.1 Remove the Engine........................................................................................................65
8.1.2 Mounting the Engine......................................................................................................69
8.2 Replace the Alternator.............................................................................................................72
8.3 Replace the Engine Oil Filling Tank........................................................................................72
8.3.1 Remove the Engine Oil Filling Tank...............................................................................72
8.3.2 Install the Engine Oil Filling Tank...................................................................................74
9 Door Control System......................................................................................... 76

9.1 Replace the Door......................................................................................................................76
9.2 Replace the Door Control Cylinder.........................................................................................76
9.3 Adjust the Doors.......................................................................................................................76
10 Bodywork Groups........................................................................................... 77
10.1 Replace the Right Rear-View Mirror.....................................................................................77
10.1.1 Remove the Right Rear-View Mirror............................................................................77
10.1.2 Fit the Right Rear-View Mirror.....................................................................................77
10.2 Replace the Left Rear-View Mirror.......................................................................................77
10.2.1 Remove the Left Rear-View Mirror...............................................................................77
10.2.2 Fit the Left Mirror..........................................................................................................78
10.3 Replace the Driver’s Seat......................................................................................................78
5
10.3.1 Remove the Driver’s Seat............................................................................................79
10.3.2 Fit the Driver’s Seat......................................................................................................80
11 Window Group................................................................................................. 81
11.1 Replace the Driver’s Side Window........................................................................................81
11.1.1 Remove the Driver’s Side Glass...................................................................................81
11.1.2 Mount the Driver’s Side Glass......................................................................................82
11.2 Replace the Side Windows....................................................................................................83
11.2.1 Remove the Side Windows..........................................................................................84
11.2.2 Fit the Side Windows....................................................................................................84
11.3 Replace the Front Glass........................................................................................................85
11.3.1 Remove the Front Glass...............................................................................................86
11.3.2 Mount the Front Glass..................................................................................................87
11.4 Replace the Rear Window......................................................................................................88
11.4.1 Remove the Rear Glass...............................................................................................88
11.4.2 Mount the Rear Window...............................................................................................89
12 Pneumatic Systems........................................................................................ 91
12.1 Replace the ECAS Solenoid Valve........................................................................................91
12.1.1 Remove the ECAS Solenoid Valve..............................................................................91
12.1.2 Replace the Solenoid Valve.........................................................................................92
13 Water Circulation Systems............................................................................. 93

13.1 Replace the Engine Cooling Water Radiator.......................................................................93
13.1.1 Disassemble the Engine Cooling Water Radiator........................................................93
13.1.2 Mount the Engine Cooling Water Radiator...................................................................96
13.2 Replace the Heating Element in the Driver’s Seat..............................................................99
13.3 Replace the Passenger Heating Convector.........................................................................99
13.4 Replace the Air Heater...........................................................................................................99
13.5 Replace the Boiler of the Pre-heater....................................................................................100
14 Hydraulic Installations.................................................................................... 101
6
14.1 Replace the Fan Oil Reservoir..............................................................................................101
14.1.1 Disassemble the Fan Oil Reservoir..............................................................................101
14.1.2 Mount the Fan Oil Reservoir........................................................................................102
14.2 Replace the Fan Oil Cooler....................................................................................................103
14.2.1 Remove the Fan Oil Cooler..........................................................................................103
14.2.2 Mount the Fan Oil Cooler.............................................................................................105
14.3 Replace the Fan Control Pump.............................................................................................107
15 Electrical System............................................................................................. 108

15.1 Replace the Batteries.............................................................................................................108
15.1.1 Remove the Batteries...................................................................................................109
15.1.2 Mounting the Batteries................................................................................................110
16 Air Conditioning System................................................................................. 113

16.1 Replace the Compressor of the Air Conditioning System.................................................113
17 Attached Documentation................................................................................ 114
7
1 Introduction
1.1 Important Information
Read this manual carefully before using the vehicle.
Industry Italiana Autobus S.p.A. can not be held responsible for any damage to
people or things caused by non-application of the warnings contained in the
manuals that are part of the package.
Italian Industry Bus S.p.A., in order to improve its vehicles, reserves the right to
make changes without obligation to notify it preventively.
1.2 Editorial Series

The following table lists the editorial manuals that accompany the vehicle with their
identification codes.
Driving instructions Code. 051017-1

Use and maintenance Code 051017-2
Repair Regulations Code. 051017-3
1.3 Purpose of This Manual

This manual explains how to properly and safely maintain the vehicle. It provides the following
chapters:
Introduction
• Provides general information on how to read this manual.
Safety
• Provides general information on the safe use of the vehicle.
Technical Data
• Provides information on tightening pairs, fuse location and on keys.
Maintenance Cards
• Provides information on when to perform maintenance work.
8
1.4 Target Audience of This Manual
This manual is intended for maintenance and repair personnel of the vehicle workshop.
1.5 How to Read This Manual

Warning and information signals
The following warning signs and symbols are used in this manual to explain
situations;
DANGER
Symbol of danger
►► To draw attention to a danger that can cause physical damage if the warning is
ignored.
NOTICE
Symbol of vehicle damage
►► To draw attention to a danger that can cause damage to materials if the warning is
ignored.
RESPECT FOR THE ENVIRONMENT

Environmental Warning Symbol
►► To draw attention to a danger that can cause damage to environment.
INFORMATION
To provide additional information.
Graphic Conventions
Below are the main graphic conventions used in this manual.
Left: Represents the active position of a selector.
Start / Stop: Represents the name of a button.
VEHICLE IGNITION : Represents a digital display message.
• Represents an unordered list of items or actions to run without a sequential order.
- Represents the second level of unordered actions or items.
9
√√ It is a prerequisite. The assumption is a situation that must be met before you can start a
procedure.
►► Represents a procedure that can be completed with a single action.
1. Represents the first step of an orderly procedure.
2. Represents the second step of an orderly procedure. The steps of a procedure ordered
must be executed in the order in which they are written.
⇒⇒ Represents the result of a step in the procedure.
⇒⇒ Represents the result of a procedure.
INFORMATION
The left and right directions are always used by referring to it driving direction of the vehicle.
1.6 Regulations and Certifications

This volume complies with the ASSTRA SPECIFICATION “Recommendations for bus service”
(2011 edition).
10
2 Safety
2.1 General Safety Tips
Misuse of the vehicle may cause death, physical, material, and environmental damage.
►► To avoid possible dangers and damages, carefully read the general safety rules and
recommendations.
►► Read this manual carefully before starting the vehicle and before carrying out any work on
the vehicle.
►► Comply with current safety regulations and any company safety advice.
Vehicle maintenance personnel are responsible for any physical, material, and environmental
damage caused by failure to comply with the instructions.
2.2 Vehicle Repair Personnel Skills

Vehicle maintenance personnel must have the minimum qualifications required by local
regulations and the qualifications required to operate on a vehicle with these features.
2.3 Proper Use of the Vehicle

The vehicle is intended solely for the carriage of passengers and theirs luggage. To know
the maximum cargo capacity of the vehicle please observe capacity label.
Any other use of the vehicle is considered as improper usage. The personnel responsible for
the use of the vehicle is liable for any damages caused by improper use of vehicle.
INFORMATION
Vehicle repair personnel must ensure the presence and readability of all signs and labels
on the vehicle throughout the service life. Unauthorized modifications may result in loss of
vehicle approval.
11
DANGER
Possible physical damage.
►► Exhaust gases are toxic. Ensure adequate ventilation when starting the vehicle in
closed environments. Use a fan to extract the gases.
►► Never touch the engine in hot working conditions.
►► Do not touch the catalytic converter or near the catalyst with the engine started.
►► Observe the safety distance when the engine is running.
►► Wear a tight work suit.
►► Keep the floors and stairs free of grease and oil.
►► Do not touch live areas.
►► Do not work with liquids near wires or live parts.
►► Do not let fluids to touch live parts.
►► Properly enclose the intervention area to prevent access by strangers.
►► Perform the operations as indicated by the vehicle manufacturer.
►► Keep the surrounding area unobstructed and with no slippery floor.
►► Use workshop equipment and tools in good condition.
►► Wear individual protections when the manufacturer indicates it.
►► Remove the key from dashboard by signaling the current intervention with a sign.
►► Only use original spare parts.
►► Perform the work in a sufficiently lit and ventilated environment.
►► Do not let strangers to pass or stay in the intervention zone.
►► Only work under the vehicle under safety conditions.
►► Do not weld or use free flames in the presence of flammable products.
►► Do not use gasoline, solvents or other flammable liquids to clean the parts.
►► Disconnect the batteries before performing any work on the electrical or pneumatic
parts.
►► Disconnect the batteries before making welding operations on the vehicle.
NOTICE
Risk of hazard
►► Only start the engine with the battery inserted
12
Engine startup and operation of the vehicle are only permitted by authorized personnel.
►► Before starting the engine, read the engine manufacturer’s manual and, above all, the
safety advice.
►► If in doubt, please contact Industria Italiana Autobus S.p.A..
13
3 Technical Data
3.1 Tightening Torques
3.1.1 Tightening Class
The following table shows the tightening classes, percentage tolerances and rated torque
values, and their application ranges.
Tightening class Tolerance value Applications

1 +5 % / -8 % Very demanding
2 +5 % / -15 % Challenging
3 +5 % / -25 % Common
3.1.2 Tightening Torques of Important Chassis Components
5 4
Torsion Torsion
Front suspension Dimension Tightening class
Nm kgm
1 Pneumatic spring fixing M18x2 70 7,1 2
2 Pneumatic spring fixing M18x2 70 7,1 2
3 Upper triangle fastening to the chassis -- 446 45,5 1
4 Lower triangle fastening to the chassis M18x70 845 86,2 1
5 Shock absorber fixing -- 80 8,1 2
14
3
4
1
Torsion Torsion Tightening

Steering Dimension
Nm kgm class
1 Fixing steering wheel to the column -- 49 5,0 1
2 Fixing angular transmission to the frame M12x45 85 8,7 1
3 Fixing angular transmission to the column M10x56 50 5,1 1
4 Fixing telescopic shaft to the bevel gearbox -- 48+5 4,9+0,5 1
15
5
10
9
7
6
7

Steering Dimension
Nm kgm class
Fix left / right tie rod to the left / right wheel
5 M20x1,5 25 2,5 1
lever
Fixing of the coupling bar to the transmission
6 M24x1,5 280 28,6 1
levers
7 Fixing left / right tie rod to left / right lever M20x1,5 230 23,5 1
8 Fixing rod to the left lever -- 280 28,6 1
9 Fixing right / left lever brackets to chassis M16x55 307 31,3 1
10 Fixing right / left lever brackets to chassis M18x75 446 45,5 1
16
1
3 3
5 5
4 4

Rear suspension Dimension
Nm kgm class
1 Upper shock absorber fixing -- 70 7,1 2
2 Lower shock absorber fixing -- 70 7,1 2
3 Fixing reaction bars above the frame M8x100 402 41,0 1
4 Fastening reaction bars above the axle M8x100 402 41,0 1
5 Fixing reaction bars below the chassis -- 440 44,9 1
17
1
3 7 8
6 9
10
14
3 5 4
11
13
3
4
12
8
3
8

Transmission engine coupling Dimension
Nm kgm class
1 Fixing the flange to the gearbox M12x1,5x22 83 8,5 --
2 Fixing the flange to the engine M12x1,75x30 110 11,2 --
Engine supports
3 Fixing the engine / gearbox support M10x30 62 6,3 2
4 Fixing the gearbox support M10x90 402 41,0 2
5 Fixing the gearbox support M16x60 198 20,2 2
7 Fixing the engine support M16x100 198 20,2 2
18
1
3 7 8
6 9
10
14
3 5 4
11
13
3
4
12
8
3
8

Transmission engine coupling Dimension
Nm kgm class
12 Fixing the gearbox support M16x60 100+60° 10,2 1
Transmission shaft
Fixing the transmission shaft to the bevel
13 M12x50 128 13,1 1
gearbox
14 Fixing the transmission shaft to the differential M12x20 128 13,1 1
19
1 23
4

Radiator Dimension
Nm kgm class
1 Collector bracket fixing M8x45 25 2,5 2
Fixing top end bracket with radial support
4 M12x70 116 11,8 2
bracket
5 Clamp fixing -- 6 0,6 --
6 Fixing to the lower part of the chassis M8x20 25 2,5 2
7 Frame conveyor fixing M8x20 48 4,9 2
20
3
2 1

Battery Case Dimension
Nm kgm class
1 Fixing telescopic guide frame M6x14 10 1,0 --
2 Fixing of frame protection sheet M6x20 10 1,0 --
3 Fixing bracket on the arm M8x20 25 2,5 --
21
Tow hook Dimension
Nm kgm class
1 Mounting hook to the chassis M12x35 91 9,2 1
22
3.2 Thermal Switches
3.2.1 Comprehensive Retro-Driver Control Panel
Thermal switch 3A Color VIOLET
Thermal switch 5A Color ORANGE
Thermal switch 6A Color GREEN
Thermal switch 7.5A Color BROWN
Thermal switch 10A Color RED
Thermal switch 15A Color BLUE
Thermal switch 20A Color YELLOW
Thermal switch 25A Color WHITE
23
3.2.2 Complex Control Panel “D”
24
3.2.3 Complex Control Panel “F”
25
3.3 Keys
Key Function
Triangular head key for opening and closing the doors.
Triangular head key for opening and closing the doors.
Square head key for opening and closing the disabled footrest.
Key for opening and closing the doors.
26
3.4 Warning and Information Labels
3.4.1 Warning and Information Labels Outside the Vehicle
camp. 148
press. 9 bar
uscita di emergenza
in caso di necessità
rompere il vetro
80
0 100 servizio pubblico
in caso di necessità
ruotare la maniglia
e spingere la porta
camp. 148
press. 9 bar
camp. 148 AP d p
del bera ve colo
duz ne c aud d e be a
press. 9 bar
27
3.5 Technical Features
3.5.1 Bus and Homologation
Bus
Brand BredaMenarinibus
Model CityMood 18 Diesel
Type Urban Class 1
Approval
European Approval e3*2007/46*0387*00
3.5.2 Configurations
External dimensions
Length mm 18125
Width mm 2525
Max Height mm 3373
Minimum floor height mm 150
Step (between first and second axis) mm 5315
28
4 Front Axle
4.1 Replace the Axle
√√ The engine must be switched off for at least 90 seconds.
√√ The battery isolation switch must be in open position.
√√ The parking brake must be applied.
4.1.1 Remove the Axle
1. Raise the vehicle by means of appropriate

lifters and place it on special stands located
at the points shown in the figure.
2. Remove the wheels with lifting equipment.

3. Disconnect the leveling rod (only on the right
side).
4. To discharge the air contained in the

pneumatic spring, slowly loosen the fitting A.
5. As soon as the system is unloaded, lock the A
fitting A.
29
6. Disconnect tube B and the electrical
connections.
7. To disconnect the tie rod C, unscrew the lock

nut.
8. Place the column lift under the axle assembly.
9. Secure the axle assembly to the forks of the
column with a chain.
10. Unscrew D and disconnect the shock absorbers

from the lower triangle.
11. Unscrew the fixing screw E and lower the

pneumatic spring from its seat.
30
12. To disconnect the lower triangle from the
chassis, unscrew the 4 nuts F.
F
13. To disconnect the upper triangle from the

chassis, unscrew the 4 screws G. 70-80 Nm
14. Lower the axle assembly with the lifting 7,1-8,2 kgm
device.
E
4.1.2 Mount the Axle
1. Place the axle assembly under the vehicle with

the mobile lifting device.
2. To connect the upper triangle to the chassis, G
tighten the 4 screws G respecting the
tightening torque shown in the illustration
(class 1).
446 Nm
45,5 kgm
31
3. To connect the lower triangle to the frame,
tighten the 4 nuts F, respecting the tightening
torque shown in the figure (class 1). F 845 Nm
86,2 kgm
4. To position the spring, center the reference pin

and top plate and tighten the screw E. 70-80 Nm
7,1-8,2 kgm
5. To connect the shock absorbers to the lower

triangle, tighten the fastening nut D, respecting
the tightening torque shown in the illustration
(class 2). 317 Nm
32,3 kgm
6. Remove the mobile lifting device.
7. To attach the tie rod C, tighten the lock nut,

respecting the tightening torque shown in the
figure (class 1).
230 Nm
23,4 kgm
32
8. Connect electrical connections and tube B.
9. Connect the leveling rod (only on the right
side).
10. To load the pneumatic air spring, loosen the

fitting A.
A
11. To assemble the wheels, secure them to the

forks of the lifter with a rope and lift them with
a column lift.
12. Lower the vehicle.
13. Check the height of the membranes and the
characteristic angles of the wheels.
14. To test the functionality of all parts, run a test
drive with the vehicle.
4.2 Check the Brakes

√√ The battery disconnect lever must be in the open position.
4.2.1 Locate Brake Faults
►► To locate the brake failure, refer to the following diagram.
33
Raise the vehicle and
turn the wheel with
your hands.
Does the wheel rotate

freely?
NO YES
Any residual Is the clearance

pressure in the between pads and
brake cylinder? disk OK?
NO YES NO YES
Is the clearance Check the brake Check the Is pad wear

between pads and cylinders and automatic homogeneous?
disk OK? replace them if clearance
NO YES necessary. recuperation NO YES
END END END
Is the automatic
clearance Check the brake
Is the brake caliper assembly
recuperation OK?
caliper guide and, if necessary,
NO YES
system OK? revise it.
NO YES
END
Check the
Replace the installation of the The problem does
brake caliper. brake caliper and, not depend on the
if necessary, disc brake caliper.
revise it.
END
END
END
34
4.2.2 Wear Limits
C B
D E
NOTICE
Possible breaking of the brakes due to excessive wear.
►► Keep wear limits between the brake disc and pads.
►► Check the thickness of the brake disc and pads:
• A (new disc thickness) = 45 mm
• B (disc thickness used - disk replacement required) = 37 mm
• C (thickness of the new pad) = 30 mm
• D (brake plate thickness) = 9 mm
• E (minimum friction material thickness) = 2 mm
• F (minimum thickness of pad used - pad replacement required) = 11 mm
35
4.3 Replace the Front Brake Cylinder
NOTICE
Possible damages to the vehicle due to unsuitable material.
►► Only use the cylinders recommended by the vehicle manufacturer.
►► Do not use grease containing molybdenum disulphide.

√√ The pneumatic system of the vehicle must be discharged.
4.3.1 Remove the Front Brake Cylinder
1. Disconnect the pneumatic tube of the cylinder

very slowly.
2. Unscrew the cylinder retaining nuts.
3. Remove the cylinder. 2.
1.
4.3.2 Fit the Front Brake Cylinder
1. Clean the lever compartment and grease it with

white grease.
1.
2. Clean the gasket and the rod area.
2.
36
3. Place the cylinder.
4. Screw the cylinder with new nuts respecting 1.
the tightening torque shown in the figure.
5. Connect the pneumatic pipes.
6. Check that there are no twisted tubes or 180 30 Nm
rubbing.
2.
7. Check the efficiency of the brake system.
4.4 Replace the Front Pneumatic Spring

√√ The battery disconnect lever must be in the closed position.
4.4.1 Remove the Front Pneumatic Spring
1. Raise the vehicle in correspondence with the

spring to be replaced.
2. Place appropriate chock.
3. Remove the wheel.

4. Disconnect the leveling rod (only on the right
side).
37
5. To discharge the air contained in the pneumatic
spring, slowly loosen the fitting A.
A
6. As soon as the system is unloaded, lock the
fitting A.
7. Unscrew the fixing screw B.
NOTICE
Possible damages to the pneumatic spring due to damage to the upper cone.
►► Avoid damaging or scratching the upper cone.
8. Remove the complete front air spring by

removing it from the upper retaining housing
with soft material tools (eg brass).
38
4.4.2 Mount the Front Pneumatic Spring
1. To position the spring, center the reference pin

and top plate and tighten screw B. 70-80 Nm
7,1-8,2 kgm
NOTICE
►► When lowering the vehicle, make sure that the upper cone fits perfectly to the top of
the diaphragm.

3. To charge the pneumatic air spring, loosen the
A
fitting A.
4. Check for leaks.
5. Connect the leveling rod (only on the right
side).
6. Fit the wheel.
39
7. To lower the vehicle, remove the chock.
4.5 Check the Leveling of the Vehicle

√√ The battery disconnect lever must be in the open
position.
DANGER
When you insert the batteries and the ignition key, the ECAS system is activated.
The ECAS system can regulate the leveling of the vehicle in an autonomous and
unpredictable way.
►► Make sure there are no operators near the vehicle.
40
►► Check the following points:
A C
• The constant height of the front C
pneumatic springs is 250 mm (independent B
of the load to which the vehicle is
D
subjected).
A
• The constant height of the rear C h
pneumatic springs is 290 mm (independent D
of the load to which the vehicle is C
subjected). B
⇒⇒ If the feed pressure of the springs C is
regular, the height is maintained constant by
the level sensors A that continuously read the
height h through the rod D.
►► To change the leveling of the vehicle, change
the length of the rod D.
►► After replacing one of the suspension
components, check and, if necessary, reset the
vehicle’s leveling as follows:
• Make sure that the suspension tank is fully
loaded.
• Lower the vehicle completely with the
appropriate command.
• Return the vehicle to the static level with
the command.
• Check and, if necessary, adjust the height h
of all pneumatic springs.
• Loosen the lock nuts.
• To adjust the angle of lever B, turn the rod
D clockwise or counterclockwise to form a
right angle of the eccentric to the normal
level (distance from the ground) of the
vehicle.
• Tighten the locknuts after adjustment.
INFORMATION
The maximum permissible measured heights of tolerance between the 6 pneumatic springs
is 5 mm (compare the minimum height and maximum height measured).
41
INFORMATION
If it is necessary to disconnect the rod D, it is advisable to measure and maintain the length
of the rod unchanged to avoid or facilitate the adjustment of the vehicle leveling.
The “0” position is considered as static vehicle when the lever B is orthogonal to the level A
sensor axis.
►► Observe the correct action of the level sensor A.
A A
E
B D
When lifting the bodywork, it is necessary to

increase the counting value that is measured at the
control unit.
►► Check with the “Diagnostic Controller”.
►► Before dismounting the lever B, mark the
fastening position on the flange of the level
sensor A.
⇒⇒ The flange has the reference to the fins E

that are higher than the lever fastening plane.
►► Observe the position of the fins E.
4.6 Replace Brake Discs
INFORMATION
For more information, refer to the product’s operating manual.
4.7 Replace the Shock Absorbers
INFORMATION
42
5 Rear Axle
5.1 Replace the Complete Rear Axle
5.1.1 Remove the Full Rear Axle
1. Lift the vehicle with appropriate lifters and

place it on special stands located at the points
shown in the figure.
2. Remove the wheels with lifting pulleys for

removal.
3. To discharge the air contained in the

pneumatic springs, slowly loosen the fitting A.
4. As soon as the system is unloaded, lock the
fitting.
43
5. Disconnect the leveling rod B and the electrical
cables connected to the rear axle. B
INFORMATION
The transmission shaft is telescopic. We recommend shortening it as much as possible.
6. Secure the transmission shaft to the chassis

with a rope.
7. If necessary, disassemble the gearbox cover.
INFORMATION
To find the ideal position for accessing the 4 screws, turn the raised wheel properly.
8. Unscrew the 4 screws that connect the drive

shaft to the rear axle.
4x
44
9. Disconnect the C tubes of the service brake
and parking brake.
4x
10. Place a suitable mobile lifting device

underneath the axle.
11. To avoid mistakes in the replacement, mark
the position of the shims.
12. Disconnect the upper and lower reaction arms

D.
4x
D
13. Disconnect the shock absorbers E.
45
14. Lower the axle with the mobile lifting device by
removing the membranes at the same time with
tools made of soft material (eg brass).
5.1.2 Reinstall the Complete Rear Axle

1. Place the axle under the vehicle with a suitable
mobile lifting device.
2. Match the hole of the membranes with the plate
cones attached to the frame.
3. Attach the shock absorbers E and respect the

tightening torque shown in the figure (class 2).
4. If one or more reaction bars or axle have been
replaced, reselect the register thicknesses to
get the axle layout described below. E
70 Nm
7,1 kgm
46
5. Connect the upper and lower reaction arms D,
respecting the tightening torque shown in the 440 Nm
figure (class 1) and position the thicknesses in 44,9 kgm
the previously marked position. 4x
440 Nm
44,9 kgm
4x
6. Connect the C-tubes of the parking brake and

parking brake systems.
4x
7. To connect the drive shaft to the axle, tighten

the 4 screws by turning the raised wheel
properly.
128 Nm
8. Remove the rope. 13 kgm
4x
9. Connect the leveling rod B and the electrical

cables. B
47
10. To mount the wheels, lift them with a column lift
and secure them to the forks of the lifter with a
rope to prevent them from tipping over during
the operation.
11. Lower the vehicle making sure that the top
plate cones enter the holes of the membranes
perfectly.
12. Check and, if necessary, restore the axle oil

level:
• Make sure the vehicle is on a horizontal
plane.
• Open cap F and check that the oil reaches
the bottom edge of the hole.
• If the oil level is below the edge of the hole,
refill the oil.
F
• If the axle is completely free of oil, insert 17
liters through the hole.
• To allow the lubricant to distribute uniformly
across the axle, wait 15 minutes.
• Check the level through the hole and fill as
necessary.
13. To test the functionality of all parts, run a test
drive with the vehicle.
48
14. When connecting, check the angle with a
magnetic level and using the reference notches
stamped on the 4 dampers.
G
The maximum difference between the right rear
wheel and the left rear wheel must be 5 mm. To H
change the step on the left side of the vehicle you
can enter: I
• At most one pair of shims in the lower right
reaction bar G (frame side)
• At most one pair of shims in the lower left
reaction bar H (frame side)
• At most two pairs of shims in the upper
right reaction bar I (frame side).
⇒⇒ To change the pitch on the right side of
the vehicle, proceed in a way symmetrically
opposite.
⇒⇒ Thicknesses cause a pitch change of about
6 mm.
15. Once the connection has been made, check

the inclination with a magnetic level and with 478 ±3
the reference notches printed on the 4 shock
absorbers. 290
• To obtain the 7 ° angle of the bridge
pinion (transmission shaft coupling
flange), respect the 10 ± 1 shock absorber
dimensions acting on the shims to be
7°±10'
inserted in the lower reaction bars G and H
(bridge side) or by acting on the shims to
be inserted into the upper reaction bars I
(axle side).
• The permissible angular error is ± 30 ‘.
• Each pair of thickness modifies the axle
angle of about 20 ‘.
• The maximum allowed shims is 2 pairs per
bar (axle side).
49
5.2 Replace the Rear Brake Cylinder
NOTICE
Possible damages to the vehicle due to unsuitable material.
►► Only use the cylinders recommended by the vehicle manufacturer.
►► Do not use grease containing molybdenum sulphide.

√√ The pneumatic system of the vehicle must be discharged.
5.2.1 Remove the Rear Brake Cylinder
DANGER
Possible serious injury due to the displacement or fall of heavy parts.
►► Before releasing the brakes, secure the vehicle with wedges under the wheels.
►► Always use appropriate equipment.
►► Perform all operations with utmost care.
1. Disconnect the pneumatic cylinder hoses very

slowly.
2. Unscrew the cylinder fixing nuts. 2.

3. Remove the cylinder.
1.
50
5.2.2 Install the Rear Brake Cylinder
1. Grease the lever compartment with white

grease.
2. Open the vent hole cap under the cylinder.
3. Fit the cylinder.

4. Screw the cylinder with new nuts respecting the
180 30 Nm
tightening torque shown in the figure.
5. Connect the pneumatic hoses.

6. Verify that there are no air leaks.
7. Check the efficiency of the brake system.
25 30 Nm
5.3 Replace the Rear Pneumatic Spring

51
5.3.1 Remove the Rear Pneumatic Spring
1. Raise the vehicle in correspondence with the

spring to be replaced.
2. Place appropriate chock.
3. Remove the wheel.
4. To discharge the air contained in the pneumatic

spring, slowly loosen the fitting A.
5. Disconnect the spring from the upper plate with
soft material tools (eg brass).
A
6. Unscrew the fixing screw B.
NOTICE
►► Avoid damaging or scratching the upper cone.
52
7. Remove the pneumatic spring with the top
plate.
5.3.2 Fit the Rear Pneumatic Spring
1. Place the rear pneumatic spring on the support

by centering the reference pin.
2. Tighten the fixing screw B.
90 Nm
9,2 kgm
NOTICE
►► When lowering the vehicle, make sure that the upper cone fits perfectly to the top of
the diaphragm.
53
4. Connect the fitting A.
5. Introduce the air inside the front pneumatic
diaphragm.
6. Check for leaks.
7. Only connect the leveling rod on the right side.
8. Fit the wheel.
9. Remove the chocks.
5.4 Checking Wheel Hub
NOTICE
5.5 Checking the Rear Side Gear Reducer
NOTICE
54
5.6 Replace Brake Discs
NOTICE
5.7 Replace the Shock Absorbers
NOTICE
55
6 Transmission Shaft
6.1 Replace the Transmission Shaft
√√ The power packs must be disconnected.
√√ The parking brake must be switched on.
6.1.1 Remove the Drive Shaft
1. Lock the front wheels with the wedges.

2. To lift the vehicle as shown in the figure, detach
the wheel from the ground with a lifting device A
positioned at the lifting point.
3. Secure the vehicle raised with a suitable
thickness.
2.
A
1.
4. Secure the transmission shaft to the frame with

a rope.
5. If necessary, remove the gearbox cover.
INFORMATION
To find the ideal position for accessing the 4 screws, turn the raised wheel properly.
56
6. Unscrew the 4 fastening screws on the axle.
4x
7. Undo the 4 fixing screws at the gearbox and

remove the transmission shaft.
4x
6.1.2 Mount the Transmission Shaft
1. To connect the transmission shaft, tighten

the 4 fixing screws to the gearbox, respecting
the tightening torque shown in the illustration
(class 1).
128 Nm
13 kgm
4x
57
2. To connect the transmission shaft to the axle,
tighten the 4 screws by turning the raised wheel
appropriately.
128 Nm
3. If disassembled, mount the gearbox cover. 13 kgm
4. Remove the rope. 4x

5. Lift the vehicle slightly.
6. Remove the stand and lower the vehicle.

7. Remove the wedges.
1.
A
2.
58
7 Automatic Speed Change
7.1 Replace the Automatic Gearbox
√√ The pneumatic springs must be completely discharged.
√√ Batteries must be disconnected.
7.1.1 Remove the Automatic Gearbox
1. Open the engine compartment door A.

2. Open Door B.
3. Remove bumper C and D lamp.
1. A
2.
C
B 3.
D 4.
4. Raise the vehicle by means of suitable column

lifters and place it on special trestles positioned
at the points shown in the figure.
5. Remove the 2 covers under the engine.
6. To unload the engine cooling system, open the

plug E and plug F. E
7. Disconnect all electrical cables and pneumatic
tubes connected to the gearbox.
59
8. Disconnect the transmission shaft.
4x
9. Disconnect the G and H tubes.
G H
10. Insert a suitable lifting device underneath the

gearbox.
11. To disconnect the flange gear, unscrew the

fixing screws through the opening at the bottom
of the gearbox and engine.
12. Rotate the flange by using a screwdriver.
10x
60
13. To disconnect the gearbox brackets, unscrew
the 4 screws.
4x
14. To disengage the gearbox from the engine,

unscrew the screws.
12x
15. Remove the gearbox using the lifting device

previously installed.
61
7.1.2 Mount the Automatic Gearbox
1. Position the gearbox using the lifting device.
2. Secure the gearbox to the engine using screws

respecting the tightening torque shown in the 110 Nm
figure. 11,2 kgm
12x
3. Connect the brackets to the gearbox using the 4

screws respecting the tightening torque shown
in the figure (class 1). 208 Nm
21,2 kgm
4. To connect the gearbox to the engine flange,

tighten the screws according to the tightening
torque shown in the illustration. 83 Nm
5. Rotate the engine flywheel by using a 8,5 kgm
screwdriver. 10x
62
6. Connect the G and H tubes.
G H
7. Connect the drive shaft with the tightening

torque shown in the figure (class 1).
8. Connect all electrical cables and pneumatic
tubes.
9. Lower the vehicle using the column lifters.
128 Nm
13 kgm
4x
10. Open the tap I.

11. Fill the cooling system.
12. Check the gear oil level with the dipstick.

13. If necessary, refill it through plug J when the
engine idling.
63
14. Connect the battery cables.
15. Fit the protections underneath the gearbox..
16. Fit bumper C and D lamp.

17. Close the door B.
18. Close the engine compartment door A.
19. To test the correct mounting of all parts, run a
test drive with the vehicle. A
B D
64
8 Engine
8.1 Replace the Engine
If it is impossible to start the engine, very slowly loosen one of the primary line connections
downstream from the isolating valve until the pipes are completely emptied.
After reassembling, before reconnecting the batteries, check with the appropriate gas leakage
markers that there are no leaks on the fittings and the components on which it has been
operated.
INFORMATION
Refer to the manufacturer’s manual for engine overhaul.
√√ The power plugs must be disconnected.
√√ The pneumatic springs must be completely discharged.
8.1.1 Remove the Engine
1. Open the engine compartment door A

2. Open hatch B. A
3. Remove bumper C and D lamp.
B D
4. Raise the vehicle by means of suitable

column lifters and place it on special trestles
positioned at the points shown in the figure.
5. Remove the 2 covers under the engine.
65
6. Disconnect transmission shaft from gearbox.
7. Secure the transmission shaft to the vehicle.
4x
9. To unload the engine cooling system, open the

plug E and plug F. E
10. Disconnect fuel pipes and compressor pipes.
11. Disconnect the engine suction system H.
66
12. Disconnect Engine Exhaust System I.
I
13. Drain the fan control unit K and disconnect it.

K
14. Drain the hydraulic system L and disconnect

L
it.
67
15. Drain the engine oil filler assembly and
disconnect the hose M.
16. Disconnect the electrical connections on the M
engine and gearbox.
17. To completely unload the frame from the weight

of the engine, place a mobile lifting device of
adequate capacity and equipped with a special
cradle under the engine.
18. Unscrew 4 screws N.

19. Remove the fixing screws O.
O
20. Remove the rear cross.
N
21. Pull out the engine and gear unit using the
lifting device previously applied.
68
8.1.2 Mounting the Engine
1. Position the engine using a suitable lifting

device.
2. Fit the crossbar and secure it with the screws

O respecting the tightening torque shown in O
the figure.
3. Screw the 4 N fixing screws of the engine to N
the brackets.
4. Connect the electrical connectors that arrive
at the gearbox and the engine. 106 Nm
5. Connect the fuel supply system and 10.8 kgm
compressor pipes
6. Connect the engine cooling system and close
plug E and plug F.
F A
E
D B
C
69
7. Connect the engine suction system H.
8. Connect the engine exhaust system I.

I
9. Connect the fan control system K

K
70
10. Connect the power steering system L.
L
11. Connect the manual filling of the engine oil M.

12. Fill up all the facilities.
13. If present, re-open the system sealing tap. M
14. Connect the drive shaft with the tightening

torque shown in the figure (class 1).
15. Fit the protections underneath the gearbox.
128 Nm
13 kgm
4x
16. Fit bumper C and D lamp.

17. Close the door B.
18. Close the engine compartment door A.
B D
71
DANGER
Explosion danger!
Replacement, before re-connecting the batteries, check with special gas leak proofs that
there is no leakage on the fittings and components
19. Connect the battery cables.

20. To test the correct mounting of all parts, run a
test drive with the vehicle.
8.2 Replace the Alternator
INFORMATION
8.3 Replace the Engine Oil Filling Tank

8.3.1 Remove the Engine Oil Filling Tank
1. Open the rear door.

2. Open the plug A of the oil filling oil reservoir.
72
3. To empty the oil filling tank, use a pump.
• The oil collected during the assembly
phase can be reused.
4. Disconnect the hose.
5. Unscrew the 2 fixing screws.

7. Remove the tank.
73
8.3.2 Install the Engine Oil Filling Tank
1. Place the tank.

2. Secure the tank with the 4 fixing screws.
3. Secure the tank with the 2 fixing screws.
4. Connect the hose.

5. Introduce the previously retrieved oil until
reaching the highest level.
6. Start the engine and run the whole system with
the engine at maximum.
74
7. Close the rear door.
75
9 Door Control System
9.1 Replace the Door
INFORMATION
9.2 Replace the Door Control Cylinder
INFORMATION
9.3 Adjust the Doors
INFORMATION
76
10 Bodywork Groups
10.1 Replace the Right Rear-View Mirror
10.1.1 Remove the Right Rear-View Mirror

1. Disconnect the electrical connection.
2. Push the right rear view mirror upwards from
the base plate. If necessary, use a rubber
hammer.
10.1.2 Fit the Right Rear-View Mirror
1. Insert the right rear view mirror into the base

plate. If necessary, use a rubber hammer.
2. If necessary, apply contact spray or terminal
grease to the electrical connection.
3. Connect the electrical connection.
10.2 Replace the Left Rear-View Mirror

10.2.1 Remove the Left Rear-View Mirror

1. Disconnect the electrical connection.
77
2. Pull up the left rear-view mirror from the
base plate. If necessary, use a rubber
hammer.
10.2.2 Fit the Left Mirror
1. Insert the left rear view mirror into the base

plate. If necessary, use a rubber hammer.
2. If necessary, apply contact spray
or terminal grease to the electrical
connection.
3. Connect the electrical connection.
10.3 Replace the Driver’s Seat

78
10.3.1 Remove the Driver’s Seat
1. To stop pneumatic supply to the seat, close the

tap on the front service block.
DANGER
Possible serious injury due to pressure in the system.
►► Pay attention to the possible residual pressure in the system.
2. Slowly unplug the pneumatic supply tube to the

driver’s seat.
3. Unscrew the 4 fixing screws that lock the base

of the driver’s seat to the floor.
4. Remove the driver’s seat with help of operator. 1.
4x
2.
79
10.3.2 Fit the Driver’s Seat
1. Position the driver’s seat with the aid of an

operator’s help as shown in the figure.
2. Tighten the 4 fixing screws. 2.
4x
1.
3. Connect the pneumatic supply pipe to the

driver’s seat.
4. Open the tap on the front service block.
80
11 Window Group
11.1 Replace the Driver’s Side Window
11.1.1 Remove the Driver’s Side Glass
1. Disconnect the electrical connection of the

lateral driver’s resistance to the driver.
2. Remove the left rear-view mirror.
DANGER
Possible serious injury due to glass splinters.
►► Carefully clean the area of intervention from any glass fragments.
►► Use gloves.
►► Work with one or more aides.
3. With a cutter remove from inside the pivilene

profile A and the sealing adhesive B which joins
the glass to the chassis.
4. Remove the driver’s side glass.
5. Clean the compartment from any glass and glue
residues.
A
81
6. Remove the grill plate.
1.
2.
7. Cut the sticker C.

8. Separate the driver’s side window from the frame D
D.
11.1.2 Mount the Driver’s Side Glass
1. Apply sealing adhesive C between the

driver’s side window and frame D, strictly D
respecting the thickness shown in the figure.
m
2. Apply the primer for paint in the driver’s side 1m
of the driver’s glass and its perimeter.
1
82
3. Apply the pivilene profile A.
4. Apply the sealing adhesive B in all the
perimeter zones of the frame.
5. Place the driver’s side glass in the

compartment.
6. Lock the driver’s side glass by proper
equipment.
NOTICE
Possible damage to the vehicle due to detachment of the window.
►► Before removing the equipment, wait for the sealant to dry.
7. Remove the fixing equipment.

8. Fit the left mirror.
9. Reconnect the window heater electric
connection.
11.2 Replace the Side Windows

83
11.2.1 Remove the Side Windows
DANGER
►► Use gloves.
1. With a cutter remove from the inside and, if

necessary, from the outside: A C B
• the pivilene A
• continuous sealing cord B
• sealant C
2. Remove the side glass.

3. Clean the compartment from any glass and
glue residues.
11.2.2 Fit the Side Windows

1. Degrease the new window glass.
84
2. Apply pivilene A and continuous sealant B
along the side glass perimeter. A C B
3.
2.
3. Apply sealant adhesive C in all lateral edge 1.
perimeters.
4. Fit the side glass.
2.
1.
5. Lock the window with appropriate equipment.

6. Apply the glue cord to the body ensuring
that the horizontal and vertical sections are
2.
connected and that there are no interruptions
in their construction.
1.
NOTICE
11.3 Replace the Front Glass

85
11.3.1 Remove the Front Glass
DANGER
Possible serious injury due to glass splinters.
►► Use gloves.
1. Remove the windscreen wiper.
2. Remove the Sealing Adhesive (New Cristal Car

Plus) A.
A
3. Support the front glass with suction cups.

4. To disassemble the front glass, strain the
sealing adhesive A with a lever from inside the 1.
A
vehicle starting at the top edge.
2.
86
5. Carefully clean the bodywork from any glass
and glue residues.
11.3.2 Mount the Front Glass
1. Place the front glass on the bodywork.

2. Check that the shape of the front glass
matches perfectly with the profile of the resin.
3. Apply sealant A.
4. To place the front glass in place, keep it

pressed to the resin.
87
5. Mount the windshield wipers.
11.4 Replace the Rear Window

11.4.1 Remove the Rear Glass
DANGER
Possible physical damage.
►► Use gloves.
1. Cut the Sealing Adhesive A with an electric

cutter from inside and outside.
A
88
2. Remove the rear window from the outside with
suction cups.
3. Clean the compartment from any glass and
glue residues.
11.4.2 Mount the Rear Window
1. Degrease the new rear window.
2. Apply the cork thickness B along the sides and

at the bottom of the perimeter.
3. Apply sealing adhesive C to the top of the rear A
window.
89
4. Place the rear window in the compartment.
5. Lock the rear window with appropriate

equipment.
NOTICE
Possible damages to the vehicle.
90
12 Pneumatic Systems
12.1 Replace the ECAS Solenoid Valve
12.1.1 Remove the ECAS Solenoid Valve
1. Lift the vehicle by means of appropriate lifters.

2. Place the vehicle on special stands located at
A
the points shown in the figure.
3. Drain pneumatic systems. 1.
4. Disconnect the electrical connections. B
5. Disconnect all pneumatic tubes on ECAS.
6. Unscrew the nuts A.
7. Remove ECAS B solenoid valve. 2.
91
12.1.2 Replace the Solenoid Valve
1. Place the ECAS solenoid valve.

2. Secure the ECAS B with the fastening nuts A.
A
3. Connect the pneumatic hoses.
4. Connect the electrical connections. 2.
5. Refit the pneumatic systems. B
1.
92
13 Water Circulation Systems
13.1 Replace the Engine Cooling Water Radiator
13.1.1 Disassemble the Engine Cooling Water Radiator
1. To remove the engine compartment cover

B, unscrew the fixing screws of the 2 upper
hinges
2. Remove the C and D covers.
A
3. Open hatch A.
D
4. Remove the E lamp and its brackets.
5. To remove the F pipes, disconnect the relative

sleeves.
93
6. Raise the vehicle by means of appropriate
lifters and place it on special stands located at
the points shown in the figure.
7. Remove the covers below the engine and the
gearbox
8. Close the tap.
DANGER
Possible scalding due to hot water.
►► Make sure the water temperature is low.

Possible environmental damage due to leaking water.
►► Collect the water that drains out of the drains into a special container.
9. To drain the engine cooling system, remove G

the plugs G and H.
94
Possible environmental damage due to oil leakage.
►► Collect the oil that drains out of the drains into a special container.
11. To disassemble the oil pipes I of the fan control

system, unscrew the fittings on the oil cooler.
2x
12. Disconnect the hose couplings L of the engine

cooling water system and the K tube. K L

Possible environmental damage due to oil leakage.
►► Collect the oil that drains out of the drains into a special container.
95
13. Place an oil collector under the operating zone
and disconnect the N connector and the M M
tubes.
2.
N
1.
14. Disconnect tube O.
15. Unscrew the fixing bracket screws.

16. Unscrew the upper and lower fixing screws of
the radiator.
17. Pull the radiator from the left side of the vehicle
using a fork lift.
2x
13.1.2 Mount the Engine Cooling Water Radiator
1. Place the radiator.
96
2. Refit the frame cross member over the
radiator.
116 Nm
11,8 kgm
25 Nm
2,5 kgm
25 Nm
2,5 kgm
NOTICE
Possible damages to the vehicle due to disconnection of vehicle parts.
►► Observe the specified tightening torque (Class 1 for 48 Nm pairs).
►► Observe the specified torque (Class 2).
3. Fix the radiator and the bracket using the

relative fixing screws.
9x
4. Connect the hose.
97
5. Connect the pipes M and the connector N.
M
2.
N
1.
6. Connect the sleeves of the engine cooling

water system pipes L and the K-tube. K L
7. Mount the oil pipes I of the fan control system.
2x
8. Mount the tubes F.

9. Fill the engine cooling water system.
98
10. Fit the E lamp and its brackets.
11. Close door A.

12. Mount the C and D covers.
13. To mount the engine compartment door B,
reconnect the hinges.
A
D
13.2 Replace the Heating Element in the Driver’s Seat
INFORMATION
13.3 Replace the Passenger Heating Convector
INFORMATION
13.4 Replace the Air Heater
INFORMATION
99
13.5 Replace the Boiler of the Pre-heater
INFORMATION
100
14 Hydraulic Installations
14.1 Replace the Fan Oil Reservoir
14.1.1 Disassemble the Fan Oil Reservoir
1. Open the rear door.

2. Disconnect the connector.
3. Insert a collecting vessel under the intervention

zone.
4. Disconnect the tubes and collect the oil
contained in the pan.
5. Unscrew the 4 fixing screws and remove the

tank.
1.
2.
101
14.1.2 Mount the Fan Oil Reservoir
1. Place the tank as shown in the figure and

secure it with the 4 fixing screws. 44 Nm
4,5 kgm
2.
1.
2. Connect the hoses and the electrical connector

and tighten them, respecting the tightening 7,5 Nm
torque shown in the figure. 0,8 kgm
4,5 Nm
0,5 kgm
3. Open the oil reservoir cap.

4. Introduce the previously recovered oil until the
maximum level is reached.
102
5. Close the oil reservoir cap.
6. Start the engine and let it run at maximum.
7. Close the rear door.
14.2 Replace the Fan Oil Cooler

14.2.1 Remove the Fan Oil Cooler
1. Open side doors A and B.
A B
103
2. To open the oil cooler, unscrew the screws C.
C
9x
1.
2.
3. To open the clamp, unscrew the nut.
2.
1.
2x
4. Remove the tube.
1.
2.
5. To remove the plate, unscrew the 4 fixing

screws.
1.
2. 4x
104
6. Unscrew the 2 fixing screws and extract the oil
cooler.
1.
2x
2.
7. Collect the oil contained inside the radiator in

a special container.
14.2.2 Mount the Fan Oil Cooler
1. Position the oil cooler and lock it with the 2

fixing screws.
2.
2x
1.
105
2. To mount the plate, unscrew the 4 fixing
screws.
2.
1. 4x
3. Mount the tube.
2.
1.
4. Close the clamp and tighten the nut respecting

the tightening torque shown in the figure. 6 Nm
1. 2,5 kgm
2.
2x
5. Tighten the fixing screws C, respecting the C

tightening torque shown in the figure.
9x
25 Nm
2,5 kgm
2.
1.
106
6. Open the oil reservoir cap.
7. Introduce the oil previously recovered until
reaching the maximum level.
8. Close the oil reservoir cap.

9. Start the engine and let it run at maximum.
10. Close the side doors A and B.
A B
14.3 Replace the Fan Control Pump
INFORMATION
107
15 Electrical System
15.1 Replace the Batteries
DANGER
Possible serious injury due to explosion.
►► Do not smoke or carry free flames near the battery.
►► Make sure there is adequate ventilation of the room where the batteries are housed.
DANGER
Possible serious injury due to leakage of the battery fluid.
►► Wear safety shoes and protective goggles.
►► Avoid contact with skin and clothing.
NOTICE
Possible damages to the vehicle due to short circuit.
►► Avoid supporting metal tools on the battery.

Possible damages to the environment due to the leakage of the battery fluid.
►► Dispose of exhausted batteries according to the regulations in force.

108
15.1.1 Remove the Batteries
1. To access the batteries, open the battery

compartment.
2. To remove the battery housing, raise the 2

yellow levers at the same time.
4x
1.
2.
109
4. Disconnect the positive wires from the battery
terminal.
5. Unscrew 3 adjustment dials.

6. Remove the batteries.
2.
1.
15.1.2 Mounting the Batteries
1. Place the batteries in the battery holder.

2. Secure the batteries using the 3 adjustment
dials.
1.
2.
110
3. To avoid corrosions, clean and cover with a
thin layer of pure, pure vaseline the teminals
and the cable ends, especially at the lower
parts.
4. Attach the positive wires to the battery

terminal.
5. Screw the 4 fixing screws.
10 Nm
1 kgm
4x 2.
1.
111
6. Push the battery compartment as shown in
the illustration.
7. Close the battery compartment.
112
16 Air Conditioning System
16.1 Replace the Compressor of the Air Conditioning System
INFORMATION
113
17 Attached Documentation
The attached documentation integrates information, procedures, and how to properly maintain
the vehicle.
114
CURSOR 9 SERIES
Euro VI
Automotive applications
(Breda - Menarini)
F2CFE612B*J104
F2CFE612C*J104
F2CFE612D*J104
Technical Repair Manual

This document provides data, specifications, instructions and
methods to perform repair interventions on the assembly and
its components.
Anyhow, this document is addressed to qualified and special-

ised personnel.
Before performing any intervention, check that the document

relating to the vehicle model on which the intervention is being
performed is available and also make sure that all accident pre-
vention devices, including but not limited to, goggles, helmet,
gloves, shoes, as well as work equipment, lifting and transport
equipment, etc., are available and efficient, and also make sure
that the vehicle is in safety conditions for intervention.
Making interventions strictly observing the indications given

here, as well as using specific equipment indicated, assures a
correct repair intervention, execution timing observance and
operators’ safety.
Each repair intervention must be finalised to the recovery of

functionality, efficiency and safety conditions that are provided
by FPT.
Each intervention on the vehicle that is finalised to a modifica-

tion, alteration or anything else which has not been authorised
by FPT relieves FPT of any liability, and, in particular, where the
assembly is covered by a warranty, each intervention will
immediately invalidate the warranty.
FPT declines any liability for repair work.
FPT is available to provide any information necessary for the

implementation of the interventions and to provide instruc-
tions for any cases and situations not covered in this publica-
tion.
The data contained in this issue may not be up-to-date due to

possible modifications made by the Manufacturer for technical
or commercial reasons, or to adaptations required by laws in
force in different countries.
In the event of discordance between the information in this

publication and the actual assembly, please contact the FPT
network before performing any interventions.”
The complete or partial reproduction of the text or illustra-
tions herein is forbidden.
Publication edited by:

FPT Industrial S.p.A
Via Puglia 15, 10156 Torino, Italia
www.fptindustrial.com
Print P1D32C026 E - 1st Ed. 12.2016
F2CFE612 INTRODUCTION 1
Introduction
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3
- SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Service operations . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . 5
GENERAL WARNINGS REGARDING

THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . 7
- Grounding and screening . . . . . . . . . . . . . . . . . 8
OPTIONAL ELECTRICAL AND MECHANICAL

PARTS INSTALLATIONS . . . . . . . . . . . . . . . . 9
CONVERSIONS BETWEEN THE MAIN UNITS

OF MEASUREMENT OF THE INTERNATIONAL
SYSTEM AND THE MOST COMMONLY USED
DERIVED SIZES . . . . . . . . . . . . . . . . . . . . . . . . 9
PAGE HEADER AND FOOTER

INTERPRETATION . . . . . . . . . . . . . . . . . . . . . 10
UPDATE DATA . . . . . . . . . . . . . . . . . . . . . . . . . 11
Print P1D32C026 E Base - 12/2016

2 INTRODUCTION F2CFE612
Base - 12/2016 Print P1D32C026 E

GENERAL INFORMATION
Manuals for repairs are split into Parts and Sections, each one of which is marked by a number; the contents of these sections are
indicated in the general table of contents.
Sections with mechanical contents include technical data, tightening torque collections, tool lists, assembly connections - disconnec-
tions, overhauls at the bench, troubleshooting and scheduled maintenance.
The electrical/electronic system section contains the descriptions of the electric network and the electronic systems of the assembly,
wiring diagrams, electrical characteristics of components and the component codes.
Sections 1, 2 describe engine operation and the general features of the engines.
Section 3 describes the electrical part regarding wiring, electric and electronic devices which differ depending on specific use.
Section 4 includes the scheduled maintenance.
Sections 5-6 refer to removal-installation operations of the main components and the general overhaul interventions of engines
fitted onto a rotating stand.
Section 7 and 8 include the technical characteristics of the engines, such as assembly clearances, tightening torques and specific equip-
ment.
The appendix provides a list of the general safety regulations which all operators, whether installers or maintenance technicians,
must comply with to prevent any serious injury.
The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify information. In particular, a set of
symbols has been defined to classify warnings, while another set has been specified for service operations.
SYMBOLS
Warnings
Danger for persons

Missing or incomplete observance of these prescriptions can cause serious danger for persons’ safety.
Risk of serious damage to the assembly

The partial or total non-observance of these instructions could cause serious damage to the assembly and may nullify
the warranty.
General danger
! Includes the dangers of both above described signals.
Environmental protection
Indicates correct behaviour in order for the assembly use to be as environmentally friendly as possible.
NOTE Indicates an additional explanation for a piece of information.
Service operations
Example:
j 1 Ø 1 = Housing for connecting rod

small end bush. Tighten to the specified torque + angle value
α
j 2 Ø 2 = Big-end bearing seat.

Removal
Intake
Disconnect
Refitting
Exhaust
Connect
Disassembly
Operation
Dismantling
Assembly
Assemble ρ Compression ratio
Tolerance
Tighten to the specified torque
Weight difference
Tighten to the specified torque + angle

Rolling torque
α value
Press or caulk Rotation
Registration Angle
Adjustment Angle value
Visual check
Preload
Fitting position check
Measuring
Value to be found Revolutions per time unit
Check
Tools Temperature
Surface for machining

Pressure
Finished workpiece bar
Oversized
Interference
Oversized by no more than .....
Forced assembly
Max.
Undersized
Clearance
Undersized by no more than.....
Shim
Min.
Lubricate Selection
Moisten of oversizing
Grease class
Temperature < 0o C
Coolant
Cold
Sealant
Winter
Temperature > 0o C
Bleeding air Hot
Summer

GENERAL WARNINGS
The warnings shown may not be representative of all the dangerous situations that may occur. Therefore, supervisors
! should be contacted whenever a dangerous situation that has not been described occurs.
Use both specific and general-purpose toolings according to the prescriptions contained in respective operator’s
manuals. Check the working condition and suitability of tools not subject to periodic review.
The manual handling of loads must be assessed in advance since it also depends not only on weight but also 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 show clear indications regarding maximum acceptable carrying capacity. The use of such
tools is strictly permitted by authorised personnel only. Stay at a safe distance from the load and never below it.
In disassembly operations, always observe the provided prescriptions and prevent any mechanical parts being taken out
from accidentally striking workshop personnel.
Workshop activities performed by two technicians must always been executed with caution; avoid operations that may
be dangerous for any collaborators due to lack of field of vision or incorrect position.
Keep any personnel not assigned to the operations clear of working area.
Learn the necessary concepts of operation and safety relating to the vehicle prior to working on it. Scrupulously observe
all safety warnings on the assembly.
Do not leave the assembly in motion unattended during repair work.
When working on an assembly off the ground, make sure that it is resting firmly on the appropriate supporting stands
and that the manual/automatic safety devices are activated in the event of lifting with a hydraulic ramp.
When working on assemblies fuelled with natural gas, in addition to the instructions given in the document, also observe
all the 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.
Flammable fuels and all fluids and liquids must be handled with care, according to the indications provided in the 12 point
cards of harmful materials. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames
or sparks, in order to prevent sudden fires/explosions. Adequately store inflammable, corrosive and polluting fluids and
liquids according to what provided by regulations in force. Strictly avoid using containers for food to store harmful liquids.
Avoid drilling or burning pressurised containers and discard cloths impregnated with inflammable substances into suita-
ble containers.
Worn out, damaged or consumable parts must be replaced with original spare parts.
During workshop activities, always keep the workplace clean; promptly free or clean floors of any accidental spills and
stains of liquids and oils. Electric sockets and electrical equipment necessary to perform repair operations must meet
safety rules.

Wear all required P.P.E. and garments when called for by the operation at issue. Contact with moving parts may cause
serious injuries. Use suitable, preferably tight-fitting garments and avoid wearing jewellery, scarves, etc.
Do not leave the engine running in workshops not equipped with a pipe to extract exhaust fumes outside.
Do not breathe fumes from heating or welding of paint, as they are harmful; operate outdoors or in well-ventilated areas.
Wear an appropriate respirator in the presence of paint dust.
Avoid contact with hot water or steam from the engine, radiator and hoses as they could cause serious burns. Avoid
direct contact with liquids and fluids inside vehicle systems; consult the 12 remedy points sheet if accidental contact
occurs.
Before overhauling, clean the assemblies and make sure they are integral and complete. Tidy up detached or disassem-
bled parts with their securing elements (screws, nuts, etc.) into special containers.
Check the integrity of the parts that prevent the loosening of screws: split washers, split pins, clips, etc. Self-locking nuts
with nylon inserts must always be replaced.
Avoid contact of rubber with diesel fuel, petrol or other incompatible substances.
Before pressure washing mechanical parts, protect electrical connectors and any control units.
The tightening of screws and nuts should always be carried out according to directions. FPT’s sales and assistance net-
work is available to provide any clarifications necessary to carry out any repair work not covered by this document.
Before welding:
- Disconnect all electronic control units and unplug the power cable from the battery’s positive terminal (connecting
it to the chassis ground) and connectors.
- Remove paint by using proper solvents or paint removers and clean relevant surfaces with soap and water.
- Wait approximately 15 minutes before proceeding with welding.
- Use suitable fire-resistant protections to protect hoses or other components in which fluids or other flammable
materials flow when welding.
Should the vehicle be subjected to temperatures exceeding 80C (dryer ovens), remove the electronic control units.
The disposal of all liquids and fluids should be carried out in strict compliance with specific regulations in force.

GENERAL WARNINGS REGARDING THE ELECTRICAL SYSTEM
When having to operate on the electrical/electronic circuit, disconnect the batteries from the circuit, disconnecting the
! chassis earth cable first of all from the negative terminal of the battery.
Before connecting the batteries to the system make sure the latter is well insulated.
Disconnect the external recharging apparatus from the public utility network before removing the apparatus pins from
the battery terminals.
Do not cause sparks to verify the presence of voltage in a circuit.
Do not use a test bulb to check the continuity of a circuit. Only use the appropriate testing devices.
Make sure that the wirings of electronic devices (length, type of cable, location, strapping, connection of screen braiding,
grounding, etc.) conform with the FPT system and that they are carefully restored after repair or maintenance work.
Measurements on the ECUs, jack connections and electrical connections of components must be done only on regular
test lines, with special jacks and jack bushings. Never use improvised equipment like metal wires, screwdrivers, pins or
similar. This may not only cause short circuits, but also damage the jack connectors, resulting in poor contact.
Do not use fast chargers to start up the engine. Start up must only be performed with either separate batteries or special
truck.
Incorrect polarisation of the power supply voltage for the electronic control units (e.g. erroneous battery polarisation)
may damage the components irreversibly.
Disconnect the batteries from the system before recharging them by means of an external unit.
On connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed tightening
torque.
Isolate the circuit prior to disconnecting the junction connector from an electronic control unit.
Do not directly supply current to components served by electronic control units with rated vehicle voltage.
The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Upon completing work on the electrical circuit, restore the electrical connectors and wiring as originally provided.
NOTE The connectors are shown from cable side. Connector views contained in the manual are representative of cable side.

Grounding and screening

The negative conductors connected to circuit ground point must be as short as possible and connected in ”star” form, ensuring
that their tightening is done neatly and sufficiently (Figure 1 ref. M).
The following precautions must be observed regarding the electronic components:
— electronic control units must be connected to the system ground when equipped with metal housings.
— The negative cables of the electronic control units must be connected at a circuit ground point, such as dashboard compartment
ground (avoiding ”serial” or ”chain” connections), as well as to the negative terminal of the battery or batteries.
— Even if not connected to the circuit ground/battery negative terminal, analogue ground (sensors) should have optimal insulation.
Consequently, particular care should be given to terminal parasitic resistances: oxidation, clinching defects, etc.
— The metal braid of shielded circuits must be in contact only at the ECU side to which the signal is to be sent (Figure 2).
— In the case of junction connectors, the unshielded section (d) near to the latter must be as short as possible (Figure 2).
— The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the chassis/body.
Figure 1
1. “STAR” CONNECTIONS OF NEGATIVE CABLES TO THE CIRCUIT GROUND M
Figure 2
88039
2. SHIELDING BY METAL BRAID OF A CABLE TO AN ELECTRONIC COMPONENT - C. CONNECTOR

d. DISTANCE ! 0

OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS

Accessory installation, additions and changes on the assembly must be carried out in compliance with the FPT assembly directives.
It is reminded that, especially with regard to the electric system, several electric sockets are provided for as standard (or optional)
sockets in order to simplify and normalise the electrical intervention by bodybuilders.
It is strictly forbidden to carry out any modifications or connections to the electronic control unit wiring. In particular, the
data line between the control units (CAN line) is to be considered untouchable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND THE MOST COMMONLY USED DERIVED SIZES
Power
1 kW = 1.36 CV
1 kW = 1.34 hp
1 CV = 0.735 kW
1 CV = 0.986 hp
1 hp = 0.746 kW
1 hp = 1,014 CV
NOTE the unit HP is converted into hp for simplicity according to a 1:1 ratio
1 hp = 1 HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rpm = 0.1047 rad/s
1 rad/s = 9.55 rpm
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 bar = 105 Pa
NOTE Where accuracy is not particularly required:

- the unit Nm is converted into kgm for simplicity according to a ratio of 10:1
1 kgm = 10 Nm;
- the unit bar is converted into kg/cm2 for simplicity according to a ratio of 1:1
1 kg/cm2 = 1 bar.
Temperature
0˚ C = 273.15 K
0˚ F = 255.37 K
0˚ C = 32˚ F (the conversion factor between Celsius and Fahrenheit is 1:1.8)

PAGE HEADER AND FOOTER INTERPRETATION
Type Section Page

of engine title number
Number Basic edition referring to When present, a

Language
of printed closing phase of drafting month-year update
of Publication
copies month-year (Revi) to the basic edition

UPDATE DATA
Section Section name Description of modification Page Revision date


F2CFE612 ENGINE 1
CURSOR Euro VI SERIES

Section
General information 1
Operating diagrams 2
Electrical equipment 3
Scheduled maintenance 4
Removal - refitting of main components 5
General mechanical overhaul 6
Technical specifications 7
Tools 8
Standard safety precautions Appendix

2 F2CFE612 ENGINE

F2CFE612 ENGINE SECTION 1 - GENERAL INFORMATION 1
SECTION 1
General information
Page
NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CORRESPONDENCE BETWEEN TECHNICAL

CODES AND COMMERCIAL CODES . . . . . 4
TECHNICAL CODE . . . . . . . . . . . . . . . . . . . . . . 5
COMMERCIAL CODE . . . . . . . . . . . . . . . . . . . . 6
ISO VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE CHARACTERISTICS . . . . . . . . . . . . . . . 11
CHARACTERISTIC CURVES F2CFE612D*J104 . 13
CHARACTERISTIC CURVES F2CFE612C*J104 . 13
CHARACTERISTIC CURVES F2CFE612B*J104 . 14

2 SECTION 1 - GENERAL INFORMATION F2CFE612 ENGINE

NAMEPLATE
Figure 1
249481
1. Engine designation - 2. Engine serial No. - 3. Production date - 4. Type-approval

CORRESPONDENCE BETWEEN TECHNICAL CODES AND COMMERCIAL CODES
Technical codes Commercial Codes

F2CFE612B*J104
F2CFE612C*J104 C9 EuVI StepC
F2CFE612D*J104

TECHNICAL CODE
F2 C F E 6 1 2 D * J 104
F2 C F E 6 1 2 C * J 104
F2 C F E 6 1 2 B * J 104
Version number on BOM
Type-approval adjustment
A = Tier 4 E= Step 2
B = Tier 4Full F= Euro 5
C = EURO 6 H= Step3
D = Without emissions J= Euro 6 Step C
Type-approval for performance

A = First calibration
B = Second calibration
C = Third calibration
D = Fourth calibration
Applications
0 = Different applications 6 = Marine
1 = Truck 7 = Automotive
2 = Bus 8 = Railway
3 = Industrial/Agricultural 9 = Military
4 = Industrial/Agricultural
5 = Power generator unit
Main engine features:

0 = CNG turbocharged 5 = CNG natural intake
1 = Direct diesel injection turbocharged 6 = Indirect diesel injection
diesel intercooled Turbocharged
2 = Direct diesel injection natural 7 = Indirect diesel injection
intake Turbocharged
3 = Indirect diesel injection natural 8 = Petrol turbocharged
intake 9 = Indirect diesel injection turbocharged
4 = Petrol natural intake intercooled diesel
Number of cylinders
(Note: 0 = 10 cylinders, 1 = 12 more)
Configuration of cylinders
A = 4-stroke, vertical
B = 4-stroke, horizontal H = 4-stroke V
C = 4-stroke, vertical with EGR K = 4-stroke V with post-treatment
D = 4-stroke, horizontal with EGR L = 4 stroke, vertical with EGR + post-treatment
E = 4 stroke, vertical with post-treatment M = 4-stroke V with EGR
F = 4 stroke, horizontal with post-treatment N = 4-stroke V with
G = 4-stroke, horizontal with EGR+post-treatment
EGR+post-treatment
F = Tier4/Euro6
Code Engine type

C Cursor Euro 6
F2 = NEW ENGINE FAMILY

COMMERCIAL CODE
C 87 E N T 6 W
Engine control unit: EDC17CV41
Emission levels:
A = 2002/88 CE
C = Euro 3
D = Both type-approvals Europe (NRMM)
and EPA-USA
E = Europe (NRMM)
F = Sprinkler
G = Gas
I = No emissions (without type-approval)
M = Marine
U = EPA - USA
X = Step 3A - Tier 3+
Y = Step 3B - Tier 4A
Z = Type-approval R96
4 = Euro 4
5 = Euro 5
6 = Euro 6
Intake:
A = Natural
S = Turbocharged
T = Turbocharged with intercooler
Guard:
N = Non-structural (standard distribution)
S = Non-structural (limited distribution)
R = Structural
Injection:
E = Electronic
M = Mechanical
Displacement or No. of cylinders

litres per movement > 10 litres
litres x 10 per movement < 10 litres
No. of cylinders per vehicle
For NEF, the first number is also the number of cylinders
Engine family:
C = Cursor
F = F5
N = NEF
S = F1
V = V series

ISO VIEW
Figure 2
249459
The engine is an F2CFE612 6-cylinder in-line turbocharged with intercooler with 4 valves per cylinder; it belongs to the CURSOR
series and operates according to a four-stroke diesel cycle.
The engine’s fuel supply system is electronically controlled and is based on the direct injection of the fuel into the combustion
chamber by means of a high pressure pump and the common rail.

ENGINE VIEWS
Figure 3
11
6
249460
FRONT VIEW OF ENGINE, EXHAUST SIDE

1. Turbocharger - 2. Intarder pipes - 3. Engine brake - 4. Crankshaft rpm sensor - 5. Heat exchanger (water/oil) - 6. Oil filter
- 7. Engine oil sump - 8. Turbocharger oil discharge duct - 9. Heat exchanger return pipe - 10. Delivery pipe to radiator -
11. Exhaust manifold - 12. Breather pipe.
Figure 4
11 1
10
2
7 4
5 249461
REAR VIEW OF ENGINE, INTAKE SIDE

1. Lifting eyelet - 2. Intake manifold - 3. Additional alternator - 4. Engine management control unit - 5. Alternator - 6. Starter
motor - 7. Power steering pump - 8. Compressor - 9. Hydraulic gear pump -10. High pressure fuel pump - 11. Camshaft
timing sensor.

Figure 5
225070
FRONT VIEW OF THE ENGINE
1. Turbocharger - 2. Water pump - 3. Outlet pipe from radiator - 4. Pulley - 5. Oil filter -
6. Automatic belt tensioner - 7. Alternator - 8. Automatic belt tensioner - 9. Additional alternator -
10. Inlet pipe to radiator - 11. Blow-by cover
Figure 6
10 1
7 4
6 5
249462
REAR VIEW OF ENGINE
1. Rear cover - 2. Distribution cover - 3. Hydraulic pump - 4. Flywheel - 5. Alternator - 6. Oil drain plug - 7. Oil filter -
8. Speed sensor (crankshaft) - 9. Throttle valve - 10. Intarder pipes

Figure 7
249479
ENGINE OVERVIEW
1. Turbocharger - 2. Tappet cover - 3. Additional alternator - 4. Intake manifold - 5. Fuel pump - 6. Hydraulic pump -
7. Oil plug - 8. Intarder pipes - 9 Engine brake.

ENGINE CHARACTERISTICS
F2CFE612
Type
D*J104 C*J104 B*J104
Cycle Diesel 4-stroke

Supply Turbocharged with intercooler
Injection Direct
Number of cylinders 6 in line
j
Bore mm 117
Stroke mm 135
+ + +Total displacement cm3 8710
ρ Compression
ratio
15.9 : 1
Max. power kW 228 243 265

(HP) (310) (330) (360)
rpm 2200 2200 2200
Maximum torque Nm 1300 1400 1650

(kgm) (132) (142) (168)
rpm 1100-1675 1100-1655 1200-1530
Low
idle
speed rpm 600 ± 50
High
idle
speed rpm 2450 ± 25
TURBOCHARGING Fixed geometry with Waste Gate

Turbocharger type Holset
LUBRICATION
Oil pressure with engine warmed Forced by gear pump, pressure relief valve, oil filter
up:
bar
(100 ˚C ± 5 ˚C) 2.3
- at idle speed bar 5
- at max speed bar
COOLING Fluid
Water pump drive: By means of belt
Thermostat:
- opening start ˚C 851.5
NOTE The data, specifications and performance figures are only valid if the bodybuilder complies with all the installation instruc-
tions provided by FPT.
Furthermore, the bodybuilder appliances must always be in compliance with the torque, power and engine speed for
which the engine was designed.

F2CFE612
Type
D*J104 C*J104 B*J104
Cooling
circuit (1)
Total capacity L 14.7
Lubrication circuit(2)
total capacity(3)
(7˚ engine inclination) -
Periodic replacement:
Sump at minimum level L (kg) 15.5 (13.95)
Sump at
maximum level L (kg) 38 (34.2)
Minimum sump level with
automatic top-up L (kg) 33.4 (30.06)
Fuel tank (4) L 250 - 494
Urea total capacity (5) L 30 - 39
(I) Quantity relative only to standard configuration engines.

Use a mix of water and TEXACO Havoline XLC at 50% even in summer. An alternative option to TEXACO Havoline
XLC is to use a product that conforms to the international standard SAE J 1034.
(2) Use lubricants which meet the international specifications PETRONAS TD6200720 SAE 5W-30 ACEA E6 LOW SAPS
Oil consumption is deemed acceptable when it is up to but does not exceed 0.5 % of fuel consumption.
(3) The quantities indicated refer to the first refuel only and are relative to refuelling the engine, oil sump and filter.
(4) Use STANDARD fuel type that complies with standard EN 590 (2005/55 - 2005/78). Instructions connected to the fuel
tank capacity are the responsibility of the BODYBUILDER since these are subject to changes depending on the various
vehicle configurations.
(5) Use Urea that complies with the specifications of the Manufacturer. Instructions connected to the Urea tank capacity are
the responsibility of the BODYBUILDER since these are subject to changes depending on the various vehicle configura-
tions.
Filling from drums or tanks can cause contamination of the diesel, with the consequent risk of damaging the injection
system; if necessary, perform suitable filtration or sedimentation of the impurities before refuelling.
!
The data, specifications and performance figures are only valid if the bodybuilder complies with all the installation instruc-
! tions provided by FPT.

CHARACTERISTIC CURVES F2CFE612D*J104
Figure 8
249443
Max. POWER 228 kW (310 HP) at 2,200 rpm.

Max. TORQUE 1300 Nm (132 kgm) at 1,100 - 1,675 rpm.
CHARACTERISTIC CURVES F2CFE612C*J104
Figure 9
249480
Max. POWER 243 kW (330 HP) at 2,200 rpm

Max. TORQUE 1400 Nm (142 kgm) at 1,100 - 1,655 rpm

CHARACTERISTIC CURVES F2CFE612B*J104
Figure 10
249442
Max. POWER 265 kW (360 HP) at 2200 rpm.

Max. TORQUE 1650 Nm (168 kgm) at 1200 - 1530 rpm.

F2CFE612 ENGINE SECTION 2 - OPERATING DIAGRAMS 1
SECTION 2
Operating diagrams
Page
SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Electrical system . . . . . . . . . . . . . . . . . . . . . . . . 3
- Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . 5
- Supply system components . . . . . . . . . . . . . . . 7
- Mechanical supply pump . . . . . . . . . . . . . . . . . 7
- Normal operating conditions . . . . . . . . . . . . . . 7
- Overpressure condition at outlet . . . . . . . . . . . 7
- Air bleeding conditions . . . . . . . . . . . . . . . . . . . 7
- Operating principle . . . . . . . . . . . . . . . . . . . . . . 10
- Flow regulator . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Rail (pressure accumulator) . . . . . . . . . . . . . . . 13
- Overpressure valve . . . . . . . . . . . . . . . . . . . . . 13
- CRIN 3 Electro-injectors . . . . . . . . . . . . . . . . . 14
FUEL PRE-FILTER . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LUBRICATION CIRCUIT . . . . . . . . . . . . . . . . . . 18
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Overpressure valve . . . . . . . . . . . . . . . . . . . . . 20
- Oil pressure regulator valve . . . . . . . . . . . . . . . 21
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . 22
- Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
- Filter by-pass valve . . . . . . . . . . . . . . . . . . . . . . 24
- Oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OIL VAPOUR RECIRCULATION SYSTEM

(BLOW BY) . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Description and operation . . . . . . . . . . . . . . . . 27
COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . 28
- General information . . . . . . . . . . . . . . . . . . . . . 28
- Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- Intarder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2 SECTION 2 - OPERATING DIAGRAMS F2CFE612 ENGINE
Page
INTAKE AND EXHAUST SYSTEM . . . . . . . . . . . 32
- Intake and exhaust diagram . . . . . . . . . . . . . . . 32
- Intake and exhaust system components . . . . . . 33
EXHAUST GAS AFTER-TREATMENT

SYSTEM (ATS) . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- ATS system heating/cooling system . . . . . . . . . 37
MAIN COMPONENTS OF ATS SYSTEM . . . . . . 39
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- AdBlue fluid level gauge control . . . . . . . . . . . . 39
- DeNOx 2.2 supply module

(SM - Supply Module) . . . . . . . . . . . . . . . . . . . 40
- Filter removal . . . . . . . . . . . . . . . . . . . . . . . . . . 41
- Filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . 42
- DeNOx 2.2 dosing module

(DM - Dosing Module) . . . . . . . . . . . . . . . . . . 43
- Diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . 43
- NH3 sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
- Nitrogen oxide detecting sensor . . . . . . . . . . . 45
- Exhaust gas temperature sensor . . . . . . . . . . . 46
- Temperature and humidity sensor . . . . . . . . . . 47
- Catalytic converter . . . . . . . . . . . . . . . . . . . . . . 48
- Differential pressure sensor . . . . . . . . . . . . . . . 49
SCHEDULED MAINTENANCE FOR ATS SYSTEM 50
REPLACING THE DPF (DIESEL PARTICULATE

FILTER) CATALYTIC CONVERTER . . . . . . . . 51
- Removing the DPF catalytic converter . . . . . . . 51
- Refitting the DPF catalytic converter . . . . . . . . 53

SUPPLY SYSTEM
Electric system
Figure 1
225109
1. Engine rpm sensor - 2. Engine brake throttle valve control actuator - 3. Oil level sensor -
4. Engine coolant temperature sensor.

Figure 2
249464
1. Engine oil vapour pressure sensor - 2. Air heater resistor - 3. Alternators - 4. EDC17CV41 Engine control unit -
5. Remote switch - 6. Starter motor - 7. Pressure sensor / engine oil temperature sensor - 8. Hydraulic pump -
9 Flow metering unit - 10. Timing sensor - 11. Air temperature / pressure sensor - 12. Fuel pressure sensor.

Hydraulic system
The Common Rail fuel system has a special pump that continuously keeps fuel at high pressure, independently from the stroke
and the cylinder which is to receive the injection and accumulates fuel in a common duct for all injectors.
At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the ECU.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from the rail takes
place in the corresponding cylinder.
Figure 3
225095
A. high pressure - B. Return - C. Low pressure

1. Electro-injectors - 2. Fuel filter support - 3. Engine control unit - 4. High pressure pump - 5. Common Rail.
The fuel prefilter and filter are fitted on the vehicle.

!

Fuel system diagram

Figure 4
Return circuit
Delivery circuit
189012
1. High pressure pump - 2. Fuel filter (on vehicle) - 3. Tank - 4. Fuel prefilter (on vehicle) -
5. Engine management control unit - 6. Electro-injectors - 7. Common Rail - 8. Pressure sensor
After fitting the high pressure pipes, during the next 20 hours of operation, frequently check the engine oil level.
! (IT MUST NOT INCREASE).

Supply system components Air bleeding conditions

Mechanical supply pump
Gear pump, fitted on the rear side of the high pressure pump Figure 7
and used to supply it. It is driven by the high pressure pump
shaft.
Normal operating conditions

Figure 5
72594
The by-pass valve (2) cuts in when, with engine off, the fuel
system shall be filled through the priming pump. In this situation
72592
the by-pass valve (1) stays closed, the by-pass valve (2) opens
due to inlet pressure and fuel is drained out through B.
A. Fuel inlet from tank, B. fuel outlet to filter, 1-2 by-pass
valves in close position.
Overpressure condition at outlet
Figure 6
72593
By-pass valve (1) opens in the presence of overpressure at

the outlet B. The pressure of the fuel overcomes the force
exerted by the spring of the valve (1), thereby placing the
pump outlet in communication with the inlet by way of pas-
sage (2).
HP Pump CP3.3NH
Pump with 3 radial pistons controlled by the timing gear, without needing any setting. The mechanical supply pump controlled
by the high pressure pump shaft is fitted on the rear side of the high pressure pump.
The high pressure pump cannot be serviced and therefore should not be removed nor should the fastening bolts be
tampered with.
The only permitted intervention is that of replacing the drive gear.
Figure 8
188494
1. Connection between fuel outlet and rail - 2. High pressure pump - 3. Flow regulator - 4. Drive gear - 5. Filter fuel inlet
union - 6. Fuel drain fitting - 7. Connection for fuel inlet from heat exchanger ECU - 8. Connection between fuel outlet
from mechanical pump and filter - 9. Mechanical supply pump.

Internal structure
Figure 9
Section B-B
Section C-C
70498
1. Cylinder. - 2. Triple-lobe element - 3. Cap intake valve. - 4. Ball delivery valve. - 5. Piston. -
6. Pump shaft. - 7. Low-pressure fuel inlet. - 8. Plungers supplying fuel ducts.
Every plunger unit is composed of:

- a piston (5) actuated by a three-lobe element (2) floating on the pump shaft (6). The element (2), as it floats on a misaligned
part of the shaft (6), when the shaft rotates, does not rotate with it but is only translated in a circular movement along a
wider radius, with the result of alternatively activating the three pumping elements;
- cap intake valve (3);
- ball delivery valve (4).

Operating principle
Figure 10
Sect. B - B
Sect. D - D
72597
1. Connection between fuel outlet and rail - 2. Delivery valve to rail - 3. Plunger - 4. Pump shaft - 5. Plunger supply pipe -
6. Pressure regulator supply pipe - 7. Flow regulator.
Plunger (3) is oriented to pump shaft (4) cam. During intake, the plunger is supplied through supply duct (5).
The amount of fuel to be sent to the plunger is set by the flow regulator (7). The flow regulator, based on the PWM command
from the control unit, shuts the flow of fuel to the plunger. During plunger compression stage, fuel reaches the pressure required
to open the delivery valve to common rail (2) and to feed it through outlet (1).

Figure 11 Figure 12
72598 72601
Sect. C - C Sect. A - A
1. Plunger inlet - 2. Pump lubrication pipes - 3. Plunger 1. Fuel outlet pipe - 2. Fuel outlet pipe - 3. Fuel outlet
inlet - 4. Main plunger supply pipe - 5. Flow regulator - from pump with connector for high pressure pipe
6. Plunger inlet - 7. Regulator drain pipe - 8. Pressure for the common rail.
limiting valve 5 bar - 9. Fuel discharge from regulator inlet.
The figure shows the low-pressure fuel paths inside the The figure shows the flow of the fuel at high pressure through
pump; it shows the main supply pipe of the pumping elements the outlet ducts of the pumping elements.
(4), the pumping element supply pipes (1 - 3 - 6), the pipes
used to lubricate the pump (2), the flow regulator (5), the Replacing the flow regulator
5-bar pressure relief valve (8) and the fuel discharge (7). - Greatest cleanliness must be ensured;
Pump shaft is lubricated by fuel through delivery and return - avoid letting impurities into the pump pressure channels;
ducts (2).
- replace the O-rings and moisten them with petroleum
The flow regulator (5) sets the quantity of fuel with which the jelly;
plungers must be supplied; The excess fuel flows off through
the pipe (9). - Tighten to the specified torque.
5 bar pressure relief valve acts as fuel return collector and

keeps 5 bar constant pressure at regulator inlet.

Flow regulator Operation

The fuel pressure regulator is fitted on the low pressure Figure 13
circuit of the CP3.3NH pump. The flow regulator modulates
the amount of fuel sent to the high-pressure circuit according
to the commands received directly from the engine control
unit. The flow regulator consists mainly of the following
components:
- connector,
- casing,
- solenoid
- pre-load spring
- shutter cylinder.
When there is no signal, the flow regulator is normally open,
therefore with the pump providing maximum flow rate.
The engine control unit, via the PWM (Pulse Width 185436
Modulation) signal, modulates the change in fuel flow rate in 1. Solenoid - 2. Magnetic core - 3. Shutter cylinder -
the high-pressure circuit by partially closing or opening the 4. Fuel inlet - 5. Fuel outlet.
sections of passage of the fuel in the low-pressure circuit.
When the engine control unit operates the flow regulator
(via PWM signal), the solenoid (1) is energised, which in turn
generates the movement of the magnetic core (2). The shift
of the core causes the shutter cylinder (3) to move axially,
choking the flow of fuel.
Figure 14
185437
1. Solenoid - 2. Magnetic core - 3. Preload spring -

4. Shutter cylinder.
When the solenoid (1) is not energised, the magnetic core

is pushed into the rest position by the pre-load spring (3). In
this position the shutter cylinder (4) allows the greatest
section of passage for the fuel flow.

The quantity of fuel that powers the high pressure pump is Rail (pressure accumulator)
dosed by the flow regulator on the low pressure system; the
flow regulator is controlled by the engine control unit Figure 15
through a PWM signal.
When fuel is sent to a plunger, the related piston is moving
downwards (suction stroke). When the piston stroke is
reversed, the intake valve closes and the remaining fuel in the
plunger chamber, not being able to come out, is compressed
above the supply pressure value existing in the rail.
The thereby-generated pressure makes the exhaust valve
open and the compressed fuel reaches the high-pressure cir-
cuit.
The plunger compresses the fuel till the top dead centre (deli-
144833
very stroke) is reached. Afterwards, the pressure decreases
till the exhaust valve is closed.
The plunger piston goes back towards the bottom dead cen- 1. Rail - 2. Fuel return - 3. Pipes to injectors - 4. Fuel inlet
tre and the remaining fuel is decompressed. from high pressure pump - 5. Pressure sensor -
6. Overpressure valve.
When the plunger chamber pressure becomes less than the
supply pressure, the intake valve is again opened and the The rail volume (31 cm3) is of reduced sizes to allow a quick
cycle is repeated. pressurisation at startup, at idle and in case of high flow-rates.
The delivery valves must always be free in their movements, It anyway has enough volume as to minimise pulsations cau-
free from impurities and oxidation. sed by injectors openings and closings and by the high-pres-
The pressure delivered to the rail is modulated by the elec- sure pump operation. This function is further enabled by a
tronic control unit by means of the flow regulator solenoid calibrated hole being set downstream of the high-pressure
valve. pump.
The pump is lubricated and cooled by the fuel. A fuel pressure sensor (5) is screwed to the rail. The signal
sent by this sensor to the electronic control unit is a feed-
The radialjet pump removal - refitting time on the engine is back information, depending on which the rail pressure value
highly reduced in comparison with traditional injection is checked and, if necessary, corrected.
pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump is to
be removed-refitted, be sure that hands and components are
absolutely clean.
Overpressure valve
Once the valve has been fitted at one rail end, the valve task
is to protect system components in the event of a fault in
either the rail pressure sensor or CP3.3NH pump pressure
regulator causes an excessive increase in pressure in the high
pressure system. When the pressure in the rail reaches 1800
bar, the valve initially trips to run fuel off and accordingly
reduce the pressure to safe levels and then mechanically
regulates the pressure in the rail. This valve enables to have
the engine operated for long time with limited performance
and inhibits fuel excessive overheating, so preserving the
pipings returning from the tank.

CRIN 3 Electro-injectors
The electro-injectors are mounted on the cylinder head and operated by the engine control unit.
Figure 16
204302
INSTALLATION DIAGRAM FOR INJECTORS ON HEAD

1. Bracket - 2. Injector - 3. Cylinder heads - 4. Injector protrusion.
They are supplied by a HP fuel line and connected to a return line at atmospheric pressure required for operation of the pilot
valve.
Figure 17
114255
1. Fuel return to the low pressure circuit - 2. HP fuel coupling.

The electro-injector may be considered as mainly made up of two parts:

- Actuator - nozzle composed of pressure rod (4), needle (5) and nozzle (6);
- Control solenoid valve, consisting of a coil (1) and pilot valve.
Figure 18
188492
INJECTOR SECTION
1. Coil - 2. High-pressure fuel inlet union - 3. Filter - 4. Pressure rod - 5. Needle - 6. Nozzle -
7. Pressure chamber - 8. Control volume - 9. Pilot valve shutter - 10. Fuel return.
Electro-injector operation is divided into three phases:

”Idle position”
The coil (1) is not energised and the shutter (9) of the pilot valve is closed.
Under this condition, opening and closing forces are balanced as fuel pressure in the control volume (9) equals that of the
pressure chamber (7).
”Start of injection”
The coil (1) is energised and causes the shutter (9) to rise.
The fuel of the control volume (8) flows off towards the return manifold causing a drop in pressure. Simultaneously, the line
pressure exerts an opening pressure in the pressure chamber (7) that lifts the needle (5) thus causing fuel to be injected into
the cylinders.
”End of injection”
The coil (1) is de-energised and makes the shutter (9) return to its closed position. This creates a balance in the forces acting
upon the needle (5), causing it to return to its closed position and consequently halt the injection of fuel.

FUEL PRE-FILTER
Figure 19 (EXAMPLE FIGURE)
70494
The fuel pre-filter is of the high water separation type, it is fitted on the right side of the vehicle chassis with the sensor (4) for
detecting water in fuel on the cartridge (3) base.
Priming pump (5) and system air bleeding screw (2) located on the filter support.
The presence of condensate into filter is signalled by sensor (4) when a warning light on the instrument panel is lit.
If the warning light comes on, it is necessary to act immediately to remove the cause; the components of the common
! rail system will be quickly damaged if the fuel contains water or other impurities.

Fuel filter
This is fitted on the vehicle and is connected to the engine via the coupled pipes on a designated bracket near the intake mani-
fold.
Figure 20
249465
1. Clogged filter sensor - 2. Fuel temperature sensor - 3. Fuel filter - 4. Drain valve - 5. Fitting for bleeding
Characteristics: Value
12c> 200 (99.5%)
Filtering efficiency ISO 4548/12
125g 2.5 bar TBC
DHC (acc. to ISO 4548/12)
Maximum pressure 13 bar
> 20 bar
Explosion pressure (acc. to ISO 4548/3)
Cartridge collapse pressure > 6.5 bar (acc. to ISO 4548)
Operating temperature -30˚C/+120˚C
Pressure drop end of life 2.5 bar
0-15 bar (1Hz)
Pressure pulse > 50,000 cycles (ISO 4548/5)
By-pass valve opening pressure 3.4  0.3 bar

LUBRICATION CIRCUIT
A gear pump, located at the rear of the crankcase, serves to circulate the lubricant; the oil pump is driven by the crown wheel
keyed to the tang of the crankshaft.
The lubricant oil is conveyed from the oil sump to the crankshaft, to the camshaft and to the valve actuation.
The lubrication circuit also includes the heat exchanger and the turbocharger.
The pump contains a safety valve, while an oil overpressure valve for the oil is fitted on the crankcase.
Figure 21
Oil dropping
Oil under pressure
204244

Oil pump
The oil pump (1) is mounted on the crankcase. It receives the motion from the crankshaft (2).
Figure 22
114245
188474
The overpressure valve (1) houses the oil pump body.
Figure 23
112327
NOTE The oil pump shall not be overhauled.

If you find any damage, replace the entire oil pump.
Engine speed [rpm] Pump speed [rpm] Outlet pressure [bar] Flow rate [lpm]
1000 1515 2 62
2400 3636 6 128

Overpressure valve
The valve opening start pressure is 10.1 ± 0.7 bar.
Figure 24
191572
OVERPRESSURE VALVE SECTION

1. Valve housing - 2. Steel ball - 3. Spring seat - 4. Spring - 5. Locking circlip - 6. Seal ring.
Figure 25
208331
OVERPRESSURE VALVE SPRING

1. Free spring - 2. Opening start - 3. Opening end - 4. Closed spring.

Oil pressure regulator valve

The oil pressure control valve is located on the crankcase on the intake side.
Figure 26
73542
OIL PRESSURE REGULATOR VALVE SECTION

Figure 27
188496
OIL PRESSURE REGULATOR VALVE SPRING

1. Free spring - 2. Opening start - 3. Opening end - 4. Closed spring.

Heat exchanger
The heat exchanger is fitted on the crankcase inside the designated housing.
Figure 28
204197
1. Gasket - 2. Water/ oil heat exchanger - 3. Cover - 4. Oil filter bracket.
A by-pass valve (2) is fitted on the heat exchanger body.
Figure 29
188475
1. Heat exchanger body - 2. By-pass valve.
- By-pass valve opening pressure 2.5 ± 0.3 bar

Oil filter
The oil filter body (3) is mounted onto the heat exchanger; and it contains a by-pass valve (1) internally.
The filter element (or oil filter) (2) allows the lubricant circulating in the engine to rid itself of foreign bodies.
This is a new generation of filters that permit much more thorough filtration as they are able to holder back a greater amount
of particles of smaller dimensions.
Adoption of this high filtration device allows:
- reduce the wear of engine components over time;
- maintain the performance/specifications of the oil and thereby lengthen the time intervals between changes.
Figure 30
188472
- Filtering efficiency  12 c > 200 (99.5%)

- Maximum operating pressure 13 bar
- Operating temperature -30 ˚C / +120 ˚C
- By-pass valve opening pressure 3.4 ± 0.3 bar

Filter by-pass valve

Figure 31
73545
The valve quickly opens at a pressure of: 3.4 0.3 bar.

Oil sump
The oil sump has a new type of elastic anchorage to the crankcase.
The edge of the sump (1) is sealed within a thick “C“ shaped rubber gasket (4), and the assembly is contained inside and suppor-
ted by an aluminium spacer (3) secured to the crankcase with screws (2).
This solution prevents noise and improves seal quality, while using less screws than the traditional system.
Yet another benefit is that the gasket does not require replacement at every removal.
Figure 32
204239

The oil sump is fitted at an angle of 7˚.
7˚inclination:
Minimum level in sump: 15.5 litres
Maximum level in sump: 38.0 litres
Figure 33
204249
A. Vehicle axis - B. Engine axis.

1. Maximum level of oil allowed - 2. Minimum level of oil allowed - 3. Oil sump.

OIL VAPOUR RECIRCULATION SYSTEM (BLOW BY)

Description and operation
Part of the gas produced by combustion leaks out of the piston gaskets through the openings of the flexible rings of the pistons,
into the sump and mixes with the oil vapour it contains.
This mixture is conveyed upwards and is partially separated from the oil by a device located at the top of the timing system cover
and sent into the air intake circuit.
The device consists mainly of a rotating filter (1) keyed onto the camshaft and of a front cover (2) in which the diaphragm valve
(3) controlling the flow of the mixture is housed.
Figure 34
2
1
Gas with oil content greater than 10 g/h

Gas with oil content greater than  0.2 g/h
Condensed oil returning to the oil sump
208312

COOLING CIRCUIT
General information
The engine cooling system is forced-circulation closed-circuit type.
It mainly consists of the following components:
- an expansion tank (not supplied by FPT);
- a heat exchanger to cool the lubricating oil;
- a centrifugal water pump incorporated into the engine crankcase;
- a fan (not supplied);
- a thermostat to control coolant circulation;
- Intarder.
Operation
The water pump driven by a poly-V belt by the crankshaft sends coolant into the crankcase and with a greater head into the
cylinder head.
When the coolant temperature reaches and exceeds the working temperature, it causes the thermostat to open and the fluid
is channelled from here to the radiator.
Figure 35
208319
A. Water to radiator - B. Water circulating in the engine - C. Water coming into pump.

Water pump
Figure 36
188478
SECTION ON WATER PUMP

The water pump is composed of: impeller, shaft with bearing, front sealing gasket, drive pulley.
NOTE Make sure that the pump body is free of cracks and water leaks; otherwise replace the entire water pump.
Thermostat
The thermostat is inserted into the water inlet pipe into the pump; it is an N/C valve. When the valve is closed, the water arriving
from the heat exchanger on the gearbox, recirculates inside the engine via the water pump. When the valve is open, the water
arriving from the heat exchanger on the gearbox is sent directly to the radiator where it is then cooled.
Figure 37
191251
THERMOSTAT SECTION
- The valve begins to open at a temperature of: 85 ˚C ± 1.5 ˚C

- The stroke is of at least: 9.5 mm at 95 ˚C

Intarder
The engine cooling system works with a closed circuit forced circulation and is connected to an additional heater (if any) and
to the intarder heat exchanger.
The cooling circuit follows one of two paths depending on whether the thermostat valve is open or closed.
If the thermostat valve is closed, the coolant circulates inside the engine and the heat exchanger on the gearbox; if the thermo-
stat valve is open, the coolant reaches the radiator to be cooled.
Figure 38
208332
1. Arrival from radiator - 2. Head output - 3. Delivery to radiator - 4. Degassing - 5. Delivery to heat exchanger on
gearbox - 6. Return from the heat exchanger to the thermostat - 7. To water pump on engine.

Operating diagram of the thermostat for engines with intarder
Figure 39 Figure 40
191253 191254
SYSTEM WITH THERMOSTAT OFF SYSTEM WITH THERMOSTAT ON
A. Heat exchanger on gearbox. - B. Engine - C. Thermostat closed - D. Thermostat open

1. Arrival from radiator - 2. Return from the heat exchanger to the thermostat - 3. Delivery to radiator - 4. Recirculation
(breather) - 5. To the water pump on the engine - 6. Head output - 7. Delivery to heat exchanger on gearbox.

INTAKE AND EXHAUST SYSTEM

Intake and exhaust diagram
When the engine has started, the exhaust gases cause rotation of the turbine keyed to the centrifugal compressor by means
of a connecting shaft. Rotation of the turbine involves the rotation of the compressor which compresses the air coming from
the filter.
This compression of the air causes an increase in temperature, its expansion and therefore a reduction in density.
In order to introduce a greater quantity of mixture into the combustion chamber, the air is inter-cooled to increase its density
at the same pressure.
A greater quantity of air introduced, corresponds to a greater quantity of fuel injected and, therefore, increased power.
Hence, to obtain an optimal mixture which generates increased power, the correct stoichiometric air-fuel ratio must be observed,
so as to ensure the complete consumption of both during combustion.
The cycle is completed with the introduction of inter-cooled air from the intercooler into the intake manifold and from there
to the cylinders to be used in combustion.
Figure 41
Engine exhaust gas

Compressed air (hot)
Intake air
208320
DIAGRAM OF TURBOCHARGING WITH TURBOCHARGER

Intake and exhaust system components

Fixed geometry turbocharger
The turbocharger is of the fixed geometry type, model ”HX27V”, and is fitted on the exhaust manifold.
Figure 42
208333
1. Exhaust gas intake - 2. Air inlet - 3. Wastegate valve - 4. Compressed air outlet - 5. Exhaust gas outlet -
6. Gasket.
The turbocharger mainly consists of:

- a central body houses a shaft supported by bushings at the ends of which the turbine wheel and the compressor rotor
are fitted;
- a turbine body and a compressor body fitted on the central body;
- an overpressure relief valve (waste-gate) fitted to the turbine body. The function of this valve is to choke the exhaust gas
outlet, by conveying part of the gas directly into the exhaust pipe, when the turbocharging pressure downstream of the
turbocharger reaches the calibration value.
Figure 43
75532
SECTION SHOWING A TURBOCHARGER

WITH A WASTE-GATE VALVE
Engine Brake
A throttle valve operated by an electric actuator is introduced into the exhaust pipe downstream of the turbine.
The valve is controlled by the ECU through an electric actuator which is cooled by the coolant from the engine.
The main new feature is an electric actuator which allows the exhaust gas outlet to be choked to increase the outlet tempera-
ture.
This possibility is exploited in order to quickly bring the catalytic converter up to standard thermal conditions (reduction of
emissions when engine is cold).
Figure 44
188487
1. Power supply - 2. Ground connection - 3. ”CAN LOW” line - 4. ”CAN HIGH” line

EXHAUST GAS AFTER-TREATMENT SYSTEM (ATS)

Schematic
Figure 45
180400
A. AdBlue pump module supply line - B. AdBlue return line to tank - C. AdBlue system heating line - D. AdBlue delivery
line to dosing module.
The ATS system consists essentially of:
- a DOC oxidizing catalytic converter DOC (6);
- a DPF particulate filter catalytic converter (5);
- a differential pressure sensor (11) which detects the difference in pressure of the particulate filter inlet and outlet;
- a tank (8) for reagent solution (water - urea: “AdBlue”) with level gauge (7);
- an H2O diverter valve (9);
- pump module (10);
- an injection and dosing module (12);
- a SCR catalytic converter (2);
- three exhaust gas temperature sensors (1): one at the DOC catalytic converter inlet (6), one after the DPF catalytic conver-
ter (5) and the other on the exhaust gas outlet pipe from the catalytic converter (2);
- one humidity detection sensor fitted on the engine air inlet pipe downstream of the air filter;
- two nitrogen oxide (NOx) detection sensors (3) fitted upstream and downstream of the catalytic converter;
- one ammonia (NH3) detection sensor (4) at the exhaust gas outlet.
To restrict the emissions in the exhaust to within the limits prescribed by legal regulations, an exhaust gas post-treatment system
(ATS) has been adopted combining two devices:
- a catalytic converter/particulate filter for the treatment of the HC (unburnt hydrocarbons), the CO (Carbon monoxide)
and the particulate;
- The DeNOx 2.2 device for the treatment of NOx (nitrogen oxide).
The ATS system is controlled electronically by the EDC17CV41 control unit which on the basis of the engine rpm, torque delive-
red, the exhaust temperature, the quantity of nitrogen oxides and the intake air humidity, adjusts the flow rate of the AdBlue
solution to be introduced into the system.
The pump module picks up the reagent solution from the tank and sends it under pressure to the mixing and injection module
to be injected into the exhaust pipe.

Figure 46
180401
1. NOx sensor upstream of catalytic converter - 2. Differential pressure sensor - 3. Dosing Module - 4. NOx sensor
downstream of catalytic converter - 5. NH3 sensor - 6. SCR catalytic converter outlet temperature sensor - 7. SCR
catalytic converter - 8. SCR catalytic converter inlet temperature sensor - 9. DPF catalytic converter - 10. DOC catalytic
converter - 11. DPF catalytic converter inlet temperature sensor.
In the first stage the exhaust gases leaving the turbine encounter the catalytic converter DOC (10) in which the hydrocarbons
(HC) and carbon monoxide (CO) are transformed, through oxidation reactions, into carbon dioxide (CO2) and water (H2O).
Subsequently the exhaust gases pass through the DPF particulate filter (9) which holds back the carbonaceous particles forming
the particulate.
In order for the system to remain efficient, it needs to be regenerated and for this purpose there is a differential pressure sensor
(2) which, by detecting the difference in inlet and outlet pressure, is able to provide the control unit with an index for the clogging
of the filter.
The particulate filter regeneration is performed through the Exhaust Flap device to choke the outlet section of the exhaust
gas from the turbine creating a dummy load to the engine. This way the exhaust gases reach the filter at a high temperature
and the particles of the particulate burn keeping the filter clean.
In the second phase the dosing module (3), through an injector placed in the exhaust pipe upstream of the SCR catalytic conver-
ter (7), introduces a solution of water and urea (AdBlue) into the exhaust gas.
The first stage of the process takes place in the first part of the SCR catalytic converter: due to the effect of the exhaust gas
temperature, the reagent solution evaporates instantly and is hydrolysed to ammonia (2NH3) and carbon dioxide (CO2); at
the same time, the solution evaporates lowering the exhaust gas temperature to levels close to the optimum temperature
required for the process.
Exhaust gases containing ammonia at the temperature required for the reaction enter the SCR catalytic converter (7), where
the second stage of the process takes place: By reacting with the oxygen in the exhaust gas the ammonia is converted into
free nitrogen (N2) and water vapour (H2O).
The Clean Up Catalyst (CUC) is in the end section of the catalytic converter and serves to retain the excess ammonia produced
by the engine in the transient operating phases.
The amount of AdBlue injected is controlled through a NH3 sensor (5) fitted on the outlet pipe of the silencer, which detects
the presence of ammonia in the exhaust gas and sends a signal to the engine management control unit thereby providing a
feedback signal.
The engine control unit, on the basis of the engine rpm, torque, exhaust gas temperature, intake air humidity, amount of nitrogen
oxide and the amount of urea present in the exhaust gas, detected by the respective sensors, regulates the flow of AdBlue
to be injected into the system.

ATS system heating/cooling system

The system has two functions:
- continuous cooling of the dosing module;
- heating the AdBlue tank, the supply module and the AdBlue pipes and, at the same time, cooling the dosing module.
Figure 47
Engine coolant
AdBlue path
185019
COOLING CONDITIONS
1. Dosing module - 2. Engine - 3. Diverter valve - 4. AdBlue tank - 5. Feeder module.
Given the unfavourable assembly position from the point of view of cooling and given the high temperatures that the exhaust
gas reach downstream of the catalytic converter, the dosing module is connected to the engine cooling circuit and continuously
cooled.

Figure 48
Engine coolant
AdBlue path
185023
SIMULTANEOUS HEATING AND COOLING CONDITIONS

1. Dosing module - 2. Engine - 3. Diverter valve - 4. AdBlue tank - 5. Feeder module.
The liquid AdBlue freezes at a temperature of -11˚C.

When the temperature of AdBlue in the tank falls below the limit value, the diverter valve (2) switches allowing the passage
of the engine coolant into the coil inside the tank (3) and then into the supply module (4).
In this stage, the engine cooling temperature is such that it acts as a heater for the components mentioned above.
After this, the engine coolant is conveyed towards the dosing module to lower the temperature.

MAIN COMPONENTS OF ATS SYSTEM

Tank
Figure 49
185024
The tank with the level indicator command (1) contains the reducing substance comprising a solution of 35% urea and water,
known as AdBlue. There is a gauze filter (3) on the filler (2)..
AdBlue fluid level gauge control

Figure 50
116181
1. AdBlue liquid delivery pipe - 2. AdBlue liquid return pipe - 3. Engine cooling hot liquid inlet pipe - 4. AdBlue temperature
sensor (NTC) - 5. Engine cooling hot liquid outlet pipe - 6. Float (level sensor) - 7. AdBlue liquid heating coil -
8. AdBlue breather.
The indicator control for the AdBlue liquid level is a device consisting of:
- a float (level sensor);
- an NTC temperature sensor;
- a coil for heating the liquid in low temperatures.
It informs the ECU of changes in the current due to the resistance, caused by the position of the float in relation to the level
of the AdBlue liquid.

DeNOx 2.2 supply module (SM - Supply Module)

Figure 51
185025
1. Main filter - 2. Electric connector - 3. Pressure compensation diaphragm - 4. Feed pipe from tank - 5. Pump module
heating liquid inlet pipe - 6. AdBlue return pipe to tank - 7. Pump module heating liquid outlet pipe - 8. Delivery line to
dosing module
The AdBlue supply module consists mainly of a diaphragm pump which takes up the AdBlue from the tank and sends it to the
dosing module.
It is equipped with a circuit connected to the engine cooling system which, in low temperatures, stops the AdBlue from freezing.
Inside there is a pressure sensor.
The amount of AdBlue sent to the dosing module and the injection pressure are controlled by the engine control unit and are
dependent on the operating conditions of the engine and from the signals sent by the sensors.
Figure 52
185029
1. Engine coolant connector - 2. AdBlue inlet from tank - 3. AdBlue return to tank -
4. AdBlue outlet to dosing module - 5. Pressure sensor - 6. Filter - 7. Diaphragm pump - 8. Valve 4/2.
To prevent any damage to the pump and the dosing module, the supply module contains a filter which cleans the AdBlue of
any impurities.
Refer to the procedure described below to replace the filter.

Filter removal Figure 56
Figure 53
185430
185435 - On the basis of the colour of the filter, insert the correct
part of the tool (1) into the filter
NOTE During installation of the supply module, bear in
mind the minimum clearance for replacing the filter.
The minimum measurement is approximately Figure 57
155 mm.
Figure 54
185431
- Insert the specific tool (1) until a click is heard indicating

that the filter (2) has been completely engaged.
185428
- Unscrew and remove the filter cover (1).

Figure 58
Figure 55
185432
185429
- Remove the equalizing element (1). - Remove the filter (1).

Filter assembly Figure 62

Figure 59
185428
185433 - Thoroughly clean the filter cover (1).

- Thoroughly clean the contact surface (1) with water. - Screw on the filter cover and tighten to a torque of 20
± 5 Nm.
Figure 60
Figure 63
185434
- Moisten the gaskets and insert the new filter (1).
185435
Figure 61
NOTE During installation of the supply module, bear in

mind the minimum clearance for replacing the filter.
The minimum measurement is approximately
155 mm.
185429
- Insert the new equalizing element (1).
NOTE Make sure that the filter cover and the contact sur-
face of the supply module show no signs of being
cracked or damaged. If they do, replace the dama-
ged components.

DeNOx 2.2 dosing module (DM - Dosing Module)

Figure 64
193974
1. Power connection - 2. AdBlue inlet - 3. Coolant inlet/outlet.

The dosing module is controlled by the engine control unit. Its function is to dose the AdBlue to be injected into the exhaust
pipe upstream of the SCR catalytic converter.
It is fitted on the catalytic converter and while in operation it is subject to high temperatures. For this reason it is connected
to the engine cooling circuit by means of the pipes (3).
Maximum AdBlue injection pressure: 9 bar.
Diverter valve
Figure 65
204270
1. Power connection - 2. AdBlue tank heating fluid delivery pipe to the level gauge -
3. AdBlue tank heating fluid pipe from the engine.
The diverter valve is a 2 position/2 way type solenoid valve; it heats the AdBlue tank and the engine coolant pipes.
The NTC temperature sensor, on the basis of the temperature measured, checks that the diverter valve opens and/or closes
the flow of engine coolant to the heating coil in the AdBlue tank.

NH3 sensor
Figure 66
208338
PIN-OUT
1. Heater (+) - 2. Resistor - 3. Resistor ground - 4. EMF_2 - 5. Heater (-) - 6. Temperature sensor - 7. Ground -
8. EMF_1
The NH3 sensor is connected to the engine management control unit and by detecting the amount of ammonia (NH3) present
in the exhaust gas leaving the catalytic converter it allows an exact adjustment of the amount of AdBlue to be injected.
Figure 67
185028
A. Vehicle side connector - B. Sensor side connector.

101. Power supply - 102. CAN line H - 103. CAN line L - 104. Ground.
NH3 SENSOR CHARACTERISTICS VALUE
Operating voltage 10 - 32 V
Average current 1.2 A
Peak current 4.0 A
Operating limit values -40 - 105 ˚C
Tightening torque: 50 ± 10 Nm

Nitrogen oxide detecting sensor
Figure 68
102302
1. Positive - 2. Ground connection - 3. CAN line L - 4. CAN line H - 5. Spare

The NOx sensor detects the amount of nitrogen oxide present in the exhaust gas entering and leaving the catalytic converter.
On the basis of this information the engine control unit adjusts the amount of AdBlue to be injected and also measures the
efficiency of the catalytic converters.
NOx SENSOR CHARACTERISTICS VALUE

Ambient temperature: - 40 - +105 ˚C
(+105 - +115 ˚C allowed for 10 min)
Cable temperature: 230 ˚C allowed for 100 h
Tightening torque: 50 ± 10 Nm

Exhaust gas temperature sensor
Figure 69
102303
Figure 70
102304
FUNCTIONAL WIRING DIAGRAM

1. Supply voltage - 2. Variable power voltage at output - 3. Connector - 4. Grey signal cable - 5. White ground cable -
6. Sensor
It has the function of sending information to the control unit regarding the temperature of the exhaust gas entering and exiting
the catalyst that is necessary for calculating the amount of urea to inject in the system.
EXHAUST GAS TEMPERATURE SENSOR CHARACTERISTICS VALUE
Supply 5.00 V ± 0.1%
Voltage at a temperature -40 - 1,000 ˚C 0.727 - 2.297 V
Pull-up resistance 1,000  ± 0.1%
Cable resistance 1
Tightening torque: 45 ± 4.5 Nm

Temperature and humidity sensor

Figure 71
125531
1. Supply - 2. Percentage of humidity - 3. Ground - 4. Temperature

This sensor, which is mounted to the air filter outlet duct, sends the humidity percentage and temperature of the intake air to
the ECU. These data are used by the ECU to determine the level of nitrogen oxide emissions.
Figure 72
102312
ELECTRIC BLOCK DIAGRAM

1. Power supply unit - 2. Percentage of humidity - 3. Ground - 4. Temperature - A. Sample frequency generator -
B. Reference oscillator - C. NTC temperature sensor - D. Low pass amplifier filter
HUMIDITY SENSOR SPECIFICATIONS VALUE
Supply voltage 5.00 ± 0.25 VDC
Current absorption 10 mA
Operating range 0% RH - 100% RH
Output impedance 70 ohms
Insulating resistance 1 Mohm @ 500 V
TEMPERATURE SENSOR SPECIFICATIONS VALUE

Operating range -40 - 125 ˚C
Resistance at 25 ˚C NTC 2,186 kohms ± 1%
Maximum power at 25 ˚C 100 mW
Tightening torque: 14.5 ± 2.5 Nm

Catalytic converter
Figure 73
192084
1. Temperature sensors - 2. Differential pressure sensor pressure socket fittings - 3. APU exhaust - 4. SCR catalytic
converters - 5. Particulate filter (DPF) - 6. Oxidyzing catalytic converter (DOC) - 7. NOx sensor - 8. NH3 sensor -
9. AdBlue dosing module.
The catalytic converter consists of 2 main parts:
- the first stage is made up of a DOC catalytic converter (6) followed by a DPF catalytic converter (7) in which the exhaust
gas is cleaned of the HC (unburnt hydrocarbons), CO (carbon monoxide) and the particulate;
- the second stage is made up of 3 SCR catalytic converters (4) fitted in parallel, upstream of which is the AdBlue dosing
module (1); the reactions to reduce the NOx (nitrogen oxide) takes place in these catalytic converters.

Differential pressure sensor

The differential pressure sensor (1), connected downstream and upstream of the DPF particulate filter, measures the corre-
sponding difference in pressure.
Figure 74
192083
This difference in pressure is converted into a voltage signal sent to the engine management control unit and consists of a clog-
ging index of the DPF particulate filter.

SCHEDULED MAINTENANCE FOR ATS SYSTEM

Below are indicated the checks, tests and adjustments which are to be carried out on the components of the ATS system at
the established time interval.
The frequency of the operations are indicative since the engine use and its characteristics are essential in evaluating replacements
and checks.
Not only it is permitted, but it is also recommended that the staff in charge of maintenance also perform those checking and
maintenance operations which may not be included in the list below but which are recommended by good-practices and particu-
lar conditions of use of the engine.
Furthermore, in case of clear malfunctioning of the system, prompt measures must be taken to verify the causes of the defect.
Operators are also reminded that any maintenance operation, even the easiest one, is to be performed in compliance with
accident-prevention laws for the safety of the staff in charge of maintenance.
Standard Frequency Notes

Tank filler filter (100 m) No regular service planned (clean if necessary)
Tank breather filter (5* m/10m) No regular service planned (clean if necessary)
Supply module pre-filter (70m) Clean at each interval of oil change
Supply module intake filter (100 m) No regular service planned (clean if necessary)
Supply module main filter Change every 300,000 km or 3,600 operating
hours or every 2 years (depending on which of
the indicated conditions occurs first)
Supply module backflow filter (100 m) No regular service planned (clean if necessary)
Dosing module filter (36 m) No applicable service
DPF filter Change every 240,000 km or 4 years or 3,200
hours
Figure 75
FILTER LOCATION 185427

1. Dosing module filter - 2. Dosing module - 3. AdBlue return filter from supply module to tank -
4. Supply module pre-filter - 5. Tank pre-filter - 6. AdBlue tank - 7. AdBlue inlet filter to supply module -
8. Supply module - 9. Supply module filter.

REPLACING THE DPF (DIESEL Figure 78

PARTICULATE FILTER) CATALYTIC
CONVERTER
Removing the DPF catalytic converter
Figure 76
203464
- Remove the cover (1).
The weight of the cover (1) is ~ 8.3 kg.

204283 !
- Unscrew the screws (1) and remove the guards that are
on the catalytic converter.
Figure 77 Figure 79
204285
204284 - Remove and scrap the cage nuts (2).

- Undo the screws (1) fixing the cover (2).
Ref. No. Description Ref. No. Description

(1) 8 M8x25 (2) 8 M8
Pay maximum attention to sharp edges (1); when

! removing DPF catalytic converter always wear pro-
tective gloves.

Figure 80 Figure 82
204287
204286
- Loosen the screws (2) and move the flat band clamp (1)
NOTE Mark axial position of flat band clamp (1) on cone approx. 60 mm in the direction indicated by the arrow
with marker pen (minimum 120˚ of circumfe- ().
rence).
NOTE Once the flat band clamp (1) has been removed it
must not be reused but replaced.
NOTE When removing the screws, make sure they do not

Figure 81 fall in the ATS system.
Figure 83
204288
- Loosen the V-Clamp (2) by turning the screws (1) and

(3) at the same time and remove it.
NOTE Once the V-Clamp (2) has been removed it must 204289
not be reused but replaced.

- Remove the DPF catalytic converter (1) from its seat
using a suitable lifting device.
NOTE When removing the screws, make sure they do not The weight of the cover (1) is ~ 24 kg.
fall in the ATS system. !

Figure 84 Refitting the DPF catalytic converter

Figure 86
204290
204295
Pay maximum attention to sharp edges; always 1. Cover - 2. Flat band clamp - 3. DPF catalytic converter -
! wear protective gloves. 4. Rings - 5. Gasket - 6. V-Clamp.
- Remove the 2 pressure rings (1) from the catalytic con- NOTE All the screws must be tightened first with 3 turns
verter and DPF. by hand to prevent damage to the ATS screws and
cables.
NOTE The pressure rings may be reused when refitting
after they have been cleaned.
One pressure ring stays on the DOC, second ring
has to be switched to the new (cleaned) DPF.
Figure 87
Figure 85
204291
- Fit a new metal gasket (1) by clips (6x). The gasket which
has been removed cannot be reused.
- Clean and fit the pressure rings previously removed from
their seats on the DOC; once the second one is clean,
204291 it is inserted in the new DPF.
- Remove the metal gasket (1). - Fit 8 new M8 nuts.
NOTE Clean the sealing surfaces and make a visual inspec-

tion of the DOC.

Figure 88 Figure 91
204292
Position of flat band clamp (1) according to marking

203474
! with pen on cone.
- Insert a new flat band clamp (1) on the DPF catalytic con- Rotational positioning of DPF with label (2) sho-
verter (2). wing towards the outside.
Figure 89 Figure 90
204289 204293
- Position the new DPF catalytic converter (1) in its seat. - Push the new flat band clamp (1) in the direction indica-
ted by the arrow () until it reaches its correct position.
The weight of the cover (1) is ~ 24 kg. NOTE Sliding of new flat band clamp into the direction of
! the rolled cone until clamp hits the marking done
with a pen.

Figure 92 Figure 93
204294
- Positioning the screw joints of V-clamp by using dimple

in front system baffle (see detail A);
204296 - Positioning of screw joint of flat band clamp by using dim-
ple in rear system baffle (see detail B).
- Install a new V-Clamp (5) and tighten screws by hand
first; tighten in sequence the fixing screws (1) and (2) to
the required torque.
Ref. No. Description Tightening

torques
(1, 2) 2 1st phase 11 Nm Figure 94
2nd phase 18 ± 1 Nm
- Tighten in sequence the screws (3) and (4) by hand first

and then to the required torque.

torques
(3, 4) 2 1st phase 25 Nm
2nd phase 35 Nm
3rd phase 42.5 ± 2.5 Nm
204285
NOTE Open the clamp completely on one side and let it
slide around the DPF. Close screws (6) by hand
first. - Check cage nuts (2).
Ref. No. Description
(2) 8 M8
NOTE If the nuts have been lost, check that there are no
parts which have not been correctly tightened in
the DPF chamber and reposition the parts in the
correct position if they need to be removed.
Pay maximum attention to sharp edges (1); when

! installing DPF catalytic converter always wear pro-
tective gloves.

Figure 95 Figure 97
204283
- Refit the guards on the silences and tighten the fixing

203481 screws (1) to the required torque.
- Fit the cover (1) back on.
The weight of the cover (1) is ~ 8.3 kg. torques
! (1) 12 14 ± 1.4 Nm
Figure 96
203484
- Tighten the screws (1) fixing cover (2) to the required

torque.

torques
(1) 8 M8x25 15 ± 1 Nm

F2CFE612 ENGINE SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . 3
- Main engine electrical components . . . . . . . . . 3
- Engine wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- EDC 17CV41 control unit . . . . . . . . . . . . . . . 6
EDC SYSTEM OPERATION . . . . . . . . . . . . . . . . 7
- Pin out EDC 17CV41 control unit -

Chassis side connector (connector 1) . . . . . . . 9
- Pin out EDC 17CV41 control unit -

Engine side connector (connector 2) . . . . . . . 12
- CRIN 3 Electro-injectors . . . . . . . . . . . . . . . . . 15
- Engine coolant temperature sensor . . . . . . . . 16
- Fuel temperature sensor . . . . . . . . . . . . . . . . . 17
- High pressure pump (fuel flow regulator) . . . . 18
- Engine speed sensor . . . . . . . . . . . . . . . . . . . . 19
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Oil pressure and temperature sensor . . . . . . . 21
- Air temperature / pressure sensor . . . . . . . . . 22
- Fuel pressure on rail sensor . . . . . . . . . . . . . . . 23
- Oil vapour pressure sensor (blow-by) . . . . . . 24
- Oil level sensor . . . . . . . . . . . . . . . . . . . . . . . . 24
- Engine brake throttle control actuator . . . . . . 25
- Air heater resistor . . . . . . . . . . . . . . . . . . . . . . 26
- Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . 28

2 SECTION 3 - ELECTRICAL EQUIPMENT F2CFE612 ENGINE

GENERAL INFORMATION
Main engine electrical components
Figure 1
225109
1. Engine rpm sensor - 2. Engine brake throttle valve control actuator - 3. Oil level sensor -
4. Engine coolant temperature sensor.

Figure 2
12 1
249464
1. Engine oil vapour pressure sensor - 2. Air heater resistor - 3. Alternators - 4. EDC17CV41 Engine control unit -
5. Remote switch - 6. Starter motor - 7. Pressure sensor / engine oil temperature sensor - 8. Hydraulic pump -
9. Flow metering unit - 10. Timing sensor - 11. Air temperature / pressure sensor - 12. Fuel pressure sensor.

Engine wiring
Topographic view
Figure 3
225113
1. Oil level sensor - 2. Oil temperature/pressure sensor - 3. Control unit connection - 4. Air temperature / pressure sensor -
5. Fuel flow regulator - 6. Crankshaft speed sensor - 7. Crankshaft increase speed sensor - 8. Guard pressure sensor -
9. Motorized throttle valve - 10. Electro-injectors - 11. Coolant temperature sensor.

EDC 17CV41 control unit

The connection of the ECU to the components of the EDC system is achieved by two connectors mechanically polarised in the
coupling system in order to prevent mismatching:
- Connector 1 for frame side components.
- Connector 2 for components present on engine;
There is an internal ambient pressure sensor used to further improve the injection system control.
Figure 4
189003
1. Chassis connector (Connector 1) - 2. Chassis connector (Connector 2)

EDC SYSTEM OPERATION

The electronic control unit EDC 17CV41 manages the following main functions:
Fuel injection
Other functions (cruise control, speed limiter, power take-off etc.)
Self-diagnostics
Recovery
DeNox management
Also permits:
Interfacing with other on-board electronic systems (where present)
Diagnostics
Fuel dosing
The fuel metering is calculated in relation to:
- accelerator position
- engine speed
- quantity of air introduced.
The outcome may be corrected in relation to:
- the water temperature
or to prevent:
- noise
- smoke emissions
- overloading
- overheating
The delivery can be modified in the case of:
- throttle valve actuation
- intervention of external devices (such as speed limiter, cruise control etc.)
- serious trouble decreasing the load or stopping the engine.
After determining the mass of air introduced by measuring its volume and temperature, the control unit calculates the correspon-
ding mass of fuel to be injected into the cylinder involved also taking into account the diesel fuel temperature.
Correcting flow rate according to water temperature
When it is cold, the engine encounters greater resistance to its action: the mechanical friction is high, the oil is still very viscous,
the operating clearances are not yet optimum.
In addition to this, injected fuel tends to condense on the still cold metallic surfaces.
The fuel supply for a cold engine is therefore greater than for a warm one.
Correction of the flow rate to avoid noise, smoke or overloads.

The behaviour that could lead to this kind of trouble is well known.
The designer has therefore included special instructions in the control unit to avoid it.
De-rating
This function is activated:
In the event of the engine overheating, injection is modified, decreasing the delivery to a varying degree, in proportion to the tempe-
rature reached by the coolant.
In the case of a reduction in the fuel pressure in the rail following activation of the overpressure valve.

Injection advance electronic control

The advance (start of delivery, expressed in degrees) may differ from one injection to the next and from one cylinder to another.
It is calculated, in the same way as the flow, in relation to the engine load (accelerator position, engine speed and air introduced).
The advance is appropriately corrected:
- in the acceleration
phases according to the water temperature
and to obtain:
- lower emissions, noise and overloading
- better vehicle acceleration
When starting the engine, a high degree of advance is used based on water temperature.
Feedback from the start of delivery is supplied by the change in impedance of the injector solenoid valve.
Starting the engine
During the first few turns of the engine, the timing and cylinder no. 1 recognition signals (flywheel sensor and camshaft sensor)
are synchronised.
The accelerator pedal signal is ignored upon engine start. Engine start-up fuel flow is set exclusively on the basis of the water tempe-
rature, following a dedicated map.
When the ECU detects enough speed and acceleration in the flywheel to indicate that the engine is started up and no longer driven
by the starter motor, it re-activates the accelerator pedal.
Run Up
When the key contact is excited, the ECU transfers the information stored at the time of the previous engine stop (see: After run)
into the main memory, and runs system diagnostics.
After Run
Whenever the engine is switched off with the key, the control unit stays powered for a few seconds by the main relay.
This enables the microprocessor to transfer certain data from the main memory (volatile) to a non-volatile EEPROM, to make it
available for the next starting cycle (see: Run Up).
The data mainly consists of:
- various settings (engine idle etc.)
- settings of some components
- faults memory
The process lasts a few seconds, normally from 2 to 60 (depending on the quantity of data to be saved) after which the electronic
control unit sends a command to the main relay and causes it to disconnect from the battery.
This procedure should never be interrupted, for instance by switching off the engine with the battery isolator or disconnecting the
battery isolator before at least 10 seconds have passed after the engine is switched off.
If this happens, the system functions are guaranteed until the fifth incorrect shutdown operation (not necessarily consecutive) after
which an error is stored in the faults log and the engine will run with reduced performance the next time it is switched on, while
the EDC indicator stays on.
Repeated interruptions of the procedure could in fact lead to damage to the ECU.
Cut - off
This is the function which interrupts delivery in deceleration.
Cylinder balancing
The individual balance of the cylinders contributes to improving comfort and driveability.
This function permits individual, customised control over the delivery of fuel and the start of delivery for each cylinder, which can
even differ from one cylinder to another, to compensate for the hydraulic tolerances of the injector.
The differences in flow (flow specifications) between the various injectors cannot be evaluated directly by the control unit. This
information is supplied by entering the code of each injector with the diagnostics tool.
Synchronisation search
If the camshaft sensor signal fails, the control unit can still recognise the cylinders into which fuel is to be injected.
If this occurs when the engine is already running, the combustion succession has already been obtained, and therefore the control
unit continues with the sequence on which it is already synchronised.
If this occurs when the engine is off, the ECU energises a single solenoid valve. Within a maximum of 2 revolutions of the crankshaft,
injection will take place in that cylinder, so the ECU simply needs to synchronise with the firing sequence and to start up the engine.

Pin out EDC 17CV41 control unit - Chassis side connector (connector 1)
Figure 5
189004
Pin Description
01 Positive +30
02 -
03 Ground
04 -
05 Ground
06 -
07 Urea pressure signal
08 Signal of urea tank temperature
09 Catalytic converter outlet temperature signal
10 Ground for temperature sensor upstream and downstream of catalytic converter
11 Signal for engine compartment start switch
12 -
13 Water in fuel filter signal
14 -
15 Signal for R.H. of fuel air
16 Temperature upstream of the catalytic converter sensor positive
17 -
18 -
19 -
20 Ground for NOX and ammonia sensors power supply contactor
21 -
22 -
23 Supply for SCR dosing module solenoid valve
24 -
25 Positive +30
26 Positive +30
27 Ground for fuel prefilter heating resistor
28 Ground
29 -
30 -
31 Urea level in the tank signal
32 Intake catalytic converter temperature signal
33 -
34 -

Pin Description
35 -
36 -
37 -
38 Signal from the engine compartment start switch
39 Ground for urea tank level and temperature sensor
40 Fuel air temperature signal
41 -
42 -
43 Ground for combustion air temperature and R.H. sensor /
44 ”EDC” system fault warning light
45 Positive for NOX and ammonia sensors power supply contactor
46 CAN H line (ECB)
47 CAN L line (ECB)
48 -
49 Positive +30
Positive for engine water circulation solenoid valve for tank heater / urea return valve to tank / urea module
50
electro pump to tank / urea module electro-pump
51 -
52 Ground
53 -
54 -
55 Signal 
56 -
57 -
58 -
59 -
60 -
61 Positive for fuel prefilter heating resistor
62 Engine fan solenoid valve negative signal
63 -
64 -
65 -
66 -
67 -
68 Urea pressure sensor positive
69 User positive under key (+15)
70 Engine control unit diagnostics line pin 7 of the OBD connector
71 -
72 Ground for engine water circulation solenoid valve control for urea tank heating (78267)
73 Positive +30
74 Control signal for thermostarter activation consent contactor
75 Ground
76 -
77 -
78 -
79 -
80 -
81 -
82 -

Pin Description
83 Contactor for thermostarter activation consent ground
84 Ground for urea module electropump control
85 Urea to tank return valve (85140)
86 -
87 Baruffaldi contactor ground (25737)
88 -
89 Ground for urea module electropump
90 Supply for combustion air temperature and R.H. sensor / 
91 -
92 -
93 -
94 -
95 -
96 Ground for metering module solenoid valve control

Pin out EDC 17CV41 control unit - Engine side connector (connector 2)
Figure 6
Colour key
C ORANGE
A LIGHT BLUE
B WHITE
L BLUE
G YELLOW
H GREY
M BROWN
N BLACK
W LIGHT BROWN
S PINK
R RED
189005
V GREEN
Z PURPLE
Pin Cable colour Component

01 - Electro-injector cylinder 4
04 - -
05 - -
06 G Engine oil temperature and pressure sensor
07 V Air pressure temperature sensor
08 - -
09 - -
10 - -
11 G Fuel pressure sensor on rail
12 B Engine oil level sensor
13 V Engine oil temperature and pressure sensor
14 - -
15 - -
16 - -
17 G Engine brake throttle control actuator
18 C Engine brake throttle control actuator
19 - -
20 - -
21 - -
22 - -
23 - -
24 - -


26 Electro-injector cylinder 6
28 - -
29 - -
30 - -
31 R Oil pressure and temperature sensor
32 L Oil vapour pressure sensor
33 - -
34 - -
35 Z Oil pressure and temperature sensor
36 S Rail fuel pressure sensor
37 R Air pressure temperature sensor
38 - -
39 H Coolant temperature sensor
40 - -
41 -
42 Z Oil vapour pressure sensor
43 - -
44 - -
45 -
46 - -
47 - -
48 - -
52 - -
53 - -
54 - -
55 - -
56 - -
57 - -
58 S Fuel pressure regulator
59 L Coolant temperature sensor / Oil level sensor
60 N Rail fuel pressure sensor
61 G Oil vapour pressure sensor
62 - -
63 - -
64 - -
65 N Engine speed sensor
66 B Engine speed sensor
67 N Timing sensor


68 B Timing sensor
69 C Engine speed sensor / Timing sensor
70 - -
71 - -
72 - -
76 - -
77 - -
78 - -
79 - -
80 - -
81 - -
82 - -
83 V Fuel pressure regulator
84 - -
85 - -
86 Z Air pressure temperature sensor
87 - -
88 - -
89 - -
90 G Air pressure temperature sensor
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -

CRIN 3 Electro-injectors
Figure 7
114255
The electro-injectors are mounted on the cylinder head and operated by the engine control unit.
They are supplied by a HP fuel line and connected to a return line at atmospheric pressure required for operation of the pilot valve.
This is a N.O. solenoid valve. The solenoid valve controls the needle lift of the nozzle. The coil resistance of each individual injector
is 0.56 - 0.57 .
The injectors are connected to the control unit via the engine cable.
Injector No. Injector PIN Control unit PIN

1 49
1
2 73
1 50
2
2 74
1 51
3
2 75
1 25
4
2 01
1 27
5
2 03
1 26
6
2 02

Engine coolant temperature sensor

It is a N.T.C. sensor located on the head water output manifold on the engine left side.
It determines the coolant temperature for the various control logics of operation of the engine when hot or cold and identifies the
need to enrich the mixture when the engine is cold or reduce fuel injection when it is hot.
Figure 8
104266
Description Cable colour

Pin 39 of EDC control unit H
Pin 59 of EDC control unit L

Fuel temperature sensor

The fuel temperature sensor is connected to the fuel filter mount.
It allows the control unit to record the fuel temperature.
Characteristics
Supplier BOSCH
Max tightening torque 20±5
Figure 9
104267

High pressure pump

(fuel flow regulator) Figure 10
Pump with 3 radial pistons controlled by the timing gears,
requiring no timing adjustment, with rotor type feed pump fit-
ted to the back.
A. Fuel discharge outlet fitting.
B. Connection for fuel inlet from control unit heat exchanger
C. Connection for fuel inlet from fuel filter
D. Connection between fuel outlet from feed pump and fil-
ter
E. Connection between fuel outlet and rail
1. High pressure pump
2. Feed pump
3. Flow regulator (NO solenoid valve regulated by the con-
trol unit by means of PWM signal).
Flow regulator
Situated at the inlet of the high pressure pump, on the low
pressure system, this device adjusts the quantity of fuel rea-
ching the high pressure pump in accordance with the com-
mands received from the ECU.
It mainly consists of the following parts: A
- tapered shutter;
B
- valve control pin;
C
- pre-load spring;
- coils. D
In the absence of a control signal, the flow regulator is normally
open, and thus the high pressure pump is in maximum delivery
mode. 3
The ECU regulates a PWM control signal which reduces, to
a greater or lesser extent, the section carrying fuel to the high
pressure pump.
E
This component cannot be replaced individually and thus
should not be dismantled.
The amount of fuel feeding the high pressure pump is metered 191577
by a proportional valve on the low pressure system - managed

by the engine management control unit.
The delivery pressure to the rail is regulated at between 250
and 1400 bar by the electronic control unit acting on the flow
regulator solenoid valve.
It is a N.O. solenoid valve.
Its resistance is approximately 3.2 .
It is connected to control unit pins 58 - 83.

Engine speed sensor

The crankshaft rpm sensor is fitted on the gearbox.
It generates signals obtained from magnetic flux lines which close through the holes situated on the flywheel, keyed onto the crank-
shaft.
Supplier BOSCH
Tightening torque 9  1 Nm
Figure 11
104269

Pin 66 of EDC control unit B
Pin 65 of EDC control unit N

Timing sensor
Supplier BOSCH
Tightening torque 9  1 Nm
This inductive sensor is located on the camshaft.
It generates signals obtained from changes in magnetic flux created by spaces between the teeth on the phonic wheel fitted to
the crankshaft. Number of teeth 6 plus 1 for timing.
The signal generated by this sensor is used by the ECU as the injection timing signal.
This sensor’s air gap is NOT ADJUSTABLE.
Figure 12
104269

Pin 67 of EDC control unit N
Pin 68 of EDC control unit B

Oil pressure and temperature sensor

It is mounted on the crankcase.
It measures the engine oil temperature and pressure.
The values sent are transmitted to the EDC control unit which, in turn, governs the indicator on the dashboard (indicator/low
pressure warning light).
The engine oil temperature is used by the EDC control unit only.
Figure 13 Figure 14
50323
Connector 50344
Wiring Diagram
Control unit
Ref. Description
pin
1 Ground 06-G
2 Temp. Sign 13-V
3 +5 31-R
4 Press. signal. 35-Z

Air temperature / pressure sensor

This component incorporates a temperature sensor and a pressure sensor.
It is fitted to the intake manifold so that, by measuring the maximum quantity of air taken in, it makes it possible
to determine the exact amount of fuel to be injected at each cycle.
It runs on 5 Volts.
The output voltage is proportional to the pressure (or temperature) measured by the sensor.
Figure 15 Figure 16
114273
Connector
50344
Wiring Diagram
Control unit
Ref. Description
pin
1 Ground 90 - G
2 Temp. Sign 37 - R
3 +5 07 - V
4 Press. signal. 86 - Z

Fuel pressure on rail sensor

Fitted to one end of the rail, this sensor measures the pressure of the fuel so as to determine injection pressure.
The value of the injection pressure is used to keep the pressure level under control and to determine the time duration of the
injection electronic command.
It runs on 5 Volts.
Figure 17
114620
Control unit
Ref. Description
pin
1 Ground 60 - N
2 Pressure 36 - S
3 Supply 11 - G

Oil vapour pressure sensor (blow-by)

This is a sensor fitted on the head; it measures the pressure generated inside the head due to oil vapour pressure.
Figure 18
178245
Sensor PIN Control unit PIN Cable colour

1 32 L
2 42 Z
3 61 G
Oil level sensor

It is mounted on the oil sump; it controls the maximum/minimum level of lubricant inside the sump. The oil level sensor is connec-
ted to the electronic control unit by means of the engine cable.
Figure 19
188488

Engine brake throttle control actuator

The sensor serves to actuate the throttle valve installed on the exhaust pipe of the turbocharger.
Figure 20
188487
Sensor PIN Control unit PIN Cable colour

1 - - R
2 - - L
3 Ground 18 C
4 Supply 17 G

Air heater resistor

This element is located on the intake manifold.
It is utilised to heat the air in the operations of pre / post heating. It is powered via contactor.
Its resistance is approximately 0.5 .
Figure 21
299447
Rated voltage: 24 V D.C.

Steady current: 120A - 150A @ 24 V
Pick-up current: 160A - 290A @ 24 V
Insulation resistance: >1 MOhm @ 500 V D.C.

Alternators
Supplier BOSCH
Technical specifications 28V - 150A
Weight 9.2 kg
Current at 1600 rpm 0A
Current at 1800 rpm 30 A
Current at  6000 rpm 150 A
Direction of rotation clockwise
Figure 22
189006
Figure 23
189007
Connector Description
DFM Digital Field Monitor
BS + 30
15 Power supply +15
L Failed recharge signal
W Battery recharge warning light
B1+ Positive 1
B2+ Positive 2

Starter motor
Characteristics
Supplier DENSO
Type 2280005641
Electrical system 24 Volt
Rated output 4.5 kW
Figure 24
114283

F2CFE612 ENGINE SECTION 4 - SCHEDULED MAINTENANCE 1
SECTION 4
Scheduled maintenance
Page
SCHEDULED MAINTENANCE . . . . . . . . . . . . . 3
- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Checks and scheduled maintenance procedures 3
- Extra-plan operations - daily checks . . . . . . . . 5
MAINTENANCE PROCEDURE . . . . . . . . . . . . . 6
- Checks and tests . . . . . . . . . . . . . . . . . . . . . . . 6

2 SECTION 4 - SCHEDULED MAINTENANCE F2CFE612 ENGINE

SCHEDULED MAINTENANCE
Introduction
To ensure best operating conditions, on the following pages are indicated the checks, tests and adjustments which shall be carried
out on the different parts at the established time.
The frequencies of the maintenance operations are indicative since the engine use and its characteristics are essential to evaluate
replacements and checks.
Not only it is permitted, but we also suggest that the staff in charge of maintenance should also perform those checking and
maintenance operations which do not fall among those listed below, but are recommended by good-practices and particular
conditions of use of the engine.
Furthermore, in case of clear malfunctioning of the engine, for example excessive grade of smoke of exhaust gases, high tempera-
ture of the coolant or low oil pressure, prompt measures must be taken to verify the causes of the defect.
Operators are also reminded that any maintenance operation, even the easiest one, is to be performed in compliance with acci-
dent-prevention laws for the safety of the staff in charge of maintenance.
Checks and scheduled maintenance procedures
Change engine oil 60,000 km/2 years (3)

Replacing the engine oil filter 60,000 km/2 years (3) (4)
Replacing the fuel filter 60,000 km/2 years (1) (4)
Change engine blow-by filter 60,000 km/2 years
Replace fuel prefilter (component fitted on the vehicle) 120,000 km(1)
Check condition of ancillary belt 6 months (2)
Check engine parts for leaks (oil, coolant) 60,000 km
Check fuel lines for leaks 60,000 km
Replace ancillary belt 180,000 km/4 years
Air filter replacement (part not supplied by FPT) 120,000 km/2 years
Check the tappet clearances and adjusting if necessary 240,000 km
Change engine coolant 3 years
1) Maximum period relative to the use of high quality fuel, (specification EN 590); this is reduced based on fuel contamination
and the alarm filter clogged signals and/or the presence of water in the filter/pre-filter. The filter clogging signal indicates that
the filter must be replaced. If the water present warning light does not go off after drainage, then the filter must be replaced.
2) In reference to engines with traditional and automatic tensioners.
3) Frequency of the lubricants PETRONAS TD6200720 SAE 5W-30 ACEA E6 LOW SAPS.
4) Only use filters with the following specifications:
- degree of filtering < 12 m
- filtering efficiency  > 200.

NOTE The scheduled maintenance operations are only valid if the bodybuilder observes all installation regulations provided
by FPT.
NOTE The engine lubrication intervals are based on the percentage of sulphur present in the diesel being less than 0.5%.
If using diesel fuel with a sulphur content exceeding 0.5%, the foreseen number of kilometres to be travelled before
changing the oil should be halved.
NOTE Diesel oil for low temperatures.

With low temperatures the degree of fluidity of the fuel can drop due to the separation of the paraffin resulting from
clogging of the filters.
Standard EN590 defines different diesel classes, identifying the characteristics of those most suitable for use at low
ambient temperatures.
It is entirely the responsibility of the oil companies to comply with the regulations regarding the distribution of fuels
suitable for the climatic and geographical conditions of the various countries.
Early clogging of the air filter is generally due to adverse environmental conditions. For this reason the filter must be
replaced when the sensor indicates such, regardless of when replacement is due. When specific indications are not given,
the part should be replaced according to schedule.
The time intervals given in the plan are merely indicative since they are representative of industrial engine use with
average use in relation to displacement.

Extra-plan operations - daily checks

Before starting, it is recommended to carry out a series of simple checks that can significantly help avoid problems, also of a series
nature, while the engine is operating. These checks are usually performed by the vehicle operators and drivers.
- Checking the levels and checking for any leaks from the fuel, cooling and lubrication circuits.
- Informing maintenance personnel if any problems are found; top up if necessary.
After starting the engine and with the engine operating, perform the following checks and controls:
- Checking for any leaks from the fuel, cooling and lubrication circuits.
- Making sure there is no unusual noise or knocking during operation.
- Using the vehicle instruments to check the specified pressure, temperature values, etc.
- Visually checking the smoke (colour of the exhaust gas).
- Visually checking the level of the coolant in the expansion tank.
Every year - before Winter

Where possible in conjunction with a maintenance service.
Check the percentage of antifreeze in the engine cooling water
NOTE Early clogging of the air filter is generally due to adverse environmental conditions. For this reason the filter must
be replaced when the sensor indicates such, regardless of when replacement is due. When specific indications are
not given, the part should be replaced according to schedule.

MAINTENANCE PROCEDURE
Checks and tests The engine oil is highly pollutant and toxic.
Check engine oil level In case of contact with skin wash thoroughly with
water and detergent.
The check must be performed when the engine is stopped
and possibly cold. Adequately protect skin and eyes; take measures as
set forth by safety regulations.
The check is carried out with the flexible dipstick.
Suitably dispose of the residuals and in accordance
with regulations.
Figure 1
Lubrication system control

The check should be performed both when the engine is
stopped and when it is running.
Check that there is no oil leakage from the head, the engine
sump or the heat exchanger.
The engine oil is highly pollutant and toxic.

In case of contact with skin wash thoroughly with
Adequately protect skin and eyes; take measures as
with regulations.
Fuel system control

The check is carried out by observing the fuel pipes from the
tank to the prefilter (if present), to the filter, to the high pres-
sure pump and to the rail tube and from the rail vent to the
head.
225099
Particular attention should be paid to the high pressure pipe
connections.
Remove the dipstick (1) from its housing and check that the
level is between the minimum and maximum ends etched on Considering the high pressure inside the pipes which
it. go from the high pressure pump to the rail vent and
from this to the electro-injectors, great care must be
If the reading is unclear, clean the dipstick with a cloth with taken when checking for leaks.
no looses threads and put it back in its seat. Take it off again
and check the level. Protect eyes and skin from any unexpected high
pressure jets: these in fact may get under the skin
If the level results to be close to the minimum reference level, causing serious poisoning.
top up.
Always make sure to add oil with the same characteristics as
the one contained in the sump. Mixtures which do not
ensure the proper lubrication of the internal parts of the Checking for water in fuel filter or prefilter
engine are not permitted.
Re-fill through the prearranged plug (2). During the refilling, NOTE The components of the common rail system will be
the dipstick must be removed in order to facilitate the oil rapidly damaged if the fuel contains water or impu-
flow. rities.
Intervene immediately on the prefilter (not present
on the engine body) to drain the water present in
the fuel supply circuit.

Checking belt tension Changing engine oil and filter

Belt tensioning is carried out by means of the automatic ten-
sioner and therefore does not require any intervention other
than verification of the state of wear of the belt. Attention: given the high operating temperature of
the engine, suitable protective equipment should be
worn.
Checking belt wear The oil reaches very high temperatures: always wear
protective gloves.
Carefully check that the surface of the belt shows no sign of
cuts, rubbing, excessive wear on the teeth or pulling on the
sides and on the surface.
Given the different applications, the shape of the sump and
the amount of oil it contains can vary significantly.
Attention: When the engine is off, but still hot, the The operations listed below are however valid for all applica-
belt may start to move without warning. tions.
It is recommended that the oil is drained while hot.
Wait for the engine temperature to decrease to pre-
vent serious danger of an accident. - Place an appropriate container for the oil collection
under the sump in correspondence with the drain plug.
- Unscrew the cap and then remove the oil level dipstick
and the filler plug to facilitate the lubricant oil flow.
Cooling system control

Check the pipes from the engine to the radiator, from the
expansion tank and vice versa; detect leakages, the state of In case of contact with skin wash thoroughly with
the pipes, in particular near the junction clamps. water and detergent.
Check the cleanliness of the radiator, the integrity of the fan Adequately protect skin and eyes; take measures as
fins, any leakage from the clamps, sleeves, and the radiant set forth by safety regulations.
body. Suitably dispose of the residuals and in accordance
with regulations.
Given the high temperatures which are reached - When draining is complete, tighten the plug and then fill
inside the system, do not carry out operations imme- with clean oil.
diately after the engine has stopped but wait until the
temperature has fallen.
Only use recommended oils or oils with the proper-
Protect eyes and skin from any unexpected high ties required for proper engine operation.
pressure jets of coolant. !
If topping up, do not mix oils with different proper-
ties.
The density of the coolant must however be checked every Failure to observe these standards will invalidate the
year before the winter and be changed every two years. service warranties.
NOTE In case of new refilling proceed with the de-aera-

tion of the system by means of the breathers on the - Check the level with the dipstick until obtaining a filling
engine. near the maximum level notch shown on the dipstick.
Failure to de-aerate the system could cause serious
damage to the engine as a result of air pockets in
the engine head.

The filter must also be replaced when the lubricant oil is chan- Replacing fuel filter
ged.
Figure 4
- The filter consists of a support and a filtering cartridge.
Attention, the oil filter contains approximately 2 kg

of engine oil.
Position a suitable container to collect the oil.
Attention! Avoid skin contact with the engine oil: in
case of contact, wash thoroughly with water.
The engine oil is highly pollutant: it must be disposed
of according to applicable laws.
- Replace the filter cartridge with a new one.

- Screw the oil filter on by hand until it comes into contact
with the support and then tighten by 3/4 of a turn to the 204238
required tightening torque. Through the filler cap, intro-

duce the oil into the engine in the specified quantity and Do not smoke or use open flames during this opera-
of the quality prescribed. tion.
- Operate the engine for a few minutes and then check Do not inhale the vapours that exit the filter.
the level using the dipstick. If necessary, top up to com-
pensate for the quantity of oil used to fill up the filtering
cartridge.
Replacing the Blow-by filter When replacing the filters, the feed system must
then always be deaerated.
Figure 2
- Drain the fuel inside the filter by acting on the water

bleed screw (2). Collect the fuel in a clean container.
- Unscrew the cartridge using the designated tool.
- Collect any fuel still present in the filtering cartridge.
- Clean the gasket seat on the support and lightly oil the
gasket on the new filtering cartridge.
- Manually tighten the new filtering cartridge until the
gasket rests completely on its seat.
249466
Unscrew the screws (2) and remove the cover (1). - Screw the cartridge on by hand until it is in contact with
the support and then tighten by ¾ of a turn to the requi-
Figure 3
red tightening torque.
When replacing the filter cartridge do NOT fill it.

!
This operation is banned to avoid impurities entering
into the circuit, which would damage the injector/
pump system components.
Bleed air from the supply system as described below.
Bleeding air
208414 Loosen the bleed screw (1) connecting the drainage by a
Unscrew the screws (2) and remove the blow-by rotating fil- transparent flexible hose to a suitable container.
ter (1).
Figure 5 Replacement of the coolant

Only proceed when the engine is not turning and is at low
temperature in order not to run the risk of burns.
NOTE When the engine is hot, a pressure is stabilised in

the cooling circuits which is able to eject the hot
liquid in a very violent manner, resulting in a risk of
burns.
- Use suitable containers to ensure that the coolant is not

dispersed in the environment.
- Loosen the retaining elements and remove the sleeves
that couple the engine circuit with the heat exchanger
and wait for them to empty completely. Once emptied,
restore the condition of the circuit, ensuring the perfect
191580
seal of the sleeves.
With the hand pump (2) of the fuel pre-filter (1) pump until - Refill the circuit.
fuel completely free of air bubbles flows from the bleed - Refill the engine and the exchanger until the exchanger
screw. is completely full.
After the operation, tighten the bleed screw. - With the filler plug open, start the engine and idle it for
Start engine and let it run idle for a few minutes to remove approximately 1 minute. This phase helps to completely
any residual air. bleed the air contained in the cooling circuit.
- Stop the engine and then top up with the amount which
is still needed.


F2CFE612 ENGINE SECTION 5 - REMOVAL - REFITTING OF MAIN COMPONENTS 1
SECTION 5
Removal/refitting of the main engine
components
Page
ANCILLARY BELT REMOVAL/REFITTING . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL AND REFITTING OF

THE ALTERNATORS . . . . . . . . . . . . . . . . . . 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WATER PUMP REMOVAL/REFITTING . . . . . . . 5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL/REFITTING OF THERMOSTAT . . . 6
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE MANAGEMENT CONTROL UNIT

REMOVAL/REFITTING . . . . . . . . . . . . . . . . . 7
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FUEL PRESSURE PUMP REMOVAL/REFITTING 8
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RAIL REMOVAL/REFITTING . . . . . . . . . . . . . . . 10
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ROCKER ARM SHAFT REMOVAL/

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 12
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
- Adjustment of clearance between the intake and

exhaust rocker arms . . . . . . . . . . . . . . . . . . . . 13

2 SECTION 5 - REMOVAL - REFITTING OF MAIN COMPONENTS F2CFE612 ENGINE
Page Page
ELECTRO-INJECTOR REMOVAL/REFITTING . . 14 HYDRAULIC PUMP REMOVAL /

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 33
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Adjustment of clearance between the intake and
exhaust rocker arms . . . . . . . . . . . . . . . . . . . 18 ENGINE RIGHT AND LEFT SUPPORTING BRACKET -
REMOVAL / INSTALLATION . . . . . . . . . . . . . 34
INTAKE MANIFOLD REMOVAL/REFITTING . . . 19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
AIR COMPRESSOR REMOVAL /
STARTER MOTOR REMOVAL/REFITTING . . . . 20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 35
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
TURBOCHARGER REMOVAL/REFITTING . . . . . 20
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
EXHAUST MANIFOLD REMOVAL/REFITTING . 22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
OIL FILTER HOUSING REMOVAL/REFITTING . 26
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HEAT EXCHANGER REMOVAL/REFITTING . . . 27
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OIL SUMP REMOVAL/REFITTING . . . . . . . . . . . 29
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BLOW-BY REMOVAL/REFITTING . . . . . . . . . . . 32
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

ANCILLARY BELT REMOVAL/REFITTING Figure 3

Removal
Figure 1
192085
225074
INSTALLATION DIAGRAM OF WATER PUMP DRIVE
Using the appropriate tool (4), act on the automatic tensio- BELT
ners (1) and (5) and remove the belts (2) and (3). 1. Automatic tensioner - 2. Water pump - 3. Crankshaft
pulley - 4. Belt
Refitting Fit the water pump drive belt in accordance with the diagram
in the figure.
Figure 2
Figure 4
225074
Using the appropriate tool (4), act on the automatic tensio-

ners (1) and (5) then fit the belts (4) and (3).
192089
Rotate the crankshaft anticlockwise until the complete enga- INSTALLATION DIAGRAM ALTERNATOR DRIVE BELT
gement of the belts on the pulley.
1. Automatic tensioner - 2. Alternator pulley -
3. Fixed guide pulley - 4. Belt - 5. Crankshaft pulley
Fit the alternator drive belt in accordance with the diagram
in the figure.

Figure 5 Figure 7
225076
Unscrew the screws (1, 2) and remove the alternator (6).

192090 Ref. No. Description
GENERAL INSTALLATION DIAGRAM DRIVE BELTS (2) 1 M10x45
(2) 1 M12x160
Unscrew the screws (3, 4) and remove the additional alternator
NOTE Belt tensioner is of automatic type; therefore, fur- (5).
ther adjusting is not provided after mounting.
(3) 1 M12x160
REMOVAL AND REFITTING OF THE (4) 1 M10x45
ALTERNATORS
Removal Refitting
Figure 6
Figure 8
225076
225075
Fit the alternator (6) and tighten the screws (1, 2) to the tor-
Using the appropriate tool (2), adjust the automatic tensio- que indicated in the table.
ner (3) and remove the belt (1).
Ref. No. Description Tightening torques
(2) 1 M10x45 67.5 ± 6.5 Nm
(2) 1 M12x160 80±8 Nm
Fit the additional alternator (5) and tighten the screws (3, 4).

(3) 1 M12x160 80±8 Nm
(4) 1 M10x45 68±7 Nm

Figure 9 WATER PUMP REMOVAL/REFITTING

Removal
Drain the coolant.
Figure 11
225075

ner (3) and fit the belt (1).
Rotate the crankshaft anticlockwise until the belt completely
engages on the pulley. 225074
Figure 10 Using the appropriate tool (4), act on the automatic tensio-
ners (1, 5) and remove the belts (2) and (3).
Figure 12
193032
192089
Unscrew the screws (1) and remove the water pump (2).
INSTALLATION DIAGRAM ALTERNATOR DRIVE BELT
1. Automatic tensioner - 2. Alternator pulley -
3. Fixed guide pulley - 4. Belt - 5. Crankshaft pulley Ref. No. Description
(1) 4 M8x1.25x25
Fit the alternator drive belt in accordance with the diagram
in the figure.
NOTE The belt tensioner is of the automatic type; there-

fore, further adjusting is not anticipated after fitting.

Refitting Figure 15
Figure 13
193032
Fit the water pump (2) and tighten the screws (1) to the tor-
que indicated in the table. 192085
INSTALLATION DIAGRAM OF WATER PUMP DRIVE

BELT
(1) 4 M8x1.25x25 24 ± 3 Nm
1. Automatic tensioner - 2. Water pump - 3. Crankshaft
pulley - 4. Belt
Fit the water pump drive belt in accordance with the diagram
NOTE After fitting the water pump, top-up the cooling cir- in the figure.
cuit. Start the engine and check the coolant level.
REMOVAL/REFITTING OF THERMOSTAT
Removal
Figure 16
Figure 14
193035
Disconnect the sleeve (2) from the pipe (3); unscrew the
screws (1) and remove the pipe (3).
225074
Using the appropriate tool (4), act on the automatic tensio- (1) 3 M8x1.25x70
ners (1, 5) and fit the belts (4) and (3) in this order.
Rotate the crankshaft anticlockwise until the complete enga-
gement of the belts on the pulley.

Figure 17 ENGINE MANAGEMENT CONTROL UNIT

REMOVAL/REFITTING
Removal
Figure 20
193036
Disconnect and remove the thermostat (1) from the pipe (2).
Refitting
Figure 18
225097
Disconnect the electrical connection (4) from the engine

control unit.
Loosen the fitting (1) and disconnect the fuel delivery pipe
from the fuel filter.
(2) 1 M18x1.5
Unscrew the screw in the bracket (2), the fitting (3) and
disconnect the fuel delivery pipe from the pressure pump.

Fit a new thermostat (1) and connect it to the pipe (2). (2) 1 Connector M18x1.5
(3) 1 Screw M8x1.25x14
Figure 19
Figure 21
193035
249468
Fit the pipe (3) and tighten the screws (1) securing the ther-
mostat to the torque indicated in the table. Unscrew the screw (1), the nuts (2) and remove the engine
management control unit (3).
Ref. No. Description Tightening torques Ref. No. Description
(1) 3 M8x1.25x70 23 ± 2 Nm (1) 1 M8x1.25x45
Connect the sleeve (2) to the pipe (3). (2) 2 M8x1.25

Refitting FUEL PRESSURE PUMP REMOVAL/

REFITTING
Figure 22 Removal
Figure 24
193039
Fit the engine management control unit (1) on the spacers

204101
(3).
Unscrew the fittings (1) of the fuel return and delivery pipes
Tighten the screw (4) and the nuts (2) to the torque indica-
from the pump to the filter.
ted in the table.
Ref. No. Description Tightening torques Ref. No. Description
(4) 1 M8x1.25x45 19 ± 3 Nm (1) 4 M16x1.5
(2) 2 M8x1.25 19 ± 3 Nm
Unscrew the fitting (2) of the fuel delivery pipe to the pres-
Figure 23 sure pump.

(2) 2 M16x1.5
Figure 25
225097
Connect the fuel pipe to the pressure pump, tighten the fit-
ting (3) and the bracket screws (2) to the torque indicated
in the table.
208301
Disconnect the electrical connection (1) of the fuel pressure

Ref. No. Description Tightening torques sensor.
(2) 1 M8x1.25x14 40±2 Nm Open the retaining clip (5), unscrew the fitting and remove
(3) 1 M18x1.5 23±2 Nm the fuel pipe (4) from the pressure pump to the control unit.
Connect the fuel pipe to the fuel filter and tighten the fitting
(1) to the specified torque.
Ref. No. Description Tightening torques (4) 1 M16x1.5
(1) 1 M18x1.5 40±2 Nm Unscrew the fittings and remove the fuel return and delivery
Connect the electrical connection (4) to the engine control pipes (2) from the pump to the filter.
unit.
Ref. No. Description Ref. No. Description Tightening torques

(2) 2 M16x1.5 (1) 3 M8x1.25x40 30 ± 5 Nm
Unscrew the fitting (3), loosen the screw of the intermediate Figure 28
retaining collar and move the fuel drain pipe to one side.

(3) 1 M16x1.5
Unscrew the fitting (6), open the retaining collar (7) and
move the fuel pipe from the pressure pipe to the interme-
diate fitting to one side.
(6) 1 M16x1.5
Figure 26
208301
Fit the fuel pipe from the pressure pump to the intermediate
fitting (6), close the retaining collar (7) and tighten to the tor-
que indicated in the table.
(6) 1 M16x1.5 35 ± 5 Nm
Fit the fuel drain pipe (3), tighten the screw of the interme-
diate retaining clip and tighten the fitting to the torque indica-
ted in the table.

204103 (3) 1 M16x1.5 35 ± 5 Nm
Unscrew the screws (1) and remove the pressure pump (2) Fit the fuel return and delivery pipes (2) from the pump to
together with the pressure regulator. the filter and tighten the fittings to the torque indicated in the
Ref. No. Description table.
(1) 3 M8x1.25x40 Ref. No. Description Tightening torques
(2) 2 M16x1.5 35 ± 5 Nm
Fit the fuel pipe (4) from the pressure pump to the control
Refitting unit, tighten the fitting to the torque indicated in the table and
close the retaining collar (5).
Figure 27
(4) 1 M16x1.5 35 ± 5 Nm
Connect the electrical connection (1) of the fuel pressure
regulator.
204103
Fit the pressure pump (2) together with the pressure regula-
tor and tighten the screws (1) to the torque indicated in the
table.

Figure 29 Figure 31
204101 193949
Tighten the fitting (2) of the fuel delivery pipe to the pressure Disconnect the connection pipes (1) between the rail and
pump to the torque indicated in the table. the electro-injectors, the connection pipe (2) between the
intermediate fitting and the rail and the fuel return pipe (3).
(2) 2 M16x1.5 35 ± 5 Nm
Tighten the fittings (1) of the fuel return and delivery pipes (1) 6 M18x1.5
from the pump to the filter to the torque indicated in the (1) 6 M14x1.5
table.
(2) 1 M18x1.5
(2) 1 M14x1.5
(1) 4 M16x1.5 35 ± 5 Nm
(3) 1 M16x1.5
(3) 1 M14x1.5
RAIL REMOVAL/REFITTING
Removal
Figure 30 Figure 32
204105
169832
Unscrew the screws (2).
Unscrew the screws (1), remove the rail (2) and the spacers
Ref. No. Description (3).
(2) 20 M6x1x50
Remove the tappet cover (1) together with the gasket. (1) 3 M8x1.25x45
Remove the engine cable connected inside the head.

Refitting Fit the new fuel return pipe (3) and tighten the fittings to the
torque indicated in the table.
Figure 33
(3) 1 M16x1.5 35 ± 2 Nm
(3) 1 M14x1.5 35 ± 2 Nm
After fitting the high pressure pipes, during the next

! 20 hours of operation, frequently check engine oil
level (THIS LEVEL MUST NOT INCREASE).
NOTE After the assembly operation, the feed pipes must

not, under circumstances, touch. This is to prevent
them from being damaged as a result of the high
169832 stress caused by the engine vibrations.
Fit the rail (2) and the spacers (3) on the cylinder head. The MINIMUM distance between the individual
pipes must NOT be LESS than 2mm.
Tighten the screws (1) to the torque specified in the table.
When the assembly operation is finished, connect the engine
(1) 3 M8x1.25x45 23 ± 2 Nm cable on the head to the electro-injectors and to the sensor
on the rail.
The pipes which were removed cannot be refitted. Figure 35
They must be replaced.
NOTE Be very careful when fitting the high pressure pipes.
Figure 34
204105
Fit the tappet cover (1) together with the gasket.

(2) 20 M6x1x50 10 ± 1 Nm
193949
Fit the new pipes (1) connecting the rail to the electro-injec- Figure 36
tors and tighten the fittings to the torque indicated in the
table.
(1) 6 M18x1.5 40 ± 2 Nm
(1) 6 M14x1.5 35 ± 2 Nm
Fit the new pipe (2) connecting the intermediate fitting and
the rail and tighten the fittings to the torque indicated in the
table. 225091
(2) 1 M18x1.5 40 ± 2 Nm Follow the tightening sequence indicated in the figure.
(2) 1 M14x1.5 35 ± 2 Nm

ROCKER ARM SHAFT Figure 39

REMOVAL/INSTALLATION
Removal
Figure 37
204108
Using tool 99360558 (1) remove the shaft together with the
rocker arms (2).
204105
Remove the bridges (3) from the cylinder head.
Unscrew the fastening screws (2) and remove the tappet
cover (1) together with the gasket.
Refitting
(2) 20 M6x1x50
Remove the engine cable connected inside the head. NOTE Before refitting the rocker-arm shaft assembly,
make sure that all the adjustment screws have been
fully unscrewed.
Figure 38
Figure 40
204107
Unscrew the screws (1) securing the rocker arm shaft.

204108
Ref. No. Description Fit the bridges (3) on the valve stem.
(1) 7 M12x1.75x130
Using tool 99360558 (1), fit the rocker arm shaft (2).
Remove tool 99360558 (1).

Figure 41 Adjustment of clearance between the intake

and exhaust rocker arms
Figure 43
204107
Tighten the rocker arm fastening screws (1) to the torque

indicated in the table. 114287
The adjustment of clearance between the rocker arms and

intake and exhaust valve control bridges must be done very
(1) 7 M12x1.75x130 105 ± 10 Nm carefully. Take the cylinder whose clearance has to be adju-
sted into the combustion phase; the valves of this cylinder are
closed as they balance those of the symmetric cylinder.
Symmetric cylinders are 1-6, 2-5 and 3-4.
In order to properly operate, follow these instructions and
data specified on the table.
- Use a polygonal wrench to slacken the locking nut (1)
of the rocker arm adjusting screw (2);
- Insert the strip of feeler gauge (3) corresponding to the
Figure 42
working clearance as indicated in the table “Characteri-
stics and data
- Tighten or slacken the adjustment screw with the appro-
priate wrench;
- Make sure that the feeler gauge (3) can slide with a slight
friction;
- Lock the nut (1) holding the adjustment screw still.
Follow the firing order indicated in the table below.
70567A
FIRING ORDER 1-4-2-6-3-5
Tighten the rocker arm shaft fastening screws following the CLOCKWISE BALANCING ADJUSTING
tightening order shown in the figure. START-UP CYLINDER CLEARANCE
AND VALVES NO. OF CYLINDER
ROTATION VALVE NO.
1 and 6 at TDC 6 1
120˚ 3 4
120˚ 5 2
120˚ 1 6
120˚ 4 3
120˚ 2 5
NOTE To perform the adjustments described above cor-

rectly, the order indicated in the table must be fol-
lowed. Check the accuracy of position during each
rotation phase using the pin 99360612.

Figure 44 ELECTRO-INJECTOR REMOVAL/

REFITTING
Removal
Figure 47
115880
Fit the cable inside the head (electro-injectors + pressure

sensor) passing it through the hole and securing it with the
clip as shown in the figure. 204105
Unscrew the fastening screws (2) and remove the tappet

Figure 45 cover (1) together with the gasket.

(2) 20 M6x1x50
Remove the engine cable connected inside the head.
Figure 48
204105
Fit the tappet cover (1) together with the new gasket and
tighten the screws (2) to the torque indicated in the table.

(2) 20 M6x1x50 10 ± 1 Nm
204107

Figure 46
(1) 7 M12x1.75x130
225091
Follow the tightening sequence indicated in the figure.

Figure 49 Figure 51
204108
Using tool 99360558 (1) remove the shaft together with the
rocker arms (2).
Remove the bridges (3) from the cylinder head.
169827
Figure 50
Unscrew the screws (1) securing the electro-injectors (2).

(1) 1 M10x1.5x40
Figure 52
193949
Disconnect the connection pipe (1) between the rail and the
electro-injectors, the connection pipe (2) between the feed
pump and the rail and the fuel return pipe (3).

(1) 6 M18x1.5
(1) 6 M14x1.5
(2) 1 M18x1.5
(2) 1 M14x1.5
(3) 1 M16x1.5
(3) 1 M14x1.5
169826
Fit the tool 99342157 (1) on the electro-injectors (2).

Figure 53 Figure 54
169828 169828
Remove the electro-injector (1) together with the bracket Fit the electro-injector (1) on the cylinder head together with
and gaskets (2). the bracket and gasket (2).
Tighten the screw on the electro-injector bracket to the tor-
(-) 1 M10x1.5x40 46 ± 3 Nm
Refitting
Lubricate the O-Ring securing the electro-injector The pipes which were removed cannot be refitted.
with lubricants PDE SILIKONFETT 22, NLG 12, PDE
They must be replaced.
LUBRICOMET GR 220 NLG12.
NOTE During assembly of the high pressure fuel pipes,

proceed with the utmost caution.

Figure 55 Figure 56
193949 204108
Fit the new pipes (1) connecting the rail to the electro-injec- Fit the bridges (3) on the valve stem.
Using tool 99360558 (1), fit the rocker arm shaft (2).
table.
Remove tool 99360558 (1).
(1) 6 M18x1.5 40 ± 2 Nm
Figure 57
(1) 6 M14x1.5 35 ± 2 Nm
Fit the new pipe (2) connecting the feed pump to the rail and
tighten the fittings to the torque indicated in the table.

(2) 1 M18x1.5 40 ± 2 Nm
(2) 1 M14x1.5 35 ± 2 Nm
Fit the new fuel return pipe (3) and tighten the fittings to the

(3) 1 M16x1.5 35 ± 2 Nm
204107
(3) 1 M14x1.5 35 ± 2 Nm
After fitting the high pressure pipes, during the next (1) 7 M12x1.75x130 105 ± 10 Nm
! 20 hours of operation, frequently check engine oil
level (THIS LEVEL MUST NOT INCREASE).
Figure 58

them from being damaged as a result of the high
stress caused by the engine vibrations.
The MINIMUM distance between the individual
NOTE Before refitting the rocker-arm shaft assembly, 70567A

fully unscrewed. Tighten the rocker arm shaft fastening screws following the
tightening order shown in the figure.

Adjustment of clearance between the intake

and exhaust rocker arms NOTE To perform the adjustments described above cor-
rectly, the order indicated in the table must be fol-
Figure 59 lowed. Check the accuracy of position during each
rotation phase using the pin 99360612.
Figure 60
114287

intake and exhaust valve control bridges must be done very
carefully. Take the cylinder whose clearance has to be adju-
sted into the combustion phase; the valves of this cylinder are
115880
closed as they balance those of the symmetric cylinder.
Fit the cable inside the head (electro-injectors + pressure
Symmetric cylinders are 1-6, 2-5 and 3-4.
sensor) passing it through the hole and securing it with the
In order to properly operate, follow these instructions and clip as shown in the figure.
data specified on the table.
- Use a polygonal wrench to slacken the locking nut (1)
of the rocker arm adjusting screw (2); Figure 61
- Insert the strip of feeler gauge (3) corresponding to the
working clearance as indicated in the table ”Data -
Assembly Clearance“;
priate wrench;
friction;
- Tighten the nut to a torque of 34  44 Nm
FIRING ORDER 1-4-2-6-3-5
204105
Fit the tappet cover (1) together with the new gasket and
CLOCKWISE BALANCING ADJUSTING tighten the screws (2) to the torque indicated in the table.
START-UP CYLINDER CLEARANCE
AND VALVES NO. OF CYLINDER Ref. No. Description Tightening torques
ROTATION VALVE NO. (2) 20 M6x1x50 10 ± 1 Nm
1 and 6 at TDC 6 1
120˚ 3 4
120˚ 5 2
120˚ 1 6
120˚ 4 3
120˚ 2 5

INTAKE MANIFOLD REMOVAL/REFITTING Refitting

Removal
Figure 64
Figure 62
249469
208302
Fit the intake manifold (3) together with new gaskets (5) and
Disconnect the electrical connection of the air temperature heater (4) on the cylinder head (5).
and pressure sensor (1).
Tighten the screws (1) and (2) to the torque indicated in the
table.
(1) 5 M10x1.5x100 50 ± 5 Nm
Figure 63
(2) 1 M10x1.5x150 50 ± 5 Nm
Figure 65
225092

Figure 66
249469
Unscrew the screws (1) (2), remove the intake manifold (3),
the gaskets (5), the heater (4) and the gasket (4) from the
cylinder head (6).

(1) 5 M10x1.5x100
(2) 1 M10x1.5x150
208302
Connect the electrical connection of the air temperature and

pressure sensor (1).

STARTER MOTOR REMOVAL/REFITTING TURBOCHARGER REMOVAL/REFITTING

Removal Removal
Figure 69
Figure 67
193050
Unscrew the nuts (2) and remove the starter motor (1).

(2) 3 M10x1.5
208303
Refitting Unscrew the screws (1), the fitting (2) and remove the engine
oil outlet pipe from the turbocharger (3).
Figure 68 Ref. No. Description
(1) 2 M8x1.25
(2) 1 M30x2
Figure 70
193050
Fit the starter motor (1) and tighten the nuts (2) to the tor-
208304
Ref. No. Description Tightening torques Disconnect the fittings and remove the engine coolant return
(2) 3 M10x1.5 80 ± 8 Nm and delivery pipes to the engine brake control actuator (1).

(1) 4 M12x1.5
Unscrew the fitting (2) of the engine oil delivery pipe to the
turbocharger.

(2) 1 M16x1.5
Unscrew the screw (3) on the retaining bracket of the engine

oil delivery pipe to the turbocharger.

Refitting
(3) 1 M8x1.25x16 Figure 73
Disconnect the electrical connection (4) of the engine brake

throttle control actuator.
Figure 71
208306
Fit the turbocharger (2) together with a new gasket and

tighten the nuts (1) to the torque indicated in the table.
208305 Ref. No. Description Tightening torques

Unscrew the fitting (1) and remove the oil delivery pipe to (1) 4 M10x1.5 46 ± 2 Nm
the turbocharger.
(1) 1 M16x1.5
Figure 74
Unscrew the collar screw and remove the engine brake (2).

(2) 1 M8x70
Figure 72
208305
Fit the engine brake (2) and tighten the nut on the collar to
the torque indicated in the table.

(2) 1 M8x70 14 ± 1 Nm
Fit the engine oil delivery pipe to the turbocharger and

tighten the fitting (1) to the torque indicated in the table.
208306
Unscrew the nuts (1) and remove the turbocharger (2). Ref. No. Description Tightening torques
(1) 1 M16x1.5 42.5 ± 2.5 Nm
(1) 4 M10x1.5
Remove the gasket.

Figure 75 EXHAUST MANIFOLD REMOVAL/

REFITTING
Removal
Figure 77
208304
Tighten the fitting (2) of the engine oil delivery pipe engine
to the turbocharger to the torque indicated in the table.
(2) 1 M16x1.5 42.5 ± 2.5 Nm
Tighten the screw (3) on the retaining bracket of the engine
oil delivery pipe to the turbocharger to the torque indicated
in the table. 208303
Ref. No. Description Tightening torques Unscrew the screws (1), the fitting (2) and remove the engine
(3) 1 M8x1.25x16 23 ± 2 Nm oil outlet pipe from the turbocharger (3).
Fit the engine coolant return and delivery pipes to the engine Ref. No. Description
brake control actuator (1) and tighten the fittings to the tor- (1) 2 M8x1.25
que indicated in the table. (2) 1 M30x2
Ref. No. Description Tightening torques Figure 78
(1) 4 M12x1.5 25 ± 5 Nm
Connect the electrical connection (4) of the engine brake
Figure 76
7777777777777777777
208304
Disconnect the fittings and remove the engine coolant return

and delivery pipes to the engine brake control actuator (1).
(1) 4 M12x1.5
Unscrew the fitting (2) of the engine oil delivery pipe to the
turbocharger.
208303
(2) 1 M16x1.5
Fit the engine oil outlet pipe from the turbocharger (3), Unscrew the screw (3) on the retaining bracket of the engine
tighten the screws (1) and the fitting (2) to the torque indica- oil delivery pipe to the turbocharger.
ted in the table. Ref. No. Description
Ref. No. Description Tightening torques (3) 1 M8x1.25x16
(1) 2 M8x1.25x20 25 ± 5 Nm Disconnect the electrical connection (4) of the engine brake
(2) 1 M30x2 25 ± 5 Nm throttle control actuator.
Figure 79 Figure 81
208305 249470
Unscrew the fitting (1) and remove the oil delivery pipe to Unscrew the screws (1), loosen the collars to release the
the turbocharger. engine coolant return and delivery pipes (2).
(1) 1 M16x1.5 Ref. No. Description
(1) 2 M8x1.25x16

Figure 82
(2) 1 M8x70
Figure 80
204119
Loosen the collar and disconnect the engine coolant sleeve

(1).
208306
Disconnect the electrical connection of the engine coolant
temperature sensor (2).
1. Unscrew the nuts (1) and remove the turbocharger (2).
Loosen the collar and disconnect the engine coolant sleeve
Ref. No. Description (3).
(1) 4 M10x1.5 Unscrew the fittings and remove the degassing pipes (4).
Unscrew the screws (5) and remove the intarder pipes (6).
Remove the gasket.
(5) 2 M10x1.5x130

Figure 83 Figure 85
249471
204119
Unscrew the screws (2) and remove the exhaust manifold Fit the Intarder pipes (6) and tighten the screws (5) to the
(3) together with the gaskets (1). torque indicated in the table.
Ref. No. Description Ref. No. Description Tightening torques
(2) 24 M10x1.5x38 (5) 2 M10x1.5x130 20 ± 2 Nm
Fit the degassing pipes (4) and connect the fittings.

Connect the engine coolant sleeve (3) and tighten the rela-
tive collar.
Refitting Connect the electrical connection of the engine coolant tem-
perature sensor (2).
Figure 84
Connect the engine coolant sleeve (1) and tighten the rela-
tive collar.
Figure 86
249471
Fit the exhaust manifold (3) together with the new gaskets
(1) and tighten the screws (2) to the torque indicated in the
table.
(2) 24 M10x1.5x38 45 ± 5 Nm
249470
Reposition the engine coolant return and delivery pipes (2)

in their seats and tighten the screws (1) of the collars to the
(1) 2 M8x1.25x16 23 ± 2 Nm

Figure 87 Figure 89
208304
208306 Connect the electrical connection (4) of the engine brake

Fit the turbocharger (2) together with a new gasket and throttle control actuator.
tighten the nuts (1) to the torque indicated in the table. Tighten the fitting (2) of the engine oil delivery pipe engine
(1) 4 M10x1.5 46 ± 2 Nm Ref. No. Description Tightening torques
(2) 1 M16x1.5 42.5 ± 2.5
Figure 88 in the table.
(3) 1 M8x1.25x16 23 ± 2 Nm
Fit the engine coolant return and delivery pipes to the engine
brake control actuator (1) and tighten the fittings to the tor-
que indicated in the table
(1) 4 M12x1.5 25 ± 5 Nm
Figure 90
208305
Fit the engine brake (2) and tighten the collar screw.
(2) 1 M8x70 14±1 Nm


(1) 1 M16x1.5 42.5 ± 2.5
208303
Fit the engine oil outlet pipe from the turbocharger (3),
tighten the screws (1) and the fitting (2) to the torque indica-
ted in the table.
(1) 2 M8x1.25x20 25 ± 5 Nm
(2) 1 M30x2 25 ± 5 Nm

OIL FILTER HOUSING REMOVAL/ Refitting

REFITTING
Removal Figure 93
ATTENTION:
the oil filter contains approximately 2 kg of engine oil.
Avoid skin contact with the engine oil: in case of con-
tact, wash thoroughly with water.
249472
Fit the oil filter bracket (3) together with the new gasket (1).
Figure 91
Tighten the oil filter housing fastening screws (2) to the tor-

(2) 5 M8x1.25x65 34 ± 4 Nm
NOTE Before fitting the new filter element, moisten the

gasket with engine oil.
249473 Figure 94
Using a suitable tool, unscrew the oil filter body (2) and
remove the filter element (1).

(2) 1 -
Figure 92
249472
Fit the new filter element (1) and tighten the oil filter body
(1) to the torque indicated in the table.
(1) 1 - 60 ± 5 Nm
249472
Unscrew the screws (2) and remove the oil filter bracket (3)
and the gasket (1).
(2) 5 M8x1.25x65

HEAT EXCHANGER REMOVAL/REFITTING Figure 97

Removal
ATTENTION:
the oil filter contains approximately 2 kg of engine oil.
Avoid skin contact with the engine oil: in case of con-
tact, wash thoroughly with water.
249474
Figure 95 Unscrew the fittings (1) and remove the oil outlet pipe from
the turbocharger (4).
(1) 1 M27x1.5
(1) 1 M30x2
Unscrew the screws (3) and remove the retaining bracket (2)
for the oil delivery pipe to the turbo.

(3) 3 M8x1.25x16
NOTE Before removing any pipes, make sure that the

249473 mounting brackets have already been removed.
Figure 98
(2) 1 -
Figure 96
193057

Unscrew the fittings and remove the engine coolant inlet and
249472 outlet pipes (1).
Unscrew the screws (2) and remove the oil filter bracket (3) Ref. No. Description
and the gasket (1).
(1) 4 M12x1.5
(2) 5 M8x1.25x65

Unscrew the collar screw and remove the engine brake (2). Ref. No. Description Tightening torques
Ref. No. Description (5) 4 M8x45 23 ± 2 Nm
(2) 1 M8x70
Fit the heat exchanger body (4) together with the new gasket
NOTE Position a suitable container below the heat table.
exchanger for the engine coolant draining opera- Ref. No. Description Tightening torques
tion.
(1) 14 M8x40 23 ± 2 Nm
(1) 3 M8 23 ± 2 Nm
Figure 99 (1) 1 M8x55 23 ± 2 Nm
Figure 101
193058
Unscrew the screws (1) and remove the heat exchanger

193057
body (4) together with the gasket (2).
Fit the engine brake (2) and tighten the collar screw to the
Ref. No. Description torque indicated in the table.
(1) 14 M8x40
(1) 3 M8
(2) 1 M8x70 14±1 Nm
(1) 1 M8x55
Fit the engine coolant inlet and outlet pipes (1) and tighten
Unscrew the screws (5) and release the heat exchanger (3) the fittings to the torque indicated in the table.
from the heat exchanger body.
(5) 4 M8x45
(1) 4 M12x1.5 25 ± 5 Nm
Refitting Connect the electrical connection (3) of the engine brake
Figure 100 throttle control actuator.
193058
Secure the heat exchanger (3) to the heat exchanger body

table.

Figure 102 Figure 104
249473
249474
Fit the retaining bracket (2) for the oil delivery pipe to the Fit the new filter element (1) and tighten the oil filter body
turbo and tighten the screws (3) to the torque indicated in (2) to the torque indicated in the table.
the table.
(3) 3 M8x1.25x16 23 ± 2 Nm
(2) 1 - 60 ± 5 Nm
Fit the oil outlet pipe from the turbocharger (4) and tighten
the fittings (1) to the torque indicated in the table.
OIL SUMP REMOVAL/REFITTING

Ref. No. Description Tightening torques Removal
(1) 1 M27x1.5 25 ± 5 Nm
(1) 1 M30x2 25 ± 5 Nm
NOTE Position a suitable container below the sump to
Figure 103 collect the oil as it drains out of the drain plug.
Figure 105
249472
204242
Unscrew the drain plug (1).

(2) 5 M8x1.25x65 34 ± 4 Nm
(1) 1 M22x1.5
NOTE Before fitting the new filter element, moisten the Unscrew the screws and remove the filler closing flange (2)
gasket with engine oil. to facilitate the engine oil flow.

Figure 106
In case of contact with skin wash thoroughly with
Adequately protect skin and eyes; take measures as

with regulations.
Refitting
Figure 108
208307
Unscrew the screws (1) and remove the engine oil sump (3)
together with the spacer (2) and the gasket (4).
170127
Rotate the engine.
(1) 26 M10x1.5x50
Figure 107
NOTE Before fitting the suction strainer it is essential that
the contact area between the crankcase, flywheel
housing and front cover is sealed with LOCTITE
following the indications below. Clean the coupling
surfaces in order to remove any impurities and oil
residue.
Apply LOCTITE 5970 (1) silicone as shown in the figure. The

sealant bead diameter is to be 1.5 ± 0.5/0.2 mm.
193943
Unscrew the screws (2) and remove the suction strainer (1)
together with the O-ring.

(2) 3 M8

193943 204242
Fit the suction strainer (1) together with the new O-ring and Fit the drain plug (1) and tighten to the torque indicated in
tighten the screws (2) to the torque indicated in the table. the table.
Ref. No. Description Tightening torques Ref. No. Description Tightening torques
(2) 3 M8 20 ± 2 Nm (1) 1 M22x1.5 40 ± 10 Nm
Through the filler cap, introduce the oil in the specified quan-
Figure 110 tity and quality prescribed.
Fit the filler closing flange (2) together with the gasket and
tighten the relative screws.
NOTE Only use recommended oils or oils with the pro-

perties required for proper engine operation.
If topping up, do not mix oils with different proper-
ties.
Failure to observe these standards will invalidate
the service warranties.
Check the level with the dipstick until obtaining a filling near
204240 the maximum level notch shown on the dipstick.
Fit a new gasket (4) on the oil sump (3) and position the spa-
cer (2).
Fit the oil sump (3) on the crankcase and tighten the screws Figure 112
(1) 26 M10x1.5x50 44±4 Nm
193945

BLOW-BY REMOVAL/REFITTING Refitting

Removal
Figure 116
Figure 113
249467
204113 Fit the blow-by rotating filter (1) and tighten the screws (2)
Unscrew the screws (1) and remove the blow-by valve body to the torque indicated in the table.
(2). Ref. No. Description Tightening torques
Ref. No. Description (2) 3 M6x1x16 9 ± 1 Nm
(1) 3 M6x1x20
Figure 117
Figure 114
249466
249466
Unscrew the screws (2) and remove the cover (1). Fit the cover (1) and tighten the screws (2) to the torque indi-
cated in the table.
(2) 3 M6x1x16
(2) 3 M6x1x16 9 ± 1 Nm
Figure 115 Clean the coupling surfaces in order to remove any impurities
and oil residue.
249467
Unscrew the screws (2) and remove the blow-by rotating fil-
ter (1).
(2) 3 M6x1x16

Figure 120 Refitting

Figure 121
248895
204113
Fit the blow-by valve body (2) and tighten the screws (1) to Introduce the gasket (2) and tighten the screws (1) to the
the torque indicated in the table. torque indicated in the table.
(2) 3 M6x1x16 9 ± 1 Nm (1) 3 Screw M10x70 44 ± 4 Nm
HYDRAULIC PUMP REMOVAL /

INSTALLATION
Removal
Figure 118
Figure 122
248894
Unscrew the screws (2) and remove the hydraulic pump (1).

(2) 2 Screw M10x1.5x26
Figure 119
248894
Introduce the hydraulic pump (1) and tighten the screws (2)
to the torque indicated in the table.

(2) 2 Screw 44 ± 4 Nm
M10x1.5x26
248895
Unscrew the screws (1) and remove the gasket (2).

(1) 3 M10x70

ENGINE RIGHT AND LEFT SUPPORTING Figure 126

BRACKET - REMOVAL / INSTALLATION
Removal
Figure 123
249476 249477
Unscrew the screws (2) and remove the left engine suppor- Insert the left engine supporting bracket (1) and tighten the
ting bracket (1). screws (2) to the torque indicated in the table.
(2) 4 M16x3x55 Ref. No. Description Tightening torques
(2) 2 M16x3x55 29.5 ± 30 Nm
Figure 124
Figure 127
249477
249478
Unscrew the screws (2) and remove the left engine suppor-
ting bracket (1).
(2) 4 M16x3x55
Refitting
Figure 125
249476
Insert the left engine supporting bracket (1) and tighten the
screws (2) to the torque indicated in the table.

(2) 2 M16x3x55 29.5 ± 30 Nm

AIR COMPRESSOR Refitting

REMOVAL / INSTALLATION
Removal Figure 130
Figure 128
208310
Fit the compressor (3) and tighten the screws (2) to the tor-
208309 que indicated in the table.
Unscrew the screws (1) and remove the power steering
pump (2). Ref. No. Description Tightening torques
Ref. No. Description (3) 3 M12x35 74 ± 8 Nm
(1) 2 M10x1.5 Fit the engine coolant return and delivery pipes to the air
compressor and tighten the fittings (1) to the torque indica-
ted in the table.
Figure 129
(1) 2 M18x1.5 50 Nm
Figure 131
208310
Disconnect the fittings (1) and remove the engine coolant

return and delivery pipes to the air compressor.
(1) 2 M18x1.5 208309
Unscrew the screws (2) and remove the air compressor (3). Fit the power steering pump (2) and tighten the screws (1)
(3) 3 M12x35
(1) 2 M10x1.5 44 ± 4 Nm


F2CFE612 ENGINE SECTION 6 - GENERAL MECHANICAL OVERHAUL 1
SECTION 6
General mechanical overhaul
Page
FITTING THE ENGINE ONTO THE ROTATING
STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
- Removal of components hindering bracket assembly 5
- Fitting the engine onto the rotating stand . . . . 7
DISASSEMBLY OF ENGINE AT BENCH

(COMPONENTS AT THE FRONT) . . . . . . . 8
- Removal of auxiliary device drive belts . . . . . . 8
- Removal of crankshaft pulley . . . . . . . . . . . . . . 8
- Removal of alternators and water pump . . . . . 8
- Removal of alternator supports . . . . . . . . . . . . 9
- Removal of crankcase front cover . . . . . . . . . . 9

(COMPONENTS AT THE TOP - PART 1) . . 9
- Tappet cover removal . . . . . . . . . . . . . . . . . . . 9

(SIDE VIEW OF COMPONENTS - PART 1) 10
- Removal of fuel pipes . . . . . . . . . . . . . . . . . . . 10
- Intake manifold removal . . . . . . . . . . . . . . . . . 10

(COMPONENTS AT THE REAR) . . . . . . . . . 10
- Removal of camshaft drive gear -

pressure pump . . . . . . . . . . . . . . . . . . . . . . . . 10
- Removal of pressure pump . . . . . . . . . . . . . . . 11
- Removal of engine flywheel . . . . . . . . . . . . . . . 11
- Removal of engine flywheel housing . . . . . . . . 11
- Removal of oil pump - double gear . . . . . . . . . 12

(COMPONENTS AT THE BOTTOM) . . . . . 12
- Removal of engine oil sump - suction strainer 12

(SIDE VIEW OF COMPONENTS - PART 2) 13
- Removal of water inlet pipe to pump . . . . . . . 13

2 SECTION 6 - GENERAL MECHANICAL OVERHAUL F2CFE612 ENGINE
Page Page
ENGINE ASSEMBLY AT BENCH

- Intarder removal . . . . . . . . . . . . . . . . . . . . . . 13 (CRANKCASE COMPONENTS) . . . . . . . . . . 51
- Exhaust manifold removal . . . . . . . . . . . . . . . 13 ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE TOP - PART 1) . . 51
(COMPONENTS AT THE TOP - PART 2) . . 13 - Installing cylinder head . . . . . . . . . . . . . . . . . 51
- Removal of rail - electro-injectors . . . . . . . . . 13 - Refitting the rail - electro-injector . . . . . . . . . 52
- Removal of rocker arm shaft . . . . . . . . . . . . 14 - Refitting the rocker arm shaft . . . . . . . . . . . . 53
- Removal of blow-by valve . . . . . . . . . . . . . . . 14 ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE REAR) . . . . . . . . . . 54
- Cylinder head removal . . . . . . . . . . . . . . . . . 15
- Refitting oil pump - double gear . . . . . . . . . . 54
- Intake and exhaust valve removal . . . . . . . . . 15
- Refitting engine flywheel housing . . . . . . . . . 54
(CRANKCASE COMPONENTS) . . . . . . . . . . 15 - Refitting engine flywheel . . . . . . . . . . . . . . . . 55
- Removal of connecting rod and piston - Refitting camshaft . . . . . . . . . . . . . . . . . . . . . 55
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Refitting pressure pump . . . . . . . . . . . . . . . . 62
- Removal of main bearing caps . . . . . . . . . . . 16
- Adjustment of clearance between the intake
- Removal of crankshaft and piston cooling spray and exhaust rocker arms . . . . . . . . . . . . . . . 63
nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ASSEMBLY OF ENGINE AT BENCH
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 (COMPONENTS AT THE TOP - PART 1) . . 63
- Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . 17 - Refitting blow-by valve . . . . . . . . . . . . . . . . . 63
- Refitting and protrusion check . . . . . . . . . . . 19 ASSEMBLY OF ENGINE AT BENCH
(COMPONENTS AT THE BOTTOM) . . . . . 64
- Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Refitting engine oil sump - suction strainer . . 64
PRELIMINARY DATA READING FOR SELECTING
THE MAIN AND BIG END HALF-BEARINGS 24 ENGINE ASSEMBLY AT BENCH
(SIDE VIEW OF COMPONENTS - PART 1) . 65
- Selecting the main and big end half-bearings 25
- Refitting exhaust manifold . . . . . . . . . . . . . . . 65
- Connecting rod and piston assembly . . . . . . 33
- Refitting Intarder . . . . . . . . . . . . . . . . . . . . . . 65
- Main data of piston assembly . . . . . . . . . . . . 35
- Refitting water inlet pipe to pump . . . . . . . . 65
- Checking the piston pins . . . . . . . . . . . . . . . . 36
- Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . 41 (COMPONENTS AT THE TOP - PART 2) . . 66
- Intake and exhaust valves . . . . . . . . . . . . . . . 42 - Refitting tappet cover . . . . . . . . . . . . . . . . . . 66
- Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . 42 ENGINE ASSEMBLY AT BENCH

(SIDE VIEW OF COMPONENTS - PART 2) . 66
- Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . 43
- Refitting intake manifold . . . . . . . . . . . . . . . . 66
- Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . 44
- Refitting fuel pipes . . . . . . . . . . . . . . . . . . . . . 67
- Timing system . . . . . . . . . . . . . . . . . . . . . . . . 44

Page

(COMPONENTS AT THE FRONT) . . . . . . . . 67
- Refitting front cover of crankcase . . . . . . . . . 67
- Refitting alternator supports . . . . . . . . . . . . . 68
- Refitting alternators and water pump . . . . . . 69
- Refitting crankshaft pulley . . . . . . . . . . . . . . . 69
- Refitting auxiliary device drive belts . . . . . . . 70
REMOVING THE ENGINE FROM THE

ROTATING STAND . . . . . . . . . . . . . . . . . . . . 70
- Refitting starter motor . . . . . . . . . . . . . . . . . 70
- Refitting engine management control unit . . 70
- Refitting heat exchanger . . . . . . . . . . . . . . . . 71
- Refitting the engine oil filter support . . . . . . . 71
- Turbocharger refitting . . . . . . . . . . . . . . . . . . 71
- Refitting engine cable . . . . . . . . . . . . . . . . . . 72


FITTING THE ENGINE ON THE ROTATING Unscrew the fitting (2) of the engine oil delivery pipe to the
STAND turbocharger.
Removal of components hindering bracket Ref. No. Description
assembly
Engine cable removal (2) 1 M16x1.5
Before fitting the engine onto the rotating stand 99322230, Unscrew the screw (3) on the retaining bracket of the engine
remove the engine cable disconnecting it from the control oil delivery pipe to the turbocharger.
unit and from all sensors/senders to which it is connected.
Turbocharger removal Ref. No. Description
Figure 1 (3) 1 M8x1.25x16

Figure 3
208305
208303 Unscrew the fitting (1) and remove the oil delivery pipe to
Unscrew the screws (1), the fitting (2) and remove the engine the turbocharger.
oil outlet pipe from the turbocharger (3). Ref. No. Description
Ref. No. Description (1) 1 M16x1.5
(1) 2 M8x1.25
(2) 1 M30x2
(2) 1 M8x70
Figure 2
Figure 4
208304
208306
Disconnect the fittings and remove the engine coolant return
1. Unscrew the nuts (1) and remove the turbocharger (2).
and delivery pipes to the engine brake control actuator (1).
(1) 4 M12x1.5 Remove the gasket.

Engine oil filter housing removal Removal of heat exchanger
ATTENTION: ATTENTION:
the oil filter contains approximately 2 kg of engine oil. the oil filter contains approximately 2 kg of engine oil.
Position a suitable container to collect the oil. Position a suitable container to collect the oil.
Avoid skin contact with the engine oil: in case of con- Avoid skin contact with the engine oil: in case of con-
tact, wash thoroughly with water. tact, wash thoroughly with water.
The engine oil is highly pollutant: it must be disposed The engine oil is highly pollutant: it must be disposed
of according to applicable laws. of according to applicable laws.
Figure 5
Figure 7
249473
193058
Ref. No. Description Unscrew the screws (1) and remove the heat exchanger
(1) 1 - body (4) together with the gasket (2).
Unscrew the screws and remove the oil pressure regulator Ref. No. Description
valve (3). (1) 14 M8x40
Ref. No. Description (1) 3 M8
(3) 2 M8x1.25 (1) 1 M8x55
Unscrew the screws (5) and release the heat exchanger (3)
Figure 6 from the heat exchanger body.

(5) 4 M8x45
249472
Unscrew the screws (2) and remove the oil filter bracket (2)
and the gasket (1).
(2) 5 M8x1.25x65

Removal of engine management control unit Removal of starter motor

Figure 9 Figure 8
208311 208317
Unscrew the screw (1) of the retainer bracket for the fuel Unscrew the nuts and remove the starter motor (1).
delivery pipe from the heater to the pressure pump and
release it from the intermediate clip.
(1) 3 M10x1.5
(1) 1 M8x1.25 Disconnect the fittings (3) and remove the engine coolant
return and delivery pipes to the air compressor (4).
Unscrew the fittings and remove the fuel delivery pipe (2)
from the heater to the pressure pump heater.
(3) 4 M18x1.5
(2) 1 M18x1.5
(2) 1 M16x1.5 Unscrew the screws and remove the power steering pump
(5).
Unscrew the screw and nuts and remove the engine manage-
ment control unit (3). Ref. No. Description
(5) 2 M10x1.5
(3) 1 M8x1.25x45
Unscrew the screws and remove the compressor (2).
(3) 2 M8x1.25
Unscrew the screws and remove the contactor (4).
(2) 3 M12x35
Unscrew the fittings (5), loosen the intermediate retaining
collar screw and remove the fuel drain pipe.
Ref. No. Description Fitting the engine onto the rotating stand
(2) 1 M16x1.5 Fit brackets 99361046 onto the crankcase and the engine
onto rotating stand 9932230.
Drain the engine oil by removing the plug from the oil sump.
(-) 1 M22x1.5

DISASSEMBLY OF ENGINE AT BENCH Removal of alternators and water pump

(COMPONENTS AT THE FRONT)
Figure 12
Removal of auxiliary device drive belts
Figure 10
225074

ners (1) and (5) and remove the belts (2) and (3).
Removal of crankshaft pulley
225078
Figure 11
Unscrew the screws (7, 8) and remove the alternator (9).
Unscrew the screws (5, 6) and remove the additional alterna-
tor (10).
(5) 1 M10x45
(6) 1 M12x160
(7) 1 M12x1.75x160
(8) 1 M10x1.5x40
Unscrew the screws (4) and remove the water pump with
the gasket.

191598
(4) 4 M8x1.25x25
Unscrew the screw (1) securing the pipe retaining bracket for
the oil level dipstick.
Loosen the collars and disconnect the sleeves (1) and (3)
Unscrew fitting (9) and remove pipe (8) together with the
from the
oil level dipstick.
engine coolant outlet pipe from the cylinder head
Unscrew the fastening screws and remove the pulley (4), the (3).
damper pulley (5) and the crankshaft pulley (6).
Unscrew the screws (2) and remove the engine coolant
Ref. No. Description outlet pipe from the cylinder head (11) together with the
(5) 6 M12x1.75x60 gasket.
(6) 6 M14x2x60 Ref. No. Description
Unscrew the screws (2) and remove the bracket (3) together (2) 5 M8x1.25x70
with the mobile water pump drive belt tensioner.
(2) 2 M8
Unscrew the screw and remove the fixed alternator drive
belt tensioner (7).
(7) 1 M10x1.5x70

Removal of alternator supports Removal of crankcase front cover

Figure 13
Figure 14
204106
Unscrew the screws (1) and remove the crankcase front

cover (2) together with the seal ring.

(1) 9 M8x1.25x25

(COMPONENTS AT THE TOP - PART 1)
Tappet cover removal
204120
Figure 15
Unscrew the screws (1) and remove the upper alternator

mount.
(1) 2 M8x35
Unscrew the screws (2) and remove the lower alternator

mount.
(2) 3 M10x30
204100
Unscrew the screws (3) and remove the alternator support
(4) and the belt tensioner. Unscrew the screws (2) and remove the tappet cover (1).
(2) 20 M6x1x50
Remove the rail-electro-injector wiring.

DISASSEMBLY OF ENGINE AT BENCH DISASSEMBLY OF ENGINE AT BENCH

(SIDE VIEW OF COMPONENTS - PART 1) (COMPONENTS AT THE REAR)
Removal of fuel pipes Removal of camshaft drive gear - pressure
pump
Figure 16 Figure 18
204121 208336
Unscrew the fittings and remove the return and delivery Unscrew the screws (2) and remove the cover (1).
pipes from the pressure pump to the fuel filter (1).
Ref. No. Description (2) 3 M6x1x16
(1) 4 M16x1.5
Unscrew the screws and remove the rotating filter (3).
Open the retaining clip (2), unscrew the fittings and remove
the fuel pipe from the pressure pump to the intermediate fit- Ref. No. Description
ting (3). (3) 3 M6x1x16
Figure 19
(3) 2 M16x1.5
Unscrew the screws and remove the fitting (4) from the
cylinder head.
Intake manifold removal
Figure 17
208337
Unscrew the screws (2) and remove the camshaft drive gear
together with the complete phonic wheel (3).
(2) 4 M10x1.5x45
Unscrew the nut (4) and remove the high pressure drive gear
249475 (5).
Unscrew the screws (2, 3) and remove the intake manifold Ref. No. Description
(1). (4) 1 M18x1.5
Ref. No. Description Unscrew the screw and remove the timing sensor (1).
(3) 5 M10x1.5x100
(2) 1 M10x1.5x150
(1) 1 M6x1

Removal of pressure pump Removal of engine flywheel

Figure 21 Figure 20
192060 192061
Unscrew the screws (1) and remove the high pressure pump Unscrew the screw and remove the rpm sensor (3).
(2). Ref. No. Description
Ref. No. Description (3) 1 M6x1
(1) 3 M8x1.25x40
Fit flywheel locking tool 99360351.
Unscrew the screws (1) and remove the engine flywheel (2).
Figure 22 Ref. No. Description
(1) 8 M18x1.5x120
Removal of engine flywheel housing

Figure 23
5 1
4
2
208334
Unscrew the screws (1) and remove the shoulder plate (2). 3 3

(1) 5 M8x1.25x20
Unscrew the screws (4) and remove the transmission gear
(5).
299456
(4) 3 M12x1.5
Remove the pressure pump coupling flange (3). Unscrew the screws (1) and remove the flywheel housing (2)
together with the seal ring.
Unscrew the screws (6) and remove the hydraulic pump for
the viscostatic fan.
Ref. No. Description (1) 2 M12x1.75x193
(6) 2 M10x1.5x26 (2) 1 M10x1.5x80
(3) 7 M12x1.75x80
(4) 2 M12x1.75x193
(5) 1 M8x30

Removal of oil pump - double gear DISASSEMBLY OF ENGINE AT BENCH

Figure 24 (COMPONENTS AT THE BOTTOM)
Removal of engine oil sump - suction strainer
Figure 25
114023
Unscrew the screws (2) and remove the double gear (3).
Ref. No. Description 204241
(2) 3 M12x1.75x90 Unscrew the screws (1) and remove the engine oil sump (3)
with the spacers (2) and the seal.
Unscrew the screw (5) and remove the articulated rod (4).
Unscrew the screws and remove the oil pump (1). Ref. No. Description
Ref. No. Description (1) 26 M10x1.5x50
(1) 5 M8x1.25x60
(1) 3 M8x1.25x45
Figure 26
192063
Unscrew the screws and remove the suction strainer (1).

(1) 3 M8

DISASSEMBLY OF ENGINE AT BENCH Exhaust manifold removal

(SIDE VIEW OF COMPONENTS - PART 2)
Removal of water inlet pipe to pump Figure 29
Figure 27
192066
Unscrew the screws (1) and remove the exhaust manifold

(2) together with the gaskets.
192064
Loosen the clip and disconnect the sleeve (3) from the water Ref. No. Description
inlet pipe to the pump (2). (1) 24 M10x1.5x38
Unscrew the screws (1) and remove the water inlet pipe to
the pump (2). DISASSEMBLY OF ENGINE AT BENCH
Ref. No. Description (COMPONENTS AT THE TOP - PART 2)
(1) 2 M8x1.25 Removal of rail - electro-injectors
Unscrew the fittings and remove the engine coolant pipes (4, Figure 30
6) and the degassing pipe (5).

(4) 1 M8x1.25
(5) 1 M12x1.5
(6) 1 M8x1.25
Intarder removal
Figure 28
192067
Unscrew the fittings and remove the fuel pipes (1) from the
rail to the electro-injectors.

(1) 6 M18x1.5
(1) 6 M14x1.5
Disconnect the fittings and remove the fuel delivery pipe (2)
from the intermediate fitting to the rail.

Unscrew the screws (1, 2) and remove the intarder pipes (3). (2) 1 M18x1.5
(1) 2 M10x1.5x130 Unscrew the fittings and remove the fuel return pipe (3).
(2) 2 M8x1.25x16

Removal of rocker arm shaft

(3) 1 M16x1.5 Figure 33
(3) 1 M14x1.5

(4) 7 M12x1.75x130
Figure 31
192075
Using tool 99360558 (1), unscrew the screws and remove

the shaft together with the rocker arms (2).
(2) 7 M12x1.75x130
Remove the bridges from the cylinder head.

114027
Unscrew the screws (1) and remove the rail (2).

Removal of blow-by valve
(1) 3 M8x1.25x45
Figure 34
Unscrew the screws securing the electro-injector (4) brac-
kets (3).
(3) 1 M10x1.5x40
Figure 32
204128
Unscrew the screws (1), remove the blow-by valve body (2)
and the gasket.
(1) 3 M6x1x20
169826
Using tool 99342157 (1) remove the electro-injector (2)

together with the bracket and gaskets.

Cylinder head removal DISASSEMBLY OF ENGINE AT BENCH

(CRANKCASE COMPONENTS)
Figure 35 Removal of connecting rod and piston
assembly
Figure 37
192068
Remove the camshaft from the cylinder head.

115882
Unscrew the screws securing the cylinder head.
Unscrew the screws (2) and remove the connecting rod cap
(3).
- 26 M16x2x170 Ref. No. Description
Using metal ropes and a suitable hoist, remove the cylinder 2 12 M10x1.5x20
head (1) from the crankcase. Remove the piston (1) together with the connecting rod.
Remove the cylinder head gasket (2) from the centring Repeat these operations for the other pistons.
bushes.
Intake and exhaust valve removal NOTE Keep the half-bearings in their housings since in
case of use they shall be fitted in the same position
NOTE Before removing cylinder head valves, number found at removal.
them in view of their remounting in the same posi-
tion should they not have to be overhauled or
replaced.
Intake valves are different form exhaust valves in
that they have a notch placed at valve head centre.
Figure 36
47583
Fit tool 99360264 (2) with the bracket (4); using the lever (1)
tighten and remove the cotters (3); remove the tool (2), the
top plate (5), the spring (6) and the bottom plate (7).
Repeat this operation for all the valves.
Overturn the cylinder head and remove the valves (8).

Removal of main bearing caps Figure 40
Figure 38
208343
Remove the main half-bearings (1).

Unscrew the screws and remove the piston cooling spray
nozzles (2).

2 6 M14x2x18
191584
Unscrew the screws (1 and 3), remove the stiffening plate (2)
and the main bearing caps (4).
1 8 M10x1.5x20
3 14 M16x2x168
NOTE Mark the upper and lower half-bearings so that

they can be refitted in the same position noted
during removal.
Removal of crankshaft and piston cooling spray

nozzles
Figure 39
114034
Using tool 99360500 (1) and a suitable hoist, remove the

crankshaft (2) from the crankcase.

CHECKS
Cylinder block NOTE Use a micrometer to rest the bore gauge if a ring
Checking cylinder liners gauge is not available.
Figure 41
Figure 42
70166
114035
After disassembling the engine, thoroughly clean the cylinder
I = 1st measurement
assembly.
2 = 2nd measurement
Use the suitable rings to handle the cylinder assembly. 3 = 3rd measurement
Carefully inspect the crankcase for cracks. Measurements should be carried out for every single cylinder
liner at three different heights and on two (A-B) perpendicu-
Check the condition of the machining plugs. If they are worn, lar plane levels as illustrated in Figure.
replace them.
Check the condition of the surfaces of the cylinder liners
which should show no signs being scored, seized, ovalised, Figure 43
tapered or excessively worn.
To check the ovalisation, taper and wear of the cylinder liners,
check the internal diameter using the bore gauge (1) together
with the dial gauge which has been previously reset on the
ring gauge (2).
114036
A = Selection class Ø 117 - 117.012 mm

B = Selection class Ø 117.010 - 117.022 mm
When wear is over 0.150 mm or maximum ovalisation is
0.100 mm compared to the values shown in the figure,
replace the cylinder liner since it is not possible to adjust, lap
or dress it.
NOTE Cylinder liners are supplied as spare parts belonging

to selection class ”A”.

Figure 44 Figure 46
114037
A = Ø 130.500 - 130.525 mm
B = Ø 129.510 - 129.535 mm 208340
C = Ø 130.461 - 130.486 mm CRANKCASE ASSEMBLY WITH CYLINDER LINERS

D = Ø 129.475 - 129.500 mm
The illustrated diagram refers to the cylinder liner outer dia-
meters and their housing inner diameters.
Cylinder liners can be removed and fitted several times into
different housings, if needed.
Figure 45 Figure 47
Measu
rement section
47577
Fit tools 99360706 (1 and 2) and the plate 99360724 (4) as

shown in the figure.
Check that the plate (4) rests correctly on the cylinder liner.
Tighten the screw nut (1) and remove the cylinder liner (3)
from the crankcase. 208345
CYLINDER LINER MAIN DATA

Selection class: A mm 117.000 to 117.012 - B mm 117.010
to 117.022
X = Selection class marking area

Figure 48 Refitting and protrusion check

Figure 50
208341
Always replace the water-proof rings (3, 4 and 5).

Install the adjustment ring (1) on the cylinder liner (2); lubri-
cate the lower part of the liner and install it in the cylinder
assembly using a suitable tool.
NOTE The adjustment ring (1) is supplied as a spare part

with the following thickness: 0.08 mm - 0.10 mm -
Detail A 0.12 mm.
145837
Figure 51
Figure 49
77812
Check cylinder liner protrusion using tool 99360334 (1-2),

99360335 (3-4) and tighten the screw (1) to a torque of 225
Nm.
Using dial gauge 99395603 (5) positioned on base 99370415
Detail B (6), measure the cylinder liner protrusion from the cylinder
head supporting surface this measurement should be 0.035
- 0.065 mm; if the measurement is not as indicated, replace
145838 the adjustment ring (1, previous Figure), supplied as spare
part in different thicknesses.

Figure 52 Figure 53
114041 208342
CYLINDER LINER PROTRUSION Once assembly is complete, block the cylinder liners (1) at
the crankcase (2) with stud bolts 99360703 (3).

Crankshaft
Checking main journals and crankpins
Figure 54
Upper main half-bearings
Lower main half-bearings
144835
CRANKSHAFT MAIN DATA AND HALF-BEARINGS FOR MAIN SUPPORT

Check the condition of the crankshaft main journals and crankpins; there must be no sign of scoring, ovalisation or excessive
wear. The values shown refer to the regular pin diameter.

Figure 55 Figure 58
114043 47536
X. Main journals fillet detail MEASURING CRANKPINS

Figure 56 During the grinding operation, pay attention to the values of
the main journals and the crankpins shown in the previous
figures.
NOTE All journals and crankpins must also be ground to

the same undersizing class, in order to avoid any
alteration to shaft balance.
114044
Y. Crankpin fillet detail

Before grinding the crankpins, measure the crankpins (2) with
a micrometer (1) and on the basis of the undersizing of the
half-bearings, determine the final diameter to which the pins
are to be ground.
Figure 57
47535
MEASURING MAIN JOURNALS
NOTE It is recommended that the values measured are

noted in a table.

Fill in this table with the measurements of the crankshaft main journals and crankpins.
Figure 59
MAIN JOURNALS
MINIMUM
MAXIMUM
MINIMUM
MAXIMUM
CRANKPINS
114045

PRELIMINARY DATA READING FOR SELECTING THE MAIN AND BIG END
HALF-BEARINGS
For each of the journals of the crankshaft, it is necessary to carry out the following operations:
MAIN JOURNALS: CRANKPINS:
- Determine the class of diameter of the seat in the crank- - Determine the class of diameter of the seat in the con-
case necting rod
- Determine the class of diameter of the main journal - Determine the diameter class of the crankpin
- Select the class of half-bearings to install. - Select the class of half-bearings to install.
DEFINING THE DIAMETER CLASS OF THE SEATS FOR HALF-BEARINGS ON THE CRANKCASE
On the front of the crankcase, two sets of numbers are marked in the position shown (Figure below, at the top):
- The first set of digits (four) is the coupling number of the crankcase with the respective cap (Figure below, at the bottom);
- the following seven digits, taken individually, represent the diameter class of each of the seats to which they refer (Figure
below, at the bottom);
- Each of these digits may be 1, 2 or 3.
Figure 60
RATED DIAMETER OF
CLASS
MAIN BEARINGS
99.000  99.009
99.010  99.019
99.020  99.030
114046

Selecting the main and big end half-bearings

NOTE To obtain the required assembly clearances, the main and big end half-bearings need to be selected as described
hereunder.
This operation makes it possible to identify the most suitable half-bearings for each of the journals (the half-bearings, if necessary,
can have different classes from one journal to another).
Depending on the thickness, the half-bearings are selected in classes of tolerance marked by a coloured sign (red-green - red/black
- green/black).
The following tables give the specifications of the main and big end bearings available as spares in the standard sizes (STD) and
in the permissible oversizes (+0.127, +0.254, +0.508).
Figure 61
STD +0.127
red 1.994  2.002
red/black 2.057  2.065
green 2.002  2.010
green/black 2.065  2.073
yellow* 2.010  2.018
yellow/black* 2.073  2.081
STD +0.127
red 2.965  2.974
red/black 3.028  3.0371
green 2.975  2.984
green/black 3.038  3.0471
yellow* 2.985  2.995
yellow/black* 3.048  3.058
* Fitted in production only and not supplied as spares

DEFINING THE DIAMETER CLASS OF THE MAIN JOURNALS AND CRANKPINS

(PINS WITH NOMINAL DIAMETER)
Main journals and crankpins: determining the class of diameter of the journals.
Three sets of digits are marked on the crankshaft in the position shown by the arrow (Figure below, at the top):
- The first number, of five digits, is the part number of the shaft
- Under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit showing the status
of the journals (1 = STD, 2 = -0.127), the other six digits, taken individually, give the class of diameter of each of the crankpins
they refer to (Figure below, at the top);
- The set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit shows the
status of the journals (1 = STD, 2 = -0.127), the other seven digits, taken individually, give the class of diameter of each of
the main journals they refer to (Figure below, at the bottom).
Figure 62
CRANKPINS
CLASS
NOMINAL DIAMETER
81.915  81.924
81.925  81.934
81.935  81.945
CLASS NOMINAL DIAMETER

MAIN JOURNALS
92.970  92.979
92.980  92.989
92.990  93.000

Main half-bearing selection (nominal diameter pins)
After detecting, for each journal, the necessary data on crankcase and crankshaft, select the type of half-bearings to be used, in
compliance with the following table:
Figure 63
STD.
114048
1 2 3
green green yellow
1
green yellow yellow
red green green
2
green green yellow
red red green
3
red green green
114055

Main half-bearing selection (rectified)

If the journals have been rectified, the procedure described up until this point cannot be applied.
In this case, make sure that the new diameter of the journals is as specified on the table and install the only half-bearing type
required for this undersizing.
Figure 64
red/black =
mm 3.028  3.037
green/black = -0.127
mm 3.038  3.047
yellow/black =
mm 3.048  3.058
1 2 3
92.843 green/black green/black yellow/black
92.852 1
green/black yellow/black yellow/black
92.853 red/black green/black green/black

92.862 2
green/black green/black yellow/black
92.863 red/black red/black green/black

92.872 3
red/black green/black green/black

BIG END HALF-BEARING SELECTION Figure 65

(NOMINAL DIAMETER PINS)
On the connecting rod body, there are 4 markings in the

positions indicated in the figure:
1. Coloured mark to identify weight
2. Coloured mark to identify diameter class
3. Positioning socket visible from the front end of the
engine
4. Progressive number for identifying connecting rod
NOTE The identification colours of the brands are indica-

ted in the table in the paragraph CONNECTING
ROD.
Identify the type of big end half-bearing to be fitted on each

pin by following the indications in the table (Figure below).
193968
Figure 66
STD.
Class 1 2 3
yellow green blue
green green yellow

1
green yellow yellow
red green green
2
green green yellow
red red green
3
red green green

Big end half-bearing selection (rectified crankpins)

If the journals have been rectified, the procedure described up until this point cannot be applied.
In this case, it is necessary to check (for each of the undersizings) which field of tolerance includes the new diameter of the crank-
pins and to mount the bearing shells identified with the relevant table.
Figure 67
red/black =
mm 2.057  2.065
green/black = -0.127
mm 2.065  2.073
yellow/black =
mm 2.073  2.081
1 2 3
81.788 green/black green/black yellow/black
81.797 1
green/black yellow/black yellow/black
81.798 red/black green/black green/black

81.807 2
green/black green/black yellow/black
81.808 red/black red/black green/black

81.818 3
red/black green/black green/black

Replacing the timing and oil pump control gear Checking crankshaft shoulder clearance
Check that the teeth of the gears are not damaged or worn
and, if they are, remove them using the appropriate extractor. Figure 69
Figure 68
114049
Fit the oil spray nozzles (2), making the dowel match the hole
(3) on the crankcase and tighten the screws to torque.
144834

NOTE Before fitting the gear, smear a 5 mm wide band of
Loctite 603 on the crankshaft 30 mm from the (2) 6 M14x2x18 50  5 Nm
shim.
Check that the teeth of the gears are not damaged or worn
and, if they are, remove them using the appropriate extractor.
Fit the half-bearings (1) and the half ring thrust bearing on
main journals as shown in the figure.
When fitting the gear (1) on the crankshaft (2), heat it for
approximately 15 minutes in the oven at a temperature of no
more than 180 ˚C.
Let it cool down after pressing.

Figure 70 Figure 72
114034
Using tool 99360500 (1) and a suitable hoist, fit the crank-
shaft (2) on the crankcase.
191584
Fit the main bearing caps (4) and the stiffening plate (2).
Screw in but do not tighten the screws (3 and 1) starting from
Figure 71 main bearing cap 7 to main bearing cap 1.
Tighten the screws (3 and 1) to the torque indicated in the
table.
3 14 M16x2x168
1st phase 140  7 Nm
2nd phase 60˚
3rd phase 60˚
1 8 M10x1.5x20 49  3 Nm
Figure 73
114050
Fit the half-bearings (1) on the main bearing caps (2).

Thoroughly clean the parts and remove any trace of oil.
208346
End float is checked by placing a magnetic stand dial gauge

(1) on the crankshaft (2), as shown in the figure. If the value
obtained is higher than specified, replace the rear big end half-
bearings and repeat this check.

Connecting rod and piston assembly

Figure 74
193957
PISTON-CONNECTING ROD ASSEMBLY

1. Connecting rod body - 2. Half-bearings - 3. Connecting rod cap - 4. Cap fastening screws - 5. Circlip - 6. Slotted oil
scraper ring with spiral spring - 7. Claw seal ring - 8. Trapezoidal seal ring - 9. Piston pin - 10. Piston
Make sure the pistons do not show any sign of seizing, scoring, cracking or excessive wear; otherwise, replace them
Pistons are equipped with three circlips: the first is a sealing ring, with a trapezoidal section; the second is a sealing ring with cham-
fer cut; the third
oil scraper.
Pistons are grouped into classes A and B for diameter.

Disassembly of connecting rod and piston Figure 77

Figure 75
49026
126311 Remove the piston pin (1).

Removal of piston circlips (2) using caliper 99360183 (1). If removal is difficult use the appropriate drift.
Figure 76
126312
The pin retaining circlips (2) are removed using a suitable cal-
liper (1).

Main data of piston assembly

Figure 78
208324
MAIN DATA ON THE PISTON, CIRCLIPS, AND FEDERAL MOGUL PIN
Figure 79
208325
MAIN DATA ON THE PISTON, CIRCLIPS, AND MAHLE PIN

Checking piston diameter Checking the circlips

Figure 80 Figure 82
32615
16552
Using a micrometer (2), measure the piston diameter (1) to Check the thickness of the piston rings (2) with a micrometer
determine the assembly clearance. (1).
NOTE The diameter is to be measured at 15.0 mm from

the piston skirt end.
Figure 83
Checking the piston pins

Figure 81
32620
Check the clearance between the sealing rings (3) of the 2nd
and 3rd slot and the relative seats on the piston (2), using a
feeler gauge (1).
18857
Measuring the piston pin diameter (1) with a micrometer (2).

Figure 84 Checking the connecting rod and bushes
NOTE The connecting rods have a determined fracture

point and are supplied already fractured together
with the screws fastening the caps; the connecting
rod caps are not interchangeable because the pro-
file of the fracture varies from component to com-
ponent.
41104
DIAGRAM FOR MEASURING THE CLEARANCE X

BETWEEN THE FIRST PISTON SLOT AND THE
TRAPEZOIDAL RING
Since the first piston ring section is trapezoidal, the clearance
between the slot and the ring is to be measured as follows:
make the piston (1) protrude from the crankcase so that the
ring (2) protrudes half-way from the cylinder liner (3).
In this position and using a feeler gauge, check that the clea-
rance (X) between the ring and the slot falls within the pre-
scribed values.
Figure 85
204330
Check the end gap of the sealing rings (1), using a feeler gauge
(2), entered in the cylinder liner (3).
If the distance between the ends is lower or higher than the
required value, replace the circlips.

When installing connecting rods, make sure they all belong to the same weight class and of the same supplier.
The connecting rod/cap is of the “fractured” type; before assembly, check that the connecting rod is not ruined. Each
connecting rod may only be mounted with its cap. If the cap is mounted backwards, the connecting rod must be discar-
ded.
Figure 86
52.015-52.030
23.60.2
( 56.8)
R38.50.5
10.5
Ř52.015-52.030
R45
207 0.025
40
(860.013)
22
2x45
43
+0.1
0
0
470.5
-0.4
51.50.08
70
Ř12.3
750.5
+10
51.50.08
62.1
204278
MAIN DATA FOR THE BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS
NOTE All the measurements indicated in the figure must be checked when the bushing is assembled and processed.
1. A free area of less than 5 mm2 is allowed on the external fracture line.
2. No cracks are allowed in the threaded area.
NOTE Make sure that the diameters of the connecting rod small end bush are included in those specified in section 8: DATA
- ASSEMBLY CLEARANCES - CYLINDER ASSEMBLY AND CRANK MEMBERS
Otherwise replace the connecting rod.

Figure 87
193969
1. Coloured mark to identify weight - 2. Coloured mark to identify diameter class -

3. Positioning stud visible from the front of the engine - 4. Progressive number for identifying connecting rod
WEIGHT DIAMETER
85.987-85.996 Yellow
CLASS A
3,308 g - 3,338 g 85.997-86.005 Green
Yellow
86.006-86.013 Blue
85.987-85.996 Yellow
CLASS B
3,339 g - 3,368 g 85.997-86.005 Green
Green
86.006-86.013 Blue
85.987-85.996 Yellow
CLASS C
3,369 g - 3,398 g 85.997-86.005 Green
Blue
86.006-86.013 Blue

Connecting rod and piston assembly Figure 90

Figure 88
126312
70198 Fit the circlips (2) securing the pins using a suitable caliper (1).
The piston crown is marked as follows:
1. Spare part number and design modification number. Figure 91
2. Arrow showing piston cylinder liner assembling direction
into cylinder liners. This arrow is to face the front side of
the crankcase.
3. Marking showing 1st slot insert testing.
4. Manufacturing date.
Figure 89
49029
Use caliper 99360184 (3) to fit the circlips (1) on the piston
(2).
The rings need to be mounted with the word ”TOP” (4)
facing upwards; direct the openings of the circlips so they are
offset by 120˚.
Figure 92
102596
Connect the piston (2) to the connecting rod (4) with pin (3)
so that the reference arrow (1) for fitting the piston (2) into
the cylinder liner and the numbers (5) stamped on the con-
necting rod (4) are as shown in the figure.
115885
Mount the half bearings (1) on both the connecting rod and
the cap.

Crankpin fitting clearance check

NOTE If the same big-end bearings are to be reused, refit Place a piece of calibrated wire on the crankpins (Plastigage).
them in the same order and position as when they
were removed.
Figure 94
Do not make any adjustment on the half-bearings.
NOTE The pistons are supplied as spare part in class A and

can also be fitted in class B cylinder liners.
Figure 93
115886
Fit the connecting rod caps (1) together with half-bearings

and tighten the screws (2) to the torque indicated in the table
using tool 99395216 (3).

2 12 M12x1.25x69
1st phase 50  2.5 Nm
2nd phase 90˚
208347
Using tool 99360605 (1), fit the connecting rod-piston

assemblies (2) in the cylinder liners checking that: Unscrew the screws (2), remove the connecting rod caps (1)
- The circlip’s openings are offset from one another by and identify the clearance by comparing the width of the cali-
120˚; brated wire with the graduation of the scale supplied.
- all pistons belong to the same class, A or B; Refit the connecting rod caps as described above.
- the ideogram stamped on the piston crown is facing the

engine flywheel; or the recess in the piston skirt matches
the position of oil nozzles. Cylinder head
Cylinder head hydraulic seal check
Check the hydraulic tightness using a suitable tool.
Replace if there are any leaks from the cylinder head.
NOTE After assembly, check that the protrusion of the
pistons from the cylinder liners is within the prescri-
bed values.
NOTE Before fitting, smear the plug surfaces with sealant
LOCTITE 270.

Cylinder head contact surface check Descaling, checking and grinding valves
Figure 95 Figure 97
208344
204301
The planarity (1) is checked using a ruler (2) and a feeler
gauge (3). If deformations exist, surface the head using proper Remove all carbon deposits from the valves using a wire
surface grinder; the maximum amount of material to be brush.
removed is 0.2 mm. Check that the valves show no signs of seizing, cracks or
burns.
Use a micrometer to check that the valve stem diameter falls
within the prescribed values; Otherwise, replace valves.
NOTE After this operation, check the valve recessing and

injector protrusion.
Intake and exhaust valves Valve springs

Figure 96
Figure 98
92841
114215
MAIN DATA - VALVES AND VALVE GUIDES
INTAKE AND EXHAUST VALVE SPRING MAIN DATA
* Measurement obtained after fitting the valve guides
Using a micro-meter, measure the valve stem and check that
it falls within the prescribed values; grind the valve seats, if
required, using a valve seats grinding machine and removing
as little material as possible.

Valve guides
Figure 99
191585
INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES

* Measurement to be obtained after driving in the valve guides
Replacing the valve guides
Remove valve guides by means of drift 99360288.
Assembly is carried out with the drift 99360288 equipped with part 99360294.
Part 99360294 determines the exact valve guide fitting position in cylinder head; if these are not available, the valve guides should
be mounted in the cylinder head so that they protrude from it by 16.3 - 16.7 mm (previous Figure).
After installing the valve guides, smooth their holes with sleeker 99390310.

Valve seats Timing system

Regrinding and replacing the valve seats Timing system drive
193958
41032
Check the valve seats (2). If they are scored or burnt, regrind TIMING CONTROL COMPONENT PARTS
using the tool (1). 1. Camshaft - 2. Bush - 3. Pin - 4. Articulated rod -
5. Camshaft control gear - 6. Transmission gear -
7. Double idle gear - 8. Crankshaft driving gear.
NOTE The valve seats are reground whenever the valves
or valve guides are ground and replaced.
After regrinding the valve seats, use tool 99370415 to make

sure that the valve position in relation to the cylinder head
surface is:
- -0.5 - -0.8 mm (recessing) of intake valve;
- -1.65 - -1.95 mm (recessing) of exhaust valves.
Checking protrusion of injectors

Figure 101
47585
Check injector protrusion (2) with the dial gauge (1).

The protrusion must be 1.53 mm.

Camshaft
Figure 103
1x45
6.3
6.3
6.3 12.5 1.6 6.3
80 0.02
0.010
0.029
0.2
0
65
62
0.25
204131
MAIN CAMSHAFT DATA
The surfaces of the supporting pins of the shaft and those of the cams need to be extra smooth; if they show any signs of seizing
or scoring, the shaft and the relevant bushings should be replaced.
TOLERANCES TYPICAL TOLERANCE GRAPHIC SYMBOL

ORIENTATION Perpendicularity ┴
POSITION Concentricity or coaxiality
OSCILLATION Circular oscillation
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL 
IMPORTANT
SECONDARY

Figure 104
208330
MAIN DATA FOR THE CAMSHAFT BUSHES AND RELATIVE SEATS ON THE CYLINDER HEADS
* Bush inner diameter after installation
The surface of the bushings must show no sign of seizing or scoring; replace them if they do.
Measure the bush inner diameters with a boremeter and replace them, if the value measured exceeds the tolerance value.
To take down and fit back the bushes, use the proper drift 99360505.

Transmission gear pins Double transmission gear

208327
204132
The bushings (1) can be replaced when they are worn. After
Transmission gear pin driving the bushing, grind to bring it to Ø 65.010 - 0.10 mm.
Figure 106
NOTE Bushings must be driven into gears (2, previous

figures) following the direction of the arrow and be
positioned at the position shown in the previous
figures.
208328
Double transmission gear pin Checking cam lift and camshaft pin alignment
Rated assembly clearance between transmission gear
bushings/pins: 0.040 - 0.080 mm. Figure 109
Transmission gear
Figure 107
47506
Place the camshaft (4) on tailstocks (1) and using a centesimal

dial gauge (2) check that the lift value of the cams (3) is as
indicated in the DATA - ASSEMBLY CLEARANCE table.
208326

Figure 110 Bushing replacement
Figure 112
47507
Still with the camshaft (4) set on tailstocks (1), check the ali- 114280
gnment of the supporting pins (3) with the centesimal dial
gauge (2); it must not exceed 0.030 mm. To check the assem- Remove the bushings (2) with tool 99360505 (3) fitted as
bly clearance, measure the inside diameter of the bushings shown in the figure.
and the diameter of the journals of the camshaft. Position the drift accurately during the phase of removal.
To assemble, carry out the operations for removal but in the
reverse order making sure that the lubrication hole (1) on the
bushing is in line with the corresponding seat.
Figure 111
47505
To check the assembly clearance, measure the internal dia-

meter of the bush and the camshaft pin diameter (1), the dif-
ference represents the clearance.
If clearance exceeds 0.150 mm, replace the bushes and, if
necessary, the camshaft.

Rocker shaft
Figure 113
114216
The camshaft cams directly control the 12 rocker arms for the valves. The valve rocker arms are fitted directly onto the rocker
shaft. Rockers slide directly on the cam profiles via rollers. The other end acts on a bar directly supported by the two valves stems.
A pad is placed between the rocker adjusting screw and the bar. Two lubrication holes are obtained inside the rockers. The rocker
arm shaft covers practically all of the cylinder head; it has to be detached completely to reach all parts beneath.
Figure 114
114217
MAIN ROCKER ARM SHAFT DATA

Check the shaft surface shows any trace of scoring or seizure; otherwise, replace it.

Figure 115
114219
EXHAUST VALVE ROCKER ARM
Figure 116
114218
ROCKER ARM FOR INTAKE VALVES

Check the surfaces of the bushings for signs of scoring or excessive wear; if they are present, replace the rocker arm assembly.

ENGINE ASSEMBLY AT BENCH Figure 118

(CRANKCASE COMPONENTS)
NOTE The internal components of the crankcase, liners,

crankshaft, piston-connecting rod are in the chap-
ter ”Tests and Checks”.

(COMPONENTS AT THE TOP - PART 1)
Installing cylinder head
Refitting valves and springs
Figure 117
86290
Fit the springs (6) and the upper plate (5).

Fit tool 99360264 (2) and the bracket (4).
Screw in the lever (1), fit the cotters (3) and remove the tool
(2).
Installing cylinder head

Figure 119
87051
Lubricate the valve stem.

Fit the valves into the respective valve guides.
192068
Fit the lower plates (1). Check that pistons 1-6 are exactly at the T.D.C.
Use keying device 99360292 fit the oil seal (2) on the valve Fit the seal (2) on the crankcase.
guides (3) of the exhaust valves.
Fit the cylinder head (1), fit the new screws and tighten them
Fit the valves as follows. in four stages as indicated in the table following the order and
manner shown in the following figure.
NOTE Should valves not have been overhauled or repla-

ced, remount them according to numbering per- Use new cylinder head fastening screws.
formed on dismounting.
Intake valves are different form exhaust valves in
that they have a notch placed at valve head centre.
(-) 26 M16x2x170
1st phase 50 ± 2.5 Nm
2nd phase 100 ± 2.5 Nm
3rd phase 90˚
4th phase 75˚

Figure 122
NOTE Use tool 99395216 for the angle tightening.
Figure 120
204123
Refitting the rail - electro-injector

Figure 121
169828
Fit the electro-injector (1) on the cylinder head together with

the bracket and gasket (2).
Tighten the screw on the electro-injector bracket to the tor-
(-) 1 M10x1.5x40 46 ± 3 Nm
169832
Fit the rail (2) and the spacers (3) on the cylinder head.
NOTE During assembly of the high pressure fuel pipes,
proceed with the utmost caution.
(1) 3 M8x1.25x45 23 ± 2 Nm
Lubricate the O-Ring securing the electro-injector

with lubricants PDE SILIKONFETT 22, NLG 12, PDE
LUBRICOMET GR 220 NLG12.

Figure 123 Refitting the rocker arm shaft

Fit the bridges on the valve stem.
NOTE Before re-installing the rocker-arm shaft assembly,

fully unscrewed.
Figure 124
193949
Fit the new pipes (1) connecting the rail to the electro-injec-
table.

(1) 6 M18x1.5 40 ± 2 Nm
(1) 6 M14x1.5 35 ± 2 Nm
Fit the new fuel return pipe (2) between the intermediate fit- 192075
ting and the rail and tighten the fittings to the torque indicated
in the table. Fit the tool 99360558 (1) on the rocker arm shaft (2).
Ref. No. Description Tightening torques Fit the rocker arm shaft (2) on the cylinder head and tighten
the screws to the torque indicated in the table following the
(2) 1 M18x1.5 40 ± 2 Nm
order shown in the following figure.
(2) 1 M14x1.5 35 ± 2 Nm
Fit the new fuel return pipe (3) and tighten the fittings to the
torque indicated in the table. Ref. No. Description Tightening torques
(2) 7 M12x1.75 x130 105 ± 10 Nm
(3) 1 M16x1.5 35 ± 2 Nm
(3) 1 M14x1.5 35 ± 2 Nm

them from being damaged as a result of the high Figure 125
stress caused by the engine vibrations.
The MINIMUM distance between the individual
204133

ASSEMBLY OF ENGINE AT BENCH Refitting engine flywheel housing

(COMPONENTS AT THE REAR)
Figure 128
Refitting oil pump - double gear
Figure 126
192069
Clean the coupling surfaces in order to remove any impurities

145833 and oil residue. Apply LOCTITE 5970 (2) silicon on the gear
housing (1) as shown in the figure.
Fit the oil pump (1) and tighten the screws to the torque indi-
cated in the table. The sealant bead diameter is to be 1.3 ÷ 2 mm.
(1) 5 M8x1.25x60 25 ± 2 Nm
(1) 3 M8x1.25x45 25 ± 2 Nm
Figure 127 Fit the gear housing within 10 minutes of applying

! the sealant.
Figure 129
5 1
4
2
3 3
299456
225096
Fit the engine flywheel housing and using a torque wrench
Follow the tightening sequence indicated in the figure. tighten the screws (1) to the torque indicated in the table.
Fit the articulated rod (4) and screw in but do not tighten the
relative screw. Ref. No. Description Tightening torques
Fit the double gear (3) and tighten the screws (2) to the tor- (1) 2 M12x1.75x193 63 ± 7 Nm
(2) 1 M10x1.5x80 63 ± 7 Nm
Ref. No. Description Tightening torques (3) 7 M12x1.75x80 63 ± 7 Nm
(2) 3 M12x1.75x90 (4) 2 M12x1.75x193 63 ± 7 Nm
1st phase 30 Nm
2nd phase 90˚ (5) 1 M8x30 42 ± 3 Nm

Refitting engine flywheel Figure 131
NOTE If the teeth of the crown wheel fitted on the engine

flywheel are damaged, replace the crown wheel.
It must be fitted after heating the crown wheel to
a temperature of approx. 200˚C. α
Figure 133
145832
Position the flywheel (1) on the crankshaft, lubricate the

thread of the screws (2) with engine oil and screw them
down.
Lock rotation with tool 99360351.
Using the torque wrench (3), tighten the screws (2) to the
(1) 8 M18x1.5x120
1st phase 120 ± 5 Nm
2nd phase 150˚
203848
Fit the seal ring (1) on tool 99346260 (2) and tighten the nut
(3) until flush.
Refitting camshaft
Figure 132
NOTE The crankshaft has a centring pin that has to couple
with the relevant seat on the flywheel.
Figure 130
193964
Position the crankshaft with the pistons 1 and 6 at the top

dead centre (T.D.C.).
This situation occurs when:
1. the hole of the engine flywheel (4) with a reference mark
(5) can be seen through the inspection window.
192071
2. The tool 99360612 (1), through the seat (2) of the
A. Hole on the flywheel with a reference mark, correspon- engine speed sensor, enters the hole (3) in the flywheel
ding to the TDC of pistons 3-4 - B. Hole on the flywheel (4).
with reference mark, corresponding to the TDC of pistons
1-6 - C. Hole on the flywheel with reference mark, corre- If this condition does not occur, turn the engine flywheel (4)
sponding to the TDC of pistons 2-5 - D. Hole on flywheel as necessary.
with two reference marks, position corresponding to 54˚. Remove tool 99360612 (1).
114269
Fit gauge 99395222 (1), check and adjust the position of the
transmission gear articulated rod (3), tighten the screw (2).
Figure 136
114267
Fit the camshaft (3), positioning it with the reference marks

() as shown in the figure.
Clean the coupling surfaces of the plate (1) in order to
remove any impurities and oil residue.
Apply LOCTITE 5970 (6) silicone to the plate (1) as shown
in the figure.
NOTE Make sure NO sealant is deposited on the inner

groove (5).
The sealant bead diameter is to be 1.3 - 2 mm.

114270
Fit the shoulder plate (1) within 10 minutes of applying the
sealant with the gasket (2) and tighten the screws (4) to the Fit the transmission gear (2) and using a splined wrench
torque indicated in the table. tighten the screws (1) to the torque indicated in the table.
Ref. No. Description Tightening torques (1) 3 M12x1.5 25 ± 5 Nm
(4) 5 M8x1.25x20 20 ± 2 Nm
NOTE Replace the transmission gear bushing (2) when

wear is detected. After driving the bushing, grind to
bring it to 58.010 ± 0.10 mm.
Fit the pressure pump coupling flange.

Camshaft timing with tool 99395223 Figure 139

Figure 137
192073
Rotate the tool 99395223 (1) so that the pin (3) enters the
hole (2, previous Figure) on the head.
Secure the tool 99395223 (1) using two screws (2) M8x1.25.
193960
Rotate the crankshaft with tools 99360321 and 99360325 so

that the hole marked with two notches (5) is visible through
Figure 140
the inspection window of the flywheel housing.
Insert tool 99360612 (1) into the hole (3) on the flywheel
housing (4) through the engine speed sensor seat (2).
α
Figure 138
117691
Fit the camshaft drive gear (1) so that the fastening holes on
the shaft coincide with the slots (2) on the drive gear.
Fit the gear (1) making sure that the spokes (4) are positioned
as shown in the figure.
NOTE This operation is necessary so that the phonic

192072 wheel, which has only one assembly position in
Fit the tool 99395223 (1) on the front of the camshaft. relation to the gear, can be fitted correctly.
Tighten the camshaft drive gear fastening screws (3) to the


(3) 4 M10x1.5x45
2nd phase 45˚

Phonic wheel timing with tool 99395223 Camshaft timing without tool 99395223
145834
Fit the high pressure pump gear (5) and tighten the nut (4)

(4) 1 M18x1.5 105 ± 5 Nm
Together with the nut (4) use the flat washer (P/N
17095914) in place of the one supplied with the pump.
Fit the phonic wheel (6) so that the tooth marked with the
arrow () corresponds with the timing sensor seat (2).
192079
In order to check the correct positioning, insert the tool
99360613 (1) into the timing sensor seat (2). Fit tool 99360321 on the gear housing for the engine fly-
wheel rotation.
NOTE The arrow shows the direction of rotation of the

Ref. No. Description Tightening torques engine when running.
(6) 3 M8x1.25 23 ± 2 Nm
Turn the engine flywheel (1) in the direction of the engine

Remove tools 99395223, 99360612 and 99360613. rotation so as to bring cylinder piston 1 to 54˚ before the
T.D.C. during compression (cylinder 6 in discharge phase).
This condition occurs when the hole with two notches (3)
on the engine flywheel (1), can be seen through the small
inspection window (2).

117691
Fit the camshaft drive gear (1) so that the fastening holes on
71774 the shaft coincide with the slots (2) on the drive gear.
The exact position of piston 1 at 54˚ before T.D.C. is obtai- Fit the gear (1) making sure that the spokes (4) are positioned
ned when, under the conditions described above, the tool as shown in the figure.
99360612 (1) is inserted into the hole (3) on the engine fly-
wheel (4) through the engine speed sensor seat (2).
If this is not the case, turn and adjust the engine flywheel (4)
appropriately. NOTE This operation is necessary so that the phonic
Remove tool 99360612 (1). wheel, which has only one assembly position in
relation to the gear, can be fitted correctly.
Figure 144
Tighten the camshaft drive gear fastening screws (3) to the

(3) 4 M10x1.5x45
2nd phase 45˚
Figure 146
115063
Turn the camshaft so that the holes on the rear side of the
engine are positioned as indicated in the figure. 185253
Fit the dial gauge (1) with the flat based rod (3) on the roller
(4) of the rocker arm controlling the discharge valve of cylin-
der 3 and preload it to at least 7 mm.

Figure 148
NOTE Position the flat based dial gauge rod (see detailed
part) so that its axis passes through the centre of
the roller on which it is resting. During the CHECK
phase, not during the engine overhaul phase, the
allowed tolerance of the measurement is between
-0.05 - +0.12 mm. During OVERHAUL, the allo-
wed tolerance is ± 0.05 mm.
Figure 147
115064
The camshaft is set if at cam lift values of 4.70 ± 0.05 mm fol-

lowing conditions occur:
1) the hole marked with two notches (5) can be seen from
the small inspection window;
177714 2) The tool 99360612 (1) inserts in the hole (3) in the
With tool 99360321, turn the engine flywheel clockwise until engine flywheel (4) through the seat (2) of the engine
the pointer of the dial gauge reaches the minimum value speed sensor.
beyond which it can no longer fall.
Figure 149
NOTE The measurement is to be taken keeping the roc-
ker arm roller in contact with the profile of the
exhaust cam on the camshaft. The dial gauge is to
be zeroed with the rocker arm roller in contact
with the base radius of the cam profile.
reset the dial gauge.

Turn the engine flywheel anticlockwise until the camshaft
cam lift is 4.70 ± 0.05 mm.
114281
If the conditions shown in the previous figure and described

in points 1 and 2 are not obtained, proceed as follows:
- turn the engine flywheel until the required cam lift value
appears on the dial gauge;
- loosen the screws (2) securing the camshaft gear (1) so
that the drive gear and camshaft are independent of each
other;
- turn the flywheel appropriately so as to bring about the
conditions described in points 1 and 2 (previous figure)
with of course the cam lift remaining the same;
- use the slots on the gear (1); Lock the screws (2) and
repeat the check as described above.
- Tighten the screws (2) to the torque specified in the
table.

Ref. No. Description Tightening torques Figure 151

(2) 4 M10x1.5x45
2nd phase 45˚
NOTE While performing this operation recover the clea-

rance between the camshaft gears.
α
When adjustment via the slots is not sufficient for recovering
the offset, proceed as follows:
- Lock the screws (2) and turn the flywheel 1/2 turn in a
clockwise direction.
- Turn the engine flywheel anticlockwise until the cam-
114281
shaft cam lift is 4.70 ± 0.05 mm.
Fit the gear (1) with the four slots centred in relation to the
- Unscrew the screws (2) and remove the gear (1) from camshaft fastening holes and tightening the relevant screws
the camshaft. (2) to the torque indicated in the table.
(2) 4 M10x1.5x45
2nd phase 45˚
Recover the clearance between the timing gears by turning

Figure 150 the flywheel first clockwise and then anticlockwise until the
dial gauge shows the value of 4.70 ± 0.05 mm. Check the con-
ditions described above.
185523
Turn the flywheel (4) again until it reaches the following con-
ditions:
- the hole marked with two notches (5) can be seen from
the small inspection window;
- The tool 99360612 (1), through the seat (2) of the
engine speed sensor, enters the hole (3) in the engine
flywheel (4).

Phonic wheel timing without tool 99395223 Refitting pressure pump

192060
Fit the pressure pump (2) and tighten the screws (1) to the
(1) 3 M8x1.25x40 30 ± 5 Nm
Fit the timing sensor and tighten the screw to the torque indi-
cated in the table.
(-) 1 M6x1x12 9 ± 1 Nm
Fit the rpm sensor and tighten the screw to the torque indica-
ted in the table.
114284
Fit the high pressure pump gear (7) and tighten the nut (8) Ref. No. Description Tightening torques
to the torque indicated in the table. (-) 1 M6x1x12 9 ± 1 Nm

(8) 1 M18x1.5 105 ± 5 Nm Figure 154
NOTE During assembly, use the nut together with the flat
washer in place of the one supplied with the high
pressure pump.
Turn the flywheel in an anticlockwise direction until the

inspection window (3) corresponds with the hole marked
with 2 notches (2) (cylinder 1 compressing).
Insert tool 99360612 (1) through the rpm sensor seat.
Fit the phonic wheel (4) so that the tooth marked with the
arrow () corresponds with the sensor seat (6).
In order to check the correct positioning, insert the tool
208335
99360612 (1) into the timing sensor seat (6).
Fit the rotating filter (3) on the phonic wheel and tighten the
Tighten the screws (5) to the torque specified in the table. screws to the torque indicated in the table.
(3) 3 M6x1x16 9 ± 1 Nm
(5) 3 M8x1.25 23 ± 2 Nm
Fit the cover (1) and tighten the screws (2) to the torque indi-
Remove tools 99360612 and 99360321. cated in the table.

Ref. No. Description Tightening torques NOTE To perform adjustments correctly, the order indi-
(2) 3 M6x1x16 9 ± 1 Nm cated in the table must be followed; check the
accuracy of position during each rotation phase
Fit the hydraulic pump for the viscostatic fan, complete with
using the pin 99360612.
the support (5) and tighten the screws (4) to the torque indi-
cated in the table.
(4) 3 M10x1.5x26 -
Adjustment of clearance between the intake ASSEMBLY OF ENGINE AT BENCH
and exhaust rocker arms (COMPONENTS AT THE TOP - PART 1)
Figure 155 Refitting blow-by valve
Figure 156
114287

bridges controlling the intake and exhaust valves must be
204128
done very carefully. Take the cylinder whose clearance has
to be adjusted into the combustion phase; the valves of this Fit the blow-by valve body (2) together with a new gasket and
cylinder are closed as they balance those of the symmetric tighten the screws (1) to the torque indicated in the table.
cylinder. Symmetric cylinders are 1-6, 2-5 and 3-4. Ref. No. Description Tightening torques
In order to carry out these operations correctly, follow the (1) 3 M6x1x20 9 ± 1 Nm
instructions provided and specified on the table.
- Use a polygonal wrench to loosen the locking nut (1) of
the rocker arm adjusting screw (2). NOTE The blow-by valve body must be fitted perfectly in
- Insert the strip of feeler gauge (3) corresponding to the line with the camshaft so as to avoid any damage
working clearance as indicated in the table ”Data - to the gasket.
Assembly Clearance”.
priate wrench; Figure 157
friction;
- Tighten the nut to a torque of 34 - 44 Nm.
CLOCKWISE BALANCING ADJUSTING

START-UP CYLINDER CLEARANCE
AND VALVES NO. OF CYLINDER
ROTATION VALVE NO.
1 and 6 at TDC 6 1
120˚ 3 4
120˚ 5 2
115880
120˚ 1 6
Fit the electro-injector-rail wiring and secure it with the clips
120˚ 4 3 as shown in the figure.
120˚ 2 5


(COMPONENTS AT THE BOTTOM)
Refitting engine oil sump - suction strainer
Figure 158
117695
Rotate the engine. Before fitting the suction strainer it is essential that the contact area (1) between the crankcase, flywheel hou-
sing and front cover is sealed with LOCTITE following the indications below. Clean the coupling surfaces in order to remove
any impurities and oil residue. Apply LOCTITE 5970 (1) silicone as shown in the figure. The sealant bead diameter is to be 1.5
± 0.5/0.2 mm.
192063 204241
Fit the suction strainer (1) and tighten the screws to the tor- Fit a new gasket and spacers (2).
Fit the engine oil sump (3) and tighten the screws (1) to the
(1) 3 M8 20 ± 2 Nm Ref. No. Description Tightening torques
(1) 26 M10x1.5x50 44 ± 4 Nm

Tighten the engine oil drain plug together with the new Refitting Intarder
gasket to the specified torque.
Figure 163
(-) 1 M22x1.5 40 ± 10 Nm
ENGINE ASSEMBLY AT BENCH

(SIDE VIEW OF COMPONENTS - PART 1)
Refitting exhaust manifold
Figure 161
192065
Fit the Intarder pipes (3) and tighten the screws (1, 2) to the
(1) 2 M10x1.5x130 20 ± 2 Nm
(2) 2 M8x1.25x16 23 ± 2 Nm
192066 Refitting water inlet pipe to pump

Fit the exhaust manifold (2) together with the new gaskets Figure 164
and tighten the screws (1) to the torque indicated in the table
and following the order shown in the next figure.
(1) 24 M10x1.5x38 45 ± 5 Nm
Figure 162
192064
Fit the engine coolant pipes (4, 6) and the degassing pipe (5)
and then tighten the fittings to the torque indicated in the
table.
(4) 1 M12x1.5 20 ± 2 Nm
(5) 1 M12x1.5 20 ± 2 Nm
(6) 1 M12x1.5 20 ± 2 Nm
Fit the water inlet pipe to the pump (2) and tighten the
screws (1) to the torque indicated in the table.
(1) 2 M8x1.25 20 ± 2 Nm
204112
Connect the sleeve (3) to the water inlet pipe to the pump
(2) and tighten the relative clip.

ASSEMBLY OF ENGINE AT BENCH ENGINE ASSEMBLY AT BENCH

(COMPONENTS AT THE TOP - PART 2) (SIDE VIEW OF COMPONENTS - PART 2)
Refitting tappet cover Refitting intake manifold
249475
204100
Fit the tappet cover (1) and tighten the screws (2) to the tor- Fit the intake manifold (1) and tighten the screws (2, 3) to the
que indicated in the table. torque indicated in the table.
(2) 20 M6x1x50 10 ± 1 Nm Ref. No. Description Tightening torques
(3) 5 M10x1.5x100 50 ± 5 Nm
(2) 1 M10x1.5x150 50 ± 5 Nm
225091
225092

Refitting fuel pipes ASSEMBLY OF ENGINE AT BENCH

Figure 169
(COMPONENTS AT THE FRONT)
Refitting front cover of crankcase
Figure 170
225086
Fit the fitting (12) on the cylinder head and tighten the 204099
screws.
Clean the coupling surfaces in order to remove any impurities
Fit the fitting (2) on the cylinder head and tighten the fitting and oil residue. Apply LOCTITE 5970 silicone to the cover
to the specified torque. as shown in the figure.
Ref. No. Description Tightening torques The sealant bead diameter is to be 1.5 ± 0.5/0.2 mm.
(2) 1 M16x1.5 35 ± 2 Nm
Fit the return pipes (5) from the pressure pump to the crank-
case and tighten the fittings (3, 6) and the bracket screws (5) Fit the front cover within 10 minutes of applying the
to the specified torque. sealant.
(3, 6) 2 M16x1.5 35 ± 2 Nm
(5) 1 M8x1.25x14 23 ± 2 Nm
Fit the delivery pipes (4) from the pressure pump to the fuel
filter, tighten the fittings (1, 7, 8) and the bracket screws (4)
to the specified torque.
(1, 7, 8) 4 M16x1.5 35 ± 2 Nm
(4) 1 M8x1.25x14 23 ± 2 Nm
Fit the delivery and return pipe from the pressure pump to
the fuel filter, tighten the fittings (9, 11) to the torque indica-
ted in the table and close the retaining collar (10).
(9, 11) 2 M14x1.5 35 ± 2 Nm
Due to the high pressure in the fuel pipes in the section bet-
ween the feed pump to the electro-injectors, do not:
- Re-use the disassembled pipes.

Figure 171 Refitting alternator supports

Figure 173
204106
Fit the crankcase front cover (2) and tighten the screws (1)
(1) 9 M8x1.25x25 19 ± 3 Nm
225079
Fit the alternator supports (4) using the pretensioner and

Figure 172 tighten the screws (3) to the torque indicated in the table.
(3) 4 M10x1.5x50 46 ± 5 Nm
Fit the lower alternator mount and tighten the screws (2) to

(2) 3 M10x30 68 ± 7 Nm
Fit the upper alternator mount and tighten the screws (1) to
(1) 2 M8x35 23 ± 2 Nm
166332
Fit the seal ring (1) on tool 99346265 (2) and tighten the nut
(3) until flush.

Refitting alternators and water pump Refitting crankshaft pulley

191598
Fit the alternator drive belt fixed tensioner (7) and tighten the
screw to the torque indicated in the table.
(7) 1 M10x1.5x70 61.5 ± 6.5 Nm
Fit the bracket (3) together with the new mobile water pump
drive belt tensioner and tighten the screw (1) to the torque
225078
indicated in the table.
Fit the coolant outlet pipe from the cylinder head (11) toge-
ther with the new gasket and tighten the screws (2) to the (2) 2 M8 45 ± 5 Nm
Fit the crankshaft pulley (6), the damper pulley (5) and the
pulley (4) and then tighten the screws to the torque indicated
Ref. No. Description Tightening torques in the table.
(2) 5 M8x1.25x70 23.5 ± 2 Nm
Connect the sleeves (1) and (3) to the engine coolant outlet (5) 6 M12x1.75x60 115 ± 5 Nm
pipe from the cylinder head (11) and tighten the relative col- (6) 6 M14x2x60
lars. 1st phase 70 Nm
2nd phase 50˚
Fit the water pump together with the new gasket and tighten
the screws (4) to the torque indicated in the table. Fit the pipe (8) together with the oil level dipstick and tighten
the fitting (9).
Tighten the screw (1) securing the retaining bracket for the
(4) 4 M8x1.25x25 24 ± 3 Nm oil level dipstick.
Fit the alternators (10) and tighten the screws (7, 8) to the
(7) 1 M12x1.75x160 80 ± 8 Nm
(8) 1 M12x1.75x160 46 ± 5 Nm

Refitting auxiliary device drive belts Fit the engine coolant return and delivery pipes to the air
compressor (4) and tighten the fittings (3) to the torque indi-
Figure 176 cated in the table.
(3) 4 M18x1.5 40 ± 5 Nm
Fit the starter motor (1) and tighten the nuts to the torque
indicated in the table.
(1) 3 M10x1.5 80 ± 8 Nm
Refitting engine management control unit

Figure 178
225105

ners (1) and (5) and fit the belts (2) and (3).
REMOVING THE ENGINE FROM THE

ROTATING STAND
Apply the arm 99360585 to engine lifting hooks, hook the
arm to a suitable hoist and remove the engine from the rota-
ting stand. Remove brackets 99361046.
Refitting starter motor 208311
Fit the contactor (4) and tighten the relative screws.

Figure 177 Fit the engine management control unit (3) and tighten the
screw and the nuts to the torque indicated in the table.
(3) 1 M8x1.25x45 19 ± 3 Nm
(3) 2 M8x1.25 19 ± 3 Nm
Fit the fuel delivery pipe (2) from the pressure pump, tighten
the fittings and the screw (1) of the retaining bracket to the
(1) 1 M8x1.5 24 ±4 Nm
(2) 1 M16x1.5 35±5 Nm
(2) 1 M18x1.5 40±5 Nm
208317 Fit the fuel drain pipe, tighten the screw of the intermediate
Fit the compressor (2) and tighten the screws to the torque retaining collar and tighten the fittings (5) to the torque indi-
indicated in the table. cated in the table.
(2) 3 M12x35 74 ± 8 Nm (5) 2 M16x1.5 35±5 Nm
Fit the power steering pump (5) and tighten the screws to
(5) 2 M10x1.5 44 ± 4 Nm

Refitting heat exchanger Figure 181

Figure 179
204299
193058 Fit the oil pressure control valve (3) and tighten the screws
Fit the heat exchanger (3) to the heat exchanger body and
tighten the screws (5) to the torque indicated in the table. Ref. No. Description Tightening torques
Ref. No. Description Tightening torques (3) 2 M8x1.25 23.5 ± 2.5 Nm
(5) 4 M8x45 23 ± 2 Nm Fit the new filter element (2) and tighten the oil filter body
Fit the heat exchanger body (4) together with the new gasket
(2) and tighten the screws (1) to the torque indicated in the Ref. No. Description Tightening torques
table. (1) 1 - 60 ± 5 Nm
(1) 14 M8x40 23 ± 2 Nm Turbocharger refitting
(1) 3 M8 23 ± 2 Nm Figure 182
(1) 1 M8x55 23 ± 2 Nm
Refitting the engine oil filter support

Figure 180
208306
Fit the turbocharger (2) together with a new gasket and

tighten the nuts (1) to the torque indicated in the table.

249472
(1) 4 M10x1.5 46 ± 2 Nm

(1) 5 M8x1.25x65 34 ± 4 Nm

Figure 183 Fit the engine coolant return and delivery pipes to the engine
brake control actuator (1) and tighten the fittings to the tor-

(1) 4 M12x1.5 25 ± 5 Nm
Connect the electrical connection (4) of the engine brake

Figure 185
208305
Fit the engine brake (2) and tighten the nut on the collar to
(2) 1 M8x70 14 ± 1 Nm


(1) 1 M16x1.5 42.5 ± 2.5 Nm
Figure 184
208303
Fit the engine oil outlet pipe from the turbocharger (3),
tighten the screws (1) and the fitting (2) to the torque indica-
ted in the table.

(1) 2 M8x1.25x20 25 ± 5 Nm
(2) 1 M30x2 25 ± 5 Nm
208304
When fitting is completed, top-up the engine lubricant oil
with the specified quantity and quality of lubricant oil.
Tighten the fitting (2) of the engine oil delivery pipe engine
Refitting engine cable
(2) 1 M16x1.5 42.5 ± 2.5 Nm
Fit the engine cable and connect it to the control unit and to
all the disconnected sensors/senders.
in the table.
(3) 1 M8x1.25x16 23 ± 2 Nm

F2CFE612 ENGINE SECTION 7 - TECHNICAL SPECIFICATIONS 1
SECTION 7
Technical specifications
Page
MAIN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . 3
DATA - INSTALLATION CLEARANCES . . . . . . 5
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . 11

2 SECTION 7 - TECHNICAL SPECIFICATIONS F2CFE612 ENGINE

MAIN FEATURES
F2CFE612
Type
D*J104 C*J104 B*J104
Cycle Diesel 4-stroke

Supply Turbocharged with intercooler
Injection Direct
Number of cylinders 6 in line
j
Bore mm 117
Stroke mm 135
+ + +.. = Total displacement cm3 8710

F2CFE612
Type
D*J104 C*J104 B*J104
A
TIMING GEAR
start before T.D.C. A 15
end after B.D.C. B 30

B
start before B.D.C. D 50
end after T.D.C. C 5

D
For timing check
mm -
X
mm -
X
Of operation
mm 0.4 ± 0.05
X
mm 0.4 ± 0.05
Bosch Common Rail with CRIN3 injectors and CP3.3 NH high

SUPPLY pressure pump
Nozzle type DLLA 145
Firing order 1-4-2-6-3-5
bar
Max. injection
pressure bar 1800
NOTE The data, specifications and performance figures are only valid if the bodybuilder complies with all the installation instruc-
tions provided by FPT.

DATA - INSTALLATION CLEARANCES
F2CFE612
Type
D*J104 C*J104 B*J104
CYLINDER ASSEMBLY AND

CRANK MEMBERS mm
j 1
Cylinder liner housings:
upper 130.500  130.525
1
lower 129.510  129.535
Cylinder liners:
outer diameter:
L upper 130.461  130.486
2
lower 129.475  129.500
j2 length L 226.15
Cylinder liners -
crankcase seat
upper 0.014  0.064
lower 0.010  0.060
Outer diameter 2 -
Cylinder liners:
j 3 inner diameter 3A* 117.000  117.012
inner diameter 3B* 117.010  117.022
X Stand-out X 0.035  0.065
* Selection class
Pistons: Federal Mogul Mahle

j1
X measuring point X 15 18
outer diameter 1A* 116.894  116.906 116.871  116.883
j 2 outer diameter 1B* 116.904  116.916 116.881  116.893
* Selection class pin seat 2 52.016  52.022 52.010  52.018
Piston - cylinder liner Federal Mogul Mahle
A* 0.094  0.118 0.117  0.141
B* 0.094  0.118 0.117  0.141
* Selection class
Piston diameter 1 -
X
Piston protrusion X 0.094  0.118
j 3 Piston pin 3 51.994  52.000
Federal Mogul Mahle

Piston pin - pin seat
0.016  0.028 0.010  0.024

F2CFE612
Type D*J104 C*J104 B*J104
mm
Federal Mogul Mahle
X1
X1 2.582  2.716 2.585  2.615
X2
X3 Piston ring slots X2 2.550  2.570 2.550  2.570
X3 4.020  4.040 4.020  4.040
Federal Mogul Mahle
Piston rings:
S1 trapezoidal sealing S1 2.429  2.473 -
S2 bevelled S2 2.470  2.500 -
S3 milled scraper ring
with slots
and internal spring S3 3.970  3.990 -
Federal Mogul Mahle
1 0.109  0.287 -
Piston rings - slots 2 0.050  0.100 -
3 0.030  0.070 -
Circlips - -
X1 Piston ring end gap in
X2 cylinder liners Federal Mogul Mahle
X1 0.30  0.40 -
X3
X2 0.60  0.75 -
X3 0.35  0.65 -
Connecting rod small end
j 1 bushing seat Ø1
55.700  55.730
Big-end
bearing seat Ø2
j 2 A yellow 85.987  85.996
Selection classes { B green
C blue
85.997  86.005
86.006  86.013
Diameter of
connecting rod small end
bush
internal 3 52.015  52.030
Big end half-bearings S
red 1.994  2.002
green 2.002  2.010
yellow 2.010  2.018
Piston pin - bushing 0.015  0.036
Big end half-bearings 0.127* - 0.254 - 0.508
Connecting rod weight g -
A yellow 3308  3338
Class B green 3339  3368
C blue 3369  3398

F2CFE612
mm
Main journals 1
- rated 92.970  93.000
- class 1 92.970  92.979
- class 2 92.980  92.989
- class 3 92.990  93.000
Crankpins 2
j 1 j 2 - rated 81.915  81.945
- class 1 81.915  81.924
- class 2 81.925  81.934
- class 3 81.935  81.945
Main
S1 S 2 half-bearings S1
2.965  2.974
red
2.975  2.984
green
2.985  2.995
yellow
Big end
half-bearings S2
1.994  2.002
red
2.002  2.010
green
2.010  2.018
yellow
Main journals 3
- rated 99.000  99.030
j 3 - class 1 99.000  99.009
- class 2 99.010  99.019
- class 3 99.020  99.030
Half-bearings -
main journals 0.050  0.090
Half-bearings -
crankpins 0.040  0.080
Main
half-bearings 0.127* - 0.254 - 0.508
Big end half-bearings 0.127* - 0.254 - 0.508
Thrust main
journal X1
1-2-3-4-5-6 39.900 ÷ 40.100
X1 7 39.960 ÷ 40.040
Main journal
for thrust X2 32.70  33
X2
X3 Thrust
half rings X3 3.38  3.43
Crankshaft
thrust 0.11  0.34
1 2
Concentricity 0.040
Ovalisation 0.016
Conicality -

F2CFE612
Type
D*J104 C*J104 B*J104
CYLINDER HEAD - TIMING SYSTEM mm

j 1
Valve guide
seats on cylinder head
1 12.980  12.997
j 2
8.023  8.038
2
Valve guides
3
13.012  13.025
j 3
Valve guides
and seats on the head 0.015  0.045
Valve guides 0.2 - 0.4

j 4 Valves
4 7.970  7.985
 60 30  7 30
4 7.970  7.985
 60 30  7 30
a
Valve stem
and relative guide 0.038  0.068
Housing on head
for valve seat:
1 41.985  42.020
j 1 1 40.985  41.020
External diameter
of valve seats; valve seat
j 2 inclination on cylinder
head
42.060  42.075
2 59˚ 30’  60˚

41.060  41.075
a 2 59˚ 30’  60˚ 30’

X 0.5  0.8
Recessing
X X 1.65  1.95
Between valve seat

and cylinder head 0.040  0.090

Table 1
F2CFE612
mm
Valve spring
height A* B*
free spring H 70.77 71.34

Under a load of:
H H1 N 460 23 H1A {
H 2 N 460 22 H1B 51
N 740 33 H2A {
N 731.4 42 H2B 39
Injector protrusion X 1.53

X
Seats for camshaft bush

in cylinder
head
1 7 Ø 69.000  69.030
j j j
j 2
Camshaft
main journals
17 Ø 64.924  64.940
j 1 j 3
External diameter of cam-

shaft
j bushes
69.090  69.115

Inner diameter
j of bushes  65.080  65.116
Bushes and housing on cyl-

inder 0.060  0.115
head
Bushes and
supporting pins 0.140  0.192
Cam lift
H 7.404
8.211
 1
Rocker-arm shaft
1 31.964  31.980
* With reference to different supply

F2CFE612
mm
Seats for bushes
in rocker arms
35.000 ÷ 35.016
 35.000 ÷ 35.016
Rocker arm bush outer dia-

meter:
j 35.070 ÷ 35.110
35.070 ÷ 35.110
Rocker arm bush inner dia-

meter:
32.025 ÷ 32.041
j
32.025 ÷ 32.041
Bushes and housing:

0.054 ÷ 0.110
0.054 ÷ 0.110
Rocker arm bushes and

shaft:
0.045 ÷ 0.077
0.045 ÷ 0.077

TIGHTENING TORQUES
DETAIL TORQUE
Nm kgm
Piston cooling spray nozzles (6 screws M14x2x18) 50 ± 5 5.0 ± 0.5
Camshaft shoulder plate (5 screws M8x1.25x20) 20 ± 2 2.0 ± 0.2
Crankcase stiffening plate (8 screws M10x1.5x20) 49 ± 3 4.9 ± 0.3
Main bearing caps (14 screws M16x2x168)
1st phase 140 ± 7 14.0 ± 0.7
2nd phase 60˚
3rd phase 60˚
Camshaft gear (4 screws M10x1.5x45)
1st phase 25 ± 5 2.5 ± 0.5
2nd phase 45˚
Transmission gear (3 screws M12x1.5) 25 ± 5 2.5 ± 0.5
Connecting rod caps (12 screws M12x1.25x69)
1st phase 50 ± 2.5 5.0 ± 0.25
2nd phase 90 ˚
High pressure pump (3 screws M8x1.25x40) 30 ± 5 3.0 ± 0.5
High pressure pump gear (1 nut M18x1.5) 105 ± 5 10.5 ± 0.5
Phonic wheel timing sensor (3 screws M8x1.25) 23 ± 2 2.3 ± 0.2
Blow-by rotating filter (3 screws M6x1x16) 9±1 0.9 ± 0.1
Blow-by rotating filter cover (3 screws M6x1x16) 9±1 0.9 ± 0.1
Blow-by valve cover (3 screws M6x1x20) 9±1 0.9 ± 0.1
Fuel pipe from rail to electro-injectors
(6 fittings M18x1.5) 40 ± 2 4.0 ± 0.2
(6 fittings M14x1.5) 35 ± 2 3.5 ± 0.2
Fuel pipe from intermediate fitting to rail
(1 fitting M18x1.5) 40 ± 2 4.0 ± 0.2
(1 fitting M14x1.5) 35 ± 2 3.5 ± 0.2
Fuel return pipe
(1 fitting M16x1.5) 35 ± 2 3.5 ± 0.2
(1 fitting M14x1.5) 35 ± 2 3.5 ± 0.2
Fuel pipe from pressure pump to intermediate fitting
(2 fittings M16x1.5) 35 ± 5 3.5 ± 0.5
Fuel delivery and return pipe from pressure pump to fuel filter
(4 fittings M16x1.5) 35 ± 5 3.5 ± 0.5
Fuel pipe from injection control unit heater to pressure pump
(1 fitting M18x1.5) 40 ± 5 4.0 ± 0.5
(1 fitting M16x1.5) 35 ± 5 3.5 ± 0.5
Retaining bracket for fuel pipe from injection control unit heater to pressure pump
(1 screw M8x1.5) 24 ± 4 2.4 ± 0.4
Cylinder head (26 screws M16x2x170)
1st phase 50 ± 2.5 5.0 ± 0.25
2nd phase 100 ± 2.5 10.0 ± 0.25
3rd phase 90 ˚
4th phase 75˚
Figure 1
204123
Tightening sequence
A = Front
TIGHTENING TORQUES
DETAIL TORQUE
Nm kgm
Rocker arm shaft (7 screws M12x1.75x130) 105 ± 10 10.5 ± 1.0
Tappet cover (20 screws M6x1x50) 10 ± 1 1.0 ± 0.1
Engine oil pump
(5 screws M8x1.25x60) 25 ± 2 2.5 ± 0.2
(3 screws M8x1.25x45) 25 ± 2 2.5 ± 0.2
Double gear (3 screws M12x1.75x90)
1st phase 30 3.0
2nd phase 90 ˚
Crankcase front cover (9 screws M8x1.25x25) 19 ± 3 1.9 ± 0.3
Engine flywheel housing
(2) screws M12x1.75x193 67 ± 7
(1) screws M10x1.5x80 67 ± 7
(7) screws M12x1.75x80 67 ± 7
(2) screws M12x1.75x193 63 ± 7
(1) screws M8x30 42 ± 3
Engine oil sump (26 screws M10x1.5x50) 44 ± 4 4.2 ± 0.3
Engine oil intake suction strainer (3 screws M8) 20 ± 2 2.0 ± 0.2
Engine oil drain plug (1 M22x1.5) 40 ± 10 4.0 ± 1.0
Engine oil filter bracket (5 screws M8x1.25x65) 34 ± 4 3.4 ± 0.4
Engine oil filter body 60 ± 5 6.0 ± 0.5
Heat exchanger (4 screws M8x45) 23 ± 2 2.3 ± 0.2
Heat exchanger body
(14 screws M8x40) 23 ± 2 2.3 ± 0.2
(3 screws M8) 23 ± 2 2.3 ± 0.2
(1 screw M8x55) 23 ± 2 2.3 ± 0.2
Damper pulley (6 screws M12x1.75x60) 115 ± 5 11.5 ± 0.5
Crankshaft pulley (6 screws M14x2x60)
1st phase 70 7.0
2nd phase 50˚
Electro-injector brackets (6 screws M10x1.5x40) 46 ± 3 4.6 ± 0.3
Rail (3 screws M8x1.25x45) 23 ± 2 2.3 ± 0.2
Intake manifold
(5 screws M10x1.5x100) 50 ± 5 5.0 ± 0.5
(1 screws M10x1.5x150) 50 ± 5 5.0 ± 0.5
Air compressor
(3 screws M12x35) 74 ± 8 7.4 ± 0.8
Engine coolant return and delivery pipes to air compressor
(4 fittings M18x1.5) 40 ± 5 4.0 ± 0.5
Starter motor (3 nuts M10x1.5) 80 ± 8 8.0 ± 0.8
Power steering pump (2 screws M10x1.5-8.8) 44 ± 4 4.4 ± 0.4
Engine brake collar (1 screw M8x70) 14 ± 1 1.4 ± 0.1
Engine coolant return and delivery pipes to engine brake control actuator (4 fittings
M12x1.5) 25 ± 5 2.5 ± 0.5
Turbocharger (4 nuts M10x1.5) 46 ± 2 4.6 ± 0.2
Hydraulic pump for viscostatic fan (2 screws M10x1.5x26) 44 ± 4 4.4 ± 0.4

TIGHTENING TORQUES
DETAIL TORQUE
Nm kgm
Oil outlet pipe from turbocharger
(2 screws M8x1.25x20) 25 ± 5 2.5 ± 0.5
(1 fitting M27x1.5) 25 ± 5 2.5 ± 0.5
(1 fitting M30x2) 25 ± 5 2.5 ± 0.5
Oil delivery pipe to turbocharger (2 fittings M16x1.5) 42.5 ± 2.5 4.25 ± 0.25
Retaining bracket for oil delivery pipe to turbocharger (3 screws M8x1.25x16) 23 ± 2 2.3 ± 0.2
Intarder pipe bracket (2 screws M10x1.5x130) 20 ± 2 2.0 ± 0.2
Intarder pipe collars (2 screws M8x1.25x16) 23 ± 2 2.3 ± 0.2
Exhaust manifold (24 screws M10x1.5x38) 45 ± 5 4.5 ± 0.5
Lower alternator mount (4 screws M10x1.5x60) 44 ± 4 4.4 ± 0.4
Upper alternator mount
(3 screws M10x1.5x30) 67.5 ± 6.5 6.75 ± 0.65
(2 screws M8x1.25x35) 23 ± 2 2.3 ± 0.2
Lower alternator (1 screw M10x45) 67.5 ± 6.5 6.75 ± 0.65
(1 screw M12x160) 80 ± 8 8 ± 0.8
Upper alternator (1 screw M10x45) M10x1.5x40 67.5 ± 6.5 6.75 ± 0.65
(1 screw M12x160) M12x1.75x160 80 ± 8 8 ± 0.8
Engine management control unit (1 screw M8x1.25x45) 19 ± 3 1.9 ± 0.3
Engine management control unit (2 nuts M8x1.25) 19 ± 3 1.9 ± 0.3
Timing sensor (1 screw M6x1x12) 9±1 0.9 ± 0.1
Engine speed sensor (1 screw M6x1x12) 9±1 0.9 ± 0.1
Air temperature and pressure sensor (1 screw M6) 20 ± 0.5 2.0 ± 0.5
Engine oil temperature and pressure sensor (2 screws M6) 11.5 1.15
Coolant temperature sensor 20 ± 5 2.0 ± 0.5
Fuel pressure sensor on rail (M18x1.5) 140 14
Alternator drive belt fixed tensioner (1 screw M10x1.5x70) 61.5 ± 6.5 6.15 ± 0.65
Water pump drive belt mobile tensioner (1 screw M10x1.5x80) 45 ± 5 4.5 ± 0.5
Bracket for water pump drive belt mobile tensioner (2 screws M8) 45 ± 5 4.5 ± 0.5
Engine flywheel (8 screws M18x1.5x120)
1st phase 120 ± 5 12.0 ± 0.5
2nd phase 150˚
Thermostat (3 screws M8x1.25x70) 23 ± 2 2.3 ± 0.2
Water pump (4 screws M8x1.25x25) 24 ± 3 2.4 ± 0.3
Engine coolant pipes (2 fittings M12x1.5) 20 ± 2 2.0 ± 0.2
Degassing pipe (2 fitting M12x1.5) 20 ± 2 2.0 ± 0.2
Fluid inlet pipe to water pump (2 screws M8x1.25) 20 ± 2 2.0 ± 0.2
Engine coolant outlet pipe from cylinder head (5 screws M8x1.25) 20 ± 2 2.0 ± 0.2
DPF catalytic converter guard (12 screws) 14 ± 1.4 1.4 ± 0.14
DPF catalytic converter cover (8 screws M8x25) 15 ± 1 1.5 ± 0.1
DPF catalytic converter collar (screws)
1st phase 11 1.1
2nd phase 18 ± 1 1.8 ± 0.1
DPF catalytic converter flat collar (screws)
1st phase 25 2.5
2nd phase 35 3.5
3rd phase 42.5 ± 2.5 4.25 ± 0.25


F2CFE612 ENGINE SECTION 8 - TOOLS 1
SECTION 8
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 8 - TOOLS F2CFE612 ENGINE

TOOLS
TOOL No. NAME
99322230 Rotary telescopic stand (range 2000 daN, torque 375 daNm)
99342157 Extraction tool for injectors
99346260 Key to fit crankshaft rear gasket
99346265 Key to fit crankshaft front gasket
Calliper for piston circlip removal and refitting (105-160 mm)

99360184
99360264 Tool to remove and reattach engine valves

TOOLS
TOOL No. NAME
99360288 Punch for valve guide removal
99360292 Adjuster for gasket assembly on valve guide
99360294 Tool to drive valve guide (use with 99360288)
99360321 Tool for rotating the flywheel
99360325 Spacer (to be used with 99360321)
Tool for checking cylinder liner protrusion

99360334 (use with tools 99370415-99395603 and specific plates)

TOOLS
TOOL No. NAME
Cap for cylinder liners compression (to be used with 99360334)

99360335
Tool to retain engine flywheel

99360351
99360500 Tool for lifting the crankshaft
99360505 Drift to remove and refit camshaft bushes
99360558 Tool to lift and transport rocker shaft
99360585 Arm for removing and installing engine

TOOLS
TOOL No. NAME
Band for inserting piston into cylinder liner (60-125mm)

99360605
99360612 Tool for engine T.D.C. positioning
99360613 Tool for timing of phonic wheel on camshaft
99360703 Check tool for cylinder liners
99360706 Tool to extract cylinder liners (to be used with specific rings)
99360724 Plate (115 mm) (to be used with 99360706)

TOOLS
TOOL No. NAME
99361046 Brackets for fastening engine to 99322230 rotary stand
Set of 9 insert wrenches 14x18 (13-17-18-19-21-22-24-27-30 mm)

99368542
Tool for checking timing (use with 99395606)

99370400
99370415 Dial gauge base for measuring cylinder liner protrusion

(use with 99395603)
99389833 14x18 coupling torque wrench (20-120 Nm)
Torque screwdriver to calibrate screws for injector solenoid valve

99389834

TOOLS
TOOL No. NAME
99390310 Sleeker for valve guide
Pair of angle tightening measuring devices with 1/2” and 3/4”

99395216 square attachment
Gauge for defining the distance between the centres of camshaft

99395221 and high pressure pump
Gauge for defining the distance between the centres of camshaft

99395222 and idler gear
99395223 Gauge for camshaft timing
99395603 Dial gauge (0 - 5 mm)

TOOLS
TOOL No. NAME
99395606 Dial gauge (0-30 mm)
99327210 Diagnostics tool PT-Plus (I)
99327220 Diagnostics tool PT-Plus (E)
99327230 Diagnostics tool PT-Plus (UK)
99327240 Diagnostics tool PT-Plus (F)
99327250 Diagnostics tool PT-Plus (D)

TOOLS
TOOL No. NAME
99327282 Diagnostics interface with the prepaid card
99327301 Prepaid card
99331043 Adapter for 38 to 30 pin connectors (use with E.A.SY.)
99368555 30 to 19 pin adapter (component of 99368554)
99368556 Adapter (5 m) for connecting the PT01 tester to

the 30 pin diagnostics connector (component of 99368554)
99368558 Adapter (80 m) for connecting the PT01 tester

to the 30-pin diagnosis socket for DENOX 2
(component of 99368554)

F2CFE612 ENGINE APPENDIX 1
Appendix
Page
SAFETY REGULATIONS . . . . . . . . . . . . . . . . . . . . 3
- Standard safety precautions . . . . . . . . . . . . . . 3
- Accident prevention . . . . . . . . . . . . . . . . . . . . 3
- During maintenance . . . . . . . . . . . . . . . . . . . . 3
- Protection of the environment . . . . . . . . . . . . 4

2 APPENDIX F2CFE612 ENGINE
Base - 12/2016 P1D32C026 E

F2CFE612 ENGINE APPENDIX 3
SAFETY REGULATIONS - Do not perform operations without the necessary

Standard safety precautions instructions.
We direct your attention on some precautions that must be - Do not use equipment to perform works other than
necessarily followed in a regular work environment and, in those for which they have been designed, you may
case of non-compliance, any other precaution will not be suf- sustain accidents, even of serious type.
ficient to protect the safety of the staff in charge of mainte- - In case of checks or calibrations that require the engine
nance. to be on, make sure that the room is properly ventilated
- Please obtain information and inform the staff on applica- and use proper fans to remove exhaust gases: intoxica-
ble laws on safety, making the informative material availa- tion and death hazard.
ble for consultation.
- Please keep the rooms as clean as possible and properly During maintenance
ventilated. - Never open the filling cap of the cooling circuit when the
- Equip the rooms with specific, well-visible first-aid boxes, engine is hot. The operating pressure will spill the high
always stocked up with suitable medical aids. temperature liquid with serious risk of burns. Wait until
the temperature drops below 50 ˚C.
- Be equipped with suitable fire extinguishing devices, pro-
perly signalled and never obstructed. Check their opera- - Never add coolant to an overheated engine and only use
tion on a regular basis and train the staff on the interven- appropriate fluids.
tion priorities and methods. - Always operate with engine off: in case particular circum-
- Arrange gathering points for the evacuation of the stances require maintenance interventions with the
rooms, properly signalling the exit routes. engine on, consider all the risks involved in these opera-
tions.
- Absolutely prohibit smoking in the areas where the
works subject to fire hazard are carried out. - Use adequate and safe containers for draining the engine
fluids and exhaust oil.
- Draw the attention on prohibitions and indications with
suitable signs, which are immediately comprehensible - Keep the engine clean from oil, diesel and/or chemical
always in case of emergency. solvents.
- The use of solvents or detergents during maintenance
Accident prevention may develop toxic vapours. Always ventilate the work
rooms. Use safety masks when required.
- Do not wear cloths with loose edges, rings and chains, - Do not leave cloths soaked with flammable substances
while working near engines and moving organs. near the engine.
- Use protective gloves and glasses when: - When starting up the engine after a repair operation,
- filling up inhibitors or antifreeze; arrange for suitable measures to stop air suction in case
- replacing or filling up lubricant; of over-revving.
- using air or liquids under pressure (allowed pressure
2 bar) - Do not use quick screwdrivers.
- Wear a protective helmet if working in an area with - Do not disconnect the batteries whilst the engine is run-
suspended loads or overhead systems. ning.
- Always wear safety shoes and cloths fitted to the body, - Before any interventions involving the electrical circuits,
better if equipped with rubber bands at the edges. disconnect the batteries.
- Use protective creams for hands. - Disconnect the batteries from the on-board network
while charging.
- Change wet clothes as soon as possible.
- After each intervention, make sure the polarity of the
- In the presence of voltage higher than 48-60V, check the battery’s terminals is respected and the latter are well
effectiveness of the ground electric connections. Make tightened and protected against accidental short circuits
sure your hands and feet are dry and perform the work and oxidation phenomena.
standing on insulating platforms.
Do not proceed if not qualified! - Do not disconnect and connect the electric connections
when power is on.
- Do not smoke or spark free flames near batteries and any
combustible material. - Before carrying out removal operations on pipes (pneu-
matic, hydraulic or fuel pipes) check the possible pre-
- Return oily rags or solvents to fire-proof containers. sence of fluid or air under pressure. Adopt the necessary
precautions, exhausting the residual pressures or closing
the shut-off valves. Always wear suitable masks or pro-
tective glasses. Failure to follow these rules may cause
serious accidents and intoxication.

4 APPENDIX F2CFE612 ENGINE
- Avoid improper tightening operations or out of torque. Protection of the environment

The engine’s components may be damaged also seriou-
sly, thus prejudicing their life cycle. - Allows prioritise protection of the environment imple-
menting all necessary precautions to protect the safety
- Avoid draughts from fuel tanks in copper alloy and/or and health of staff.
pipes without filters.
- Make sure you and all staff are fully aware of current stan-
- Do not apply changes to the cabling, their length must dards for the treatment and disposal of fluids and engine
not be modified. oils. Set up adequate signage and specific courses to
- Do not connect any device to the electrical equipment ensure a full understanding of the rules and the basic pre-
of the engine unless specifically approved by FPT. vention measures.
- Do not modify the fuel or hydraulic systems without - Collect used oil in suitable containers with water tight
authorisation from FPT. Any unforeseen change will void seals also providing storage in areas which are adequately
the warranty and may prejudice the engine’s duration marked,ventilated, away from sources of heat and pre-
and life cycle. sent no fire hazard.
For engines equipped with electronic units: - Handle batteries with care in well ventilated areas and
in antacid containers. Beware of fumes coming from the
- Do not carry out any arch welding without previously batteries: they may pose a serious risk of poisoning and
removing the electronic units. contamination of the environment.
- Remove the electronic control units in case of interven-
tions in which the temperatures will exceed 80 ˚C.
- Do not paint the electronic components and connec-
tions.
- Do not modify or alter the data contained in the engine
management electronic control unit. Any manipulation
or alteration of the electronic components will invalidate
the service warranty of the engine and may also affect its
operation and duration.
Base - 12/2016 P1D32C026 E

REPAIR INSTRUCTIONS
ZF-ECOLIFE
6 AP 1000 B / 6 AP 1200 B / 6 AP 1400 B / 6 AP 1700 B / 6 AP 2000 B
and the corresponding angle drive variants
Stages 1-2
BUSES
Copyright © ZF Friedrichshafen AG
This document is protected by copyright. Complete or partial reproduction

or dissemination of this document is prohibited without the consent of
ZF Friedrichshafen AG. Infringements lead to civil and criminal prosecution.
This document is a translation of the German original.
ZF-EcoLife Table of Contents
Page
Preface ..................................................................... 5
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Instructions for repair and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operating supplies and auxiliary material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Classification of peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sectional drawing ZF-EcoLife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Product designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Shift element combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Oil quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Oil grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4.1 Initial check of the oil level in order to ensure a minimum oil quantity . . . . . . . . . . . . . . . . . 1-3
1.4.2 Check at operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4.3 Electric oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4.4 Option for heating up transmission oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 Variant 1 – Oil change with standard oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5.1 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5.2 Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.6 Variant 2 – Oil change with VRM special oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.1 Oil drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6.2 Oil fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Replacing electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.1 Removing electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.2 Installing electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3 Completely replacing the hydraulic shift control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3.1 Removing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3.2 Removing suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3.3 Removing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3.4 Removing the hydraulic shift control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.3.5 Removing speed sensor, turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.6 Installing speed sensor, turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3.7 Installing the hydraulic shift control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.3.8 Installing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.3.9 Installing the suction filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.3.10 Attaching the oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2.4 Replacing retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.4.1 Removing retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.4.2 Installing the retarder accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
EN 4181 751 102c - 2014-02 3

ZF-EcoLife Table of Contents
Page
2.5 Replacing speed sensor, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

2.5.1 Removing speed sensor, output (coaxial transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.5.2 Installing speed sensor, output (coaxial transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.5.3 Removing speed sensor, output (RHD / LHD angle drive) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2.5.4 Installing speed sensor, output (RHD / LHD angle drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2.6 Replacing output shaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.6.1 Removing shaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.6.2 Installing shaft sealing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2.7 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.7.2 System check at high speed (turbine speed 2200 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
2.7.1 System check at idling speed (turbine speed 620 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Test with terminal tester 6008 006 002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Pin assignment with measured values at EcoLife transmission . . . . . . . . . . . . . . . . . . . . . . 3-2
Tolerance table for sump temperature sensor/Retarder temperature sensor . . . . . . . . . . . . 3-3
3.3 Connect ZF-TESTMAN to diagnostic connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4 ZF-TESTMAN diagnosis system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
4 Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Circuit Diagram, General
CAN-End / CAN-Mit / SAE J1708, from Drawing No.: 6029 739 017 . . . . . . . . . . . . . . . . . 4-1
Terminal Connection Diagram

CAN-End, Diagn: SAE J1708, from Drawing No.: 6029 739 018 . . . . . . . . . . . . . . . . . . . . . 4-3
CAN-Mit, SAE 1708, from Drawing No.: 6029 739 021 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Hydraulic Plan
from Drawing No.: 4181 700 003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Hydraulic ZF-EcoLife Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
5 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Overview of revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6 Enclosed Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
EN 4181 751 102c - 2014-02 4

ZF-EcoLife Preface
Preface
This documentation was developed for specialized staff trained in the operation of ZF products by
ZF Friedrichshafen AG (hereinafter referred to as "ZF").
The work described below may be performed by authorized, trained, and instructed staff only. It is the
responsibility of the user's company or service company to ensure that their specialized staff is properly
trained and that current documents are made available.
Object of documentation is a volume-produced ZF product. State of design acc. to date of issue.
The images illustrate the work sequence and do not always represent the original. Illustrations and figures
are not drawn to scale; no conclusions about size and weight can be drawn.
The repair or assembly of the ZF product available to you may require different work steps as well as
different settings and test data as a result of technical further developments. We therefore recommend
that work done on your ZF product be carried out only by skilled mechanics and fitters who have had their
practical and theoretical knowledge updated on a regular basis at ZF.
The ZF service locations which have been put in place for you worldwide by ZF offer the following services:
▪ Well-trained specialized personnel
▪ Specified workshop equipment, e. g. special tools, diagnostic software, etc.
▪ Genuine ZF spare parts in accordance with the latest volume production specifications
ZF Friedrichshafen AG
EN 4181 751 102c - 2014-02 5

ZF-EcoLife Safety Instructions
Safety Instructions
General safety instructions
Read all safety instructions. Failure to comply with safety instructions may lead to material damage, serious
injury, possibly even to death.
Intended use / liability / guarantee / warranty

The ZF product is exclusively designed for the purpose specified in the contract and agreed on at the
time of delivery. Any other or extended form of use does not comply with this definition of intended use.
ZF Friedrichshafen AG is not liable for any damage resulting from this. Instead, the user is fully liable for this
risk. The intended use includes compliance with this documentation and other applicable documents in
order to avoid malfunctions and damage in operation.
The ZF product is designed and produced in line with state-of-the-art technology and is safe to operate.
However, this product may cause hazardous situations if used incorrectly by unauthorized, untrained, and
uninstructed specialized staff or if not used for its intended purpose.
This version of the document complies with the relevant standards and regulations as well as with
European product liability law.
We offer guarantee for the ZF product in accordance with our Terms and Conditions. Warranty claims
cease to apply if damage and secondary damage result from incorrect and unprofessionally performed
work. Work that is performed by unauthorized, untrained, and uninstructed specialized staff leads to
ceasing of all warranty claims.
We offer warranty for the ZF product in accordance with our Terms and Conditions.
Damage, secondary damage, defects, and possibly resulting costs are excluded from contractual liability or
warranty in the event of non-compliance with one of the following points:
▪ All work must be performed in a professional manner.
▪ Work must only be performed by trained, instructed and authorized specialized staff.
▪ Only genuine ZF spare parts may be used which have been tested and released by ZF.
▪ Only genuine ZF accessories may be used which have been tested and released by ZF.
▪ Only genuine ZF special tools may be used which have been tested and released by ZF.
▪ Revisions and modifications on the ZF product must be approved by ZF.
EN 4181 751 102c - 2014-02 6

In case of damage, immediate action is mandatory in order to restore full functionality and safety /
operational safety of the ZF product and to minimize the extent of damage. In the event of non-compliance,
ZF will not accept liability or warranty claims.
In case of damage, contact ZF Services and have the following data available:
▪ Product type, product parts list number, and serial number
▪ Total mileage
▪ Damage history
▪ Damage pattern
Specialized staff
Work must only be performed by trained and instructed specialized staff. As a result of specialized training
and practical experience, the specialized staff must be capable of detecting risks and avoiding possible
dangers which may be caused by the operation, maintenance, and repair of the ZF product.
To avoid injury to personnel and damage to ZF products, all safety regulations and legal requirements must
be adhered to. The specialized staff must have read and understood these regulations prior to beginning
work.
Country-specific safety, accident prevention, and environmental regulations apply irrespective of the
instructions provided in this document.
Safety-relevant workwear is to be used for all work. Depending on the type of work, additional protection,
e. g. protective goggles, protective gloves, a hard hat, and a skirt, is to be used. The workwear must fit
properly and be tight so that it cannot get caught in turning or protruding parts.
After completion of repair work and inspections, the specialized staff must ensure that the ZF product is
again functioning perfectly and is safe to operate.
The user/operator is responsible for assigning the corresponding section of the documentation to the
correct target group. The former must ensure that the respective section of the documentation is stored
in the immediate vicinity of the ZF product and that the relevant target group has access to it.
EN 4181 751 102c - 2014-02 7

Handling of ZF products
Impermissible superstructures, add-ons, modifications, and changes to the ZF product may affect the
ZF product’s operational safety and are only permitted with the approval of ZF Friedrichshafen AG.
Unless explicitly permitted, no work may be performed while the engine is running.
Secure the engine against unintentional setting off and the vehicle against moving.
Attach a “Do not operate” sign which is visible for everyone!
Keep uninvolved parties away.
Always secure the ZF product before starting work according to specification and using suitable means.
Do not work on ZF products which are only held by a lifting device or a hoist.
Risk of injury from tilting or falling parts and/or tools.
▪ Do not walk under suspended loads.
▪ Keep distance.
Lifting and moving heavy parts without tools may lead to health damage or serious injury.
▪ Only use permitted means of transport, lifting equipment with sufficient load capacity, and suitable
chain hoist.
▪ Observe safety regulations.
Increased risk of injury at contact with cooled down or heated parts. Only touch parts when wearing
suitable protective gloves.
EN 4181 751 102c - 2014-02 8

Noise
Wear suitable ear protection at all workplaces with a sound pressure level above 85 dB(A).
Country-specific safety and accident prevention regulations apply regardless of this.
Noise can mean a higher risk of accidents if the noise affects the perception of acoustic signals, warning
calls, or other sounds alerting to danger.
Handling operating fluids and consumables

Increased risk of injury at contact with heated, cooled down, or caustic operating fluids and consumables
(e. g. lubricants, cleaning agents, nitrogen).
▪ Prevent skin contact.
▪ Do not drink.
▪ Do not inhale vapors.
▪ Keep away from ignition sources, do not smoke.
Store operating fluids and consumables in suitable and correctly labeled containers.
Use suitable protective clothing, protective gloves, and protective goggles/face protection.
Pay attention to manufacturer’s and accident prevention regulations.
Immediately seek medical assistance after contact with heated, cooled down, or caustic operating fluids
and consumables.
Environment
Operating fluids and consumables must not be allowed to enter the soil, groundwater, or sewage system.
▪ Ask your local environmental protection agency for the safety data sheets of the relevant ZF products
and observe these requirements.
▪ Collect operating fluids and consumables in a sufficiently large container.
▪ Dispose of operating fluids and consumables, waste, containers, soaked cleaning cloths, contaminated
filters etc. in accordance with the regulations of the environmental protection laws.
▪ Pay attention to manufacturer’s and accident prevention regulations.
When selecting operating fluids and consumables, bear in mind health risks, environmental compatibility,
disposal regulations, and country-specific possibilities for approved disposal.
EN 4181 751 102c - 2014-02 9

Signal words and symbols
This document contains particularly highlighted safety instructions which start with one of the following
signal words depending on the danger’s severity.
NOTE
Refers to special working procedures, methods, information, use of auxiliary equipment, etc.
CAUTION
Is used when the instructions are not complied with or not followed precisely and could lead to the
product being damaged.
DANGER!
Is used when lack of care could result in personal injury or danger to life.
Product-related safety instructions
CAUTION
The transmission must NOT be suspended by the input shaft OR by the output flange/add-on parts.
EN 4181 751 102c - 2014-02 10

ZF-EcoLife Instructions for Repair and Assembly
Instructions for Repair and Assembly
General notes
▪ Please read carefully through this documentation prior to starting repair or assembly work.
▪ Prior to starting repair or assembly work, please find out whether ZF Service Information on the ZF
product is available. ZF Service Information can contain tests, supplements to the product or to repair
processes which may not yet be included in this documentation. The ZF Service Information details are
available from all ZF Service Centers or from the ZF-ServiceLine.
▪ In cases of doubt, always contact the relevant expert departments of the ZF Customer Service.
▪ All work on the ZF product must be performed expertly and under clean conditions.
▪ Use the specified special tools and equipment intended for the described working procedures.
▪ All work must be performed according to the described working procedure.
▪ Carefully cover opened ZF products to prevent the entry of foreign matter.
▪ Cover all parts that have been removed and that are reusable and protect them against dirt and damage.
▪ After completion of work and inspections, the specialized staff must ensure that the ZF product is again
functioning perfectly and is safe to operate.
Cleaning the ZF product prior to disassembly
▪ Use an appropriate cleaning agent to thoroughly clean the ZF product prior to repair or assembly work.
Thoroughly clean the angles and recesses of housing and cover.
CAUTION
Be careful when using a high-pressure cleaner on the ZF product.
Penetrating water might lead to operational disruption and damage to the ZF product.
EN 4181 751 102c - 2014-02 11
Cleaning parts
▪ Thoroughly clean all reusable components after disassembly.

▪ Thoroughly remove sealing compound residue on sealing faces or retaining agent residue, e. g. in
tapped holes or on splines.
▪ Thoroughly clean joining surfaces and check for damage.
▪ Thoroughly wash out blind holes and blind hole threads and remove contamination.
▪ Lubricating bores, oil clearance holes, oil ducts, bores for oil press fits, and lubricating grooves must be
free from dirt, preservative, and foreign matter. If possible, blow through with compressed air. Check for
free passage.
▪ Hose assemblies, oil tubes, and joining elements must be free from dirt, oil, and chafe marks. Dirty or
oily parts must be thoroughly cleaned and, if necessary, blown through with compressed air. Replace
damaged parts.
▪ Thoroughly clean all cavities and reliefs.
▪ All edges which can cause chip formation during assembly or represent a risk of injury for the fitter must
be deburred.
▪ Carefully remove burrs or other similar rough surfaces using a honing stone.
▪ Thoroughly remove preservative from new parts (e. g. on bearing).
Reusing parts
Authorized, specialized staff assess whether parts can be reused.

▪ Replace parts if they are damaged.
▪ Replace parts if they are worn, e. g. rolling bearings, multidisks, thrust washers, etc.
▪ Replace parts if they have a permanent deformation.
▪ Replace parts if they have been overheated during operation or during disassembly.
Always replace:
▪ Bolts with reduced shank, seals, etc., and parts that are intended for single use only
▪ Sealing rings
▪ Safety plates
▪ Shaft sealing rings
The parts must be replaced with genuine ZF parts or parts released by ZF. Please refer to the spare parts
catalog for the ZF product.
EN 4181 751 102c - 2014-02 12

Reworking parts
Authorized, specialized staff assess whether parts need to be reworked or replaced.

Minor damage on reusable components can be removed and reworked with suitable special tools if the
component’s function is not impaired.
Minor damage includes:
▪ Indentation marks on sealing faces
▪ Score marks or burrs caused by the disassembly of the ZF product
▪ Frictional corrosion
▪ Paint and rust damage
If rework is needed on spacer washers or shims because of clearance settings, ensure that the reworked
surface is level with the starting face and has the same surface quality.
Disassembly
▪ To avoid mixing up parts, the parts must be clearly assigned to the disassembled ZF product. In
particular, this applies to gear parts, reusable spacer washers or shims, electronic components, etc.
▪ Assemblies which must not be disassembled or are only available as spare parts assembly are described
accordingly. Please refer to the spare parts catalog for the ZF product.
▪ Inspect the parts during disassembly in order to find a potential cause of damage.
EN 4181 751 102c - 2014-02 13

Assembly
Assemble the ZF product at a clean workplace. The order, settings, and tightening torques must be
observed.
Bearings
The bearings’ assembly specifications are described in the corresponding work step. After assembly, each
mounted bearing must be lubricated with transmission oil.
Sealing
If a sealing agent* is recommended for sealing, then it is essential to adhere to the manufacturer’s
directions for use. A thin layer of sealing agent should be applied to the surfaces and coat them evenly. Do
not allow sealing agent to enter oil ducts and oil bores. In the case of oil transfer channels and/or oil
transfer bores in the sealing face areas, the sealing agent should be scraped off around the openings so
that no sealing agent gets into the oil supply lines when the parts are pressed together.
Retaining agents
Only use retaining agents* if specified in the work step. Follow the safety instructions and the processing
instructions of the manufacturer.
Transmission oil
Prior to initial operation, fill the transmission with transmission oil. For the procedure and approved oil
grades, refer to the technical manual, the operating instructions, the type plate, and/or the latest List of
Lubricants TE-ML. These documents are available from the ZF Service Centers and at www.zf.com.
* refer to Operating supplies and auxiliary materials
EN 4181 751 102c - 2014-02 14

ZF-EcoLife Tightening Torques
Tightening torques for screws and nuts, extract from ZFN 148
This standard applies to bolts according to DIN 912, DIN 931, DIN 933, DIN 960, DIN 961 as well as
ISO 4762, ISO 4014, ISO 4017, ISO 8765, ISO 8676, and for nuts according to DIN 934 and ISO 4032,
ISO 8673.
This standard contains data on tightening torques for screws/bolts and nuts of strength categories 8.8,
10.9, and 12.9, as well as nuts of strength categories 8, 10, and 12.
Surface condition of screws/nuts: Heat-treated blackened finish and oiled or galvanized and oiled.
The bolts are tightened using a calibrated torque wrench.
NOTE
Differing tightening torques are listed separately in the repair manual.
Coarse thread Fine thread
Measurement Tightening torque in Nm for Measurement Tightening torque in Nm for

Screw 8.8 10.9 12.9 Screw 8.8 10.9 12.9
Nut 8 10 12 Nut 8 10 12
M4 2,8 4,1 4,8 M8x1 24 36 43

M5 5,5 8,1 9,5 M9x1 36 53 62
M6 9,5 14 16,5 M10x1 52 76 89
M7 15 23 28 M10x1,25 49 72 84
M8 23 34 40 M12x1,25 87 125 150
M10 46 68 79 M12x1,5 83 120 145
M12 79 115 135 M14x1,5 135 200 235

M14 125 185 215 M16x1,5 205 300 360
M16 195 280 330 M18x1,5 310 440 520
M18 280 390 460 M18x2 290 420 490

M20 390 560 650 M20x1,5 430 620 720
M22 530 750 880 M22x1,5 580 820 960
M24 670 960 1100 M24x1,5 760 1100 1250

M27 1000 1400 1650 M24x2 730 1050 1200
M30 1350 1900 2250 M27x1,5 1100 1600 1850
M27x2 1050 1500 1800

M30x1,5 1550 2200 2550
M30x2 1500 2100 2500
Status: August 1991
EN 4181 751 102c - 2014-02 15

ZF-EcoLife Tightening Torques
Tightening torques for hex head screws according to EN ISO 10644 and DIN EN 1665
CAUTION
Depending on the screw design, different tightening torques for hex head screws arerequired:
Screw with washer assembly according to EN ISO 10644

(hex head screw with washer)
M 8 = Tightening torque: 23 Nm
033381
Flange-head screw according to DIN EN 1665

(hex head screw without washer)
033380
EN 4181 751 102c - 2014-02 16

ZF-EcoLife Operating supplies and auxiliary material
Designation Name Quantity Application Comment

ZF item number approx.
Grease For example Assembly aid, general

0750 199 001 Spectron FO 20
Grease Techn. Vaseline 8420 Assembly aid, general

0671 190 016
Operating oil Refer to TE-ML 20 Assembly aid, general

List of Lubricants
NOTE: Inquire as to size of containers before ordering!
EN 4181 751 102c - 2014-02 17

ZF-EcoLife Special tools
Image Figure Order no. Application Quantity Comment

no.
1X56 137 452 1
Adapter
1 for safety plate at output flange
1X56 138 625 1

Adapter
for shaft sealing ring, output
2
1X56 138 590 1
Washer
for the second position of shaft
sealing ring, output
1P01 136 670 1
Test gage
3 0 – 25 bar with connection socket
M10x1
1P01 137 856 1
Test gage
4 0 – 10 bar with connection socket
M10x1
1P82 139 839 1 Refer to

Chapter 2.7
Adapter Pressure test
5 for EcoLife test gage
To be used at pressure measuring

points PD8, PD6, A8, PHD, PVF
EN 4181 751 102c - 2014-02 18


no.
4181 302 009 1 Refer to

Chapter 2.7
Screw plug (without valve) Pressure test
6 for EcoLife test gage in combination
with adapter 1P82 139 839
To be used at measuring connection
Main pressure – PHD (2) and
pressure upstream of filter – PVF (3)
6008 006 002 1
68-pin terminal tester

7 for troubleshooting
in electrical part
6008 208 550 1 System

requirements:
Diagnostic system - WIN. XP SP2
ZF-TESTMAN Service Edition
- WIN. Vista
(full version, only for ZF Service)
(32 & 64 Bit)
Complete system without PC - WIN. 7
(32 & 64 Bit)
8 This includes: - WIN. 8
ZF-TESTMAN software
- IE 5.01 <
6008 208 500 on DVD
- WIN. Installer
The diagnostic tool 6008 208 100 3.0 <
comprises various connection cables
including the DPA 05 diagnostic
adapter
6008 208 500 1
Software
9 ZF-TESTMAN Service Edition
(full version, only for ZF Service)
on DVD
EN 4181 751 102c - 2014-02 19


no.
6008 208 450 1 System

requirements:
Diagnostic system - WIN. XP SP2
ZF-TESTMAN IAM Edition
- WIN. Vista
(customer version)
(32 & 64 Bit)
Complete system without PC - WIN. 7
(32 & 64 Bit)
10 This includes: - WIN. 8
ZF-TESTMAN software
- IE 5.01 <
6008 208 400 on DVD
- WIN. Installer
The diagnostic tool 6008 208 100 3.0 <
comprises various connection cables
including the DPA 05 diagnostic
adapter
6008 208 400 1
Software
11 ZF-TESTMAN IAM Edition
(customer version)
on DVD
6008 206 038 1
Adapter cable
12
between transmission control unit
and terminal tester
6008 206 039 1
Adapter cable
13
between transmission connector and
terminal tester
EN 4181 751 102c - 2014-02 20


no.
6008 206 040 1
Adapter kit
14 contains 6008 206 038 and
6008 206 039
6008 206 042 1
T adapter
15 between transmission control unit
and vehicle-side connector with
CAN2 interface and power supply
6008 207 038 1
TMA table mode adapter

16 for table mode-based programming
of electronics
6008 207 043 1
Adapter
17 Diagnostic connection for ZF speed
range selector
6008 207 048 1
Adapter
18 MAN diagnostic connection
EN 4181 751 102c - 2014-02 21

ZF-EcoLife Classification of peripheral equipment
Classification of peripheral equipment
Accelerator pedal Vehicle-CAN 11 10 1 2

Engine
Kick-Down On-board computer 3
Brake system
Retarder lever
ZF-CAN 12
Brake pedal
E-Modul
Inputs and Speed range selector

outputs
1 2 3 D N R
12.1
Diagnosis Tool 13
• Diagnosis
• EOL
• Measuring
Signal
• Parameterization converter
7 4 5 6
8 9
035558
1 Cable connection between electronic control unit 12 ZF-CAN

and transmission – E module 2 (optional)
2 Electronic control unit – Inputs
3 Electronic control unit's connector – Kickdown, retarder lever, step plate
4 Oil filler tube with dipstick – Outputs
5 Impulse sensor for speedometer
– Speed range selector (pushbutton range
(optional at 10 o’clock/2 o’clock)
selector)
6 Cooling water connections
– Inputs
7 Pressure filter
– Kickdown, retarder lever, step plate
8 Oil pan
– Outputs
9 Oil drain plug
10 Breather – ZF diagnostic access (12.1)
11 Vehicle CAN 13 Diagnostic tool, ZF-Testman

– Engine/on-board computer/brake system – Diagnosis
– Accelerator pedal – EOL
– Kickdown, retarder lever, step plate – Measurement
– Parameterization
EN 4181 751 102c - 2014-02 22

ZF-EcoLife Sectional drawing
6 AP 1000 B, 6 AP 1200 B, 6 AP 1400 B, 6 AP 1700 B and 6 AP 2000 B
8 9 10 11 1
7
2
6 5 4 3
027965_3
Key to drawing
1 Brakes D, E, F 6 Torsional vibration damper

2 Output 7 Input
3 Retarder oil cooler (ROC) 8 Torque converter lock-up clutch (LuC)
4 Hydraulic shift control unit 9 Torque converter
5 Oil pump 10 Retarder
11 Clutches A, B
EN 4181 751 102c - 2014-02 23

ZF-EcoLife Product designation
ZF-EcoLife - Product designation
The entire ZF-EcoLife transmission family at a glance.
The new nomenclature: Clear and standardized for all ZF model ranges.
ily
ion
am
e
qu
rs
at
lf
ea
er
or
ica
g
en
0) t t
g
of
10 pu
tg
olo
r
(x x . In
uc
be
nt
hn
e
od
od
ria
m
a
Te
Nu
Pr
M
Va
m
6 AP 1 4 0 0 B
( R D) *
dr e (L ax),
k
)
Tr s
er c
HD
uc
ift
Bu
w at i
ive H
gl riv co
sh
Po om
=
an le d rd (
=
B
t
T
ith g a
Au
w an nd
=
= h ta
e
AP
3 wit = S
= 0
2
033293_1
Transmission types
6 AP 2000 B
6 AP 1700 B
6 AP 1400 B
6 AP 1200 B
6 AP 1000 B
lbft* 738 886 1 033 1 255 1 476
lbft* 500 600 700 800 900 1 000 1 100 1 200 1 300 1 400 1 500
Nm 1 000 1 200 1 400 1 700 2 000
* 1 Nm @ 0,738 lbft 033292
The installation conditions and connection points of all transmission types are identical.
EN 4181 751 102c - 2014-02 24

ZF-EcoLife Shift Elements
Shift element combinations
The table shows the shift element combinations depending on the gears engaged and the ratios activated.
Clutch/brake combinations/ratios
6 AP xx00 B 6 AP xx02 B; 6 AP xx03 B
Gear A B D E F
i Gear φ φ total i Gear φ φ total
1. · · 3.364 3.265
1.762 1.762
2. · · 1.909 1.853
1.343 1.343
3. · · 1.421 1.380
1.421 5.469 1.421 5.469
4. · · 1.000 0.971
1.389 1.389
5. · · 0.720 0.699
1.171 1.171
6. · · 0.615 0.597
AIS 1. ·
R · · 4.235 4.112
AIS 2.1) ·
AIS R 1) ·
1) AIS special versions
Permissible transmission input speeds*
6 AP 1000 B
6 AP 1700 B 6 AP xx02 B
Transmission type 6 AP 1200 B
6 AP 2000 B 6 AP xx03 B 2)
6 AP 1400 B
Speeds
Minimum
nmin [rpm] 400 400 400
idling speed
Maximum 2800 (1st to 5th gear) 2600 (1st to 5th gear) 2400 (1st to 5th gear)
nmax [rpm]
input speed 2100 (6th gear) 2100 (6th gear) 2100 (6th gear)
2) For increased input speeds at reduced input torques, refer to the technical manual 4181 765 101, Chapter 2.4.2.
* For latest data, reference the technical manual 4181 765 101, Chapter 2.4.2
EN 4181 751 102c - 2014-02 25

EN 4181 751 102c - 2014-02 26
ZF-EcoLife Maintenance
1 Maintenance
1.1 Oil change intervals
NOTE
The pressure filter must be replaced at each oil change.
Only genuine ZF oil filters may be used.
Transmission oil change Oil-change interval
List of Lubricants TE-ML 20

- Vehicle classification TE-ML 20.100, lubricant class 20C every 120 000 km mileage/km
or every 2 years 1)
- Vehicle classification TE-ML 20.100, lubricant class 20E / 20F every 240 000 km mileage/km
or every 3 years 1)
- Vehicle classification TE-ML 20.105, lubricant class 20E / 20F every 180 000 km mileage/km
or every 3 years 1)
- Vehicle classification TE-ML 20.110, lubricant class 20F every 120 000 km mileage/km
or every 3 years 1)
1) Depending on what occurs first.
1.2 Oil quantities
• For oil change with standard oil drain

(draining time approx. 10 min.) approx. 24 liters
• For oil change with VRM special oil drain system approx. 17 litres
• For initial filling of the empty transmission
- 6 AP 1000 B / 1200 B / 1400 B approx. 38 liters
- 6 AP 1700 B / 2000 B approx. 42 liters
- 6 AP 100x B / 120x B / 6 AP 140x B / 170x B approx. 43 liters
NOTE
These values are reference values! The oil quantity after the oil level check at operating temperature
(90 °C) is definitive.
1.3 Oil grade
• The data in the ZF List of Lubricants TE-ML 20 are binding
Only oil of the 20C/20E/20F lubricant class may be used for filling of EcoLife transmissions.
The current List of Lubricants can be obtained directly from ZF or via the Internet at
http://www.zf.com.
EN 4181 751 102c - 2014-02 1-1

1.4 Oil level check
CAUTION
It is absolutely necessary to maintain the correct
oil level:
• Insufficient oil quantities lead to malfunctions
and damage of the transmission
• Excessive oil quantities lead to overheating of
the transmission
DANGER 4/5
Insufficient oil quantities lead to partial or Fig. 1.1 Coaxial transmission
035559_1
complete failure of the retarder, i.e. results in 4 Oil filler tube

reduced braking effect or no braking effect at all. 5 Oil dipstick
The following general rules apply:

5
• Transmission delivered with status 'not oil-filled'

must be filled with the specified oil volumes prior
to initial operation.
4
• In order to ensure minimum oil volumes for initial

operation or after an oil fill (e.g. oil change,
repair), an initial check is to be conducted with
cold transmission oil, refer to Chapter 1.4.1.
• The relevant oil level check is to be conducted at
operating temperature (90 °C), also refer to
Chapter 1.4.2.
Fig. 1.2 Transmissions with angle drive of 80°, RHD
035560_1
• For options to heat up transmission oil, refer to 4 Oil filler tube

Chapter 1.4.4. 5 Oil dipstick
• Oil level check at least quarterly

• Regular visual inspection of the transmission for
5
signs of leakage
4
Fig. 1.3 Transmissions with angle drive of 80°, LHD

035561_1
4 Oil filler tube

5 Oil dipstick
EN 4181 751 102c - 2014-02 1-2

1.4.1 Initial check of the oil level in order to 1.4.2 Check at operating temperature
ensure a minimum oil quantity
Oil level check when transmission oil is hot (90 °C):
NOTE
• Vehicle is parked on level ground
For commissioning or after an oil filling (e.g. oil
change, repair), an initial check of the oil level • Shift speed range selector (pushbutton range
has to be conducted after engine start to ensure selector) to “Neutral”
the minimum oil quantity.
• Let engine run at 1 200 – 1 500 rpm for 15 to 20
seconds
Oil level check with cold transmission oil (30 °C):
• Let engine run at idle speed
• Vehicle is parked on level ground
• Shift speed range selector (pushbutton range CAUTION
selector) to “Neutral” The idle speed should be set to between 500 and
700 rpm. It must never drop below 400 rpm.
• Let engine run at 1 200 – 1 500 rpm for 15 to
20 seconds
• Oil must be within “90 °C (hot)” range
• Let engine run at idle speed
CAUTION
The idle speed should be set to between 500 and
700 rpm. It must never drop below 400 rpm.
• Oil level must be within “30 °C (cold)” range
} 90 °C (hot)
Fig. 1.5 Oil level in the "90 °C (hot)" range

031567
} 30 °C (cold)
1.4.3 Electric oil level check
The Technical Customer Information "Electric Oil

Fig. 1.4 Oil level in the "30 °C (cold)" range
031567
Level Sensor EcoLife, 4181 761 022" is obligatory.
EN 4181 751 102c - 2014-02 1-3

1.4.4 Option for heating up transmission oil NOTE

Drain oil only at operating temperature and at least
The transmission oil can be heated up to the for 10 minutes:
specified operating temperature for oil level check
• Engine standstill
purposes by normal driving operation with retarder
cycles until the oil sump temperature reaches • Unscrew oil drain plug (1) and drain oil
90 °C. • Change filters according to Chapter 2.1
NOTE
CAUTION
Pressure filter must be replaced when oil is
Max. permissible continuous oil temperature in oil
changed.
sump is 120 °C and must not be exceeded.
When the operating temperature is reached carry 2
out “Check at Operating Temperature” (Chapter

1.4.2).
1.5 Variant 1 –
Oil change with standard oil drain
1
1.5.1 Oil drain Fig. 1.6 Coaxial transmission with standard oil drain
035580
DANGER
ZF angle drive 80° RHD / LHD
Risk of burns!
The angle drive does not have its own oil drain plug.
Contact with hot transmission or hot
Drain oil via main transmission’s oil drain plug
transmission oil may result in burns.
according to Chapter 1.5.
Wear suitable protective clothing,
protective gloves, and safety goggles/face
protection.
DANGER
Environmental hazard!
When draining oil, oil can get into the
environment!
Collect oil in a sufficiently large container
and dispose of it in accordance with the
regulations of the environmental
protection laws.
EN 4181 751 102c - 2014-02 1-4

1.5.2 Oil fill
CAUTION
Always use genuine ZF oil drain plugs.
The torque converter drain valve is operated via
the oil drain plug.
• Screw in oil drain plug (1) with new O-ring (refer

to Fig. 1.6).
Tightening torque: 35 Nm
• Fill in oil at oil filler tube (4) according to
Chapter 1.2
4/5
Fig. 1.7 Coaxial transmission
035559_1
• Check oil level at oil dipstick (5); refer to

Chapter 1.4
• For oil grade, see Chapter 1.3
5
Fig. 1.8 Transmissions with angle drive of 80°, RHD

035560_1
Fig. 1.9 Transmissions with angle drive of 80°, LHD

035561_1
EN 4181 751 102c - 2014-02 1-5

1.6 Variant 2 –
Oil change with VRM special oil drain
2 6.1
1.6.1 Oil drain
DANGER
Risk of burns!
Wear suitable protective clothing,
protective gloves, and safety goggles/face
protection. 1 6.2
Fig. 1.10 Coaxial transmission with VRM special oil

035581
DANGER drain
When draining oil, oil can get into the
environment! 1.6.2 Oil fill
Collect oil in a sufficiently large container
and dispose of it in accordance with the • Screw in special screw plug (6.1 or 6.2,
regulations of the environmental depending on installation position); (refer to
protection laws. Fig. 1.10).
• Fill in oil at oil filler tube (4) according to
NOTE
Chapter 1.2 (reference Figs. 1.7 up to 1.9).
- Oil drain only at operating temperature.
- No torque converter draining for oil drain with the • Check oil level at oil dipstick (5); refer to
VRM special oil drain. Chapter 1.4 (reference Figs. 1.7. up to 1.9).
- For VRM special oil drain, harmonization and
• For oil grade, see Chapter 1.3.
approval from the "Sales and Application"
department is required for the specification of
the oil and filter change intervals.
• Engine standstill
• Unscrew special screw plug (6.1 or 6.2,
depending on installation position) and drain oil
via quick plug system.
• Change filters according to Chapter 2.1.
NOTE
Pressure filter must be replaced when oil is
changed.
EN 4181 751 102c - 2014-02 1-6

ZF-EcoLife Repair
2 Repair
2.1 Filter change
DANGER
Oil can leak out and contaminate the
environment!
Collect oil in a sufficiently large container and
dispose of it in accordance with regulation of
environmental protection laws.
Dispose of contaminated filters in accordance
with regulations of environmental protection
laws.
1 Switch off engine.
DANGER
Risk of burns!
Wear suitable protective clothing, protective 1
gloves, and safety goggles/face protection.
2 If available, unscrew screw plug (1) and drain

oil from filter chamber. No screw plugs used
anymore as of serial number 344696.
032293
3 Remove O-ring (2).
032263
EN 4181 751 102c - 2014-02 2-1

ZF-EcoLife Repair
DANGER
Risk of burns! 1
Wear suitable protective clothing, protective
gloves, and safety goggles/face protection.
4 Unscrew six hex head screws (1) from the 2

filter cover (2).
NOTE
Watch for possibly leaking residual oil when
removing the filter cover.
5 Remove filter cover (2).

032292
6 Remove O-ring (1) of filter cover.
032265
7 Take out filter (1).
NOTE 1
Check filter for contamination.
032291
EN 4181 751 102c - 2014-02 2-2

ZF-EcoLife Repair
CAUTION
Use new filter. Ensure correct position of O-ring
(2) on the filter.
1
8 Coat the O-ring (2) with technical Vaseline 1
and insert new filter (1).
032721 032266
9 Coat new O-ring (1) with technical Vaseline.
10 Insert O-ring (1) into filter cover (2).

2
032264
11 Insert filter cover (1).
12 Screw in four M8x30 hex head screws (2)

and tighten.
Tightening torque:
Screw with washer assembly: 23 Nm 3
Flange-head screw: 29 Nm 2
13 Screw in two M8x55 hex head screws (3)

and tighten.
Tightening torque:
Screw with washer assembly: 23 Nm
Flange-head screw: 29 Nm 1
032292
EN 4181 751 102c - 2014-02 2-3

ZF-EcoLife Repair
15 Fit new O-ring (1) to screw plug.
NOTE
No screw plugs used anymore as of serial number
344696. 1
032263
16 Screw M14x1.5 screw plug (1) into filter cover

and tighten.
NOTE
344696. 1
032293
EN 4181 751 102c - 2014-02 2-4

ZF-EcoLife Repair
2.2 Replacing electronic control unit
2.2.1 Removing electronic control unit

1
1 Unscrew the four hexagon screws (1) of the

electronic control unit.
032314
2 Loosen securing device (1) and disconnect

the connector.
NOTE
The connector comes lose when turning
the securing device counterclockwise.
032315
3 Take off the electronic control unit (1) together

with the wiring harness (3).
4 Open the connector's (2) safeguard and 1

separate the connector (2) from the electronic
control unit.
2
3
032294
EN 4181 751 102c - 2014-02 2-5

ZF-EcoLife Repair
2.2.2 Installing electronic control unit
1 Plug wiring harness (3) with connector (2)

into the new electronic control unit (1) and 1
close lock (2).
2
3
032294
CAUTION
1
The contact faces of the electronic control unit 5
and the transmission must be even and clean;
otherwise, electronic control unit might be
damaged.
2 Position electronic control unit (1) with wiring 2

harness (2) on the transmission.
3
3 Insert connector (3). 4
4 Turn in the securing device (4) in clockwise

direction and snap it in.
5 Screw in four M6x26 hex head screws (5) and

tighten. 032314
Tightening torque: 9.5 Nm
EN 4181 751 102c - 2014-02 2-6

ZF-EcoLife Repair
2.3 Completely replacing the hydraulic shift

control unit
2.3.1 Removing oil pan
1 Remove cover (1) and filter according to

Chapter 2.1 “Filter change”. 1
032293
2 Unscrew two hex head screws (1).
3 Unscrew 29 hex head screws (2) from

circumference of oil pan.
032267
4 Remove oil pan (1).
032268
EN 4181 751 102c - 2014-02 2-7

ZF-EcoLife Repair
5 Remove gasket (1) from oil pan.
032984
2.3.2 Removing suction filter

1
1 Unscrew three torx screws (1, 2, 3) from the
suction filter (4).
NOTE
If available, remove washer from underneath the 2
torx screw (3). No washers used anymore as of 4
serial number 300214.
032270
2 Remove suction filter (1).
032271
EN 4181 751 102c - 2014-02 2-8

ZF-EcoLife Repair
2.3.3 Removing temperature sensor
CAUTION
Do not pull on the cable. This could lead to
damage of the connector.
1 Remove the temperature sensor's connector 2

(1).
2 Remove retaining clamp (2).
032273
3 Take out the temperature sensor (1).
032274
4 Remove the temperature sensor's O-ring (1).
02198
EN 4181 751 102c - 2014-02 2-9

ZF-EcoLife Repair
2.3.4 Removing the hydraulic shift control unit
1 Pull out the speed sensor's output connector

(1).
NOTE
Depending on the version, variant A or B (molded
hose) is possible.
1
A
B
032276/035456
2 Unscrew two torx screws (1) from transmis-

sion connector mounting plate.
3 Remove the mounting plate (2). 2
032990
CAUTION
Do not pull on the cable. This could lead to
2
1
4 Push out transmission connector (1) from

behind.
5 Pass through the transmission connector (2)

underneath oil pipe.
NOTE
In the case of a sand cast version, the transmission
connector is routed through the oil tube.
032989/032988
EN 4181 751 102c - 2014-02 2-10

ZF-EcoLife Repair
CAUTION
In the event of overhead work with the
transmission still installed, the hydraulic shift 2
control unit must be prevented from falling down
by means of two M8x100 auxiliary screws at
position 2 and 3 before all torx screws (1) are
removed.
6 Unscrew all torx screws (1) at the hydraulic 1

shift control unit.
0032281
7 Place hydraulic shift control unit on screw

heads of M8x100 auxiliary screws (1).
CAUTION
Do not pull on the cable. This could lead to 2
8 Pull out the speed sensor's turbine connector

(2). 1
032282
9 Unscrew M8x100 auxiliary screws and take

out hydraulic shift control unit (1).
1
032995
EN 4181 751 102c - 2014-02 2-11

ZF-EcoLife Repair
2.3.5 Removing speed sensor, turbine
1 Unscrew torx screw (1).
032285
2 Take out the speed sensor, turbine (1).
032286
2.3.6 Installing speed sensor, turbine
1 1 Insert the speed sensor (1) in the

transmission housing.
2
2 Screw in M6x17 torx screw (2) and tighten.
032285
EN 4181 751 102c - 2014-02 2-12

ZF-EcoLife Repair
2.3.7 Installing the hydraulic shift control unit
1 Insert the hydraulic shift control unit (1) into

the transmission housing and prevent it from 4
falling down by means of two auxiliary screws
(2/3).
2
2 Insert the speed sensor's turbine connector

(4).
1
032282
NOTE
After screwing in first torx screws, auxiliary screws
are removed again.
3 Screw eleven torx screws (1) into the

hydraulic shift control unit and tighten.
0032281
NOTE
When tightening the torx screw (1), make sure
position of retaining plate (2) (A or B) is correct.
4 Insert the speed sensor's output connector

(3).
3
NOTE
Depending on the version, variant A or B (molded A
B
hose) is possible.
2
1 1
2 3
032276/035456
EN 4181 751 102c - 2014-02 2-13

ZF-EcoLife Repair
5 Fit two new O-rings (1) to the transmission

2
connector (2). O-ring part number:
0501 325 589
3
NOTE
Mind anti-twist protection (3) for transmission
connector. 1
6 Pass through the wiring harness with

transmission connector (2) underneath oil
pipe.
NOTE
In the case of a sand cast version, the transmission
connector is routed through the oil tube.
032988032987/
7 Insert transmission connector (1).
NOTE
Mind anti-twist protection for transmission
1
connector.
032989
8 Put on the mounting plate (1).
9 Screw in two M6x17 torx screws (2) and

tighten. 1
2
032990
EN 4181 751 102c - 2014-02 2-14

ZF-EcoLife Repair
2.3.8 Installing temperature sensor
1 Coat new O-ring (1) of temperature sensor (2)

with technical Vaseline.
2
2 Mount O-ring (1) on temperature sensor (2). 1
024198
3 Insert the temperature sensor (1).
4 Fit retaining clip (2).
032274 / 032273
5 Plug in the temperature sensor's (1)

connector.
032272
EN 4181 751 102c - 2014-02 2-15

ZF-EcoLife Repair
2.3.9 Installing the suction filter

1
2 Fit O-ring (1) to suction filter (2).
032271
CAUTION
When inserting the suction filter, the wiring 2
harness must not be pinched.
3 Insert suction filter (1).
4 Screw in two M6x25 torx screws (2 and 3). 3

1
5 Screw in M6x25 torx screw (4) with washer
and tighten all three screws.
NOTE
There must be a washer underneath the torx screw
(4). No washers used anymore as of serial number 4
300214. 032270
EN 4181 751 102c - 2014-02 2-16

ZF-EcoLife Repair
2.3.10 Attaching the oil pan
1 Check O-rings on oil tube (1) and at the valve

(2), replace if necessary. Coat O-rings with
technical Vaseline.
032991
2 Place new seal (1) on the oil pan.

2
3 Insert two M8x30 hex head screws (2) into
oil pan.
1
2
032288
CAUTION
1
When putting on oil pan, ensure that O-ring
of oil pipe (2) is positioned correctly and is not
damaged.
4 Carefully put on oil pan and screw in two hex

4 2
head screws (1).
NOTE
In terms of the torque converter counter-pressure, 3
the ball-and-socket bearing must correctly snap into
place, namely the bore for the pressure measure-
ment point (3).
1
032290
EN 4181 751 102c - 2014-02 2-17

ZF-EcoLife Repair
5 Screw in remaining 27 M8x30 hex head

screws (1) at circumference of oil pan – do
not tighten yet.
6 Screw in two M12x55 hexagon screws (2)

and tighten. 2
Tightening torque:
Flange head screw: 99 Nm 1
7 Tighten all 29 M8x30 hex head screws (1) at

circumference of oil pan.
Tightening torque:
Flange-head screw: 29 Nm
032267
CAUTION
Use new filter. Ensure correct position of O-ring
(1) on the filter.
8 Coat O-ring (1) with technical Vaseline and 2

insert new filter (2).
32721
9 Coat O-ring (1) with technical Vaseline.
10 Insert new O-ring (1) in the filter cover (2).

2
032264
EN 4181 751 102c - 2014-02 2-18

ZF-EcoLife Repair
11 Insert filter cover (1).
12 Screw in four M8x30 hex head screws (2)

and tighten.
Tightening torque:
Flange-head screw: 29 Nm 2 3
13 Screw in two M8x55 hex head screws (3)

and tighten.
Tightening torque:
025016
15 Fit new O-ring (1) to screw plug.
NOTE
344696. 1
16 Screw in M14x1.5 screw plug (1) and tighten.

NOTE
344696.
1
032293
EN 4181 751 102c - 2014-02 2-19

ZF-EcoLife Repair
2.4 Replacing retarder accumulator
2.4.1 Removing retarder accumulator
1 Unscrew three torx screws (1).
1 1
032316
2 Pull retarder accumulator (1) towards output

(see arrow) and take out.
DANGER
Failure to do so could cause major injury!
Do not dismantle the retarder accumulator
without the special tools specified.
Failure to do so could cause major injury.
032317
032318
EN 4181 751 102c - 2014-02 2-20

ZF-EcoLife Repair
2.4.2 Installing the retarder accumulator
1 Coat new O-ring (1) with technical Vaseline

and insert it.
032318
2 Insert retarder accumulator (1) with tube (2)

in housing bore.
032317
3 Screw in three M8x36 (1, 2) torx screws.

1 2
032316
EN 4181 751 102c - 2014-02 2-21

ZF-EcoLife Repair
2.5 Replacing speed sensor, output
2.5.1 Removing speed sensor, output (coaxial

transmission)
1 Remove three M8 hex head screws (1). 1
2
2 Take off cover (2).
032309
3 Take out seal (1) from the speed sensor's (2)

cover. 2
032311
4 Disconnect connector (1).
032312
EN 4181 751 102c - 2014-02 2-22

ZF-EcoLife Repair
5 Screw out one M6 torx screw (1).
032313
6 Take out the speed sensor, output (1).
032286
EN 4181 751 102c - 2014-02 2-23

ZF-EcoLife Repair
2.5.2 Installing speed sensor, output (coaxial

transmission)
1 Insert the new speed sensor, output (1).
2 Screw in M6x17 torx screw (2) and tighten.

Tightening torque: 9.5 Nm 2
1
032313
3 Fit connector (1).
032312
4 Coat new seal (1) with technical Vaseline.
5 Insert seal (1) in the speed sensor's (2) cover.

1
032310
EN 4181 751 102c - 2014-02 2-24

ZF-EcoLife Repair
6 Fit cover (1).
7 Screw in three M8x30 hex head screws (2)

and tighten.
Tightening torque:
2
032309
EN 4181 751 102c - 2014-02 2-25

ZF-EcoLife Repair
2.5.3 Removing speed sensor, output (RHD / LHD

angle drive)
1 Screw out screw plug (1).
033063
025042
3 Screw out one M6 torx screw (1).
033064
EN 4181 751 102c - 2014-02 2-26

ZF-EcoLife Repair
4 Take out the speed sensor, output (1) with the

cable.
5 Unplug connector (2) and remove speed

sensor with screw (3) and O-ring (4).
NOTE
The O-ring (4) serves as loss protection for the
screw (3).
2
1
1
030148
6 Remove screw (1) and O-ring (2).
1
2
025043
EN 4181 751 102c - 2014-02 2-27

ZF-EcoLife Repair
2.5.4 Installing speed sensor, output (RHD / LHD

angle drive)
1 Assemble speed sensor, output (1) with screw 1

(2) and O-ring (3).
NOTE
The O-ring (3) serves as loss protection for the
screw (2). 2
3
025043
2 Install inductive sensor, output (2) with M6x17

torx screw (1) and O-ring.
Tightening torque: 9.5 Nm 1
3 Fit connector (3). 2
033064
5 Fit O-ring (1) to screw plug.
025042
EN 4181 751 102c - 2014-02 2-28

ZF-EcoLife Repair
6 Screw in M42x1.5 screw plug (1).

033063
EN 4181 751 102c - 2014-02 2-29

ZF-EcoLife Repair
2.6 Replacing output shaft sealing ring
2.6.1 Removing shaft sealing ring
NOTE
The procedure is identical for transmissions with
angle drive. 1
1 If needed, remove the safety plate (1) by

means of a small flat chisel.
032307
2 Unscrew two hex head screws (1) from

flange.
3 Remove fixing plate (2).
032295
4 Manually pull off output flange (1).
032297
EN 4181 751 102c - 2014-02 2-30

ZF-EcoLife Repair
034078
6 Remove shaft sealing ring (1) using a suitable

tool.
032298
EN 4181 751 102c - 2014-02 2-31

ZF-EcoLife Repair
2.6.2 Installing shaft sealing ring
NOTE
The procedure is identical for transmissions with
angle drive.
CAUTION
If the output flange shows running-in wear from
the shaft sealing ring, the shaft sealing ring must
be installed in the output housing in a new
position. 2
1 If required, fit washer 1X56 138 590 (1) onto

1
tool 1X56 138 625 (2).
032303
2 Sprinkle shaft sealing ring's outside diameter

with spirit (ethanol).
3 Position new shaft sealing ring (1) onto tool

1X56 138 625.
032302
4 Drive shaft sealing ring in until firmly home

using tool 1X56 138 625 (1).
032301
EN 4181 751 102c - 2014-02 2-32

ZF-EcoLife Repair
NOTE
The shaft sealing ring's (1) installation dimension is
predetermined by the tool.
1
032298
5 Slide on output flange (1).
032297
6 Insert new O-ring (1) and press into groove.
032296
EN 4181 751 102c - 2014-02 2-33

ZF-EcoLife Repair
7 Position fixing plate (1).
8 Screw in two new M12x60 hex head screws

(2) and tighten.
032295
9 Place safety plate (1), part no. 4132 304 015,

onto tool 1X56 137 452 (2).
1
2
032304
DANGER
Risk of injury!
Pushing on the safety plate (1) might produce
a sharp-edged bur!
Carefully remove bur with a suitable tool.
1
10 Push safety plate (1) onto M12 hex head
screws until firmly home with pressure plate
2
by using tool (2).
CAUTION
Ensure cleanliness! Carefully remove chips and
other abraded material.
032305/032306
EN 4181 751 102c - 2014-02 2-34

ZF-EcoLife Pressure Test
2.7 Pressure test
Pressure test with the transmission installed in

the vehicle:
Pressure measuring connections: 1
1 = PD8 Lubricating pressure

2 = PHD Main pressure
3 = PVF Pressure upstream of filter
4 = PD6 Measuring connection for pressure
downstream of retarder oil cooler (ROC)
is mounted at output end on all sand-cast
2
and die-cast transmissions with ROC. 3 4
4 = PD5 Measuring connection for pressure
upstream of retarder oil cooler (ROC) is 032994
flange-mounted laterally on all die-cast

transmissions with ROC.
5 = A8 Torque converter counter-pressure
Test gage 1P01 136 670 (up to 25 bar)
Test gage 1P01 137 856 (up to 10 bar)
NOTE
The method for pressure testing at pressure
measuring connections PD8 (1) and PD5/6 (4)
described under work step 1 must be applied to all Adapter 1P82 139 839
transmission housings prior to introduction of
standard transmission housings 4181 302 025,
starting from transmission no: 1020 (approx.).
After that number, continuous testing is possible
without removing non-return valves with adapter
1P82 139 839.
1 Unscrew M10x1 screw plug at pressure

measuring point PD8 (1) and depending on
cooler mounting PD5/6 (4), screw out non-
return valves using a screwdriver, screw in
adapter 1P82 139 839 with O-ring and
connect test gage.
2 Unscrew M10x1 screw plug at pressure

measuring point A8 (5), screw in adapter
5
1P82 139 839 with O-ring and connect test
gage.
032262
EN 4181 751 102c - 2014-02 2-35

ZF-EcoLife Repair
NOTE
The method for pressure testing at pressure
measuring point PHD (2) and PVF (3) described
under work step 3 must be applied to all screw
plugs prior to introduction of standard screw plug
4181 302 029, or prior to introduction of die-cast
transmissions.
After that, continuous testing is possible without Screw plug 4181 302 009 (without valve)
changing screw plugs with adapters 1P82 139 839.
3 Unscrew SW 22 and/or SW 24 at pressure
measuring point PHD (2) and/or PVF (3) and
replace by screw plug 4181 302 009 (without
valve).
Screw in adapter 1P82 139 839 with O-ring Adapter 1P82 139 839
and connect test gage.
4 Carry out pressure test.
5 Remove test gage and adapter after
completed pressure measurement.
6 Re-insert original SW 22 or SW 24 screw plug
at PHD (2) or PVF (3), respectively. 1
Screw in M10x1 screw plug with new O-
rings.
7 Non-return valves do not have to be inserted
anymore in pressure measuring point PD8 (1)
and depending on cooler mounting PD5/6 (4).
2
Screw in M10x1 screw plug with new O- 3 4
rings.
Tightening torque: 12 Nm 032994
8 At pressure measuring point A8 (5), screw in

M10x1 screw plug with new O-ring.
NOTE
In the following, you will find an excerpt of the test
record for KD functional tests. The latest test record
for the EcoLife KD functional test can be ordered
under print number 4181 754 103 or accessed on
the ZF-ServiceLine.
5
032262
EN 4181 751 102c - 2014-02 2-36

ZF-EcoLife Pressure Test
2.7.1 System check at idling speed (turbine speed 620 rpm) UG = lower limit
OG = upper limit
PHD PA 8 PD 5 / PD 6 PD 8 Psch. WTR*

(bar) (bar) (bar) (bar) (bar)
Gear UG – OG UG – OG UG – OG UG – OG UG – OG
8.0 – 12.0 5.0 – 6.5 1.0 – 2.0 0.4 – 1.5 0.1 – 1.0
ACTUAL ACTUAL ACTUAL ACTUAL ACTUAL
N WK open**
2.7.2 System check at high speed (turbine speed 2 200 rpm) UG = lower limit
OG = upper limit
PHD PA 8 PD 5 / PD 6 PD 8 Psch. WTR*
(bar) (bar) (bar) (bar) (bar)
Gear UG – OG UG – OG UG – OG UG – OG UG – OG
10.0 – 12.0 5.0 – 6.5 3.0 – 5.0 1.8 – 3.0 0.6 – 3.0
ACTUAL ACTUAL ACTUAL ACTUAL ACTUAL
N WK open**
* Psch.WTR = Lubricating pressure angle drive

** WK = Torque converter lock-up clutch
EN 4181 751 102c - 2014-02 2-37

2-38
ZF-EcoLife Diagnosis/Troubleshooting
3 Troubleshooting 3.2 Test with terminal tester 6008 006 002
3.1 Electronic control unit Use of terminal tester 6008 006 002 with adapter
kit 6008 206 040.
CAUTION
Disconnecting the battery while the engine is For troubleshooting purposes, the terminal tester
running might destroy the electronic control unit! 6008 006 002 together with the adapter kit
6008 206 040 can be connected as follows: Either
Checking the ground and supply wires (ZF between the transmission cable and the electronic
requirement): control unit or between the electronic control unit
and the vehicle connector.
• Ground (–), cable cross-section: 2.5 mm2
• Supply (+), cable cross-section: 2.5 mm2
DANGER
Driving with terminal tester and adapter
CAUTION
cable is only permitted for test purpose
Battery master switch in the vehicle:
and is not allowed on public roads!
When master switch is OFF, battery and
generator must both be disconnected from
vehicle electric system!
CAUTION
Otherwise, power supply to the electronic control
Do not supply voltage to the emergency switch,
unit needs to be assured via terminal 30/battery,
the inductive sensor, and the proportional valves
even when master switch is OFF (power
(gear clutches, main pressure, and retarder),
consumption < 1 mA, non-critical!).
because this would cause short circuit and failure
The electronic control unit must not be operated
of affected components. The proportional valves
without battery. Risk of destruction through
can be supplied with a current of max. 900 mA.
overvoltage!
Carry out resistance measurements according to

“Pin assignment with measured values at EcoLife
transmission”.
NOTE
Resistance values can change with increasing and
decreasing temperature.
The resistance value of solenoid valves increases
with rising temperature.
EN 4181 751 102c - 2014-02 3-1

Pin assignment with measured values at EcoLife transmission
Pin at trans- EcoLife Comment EcoLife measured value (target value)

mission plug
Turbine speed
1 n_Tu -
Resistance value cannot be measured,
signal check with TestmanLife
Output speed
2 n_Ab -
Resistance value cannot be measured,
signal check with TestmanLife
3 VPS1 Positive supply of control valves -
4 TG_Sumpf Sump temperature sensor approx. 62 kohm between
pin 4 and 15 at (°C, refer to page 3-3)
5 VPS2 Positive supply of control valves -
6 - - -
7 - - -
8 RR3 Retarder control valve 10-15 ohm between pin 8 and 5 at 20 °C
9 WK Torque converter lock-up clutch 10-15 ohm between pin 9 and 5 at 20 °C
control valve
10 RHD Main pressure control valve 10-15 ohm between pin 10 and 5 at 20 °C
11 - - -
12 B Clutch B control valve 10-15 ohm between pin 12 and 5 at 20 °C
13 A Clutch A control valve 10-15 ohm between pin 13 and 5 at 20 °C
14 - - -
15 GM1 Ground connection of sump
temperature sensor
16 - - -
17 GM2 Ground connection of retarder -
temperature sensor
18 TG_Ret Retarder temperature sensor approx. 124 kohm between
pin 18 and 17 at (°C, refer to page 3-3)
19 F Brake F control valve 10-15 ohm between pin 19 and 5 at 20 °C
20 - - -
21 AU +5V Positive supply of output speed -
sensor
22 D Brake D control valve 10-15 ohm between pin 22 and 5 at 20 °C
23 AU +5V Positive supply of turbine speed -
sensor
24 E Brake E control valve 10-15 ohm between pin 24 and 5 at 20 °C
Notes: Do not supply voltage of 24 V to control valves!
EN 4181 751 102c - 2014-02 3-2

Tolerance table for sump temperature Retarder temperature sensor

sensor
Resistance value in kohm
NTC temperature sensor Measured current: < 1.2 mA
DKS 4261 thermometrics
Tolerance table – 40 °C to 150 °C
Temperature R/R25 R nominal R minimum R maximum °C Min Nominal Max

°C ohm ohm ohm -40 - - -
-40 33.0042179 1650061.2 1524759.4 1784945.9 -20 830.7 1000.2 1203.7
-35 23.8370981 1191746.8 1104837.5 1284978.4 0 281.3 329.4 385.6
-30 17.4083136 870336.7 809406.5 935479.3 20 108.3 123.8 141.4
-25 12.8483939 642361.4 599208.4 688346.7
40 46.39 51.88 57.98
-20 9.5788331 478898.2 448040.3 511676.7
60 21.73 23.83 26.12
-15 7.2101341 360474.0 338206.1 384054.3
80 10.98 11.84 12.75
-10 5.4770683 273828.6 257620.4 290940.1
100 5.9231 6.283 6.661
-5 4.1970599 209834.0 197939.9 222353.8
120 3.3786 3.533 3.692
0 3.2431186 162141.2 153345.4 171373.0
140 2.0234 2.088 2.154
5 2.5260344 126290.3 119738.1 133147.7
160 1.2498 1.289 1.329
10 1.9825385 99117.9 94203.5 104247.0
180 0.7932 0.8275 0.8627
15 1.5673486 78360.3 74650.3 82221.8
20 1.2477705 62382.9 59565.0 65307.9
Adjusted at 150 °C 1.633 kohm
25 1.0000000 49995.5 47842.9 52224.0
30 0.8065651 40324.6 38671.5 42031.6
35 0.6545420 32724.1 31448.2 34038.2
40 0.5342997 26712.6 25723.2 27728.9
Tau 63: <3s
45 0.4386094 21928.5 21158.0 22717.9
Operating current: < 2.5 mA
50 0.3620081 18098.8 17496.4 18714.4
55 0.3003397 15015.6 14543.0 15497.4
U B: 5V
60 0.2504222 12520.0 12148.0 12898.2 Temperature range: –40 °C to +160 °C
65 0.2098044 10489.3 10195.6 10787.0 (short-term +180 °C
70 0.1765668 8828.5 8596.2 9063.5
75 0.1492890 7463.8 7279.6 7649.6 Measurement range: –20 °C to +180 °C
80 0.1267509 6337.0 6190.7 6484.1 Housing material: Ultramid TKR 4355 G7
85 0.1080586 5402.4 5286.2 5519.1 Color: black
90 0.0924884 4624.0 4531.5 4716.5
95 0.0794644 3972.9 3887.5 4058.5
100 0.0685260 3426.0 3347.4 3505.0
105 0.0593035 2964.9 2892.7 3037.7
110 0.0514982 2574.7 2508.5 2641.6
115 0.0448682 2243.2 2182.5 2304.7
120 0.0392169 1960.7 1905.0 2017.1
125 0.0343832 1719.0 1668.0 1770.8
130 0.0302352 1511.6 1464.9 1559.2
135 0.0266644 1333.1 1290.3 1376.8
140 0.0235809 1178.9 1139.7 1219.1
145 0.0209103 1045.4 1009.4 1082.3
150 0.0185906 929.4 896.4 963.4
EN 4181 751 102c - 2014-02 3-3

3.3 Connect ZF-TESTMAN to diagnostic

connector
Carefully take off diagnostic connector’s protective

cap to connect ZF-TESTMAN via the diagnostic
connector (USB) on the speed range selector.
1
NOTE
Carefully lift protective cap on both sides (see
arrows) by using a small slotted screwdriver.
029415 / 032719
Connect adapter cable 6008 207 043 to diagnostic

connector (USB).
6008 207 043 / 029417
Connect adapter cable 6008 207 043 to

ZF-TESTMAN.
019940
EN 4181 751 102c - 2014-02 3-4

3.4 ZF-TESTMAN diagnosis system
The ZF-TESTMAN diagnosis system can be used universally, i.e. on all diagnosable ZF vehicle systems.
All necessary, transmission-specific data required for a rapid and comprehensive diagnosis can be
retrieved using the ZF-TESTMAN diagnosis system. Data are supplied on DVD and saved on the hard disk
using an installation routine.
Targeted troubleshooting allows staff trained by ZF to rapidly find the error in the transmission system.
After having identified the fault, the diagnosis system will propose remedial measures.
Communication between the transmission electronics and the interface adapter (DPA 05) is performed via
CAN. Communication between interface adapter and PC is performed via USB, serial line, or online using
mobile telephony. Each screen page can be printed out or saved for error documentation. The diagnosis
software is available in different languages.
Scope of functions
∙ Statistics data
All the statistics data which is saved on the control unit is displayed.
∙ Diagnosis
Current fault display; read error memory; delete error memory; read identification data
∙ Monitoring
Tester (displays all digital inputs and outputs); display of digital and analog parameters, e.g. speeds,
amperages, and voltages
∙ Repair aids
Tightening torques; setting data; special tools; test equipment.
Maintenance; servicing.
Pressures; circuit diagrams; electr. measured values.
As PDF file.
∙ ZF telephone directory
Telephone directory of all ZF service centers.
∙ Vehicle configuration
Depending on the product, all vehicle-specific data can be set here and/or driving programs can be
selected and adapted.
∙ Programming (Flashing)
Available programming files can be installed.
System requirements and scope of supply
Refer to Operating Instructions: ZF-TESTMAN 6008.758.004 (DE) or 6008.758.104 (EN).
EN 4181 751 102c - 2014-02 3-5

3-6
ZF-EcoLife Circuit Diagram, General, CAN-End (CAN end user) / CAN-Mid (CAN mid user) / SAE J1708 – From Drawing No.: 6029 739 017b/1
F2
KL30_+24V
F1
KL15_+24V
E1 E5 E7 E13 E6
F3 E12
25 8 9
VPI VP1 VP2
(KL15) (KL30) (KL30) 8 5
VPS2 VP2
20 18 1 8 9 10 11 12 13 20 13 I
AIM5 Y11(A)
EU1 ASIN VPE ED ED ED ED ED ED 7
SD2 Vehicle-Connector Transmission-Connector 25 9 I
Flex1 Flex2 Flex3 Flex4 Flex5 Flex6
AIM2 Y17(WK)
21 16
Limp home SD1
4 22 I
AIM7 Y14(D)
6 1 POS Legende Description
CAN_H
24 19 I
A1 Elektr. Steuergerät Getriebe Electr.control unit transm. AIM1 Y16(F)
5 RT 11
CAN_H CANF2_H A2 CAN-Fahrschalter CAN-shift selector
120 R
Tw. Pair A4 Getriebe, EcoLife Transmission, EcoLife
N A2 CAN_L
3 SW 2
CANF2_L A25 Diagnose SAE/CAN/ISO Diagnosis SAE/CAN/ISO AIM4
14 8
Y19(RR3)
120 R
A26 Diagnose ZF-CAN (Option) Diagnosis ZF-CAN (optional)

4 3 12 I
CAN_L AIM6 Y12(B)
F1 Sicherung 7,5/10 Amp., max 7,5/10 ampere fuse, max
7 A25 VP11
F2 Sicherung 15/20 Amp., max 15/20 ampere fuse, max 16 10 I
CAN_T VPI 7 AIM3 Y13(RHD)
SW F3 Sicherung 7,5/10 Amp., max 7,5/10 ampere fuse, max
CANF2_L 6
17 RT Tw. Pair H3 Lampe Temperaturwarnung Temp. warning light 5 24 I
VMHF CANF2_H 5 3 AIM8 Y15(E)
OR VMHF4(J1708_GND)
J1708"A" 2 E1 Eingang Kick Down Kickdown, input
ASOUT 1 4 3 2 5 VMGA VM AD1 AD2 AD3 GR Tw. Pair 9 3
J1708"B" 4 4 E5 Eingang Programmumschaltung Program-selection, input VPS1 VP1
19 22 2 14 15 16 GE VMHF2(CANF1_GND)
CANF1_H 8 E6 Eingang Gangfreigabe Gear release, input
3 6 9 GN Tw. Pair 6 23
2 5 8 CANF1_L 9 12 E7 Eingang AIS Automatic idle shift, input AU1 AU(+5V)
VMHF5(CANF2_GND)
1 4 7 VM1 3 E 1 2 E i n g a n g R e t a r d e r 3 s t u fi g Retarder 3-steps, input 2 1
21 E13 Eingang Ret.-Absch. bei ABS R e t . " o ff " d u r i n g A B S , i n p u t EF1 B12(nT)
VMHF1(CANF1_GND)
X25 X25 15 21
MCP 3-reihig 20 E23 Ausgang V-Signal V-signal (speed), output AU2 AU(+5V)
X26 1 7 5 6 3 2 4 8 9 E30 9-pin, Diagnose VMHF3(K_GND) E26 Ausgang Anlassperre Starter interlock, output
10 2
VM
E28 Ausgang Rückfahrscheinwerfer Back up lights, output

CANF2_H
CANF2_L
VPI
EF2 B11(nAB)
E30 Ausgang Retarder Bremslicht Retarder brake light,output
22 4 Ret.-Sumpf
CANF1 CAN, Triebstrang CAN, Power train ER1 B14(TG)
OR 10 CANF2 CAN, ZF (CAN-Fahrschalter) CAN, ZF(CAN-shift selector)
A26 SAE_J1708"A" SAE_J1708_A
VMG1
17 15
GM1
Tw. Pair
GR 19
SAE_J1708"B" SAE_J1708_B 21 18 Ret.-Austritt
H3 1
ER2 B13(Ret.-Aus)
15
18 17
VMG2 GM2
2 6
7 7
ER4
GE 23
E26 E23 E28

CANF1_High
Tw. Pair
CANF1_H
A1 AIM9
19 16
GN 5
CANF1_Low CANF1_L 11 14
AIM10
12 6
GE 14
CANF_1High CANF1_H
Tw. Pair 13 11
GN 22
120 R
CANF1_Low CANF1_L
13
1 20 A4
CANF1_T
VM1 VM2
ER3 ER3
(KL31) (KL31)
Brücke, wenn
CAN-Endteilnehmer 17 18 24 23
Bridge, if
CAN-enduser
CAN-Mittelteilnehmer
opt., lineare Andindung
CAN-miduser
opt., linear connection
Vorsicht / Caution
Abklemmen der Batterie bei laufendem Motor kann die ECU zerstören!
Don't disconnect battery, by running engine, the ECU could be distroyed !
GND
EN 4181 751 102c - 2014-02 4-1

ZF-EcoLife Circuit Diagram, General, CAN-End (CAN end user) /CAN-Mid (CAN mid user) /SAE J1708 – From Drawing No.: 6029 739 017b/2
Verkabelung-Anforderungen Harness-requirements
Stecker, ECU, fahrzeugseitig Plug, ECU, vehicle-part
Typ: 25pol, Kostal, Buchse (SLK/MLK) Type: 25pin, Kostal, female (SLK/MLK) 1 19
Stecker/Plug
10
2 20
ZF-Best-Nr.: 6029 199 156 ZF-Order-no.: 6029 199 156 11
ZF-Kabel
3 21 ZF-Harness
12
Hersteller: Fa. Kostal Manufacturer: Co. Kostal 4 22
13 Polbildansicht
5 23
Hersteller Best-Nr.: siehe TKI 0000 702 303 Manufacturer order-no: See TCI 0000 702 303 14 View of pin pattern
6 24
15
Z F - V e r a r b e i t u n g s p e z i fi k a t i o n : 0 5 0 1 7 0 0 4 5 3 Z F - p r o c e s s i n g - s p e c i fi c a t i o n : 0 5 0 1 7 0 0 4 5 3 7 25
16
Z F - S p e z i fi k a t i o n : 6 0 2 9 7 0 5 0 2 8 Z F - s p e c i fi c a t i o n : 6 0 2 9 7 0 5 0 2 8 8 17
Kostal-Verarbeitungspez: DOK 000 860 29 (verbindlich) K o s t a l - p r o c e s s i n g - s p e c i fi c : D O K 0 0 0 8 6 0 2 9 ( b i n d i n g ) 9 18
Achtung: Attention:
Kostal
Der Kabelabgang am ECU-Stecker muss nach T h e c a b l e m u s t b e fi x e d c a . 1 0 0 m m a f t e r 25-pin, ECU
ca. 100mm befestigt werden ! cable-out from the ECU-plug !
Hierzu ist eine Gewindebohrung (M8) am For this is designed a threaded hole (M8)
Getriebe-Wärmetauscher vorgesehen at the transmission heat-exchanger
Stecker, CAN-Fahrschalter Plug, CAN shift-seletor 22

20
21
19
Typ: 22pol, Tyco, Buchse, Jun.P.T., 2reihig Type: 22pin, Tyco, female, jun.p.t., 2-array 18 17 AMP JPT
16 15 22-pin, FS
ZF-Best-Nr.: 6029 199 132 ZF-Order-no.: 6029 199 132 14 13
12 11
10 9
Hersteller: Fa. Tyco Manufacturer: Co. Tyco 8 7
6 5
Hesteller Best-Nr.: 929504-7 (Stecker-Gehäuse) Manufacturer order-no: 929504-7 (plug-housing) 4 3
2 1
Herteller Best-Nr.: 927771-3 (Kontaktbuchse) Manufacturer order-no: 927771-3 (female terminal)
Stecker, Diagnose Plug, diagnoses 3 6 9

2 5 8
Typ: 9pol, Tyco, Buchse, MCP, 3reihig Type: 9pin, Tyco, female, MCP, 3-array
1 4 7
ZF-Best-Nr.: 6029 199 157 ZF-Order-no.: 6029 199 157
X25
Hersteller: Fa. Tyco Manufacturer: Co. Tyco MCP 3-reihig
9-pin, Diagnose
Hesteller Best-Nr.: 8-968971-1 (Stecker-Gehäuse) Manufacturer order-no: 8-968971-1 (plug-housing)
Herteller Best-Nr.: 1-968849-1 (Kontaktbuchse) Manufacturer order-no: 1-968849-1 (female terminal)
Stecker, Bordnetz (Vorschlag-ZF) Plug, vehicle interface (ZF proposel) 3 6 9 12 15
2 5 8 11 14
Typ: 15pol, Tyco, Buchse, MCP, 3reihig Type: 15pin, Tyco, female, MCP, 3-array
1 4 7 10 13
ZF-Best-Nr.: 6029 199 161 ZF-Order-no.: 6029 199 161
MCP, 3-reihig
Hersteller: Fa. Tyco Manufacturer: Co. Tyco
15-pin, Bordnetz
Hesteller Best-Nr.: 8-968973-1 (Stecker-Gehäuse) Manufacturer order-no: 8-968973-1 (plug-housing)
Herteller Best-Nr.: 1-968849-1 (Kontaktbuchse, 1,0qmm) Manufacturer order-no: 1-968849-1 (female terminal, 1,0qmm)
Herteller Best-Nr.: 1-968851-1 (Kontaktbuchse, 2,5qmm) Manufacturer order-no: 1-968851-1 (female terminal, 2,5qmm)
Leitungen, CAN-Schnittstellen Wires, CAN-interface

Schnittstellen nach: SAE J1939 / SAE J 1708 Interfaces according: SAE J1939 / SAE J 1708
Verdrilltes Leitungspaar: Schläge 32mm (32 S/m) Twisted pair wires: Twisted 32mm (32 S/m)
Empfohlener Leiterquerschnitt: 1,0qmm Recommended wire cross-section: 1,0qmm
Leitungen, BN(+)Kl.30, BN(-)Kl.31 Wires, power supply, Kl.30, Kl.31

Kl.30 (VPE1/VPE2), Pin 8 / 9 Kl.30 (VPE1/VPE2), pin 8 / 9
Kl.31 (VM1/VM2), Pin 17 / 18 Kl.31 (VM1/VM2), pin 17 / 18
Leitungen, BN(+)Kl.15 und sonstige Wires, power(+)Kl.15 and miscellaneous

Kl.15 (VPI), Pin 25 und alle sonstigen Leitungen Kl.15 (VPI), pin 25 and all other wires
Hinweis: Notice
Der Fahrzeughersteller (OEM) ist verantwortlich The Vehicle manufacturer (OEM) is responsible
für die Auslegung der Verkabelung. for the construction of the harness.
EN 4181 751 102c - 2014-02 4-2

ZF-EcoLife Terminal Connection Diagram, General, CAN-End (CAN end user), Diagn.: SAE J1708 – From Drawing No.: 6029 739 018a
2
3
17
4 5
6
Stromlaufplan: 6029.739.017
18
LM1 X1
1
10
19
X11:2/1.4 EF1 1
16
24 19 7 Circuit diagram:
Kostal, 25-pin 1 1 2 20 1 B12(nT) 15
SW WW:CBL/1.2 -CAN2L 2 CANF2_L EF1 2
EF1 X4:1/1.6 3
11
21
X11:10/1.4 EF2
2 B11(nAb)
14 23 20 8
9
AIM6 X4:12/1.6 12 X11:9/1.4 VPS1 13 22 21 X4
3 VMHF4 AIM6 3 4 22 3 VP1
Kostal, 24-pin
AIM7 X4:22/1.6 13 X11:22/1.4 ER1 12 11 10
1 19 4 VMHF2 AIM7 4 5 23 4 B14(TG)
2
10
20 GN WT:CFL/1.2 -CAN1L 5 CANF1_L
A1 AIM8 5
AIM8 X4:24/1.6 6
14
24
X11:8/1.4 VPS2
5 VP2
120 R
11 AU1 X4:23/1.6 15
3 21 6 AU1 6 7 25 6
12 16
4 22 7 SD2 ER4 7 7
13 WC:+B/1.2 V P 1 VPS2 X4:5/1.6 8 17 X11:14/1.4 AIM4 POS
5 23 8 VP1 VPS2 8 8 Y19(RR3) ITEM Legende Description
14 VPS1 X4:3/1.6 X11:25/1.4 AIM2
6 24 9 VP2 VPS1 9 9 18 9 Y17(WK)
7
15
25 OR WK:1708A/1.2 -1708A 10 J1708_A EF2 10
EF2 X4:2/1.6 X11:16/1.4 AIM3
10 Y13(RHD)
A1 Elektr. Steuergerät Getriebe Control unit transmission
16 WS:CBH/1.2 - C A N 2 H A2 CAN-Fahrschalter CAN-shift selector
RT 11 CANF2_H AIM10 11 X11 11
8 17 X11:3/1.4 AIM6 A4 Getriebe Transmission
J V J T
A4
12 VMHF5 12 Kostal, 25-pin 12 Y12(B)
X1:22/1.2 CAN1T X11:20/1.4 AIM5 A26 Diagnose ZF-CAN (Option) Diagnosis ZF-CAN (optional)
9 18 13 CANF1_T 13 13 Y11(A)
AIM4 X4:8/1.6
14 CANF1_H AIM4 14 14 F1 Sicherung 7,5/10 Amp, max 7,5/10 ampere fuse, max
AU2 X4:21/1.6 X11:17/1.4 VMG1
15 15 15
CAN-Bridge (End-User)
AU2 GM1 F2 Sicherung 15/20 Amp, max 15/20 ampere fuse, max
AIM3
LX1 WE:-/1.2 VM1
16 SD1 AIM3 16
VMG1
X4:10/1.6
X4:15/1.6 X11:18/1.4 VMG2
16 F3 Sicherung 7,5/10 Amp, max 7,5/10 ampere fuse, max
Inkl. "Stecker 17 VM1 VMG1 17 17 GM2 H3 Lampe Temperaturwarnung Temperature warning light
120 R
VMG2 X4:17/1.6 X11:21/1.4 ER2
X1 bis KN1" 18 VM2 VMG2 18 18 B13(Ret.Austr)
WL:1708B/1.2 - 1 7 0 8 B X11:24/1.4 AIM1 E1 Eingang Kick Down Kickdown, intput
Incl. "plug GR 19 J1708_B AIM9 19 19 Y16(F)
AIM5 X4:13/1.6 E5 Eingang Programmumschaltung Program-selection, input
X1 to KN1" 20 VMHF3 AIM5 20 20
ER2 X4:18/1.6 X11:15/1.4 AU2 E6 Eingang Gangfreigabe Gear release, input
21 VMHF1 ER2 21 21 AU(+5V)
X1:13/1.2 CAN1T ER1 X4:4/1.6 X11:4/1.4 AIM7 E7 Eingang AIS Automatic idle shift, input
22 CANF1_L ER1 22 22 Y14(D)
GE WQ:CFH/1.2 - C A N 1 H X11:6/1.4 AU1 E12 Eingang Retarder 3stufig Retarder 3-steps, input
23 CANF1_H ER3 23 23 AU(+5V)
AIM1 X4:19/1.6 X11:5/1.4 AIM8 E13 Eingang Ret.-Abschtl. bei ABS Retarder "off" durning ABS, input
24 ER3 AIM1 24 24 Y15(E)
WA:+Z/1.2 VPI AIM2 X4:9/1.6
25 VPI AIM2 25 E23 Ausgang V-Signal Speed-signal, output
X4 E26 Ausgang Relais Anlassperre Starter interlock, output
Nassbereich/ X1 X11 E28 Ausgang Rückfahrscheinwerfer Back up lihgts, output

Getriebe / Transmission E30 Ausgang Retarder Bremslicht Retarder brake light, output
Wet and dirty area CANF1 CAN, Triebstrang CAN, power train
CANF2 CAN, ZF (CAN-Fahrschalter) CAN, ZF (CAN-shift selector
3 6 9
WC:+B/1.2 VP1
Trockenbereich 2 5 8
WK:1708A/1.2 -1708A
1 Vehicle electric circuit(+24V/KL.30) KL.15_+24Vl Kl15_+24V
1 4 7 OR 2 Diagnosis "A" SAE J 1708
Dry area WE:-/1.2 VM1
3 Vehicle electric circuit (-/KL.31)
KL.30_+24V Kl.30_+24V
X25 GR WL:1708B/1.2 -1708B 4 Diagnosis "B" SAE J 1708
MCP, 9-pin
CANF2_H
WS:CBH/1.2 -CAN2H
CANF2_L
SW 5 CANF2-high F2 F1 F3
RT WW:CBL/1.2 -CAN2L
VPI
6 CANF2-low A26
VM
VPI
-1708A WA:+Z/1.2 7 Vehicle electric circuit(+24V/KL.15)
X3:9/1.4
GE WQ:CFH/1.2 -CAN1H 8 CANF1-high 9 7 3 6 5 4 8 2 1
OR
X25:2/1.4
X1:10/1.2
WK GN WT:CFL/1.2 -CAN1L 9 CANF1-low X26
1708A
-1708B E13 E6 E7 E5 E1 (+) 1
X3:10/1.4
WL LX25 X25 2
GR
X25:4/1.4
X1:19/1.2 1708B E12 3
-CAN1H X3:7/1.4 WC:+B/1.2 VP1 4 5 2 3 1
1 Vehicle electric circuit (+24V/KL.30) 1
X25:8/1.4 WQ 2 2 1 VPE
GE X1:23/1.2 CFH WA:+Z/1.2 VPI
3 Vehicle electric circuit (+24V/KL.15) 3 2 VM1
-CAN1L X3:8/1.4 SW WW:CBL/1.2 -CAN2L 4 CANF2-low 4
SW
3 CAN_L
- C A N 2 H Twisted Pair RT
X25:9/1.4 WT RT WS:CBH/1.2 5 CANF2-high 5 4 CAN_L
GN X1:5/1.2 CFL KN1 WQ:CFH/1.2 -CAN1H 7
6 6 5 CAN_H
GE CANF1-high 7 CANF1-high 6 CAN_H
GN WT:CFL/1.2 -CAN1L 8 CANF1-low 8 CANF1-low 7 CAN_T 22 21
LX3
120 R
VM1 OR WK:1708A/1.2 -1708A 9 Diagnosis "A" SAE J 1708 9 Diagnose"A" 8 EDFlex1 20 19
X3:11/1.4
X25:3/1.4
WE GR WL:1708B/1.2 -1708B 10 Diagnosis "B" SAE J 1708 10 Diagnose"B" 9 EDFlex2
18
16
17
15
- WE:-/1.2 VM1
X1:17/1.2
3 6 9 12 15 11 Vehicle electric circuit (-/KL.31) 11 10 EDFlex3 14 13
2 5 8 11 14 12 11
VP1
12 12 11 EDFlex4
A2 10 9
X3:1/1.4
WC
1 4 7 10 13
13 13 12 EDFlex5 8 7
X25:1/1.4 +B 14 14 13 EDFlex6 6 5
4 3
X1:8/1.2 X3 15 15 14 AD1 2 1
MCP, 15-pin
VPI 15 AD2
X3:3/1.4
X25:7/1.4
WA X3 X3a 16 AD3 X2
+Z AMP JPT
X1:25/1.2 17 VMHF
22-pin
18 ASIN
Stecker/Plug -CAN2H X3:5/1.4
WS Bordnetz-Schnittstelle 19 ASOUT
N
ZF-Kabel X25:5/1.4 Hinweis / Informatiom E23 E30 H3 E28 E26
ZF-Harness RT X1:11/1.2
CBH Vehicle interface Leitung siehe TKI:
1 20 EU1
6006.740.001 21 Limp home
Offene Stecksysteme im Trockenraum Cableling according TCI:
22
Polbildansicht -CAN2L X3:4/1.4 VMGA
View of pin pattern
X25:6/1.4
WW unterbringen 2
X2
CBL
SW X1:2/1.2 Locate open plug system in dry area
KL.31_GND Kl.31_GND
EN 4181 751 102c - 2014-02 4-3

ZF-EcoLife Terminal Connection Diagram, General, CAN-Mid (CAN mid user), SAE 1708 – From Drawing No.: 6029 739 021
4
2
3
17
5
6
Stromlaufplan: 6029.739.017
18
1 1
1
2
10
19
20
X11:2/1.4 EF1
1 B12(nT)
1
16
24 19 7 Circuit diagram:
15
X1 WW:CBL/1.2 -CAN2L EF1 X4:1/1.6 11 X11:10/1.4 EF2 14 23 20 8
Kostal, 25-pin
SW 2 CANF2_L EF1 2 3 21 2 B11(nAb)
AIM6 X4:12/1.6 12 X11:9/1.4 VPS1 13 22 21 9
3 VMHF4 AIM6 3 4 22 3 VP1 X4
AIM7 X4:22/1.6 13 X11:22/1.4 ER1 12 11 10
4 VMHF2 AIM7 4 5 23 4 B14(TG) Kostal, 24-pin
WT:CFL/1.2 -CAN1L AIM8 X4:24/1.6 14 X11:8/1.4 VPS2
1 19 GN 5 CANF1_L
A1 AIM8 5 6 24 5 VP2
120 R
10 AU1 X4:23/1.6 15
2 20 6 AU1 6 7 25 6
11 16
3 21 7 SD2 ER4 7 7
12 WC:+B/1.2 VP1 VPS2 X4:5/1.6 8 17 X11:14/1.4 AIM4
4 22 8 VP1 VPS2 8 8 Y19(RR3) POS
13 VPS1 X4:3/1.6 X11:25/1.4 AIM2 ITEM Legende Description
5 23 9 VP2 VPS1 9 9 18 9 Y17(WK)
14 WK:1708A/1.2 -1708A EF2 X4:2/1.6 X11:16/1.4 AIM3
6 24 OR 10 J1708_A EF2 10 10 Y13(RHD) A1 Elektr. Steuergerät Getriebe Control unit transmission
15 WS:CBH/1.2 -CAN2H
7 25 RT 11 CANF2_H AIM10 11 X11 11 A2 CAN-Fahrschalter CAN-shift selector
16 Kostal, 25-pin X11:3/1.4 AIM6
12 VMHF5 12 12 Y12(B) A4 Getriebe Transmission
8 17
X21:1/1.2 -CAN1H
13 CANF1_T
J V J T
13
AIM4 X4:8/1.6
X11:20/1.4 AIM5
13 Y11(A) A4 A26 Diagnose ZF-CAN (Option) Diagnosis ZF-CAN (optional)
9 18 GE 14 CANF1_H AIM4 14 14
AU2 X4:21/1.6 X11:17/1.4 VMG1 F1 Sicherung 7,5/10 Amp, max 7,5/10 ampere fuse, max
15 AU2 15 15 GM1
AIM3 X4:10/1.6 F2 Sicherung 15/20 Amp, max 15/20 ampere fuse, max
16 SD1 AIM3 16 16
WE:-/1.2 VM1 VMG1 X4:15/1.6 X11:18/1.4 VMG2 F3 Sicherung 7,5/10 Amp, max 7,5/10 ampere fuse, max
LX1 17 VM1 VMG1 17 17 GM2
120 R
VMG2 X4:17/1.6 X11:21/1.4 ER2 H3 Lampe Temperaturwarnung Temperature warning light
18 VM2 VMG2 18 18 B13(Ret.Austr)
WL:1708B/1.2 -1708B X11:24/1.4 AIM1
GR 19 J1708_B AIM9 19 19 Y16(F) E1 Eingang Kick Down Kickdown, intput
AIM5 X4:13/1.6
20 VMHF3 AIM5 20 20 E5 Eingang Programmumschaltung Program-selection, input
ER2 X4:18/1.6 X11:15/1.4 AU2
21 VMHF1 ER2 21 21 AU(+5V) E6 Eingang Gangfreigabe Gear release, input
X21:2/1.2 -CAN1L ER1 X4:4/1.6 X11:4/1.4 AIM7
22 CANF1_L ER1 22 22 Y14(D) E7 Eingang AIS Automatic idle shift, input
WQ:CFH/1.2 -CAN1H X11:6/1.4 AU1
GE 23 CANF1_H ER3 23 23 AU(+5V) E12 E i n g a n g R e t a r d e r 3 s t u fi g Retarder 3-steps, input
AIM1 X4:19/1.6 X11:5/1.4 AIM8
24 ER3 AIM1 24 24 Y15(E) E13 Eingang Ret.-Abschtl. bei ABS R e t a r d e r " o ff " d u r n i n g A B S , i n p u t
WA:+Z/1.2 VPI AIM2 X4:9/1.6
25 VPI AIM2 25
E23 Ausgang V-Signal Speed-signal, output
X4 E26 Ausgang Relais Anlassperre Starter interlock, output
X1 X11 E28 Ausgang Rückfahrscheinwerfer Back up lihgts, output
Getriebe / Transmission E30 Ausgang Retarder Bremslicht Retarder brake light, output
X1:14/1.2 -CAN1H CANF1 CAN, Triebstrang CAN, power train

KN2 X1:22/1.2 -CAN1L
1
2 CANF2 CAN, ZF (CAN-Fahrschalter) CAN, ZF (CAN-shift selector
2
4 3
3 1
LX21 4 3 6 9
WC:+B/1.2 VP1
X21 2 5 8 1 Vehicle electric circuit(+24V/KL.30) KL.15_+24Vl Kl15_+24V
WK:1708A/1.2 -1708A
LM1 X21 DIN-Baj., 4-pin 1 4 7 OR
WE:-/1.2 VM1
2 Diagnosis "A" SAE J 1708
KL.30_+24V Kl.30_+24V
Nassbereich/ X25 GR WL:1708B/1.2 -1708B
3 Vehicle electric circuit (-/KL.31)
MCP, 9-pin 4 Diagnosis "B" SAE J 1708

Wet and dirty area
CANF2_H
-CAN2H
CANF2_L
WS:CBH/1.2
SW
-CAN2L
5 CANF2-high F2 F1 F3
RT WW:CBL/1.2 6 CANF2-low A26
VPI
VM
WA:+Z/1.2 VPI
-1708A X3:9/1.4 7 Vehicle electric circuit(+24V/KL.15)
Trockenbereich X25:2/1.4
GE WQ:CFH/1.2 -CAN1H
8 CANF1-high 9 7 3 6 5 4 8 2 1
Dry area OR X1:10/1.2
WK GN WT:CFL/1.2 -CAN1L
9 CANF1-low X26
1708A
-1708B X3:10/1.4
E13 E6 E7 E5 E1 (+) 1
X25:4/1.4 WL X25 2
GR X1:19/1.2 1708B LX25 E12 3
-CAN1H X3:7/1.4 WC:+B/1.2 VP1 4 5 2 3 1
1 Vehicle electric circuit (+24V/KL.30) 1
X25:8/1.4 WQ 2 2 1 VPE
GE X1:23/1.2 CFH WA:+Z/1.2 VPI
3 Vehicle electric circuit (+24V/KL.15) 3 2 VM1
WW:CBL/1.2 -CAN2L SW
-CAN1L X3:8/1.4 SW 4 CANF2-low 4 3 CAN_L 22 21
WS:CBH/1.2 -CAN2H Twisted Pair RT
X25:9/1.4 WT RT 5 CANF2-high 5 4 CAN_L 20
18
19
17
GN X1:5/1.2 CFL KN1 WQ:CFH/1.2 -CAN1H
6 6 5 CAN_H 16 15
GE 7 CANF1-high 7 CANF1-high 6 CAN_H 14 13
WT:CFL/1.2 -CAN1L 12 11
GN 8 CANF1-low 8 CANF1-low 7 CAN_T
LK2 LX3 10 9
120 R
WK:1708A/1.2 -1708A
VM1 X3:11/1.4 OR 9 Diagnosis "A" SAE J 1708 9 Diagnose"A" 8 EDFlex1 8 7
X25:3/1.4
WE GR WL:1708B/1.2 -1708B
10 Diagnosis "B" SAE J 1708 10 Diagnose"B" 9 EDFlex2 6
4
5
3
- 3 6 9 12 15 WE:-/1.2 VM1
X1:17/1.2 11 Vehicle electric circuit (-/KL.31) 11 10 EDFlex3 2 1
2 5 8 11 14
VP1 X3:1/1.4
WC
1 4 7 10 13
12
13
12
13
11
12
EDFlex4
EDFlex5
A2 X2
X25:1/1.4 +B 14 14 13 EDFlex6 AMP JPT
X1:8/1.2 X3 15 15 14 AD1 22-pin
MCP, 15-pin
VPI X3:3/1.4 15 AD2
X25:7/1.4
WA X3 X3a 16 AD3
+Z
X1:25/1.2 17 VMHF
Stecker/Plug 18 ASIN
-CAN2H X3:5/1.4
WS Bordnetz-Schnittstelle 19 ASOUT
N
ZF-Kabel X25:5/1.4 CBH
Hinweis / Informatiom E23 E30 H3 E28 E26 20
ZF-Harness RT X1:11/1.2 Vehicle interface Leitung siehe TKI:
1 EU1
6006.740.001 21 Limp home
O ff e n e S t e c k s y s t e m e i m T r o c k e n r a u m Cableling according TCI:
22
Polbildansicht -CAN2L X3:4/1.4 VMGA
View of pin pattern
X25:6/1.4
WW unterbringen 2
X2
CBL
SW X1:2/1.2 Locate open plug system in dry area
KL.31_GND Kl.31_GND
EN 4181 751 102c - 2014-02 4-4

ZF-EcoLife Hydraulic Plan From Drawing No.: 4181 700 003c
GETRIEBEAUSFUEHRUNG RETARDERWAERME-
TAUSCHER ROC E1/E2
TD5 b
GETRIEBEAUSFUEHRUNG RETARDERWAERME-
TAUSCHER ROC B
B16 B15 PNA D5 D6
D6 TD5
WANDLERKUPPLUNG
DRUCKREGLER NA RETARDERWAERME- D5
0 - 18 BAR TAUSCHER
B47
RETARDERWAERME-
UMSCHALTVENTIL D1 / D2 TAUSCHER
ZUSCHALTEN 15 BAR D5
PHD ABSCHALTEN 5.5 BAR D6
2 NEBENABTRIEBE MOEGLICH D2 SCHALT-

SCHALT-
DRUCK
SCHALTDRUCK DRUCK SCHALTDRUCK PWK 2,8 BAR
B52 F1
B E 4,5 BAR -> D4
6,0 BAR -> T D4
WANDLER
B41 A8
B53 F2
D1
22 UMSCHALT-
VENTIL B40
SCHALTDRUCK F1 / F2 D2
8.5 BAR
A B39
B6
B22 B12
WANDLERGEGEN-
B49 B50 B51
B48
DRUCKVENTIL 14
B25 8
B13 KÜHLERUMSCHALT-
PB 21 7,9 BAR -> A3 VENTIL
B26
PA 9,1 BAR -> T
A8
PDR R1
PD PE PF
B7 7
WANDLERSICHER- B38
17 B1
16 B3 18 B46 B8 20 B10
15 HEITSVENTIL SPEICHER R3
DRUCKREGLER B DRUCKREGLER A
DRUCKREGLER D
DRUCK-
19 DRUCKREGLER F DRUCK-
0,5 l
0 - 18 BAR 0 - 18 BAR
0 - 18 BAR 0 - 18 BAR REGLER E REGLER WK
0 - 10 BAR
0 - 18 BAR B14 0 - 12 BAR 12 11 B23 D7
RETARDER- RETARDER
REGELVENTIL R2
B34 B35 B24

B32 B33
B30 B31
2,5 BAR B5
B21
0.2 BAR -> PVWK D9
WANDLERENTLEERUNG
0.2 BAR -> PVB 0.2 BAR -> PVA UEBER
OELABLASSSCHRAUBE
HAUPTDRUCKVENTIL
R4 13
6 RR3 SCHALTVENTIL
23 B20
KUV
B19 1,5 BAR
PHD 5-21 BAR
10
B18 SCHALTGETRIEBE-
5 B17 DRUCKREGLER
RETARDER
WAERMETAUSCHER
RHD 18-5 BAR
B37
B36
DRUCK-
REGLER RHD
PVF = DRUCK VOR FILTER

PVF = pressure before filter
PHD = main pressure HAUPTDRUCKVENTIL
PHD = HAUPTDRUCK
D8
RHD = precontrol pressure main pressure valve
RHD = VORSTEUERDRUCK NEBENABTRIEBE
PHD
PA = switching pressure clutch

BA
PA = SCHALTDRUCK KUPPLUNG A
PB = switching pressure clutch

D B
PB = SCHALTDRUCK KUPPLUNG SCHMIERDRUCK- WINKELTRIEBE
9
PD = switching pressure brake D D
PD = SCHALTDRUCK BREMSE VENTIL
3
PDR = return pressure 2 brake
E D
PDR = RUECKFUEHRDRUCK 2 BREMSE DRUCKFILTER
PE = switching pressure brake E

PE = SCHALTDRUCK BREMSE 1,9 BAR
PF = switching pressure brake F
PF = SCHALTDRUCK BREMSE F
PNA
PWK = = switching pressure power takeoff
PNA = SCHALTDRUCK NEBENABTRIEB
PWK = switching pressure converter clutch
SCHALTDRUCK WANDLERKUPPLUNG PVF
A1 = sump before suction filter

A1 = SUMPF VOR SAUGFILTER c
A2 = pump suction pressure

A2 = PUMPENANSAUGDRUCK PRIMAER-
A3 = pressure
NACHafter converter safety valve (for pump suction)
B43 RETARDERRAUM
A3 = DRUCK WANDLERSICHERHEITSVENTIL (ZUR PUMPENANSAUGUNG) 2 PUMPE
A8 = pressure
NACHafter converter
GANGSTUFE A8 = DRUCK WANDLER D8
N_F AIS 1 2 3 4 5 6 R 2,0 BAR
SCHALTELEM.
D2 = pressure before converter
X D2 = DRUCK VOR WANDLER B28 DRUCKAUSGLEICHS-
A X X X X
D4 = pressure
NACHafter converter back-pressure valve (before cooler switch valve)
1 A3 RAUM KUPPLUNGEN
D4 = DRUCK WANDLERGEGENDRUCKVENTIL (VOR KUEHLERUMSCH.-VENTIL) A2 FILTERBYPASS-
B X X X D5 = pressure
D5 = DRUCK before retarder heat exchanger
VOR RETARDER-WAERMETAUSCHER 4 VENTIL SCHALTELEMENTE
D6
D6 = = pressure after retarder heat exchanger
DRUCK NACH RETARDER-WAERMETAUSCHER
D7 = pressure before transmission heat exchanger
D1 X X X SCHALTGETRIEBE
D7 = DRUCK VOR GETRIEBE-WAERMETAUSCHER
D8 = lubricating pressure
D8 = SCHMIERDRUCK
1
D9 = changeover pressure cooler switch valve
D2 X SAUGSIEB
D9 = UMSCHALTDRUCK KUEHLERUMSCHALTVENTIL
E X X
R1 = pressure
R1 = DRUCK before retarder
VOR RETARDER
R2 = pressure
NACHafter retarder
F1 X X X X
1 R2 = DRUCK RETARDER
X X R3 = retarder control pressure
RR3 = precontrol pressure retarder control valve
F2 2 2 R3 = RETARDERREGELDRUCK
A1 TSU
R4 = pressure before retarder control valve
RR3= VORSTEUERDRUCK RETARDERREGELVENTIL
X REDUZIERTER DRUCK
PVA = preload pressure A
1 R4 = DRUCK VOR RETARDERREGELVENTIL TD5 = TEMPERATUR VOR
PVB = preload pressureBB

X PF > 8.5 BAR PVA = VORSPANNDRUCK A RETARDER-WT
2
PVWK
PVWK ==VORSPANNDRUCK
preload pressure CCWK(converter clutch)
PVB = VORSPANNDRUCK TSU = TEMPERATUR
F1 = AEUSSERE KOLBENFLAECHE BREMSE F SUMPF
F2 = INNERE KOLBENFLAECHE BREMSE F
EN 4181 751 102c - 2014-02 4-5

ZF-EcoLife Hydraulic Description
The hydraulic system converts electronic signals (commands) into the required
hydraulic variables and ensures oil pressures/volumetric flows.
• Suction strainer 1, pump 2, and pressure filter 3 • Pressure regulator A 16 • Torque converter drain valve 23
Pump 2 sucks oil from the oil pan through the suction strainer 1 (only when the The proportional solenoid actuates pressure regulator A 16 where main pres- The drain valve 23 is activated by removing the oil drain plug at the oil pan.
engine is running). The pressure filter 3 filters the oil supplied by the pump 2. sure pHD is applied. The proportional valve sets the switching pressure pA Thus, a part of the oil in the torque converter is also drained when draining the
depending on the control current of the transmission electronics. Switching transmission oil.
• Pump charging A3 pressure pA acts on the pressure return surface supporting the return spring.
The effluent oil quantity A3 at the converter safety valve 7 is directly fed into This limits the maximum switching pressure pA to a specified value. In an inac- • Retarder pressure regulator 10, retarder control valve 11
the pump suction port A2 and increases the pressure level in the suction port. tive condition, a preload valve prevents the switching element from running The proportional solenoid actuates the retarder pressure regulator 10 where
Pump charging is needed to reduce the suction vacuum and thus to raise the empty. main pressure pHD is applied. The proportional valve sets the pilot pressure
cavitation limit and efficiency of the pump 3. pRR3 depending on the control current of the transmission electronics. The
• Pressure regulator B 17 pilot pressure pRR3 acts on the ruled surface of the retarder control valve 11
• Filter by-pass valve 4 The proportional solenoid actuates pressure regulator B 17 where main pres- and thus determines the pR3 main pressure level. The level of the retarder con-
The filter by-pass valve 4 limits pressure loss in the pressure filter 3 to a specified sure pHD is applied. The proportional valve sets the switching pressure pB trol pressure pR3 determines the retarder effect.
value. When reaching the specified value, oil is fed into the lubricating system. depending on the transmission electronics. Switching pressure pB acts on the The retarder control pressure acts on the pressure return surface supporting
pressure return surface supporting the return spring. This limits the maximum the return spring. This limits the maximum retarder control pressure pR3 to a
• RHD pressure regulator 5 and main pressure valve 6 switching pressure pB to a specified value. In an inactive condition, a preload specified value.
The proportional solenoid actuates the RHD pressure regulator 5 where pump valve prevents the switching element from running empty.
pressure is applied. The proportional valve sets the pRHD pilot pressure • Lubrication pressure valve 9, cooler change-over switching valve 13, cooler
depending on the control current of the transmission electronics. The pRHD • Pressure regulator D 18 change-over valve 14
pilot pressure acts on the controlled surface of the main pressure valve 6 and The proportional solenoid actuates pressure regulator D 18 where main pres- (in the case of inactive retarder)
thus determines the main pressure level pHD. There is a by-pass bore between sure pHD is applied. The proportional valve sets the switching pressure pD The retarder pressure regulator 10, the retarder control valve 11, and the cool-
pHD and D2 at the main pressure valve 6 to prevent torque converter internal depending on the control current of the transmission electronics. Switching er-change over switching valve 13 are non-pressurized. Via the cooler change-
pressure drop and to guarantee a minimum quantity of lubricating oil for the pressure pFD acts on the first pressure return surface supporting the return over switching valve 13, main pressure pHD is transferred to the controlled sur-
transmission. spring. This limits the maximum switching pressure pD to a specified value. face of the cooler change-over valve 14. The cooler change-over valve 14 is
connected through. Coming from the converter back-pressure valve 8, the oil
• Torque converter safety valve 7 • Pressure regulator E 19 D4 reaches the retarder heat exchanger 27 via the cooler switch valve 14.
The torque converter safety valve 7 limits pressure D2 towards the torque con- The proportional solenoid actuates pressure regulator E 19 where main pres- Coming from the retarder heat exchanger 27, the oil reaches the transmission
verter to a specified value. The effluent oil quantity A3 is directly fed to the sure pHD is applied. The proportional valve sets the switching pressure pE heat exchanger 26 via the cooler switch valve 14. Subsequently, the cooled oil
pump suction port A2 for charging the pump. depending on the transmission electronics. Switching pressure pE acts on the flows into the transmission for lubrication. Lubricating pressure is limited to a
pressure return surface supporting the return spring. This limits the maximum specified value by the lubricating pressure valve 9 by feeding the excess oil into
• Converter counter-pressure valve 8 switching pressure pE to a specified value by feeding the excess oil into the the sump. A by-pass at the main pressure valve 6 helps prevent a pressure
Pressure from the torque converter flows to the converter counter-pressure sump. A by-pass at the main pressure valve 6 prevents pressure drop in the drop in the torque converter and guarantees the minimum oil quantity required
valve 8. There, the torque converter internal pressure A8 is set to a specified torque converter and guarantees the minimum oil quantity required for lubrica- for lubrication at the same time.
value. The A8 pressure is directed to the control surface of the lock-up clutch tion at the same time.
(WK) pressure regulator. • Lubricating pressure valve 9, cooler change-over switching valve 13, cooler
• Pressure regulator F 20 change-over valve 14
• Accumulator 12 The proportional solenoid actuates pressure regulator F 20 where main pres- (in the case of inactive retarder)
To reduce the retarder’s response time, the accumulator oil quantity is fed into sure pHD is applied. The proportional valve sets the switching pressure pF Retarder pilot pressure pRR3 acts on the activating face of the cooler change-
the retarder circuit by spring force. It is connected to R4 and is charged during depending on the transmission electronics. Switching pressure pF acts on the over switching valve 13, which is deactivated when main pressure pHD on the
traction operation. When engaging the retarder, the pressure of the retarder pressure return surface supporting the return spring. This limits the maximum activating face of the cooler change-over valve 14 reaches a specified value.
pilot control increases and the cooler change-over control valve 13 switches. switching pressure pF to a specified value. The cooler change-over valve 14 is switched by spring force. From the convert-
Now, the retarder control valve 11 charges the retarder; thus, R4 pressure er counter-pressure valve 8, the oil D4 flows through the cooler change-over
drops below a specified limit. The accumulator 12 is activated and supports • Change-over valve F/D 21 valve 14 to the transmission heat exchanger. Subsequently, the cooled oil flows
retarder filling. An orifice is installed in the filler line to make sure that the accu- Switching pressure pF acts on the activating face of the change-over valve F/D into the transmission for lubrication.
mulator 12 does not immediately suck oil once the pressure rises again. 21. Starting with a specified switching pressure pF, the change-over valve F/D Lubricating pressure is limited to a specified value by the lubricating pressure
21 switches. Thus, piston surface F2 is switched on in the switching element F. valve 9 by feeding the excess oil into the sump. A by-pass at the main pressure
• Lock-up clutch pressure regulator 15 Pressure regulator D 18 is switched to a higher control range. valve 6 helps prevent a pressure drop in the torque converter and guarantees
The proportional solenoid actuates the lock-up clutch pressure regulator 15 the minimum oil quantity required for lubrication at the same time.
where main pressure pHD is applied. The proportional solenoid is assisted by • Change-over valve D1/D2 22
the torque converter’s internal pressure A8 acting on the controlled surface. Switching pressure pD acts on the activating face of the change-over valve
The proportional valve sets the switching pressure pWK depending on the con- D1/D2 22. Starting with a specified switching pressure pD, the change-over
trol current of the transmission electronics. Switching pressure acts on the valve D1/D2 22 switches. Thus, the piston surface D2 is activated in the
pressure return surface supporting the return spring. This limits the maximum switching element D.
switching pressure pWK to a specified value. In an inactive condition, a pre-
load valve prevents the switching element from running empty.
EN 4181 751 102c - 2014-02 4-6

Annex
5 Annex
5.1 Overview of revisions
Index Date of issue Initiator Chapter Comments

a 2010-06 BKS-T All complete revision
chapters
b 2011-10 TBCI Preface Tightening torques flanged hexagon bolt/screw with washer
assembly
1 Oil quantities
2 Tightening torques flanged hexagon bolt/screw with washer
assembly
TMCC 4 Circuit diagram

c 2014-02 TUCI CI cover page, CI back page, Copyright, Preface, Safety Instruc-
tions, Repair and Assembly Instructions
Special tools: ZF-TESTMAN amended, 6008 001 021 omitted
Ratios table: Added values for WTR [angle drive]
Input speeds table: Added values for LHD
1.1 / 1.3 Added lubricant class 20C

1.2 Oil quantities (added special oil drain, VRM; updated WTR
[angle drive])
1.4 Added LHD; added electric

1.4.4 Alternatives for normal vehicle operation omitted
1.5 / 1.6 Added special oil drain, VRM
2.1 / Screw plug as of serial no. 344696 omitted
2.3.10
2.3.2 / Washer as of serial no. 300214 omitted

2.3.9
2.3.4 / Added molded hose variant

2.3.7 Amended note on transmission connector cable routing
2.5.3 / Changed work step sequence (added screw loss protection

2.5.4 section)
2.6.1 Amended work steps

2.6.2 Added a work step
3.4 Complete revision
4 Updated circuit diagram, connection diagram, and hydraulic
diagram
5/6 Added
EN 4181 751 102c - 2014-02 5-1

Enclosed Documents
6 Enclosed Documents
The documents enclosed are not subject to change management; they are for informational purposes
only. Please turn to your contact if you need binding documents and drawings.
Document no. Designation Technical information

4181.753.101a SD PDI EcoLife Hydraulic 1 - Position opened
4181.753.102a SD PDI EcoLife Hydraulic 2 - Position locked
EN 4181 751 102c - 2014-02 6-1

A8 1 Suction strainer insert
24
25
R2 26 2 Pump
R3
R1
D7 3 Pressure filter
8 D4
D2 4 Filter bypass valve

23 5 Pressure regulator (RHD)
6
14 D5
6 Main pressure valve (PHD)
D6
7 Converter safety valve
A8 D8
8 Converter counter-pressure valve
D2
13 9 Lubrication pressure
PHD
9
7 10 Pressure regulator retarder
PHD 3 R4 11 Retarder control valve
4 D9
PVF 28 13 12 Accumulator
RHD
A3
13 Shift valve (KUV)
2
14 Cooler change-over valve (KUV)
A3
29
11 15 Pressure regulator (WK)
A2
16-20 Pressure regulator A, B, D, E, F

1
R4
R3 23 Torque converter drain valve
D8 PHD
RR3 24 Torque converter
25 Retarder
5 12
RR3
26 Heat exchanger (TOC)
PE
D6
27 Heat exchanger (ROC)
28 Planet gear train

15 19 10 27
29 Clutches/Brakes A, B, D, E, F
A8
PHD
PWK 029309_1
Subject to technical change without notice
HYDRAULIC 1 - POSITION OPENED ZF Friedrichshafen AG

4181 753 101a • MC-C • 2009-12
A8 1 Suction strainer insert
24
25
R2 26 2 Pump
R3
R1
D7 3 Pressure filter
8 D4
D2 4 Filter bypass valve

23 5 Pressure regulator (RHD)
6
14 D5
6 Main pressure valve (PHD)
D6
7 Converter safety valve
A8 D8
8 Converter counter-pressure valve
D2
13 9 Lubrication pressure
PHD
9
7 10 Pressure regulator retarder
PHD 3 R4 11 Retarder control valve
4 D9
PVF 28 13 12 Accumulator
RHD
A3
13 Shift valve (KUV)
2
14 Cooler change-over valve (KUV)
A3
29
11 15 Pressure regulator (WK)
A2
16-20 Pressure regulator A, B, D, E, F

1
R4
R3 23 Torque converter drain valve
D8 PHD
RR3 24 Torque converter
25 Retarder
5 12
RR3
26 Heat exchanger (TOC)
PE
D6
27 Heat exchanger (ROC)
28 Planet gear train

15 19 10 27
29 Clutches/Brakes A, B, D, E, F
A8
PHD
PWK 029310_1
Subject to technical change without notice
HYDRAULIC 2 - POSITION LOCKED ZF Friedrichshafen AG

4181 753 102a • MC-C • 2009-12
88038 Friedrichshafen
Deutschland · Germany
Telefon/Phone +49 7541 77-0
Telefax/Fax +49 7541 77-908 000
www.zf.com
EN 4181 751 102c - 2014-02

OPERATING INSTRUCTIONS
INDEPENDENT WHEEL SUSPENSION

RL 75 E/EC
RL 82 EC
FRONT AXLE/TAG AXLE

RL 75 A
5871.197.902 en
Preface
This documentation has been developed for specialized staff trained by ZF Friedrichshafen AG for repair
and maintenance work to be done on ZF-units.
Due to the continuous technical upgrading of the product, however, the maintenance of the unit at your
disposal may require both deviating work steps and differing setting and testing data.
These operating instructions are based on the unit’s state-of-the-art at the time of printing.
They were prepared with utmost care in order to avoid errors.
ZF Friedrichshafen AG, however, shall not be liable for any possible errors in figures or descriptions.
ZF Friedrichshafen AG reserves the right to replace these operating instructions by a successive edition at
any time without advance notice. Upon request ZF Friedrichshafen AG will advise which edition is the latest
one.
The owner and the user shall be responsible for complying with the safety instructions and for
implementing any maintenance work according to the specified guidelines.
ZF Friedrichshafen AG shall not be liable for any incorrect installation, improper handling, insufficient
maintenance, improperly and incompetently performed work and any consequential damage resulting
thereof.
It is imperative to observe the relevant instructions and manuals of the vehicle manufacturer.
Important information regarding technical reliability and operational safety are highlighted by the following
symbols:
This symbol serves as a reference to special working procedures,

INFO methods, information, use of auxiliaries etc... indicated in these
operating instructions.

This symbol identifies situations in which lacking care might lead to
CAUTION damage to the product.
This symbol identifies situations in which lacking care might lead to

DANGER personal injury.
ZF Services
Donaustr. 71
D - 94034 Passau
Copyright © ZF Friedrichshafen AG.

This document is protected by copyright. Complete or partial reproduction or dissemination of this document is
prohibited without the consent of ZF Friedrichshafen AG.
Infringements lead to civil and criminal prosecution.
Subject to technical modifications!
Design level 2007/12
4th edition 2015/05
1. Grease lubrication of hub bearing
1.1 Grease quality
Approved greases for the ZF-independent wheel suspension RL 75 E/EC/A / RL 82 EC see ZF- List of Lubricants
TE-ML 12.
The ZF list of lubricants is being continuously updated and can be obtained or viewed as follows:
 in all ZF plants
 in all ZF Service Centers
 Internet: http://www.zf.com
1.2 Maintenance intervals
In this connection refer to the ZF List of Lubricants TE-ML 12.
1.3 Grease change in the hub
 A complete check of the compact bearing including a grease change is also required outside the
maintenance interval, if the following criteria apply:
- Grease overflow at the shaft seal at brake disk side. Check the shaft seals during every
brake disk change.
- Overheated brake parts (e.g. burnt bellows on pressure piece).
Also refer to chapter 4.
Legend:
7
2 6
1 = Steering knuckle assy.
2 = Bearing unit assy.
2a = Bearing outer ring /
bearing inner ring 1
2b = O ring (109x5)* 2d
2c = Cassette-type seal*
2d = Retaining ring
2e = Shaft seal *
3 = Hub with brake disk
4 = Slotted nut 5
4
5 = O ring (155x3) 2e
6 = Locking plate 2a
7 = Cover 3
2b 2c 2a
* These spare parts are available separately, and are supplied as loose parts with the
bearing unit!
Removal
1 Remove hub with brake disk (3)
2 Remove grease from the hub (3), clean hub Remove just the inner rings of the tapered
and bearing inner rings/bearing outer rings (2a). roller bearings from the hub!
5871.197.902 en 1
Reinstallation

3 Check condition and wear of tapered roller Replace worn or damaged tapered roller
bearings (2a) (inner and outer ring) bearings by a new bearing unit.
4 Thoroughly grease tapered roller bearings (2a)

and fill them with the specified grease quantity.
5 Fill quantity: 96g per hub

6 Install hub Install new shaft seal (2e), cassette-type
seal (2e) and O-ring (2b).

7 Fit wheel head Fit new locking plate (6). Seal cover (7)
with Loctite 574.
All details of operations and setting values required for disassembly and reassembly are included
in the relating repair manual (5871.197.002)!
2. Grease lubrication of steering knuckle / control arm / steering lever / relay lever
2.1 Grease quality
Approved greases for the ZF-independent wheel suspension RL 75 E/EC/A / RL 82 EC see ZF List of Lubricants
TE-ML 12.
The ZF List of Lubricants is being continuously updated and can be obtained or viewed as follows:
 in all ZF plants
 in all ZF Service Centers
 Internet: http://www.zf.com
A lithium-saponified multi-purpose grease of NLGI class 2 which is mixable with mineral oil (grease
code KP2K-30 acc. to DIN 51825 or ISO-L-XCCHB2 acc. to ISO/DIS 6743-9) is to be used at the
greasing points.
2.2 Grease interval
In this connection refer to the ZF List of Lubricants TE-ML 12.
 The grease intervals must be reduced accordingly (40,000 km or every six months) under extreme
working conditions e.g. dust, wetness, dirt, considerable strains, etc.
 Always lubricate the ZF steering axles of series RL 75 E/EC/A / RL 82 EC with the wheels on the
ground, to ensure a correct grease flow (no jacking allowed).
5871.197.902 en 2
2.3 Procedure
2.3.1 Lubrication with pneumatic pump or a different automatic lubrication system
When using a pneumatic pump or different automatic lubrication systems, the initial lubrication pressure is not allowed
to exceed 250 bar.
Example: For a pump with a ratio of 1:50 the inlet pressure must not exceed 5 bar
(5 bar x 50 = 250 bar).
Lubricate the greasing points until grease comes out at the seal rings (steering knuckle bearing) and scrapers (control
arm bearing) over the whole circumference.
 Always lubricate with the wheels on the ground, as this is the only way to ensure a correct grease
flow.
2.3.2 Lubrication with a grease gun
Use a grease gun to lubricate the greasing points until grease comes out at the seal rings (steering knuckle bearing)
and scrapers (control arm bearing) over the whole circumference.
 Always lubricate with the wheels on the ground, as this is the only way to ensure a correct grease
flow.
Position of the lubricating nipples:
1 = Steering knuckle bearing (top)

2 = Steering knuckle bearing (bottom)
3 = Control arm bearing (top)
4 = Control arm bearing (bottom)
5 = Relay lever
6 = Intermediate lever
RL 75 E
1 3
5871.197.902 en 3
RL 75 EC / RL 82 EC
3
1
3
5 6
1
4 2
RL 75 A
1
5871.197.902 en 4
3. Check of vertical play in the axle fist
The vertical play existing in the axle fist must be determined as a part of the legally stipulated periodic technical
vehicle inspection. It is necessary to repair the king pin bearing if the vertical play exceeds 1.3 mm.
For further information see Service Information 85/11.

All details of operations and setting values required for the repair are included in the relating
repair manual (5871 197 002)!
4. Check of compact bearing (hub bearing)
4.1 Check intervals
Check the bearing when brake disk is changed, in case of any ABS-fault message and if noise rises with increasing
speed.
4.2 How to check the axial play
Remove the wheels. Loosen the cylindrical screws on the cover and remove the
cover, so that the steering knuckle becomes visible.
Fix magnetic stand to the hub and position the dial indicator at the circular ring
area at front side of the steering knuckle. Push hub towards the axle with both
hands (do not tilt) and rotate by 20° to 30° in both directions, until the dial
indicator pointer remains fix. Calibrate the dial indicator to zero. Use both hands
to pull the hub away from the axle (do not tilt) and rotate it by 20° to 30°in both
directions, until the pointer remains fix. The difference corresponds to the axial
play. Repeat measurements 3 times and calculate the average. Rotate the
wheel several times between the measurements.
If the measured value exceeds 0.20 mm, the compact bearing is worn and must be replaced.
Please find further information in the Repair Manual (ZF order number 5871 197 002).
4.3 How to check grease overflow
Check shaft seal at brake disk side with regard to grease overflow.
 A small quantity of grease (slight collar of grease) is permitted and not to be regarded as leakage.
5. Wheel bolts and wheel nuts
We would recommend you to replace heavily corroded wheel bolts.
 For tightening torques see vehicle manufacturer.

Please take further information from our Service Information.
Never grease/oil the thread of wheel bolts and wheel nuts.
5871.197.902 en 5
6. Lifting jack points

Do not position the lifting jacks on other points than those marked in the following illustration:
RL 75 E
Lifting jack points
RL 75 EC / RL 82 EC
Lifting jack points
5871.197.902 en 6
RL 75 EC / RL 82 EC
Lifting jack points
RL 75 A
Lifting jack points
5871.197.902 en 7
HEATING SYSTEMS
Thermo S 160
Thermo S 230
Thermo S 300
Thermo S 350
Thermo S 400
with Control Unit 1586
Workshop Manual
Rev.02/2017
Id.No. 11114913B
Thermo S 160/230/300/350/400 Table of contents
1 Introduction 101
1.1 Content and purpose 101
1.2 Effectivity of the workshop manual 101
1.3 Meaning of highlighted content 101
1.4 Symbols 101
1.5 Further documentation to be used 101
1.6 Safety information and regulations 101
1.6.1 General safety regulations 101
1.6.2 Other safety information 102
1.7 Suggestions for Improvement and change 102
2 Technical data 201

2.1 Electrical components 201
2.2 Fuel 201
3 Assemblies and component descriptions 301

3.1 Burner 302
3.1.1 Combustion air fan 302
3.1.2 Fuel pump 302
3.1.3 Nozzle block preheater 303
3.1.4 Control unit 303
3.1.5 Electronic ignition unit with ignition electrodes 304
3.1.6 Temperature sensors with water temperature sensor and integrated overheating protection 304
3.2 Heat exchanger 304
3.3 Combustion chamber 305
3.4 Circulating pump 306
3.4.1 Aquavent 5000 (U4814) and Aquavent 5000S (U4854) circulating pumps 306
3.4.2 Aquavent 6000C (U4855) and Aquavent 6000SC (U4856) circulating pumps 307
3.5 Fuel filter 307
4 Heater functions 401

4.1 General heater functionality description 401
4.2 Operational heater sequence 402
4.2.1 Switching on and start 402
4.2.2 Heating operation 402
4.2.3 Switching off 403
4.3 Diagnosis interface and STT diagnosis 404
4.3.1 Test plug 404
4.4 Malfunction interlock and heater interlock 405
4.5 Malfunction interlock 405
4.5.1 Malfunctions during switching-on and start procedure 405
4.5.2 Malfunctions during heater operation 405
4.5.3 Malfunctions during run-down 406
4.5.4 Malfunction interlock release 406
4.5.5 Deleting the error using the diagnosis 406
4.6 Heater interlock 406
4.6.1 Heater interlock release 406
4.7 Error output 407
5 Troubleshooting and error correction 501

5.1 General 501
5.2 General error symptoms 501
1
5.3 Malfunction code output via flash code 503

5.4 Error symptoms during functional tests with malfunction code output or diagnosis 505
5.4.1 Error symptom "No start within safety period" 505
5.4.2 Error symptom "Flame interruption" 505
5.4.3 Error symptom "Low voltage" 507
5.4.4 Error symptom "Extraneous light detected prior to ignition or during run-down" 508
5.4.5 Error symptom "Flame detector defective" 509
5.4.6 Error symptoms "Temperature sensor / overheating protection defective" and "Overheating" 509
5.4.7 Error symptom "Circulating pump interruption" 509
5.5 Individual component tests 510
5.5.1 General visual inspection 510
5.5.2 Heat exchanger visual inspection 510
5.5.3 Combustion chamber visual inspection 510
5.5.4 Resistance check of the temperature sensor with integrated overheating protection 511
5.5.5 Fan and combustion air intake line visual inspection 512
5.5.6 Burner motor inspection 512
5.5.7 Electronic ignition unit inspection 513
5.5.8 Ignition electrode inspection 514
5.5.9 Flame detector inspection 514
5.5.10 Fuel pump inspection 515
5.5.11 Solenoid valve inspection 516
5.5.12 Nozzle block preheater inspection 517
5.5.13 Circulating pump inspection 518
6 Schematic diagrams 601

6.1 General 601
7 Servicing 701
7.1 General 701
7.1.1 Heater servicing 701
7.2 Servicing 701
7.2.1 CO2 content adjustment 702
8 Burner, components and heater removal and installation 801

8.1 General 801
8.2 Burner removal and installation 802
8.3 Removal and installation of the temperature sensor with integrated overheating protection 803
8.4 Hood removal and installation 803
8.5 Combustion air fan removal and installation 804
8.6 Electronic ignition unit and ignition electrode removal and installation 806
8.7 Control unit removal and installation 808
8.8 Fuel pump removal and installation 808
8.9 Solenoid valve removal and installation 810
8.10 Atomizer nozzle removal and installation 810
8.11 Combustion chamber removal and installation 811
8.12 Heat exchanger removal and installation 812
8.13 Heater removal and installation 812
8.14 Start-up after burner or heater installation 812
8.14.1 Bleeding the fuel system 812
8.14.2 Bleeding of the coolant circuit 812
2
9 Modifications and retrofits 901
10 Packing / storage and shipping 1001

10.1 General 1001
Appendix
Periodic heater maintenance A-1
3
Thermo S 160/230/300/350/400 1 Introduction
1 Introduction 1.4 Symbols
1.1 Content and purpose Symbol tightening torque value:

Identifies in graphics parts (eg nuts, bolts)
that are to be mounted with a specific tigh-
This workshop manual is used during maintenance and
tening torque. The torque values are shown
repair of water heaters (further referred to as heaters)
at the symbol and are binding.
Thermo S 160, S 230, S 300, S 350 und S 400.
ATTENTION: 1.5 Further documentation to be used

Work on the heater may only be performed by briefed
and/or trained by Spheros personnel. The use of additional service literature is required.
References are provided in the workshop manual at
appropriate locations.
Use the following documents during operation and main-
1.2 Effectivity of the workshop manual
tenance of the heaters:
• Operating and Service Instructions
The workshop manual applies to heaters listed on the title • Installation Instructions
page of this document. • Technical Information (TI)
It may be subjected to modifications and amendments. • Spare Parts List
The respectively currently effectife version is binding. This • Operating Instructions for the Spheros Thermo Test,
version can be found on the Spheros homepage under further referred to as STT Diagnosis
Service/Downloads/Heating systems.
1.3 Meaning of highlighted content 1.6 Safety information and regulations

Throughout this manual the emphasized words Warning!, Basically, general accident pevention provisions and the
Caution!, ATTENTION: and NOTE: used as follows: valid industrial safety directions must be adhered to.
"General Safety Regulations" which exceed the frame-
work of these provisions are listed below.
Warning! Danger to life and health! The specific safety regulations which affect the present
manual are issued highlighted in the individual sections or
proce-dures.
This caption is used to indicate possible severe inju-
ries or fatal accidents if instructions or procedures
are carried out incorrectly or entirely disregarded.
1.6.1 General safety regulations
Caution! Hazardous to health!
Warning! Danger to life and health!

This caption is used to indicate possible minor inju-
ries if instructions or procedures are carried out
incorrectly or entirely disregarded. Read the Thermo S Operating and Service Instruc-
tions before operating the heater for first time.
ATTENTION: Familiarize yourself with the Thermo S Installation
This caption points to actions which may cause ma- Instructions before you make any modifications to the
terial damage. existing heater installation.
NOTE: NOTE:
This caption is used to draw attention to an important The Thermo S Operating and Service Instructions contain
feature. safety instructions and regulations to be followed for safe
operation of the heater.
The Thermo S Installation Instructions contain the

statutory regulations and other safety hints and regula-
tions for the proper installation of the heater.
101
Thermo S 160/230/300/350/400 1 Introduction
1.6.2 Other safety information
1.6.2.1 Temperature sensors
ATTENTION:
The temperature sensors cable may not be mechani-
cally stressed (pull on the cable, carry the heater at
the cable etc.).
STOP!
1.7 Suggestions for Improvement

and change
Please direct any complaints, improvement or modifica-

tion suggestions regarding this manual to:
service@spheros.de
102
Thermo S 160/230/300/350/400 2 Technical data
2 Technical data
Unless limiting values are defined, the technical data

should be understood with tolerances of ±10% common
for heaters at an ambient temperature of +20° C and at
nominal voltage.
Tabelle 701 Technical data
Thermo S Thermo S Thermo S Thermo S Thermo S

Heater
160 230 300 350 400
ECE type permit number E1 122R 00 0208 0226 0227 0228 0225
Design High-pressure atomizer
Heat flow rate (at 20°C ambient temper- kW 16 23 30 35 40
ature) (kcal/h) (13 800) (20 000) (26 000) (30 000) (34 000)
Fuel Diesel / light fuel oil
Fuel consumption kg/h 1.6 2.5 3.0 3.6 4.1
Nominal voltage V= 24
Operating voltage range V= 20...30
Electrical power consumption at 24 W 50 65 90 120 180
V*
Max. permissible combustion air intake °C + 85
temperature
Permissible ambient temperature during °C
-40...+ 100
operation
Permissible storage temperature °C -40...+ 110
Permissible operating overpressure bar max. 2.0
Heat exchanger filling volume l 1.8
Minimum water flow ** l/h 1400 1900 2400 2700 3200
Minimum circulation volume l 25.0
CO2 in exhaust at nominal voltage Vol % 9.5 + 1.5
Heater dimensions (tolerance ± 3 mm) mm Length 600 / Width 247 / Height 220
Weight kg 18.4 18.8
* without circulating pump

** Minimum water flow at coolant temperatures above 50°C
Below 50°C a lower water flow is permitted, if the occurence of vapor bubbles due to local overheating safely can be excluded.
2.1 Electrical components 2.2 Fuel
Control unit, circulating pump, solenoid valve, electronic Suitable fuel is the diesel fuel specified by the vehicle ma-
ignition and the digital timer are designed for 24V nominal nufacturer. Only the on the model plate of the heater
voltage. Motor nozzle block preheater and temperature specified fuel must be used.
sensor voltages are controlled by the control unit. The following table lists the by Spheros approved fuels
and their specifications.
NOTE:
Circulating pumps must be assigned to the heaters
according to the flow resistance in the coolant circulation
system. Voltages directly applied to the burner motor for
testing purposes may not exceed 12 V.
201
Thermo S 160/230/300/350/400 2 Technical data
Fuel Requirements
acc.
Summer diesel DIN EN 590
Winter diesel DIN EN 590
Arctic diesel and Diesel for a strong DIN EN 590

winter climate
Bio diesel (FAME)* DIN EN 12214
Paraffinic diesel fuel from synthesis DIN EN 15940

or hydrogenation (HVO)*
* Further information on approved fuels contains the TI

(Technical Information) Fuels.
It can be found on the Spheros homepage under Ser-
vice/Technical Updates/Heating systems.
In case of air temperatures below 0°C a commercial avail-
able winter Diesel fuel must be used.
The usage of flow improvers respectively additives is per-
mitted. There are no negative influences due to additives
known.
ATTENTION:
While using the fuels, their operating limits must be
considered and if necessary, suitable measures
(nozzle preheating, electrical heated filter) should be
applied.
If fuel is supplied from the vehicle tank, follow the
vehicle manufacturer’s instructions on additives.
202
Thermo S 160/230/300/350/400 3 Assemblies
3 Assemblies and component Heat is generated by combustion of liquid fuels. The heat
it transferred to a coolant circulation system via the
descriptions heater's heat exchanger. Intermittent operation adjusts
the heater to changing heat demand (cyclic operation).
The Spheros Thermo S 160, S 230, S 300, S 350 and The control unit controls heater activation and deactiva-
S 400 water heater systems are used in conjunction with tion based on the temperature sensor signals.
the vehicle heating system
– to heat the passenger compartment The heaters of the Thermo S series mainly consist of the
– to defrost the windows following main components:
– to preheat water-cooled vehicle engines.
– Burner
The water heater operates independently from the vehicle – Combustion chamber
engine and is connected to the cooling system, the fuel – Heat exchanger
system and the electrical system of the vehicle. It is bolted
down to the vehicle chassis or is secured using an addi- A circulating pump is externally installed in the system, or
tional cross beam. for compact devices directly on the heater.
2 4
Version for additional

sensor 1
9
5
7
8
11 6 Exhaust outlet
7 Fuel, return
8 Combustion air, intake
1 Burner 9 Fuel, flow
2 Coolant, intake 10 Splashguard
10
3 Temperature sensor (screen alternative)
12
with integrated over- 11 Screen
heating protection 12 Hot air elbow
4 Coolant, outlet (incl. adapter)
5 Heat exchanger (screen alternative)
301
3.1 Burner 3.1.2 Fuel pump
The burner consists of components The fuel pump is responsible for fuel supply.
The pump is driven by the burner motor via a coupling.
• Burner motor Fuel is compressed in the fuel pump to approx. 10 bar and
• Combustion air fan atomised via the atomiser nozzle.
• Fuel pump with solenoid valve and atomiser nozzle The solenoid valve integrated into the fuel pump opens
• Electronic ignition unit with ignition electrode and closes the fuel supply to the atomiser nozzle.
• Nozzle block preheater, optional Three different fuel pumps are assigned to the different
• Control unit with flame detector heating capacity classes of the Thermo S series.
• Disc with inspection glass These are identified by the heating capacity class
• Adapter wiring harness as interface to the specification as well as colour dots:
temperature sensor system
• 16 KW: 1 colour dot
3.1.1 Combustion air fan • 23-35 KW: 2 colour dots
• 40 KW: 3 colour dots
The combustion air fan transports the air required for
combustion from the combustion air intake to the combus- Solenoid valve Nozzle block
tion chamber. preheater (optional)
The combustion air fan consists of burner motor, fan and

motor cross member. Air is drawn in through the air intake
opening in the hood. The air intake opening is equipped
with a splashguard, a protective screen and a hot air
elbow.
Coupling with
Motor cross member magnets
Screen
Burner motor
O-ring
Fuel pump
Fan
Shaft
circlip
Two different motors are assigned to the different heating

capacity classes of the Thermo S series. The respective
heating capacity classes are indicated on the motor. In
addition the motors are differentiated by colour.
• 16 kW - 30 KW: Motor housing
colour: silver
Colour dots for
• 35 kW - 40 KW: Motor housing identification
colour: black of the heating
capacity class
302
The fuel pump can be used in dual-line operation (fuel 3.1.4 Control unit
supply and return line).
The control unit 1586 ensures the operating sequence
If the heater is operated with and burner operation monitoring.
The flame detector is integrated into the control unit.
– a long fuel supply line Different control units are assigned to the different heating
– check valves in the fuel supply and return line capacity classes.
– a fuel filter in the fuel supply line The control units are assigned via the ID number and the
– single-line operation performance class indicated on the type plate of the
control unit.
the fuel supply line must be filled prior to first heater start-
up (see 8.14.1).
3.1.3 Nozzle block preheater
In case of very low temperatures fuel may exhibit severely

modified viscosity. Due to insufficient fuel atomisation
functional heater malfunctions may occur.
Depending on the fuel used, these temperatures vary.

When used in cold regions or if fuels different from diesel
fuel are used, we recommend the use of a nozzle block
preheater.
The nozzle block preheater consists of a heating element Type plate with
with an integrated temperature sensor. ID number and
At a temperature of < 5°C the heating element heats the heating capacity
nozzle holder and thus, fuel and atomizer nozzle. Fuel class identification
viscosity is reduced and atomisation improved.
The control unit defines the preheating time depending on
vehicle electrical system voltage and starting temperature. Control unit 1586
The use of the nozzle block preheater is optional. It is

possible to retrofit this capability without modifications to
the control unit.
Flame detector
Heating element
Nozzle block preheater

3.1.4.1 Flame detector
The flame detector monitors the flame conditions during

heater operation.
The fame detector is a photo transistor, which changes its
resistance as a function of flame luminous intensity and
thus, the voltage applied.
303
temperature is captured at the heat exchanger outlet as

Electronic ignition unit electrical resistance and transmitted to the control unit.
Disc
Overheating protection prevents inadmissibly high heater
operating temperatures.
At a temperature greater than 135°C heater deactivation
and interlocking is initiated.
The procedure to release the heater interlock is outlined
in para. 4.6.1.
Temperature
sensor
Flame detector Window
3.1.5 Electronic ignition unit with ignition

electrodes
The electronic ignition unit induces the high voltage

required for ignition of the fuel-air mixture. Ignition is
triggered by a high voltage spark, which is initiated on the ATTENTION
ignition electrode. To remove the burner head, first remove the hood, discon-
nect the temperature sensor plug and remove the cable
grommet from the burner housing. Then the burner head
Ignition electrode can be disassembled.
3.2 Heat exchanger
The heat exchanger transfers the heat generated by

combustion to the coolant circulation system.
Depending on the system integration a heat exchanger
with or without thread in the coolant inlet socket can be
installed.
Coolant inlet
Electronic ignition unit
3.1.6 Temperature sensors with water

temperature sensor and integrated
overheating protection
The water temperature sensor captures the coolant

temperature at the heat exchanger outlet as electrical Coolant outlet
resistance. This signal is transmitted to the control unit,
where it is processed.
The overheating protection integrated into the temperature Exhaust outlet
sensor is responsible for temperature limitation.
Similar to the water temperature sensor, the coolant
304
3.3 Combustion chamber
The combustion chamber is used for generation and

combustion of the fuel air mixture. The generated exhaust
gas heats the coolant flowing through the heat exchanger.
23 - 35 KW
Welding seam
Swirl plate
16 KW
Combustion chamber
Identification
of the heating
capacity class
Three different combustion chambers are used for heaters

of the Thermo S series. Deviating from the standard
combustion chamber variant for Thermo S 230, S 300 and
S 350, the Thermo S 160 is equipped with a combustion
chamber with a sheet metal swirler and the Thermo S 400
is equipped with a burner pipe with increased wall
thickness (1.5 mm). 40 KW
The combustion chambers of Thermos S 160 and Thermo

S 400 are each fitted with a stamping to distinguish the
individual combustion chambers.
305
3.4 Circulating pump
The externally arranged circulating pump ensures coolant

transport within the vehicle and/or heater circulation
system. Aquavent 5000
Depending on the application, the circulating pump is swit-
ched on via the control unit or directly via the vehicle (U4814)
electrical system and operated during the entire heater
operation duration.
Heaters can be operated with Aquavent 5000 (U4814),
Aquavent 5000S (U4854), Aquavent 6000C (U4855) or
Aquavent 6000SC (U4856) circulating pumps.
Operating voltage
Circulating pump
Nominal voltage
Nominal power
consumption
Aquavent 5000S
Flow rate
(U4854)
Weight
range
l/h V= V= W kg
U 4814 5000 12 10…14 104 2.1
Aquavent (against 0.2 or or
5000 bar) 24 20…28
U 4854 5000 24 20…28 104 2.2
Aquavent (against 0.2 bar)
5000S
U 4855 6000 24 20…28 210 2.4 Aquavent 6000C

Aquavent (against 0.4 bar) (U4855)
6000C
U 4856 6000 24 20…28 210 2.5

Aquavent (against 0.4 bar)
6000SC
The safety device of the circulating pump may never be

pulled, while the pump is running, and may not be
replaced, when the pump is switched on. Aquavent 6000SC
(U4856)
3.4.1 Aquavent 5000 (U4814) and Aquavent
5000S (U4854) circulating pumps
The Aquavent 5000 (U4814) and 5000S (U4854) circula-

ting pumps are equipped with a brush motor.
NOTE:
Aquavent 5000 (U4814) with floating-ring type shaft seal.
Aquavent 5000S (U4854) magnetic drive (no seal)
ATTENTION:
The circulating pump motor is not equipped with an
internal inverse-polarity protection.
306
3.4.2 Aquavent 6000C (U4855) and Aquavent Inverse-polarity protection

6000SC (U4856) circulating pumps The circulating pump motor is not equipped with an
internal inverse-polarity protection.
The Aquavent 6000C (U4855) and
Aquavent 6000SC (U4856) circulating pumps are 3.5 Fuel filter
equipped with a brushless motor.
A heatable fuel filter is available as an option. The
NOTE: temperature switch switches the integrated filter heating
The Aquavent 6000C (U4855) has a floating-ring type on at a temperature of ≤ 0.5 ± 2.5 °C and switches it off at
shaft seal. a temperature of ≥ 5.5 ± 2.5 °C.
The Aquavent 6000SC (U4856) is equipped wit a
magnetic coupling (no seal)
Soft start
The circulating pump motor starts slowly and gently. Max.
rotational speed is only reached after approx. 5 seconds.
Protection against dry running

Protection against dry running is integrated into the circu-
lating pump motor.
If the circulating pump motor consumes within a time
period of approx. 45 minutes significantly less current, dry
running is detected. The circulating pump motor is swit-
ched off.
After approx. 2 minutes and circulating pump motor reac-
tivation, the operation can be continued.
Blocking protection
If the pump wheel is blocked, the motor will be switched
off via the error mode directly prior to standstill of the
pump wheel.
Overload protection
Overload protection is activated after the soft start is
completed. The current consumption will be limited.
In case of hydraulic overpressuring of the circulating
pump, the circulating pump motor will not be damaged.
Error mode
In case of malfunctions the circulating pump motor is swit-
ched off via the error mode. After approx. 5 seconds the
error mode switches the circulating pump motor into
energy-saving sleep mode.
Sleep mode
In sleep mode internal electronics consumers of the circu-
lating pump motor are switched off.
Reactivation of the circulating pump motor

It is possible to reactivate the circulating pump motor from
sleep mode. For this purpose the power supply is discon-
nected for > 2 min. After the power supply is reconnected,
the circulating pump motor restarts in soft-start mode.
307
Thermo S 160/230/300/350/400 4 Heater functions
4 Heater functions the control unit.

Depending on the equipment, the heater is switched on
and off using a
4.1 General heater functionality • digital timer
description • switch
• or climate control.
The heater principle is based on a high-pressure atomizer
burner and is monitored by an integrated control unit. During heating operation the burner is automatically
switched on and off. The heater is switched on, when the
The burner motor powers the fan and the fuel pump. The temperature falls short of a lower temperature threshold,
fuel pump is coupled to the motor using a plastic coupling. and is switched off, if the upper temperature threshold is
The fan produces the required combustion air, the combustion reached (see Table 401).
air volume is impacted by the burner motor speed.
The speed is monitored by a sensor in the control unit, which The switching thresholds depend on the heater variant
analyses the changing magnetic field of the magnets in the coupling. and the heating operation type. They cannot be changed
and are programmed into the control unit.
The speed required for the CO2-content is determined during
first calibration at Spheros and is stored in the control unit. For overheating protection of the heater the switching
In a maintenance event the workshop can adjust the CO2- thresholds are modified by the control unit, if specified
setting using the STT diagnosis (Spheros-Thermo-Test- temperature gradients are exceeded.
Diagnosis) (see 4.3).
If the specified minimum burning duration is not reached,
The fuel pressure is generated in the fuel pump and reduced the switching thresholds will be reduced. This protects the
to the required pressure using a pressure limiting valve. heater against sooting of the heat exchanger.
A solenoid valve releases the fuel via the atomizer nozzle
for combustion in the combustion chamber. An operating display is available for monitoring the operating
status. A flame indication can be optionally installed.
As an option, the fuel pump can be equipped with a nozzle The operating display is also used to output error
block preheater. The nozzle block preheater heats the messages in flash code.
nozzle holder with the atomizer nozzle at low temperatures, It is also possible to read the flash code via the two-pin
and thus the fuel. The fuel air mixture is ignited in the plug in the heater wiring harness (see 4.7 and 5.3).
combustion chamber via a high-voltage ignition spark. Use max. 2W lamps.
The flame is monitored by a flame detector integrated into
Table 401 Standard switching thresholds
Standard
Lower switching threshold: auxiliary heating in °C 78
Upper switching threshold: auxiliary heating in °C 85
Lower switching threshold: normal mode parking heating in °C 70

NOTE:
Upper switching threshold: normal mode parking heating in °C 85 Switching thresholds may deviate
per customer.
Lower switching threshold: saving mode 1 parking 55
heating in °C
Upper switching threshold: saving mode 1 parking 70

heating in °C
Lower switching threshold: saving mode 2 parking 45

heating in °C
Upper switching threshold: saving mode 2 parking 60

heating in °C
401
4.2 Operational heater sequence
Signals
Main switch off on off
Terminal 61 off (parking heating) on (auxiliary heating) off (parking heating)

Coolant temperature T > T_min T < T_min T >= T_max T < T_min T >= T_max T < T_min
generation
generation
generation
Flame
Flame
Flame
UPFA off
UPFA on
Actuators
Operating display
Flame display
Combustion air motor
Circulating pump
Solenoid valve
Nozzle block preheater
Time in s 0..108 12 1 0..15 5 ... 30 90 0..108 12 1 0..15 5 ... 30 90 0..108 12 1 0..15 5 ... 30 90
State
Run-down with safety period

Initial cycle with light check

Optional nozzle block

Stabilisation
Run-down 2
Stabilisation
Run-down 2
Stabilisation
Run-down 2
Pre-ignition
Pre-ignition
Pre-ignition
preheating
preheating
preheating
Look for
Ignition
Ignition
Ignition
OFF Standby Start Heating Run- Standby Start Heating Run- Standby Start Heating Run- Off
down down down
Fig. 401 Operational sequence
4.2.1 Switching on and start mined temperature and the vehicle electrical system
voltage the preheating time is determined. The duty cycle
When switched on, the operating display is illuminated, is limited to a maximum of 120 seconds.
the control unit starts controlled operation and checks the The burner motor does not run during the entire prehea-
coolant temperature. ting time. It starts latest 12 seconds prior to expiration of
the determined preheating time during initial cycle.
If the coolant temperature is below the upper temperature The initial cycle time can be extended to a maximum of
threshold, the initial cycle starts. 120 seconds.
Combustion air fan and circulating pump are switched on. The further sequence takes place as described.
After approx. 12 seconds (initial cycle time) the high- 4.2.2 Heating operation
voltage spark is ignited. Approx. 1 second later the
solenoid valve in the fuel pump is opened. After the flame is stabilised, the heater is in controlled
The fuel injected via the atomizer nozzle and mixed with (normal) operation.
the air of the combustion air fan, is ignited by the ignition Depending on the coolant temperature, the coolant
spark and burned in the combustion chamber. temperature is maintained at one level by switching the
The flame is monitored by a flame detector integrated into burner alternately on and off.
the control unit.
A few seconds after a flame is detected, the control unit Once the upper switching threshold is exceeded, heating
switches the electronic ignition unit off. Until then the operation is finished and run-down initiated.
flame is stabilised. The heater is not yet in heating mode. The solenoid valve is closed, the flame expires, however the
combustion air fan and circulating pump continue running.
With optional nozzle block preheater: The run-down ends approx. after 120 seconds. The
The integrated temperature sensor determines the combustion air fan is switched off.
temperature on the nozzle holder as soon as the initial The heater is in a controlled break.
cycle starts. Starting at a temperature of < 5°C the nozzle The operating display is illuminated.
block preheater is switched on. Depending on the deter- Once the temperature falls short of the lower switching
402
threshold, the heater restarts burner operation. It runs 4.2.2.3 Gradient evaluation
through the same sequence as the switching-on
sequence. In case of low coolant flow or poor coolant circuit venting
the temperature quickly increases in heating operation.
Different switching thresholds are defined for different
heater operating modes. The control unit recognises the quick temperature
The switching thresholds are selected depending on the increase and automatically sets the upper switching thres-
present condition and the selected heating operation. hold to a lower value.
The following switching thresholds may be applied. The quicker the temperature increases, the lower the swit-
ching threshold for starting the controlled break is set.
• Parking heating mode and auxiliary heating mode In addition, the burner is also switched back on again after
• Gradient evaluation the controlled break at a lower switching threshold.
• Minimum combustion period (also called hysteresis
adaptation) This prevents residual heat triggering the overheating
• Saving mode 1 and saving mode 2 protection.
The switching thresholds can be obtained from Table 401. 4.2.2.4 Minimum combustion period
4.2.2.1 Auxiliary heating mode and parking A minimum burner combustion period of 120 second is
heating mode targeted.
The control unit received the information, whether the For ambient and operating conditions this target is not
vehicle engine is running or not, from terminal D+/+61. always achieved.
In order to achieve the minimum combustion period, the
If terminal D+/+61 is connected and the vehicle engine is lower switching threshold is variably adjusted by the
running, the switching thresholds in auxiliary heating control unit.
mode are higher than in parking heating mode with the
engine not running. This process is also called hysteresis adaptation and is
In that case a saving mode is activated in parking heating applied in parking heating operation as well as auxiliary
operation. heating operation.
If terminal D+/+61 is not connected, then there is no If the combustion period falls short of the minimum
distinction. The heater always runs in parking heating combustion period, the lower switching value is lowered
operation. by 1K for the following combustion process.
The upper switching threshold remains as is.
This can be repeated until the minimum combustion
4.2.2.2 Saving modes period is reached or the lower switching threshold is
reduced by 5K.
Two different saving modes are programmed in the Further lowering is not possible.
control unit.
Saving mode 1 and saving mode 2 exist (see Table 401). Following a combustion process, where the required
In saving mode 1 the switching thresholds are higher than minimum combustion period was reached, the lower swit-
in saving mode 2. ching value is reset to its original value.
If saving mode is activated, the controlled temperatures in 4.2.3 Switching off

the heating system are maintained at a low temperature
level. The lower and upper switching threshold are Switching the heater off ends the combustion process.
reduced. The operating display expires and run-down is initiated.
The solenoid valve closes, the flame expires, the combus-
Due to lower radiation loss the fuel consumption can be tion air fan and circulating pump continue running.
reduced for a lower heat demand (e.g. warmer mode). The run-down ends approx. after 120 seconds. The
The heater burner output is not reduced. combustion air fan is switched off.
In auxiliary heating mode (signal from terminal D+/+61) If a malfunction occurs during run-down (e.g. flame detec-
saving mode is automatically deactivated (see 4.1). tion), the run-down may be shorter than 120 seconds.
During run-down it is permitted to switch the heater

back on. The burner will restart after a run-down time
of 30 seconds and subsequent initial cycle time.
403
4.3 Diagnosis interface and STT diagnosis 4.3.1 Test plug
Heaters of the Thermo S series support diagnosis During tests with the STT diagnosis menu "component
capabilities. Using the STT diagnosis adapter, STT test", the test plug is plugged directly into the control unit
diagnosis and a PC, the heaters in a vehicle can be of the heater after removal of the hood instead of the tem-
checked. For this purpose the STT diagnosis adapter is perature sensor.
connected to the diagnosis interface in the heater wiring
harness, and to a PC (see Fig. 403).
Next, STT diagnosis is started on the PC and the connec-
tion to the heater control unit is established.
Fig. 402 Test plug
24V
BUSY
PC S p h e r o s T h e r m o Te s t
approx. 3 m
cable
Diagnostic interface
Thermo S
to vehicle
Heater wiring harness
Fig. 403 STT diagnosis connection to the heater
NOTE
For protection against moisture and contamination ensure
that the diagnosis interface is sealed using protective
caps, if not in use.
The latest STT diagnosis software can be found in the

Internet on the Spheros homepage under Service /
Technical Documents.
404
4.4 Malfunction interlock and heater spark.

interlock • No start: No flame detection within 15 seconds
after opening the solenoid valve.
• Temperature sensor delivers unacceptable
Malfunction interlocks and heater interlocks are
temperature values.
distinguished.
• Heater operation outside the permissible temperature
Each malfunction interlock and heater interlock is stored
range.
in the control unit.
• Burner motor speed signal faulty.
• Voltage falling short of the low voltage threshold of
The heater should be protected against thermal loads.
approx. 20.5 V at motor start or within a duration of 20
seconds after a heating request.
Thermal loads can be triggered by:
• Voltage exceeding the high voltage threshold of approx.
30 V at motor start or within a duration of 6 seconds (run-
• Coolant flow too low
down only, no malfunction interlock).
• Coolant circuit not or only partially filled /
dry overheating.
• Circulating pump failure.
4.5.2 Malfunctions during heater operation
The control unit software detects overheating.
NOTE:
In case of malfunctions during heater operation, a
4.5 Malfunction interlock 120 seconds run-down will be executed first. Subsequently
the heater status is switched to malfunction interlock.
If one of the malfunctions listed below occurs, the heater If the circulating pump is externally actuated, it will
will initiate a fault shut-down, followed by malfunction continue operating.
interlock.
Malfunction criteria:
Depending on the error timing, no run-down or a 120 seconds • Short circuit and/or interruption of electrical
run-down will be executed. components:
Flash impulses are outputted via the operation indicator – Burner motor (stops immediately)
(see 5.3). – Circulating pump.
• Water temperature greater than the upper switching
In case of several sequential malfunction interlocks a threshold.
heater interlock is initiated (see 4.6). • Temperature sensor delivers unacceptable
temperature values.
• Heater operation outside the permissible temperature
4.5.1 Malfunctions during switching-on and range.
start procedure • Burner motor speed signal faulty.
• Flame interruption (combustion interruption for longer
NOTE: than 15 seconds).
If malfunctions occur during switching-on or during the • Voltage falling short of the low voltage threshold of
start process prior to ignition, the heater will be switched approx. 20.5 V at motor start or within a duration of
off without run-down. 20 seconds after a heating request.
• Voltage exceeding the high voltage threshold of approx.
The heater is in malfunction interlock. 30 V at motor start or within a duration of 6 seconds (run-
The motor stops immediately or does not start. down is applied, but no malfunction interlock).
• Reaching the max. number of shortfalls of the
If the circulating pump is externally actuated, it will minimum combustion duration.
continue operating. • Control unit malfunction.
Malfunction criteria:
• Short circuit and/or interruption of electrical
components:
– Burner motor (stops immediately)
– Circulating pump
– Electronic ignition unit
– Optional nozzle block preheater
• Flame or extraneous light detection by the flame
detector prior to ignition of the high-voltage ignition
405
4.5.3 Malfunctions during run-down Besides that a run-down between 30 seconds and up to 120
seconds is performed depending on error type and timing.
NOTE: Subsequently the heater status is switched to heater interlock.
If the circulating pump is externally actuated, it will If the circulating pump is externally actuated, it will
continue operating. continue operating.
Malfunction causes: Heater interlock causes:

• Short circuit and/or interruption of electrical components: • Short circuit and/or interruption of electrical
– Burner motor (stops immediately) components:
– Circulating pump. – Solenoid valve
• Heater operation outside the permissible temperature – Flame detector
range. – Overheating protection
• Motor speed signal faulty. – Water temperature sensor.
• Voltage falling short of the low voltage threshold of • The flame is not expired within 30 seconds after the
approx. 20.5 V at motor start or within a duration of run-down was started (Burner motor stops).
20 seconds after a heating request. • Overheating protection triggered.
• Voltage exceeding the high voltage threshold of approx. • Control unit error
30 V at motor start or within a duration of 6 seconds • Repeated malfunctions
(run-down is applied, but no malfunction interlock). • Repeated flame interruptions
• Control unit malfunction.
4.5.4 Malfunction interlock release 4.6.1 Heater interlock release
The malfunction interlock is released when the heater is ATTENTION:

switched off.
A distinction is made between heaters with standard
After that it will be immediately ready for operation.
control (pre-selection timer, switch, etc.) and heaters
controlled via a CAN bus.
4.5.5 Deleting the error using the diagnosis
4.6.1.1 Heaters with standard control
The detected error is stored in the error memory and can
be read out using the STT diagnosis. To release the heater interlock the heater must be discon-
It is possible to delete the stored error using the STT nected one time from the vehicle electrical system.
diagnosis (see 4.3).
Heater interlock release procedure:
4.6 Heater interlock 1. Remedy the cause of the heater interlock.
2. Switch on the interlocked heater.
The heater interlock overrides the standard malfunc- 3. Disconnect the switched on heater from the vehicle
tion interlock. electrical system.
4. Reconnect the switched on heater to the vehicle
If the heater interlock is active, neither start nor run-down electrical system.
are executed after switching the heater back on.
Prior to restarting the heater troubleshooting must be NOTE:
performed by personnel trained by Spheros in order to The heater starts after reconnection to the vehicle electri-
identify the root cause. cal system automatically.
After that the heater interlock can be released (see 4.6.1). The heater can be switched off during initial cycle.
Here it is differentiated between interlocks caused by

overheating and interlocks caused by other errors. Heater interlock release using the STT diagnosis:
1. Connect the heater with the STT diagnosis and read
NOTE: out the error memory.
If malfunctions occur during switching-on or during the 2. Correct the cause of the heater interlock.
start process prior to ignition, the heater will be switched 3. Disconnect the heater from the vehicle electrical
off without run-down. system.
The heater is in heater interlock state. 4. Reconnect the heater to the vehicle electrical system.
The burner motor stops immediately or does not start. 5. Clear the error memory using the STT diagnosis.
406
4.6.1.2 Heaters with control via CAN bus
Heater interlock release by pulling the fuse:
ATTENTION:
It is not allowed to disconnect the heater from the
vehicle mains by pulling the heater connector under
power.
1. Disconnect the switched-on and interlocked heater

from the vehicle electrical system for > 10 seconds by
pulling the vehicle-mounted heater fuse (F1).
2. Remedy the cause of the heater interlock.
3. Connect the switched-on heater to the vehicle elec-
trical system by inserting the vehicle-mounted fuse
(F1).
4. Disconnect the switched-on heater again from the
vehicle electrical system for > 10 seconds
Heater interlock release using the STT diagnosis:
ATTENTION:
It is not allowed to disconnect the heater from the
vehicle mains by pulling the heater connector under
power.
1. Read out the heater error memory using the STT

diagnosis.
2. Disconnect the switched-on and interlocked heater
from the vehicle electrical system for > 10 seconds by
pulling the vehicle-mounted heater fuse (F1).
3. Remedy the cause of the heater interlock.
4. Reconnect the heater to the vehicle electrical system
by re-inserting the vehicle-mounted fuse (F1).
5. Clear the error memory using the STT diagnosis.
4.7 Error output
If the heater is equipped with the standard timer, an error

output is displayed on the digital timer after a malfunction
occurs.
It is also possible to output an error via flash code.
An error is outputted this way via the operating display or
via the two-pin plug in the heater wiring harness (see 5.3).
Furthermore it is possible to output an error via STT
diagnosis (see 4.3).
407
Thermo S 160/230/300/350/400 5 Troubleshooting
5 Troubleshooting and error correction
5.1 General • Corrosion on plugs

• Loose plug connections
This section describes troubleshooting and error correc- • Crimp failures on plugs and/or pins
tion for Thermo S 160, S 230, S 300, S 350 and • Corrosion on cable and fuses
S 400 heaters. • Corrosion on battery terminals
• Cable insulation damage

ATTENTION
Prior to replacing a fuse troubleshooting needs to be
The safety information and regulations in Chapter 1 performed. The heater must be disconnected from the
(see 1.6 ) must be adhered. vehicle electrical system and the fuse must be replaced in
currentless state.
In case of doubt functional connections can be obtained in A properly dimensioned fuse must be inserted (see
chapters 3 and 4. chapter 6 Schematic diagrams).
After each error correction a functional test must be
Error detection is usually limited to localizing the faulty performed in the vehicle.
component.
The following malfunction causes are not taken into 5.2 General error symptoms
account and should basically always be verified and/or a
malfunction due to these reasons should be excluded: The following table lists possible, general error symptoms.
Table 501: General error symptoms
Error symptom Possible cause
Error in the electronics
Operating display is not illuminated and the heater does • No supply voltage.
not function. • Fuses.
• Supply cable to the plug contacts of plug A of the
control unit.
Fuse F2 triggered. Short circuit in the circulating pump or in the

supply cable to the heater.
Fuse F3 triggered. Short circuit in the supply cable to the heater/ burner
motor/ nozzle block preheater (if installed).
Heater is functional, however the operating display Operating display defective to cables to
is not illuminated. the operating display interrupted or shorted.
501
Error in the water system
Circulating pump not operating (Aquavent 6000S and • Error mode activated.
Aquavent 6000SC only).
In case of malfunctions the motor is switched off via the
error mode.
Reactivation of the circulating pump motor

For this purpose disconnect the power supply for > 2 min.
After the power supply is reconnected the motor
performs a soft start.
Heater stops as the connected heat exchanger provides Flow rate too small, because
insufficient heat. • Air in the heater, heat exchanger or in system
sections.
• Taps/valves (flow controllers) throttled,
contaminated, closed.
• Contaminations in the system, e.g. filters or at bottlenecks.
• Circulating pump delivery rate insufficient
(air in pump housing),
• Insufficient frost protection.
• System resistance too high (especially high in the cold).
• Circulating pump defective.
Heat exchanger provides not enough heat, because

• Air in the heat exchangers and/or system sections.
• Contaminated heat exchanger surfaces (outside).
• Insufficient air entry or air exit.
• Fan: Insufficient delivery rate /
incorrect direction of rotation / resistance too high.
• Antifreeze content too high.
Approximate flow rate determination:
Heat flow [kW] according to type plate

Flow rate in [l/h] = x 860
Temperature difference Δt in [K] or [°C]
measured on the heater between water inlet and water outlet
(e.g. using contact thermometer)
502
Error in the fuel supply
No fuel delivery to the heater. • Fuel tank empty.

• Bent, closed, clogged or
leaking lines.
• Paraffin deposits or frozen water entrapments in fuel
lines or lines.
• Venting opening in tank closed.
• Fuel lines mixed up.
• Fuel filter contaminated.
• Fuel screen (filter) in pump contaminated.
Error in the combustion
CO2 value cannot be adjusted to nominal value. • Air bubbles in fuel supply line (leaking fuel supply line).
Irregular combustion. • Fuel filter contaminated or leaking.
• Fuel integration leaking (suction lift, low pressure in
tank), observe installation instruction.
• Fuel pump defective (pump pressure).
• Screen (filter) in fuel pump contaminated.
• O-ring seal on fuel pump ineffective.
• Atomizer nozzle defective.
• Combustion air and exhaust lines throttled or closed.
• Burner motor speed too low.
• Coupling defective.
5.3 Malfunction code output via flash code

3-pin plug 2-pin plug
to STT diagnosis to flash code output
NOTE:
If the heater is equipped with a standard timer, after a Customer-specific
malfunction appears on the display an error message. plug
An further possibility is the output of a flash code via a

lamp which is connected to the two-pin plug on the heater
wiring harness.
After five short signals the long flash signals

are counted.
The number of long flash impulses corresponds to the
respective flash code. Flash codes and their respective
error meaning are presented in Tabelle 502.
Plug to the
control unit
Fig. 501 Standard Thermo S heater wiring harness
503
Tabelle 502 Error and flash codes
Error description Flash code
Control unit error (e.g. incorrect checksum, no EOL programming) 0
No start within safety period 1
Flame interruption in burner operation, repeated starts unsuccessful 2
Low voltage 3
Extraneous light (flame detector "Bright" prior to ignition) or (flame detector "Bright" in run-down 2) 4
Flame detector short circuit after terminal 31 or interruption or short circuit after terminal 30 5
Coolant temperature sensor short circuit after terminal 31 or interruption or short circuit 6
after terminal 30
Coolant temperature sensor / overheating protection defective 6
Overheating protection temperature sensor short circuit after terminal 31 or interruption or short circuit 6
after terminal 30
Solenoid valve short circuit after terminal 31or interruption or short circuit after terminal 30 7
Motor short circuit after terminal 31 or interruption or fuse F1 defective or short circuit after terminal 30 8
Circulating pump short circuit after terminal 31 or interruption or short circuit after terminal 30 9
Overheating protection triggered 10
Electronic ignition unit short circuit after terminal 31 or interruption or short circuit after terminal 30 11
Heater interlock - release required (caused by repeated malfunctions or repeated 12

flame interruptions)
Nozzle block preheater sensor short circuit after terminal 31 or interruption or short circuit after 13
terminal 30
Nozzle block preheater heating element short circuit after terminal 31 or interruption or short circuit 13
after terminal 30
Minimum combustion period undercut several times 14
Faulty speed signal 15
504
5.4 Error symptoms during functional

tests with malfunction code output or
diagnosis
5.4.1 Error symptom "No start within safety period"
If due to a malfunction the heater unsuccessfully attempted

to start eight times in a row, it will be interlocked.
No further start attempts will be tried.
The heater interlock overrides the standard malfunc-
tion interlock.
The procedure for releasing the heater interlock can be

found in point 4.6.1.
The "No start within safety period" error symptom does

not always indicate that no ignition took place.
This symptom occurs as well, if the heater fails to enter
heating operation (heating or auxiliary heating state) after
successful ignition, e.g. in case the fuel supply is interrupted.
5.4.2 Error symptom "Flame interruption"
If due to a malfunction flame interruption occurs during

heating operation five times in a row, the heater will be
interlocked.
No further start attempts will be tried.
The heater interlock overrides the standard malfunc-
tion interlock.
The procedure for releasing the heater interlock can be

found in point 4.6.1.
Flame Interruption Counter (FIC):

The error counter flame interruption is set after 40s
burning operation without malfunction or a successful
burning cycle to 0. Reaches the FIC the lock-out threshold
(standard 5 times), the heater goes into the heater inter-
lock.
NOTE
After above mentioned error symptoms occur, troubleshooting
according to page 506 is recommended.
505
NO
Are the combustion air intake opening and line and the Clean and securely mount the combustion air intake
exhaust line clean and securely mounted? opening and line and the exhaust line.
Is sufficient fresh air intake ensured and are no exhaust fumes Secure fresh air supply. Prevent
drawn in? exhaust intake.
YES
Switch heater on or start burner motor component test: Does Check the burner motor
the burner motor start?
Is the fan wheel properly secured? Properly secure the fan wheel. Make sure that all screw
Are all screw connections tightened and ensured that no air connections are tightened and that no air escapes.
escapes?
Are all electrical connection plugged in and undamaged? Connect electrical connections or replace
damaged parts.
Clean the flame detector inspection glass and/or

Is the flame detector inspection glass and/or the flame
the flame detector. If the flame detector is damaged,
detector clean and undamaged?
replace the control unit.
Is the correct disc installed and properly mounted? Install the correct disc and mount it properly.
Is the distance of the ignition electrodes OK and/or is the igni- Replace and/or properly fit ignition electrodes.
tion electrode properly fitted?
Is the atomizer nozzle clean, without deposits and properly

Replace or properly mount the atomizer nozzle. Do not
screwed in?
clean it!
Does the atomizer nozzle properly atomise?
Use fuel suitable for the operating temperature. If needed,

Is the fuel used suitable for the operating
clean all parts routing fuel and replace fuel filter.
temperature?
Switch heater on or start Is the fuel filter Is the fuel line leaking Are the O-rings installed
motor component test: contaminated, on the suction side or is Are the fuel lines in the fuel pump?
Does the fuel return work? clogged or leaking? a line closed? empty? Are they tightly
Is the fuel in the fuel supply screwed on?
line and the fuel return line
bubble-free? Replace the fuel
filter. Re-tighten screw Fill lines (several start Replace O-rings and
connections. Replace repetitions or purging filter (screen) as
or open all lines as procedure as needed.
needed. needed).
Is the pump pressure Adjust the pump pressure. If the prescribed

OK? pump presser does not achieve, replace the fuel
pump.
Does the solenoid Replace the complete

valve open? solenoid valve.
Replace control unit.
506
5.4.3 Error symptom "Low voltage"
A value is stored in the control unit as smallest "permis-

sible low voltage".
It must be noted that the voltage may be lowered during
heater start, and that the "low voltage" threshold may be
violated.
Among others this depends on the vehicle electrical system,
the temperature of optional components, such as the nozzle
block preheater, circulating pumps or heatable filters.
NO
Is the battery charge condition permanently Ensure permanent battery voltage greater
greater than 20.5V ± 0.5V? than 20.5V ± 0.5V.
YES Disconnect the A1 plug from the control unit. Is the electrical connection to the heater OK? Repair or replace the
Is the voltage between pin 2 and pin 1 of plug A1 (fuse, wiring harnesses, plug connections, electrical connection to
at least 20.5V ± 0.5V? pins, etc.) the heater.
Start heater: Is the voltage permanently applied to the heater during heater Ensure higher voltage during heater
start or during heating operation 20.5V ± 0.5V? (Verify with STT diagnosis.) start and/or heating operation.
Control unit defective, replace it.
507
5.4.4 Error symptom "Extraneous light detected

prior to ignition or during run-down"
NO
Did overheating occur? Correct overheating cause.
YES Is the burner properly screwed onto the Properly screw burner onto the heat ex-
heat exchanger? changer.
Did the heater burn longer before? Is the combustion air inlet clean/free? Clean/clear combustion air intake inlet.
Was the heater stopped or the voltage Is the motor OK and can rotate freely? Correct motor problem.
disconnected before or during run-down? Is the exhaust outlet clean/free? Clean/clear exhaust outlet.
Is the burner pipe coked, contaminated Clean / replace burner pipe. Clean
or damaged? heat exchanger.
Is the heat exchanger sooted? Insert correct combustion chamber.
Is the correct combustion chamber in-
Let heater cool down for approx. stalled? Did the error return?
2 minutes and restart again.
Did the error return?
Replace the complete solenoid valve.

Did the error return?
Control unit defective, replace it.
508
5.4.5 Error symptom "Flame detector defective"
The flame detector cannot be replaced. It can only be

tested using STT diagnosis.
In case of damage or if the target value cannot be
reached, the control unit must be replaced as needed.
5.4.6 Error symptoms "Temperature sensor /

overheating protection defective" and
"Overheating"
NO
Are the temperature sensor plugs, Correct error and/or replace the
contacts and cables OK? component.
YES
Are the adapter wiring harness
Correct error and/or replace the
plugs, contacts and cables OK?
component.
Is sufficient cooling and coolant flow

ensured? Correct error
Are all shut-off devices opened?
Is the cooling system leak-tight,
completely filled and purged?
Is a circulating pump connected and
the direction of rotation of the circula-
ting pump correct?
Is the coolant cold-resistant?
Replace control unit.
5.4.7 Error symptom "Circulating pump

interruption"
The "Circulating pump interruption" error can also be

triggered by dry operation of the circulating pump.
509
5.5 Individual component tests ATTENTION:

Soot and deposits in the heat exchanger must be
Individual components can basically be tested using removed, as they impact the heat transfer to the
visual inspection or manual electrical testing. coolant.
Severe outer deformations may impact coolant flow.
In addition, the electrical components of the burner motor,
circulating pump, electronic ignition unit, solenoid valve,
nozzle block preheater operating display and flame 5.5.2.1 Visual inspection of exhaust outlet and
display can be checked using the "Component Test" exhaust line
menu of the STT diagnosis.
The flame detector as well as the fuel pump pressure can Inspect exhaust outlet and possibly available exhaust line
also be checked using the "Component Test" menu of the for conditions, tight fit, contamination and deposits.
STT diagnosis. If exhaust fumes exit downwards under the vehicle,
exhaust gas deflection is absolutely necessary.
NOTE:
Prior to disconnecting the temperature sensor plug
connection, disconnect the heater from the vehicle 5.5.3 Combustion chamber visual inspection
electrical system.
• Remove combustion chamber (see 8.11).
For tests using the "Component test" menu of STT
diagnosis, the temperature sensor must be replaced • Inspect swirl plate and combustion chamber head for
with a test plug. damage and tight fit.
• Check and remove combustion chamber for scalings

and coke deposits as needed.
• Inspect combustion chamber for deformation and

moisture.
• Inspect welding seam and combustion chamber for

cracks.
NOTE
Cracks in longitudinal direction at the end of the welding
seam shorter than 80 mm are permissible.
A test plug must be used for the component test
with STT diagnosis. • After the inspection is completed, reinstall the
combustion chamber (see 8.11).
Fig. 502
5.5.1 General visual inspection
• Inspect components for damages (cracks, deformation,

leaks, discolourations, etc.) and replace as needed.
• Inspect plugs and cables for corrosion, contact and
crimp errors and repair as needed.
• Check plug contacts for corrosion and tight fit. Repair
as needed.
5.5.2 Heat exchanger visual inspection
• Inspect heat exchanger interior for damage,

corrosion, sooting and deposits.
• Inspect heat exchanger for outer damage,
corrosion, moisture, deformations, deposits, discolou-
Fig. 503
rations, etc.
510
5.5.4 Resistance check of the temperature sensor Resistance vs. temperature chart
with integrated overheating protection
Water temperature sensor (pin 2 and 3)
2850
Caution! Risk of scalds! 2650
Resistance in Ohm
2450
Prior to removing the temperature sensor, the over-
pressure in the cooling system must be released by 2250
opening the cooling lid. Observe the risk of injuries
due to increased coolant temperature. 2050
Possibly let heater additionally cool down and have

collecting container ready for discharged coolant. 1850
1650
Inspection -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100
Temperature in °C
• Inspect temperature sensor, plug and cable
for damage and proper fit. Overheat protection (pin 1 and 2)
700
• Remove temperature sensor (see 8.3).
650
• Perform the electrical test using a measuring device
Resistance in Ohm
suitable for resistance measurements. 600
550
The water temperature sensor and the overheating
protection should indicate values according to the 500
charts.
Preferably the resistance should be measured at an 450
approx. consistent temperature of 20° C and
approx. 100° C (immerse sensor up to the copper 400
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100
gasket ring into boiling water).
Prior to reading the value, the sensor should be Temperature in °C
exposed to the temperature for approx. 20 seconds.
• Install temperature sensor (see 8.3).

Fig. 505
2 (Masse)
Pin 1 and 2 - overheat protection connection

Pin 2 and 3 - temperature sensor connection
Fig. 504
511
5.5.5 Fan and combustion air intake line visual

inspection
• Inspect a possibly available combustion air intake line

for contamination, condition and deposits. Motor cross member
• Remove hood (see 8.4).
• Inspect fan channels for contamination and deposits.
• Inspect fan and motor shaft mount for cracks, stress

marks and deformations.
• Check cover plate for tight fit.

Motor
• Check circlip for proper fit.
• Install hood (see 8.4). Fig. 507
Fan
• Inspect the motor for bearing conditions (stiffness).
Hood For this purpose remove hood as needed (see 8.4).
• Reconnect the heater to the vehicle electrical system.
• Connect the STT diagnosis adapter to the heater and

a PC via the interface in the heater wiring harness.
Start STT diagnosis, establish connection to the
heater and open the Component Test menu.
• Select the motor in the Component Test menu.

Shaft Insert target speed and runtime. Next start the
circlip component test.
Compare the displayed actual speed with the target

Fig. 506 speed of STT diagnosis.
• After the test is completed, exit STT diagnosis

5.5.6 Burner motor inspection as needed.
NOTE: • Disconnect the heater from the vehicle electrical
It is possible to test the burner motor using the system.
Component Test menu of STT diagnosis.
• Disconnect the test plug and reconnect the
The motor can also be checked by applying direct voltage. temperature sensor plug.
The electrical connection to the control unit must be
disconnected first. • Install hood (see 8.4).
Inspection using STT diagnosis

• Disconnect the heater from the vehicle electrical
system.
• Disconnect the temperature sensor plug and connect

the test plug to the adapter wiring harness.
• Check if the motor used corresponds to the heating

capacity class.
512
5.5.7 Electronic ignition unit inspection • Reconnect the heater to the vehicle electrical system.
NOTE: • Connect the STT diagnosis adapter to the heater and

It is possible to manually test the functionality of the elec- a PC via the interface in the heater wiring harness.
tronic ignition unit, and using the Component Test menu Start STT diagnosis, establish connection to the
of STT diagnosis. heater and open the Component Test menu.
It can only be verified by visual inspection of the ignition
electrode, whether the ignition spark jumps over to the • Select the electronic ignition unit in the Component Test
ignition electrode. menu, enter a runtime and start the component test.
• Nominal condition: Ignition sparks the ignition elect-

High voltage! rode jump over with a rate of 6Hz.
Warning! Danger to life!
• After the test is completed, exit STT diagnosis as
High voltage: The voltage received by the ignition needed.
electrode is >13,000 Volt.
During operation or testing of the electronic ignition • Disconnect the heater from the vehicle electrical
unit, the ignition electrode may not be contacted by system.
persons or items.
• Disconnect the test plug.
ATTENTION:
Do not test or apply voltage to the electronic ignition • Install burner (see 8.2).
unit without an ignition electrode.
Inspect the electronic ignition unit for housing and end Manual functional test when disassembled
cover damage. • Remove electronic ignition unit (see 8.6).
No mechanical damage may be caused or be present on
housing and end cover. • Connect ignition electrode.
• Apply 24V direct voltage according to Fig. 508

(10kOhm on SE input).
Ignition electrode 13,000 Volt
• Nominal condition: Ignition sparks the ignition elect-
rode jump over with a rate of 6Hz.
• After the test is completed, install the electronic igni-

tion unit (see 8.6) and attach the ignition electrode.
• Install burner (see 8.2).
10kΩ
Fig. 508

• Remove burner (see 8.2).
• Connect the test plug to the adapter wiring harness.
513
5.5.8 Ignition electrode inspection 5.5.9 Flame detector inspection
NOTE: NOTE:
The ignition electrode insulation may not be damaged. In case of contamination the glass body of the flame
Ignition electrodes not functioning properly must be detector and the inspection glass in the disc (see Fig. 510)
replaced. must be cleaned.
The flame detector is permanently integrated into the
ATTENTION: control unit and cannot be replaced.
Functionality is verified using STT diagnosis.
Do not damage the electronic ignition unit when
In case of damage or if the target value cannot be
removing the ignition electrode.
reached, the control unit must be replaced as needed.
High voltage! Inspection

Warning! Danger to life! • Remove burner (see 8.2).
High voltage: The voltage received by the ignition • Connect the heater to the vehicle electrical system.
electrode is >13.000 Volt. • Connect the STT diagnosis adapter to the heater and
During operation or testing the ignition electrode may a PC via the interface in the heater wiring harness.
not be contacted by persons or items. Start STT diagnosis and establish the connection to
the heater.
Inspection • Cover the glass body of the flame detector.
• Remove burner (see 8.2). • Check the flame detector voltage displayed on a PC
by STT diagnosis
• Check distance of the electrode tip to the atomizer (target value: U = 4.60V...4.74V).
nozzle (see Fig. 509). • Remove the cover from the glass body of the flame
detector and illuminate from close distance using a
• Check the distance between the electrodes bright lamp.
(see Fig. 509). • Check the flame detector voltage displayed on a PC
by STT diagnosis
NOTE: (target value: U = 0.60V...1.50V).
The distance between the electrodes may b measured • After the test is completed, exit STT diagnosis as
using checking gauge, item number 310646. needed.
• If needed, lift off ignition electrode (3, Fig. 805) from system.
the electronic ignition unit by twisting a screwdriver • Disconnect the test plug as needed.
sideways (see Fig. 804). • Install burner (see 8.2).
• Inspect the ignition electrode insulation for damage.

Disc
• Functionality is verified while inspecting the electronic
ignition unit.
8 ± 0,5
4+ 1 5 ± 0,5
Flame detector Window

Fig. 509 Fig. 510
514
5.5.10 Fuel pump inspection a PC via the interface in the heater wiring harness.
ATTENTION: heater and open the Component Test menu.
The pump pressure of the fuel pump is adjusted to a • Select and start the pump pressure test in the
fixed value in the factory. Component Test menu.
The pump pressure can be re-adjusted.
• Check the information and follow the instructions
According to the manufacturer's specifications the fuel provided by STT diagnosis.
pump and fuel hoses must be replaced after 5 years.
• The motor is started using the speed programmed in
NOTE: the control unit.
If bio diesel or FAME is used, the fuel pump and fuel lines
must be replaced according to the latest technical infor- • Open the bleed port at the pressure test gauge until
mation / notification. some fuel escapes, collect it e.g. with a cloth. Close
the bleed port and read the present pressure at the
High voltage! gauge.
Warning! Danger to life!
• Compare the actual pressure with the target pressure
in Table 503.
The ignition electrode must be removed during the
pump pressure check.
If the specified pressure cannot be reached, it can be
NOTE:
readjusted. For that rotate the adjusting screw (see
The fuel pump pressure can be checked while the burner
Fig. 511) max. one revolution. If the prescribed pres-
is disassembled, using the Component Test menu of STT
sure despite readjustment not be achieved or occur
diagnosis.
leaks, the fuel pump must be replaced.
A pressure test gauge with a display range from 0 to 15
bar as well as a bleeding feature is required (Fig. 512).
The pressure test gauge can be obtained from a Spheros
Service Center or a distribution partner.
The following inspections should be performed prior

to testing the pump pressure:
• Is the CO2 content properly adjusted?

• Do the fuel pump and atomizer nozzle used corres-
pond to the heating capacity class?
• Is the fuel temperature 15...25°C?
• Are available check valves in the fuel (pre-)flow and
return line opened?
• Was the fuel filter in the fuel (pre-)flow line replaced?
• Are the filters (screens) in the pump inlet clean?
• Is the fuel delivered without bubbles?
Attach a transparent hose for testing.

• Connect the test plug to the adapter wiring harness. Adjusting screw
pump pressure
• Connect the heater to the vehicle electrical system.
• Connect the STT diagnosis adapter to the heater and Fig. 511
515
• Follow the instructions provided by STT diagnosis. 5.5.11 Solenoid valve inspection
• After the test is completed, exit STT diagnosis as

needed.
Caution! Risk of burns!
system.
The coil of the solenoid valve can heat up in switched-
• Disconnect the test plug. on condition.
• Install burner (see 8.2). The solenoid valve must only be completely replaced.
In case of replacement or assembly a new gasket ring
Table 503 Fuel pump pressures must be used.
without fuel with NOTE:
delivery by fuel deli-
Heater CO2 Due to system characteristics draining the space between
nozzle very by
nozzle
solenoid valve and nozzle bore may cause fuel dripping
from the atomizer nozzle for a short period of time.
[Vol.-%] [bar] [bar]
A leaking valve seat of the solenoid valve can be indicated
S160 9.5 + 1.5 10.1 ± 0.3 10.0 ± 0.4 by smoke development in the heater during the run-down.
S230 9.5 + 1.5 10.2 ± 0.3 9.8 ± 0.4 Fuel drips from the atomizer nozzle.
A not closing solenoid valve may cause heater deactivation
S300 9.5 + 1.5 10.6 ± 0.3 10 ± 0.4 during run-down with heater interlock activation.
S350 9.5 + 1.5 10.9 ± 0.3 10.4 ± 0.4 It is possible to manually test the electrical functionality of
S400 9.5 + 1.5 9.5 ± 0.3 9.1 ± 0.4 the solenoid valve, and using the Component Test menu
of STT diagnosis.


• Select and start the solenoid valve in the Component

Test menu.
• The solenoid valve must audibly open.
• After the test is completed, exit STT diagnosis as needed.
• Disconnect the heater from the vehicle electrical system.

Pump pressure test gauge
with bleeding feature • Install burner (see 8.2).
Fig. 512
516
Manual inspection: 5.5.12 Nozzle block preheater inspection

• Disconnect the solenoid valve plug from the control unit.

Caution! Risk of burns!
• Check the electrical functionality by applying direct
voltage:
The heating element of the nozzle block preheater can
– Opening voltage: starting at 17.0 Volt heat up during inspection.
– Power consumption at Do not pull heating element out of the nozzle holder
24V and 20°C: 9 Watt during inspection.
– Nominal current at 24V: 0.37 Ampere
NOTE:
The solenoid valve must audibly open, when voltage At a temperature of < 5°C the heating element in the
is applied. nozzle holder is switched on via a temperature sensor.
The heating duration depends on the temperature and the
• Connect the solenoid valve plug to the control unit. vehicle electrical system voltage.
The power consumption at 24 Volt amounts to approx.
• Install burner (see 8.2). 130 Watt.


• Select the optional nozzle block preheater in the

Component Test menu, select a runtime and start the
component test.
Fig. 513 Solenoid valve Nominal condition: The heating element warms up.
• After the test is completed, exit STT diagnosis

as needed.

system.
Manual inspection
• Disconnect the nozzle block preheater plug from the

control unit.
• If necessary, remove the nozzle block preheater.
• Check the electrical resistance:
Heating element between pin 1 and 2:
517
max. 3.9...4.9Ω at 20°C. • After the test is completed, exit STT diagnosis
as needed.
• If necessary, install the nozzle block preheater. • Disconnect the heater from the vehicle electrical
• Connect the nozzle block preheater plug to the control system.
unit. Disconnect the test plug and reconnect the
temperature sensor plug.
Heating element
Pin 1
Pin 2
Fig. 514
5.5.13 Circulating pump inspection
ATTENTION:
The fuse of the circulating pump may never be pulled,
while the pump is running.

system.
• Disconnect the temperature sensor plug and connect

the test plug to the adapter wiring harness.
• Check the electrical connections as well as the

cooling system for leak-tightness.

• Select and start the circulating pump in the

Component Test menu and start the component test.
518
Thermo S 160/230/300/350/400 6 Schematic diagrams
6 Schematic diagrams
6.1 General
The following figures represent customer-dependent

heater connection options to the vehicle electrical system.
The heater wiring harness cables as well as the cables of
the vehicle electrical system are shown.
ATTENTION:
In case of vehicle cable lengths up to 7.5 m the cable
cross-sections must be at least of the same size as
the respectively corresponding cable of the heater
wiring harness.
In case of vehicle cable lengths between 7.5 m and 15
m the cable cross-sections in the vehicle must be
larger dimensioned than the respectively corres-
ponding cable of the heater wiring harness. The cable
cross-sections indicated in the table must be applied.
601
BAT +
BAT –
Alt. Charge
Indicator
(D+)
F1 F2 F3
A1
X1 3pol. 2
BAT– A 2,5mm br 1
2
BAT+ B 2,5mm rd 2
2
BAT+ C 2,5mm rd/wt 3
B
2
5
1 M M1
4
M2 V
1
6
4
M 3 E1
2
X2 4pol.
2
Pump + D 2,5mm bl
A2 Vcc M
S1 Heater Enable A 0,75mm 2 bl 9 2
1 Y1
2
S3 Pump Auto / Man B 0,75mm or 8
H1 + C 0,75mm 2 bl 13 Z
2 SE
H1 U1
X3 4pol. 3 -
Controller
H2 + A 0,75mm 2 rd 6
Control unit 1 +
Operating mode B 0,75mm 2 or 10

R
4
Terminal 61 (D+) C 0,75mm 2 rd/wt 7
3
D 2
Eco 1 1
X4 3pol.
S2 (3-step switch) 0,75mm 2 bl 2 Vcc
CAN-H A
0,75mm 2 ye 3 T
Eco 2 CAN-L B 4
3
H2 Common C
0,75mm 2
br 4
coolant
Vcc
D2 B2
2
H3 + 1 0,75mm bl 5 C1 C2 2
1
H3 H3 – 2 0,75mm
2 br 14
overheating
X1 D1
0,75mm 2 ye 1
W-BUS S 1
0,75mm
2 rd 11
C BAT+ 2
0,75mm
2 br 12
B Common 3
A Heater wiring Heater

harness
X2 X3 X4 D1 D2 A1 A2
14 13
D
C D A A B 1 2 6 5
B 3
C B 1 2 1
A 2 2 1
C
Item Description Cable cross- Cable cross section for cable

section in heater lengths in vehicle
H1 Operation Indicator Light (Max. 5 W) wiring harness < 7.5 m 7.5 - 15m
H2 Flame Indicator Light (Max. 5 W) (< 24ft) (24 - 50ft.)
H3 Optional Diagnostic Light (Max. 5 W) 0.75 mm2 18 ga 0.75 mm2 1.5 mm2 14 ga
E1 Fuel Nozzle Preheater 1.0 mm2 16 ga 1.0 mm2 1.5 mm2 14 ga
Line colours
M1 Combustion Air Fan Motor 1.5 mm2 14 ga 1.5 mm2 2.5 mm2 12 ga
M2 Circulation Pump 2.5 mm2 12 ga 2.5 mm2 4.0 mm2 10 ga bl blue
B2 Temperature Sensor and Limiter 4.0 mm2 10 ga 4.0 mm2 6.0 mm2 8 ga br brown
ye yellow
Y1 Fuel Solenoid Valve
ge green
U1 Electronic Ignition Unit
gr grey
S1 Main Switch - (Heater Enable On/ Off) or orange
S2 Operation Mode Switch - (Normal/ Economy) Note: rd red
S3 Pump Control Switch - (Automatic/ Manual) For cable lengths below 7.5 m in the vehicle, at least the bl black
F1 Fuse 25A - SAE J1284 same cable cross-sections as in the heater wiring harness vi violet
must be used. For cables lengths between 7.5 m and 15 m
F2 Fuse 25A - SAE J1284 wt white
in the vehicle, the cable cross sections must be enlarged
F3 Fuse 5A - SAE J1284 according to the table.
rd/wt red/white
Legend
Fig. 601 Standard system connection to wiring harness 11115706_
602
75(15)
58
BAT +
BAT –
Alt. Charge
Indicator
(D+) 1 Digital timer P with Plus on terminal 10 = Terminal 10 open =
F1 F2 F3 Continuous operation for immediate heating Heating period can be variably programmed
(10 min to 120 min)
A1
X1 3pol.
BAT– A 2,5mm
2
br 1
BAT+ B 2,5mm
2
rd 2
BAT+ C 2,5mm
2
rd/wt 3
B
2
5
1 M M1
1 4
V
6 1
4
3 E1
1 10 11 2
M2 X2 4pol.
2
Pump + D 2,5mm bl
M A2 Vcc M
2 Heater Enable A 0,75mm 2 2
bl 9
1 Y1
2
S3 Pump Auto / Man B 0,75mm or 8
8
H1 C 0,75mm 2 bl 13 Z
2 SE
U1
X3 4pol. 3 -
Controller
12 7 4
H2 A 0,75mm 2 rd 6
Control unit 1 +
Operating mode B 0,75mm 2 or 10

R
X4 Terminal 61 (D+) C 0,75mm 2 rd/wt 7
4
3
D
2
Eco 1
X4 3pol. 1
S2 (3-step switch) 0,75mm 2 bl 2 Vcc
CAN-H A
0,75mm 2 ye 3 T
Eco 2 CAN-L B 4
3
H2 Common C
0,75mm 2
br 4
coolant
Vcc
D2 B2
2
H3 + 1 0,75mm bl 5 C1 C2 2
1
H3 H3 – 0,75mm
2 br 14
overheating
2
X1 D1
0,75mm 2 ye 1
W-BUS S 1
0,75mm
2 rd 11
C BAT+ 2
0,75mm
2 br 12
B Common 3
A Heater wiring Control unit Heater

harness
X2 X3 X4 D1 D2 A1 A2
14 13
D
C D A A B 1 2 6 5
B 3
C B 1 2 1
A 2 2 1
C
Item Description Cable cross- Cable cross section for cable

H1 Operation Indicator Light (Max. 5 W) wiring harness < 7.5 m 7.5 - 15m
H2 Flame Indicator Light (Max. 5 W) (< 24ft) (24 - 50ft.)
H3 Optional Diagnostic Light (Max. 5 W) 0.75 mm2 18 ga 0.75 mm2 1.5 mm2 14 ga
E1 Fuel Nozzle Preheater 1.0 mm2 16 ga 1.0 mm2 1.5 mm2 14 ga
Line colours
M1 Combustion Air Fan Motor 1.5 mm2 14 ga 1.5 mm2 2.5 mm2 12 ga
M2 Circulation Pump 2.5 mm2 12 ga 2.5 mm2 4.0 mm2 10 ga bl blue
B2 Temperature Sensor and Limiter 4.0 mm2 10 ga 4.0 mm2 6.0 mm2 8 ga br brown
ye yellow
Y1 Fuel Solenoid Valve
ge green
U1 Electronic Ignition Unit
gr grey
S1 Main Switch - (Heater Enable On/ Off) or orange
S2 Operation Mode Switch - (Normal/ Economy) Note: rd red
S3 Pump Control Switch - (Automatic/ Manual) For cable lengths below 7.5 m in the vehicle, at least the bl black
F1 Fuse 25A - SAE J1284 same cable cross-sections as in the heater wiring harness vi violet
must be used. For cables lengths between 7.5 m and 15 m
F2 Fuse 25A - SAE J1284 wt white
F3 Fuse 5A - SAE J1284 according to the table.
rd/wt red/white
Legend
Fig. 602 Standard system connection with digital timer to wiring harness 11115706_
603
30
31
61
F1 F2 F3
(HG) (UP)
X2 A1
2
Terminal 31 2 2,5mm br 1
2
Terminal 30(1) 4 2,5mm rd 2
2
Terminal 30(2) 3 2,5mm rt/wt 3
2
B
S1 HS 1 0,75mm bl 5
2
7
2
0,75mm bl 1 M BM
L-line
2 4
K-line 6 0,75mm rd
V
UP - 5
2
2,5mm br 6 1
4
3 DVW
2
X1 2
UP - 2 2,5mm br
M UP 1 A2 Vcc M
2 2
UP + 1 2,5mm bl
1 MV
5
X3 2
UPL UP monitoring 6 0,75mm bl 9 Z
2 SE
UPFA 2 ZFG
S3 5 0,75mm or 8
-
3
Controller
BA BA + 4 0,75mm bl
2
13 1 +
Terminal 61 (D+) 7
2
0,75mm rd/wt 7 R
4
2
K-line 2 0,75mm rd 2 3
3 2
Saving mode 1 1
normal S2 (3-step switch) 4
Vcc
Operating mode 0,75mm or 2

10
T
3
Saving mode 2 4
2 3
FA FA + 1 0,75mm rd 6
Vcc coolant
D2 2
BA + 1 0,75mm bl C1 C2 2
1
BA (Test) 2
150°C 125°C
BA - 2 0,75mm br 14 -50°C
overheating
D1 0,75mm2 ye 1
W-BUS S
2
Diagnosis+ 0,75mm rd 11
2
0,75mm br 12
Diagnosis -
Heater wiring Control unit Heater

harness
X1 X2 X3 D1 D2 A1 A2
14 13
2 1
1 7
1 3 7 2 6 5
6 1 2
3 2 1 2 1
4 6 5 3 1
2 4 2
5
Item Description Item Description

BA Operating display max. 5W BA (Test) Optionally connectible lamp for diagnosis
BM Combustion air motor purposes, max. 5W
DVW Nozzle block preheater ZFG Electronic ignition unit
F1 Vehicle blade-type fuse 25 A according to DIN 72581 part 3
Legend (cont.)
F3 Vehicle blade-type fuse 5A according to DIN 72581 part 3
FA Flame display max. 5W Cable cross- Cable cross section for cable Line colours
HS Main switch wiring harness bl blue
< 7.5 m 7.5 - 15m
MV Solenoid valve 0.75 mm2 0.75 mm2 1.5 mm2 br brown
S1 Main switch - heater On/Off 1.0 mm2 1.0 mm2 1.5 mm2 ye yellow
S2 Switch - operating mode - saving mode 1.5 mm2 1.5 mm2 2.5 mm2 ge green
S3 Switch - UP On/Off (without heating function) 2.5 mm2 2.5 mm2 4.0 mm2 gr grey
S4 Switch UP 2 On/Off 4.0 mm2 4.0 mm2 6.0 mm2 or orange
UP Circulating pump Note: rd red
For cable lengths below 7.5 m in the vehicle, at least the bl black
UPFA External circulating pump actuation
same cable cross-sections as in the heater wiring harness vi violet
UPL Optional circulating pump display for testing, max. 5W must be used. For cables lengths between 7.5 m and 15 m wt white
Legend rd/wt red/white
according to the table.
Fig. 603 EvoBus system connection to wiring harness 11111288_, watertight
604
30
31
61
F1 F2 F3
(HG) (UP)
X1 10-pin A1
2
2
Terminal 30(1) 4 2,5mm rt 2
2
Terminal 30(2) 3 2,5mm rt/ws 3
2 B
S1 HS 1 0,75mm sw 5
2
UP1 1 M BM
2
UP+ 7 2,5mm sw 4
M 2 V
S3 UPFA 5 0,75mm or 6 1
4
BA BA + 6 0,75mm bl
2 3
2
DVW
Vcc M
2
A2 1 MV
5
9 Z
2 SE
8 ZFG
X2 8-pin
Controller
3 -
2 +
Terminal 31 1 2,5mm br 13 1
2
Terminal 61 (D+) 5 0,75mm rd/wt 7 R
4
2
K-line 2 0,75mm rd 2 3
2 2
L-line 0,75mm bl 3
6
Saving mode 1 1
Vcc
2
Operating mode 0,75mm or T
4 10 10
Saving mode 2 4
2 3
FA FA + 3 0,75mm rd 6
Vcc coolant
D2 2
BA + 1 0,75mm bl C1 C2 2
1
BA (Test) 2
150°C 125°C
BA - 2 0,75mm br 14 -50°C
overheating
D11 0,75mm ye
2
1
W-BUS S
2
Diagnosis+ 2 0,75mm rd 11
2
Diagnosis - 3 0,75mm br 12

harness
X1 X2 D1 D2 A1 A2
14 13
10 9 6 5
8 7 1 2
3 2 1 2 1
2 1 2 1 1
2

Legend (cont.)
< 7.5 m 7.5 - 15m
Fig. 604 Standard system connection to wiring harness 11111289_
605
30
31
61
Marking point green

F1 F2 F3 F4
(HG) (UP) (UP2) X1 2
UP - 2 2,5mm br
M UP 1 2
UP + 1 2,5mm bl A1
Marking point yellow 1
2
X3 2
2,5mm br
UP - 2 3
B
M UP 2 2 5
2
UP + 1 2,5mm bl 1 M BM
4
X2 2 1
V
S4 Water pump 2+ 17 2,5mm bl 6
2 4
Water pump 2- 2,5mm br 3 DVW
18
2
1 2
UPL UP monitoring 8 0,75mm bl
2
Terminal 31 4 2.5mm br
2
2,5mm rd
A2 Vcc M
Terminal 30(1) 1 2
2
Terminal 30(2) 2 2,5mm rd/wt MV
1
2
BA BA + 10 0,75mm bl 5
2
S3 UPFA 7 0,75mm or 9 Z
2 2 SE
S1 0,75mm bl 8 ZFG
HS 6
Controller
3 -
13 1 +
2
2
4
0,75mm rd 2 3
K-line (MAN-Cats)
21 2
3
Saving mode 1 1
Vcc
2
11 10
Saving mode 2 4
2 3
FA FA + 9 0,75mm rd 6
Vcc coolant
D2 2
BA + 1 0,75mm bl C1 C2 2
1
BA (Test) 2
150°C 125°C
-50°C
BA - 2 0,75mm br 14 overheating
D1 0,75mm ye
2
1
W-BUS S 1
2
Diagnosis+ 2 0,75mm rt 11
2
3 0,75mm br 12
Diagnosis -

X2 harness
X1/X3 D1 D2 A1 A2
8
14 13
1 15
2 16
2 4
3 17
18 1 2 6 5
5 19
6
21
20 3
1 7
2 1 2 1 2 1
14

Legend (cont.)
< 7.5 m 7.5 - 15m
Fig. 605 MAN system connection to wiring harness 11111290_
606
30
31
61
F1 F2 F3
(HG) (UP)
Heater wiring A1
harness 1
X1 2-pin 2
3
UP - 2,5mm br B
1 2
5
M BM
M UP 1 2
1
UP + 2 2,5mm bl 4
V
6 1
4
X2 6-pin 3
2
DVW
2
Terminal 30(1)
2
2,5mm rd
A2 Vcc M
4 2
2
1
2
BA BA + 6 0,75mm bl 5
2
2 2 SE
S1 0,75mm bl 8 ZFG
HS 1
Controller
3 -
13 1 +
7 R
X3 2-pin 4
2
1 0,75mm rd 2 3
K-line or CAN-H
3 2
1
4
Vcc
10
T
4
2 3
FA FA + 2 0,75mm rd 6
Vcc coolant
D2 2
BA + 1 0,75mm bl C1 C2 2
1
BA (Test) 2
150°C 125°C
-50°C
D1 1 0,75mm ye
2
1
W-BUS S
2
2 0,75mm rd 11
Diagnosis+
2
Diagnosis - 3 0,75mm br 12
Control unit Heater
X1 X2 X3 D1 D2 A1 A2
black grey
14 13
6 5
6 3 1 2
1 1
1
3 2 1 2 1
2 5 2 2 1
2
2
4 1

Legend (cont.)
< 7.5 m 7.5 - 15m
Fig. 606 IRISBUS system connection to wiring harness 11111292_
607
30
31
61
F1 F2 F3
(HG) (UP)
X2 A1
2
2
Terminal 30(1) 4 2,5mm rd 2
2
Terminal 30(2) 3 2,5mm rd/wt 3
2
B
S1 HS 1 0,75mm bl 5
2
1 M BM
4
2 V
UP - 5 2,5mm br 6 1
4
3 DVW
2
X1 2
UP - 2 2,5mm br
M UP 1 2
A2 Vcc M
UP + 2
1 2,5mm bl
1 MV
5
X3 2
UPL UP monitoring 6 0,75mm bl 9 Z
SE
2
2 ZFG
S3 UPFA 5 0,75mm or 8
Controller
3 -
BA BA + 4 0,75mm bl
2
13 1 +
2
4
2 3
3 2
Saving mode 1 1
Vcc
2
3 10
Saving mode 2 4
2 3
FA FA + 1 0,75mm rd 6
Vcc coolant
D2 2
BA + 1 0,75mm bl C1 C2 2
1
BA (Test) 2
150°C 125°C
-50°C
D11 0,75mm ye
2
1
W-BUS S
2
2
Diagnosis- 3 0,75mm br 12

harness
X1 X2 X3 D1 D2 A1 A2
14 13
2 1
1 7
1 3 7 2 6 5
6 1 2
3 2 1 2 1
4 6 5 3 1
2 4 2
5

Legend (cont.)
< 7.5 m 7.5 - 15m
Fig. 607 Volvo system connection to wiring harness 11111293_
608
30
31
61
F1 F2 F3
(HG) (UP)
Heater wiring
A1
harness 1
2
X1 2-pin 3
2
2,5mm br B
UP - 2 2
5
M BM
M UP 1 2
1
UP + 1 2,5mm sw 4
V
6 1
4
X2 12-pin 3
2
DVW
2
Terminal 30(1) 9
2
2,5mm rd
A2 Vcc M
2
2
1
2
BA BA + 5 0,75mm bl 5
2
2 2 SE
S1 0,75mm sw 8 ZFG
HS 1
Controller
3 -
13 1 +
2
4
2
2 0,75mm rd 2 3
K-line or CAN-H
3 2
1
Saving mode 1 S2 (3-step switch) 4
Vcc
normal
2
Operating mode 0,75mm or 10
T
4
Saving mode 2 4
2 3
FA FA + 6 0,75mm rd 6
Vcc coolant
D2 2
BA + 1 0,75mm bl C1 C2 2
1
BA (Test) 2
150°C 125°C
BA - 2 0,75mm br 14 -50°C overheating
D1 0,75mm ye
2
1
W-BUS S 1
X2
2
Diagnosis + 2 0,75mm rd 11
2
3 0,75mm br 12
Diagnosis -
Control unit Heater
X1 D1 D2 A1 A2
1 9 8
2 7
14 13
10 12
6 5
2 3 6 1 2
3 2 1 2 1
1 2 1
4 11 5

Legend (cont.)
< 7.5 m 7.5 - 15m
Fig. 608 Solaris system connection to wiring harness 11112416_
609
30
31
61
F1 F2 F3
(HG) (UP)
A1
Heater wiring
harness 1
X1 2
3
B
UP - 2 2,5mm br 2
5
M BM
M UP 1 2
1
UP + 1 2,5mm sw 4
V
6 1
4
3
X2 2
DVW
2
Terminal 30(1) 4
2
2,5mm rt
A2 Vcc M
2
2
Terminal 30(2) 3 2,5mm rt/ws MV
1
2
BA BA + 6 0,75mm bl 5
2
2 2 SE
S1 0,75mm sw ZFG
HS 1 8
Controller
3 -
13 1 +
X3 2
Terminal 61 (D+) 5 0,75mm rt/ws 7 R
4
2
2 0,75mm rt 2 3
K-Line or CAN-H
2 2
6 0,75mm sw 3
L-Line or CAN-L 1
Saving mode 1 S2 (3-step Switch) 0,75mm br2 4
normal Diagnosis - 1 Vcc
Operating mode 0,75mm or

2 T
4 10
Saving mode 2 4
2 3
FA FA + 3 0,75mm rt 6
Vcc coolant
D2 2
BA + 1 0,75mm bl C1 C2 2
1
BA (Test) 2 overheating
BA - 2 0,75mm br 14
D1 0,75mm ge
2
1
W-BUS S 1
2
Diagnosis + 2 0,75mm rt 11
2
3 0,75mm br 12
Diagnosis -
Control unit Heater
X1 X2 X3 D1 D2 A1 A2
14 13
2 8 6 5
1 2
1 3 2 1 2 1
2 1
1 6 1 7

Legend (cont.)
< 7.5 m 7.5 - 15m
UP Circulating pump 4.0 mm2 4.0 mm2 6.0 mm2 or orange
UPFA External circulating pump actuation Note: rd red
UPL Optional circulating pump display for testing, max. 5W
Legend must be used. For cables lengths between 7.5 m and 15 m wt white
in the vehicle, the cable cross sections must be enlarged red/white
rd/wt
Fig. 609 IRIZAR system connection to wiring harness 11116897_
610
30
31
61
F1 F2 F3
(HG) (UP) X1 2-pin
2
UP - B 2,5mm br
M UP 1 2
UP + A 2,5mm bl A1
1
Temperature switch 0,75mm br

2 2
2
3
0,75mm rd B
2
5
X2 16-pin 2
1 M BM
Temperature monitor 16 0,75mm rd 4

2
2,5mm bl V
6 1
2
10 2,5mm bl 4
3 DVW
2 2
0,75mm br
2
2 A2 Vcc M
Terminal 30(1)15 2,5mm rd 2
2
1
2
BA BA + 4 0,75mm bl 5
2
2 2 SE
S1 0,75mm bl 8 ZFG
HS 2
Controller
3 -
13 1 +
7 R
4
2
6 0,75mm rd 2 3
K-line
3 2
Saving mode 1 2 1
S2 (3-step switch) 5 0,75mm br 4
normal Diagnosis ground Vcc
Operating mode 0,75mm or

2 T
9 10
Saving mode 2 4
2 3
FA FA + 8 0,75mm rd 6
Vcc coolant
D2 2
BA + 1 0,75mm bl C1 C2 2
1
BA (Test) 2
150°C 125°C
-50°C
D1 2
0,75mm ye 1
W-BUS S 1
2
2
Diagnosis- 3 0,75mm br 12

harness
X1 X2 D1 D2 A1 A2
B
A
14 13
6 1
3 2
4 6 5
10 7 1 2
11 3 2 1 2 1
16 14 2 1
13 15

Legend (cont.)
< 7.5 m 7.5 - 15m
UP Circulating pump 4.0 mm2 4.0 mm2 6.0 mm2 or orange
UPFA External circulating pump actuation Note: rd red
UPL Optional circulating pump display for testing, max. 5W
Legend must be used. For cables lengths between 7.5 m and 15 m wt white
in the vehicle, the cable cross sections must be enlarged rd/wt red/white
Fig. 610 Van Hool system connection to wiring harness 11112417_
611
Thermo S 160/230/300/350/400 7 Servicing
7 Servicing
7.1 General Recommended maintenance:

• In order to prevent malfunctions, the fuel filter and/or
strainer as well as the fuel pump filter (screen) must
be replaced at least once a year, in case of heavily
contaminated fuel even more often.
• Yearly visual inspection of the fuel pump, fuel and
The safety information and regulations in Chapter 1 coolant lines for leakage.
(see 1.6 ) must be adhered.
• Mandatory is:
Yearly atomizer nozzle replacement.
7.1.1 Heater servicing
The atomizer nozzle is a consumable (not covered by
warranty).
For risk of overheating, the battery main current may not be
disconnected, while the heater is operating or in run-down.
• Yearly visual inspection of inspection glass and flame
Make sure that the circulating pump is running while the
detector glass body, clean as needed.
heater is switched on for tests/inspections.
• Yearly visual inspection of the combustion chamber
7.2 Servicing and heat exchanger interior for contamination and
soot, clean as needed.
In order to ensure long-term functional reliability, the follo-
wing maintenance activities should be performed on the • Inspection of combustion air intake openings and
heater. exhaust port for contamination. Clean as needed.
Mandatory maintenance: • Outside the heating period, the heater should be

• Fuel pump and fuel lines must be immediately operated every 4 weeks for 10 min with the heater set
replaced when leaking, otherwise every 5 years. to "warm" and cold vehicle engine.
NOTE: • The heater should be inspected in periodic time inter-

If bio diesel or FAME is used, the fuel pump and fuel lines vals, latest at the beginning of the heating period by a
must be replaced according to the latest technical infor- Spheros Service Center.
mation.
You can find the latest overview on the Spheros

homepage under Service / Technical Updates /
Heating systems.
701
Thermo S 160/230/300/350/400 7 Servicing
7.2.1 CO2 content adjustment A speed increase results in a reduction of the CO2
content and vice versa.
A modification of the factory-adjusted burner motor speed
and thus of the exhaust CO2 content is permitted. NOTE:
The burner motor speed can be adjusted using STT An upper and lower speed limiting value is stored per
diagnosis. heating capacity class in the control unit.
An exhaust measurement device (CO2 measurement This should prevent incorrect adjustments during main-
device) is necessary for the adjustment. tenance/service.
STT diagnosis displays the speed limiting values.
The exhaust CO2 content must be measured and the
combustion air volume may have to be adjusted:
Table 701 CO2 heater target values
• after burner repairs.
Heater S160 S230 S300 S350 S400
• in case of combustion irregularities.
CO2 target 9.5 + 1.5 Vol.-%
• in case of heavy sooting of the heat exchanger or value
other components during a functional test.
• after atomizer nozzle replacement.

The CO2 content depends on the fuel (viscosity) and the
• if heater is mainly operated above 1500 m. height above sea level (increase by approx. 0.1 Vol-% per
100 m height increase).
• in case of modifications to the optional, application- In the case that the CO2 content cannot be properly adju-
dependent combustion air intake and exhaust line. sted, proceed as follows:
The STT diagnosis sequence defines the CO2 content • Verify that fuel pump and atomizer nozzle comply with
adjustment procedure. the heating capacity class.
The motor speed must be adjusted to ensure the CO2 • Verify burner motor speed.
content in the exhaust is set to 9.5 + 1.5 Vol-%.
• Inspect burner head on the air side for damage and
Adjustment procedure replace as needed.
• Switch heater on.
• Inspect fuel filter and fuel pump filter (screen) for
NOTE: contamination and replace as needed.
The exhaust should not be measured directly at the exhaust
outlet of the heat exchanger, as this may cause inaccuracies. • Replace atomizer nozzle.
Exhaust fumes should be sampled from the exhaust pipe
in a distance of 350 mm after the heat exchanger. The • Check fuel pump pressure acc. to 5.5.10 and if
exhaust fume temperature should be measured at the necessary readjust it or replace fuel pump.
same location.
Increased exhaust temperature may indicate a sooted
heat exchanger (see 5.5.2).
• After a combustion period of approx. 3 min. measure

the CO2 content in the exhaust and compare it to the
target value in Table 701.
• Determine smoke number as needed: Target value

according to Bacharach: ≤ 4.

heater and open the Calibration menu.
• Obtain the next steps from STT diagnosis. Adjust the

burner motor speed using STT diagnosis to achieve
the target value for the CO2 content.
702
Thermo S 160/230/300/350/400 8 Component Removal / installation
8 Burner, components and heater

removal and installation
8.1 General
The safety information and regulations in Chapter 1

(see 1.6 ) must be adhered.
ATTENTION:
Prior to disassembling components the heater must
be disconnected from the vehicle electrical system.
Sealing elements between disassembled com-
ponents must be principally scrapped and replaced.
This does not apply to the temperature sensor gasket
ring, as it is permanently attached.
Screws with coated threads must be scrapped and re-
placed.
It is permitted to remove components from the heater,
while the heater is installed in the vehicle, assuming
that sufficient space is available and no components
will be damaged.
NOTE:
If components are disassembled to a degree not covered
in this workshop manual, any warranty claim shall be
voided.
Only genuine Spheros spare parts should be used.
Removing the burner provides access to the following

components:
• Atomizer nozzle
• Fuel pump and solenoid valve
• Electronic ignition unit and ignition electrodes
• Disc with inspection glass for flame detector
• Nozzle block preheater (option)
• Flame detector (integrated into control unit)
• Combustion chamber
• Coupling with magnets
801
8.2 Burner removal and installation Burner installation

1. Bring burner (1, Fig. 801) in assembly position and
Burner removal ensure center alignment and correct fit.
1. Disconnect the heater from the vehicle electrical 2. Place nuts (2) and alternately tighten them slightly.
system and from the circulating pump as needed. 3. Tighten nuts (2).
2. If necessary, disconnect the combustion air intake line 4. If applicable, bolt fuel lines down using a banjo bolt
from the heater. and new gaskets, or slide on fuel lines and secure with
3. Remove hood (4, Fig. 801). hose clamps.
4. Disconnect the temperature sensor plug. 5. Install the cable grommet of the temperature sensor
5. Remove the cable grommet of the temperature sensor (5) into the burner housing.
(5) from burner housing. 6. Connect the temperature sensor plug.
7. Install the hood (4).
NOTE: 8. If applicable, secure the combustion air intake line to
Make sure that any fuel leaking during the following work the heater.
step is immediately bound and professionally disposed of. 9. Connect heater with the vehicle electrical system and
the circulating pump as needed.
6. Unscrew fuel lines and seal with blank plugs.
7. Unscrew nuts (2).
8. Remove burner (1). ATTENTION:
The two combination nuts M8, connecting the burner
NOTE: head and the heat exchanger, must be tightened to
Do not bent any lines when placing the burner down. 7.5 +1 Nm each and additional are to be secured
using thread lock (Spheros ident. no.: 154245Z).
1 Burner
2 Nuts (2)
3 Screws (2)
4 Hood
5 Temperature
sensor plug
6 Hollow screw (2) fuel
hose connection 1
2 7.5 +1 Nm
3 6
2 +0.5 Nm 16 ±1 Nm
Fig. 801 Burner head / hood removal and installation
802
8.3 Removal and installation of 8.4 Hood removal and installation

the temperature sensor with
integrated overheating protection Removing the hood provides access to the following
components for maintenance, inspection and repair
purposes:
• Fan
Caution! Risk of scalds!
• Burner motor
• Motor cross member
If the coolant temperature is increased, there is a risk • Control unit
of injury by contact with hot water! • Coupling with magnets
• Main wiring harness plug
Removal • Adapter wiring harness plug
1. Disconnect the heater from the vehicle electrical sys-
tem and from the circulating pump as needed. Removal
2. Remove hood (4, Fig. 801). 1. Disconnect the heater from the vehicle electrical sys-
3. Disconnect the temperature sensor plug. tem.
4. Remove the cable grommet of the temperature sensor 2. Loosen screws (3, Fig. 801).
(5) from burner housing. 3. Remove hood (4).
5. Unscrew and remove temperature sensor (1, Fig.
802). Installation
1. Place hood (4, Fig. 801) in assembly position. Ensure
Installation center alignment, proper fit and seal towards heater
1. Manually screw temperature sensor (1, Fig. 802) into wiring harness and cable grommet of the temperature
coolant outlet (2) . sensor.
2. Tighten temperature sensor (1). 2. Insert screws (3) and tighten them.
3. Install the cable grommet of the temperature sensor 3. Connect the heater to the vehicle electrical system.
(5) into the burner housing.
4. Connect temperature sensor plug.
5. Install the hood (4).
6. Connect heater with the vehicle electrical system and
the circulating pump as needed.
1 17 ± 1 Nm
1 Temperature sensor
2 Coolant outlet
Fig. 802 Temperature sensor removal and installation
803
8.5 Combustion air fan removal

and installation
NOTE:
For replacement of the combustion air fan the burner does
not need to be removed.
ATTENTION:
The shaft circlip may not be overstretched.
Removal
1. Remove hood (see 8.4).
2. If applicable, remove the fan (2, Fig. 803). For this
purpose remove the shaft circlip (1) from the motor
shaft using suitable pliers.
3. Disconnect plug (4) of the burner motor from the
control unit.
4. Remove screws (6) and pull motor (3) including the
motor cross member (5) off the burner housing.
5. If necessary, remove motor cross member (5) from
the burner motor (3). For this purpose loosen and
unscrew screws (7) from the motor flange.
Installation
1. If necessary, reconnect the burner motor (3, Fig. 803)
to the motor cross member (5). For this purpose align
the burner motor with the motor cross member.
Observe the motor cross member installation position.
Screw the countersunk screws (7) into the dedicated
recesses of the motor flange. Next tighten the
countersunk screws (7).
2. If necessary, slide the coupling with magnets (10)
onto the fuel pump shaft.
3. Align motor cross member (5) with the burner housing
(11) observing the specified installation position of the
motor cross member. Align the burner motor with the
coupling by turning the burner motor shaft.
4. Secure burner motor and motor cross member with
screws (6).
5. Tighten screws (6).
6. Connect plug (4) of the burner motor with the control
unit.
7. If applicable, install the fan (2). For this purpose slide
the fan onto the motor shaft and, using suitable pliers,
secure a new shaft circlip (1) onto the motor shaft.
8. Install hood (see 8.4).
804
11
6
10
5 +1 Nm
7
2
5 +1 Nm
4
8 3
1 1 Shaft circlip
2 Fan
3 Burner motor
4 Motor plug
5 Motor cross member
6 Screws (3)
7 Countersunk screws (3)
8 Hood
9 Screws (2)
10 Coupling with magnets
11 Burner housing
9 2 +0.5 Nm
Fig. 803 Combustion air fan removal and installation
805
8.6 Electronic ignition unit and ignition

electrode removal and installation
Removal Installation
1. Remove burner (see 8.2). 1. Bring electronic ignition unit (1, Fig. 804) into
2. Lift off ignition electrode (2, Fig. 804) from the installation position, attach ready for connection and
electronic ignition unit by twisting a screwdriver secure with screws (4).
sideways. 2. Tighten screws (4).
3. Remove disc (3). 3. Fit disc (5) onto the nozzle holder of the fuel pump
4. Removes screws (4) with retaining washers. (9, Fig. 805) and align with the flame detector in the
5. Pull electronic ignition unit (1) off and remove it. control unit (14) and the electronic ignition unit.
6. If necessary, perform a general visual inspection (see 4. Fit the ignition electrode (2, Fig. 804).
5.5.1) or test (see 5.5.7). 5. Install burner (see 8.2).
1 Electronic ignition unit

2 Ignition electrode
3 Disc
4 Screws (2)
4 3
5 +1 Nm
Fig. 804 Removal of the electronic ignition unit / ignition electrode
806
3
5 +1 Nm
20 ± 2 Nm
1 4
2
6
5
1 Electronic ignition unit 7
2 Screw (2)
4 Atomizer nozzle
5 Disc 11
6 Solenoid valve 12 5 +1 Nm
7 Nozzle block preheater, optional
8 Support
9 Fuel pump
10
10 O-rings (2)
9
11 Filter insert
12 Screws (3)
13 Burner housing
14 Control unit 13
15 Heater wiring harness 17
16 Temperature sensors assy
14
15
16
Fig. 805 Components removal and installation
807
8.7 Control unit removal and installation Installation

1. If necessary, attach solenoid valve (6, Fig. 806) to the
Removal fuel pump (9). (see 8.9)
1. Remove burner (see 8.2). 2. If applicable, install nozzle block preheater (7) and
2. Disconnect solenoid valve plug (6, Fig. 806) and, if mount support (8) to the nozzle holder using suitable
applicable, the optional nozzle block preheater (7) tools.
from the control unit (14). 3. Attach new O-rings (10) and a new filter insert (11) to
3. Remove electronic ignition unit (see 8.6). the fuel pump (9).
4. Remove combustion air fan (see 8.5). 4. Slide the coupling with magnets onto the fuel pump
5. Disconnect the heater wiring harness (15) from the shaft.
control unit (14).
6. Carefully pull control unit (14) from the burner housing ATTENTION:
(13) and remove it. In order to avoid damage to the O-rings, to not twist
fuel pump (9) during assembly.
Installation
1. Align control unit (14, Fig. 806) with the burner hou- New screws with coated threads must be used for in-
sing (13). stalling the fuel pump.
2. Carefully slide control unit (14) into the burner housing
(13) as far as it will go. 5. Align fuel pump (9) with the burner housing (13) and
3. Connect the heater wiring harness (15) to the control bring it into installation position. Align the coupling
unit (14). with magnets (17) with the burner motor by turning the
4. Install combustion air fan (see 8.5). burner motor shaft.
5. Install electronic ignition unit (1) (see 8.6). 6. Mount the fuel pump (9) using new screws (with
6. Connect solenoid valve plug (6) and, if applicable, the coated threads) (12) and tighten the screws.
optional nozzle block preheater (7) to control unit (14). 7. Connect solenoid valve plug (6) and, if applicable, the
7. Install burner (see 8.2). optional nozzle block preheater (7) to control unit (14).
8. Fit disc (5) onto the nozzle holder and align it with the
flame detector in the control unit (14) and the
electronic ignition unit (1).
9. Fit ignition electrode (3).
8.8 Fuel pump removal and installation 10. Install burner (see 8.2).
NOTE:
Make sure that any fuel leaking is immediately bound and
professionally disposed of.
Removal
1. Remove burner (see 8.2).
2. Lift off ignition electrode (3, Fig. 806) from the
electronic ignition unit by twisting a screwdriver
sideways. (see Fig. 804)
3. Remove disc (5).
4. Disconnect the solenoid valve plug (6, Fig. 806) and
the optional nozzle block preheater (7) from the
control unit (14).
5. Remove and scrap screws (12).
6. Pull fuel pump (9) with the solenoid valve (6) off and
remove it.
7. Remove and scrap O-rings (10) and filter insert (11).
8. If applicable, remove the nozzle block preheater (7).
For this purpose, remove support (8) from the nozzle
holder using suitable tools.
9. If necessary, remove the solenoid valve (6) from the
fuel pump (9). (see 8.9)
808
3
5 +1 Nm
20 ± 2 Nm
1 4
2
6
5
1 Electronic ignition unit 7
2 Screw (2)
4 Atomizer nozzle
5 Disc 11
6 Solenoid valve 12 5 +1 Nm
7 Nozzle block preheater, optional
8 Support
9 Fuel pump
10
10 O-rings (2)
9
11 Filter insert
12 Screws (3)
13 Burner housing
14 Control unit 13
15 Heater wiring harness 17
16 Temperature sensors assy
14
15
16
Fig. 806 Components removal and installation
809
8.9 Solenoid valve removal and 2. Attach solenoid valve (6, Fig. 806) to the fuel pump
installation (9).
3. Using suitable tools, tighten hexagon, wrench size 16
(6, Fig. 807) of the solenoid valve.
ATTENTION:
4. Connect the solenoid valve plug (6, Fig. 806) to the
The solenoid valve must be completely replaced and control unit (14).
may not be further dismantled! In case of replacement 5. Fit disc (5) onto the nozzle holder and align with the
or assembly and disassembly a new gasket ring must flame detector in the control unit (14) and the
be used. electronic ignition unit (1).
It is not absolutely necessary to remove the fuel pump to 6. Fit ignition electrode (3).
disassemble the solenoid valve. 7. Install burner (see 8.2).
Make sure that any fuel leaking is immediately bound and
professionally disposed of. ATTENTION:
If the nut, wrench size 12 (1, Fig. 807) was loosened,
Removal
then it must be tightened and subsequently secured
using sealing wax.
2. Lift off ignition electrode (1, Fig. 804) from the
electronic ignition unit by twisting a screwdriver
sideways. (see Fig. 804) 8.10 Atomizer nozzle removal and
3. Remove disc (5, Fig. 806). installation
4. Disconnect the solenoid valve plug (6, Fig. 806) from
control unit (14, Fig. 806). Removal
5. Using suitable tools loosen the hexagon, wrench size 1. Remove burner (see 8.2).
16 (6, Fig. 807) of the solenoid valve (6, Fig. 806) from 2. Lift off ignition electrode (2, Fig. 804) from the
the fuel pump (9, Fig. 806) and unscrew the solenoid electronic ignition unit by twisting a screwdriver
valve (6). sideways.
3. Remove disc (5, Fig. 806).
1 Nut, wrench size 12 3 Spring lock washer
2 Magnetic coil (coil 4 Core NOTE:
with cable, plug 5 Tube We recommend to use nozzle wrench item no. 66971_ for
and plate) 6 Hexagon, wrench nozzle disassembly and assembly.
size 16
7 Lifter 4. Unscrew atomizer nozzle (4). If no nozzle wrench is
8 Spring used, a tool must be used to counter on the hexagon
9 Stay of the fuel pump nozzle holder (9).
10 Gasket ring
1 1.5 + 0.3 Nm
Installation
2 1. Screw in the atomizer nozzle (4, Fig. 806) and tighten
it. If no nozzle wrench is used, a tool must be used to
5 ± 0.5 Nm
counter on the hexagon of the fuel pump nozzle
3 holder (9).
4 2. Fit disc (5) onto the nozzle holder and align it with the
5 flame detector in the control unit (14) and the electro-
6
7 nic ignition unit (1).
8 3. Fit the ignition electrode (3).
4. Install burner (see 8.2).
10
Fig. 807 Solenoid valve
Installation
1. Gasket ring (10, Fig. 807) towards the fuel pump must
be replaced. Make sure stay, spring and lifter are
correctly assembled, observe installation position
(see Fig. 807).
810
8.11 Combustion chamber removal and b) the position of cut-outs in the combustion chamber
installation head
Removal
NOTE:
– The combustion chamber should be inserted into the
2. Pull combustion chamber (1, Fig. 808) out of the heat
heat exchanger in such a way that its welding seam is
exchanger (2).
positioned between 2 and 10 o clock (not upwards!)
(Fig. 808).
Installation
A position change during maintenance is permissible
and affects the expected service life of the combustion
ATTENTION:
chamber positively.
When replacing the combustion chamber, ensure that – Position the cut-outs in the combustion chamber head
the new combustion chamber corresponds to the as shown in Fig. 808.
heating capacity class of your heating appliance. Dripping from nozzle fuel is so collected in a reservoir
between disc and burner head and will be burned at
1. Slide combustion chamber (1, Fig. 808) fully into the the next burner operation instead to soil the heater.
heat exchanger (2) against stop. Pay attention to
a) the welding seam position, and 2. Install burner (see 8.2).
7
1 Combustion chamber
6
2 Heat exchanger 5
3 Exhaust outlet 8
4 Stand
5 Coolant inlet
6 Coolant outlet
7 Coolant hose (2x) 6 ±0.6 Nm
8 Hose clamp (2x)
2
6 ±0.6 Nm
3
4
1
Not permitted!
o.k.
Cut-outs
Position of the cut-outs in the combustion Position of the welding seam

chamber head when installed when installed
Fig. 808 Combustion chamber/heat exchanger removal/installation
811
8.12 Heat exchanger removal and Removal

installation 1. Remove burner (see 8.2).
2. Remove heat exchanger (see 8.12).
Installation
1. Install heat exchanger (see 8.12).
Caution! Risk of burns! 2. Install burner (see 8.2).
3. Bleed fuel system (see 8.14.1).
The combustion chamber and heat exchanger can be 4. Bleed coolant circuit (see 8.14.2).
very hot. If necessary, let them cool down.
8.14 Start-up after burner or heater
Removal installation
2. If necessary, remove temperature sensor (see 8.3). The fuel system must be bleeded after burner installation.
3. Pull combustion chamber (1, Fig. 808) out of the heat The coolant circuit and the fuel system must be bleeded
exchanger (2) (see 8.11). after heater installation.
4. If necessary, loosen the exhaust line clamp on the The vehicle manufacturer specifications must be observed.
exhaust outlet (3). Coolant and fuel connections must be checked for leak-
5. If available, close water taps. tightness and tight fit during the test run.
If a malfunction occurs during heater operation, troubles-
hooting must be performed (see chapter 5).
Caution! Risk of scalds!
8.14.1 Bleeding the fuel system
Risk of injuries if coolant temperature is increased.
The whole fuel supply system including the fuel filter must
completely filled with fuel before initial start-up.
6. Loosen hose clamps on the coolant hoses, pull
coolant hoses from the coolant inlet (5) and the
coolant outlet (6) and seal with blank plugs. Caution if
NOTE:
coolant temperature is increased.
Never use the fuel pump to fill / bleed the fuel system!
7. Remove screws and washers of the heat exchanger
stand (4).
8. Remove heat exchanger from the vehicle. Caution if
ATTENTION:
coolant temperature is increased.
In the event no fuel comes to the fuel pump during
Installation initial start-up, there is a risk that the fuel pump will be
1. Bring heat exchanger (2, Fig. 808) into installation damaged!
position and mount stand (4) using screws, nuts and
washers to the vehicle according to the mounting
points used. 8.14.2 Bleeding of the coolant circuit
2. If necessary, secure the exhaust line using a clamp to
the exhaust outlet (3). NOTE:
3. Fit coolant hoses onto the coolant inlet (5) and the The coolant circuit must be principally bleeded according
coolant outlet (6) and secure with hose clamps. to the manufacturer specification.
4. If available, open water taps.
5. Install burner (see 8.2).
6. Bleed coolant circuit (see 8.14.2). Caution! Risk of scalds!
8.13 Heater removal and installation If the coolant temperature is increased, there is a risk
of injury by contact with hot water!
ATTENTION:
ATTENTION:
The fuel supply system must be subsequently bleed
The Aquavent 5000 (U4814) and Aquavent 6000S
(see 8.14.1).
(U4855) circulating pumps may only be switched on
The coolant circuit must be subsequently bleed for bleeding, after dry operation can be excluded.
(see 8.14.2).
The Aquavent 5000S (U4854) and Aquavent 6000SC
812
(U4856) circulating pumps may even in dry operation

be switched on for bleeding.
Adjust the vehicle heating system to "warm" and refill

coolant.
As soon as it is confirmed that the vehicle engine is filled
with coolant, run vehicle engine with increased idle speed.
Once the cooler thermostat opens, switch the vehicle
engine off and check the coolant level.
Refill coolant as needed.
While the vehicle engine is switched off, switch on the heater

with the circulating pump and the vehicle heating fan.
After the engine motor cooled down, the heater must
automatically start and stop as soon as the upper swit-
ching threshold is reached.
If the heater does not start automatically, it must be

verified, whether the heater overheating protection is
triggered and the heater is interlocked.
Release the heater (see 4.6) and repeat the bleeding

process.
813
Thermo S 160/230/300/350/400 9 Modifications / retrofits
9 Modifications and retrofits
For further optimization the heaters are continuously

improved. Units in the field can usually be upgraded or
retrofitted. For this purpose respective modification kits
will be available.
901
Thermo S 160/230/300/350/400 10 Packing / storage / shipping
10 Packing / storage
and shipping
10.1 General
The heater or its components, which are sent to Spheros

for inspection or repair, must be cleaned and packaged to
ensure that handling, transport and storage will not
damage them.
ATTENTION
If a complete heater is sent back, it must be completely
drained. Packaging and/or shipping must ensure that no
fuel or coolant can leak.
Coolant inlet and outlet fittings as well as the fuel lines

must be plugged and sealed using blank plugs.
The temperatures described in section 4 may not be

exceeded during storage.
1001
Maintenance plan
Periodic heater maintenance * prescribes the here shown maintenance intervals for
common applications.
The heater should be inspected in periodic time intervals, If heaters should be used in other vehicles and/or applica-
latest at the beginning of the heating period (time of in- tions, the maintenance intervals may be shortened or
creased heater usage due to present weather conditions). extended. In such cases please contact your dedicated
In principle the regulations of the vehicle manufacturers Spheros partner for further information.
must be adhered. If there no such regulations, Spheros
Address of the operator Date of maintenance
Vehicle data
Heater data
Type of heater: Operating/ control device data Date of commision
acc. to diagnosis STT
Ident. no.: (Spheros Thermo Test)
Serial no.:
Fuel Diesel fuel Biodiesel Heating oil EL
Check / Maintenance Important notes Check result Measured values,
OK not accomplished repairs

OK
1. Electrical connections
a) Examine electrical plug connections and the wiring harness
for visible damages, replace as required.
2. Heat exchanger Determine overheating

a) Check for external damage, discoloration caused by over- cause as needed (e.g.
heating and leaks. water circulation sys-
tem), check overheat
b) Clean the heat exchanger inside and outside, remove soot
protection.
and debris.
3. Fuel system
a) Inspect fuel lines and connections for leakage. Ensure connections to
b) Replace fuel filter insert with gasket. resp. replaceable filter. fuel flow and return
lines are sealed tight!
If biodiesel is used a
semi annual filter
change is prescribed by
the manufacturer.
Re-tighten screw con-
nections and hose
clamps.
* For rail applications the maintenance record RAIL 9008722_ is to be considered.
A-1
Maintenance plan
Check / Maintenance Important notes Check result Measured values,
OK not accomplished repairs

OK
c) Fuel pump / fuel lines Replace the fuel pump

Note: Observe technical information if biodiesel every 5 years, if biodie-
or FAME is used! sel is used this interval
is shortened
Technical Information
(TI 2009 09) -> Biodiesel
d) Replace fuel screen with gasket in the pump.
/ FAME see
www.spheros.de
4. Burner head
a) Inspect combustion air intake opening for clear passage.
b) Inspect hood for damage. Replace damaged
parts.
c) Clean flame detector inspection glass (in the disk).
d) Inspect condition of the ignition electrodes, if required adjust
or replace them.
e) Replace atomiser nozzle.
f) Check solenoid valve for leaks. Activate combustion air
motor using the diag-
nostic tool (STT),
solenoid valve must be
tight
5. Exhaust system
a) Inspect exhaust line for clear passage or damage, clean or
replace it as needed.
b) Remove combustion chamber from heat exchanger, inspect
for damage and contamination, clean and replace as
needed.
c) Insert combustion chamber and mount burner head. Ensure
proper fit and tight connection to the heat exchanger.
d) Combined nuts (M8) for burner head attachment, tightening Secure them with
torque 7.5 +1 Nm, secure them. locking compound
e) Measurements
Limits acc. to Regu-
Target values and procedures are outlined in the workshop lation ECE-R 122
manual
Ambient temperature (° C) see technical data
Exhaust temperature (° C) heater
Thermo CO2 (Vol.-%) 9.5% … 10.5% at 24V

Thermo S CO2 (Vol.-%) 9.5% … 11.0% at 24V
Fuel pump pressure according to Workshop Manual 10 bar
6. Water system
a) If available, inspect, clean as needed or replace water filter
insert.
7. Functional check
a) If available, open shut-off valve of the fuel return line and
water line.
b) Check fault memory, clear it as needed using the diagnostic
tool (STT).
c) Check heater functionality. after at least 10 min
heater operation
Attention:
During the maintenance, check all screw connections for tight-
ness (for corresponding torque values see Workshop Manual).
* For rail applications the maintenance record RAIL 9008722_ is to be considered.
A-2
memos
Valeo Thermal Commercial Vehicles Germany GmbH
Postfach 1371 - 82198 Gilching - Germany - Tel. +49 (0)8105 7721-0 - Fax +49 (0)8105 7721-889
www.valeo-thermalbus.com - service-valeobus@valeo.com
Transport Air Conditioning
OPERATION AND SERVICE

for
MODELS AC310 & AC350
Rooftop Air Conditioning Units
With
BT324 Carrier Sutrak Digital Display (CSDD)
or
280P/282P Electronic Thermostat
T--304 Rev A Change 07/09

OPERATION AND
SERVICE MANUAL
TRANSPORT
AIR CONDITIONING UNIT
MODELS
AC310 & AC350
ROOFTOP AIR CONDITIONING UNITS
*CSDD -- BT324 (*Carrier Sutrak Digital Display)
Electronic Thermostat -- 280P & 282P
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety--1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
1.2 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
1.2.1 Rooftop Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
1.2.2 Condensing Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
1.2.3 Evaporator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
1.2.4 Drivers Evaporator (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--6
1.2.5 Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--6
1.2.6 System Operating Controls And Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
1.2.7 280P & 282P (PWM) Electronic Thermostat Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
1.2.8 CSDD BT--324 (Carrier--Sutrak Digital Display) Microprocessor . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
1.2.9 Motor Fault Board (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
1.3 REFRIGERATION SYSTEM COMPONENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
1.4 ELECTRICAL SPECIFICATIONS -- MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--7
1.5 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--8
1.6 AIR CONDITIONING REFRIGERATION CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--8
1.7 HEATING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--8
OPERATION (Manual Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2.1 STARTING, STOPPING AND OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2.1.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2.1.2 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2.2 PRE--TRIP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2.3 MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.3.1 Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.3.2 Cooling Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.3.3 Heating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.3.4 Boost Pump (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.3.5 Vent Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.3.6 Compressor Unloader Control (Only with 05G or 05K Compressors) . . . . . . . . . . . . . . . . . . . . . 2--2
2.3.7 Override Mode -- AC310 (Dehumidification) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2.3.8 Evaporator Fan Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
2.3.9 Compressor Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
(A--6, TM--16, TM--21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
2.4 SEQUENCE OF OPERATION (280P / 282P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
2.4.1 Electronic Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
OPERATION BT324 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
3.1 STARTING, STOPPING AND OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
3.1.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
3.1.2 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
3.2 PRE--TRIP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
3.3 SEQUENCE OF OPERATION BT324 CSDD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
3.3.1 Function of Keys when “Engine On” and controller active: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
3.3.2 Illuminating Indications (Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
04/08 i T--304
TABLE OF CONTENTS Continued:
3.4 Operating Instructions BT324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
3.4.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
3.4.2 Interior Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
3.4.3 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
3.4.4 Reheat (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
3.4.5 Temperature Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
3.5 CHANGING BETWEEN 5F (FAHRENHEIT) AND 5C (CELCIUS ) . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.1 System Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.2 System Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.3 Abnormal Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.4 Abnormal Noise Or Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
4.5 No Evaporator Air Flow Or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4.6 Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4.7 Heating Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.2 REMOVING EVAPORATOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.3 REMOVING CONDENSER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.4 INSTALLING MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.4.1 Installing R--134a Manifold Gauge/Hose SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
5.5 PUMPING THE SYSTEM DOWN OR REMOVING THE REFRIGERANT CHARGE . . . . . . . . . . . 5--2
5.5.1 System Pump Down For Low Side Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
5.5.2 Removing Entire System Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.6 REFRIGERANT LEAK CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.7 EVACUATION AND DEHYDRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.7.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.7.3 Procedure for Evacuation and Dehydrating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.8 ADDING REFRIGERANT TO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.8.1 Checking Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
5.8.2 Adding Full Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
5.9 CHECKING FOR NONCONDENSIBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
5.10 CHECKING AND REPLACING HIGH OR LOWPRESSURE CUTOUT SWITCH . . . . . . . . . . . . . . 5--4
5.10.1 Replacing High Or Low Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
5.10.2 Checking High Or Low Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
5.11 FILTER-DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
5.11.1 To Check Filter--Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
5.11.2 To Replace Filter--Drier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
5.12 SERVICING THE HEAT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
5.12.1 Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
5.12.2 Internal Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
5.12.3 Replace Entire Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
T--304 ii 04/08
TABLE OF CONTENTS Continued:
5.13 SERVICING THE LIQUID LINE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
5.13.1 Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
5.13.2 Internal Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
5.13.3 Replace Entire Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
5.14 SERVICE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
5.15 REPLACING RETURN AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
5.16 THERMOSTATIC EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--8
5.16.1 Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--8
5.16.2 Superheat Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--9
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
LIST OF FIGURES
Figure 1--1 AC310/350 Rooftop Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
Figure 1--2 Condensing Section Components (AC310 -- Dual Loop -- GEN I) . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3
Figure 1--3 Condensing Section Components (AC350 Single Loop -- GEN II) . . . . . . . . . . . . . . . . . . . . . . . . . 1--4
Figure 1--4 Evaporator Section Components (AC310 --Dual Loop -- GEN I) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--5
Figure 1--5 Evaporator Section Components (AC350 Single Loop -- GEN II) . . . . . . . . . . . . . . . . . . . . . . . . . . 1--6
Figure 1--6 Refrigerant Flow Diagram -- Cooling (Dual Loop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--9
Figure 1--7 Flow Diagram -- Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--10
Figure 1--8 Refrigerant Flow Diagram, Cooling (Single Loop) AC350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--11
Figure 1--9 Sheet 1 -- Electrical Control Board (280P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--12
Figure 1--9 Sheet 2 Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--13
Figure 1--10 AC350 With BT324 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--14
Figure 1--11 Motor Fault Board (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--15
Figure 2.1 Control Switches (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
Figure 2.2 280P / 282P Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
Figure 3--1 Bus Dash With A/C Switch & BT324 CSDD Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
Figure 3--2 BT324 CSDD Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
Figure 5--1 Manifold Gauge Set (R--134a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
Figure 5--2 In--Line Service Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
Figure 5--3 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
Figure 5--4 Filter--Drier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
Figure 5--5 Heat Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
Figure 5--6 Liquid Line Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
Figure 5--7 Service Valve R134a (High Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
Figure 5--8 Return Air Grill Assembly With Air Filter Showing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
Figure 5--9 Diffuser and Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--8
Figure 5--10 Filter, Diffuser and Composit Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--8
Figure 5--11 Return Air Grill Assembly With Diffuser And Composit Frame Showing . . . . . . . . . . . . . . . . . . . 5--8
Figure 5--12 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--8
Figure 5--13 Thermostatic Expansion Valve Bulb and Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--9
Figure 6--1 System Controls (Typical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
Figure 6--2 Manual Controls With Manual Reheat Control (Sheet 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
Figure 6--3 Manual Controls With Manual Reheat Control (Sheet 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
04/08 iii T--304

LIST OF FIGURES Continued:
Figure 6--4 Evaporator Motors 1 -- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--5
Figure 6--5 Evaporator Motors 5 -- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--6
Figure 6--6 Condenser Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--7
Figure 6--7 BT324 Controls With (1) Compressor (AC350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--8
Figure 6--8 BT324 Control Circuit (AC350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--9
Figure 6--9 BT324 Evaporator Motors (AC350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--10
Figure 6--10 CSDD BT324 Condenser Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--11
Figure 6--11 AC350 With BT324 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--12
Figure 6--12 CSDD BT324 Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--13
Figure 6--13 CSDD BT324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--14
Figure 6--14 Thermostat (One/Two Compressors) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--15
LIST OF TABLES
Table 1--1 AC310 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
Table 1--2 AC 350 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
Table 1--3 Additional Support Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
Table 2--1 Unloader UV1 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
Table 2--2 Unloader UV2 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
Table 4--1 General System Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
Table 5--1 R-134a Temperature - Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--10
T--304 iv 04/08
SAFETY SUMMARY
GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this
manual. They are recommended precautions that must be understood and applied during operation and maintenance
of the equipment covered herein. A listing of the specific warnings and cautions appearing elsewhere in the manual
follows the general safety notices.
FIRST AID
An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.
OPERATING PRECAUTIONS
Always wear safety glasses.
Keep hands, clothing and tools clear of the evaporator and condenser fans.
No work should be performed on the unit until all start-stop switches are placed in the OFF position, and power supply
is disconnected.
Always work in pairs. Never work on the equipment alone.
In case of severe vibration or unusual noise, stop the unit and investigate.
MAINTENANCE PRECAUTIONS
Beware of unannounced starting of the evaporator and condenser fans. Do not open the unit cover before turning
power off.
Be sure power is turned off before working on motors, controllers, solenoid valves and electrical controls. Tag circuit
breaker and power supply to prevent accidental energizing of circuit.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with
the system should be diagnosed, and any necessary repairs performed by qualified service personnel.
When performing any arc welding on the unit, disconnect all wire harness connectors from the modules in the control
box. Do not remove wire harness from the modules unless you are grounded to the unit frame with a static-safe wrist
strap.
In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).
04/08 Safety--1 T--304

SPECIFIC WARNINGS AND CAUTIONS
WARNING
Be sure to observe warnings listed in the safety summary in the front of this manual before per-
forming maintenance on the hvac system
WARNING
Read the entire procedure before beginning work. Park the vehicle on a level surface, with park-
ing brake applied. Turn main electrical disconnect switch to the off position.
WARNING
Do Not Use A Nitrogen Cylinder Without A Pressure Regulator
WARNING
Do Not Use Oxygen In Or Near A Refrigeration System As An Explosion May Occur.
WARNING
The Filter-drier May Contain Liquid Refrigerant. Slowly Loosen The Connecting Nuts And Avoid
Contact With Exposed Skin Or Eyes.
CAUTION
The AC310 & AC350 Rooftop Systems have R134a service port couplings installed on the compres-
sor and 1/4 inch flare (Acme) fittings installed on the unit piping.
CAUTION
To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction
pressure before disconnecting.
T--304 Safety--2 04/08

SECTION 1
DESCRIPTION
1.1 INTRODUCTION conditioning and heating equipment interfaces with an
optional drivers evaporator (dash--air), electrical
This manual contains Operating Instructions, Service cabling, refrigerant piping, engine coolant piping (for
Instructions and Electrical Data for the Model AC310 heating), duct work and other components furnished by
and AC350 Air Conditioning and Heating equipment Carrier Transport Air Conditioning and/or the bus
furnished by Carrier Transport Air Conditioning as manufacturer.
shown in Table 1--1 and Table 1--2.
Additional support manuals are shown in Table 1--3.
Model AC310/350 systems consists of a Rooftop unit
containing the condensing section, the evaporator Operation of the unit is controlled automatically by an
section and engine compartment mounted electronic thermostat. The controlls maintain the
compressor(s). To complete the system, the air vehicle’s interior temperature at the desired set point.
Table 1--1 AC310 Models

Model AC310 Voltage Controller With Heat Dual Loop Single Loop W/Covers
77--62031--00 12 VDC Manual (280P) Yes X X
77--62031--02 12 VDC BT324 Yes X X
77--62031--03 24 VDC BT324 Yes X X
Sytronic System
77--62032--00 12 VDC & Manual (280P) Yes X X
77--62032--02 -- -- -- -- -- --
77--62032--05 12 VDC BT324 Yes X X
*77--62032--06 12 VDC BT324 (Tropic) Yes X X
*NOTE: 77--62032--06 (Tropic) -- Has an AC310 Evaporator Section & an AC350 Condenser Section.
Table 1--2 AC 350 Models

Part Number Voltage Controller With Heat Dual Loop Single Loop W/Covers
77--62041--00 24 VDC -- -- -- X --
77--62041--01 24 VDC Manual Yes -- Yes
77--62041--02 24 VDC Manual Yes X No
77--62041--03 24 VDC -- -- -- -- --
77--62041--04 24 VDC BT324 No X No
77--62041--05 24 VDC BT324 No X Yes
77--62041--06 24 VDC BT324 Yes X Yes
77--62041--07 24 VDC BT324 Yes X No
77--62041--10 24 VDC BT324 Yes X Yes
Table 1--3 Additional Support Manuals

MANUAL NUMBER EQUIPMENT COVERED TYPE OF MANUAL
T--304PL AC--310/350 Service Parts List
T--200PL 05G Compressor Service Parts List
62--02756 05G Compressor Operation & Service
62--11052 05G Compressor -- Twin Port Workshop Manual
62--11053 05G Compressor -- Twin Port Service Parts List
62--02460 05K Compressor Service Parts List
62--02491 05K Compressor Operation & Service
04/08 1--1 T--304

1.2 GENERAL DESCRIPTION
1.2.1 Rooftop Unit
The rooftop unit includes the condenser section and the evaporator section (See Figure 1--1).
Evaporator Section
Condenser Section
AC310
AC350
Evaporator Section
Condenser Section
Figure 1--1 AC310/350 Rooftop Units
1.2.2 Condensing Section than refrigerant circulating inside the tubes; this results
The dual (See Figure 1--2) and single loop (See in condensation of the refrigerant into a liquid. The
Figure 1--3) condensing sections include the condenser filter-drier removes moisture and debris from the liquid
coils, four (4) or six (6) fan and motor assemblies, refrigerant before it enters the thermostatic expansion
filter-driers, receivers, and filter drier service valves. valve in the evaporator assembly. The service valves
enable isolation of the filter-drier for service.
The condenser coils provide heat transfer surface for
condensing refrigerant gas at a high temperature and The receiver collects and stores liquid refrigerant. The
pressure into a liquid at high temperature and pressure. receiver is also fitted with a pressure relief valve which
The condenser fans circulate ambient air across the protects the system from unsafe high pressure
outside of the condenser tubes at a temperature lower conditions.
T--304 1--2 04/08

9 9
7
2
1
1
3 5
4 3 5
4
AC310 3
Dual Loop
1. Condenser Coil Assembly 6. Filter Drier Lower Support

2. Receiver 7. Condenser Fan and Motor Assembly
3. Service Valve (High Side) 8. Condenser Motor Support
4. Filter Drier Upper Support 9. Discharge Line Check Valve (Location)
5. Filter Drier
Figure 1--2 Condensing Section Components (AC310 -- Dual Loop -- GEN I)
04/08 1--3 T--304

5
4 4 4
1
2
1 Condenser Coil Assembly 3 Filter Drier

Receiver Tank (Part Of Coil Assembly) 4 Fan & Motor
2 Service Valve 5 Frame (Aluminum)
Figure 1--3 Condensing Section Components (AC350 Single Loop -- GEN II)
1.2.3 Evaporator Section valve, one liquid line solenoid valve (to add in--dash
service port), and condensate drain connections.
The dual loop AC310 & AC350 (GEN I) evaporator
section (See Figure 1--4) includes the evaporator coils, The liquid line solenoid valve closes when the system is
eight (8) or twelve (12) single--shafted blower/motor shut down to prevent flooding of coils and the
assemblies, two heater coil assemblies, two compressor with liquid refrigerant. The evaporator coils
thermostatic expansion valves, two liquid line solenoid provide heat transfer surface for transferring heat from
valves, and condensate drain connections. air circulating over the outside of the coil to refrigerant
circulating inside the tubes; thus providing cooling. The
heating coils provide a heat transfer surface for
NOTE transferring heat from engine coolant water circulating
The GEN I series of AC310 & AC350 evapora- inside the tubes to air circulating over the outside
surface of the tubes, thus providing heating. The fans
tors are supplied with single shaft blower/motor circulate the air over the coils. The air filters remove dirt
assemblies. The GEN II series have dual shaft particles from the air before it passes over the coils. The
blower/motor assemblies. thermostatic expansion valve meters the flow of
refrigerant entering the evaporator coils. The heat valve
controls the flow of engine coolant to the heating coils
The single loop AC310 & AC350 evaporator section upon receipt of a signal from the controller. The
(See Figure 1--5) includes the evaporator coils, four (4) condensate drain connections provide a means for
or six (6) double--shafted blower/motor assemblies, connecting tubing for disposing of condensate collected
heater coil assemblies, one thermostatic expansion on the evaporator coils during cooling operation.
T--304 1--4 04/08

3
7
4
9
6 4
6
Return Air 5
Section
AC310
Dual Loop
1. Evaporator Coil Assembly 6. Sight Glass

2. Heater Coil 7. Heating Line
3. Expansion Valve 8. Access Port
4. Evaporator Blower Assembly 9. Liquid Line Solenoid
5. Evaporator Motor
Figure 1--4 Evaporator Section Components (AC310 --Dual Loop -- GEN I)
04/08 1--5 T--304

6
2
4
1
8 3 6
5 7
4 1
1. Evaporator Coil Assembly 5. Control Panel

2. Heater Coil 6. Heater Line
3. Expansion Valve 7. Front Evaporator Port
4. Evaporator Blower/Motor Assembly 8. Liquid Line Solenoid
Figure 1--5 Evaporator Section Components (AC350 Single Loop -- GEN II)
1.2.4 Drivers Evaporator (Optional) c. Single Loop Compressors 05G & 05K
The drivers evaporator assembly is normally installed in
the vehicle dash area and interfaces with the rooftop unit The 05G (AC350) & 05K (AC310) compressor
electrical cabeling and refrigerant piping. assemblies used with the single loop units, includes the
clutch assembly, suction & discharge service valves,
The drivers evaporator assembly includes an high pressure switch, low pressure switch, suction and
evaporator coil, thermal expansion valve, blower motor discharge servicing (charging) ports and electric
assembly and a condensate drain connection. Refer to solenoid unloaders.
the OEM technical literature for driver’s evaporator
information. The compressor raises the pressure and temperature of
1.2.5 Compressor Assembly the refrigerant and forces it into the condenser coil
tubes. The clutch assembly provides a means of driving
a. Dual Loop Compressors A--6 & TM--21 the compressors by the vehicle engine. Suction and
The standard AC310 dual loop compressor assembly discharge servicing (charging) ports mounted on the
includes the refrigerant compressor, clutch assembly, compressor fittings enable connection of charging
in--line high & low pressure switches, suction hoses for servicing of the compressor, as well as other
accumulator and in--line suction and discharge parts of the refrigerant circuit. The high pressure switch
servicing (charging) ports. contacts open on a pressure rise to shut down the
system when abnormally high refrigerant pressures
b. Single Loop Compressor TM--31 occur.
The TM--31 compressor assembly used only with the
AC310 Single Loop Unit includes the refrigerant The electric unloaders (05G & 05K) provide a means of
compressor, clutch assembly, suction & discharge controlling compressor capacity, which enables control
service valves, high pressure switch, low pressure of temperature inside the vehicle. The suction and
switch, suction accumulator and suction and discharge discharge service valves enable servicing of these
servicing (charging) ports. compressors.
T--304 1--6 04/08

1.2.6 System Operating Controls And Compo- AC310 -- Single Loop TM--31 Compressor
nents 12 Pounds (5.4 kg) without In--Dash unit
The system is operated by an electronic thermostat type AC310 -- Single Loop 05G or 05K Compressor
controller and/or manually operated switches. The 13.2 to 15.4 Pounds (6.0 to 7.0 kg) without
manually operated switches are located on the drivers In--Dash unit
control and may consist of a single ON/OFF switch or AC350 -- Single Loop 05G or 05K Compressor
additional switches. The controller regulates the 16.5 to 18.7 Pounds (7.5 to 8.5 kg) without
operational cycles of the system by energizing or In--Dash unit
de--energizing relays on the relay board in response to For systems with In--Dash unit (Optional)
deviations in interior temperature. Modes of operation Add 2 pounds (0.9 kg) to above listed charge.
include Cooling and Heating. On systems fitted with only
an ON/OFF switch, the controller will cycle the system b. Compressors
between the operating modes as required to maintain Compressor A6 (No longer Available)
desired set point temperature (See Section 6 for wiring
diagrams). Weight, (Dry) 34.5 Lbs.
In the heat mode the heat valves are opened to allow a Oil Charge 10 Oz. PAG (07--00333--00)
flow of engine coolant through the heat coils located in Compressor TM--21
the evaporator section. The evaporator fans operate to Weight, (Dry) 7.5 Lbs. (3.4 kg)
circulate air over the heat coils in the same manner as
the cooling mode. 6.1 Oz. (180 cc) PAG
Oil Charge (46--50006--00)
In the cooling mode the compressor is energized while
the evaporator and condenser fans are operated to Compressor TM--31
provide refrigeration as required. The compressor (s) Weight, (Dry) 21 Lbs.
capacity is matched to the bus requirements. Once
interior temperature reaches the desired set point, the 16.9 Oz. (500cc) PAG
Oil Charge (46--50006--00)
compressor(s) is deenergized.
1.2.7 280P & 282P (PWM) Electronic Thermostat Compressor Carrier 05K
Controller Weight, (Dry) 108 Lbs.
This type controller has three (3) modes, Cool, Vent and 5.5 Pints POE
Oil Charge (07--00317--00pk6)
Heat.
The range on the potentiometer is 62.6° -- 86° F Compressor Carrier 05G
(17--30° C). Weight, (Dry) 146 Lbs. W/Clutch
1.2.8 CSDD BT--324 (Carrier--Sutrak Digital Display) 7.75 Pints POE
Microprocessor Oil Charge (07--00317--00pk6)
This Carrier Sutrak Digital Display (BT--324) controller c. Thermostatic Expansion Valve:
has three (3) modes, Auto, Vent (Cycle clutch type) and Superheat Setting (Externally Adjustable) Factory
Heat.
Set at 9 to 18°F (±4°F) MOP Setting: 55 ±4 psig
1.2.9 Motor Fault Board (Optional) (3.74 ±2.27 bar)
The motor fault board (See Figure 1--11) consists of red d. High Pressure Switch (HPS) Normally Closed
and green LED’s, which when illuminated, will reflect Opens at: 360 ±10 psig (20.41 ±0.68bar)
each motors state of condition. When the evaporator
and condenser motors are energized, the green LED’s Closes at: 280 ±10 psig (13.61 ±0.68bar)
will be illuminated. If a red LED is energized, it will show e. Low Pressure Switch (LPS) Normally Open
an “open circuit” condition, indicative of a motor failure.
The green LED will not be illuminated at this time. The Opens at: 6 ±3psig (0.41 ±0.20 bar)
motor fault board is a seperate circuit board that is Closes at: 25 ±3 psig (1.7 ±0.20 bar)
located at the return air section. The return air grill is f. Water Temperature Switch (WTS)
oppened to view the LED indicators.
[Bus Manufacturer Supplied -- Suggested close on
1.3 REFRIGERATION SYSTEM COMPONENT temperature rise at 105°F (41°C)]
SPECIFICATIONS 1.4 ELECTRICAL SPECIFICATIONS -- MOTORS
a. Refrigerant Charge R--134a (Approximate) a. Evaporator Blower/Motor
Permanent Magnet
NOTE Evaporator Motor
24 VDC 12 VDC
Refrigerant charge will depend on hose lengths
and diameters; or if there is an In--Dash unit Horsepower (kW) 1/8 (.09)
(front evaporator). The following should only be Full Load Amps (FLA) 9.5 19
used as a guideline. Operating Speed High/ 4200
Low (RPM) 1850
AC310 Dual Loop A--6 or TM--21 Compressor
6 Pounds (2.7 kg) -- Curbside Factory Lubricated
Bearing Lubrication (additional grease not required)
8 Pounds (3.6 kg) -- Roadside
Change 07/09 1--7 T--304

b. Condenser Fan Motor 1.6 AIR CONDITIONING REFRIGERATION
Permanent Magnet CYCLE
Condenser Motor
24 VDC 12 VDC When air conditioning (cooling) is selected by the
Horsepower (kW) 1/8 (.09) controller, the unit operates as a vapor compression
Full Load Amps (FLA) 9 18 system using R-134a as a refrigerant (See Figure 1--6
Dual Loop & Figure 1--8 Single Loop flow diagrams).
Operating Speed The main components of the system are the A/C
(RPM) 2950
compressor, air-cooled condenser coils, receiver,
Factory Lubricated filter-drier, thermostatic expansion valve, liquid line
Bearing Lubrication (additional grease not required) solenoid valve and evaporator coils.
The compressor raises the pressure and the
c. Temperature Sensors (Return Air Sensor) temperature of the refrigerant and forces it into the
Input Range: --52.6 to 158° F (--47 to 70°C) condenser tubes. The condenser fan circulates
surrounding air (which is at a temperature lower than the
Output: NTC 10K ohms at 77° F (25°C) refrigerant) over the outside of the condenser tubes.
d. Ambient Sensor (Optional) Heat transfer is established from the refrigerant (inside
the tubes) to the condenser air (flowing over the tubes).
Opens at: 25° F (10°C) The condenser tubes have fins designed to improve the
Closes at: 35° F (1.7°C) transfer of heat from the refrigerant gas to the air; this
removal of heat causes the refrigerant to liquefy, thus
liquid refrigerant leaves the condenser and flows to the
1.5 SAFETY DEVICES receiver.
The refrigerant leaves the receiver and passes through
System components are protected from damage the receiver outlet/service valve, through a filter-drier
caused by unsafe operating conditions with safety where a descecant keeps the refrigerant clean and dry.
devices. Safety devices with Carrier Transport Air
Conditioning supplied equipment include high pressure From the filter-drier, the liquid refrigerant then flows
switch (HPS), low pressure switch (LPS), circuit through the liquid line solenoid valve to the sight--glass
breakers and fuses. and then to the thermostatic expansion valve. The
thermal expansion valve reduce pressure and
a. Pressure Switches temperature of the liquid and meters the flow of liquid
refrigerant to the evaporator to obtain maximum use of
High Pressure Switch (HPS) the evaporator heat transfer surface.
During the air conditioning cycle, compressor clutch The low pressure, low temperature liquid that flows into
operation will automatically stop if the HPS switch the evaporator tubes is colder than the air that is
contacts open due to an unsafe operating condition. circulated over the evaporator tubes by the evaporator
Opening HPS contacts de-energizes the compressor fans (fans). Heat transfer is established from the
clutch shutting down the compressor. The high pressure evaporator air (flowing over the tubes) to the refrigerant
switch (HPS) is installed at the compressor assembly (flowing inside the tubes). The evaporator tubes have
(05G, 05K & TM--31). aluminum fins to increase heat transfer from the air to
Low Pressure Switch (LPS) the refrigerant; therefore the cooler air is circulated to
the interior of the bus. Liquid line solenoid valve closes
The low pressure switch is installed close to the during shutdown to prevent refrigerant flow.
compressor and opens on a pressure drop to shut down
the system when a low pressure condition occurs. The The transfer of heat from the air to the low temperature
low pressure switch is installed at the compressor (05G, liquid refrigerant in the evaporator causes the liquid to
05K & TM--31). vaporize. This low temperature, low pressure vapor
passes through the suction line and returns to the
compressor where the cycle repeats.
NOTE
On dual loop systems that use the A--6, TM--21 1.7 HEATING CYCLE
& some TM31’s, the pressure switches are not Heating circuit (See Figure 1--7) components furnished
located on the compressors. They are installed by Carrier Transport Air Conditioning include the heater
in--line. cores and solenoid operated heat valves. Components
furnished by the bus manufacturer may include a water
temperature switch (WTS) and boost water pump.
b. Fuses and Circuit Breakers
The controller automatically controls the heat valves
The Relay Board is protected against high current by an during the heating mode to maintain required
OEM supplied circuit breaker or fuse located in the bus temperatures inside the bus. Engine coolant (glycol
battery compartment (150 Amp for 12 VDC & 125 Amp solution) is circulated through the heating circuit by the
for 24 VDC systems). Independent 15 Amp, 24 VDC or engine and an auxiliary boost water pump. When the
20 Amp, 12 VDC fuses protect each motor while the heat valve solenoids are energized, the valves will open
output circuits are protected by an additional 5 Amp to allow engine coolant to flow through the heater coils.
circuit breaker. During a high current condition, the fuse The valves are normally closed so that if a failure
may open. occurs, the system will be able to cool.
T--304 1--8 04/08

5
3 6
2 4
4
1
Driver’s
Evaporator
12 7
9 10
11
8
1 Thermal Expansion Valve 7 Subcooler

2 Liquid Line Sight Glass 8 Compressor (TM--21 or A--6)
3 Service Port 9 Service Valve
4 Liquid Line Solenoid 10 Condenser Coil
5 Evaporator Coil 11 Filter--Drier
6 Heat Coil 12 Receiver
Note: Items 1 through 12 are typical, both systems.
Figure 1--6 Refrigerant Flow Diagram -- Cooling (Dual Loop)
04/08 1--9 T--304

1 1
4*
SUPPLY
RETURN
4* 3 2
1. Heat Coil 4. Heat Solenoid Valve

2. Vehicle Radiator * Optional Hand Valve
3. Boost Pump
Figure 1--7 Flow Diagram -- Heating
NOTE: In order to ensure water is entering the heater coils sufficiently heated, it is suggested that
the OEM supplied Water Temperature Switch (WTS) close on temperature rise at 150°F (65.5°C).
T--304 1--10 04/08

Discharge
Liquid
Suction Relief Valve
Coolant 11
9 9
CONDENSER
8
10
4
Discharge Check Valve

Dash Air
Suction Line 5 Dash Air
Liquid Line
4 EVAPORATOR
2
5
3
3
4
7 6 6
Figure 1--8 Refrigerant Flow Diagram, Cooling (Single Loop) AC350
1. Thermal Expansion Valve 7. Compressor

2. Liquid Line Sight Glass 8. Service Valve
3. Service Port R134a 9. Condenser Coil
4 Service Port 1/4 Flare (Acme) 10. Filter--Drier
5. Liquid Line Solenoid 11. Receiver
6. Evaporator Coil
04/08 1--11 T--304

Ref. Sutrac 60--01--21--062
29 27
28
K1M
8
F1A
30
F2A
K2M
F3A
31
9
F4A
32
frei
33
F1M
K3M
10
34
F2M
F3M
45 43 41 39 37 35
F4M
36
K4M
F5M
11
F6M
F7M
44 42 40 38
F8M
K5M
12
F13M
F14M
F15M
K6M
F16M
13
frei
frei
frei
14
K7M
46
K1A
23
K8M
15
K2A
24
K9M
25
16
K3A
26
K4A
K10M
17
K13M
22
K11M
18
K12M
6
19
A1P
K14M
20
B1N
5
V5
V4
4
V3
7
K15M
V2
3
21
V1
2
1
47 CLR1 CLR2 48
See Figure 1--9 Sheet 2 Legend Ref. Sutrak Schematic 65--01--28--056--01--3
Figure 1--9 Sheet 1 -- Electrical Control Board (280P)
T--304 1--12 04/08

LEGEND
1 V1, Diode, Dash Switch 32 F1M, Fuse, Evaporator Motor
4 V4, Diode, Thermostat, Cooling 35 F4M, Fuse, Evaporator Motor
5 V5, Diode, Thermostat, Heating 36 F5M, Fuse, Evaporator Motor
6 Thermostat 37 F6M, Fuse, Evaporator Motor
7 Return Air Sensor 38 F7M, Fuse, Evaporator Motor
8 K1M, Relay, Evaporator Low Speed 39 F8M, Fuse, Evaporator Motor
9 K2M, Relay, Evaporator High Speed 40 F13M, Fuse, Evaporator Motor
10 K3M, Relay, Evaporator High speed 41 F14M, Fuse, Evaporator Motor
11 K4M, Relay, Evaporator Low Speed 42 F15M, Fuse, Condenser Motor
12 K5M, Relay, Evaporator High Speed 43 F16M, Fuse, Condenser Motor
13 K6M, Relay, Evaporator High Speed 44 SPARE
14 K7M, Relay, Evaporator Low Speed 45 SPARE
15 K8M, Relay, Evaporator High speed 46 SPARE
16 K9M, Relay, Evaporator High Speed 47 CLR1, Clutch Lockout Relay #1
17 K10M, Relay, Evaporator Low Speed 48 CLR2, Clutch Lockout Relay #2
18 K11M, Relay, Evaporator High Speed Ambient Sensor -- (Condenser)
19 K12M, Relay, Evaporator High Speed Humidity Control Sensor -- (Return Air)
20 K14M, Relay, Evaporator Main, High speed OEM Installed Controls
21 K15M, Relay, Condenser Motors CR1 & CR2, Clutch Relays
22 K13M, Relay, Condenser Motors
23 K1A, Relay, Alternator Power
24 K2A, Relay, Compressor Clutch
25 K3A, Relay, Heat Valve and Water Pump
26 K4A, Relay, Evaporator Speed
27 F1A, Fuse, Alternator Output
28 F2A, Fuse, Heat Valve and Water Pump
29 F3A, Fuse, Compressor Clutch
30 F4A, Fuse, Compressor Clutch
31 SPARE
See Figure 1--9 Sheet 1 -- Electrical Control Board
Figure 1--9 Sheet 2 Legend
04/08 1--13 T--304

1....K1A = Compressor Clutch -- Liquid Line Solenoid -- Condenser Fans
2....K2A = Heat Valve -- Boost Pump
3....K3A = Evaporator Fans
4....K1M -- K6M = Individual Evaporator Fans (M1M -- M6M)
5....K7M -- K9M = Individual Condenser Fans (M21M -- M26M)
6....Fuse = Boost Pump & Heat Valve
7....F13M -- F18M = Individual Condenser Fans
8....F1M -- F12M = Individual Evaporator Fans
9....U Reg = Evaporator Speed Regulation
10...X1 = Condenser Fans
11...X2 = Evaporator Fans
12...X3 -- X4 (Not Shown On Drawing) = Dash To Unit Interface Plug
K1A
K2A
K3A
Relay Board
GND
+
+
K8M
K2M
K4M
K6M
K3M
K5M
K7M
K9M
K1M
RELAYS FOR COND. MOTORS

10A
F10M 10A
F12M 10A
F13M 15A
F14M 15A
F15M 15A
F16M 15A
F17M 15A
F18M 15A
F11M 10A
F1M 10A
F2M 10A
F3M 10A
F4M 10A
F5M 10A
F6M 10A
F7M 10A
F8M 10A
F9M
K7M -- K8M
K7M -- K9M
26.38.08.001
Part Number
Ureg
RELAYS FOR EVAP. MOTORS

X2
X1
K1m -- K4M
U3A
K1M -- K6M
U3
--
Contact arrangement
+
Connect X1 -- X2
Top View
AC350
AC310
UNIT
SUTRAK SCHMATIC #65, 01, 28, 056--01--3
Figure 1--10 AC350 With BT324 Control
T--304 1--14 04/08

R85
R26 R25
OPEN CIRCUIT MOTOR POWER POWER 10-- 30V
D50
R91
D14 D13 R37 R61 R73 DS13 DS1
D26 D25 R38 R62 R74
R86
EVAP1
R87
POWER
T25
C13 C12 DS14 DS2
Q2 OK
Q1
EVAP2
C16
C1
U1 U4 DS15 DS3
C19
EVAP3 DS25
C14 C15
Q3 T26
DS16 DS4
F1
Q4
D49
C20
D27 D28 R39 R63 R75 EVAP4
R88
D15 D16 R40 R64 R76
DS17 DS5
R27 R28 GROUND
EVAP5
C21
DS18 DS6
R30 R29 R89
EVAP6 R90
D18 D17 R41 R65 R77
D51
D30 D29 R42 R66 R78
DS19 DS7
D52
EVAP7
C9 C8
Q6
Q5
DS20 DS8 C23 C22
C17
EVAP8 + +
C2
U2 U5
U7
DS21 DS9
C10 C11 U8
Q7
Q8 COND1
D31 D32 R43 R67 R79
DS22 DS10
D19 D20 R44 R68 R80
R31 R32 COND2
DS23 DS11
COND3
R34 R33
D22 D21 R45 R69 R81

DS24 DS12
D34 D33 R46 R70 R82
COND4
C13 C12
Q10
Q9
C18
C3
U3 U6
C14 C15
Q11
Q12
D35 D36 R47 R71 R83
D23 D24 R48 R72 R84
R9
R8
R7
R6
R5
R4
R3
R2
R10
R11
R12
R1
R35 R36
D9
D8
D7
D6
D5
D4
D3
D2
D1
D12
D10
D11
R24
R23
R22
R21
R20
R19
R18
R17
R16
R15
R14
R13
D37 RS1
T13 X1--1
MOTOR EVAP1 WHT/RED BREAKER
R49
T1
D38
RS2
T14 X1--2
MOTOR EVAP2 BLK/RED BREAKER
R50
T2
D39
RS3
T15 X1--3
MOTOR EVAP3 WHT/YEL BREAKER
R51
T3
D40
RS4
T16 X1--4
MOTOR EVAP4 BLK/YEL BREAKER
R52
T4
D41
RS5
T17 X1--5
MOTOR EVAP5 WHT/ORN BREAKER
R53
T5
D42
RS6
T18 X1--6
MOTOR EVAP6 BLK/ORN BREAKER
R54
T6
D43
RS7
T19 X1--7
MOTOR EVAP7 WHT/GRN BREAKER
R55
T7
RS8
D44
X1--8
CARRIER CRO MOTOR FAULT BOARD
T20
MOTOR EVAP8 BLK/GRN BREAKER
R56
T8
D45
RS9
T21 X3--1
MOTOR COND1 GRN/ORN BREAKER
R57
12--00524--00
T9
D46
RS10
T22 X3--2
MOTOR COND2 GRN/WHT BREAKER
R58
T10
D47
RS11
T23 X3--3
MOTOR COND3 GRN/BLU BREAKER
R59
T11
D48
RS12
T24 X3--4
MOTOR COND4 GRN/YEL BREAKER
R60
T12
Figure 1--11 Motor Fault Board (Optional)
04/08 1--15 T--304

SECTION 2
OPERATION (MANUAL CONTROLLER)
2.1 STARTING, STOPPING AND OPERATING 2.1.1 Starting
INSTRUCTIONS a. If the engine is not running, start the engine.
The control switches supplied by Carrier Transport Air b. Actual start sequence depends on the operating co-
Conditioning will be marked with international symbols trol supplied. If only an ON/OFF switch is supplied,
(See Figure 2.1). place the switch in the ON (fan symbol) position to
start the system in the automatic mode.
Before starting, electrical power must be available from
the bus power supply. c. After the pre--trip inspection is completed, the
switches may be set in accordance with the desired
150 Amp @12 VDC or125 Amp @ 24 VDC from a fuse in control modes.
the battery compartment supplies power for the clutch, d. If low or high speed evaporator fan speed is desired,
evaporator and condenser assemblies. press the FAN SPEED (fan symbol) button to bring
speed to the desired level.
2.1.2 Stopping
Placing the ON/OFF (Snowflake) switch in the OFF
position will stop the system operation by removing
power to the Logic Board.
LOW -- -- -- HIGH
COOL HEAT
OFF ON Temperature Control
Figure 2.1 Control Switches (Typical)

2.2 PRE--TRIP INSPECTION a. Listen for abnormal noises in compressor or fan mo-
tors.
After starting system, allow system to stabilize for ten to b. Check compressor oil level (05G Compressor only).
fifteen minutes and check for the following: c. Check refrigerant charge. (Refer to section 5.8.1 )
04/08 2--1 T--304

2.3 MODES OF OPERATION unloader valves (UV1 and UV2), each controlling two
cylinders; this allows the 05G to be operated with two,
2.3.1 Temperature Control four or six cylinders.
Temperature is controlled by maintaining the return air The unloaders are used to control system capacity by
temperature measured at the return air grille. To controlling compressor capacity.
maintain cooling, turn the temperature control knob
towards the minus (--) symbol. To start heating cycle, Control of the unloaders is with the pressure switches.
turn the temperature control knob towards the plus (+) a. Suction Pressure
symbol (See Figure 2.1). The unloaders are used to control suction pressure and
2.3.2 Cooling Mode thereby prevent coil frosting:
Cooling is accomplished by energizing the compressor 1. Compressor Unloader UV1 Relay -- When the suc-
and condenser fans, opening the liquid line solenoid tion pressure decreases below 26 psig (R--134a),
valve and closing the heating valve. Once interior unloader UV1 is energized, unloading a cylinder
temperature reaches the desired set point, the system bank (2 cylinders); this output will remain energized
will de--energize the compressor clutch and allow the until the pressure increases to above 34 psig
system to operate in the vent mode until further cooling (R--134a).
is required. The temperature will be maintained within 2° 2. Compressor Unloader UV2 Relay -- When suction
C. or 3.6° F. pressure decreases below 23 psig (R--134a), un-
A controller programed for reheat will mantain loader UV2 is energized, unloading the second com-
compressor operation and cycle the heat valve to allow pressor cylinder bank; this output will remain ener-
reheating of the return air. In the reheat mode interior gized until the pressure increases to above 31 psig
temperature is maintained at the desired set point while (R--134a).
additional dehumidification takes place. b. Discharge Pressure
2.3.3 Heating Mode Discharge pressure is also controlled by the unloaders:
In the heat mode the liquid line solenoid is closed and 1. Compressor Unloader UV1 Relay -- When the dis-
the compressor and condenser fans are shut down. The charge pressure increases above setpoint A (see
heat valve is opened to allow a flow of engine coolant Table 2.1), unloader UV1 is energized; this unloader
through the heat section of the evaporator coil. The will remain energized until the pressure decreases
evaporator fans speed is varied as required to circulate below set point B (see Table 2.1).
air over the evaporator coil based on the temperature Table 2.1 Unloader UV1 Relay
difference from setpoint.
HP Switch Set Point A Set Point B
Operating in the heating mode is controlled by the water (PSIG) (PSIG) (PSIG)
temperature switch (WTS). The WTS is located on the
engine block of the vehicle and is provided by the OEM. 300 (R--134a) 275 220
It senses the engine collant temperature and reverses 350 (R--134a)
its contacts on temperature rise at 105° F. The switch (High Ambient) 325 270
prevents the circulation of cooler air throughout the
vehicle as the engine comes up to temperature. 2. Compressor Unloader UV2 Relay -- On R--134a sys-
tems when the discharge pressure increases above
2.3.4 Boost Pump (Optional) setpoint A (see Table 2.2), unloader UV2 is ener-
When the unit is in the heat mode, and if a boost pump is gized; this unloader will remain energized until the
supplied by the coach manufacturer, the boost pump pressure decreases below set point B (see
relay is energized, providing 24 VDC to activate the Table 2.2).
boost pump. Table 2.2 Unloader UV2 Relay
2.3.5 Vent Mode HP Switch Set Point A Set Point B
Once the temperature is satisfied, there is a window (PSIG) (PSIG) (PSIG)
when the unit will go into a vent mode. This is when there 300 (R--134a) 285 225
is neither heating or cooling. Only the evaporator fans
are operating. The range of the Vent mode is 2°C. or 350 (R--134a)
(High Ambient) 330 275
3.6°F. from the set point. The compressor clutch is
disengaged at this time. 2.3.7 Override Mode -- AC310 (Dehumidification)
2.3.6 Compressor Unloader Control (Only with When in the heat mode the compressor will not operate.
05G or 05K Compressors) The thermostat will allow only COOL, VENT or HEAT
When operating in cooling, the unloaders are used to modes independently. An override switch has been
reduce system capacity as return air temperature installed in the return air area to allow the compressors
approaches set point. Operation of the unloaders to run when in the HEAT mode. Moving the switch to the
balances system capacity with the load and thereby ON position will energize both clutch relays energizing
prevents overshoot from set point. the clutches. There are two temperature sensors that
are in series with the clutch relay circuit, Ambient
Relay Board mounted unloader outputs control the Sensor (mounted in the condenser) and Humidity
capacity of the compressor by energizing or Control Sensor (mounted in the return air area). As long
de--energizing unloader solenoid valves. The model as the return air temperature is above 60° F and the
05G compressor has three banks of two cylinders each. ambient is above 25° F, the override circuit will function
Enercizing a valve de--activates a bank of cylinders. The when energized, providing dehumidification. (See
outboard cylinder banks of the 05G are equipped with section 1.4 for sensor specs)
T--304 2--2 04/08

2.3.8 Evaporator Fan Speed Selection 4. Through line U3, to energize the condenser fan re-
lays (K14M & K15M). Energizing these relays will
Evaporator fan speed(s) selection is one method of send B+ power to start the condenser fan motors.
controlling the cooling and heating throughout the bus
passenger compartment. The thermostat control is the The unit is now in low speed cooling.
other. 5. To bring the evaporator fans to high speed the fan
2.3.9 Compressor Clutch Control speed switch (S1A) is placed in the HIGH (Vent 2)
position. Power flows from the switch through line U5
(A--6, TM--16, TM--21) to energize the high speed relay (K13M). The nor-
mally closed low speed relay (K4A) is de--energized
A belt driven electric clutch is employed to transmit opening the low speed circuit. Power flows from the
engine power to the air conditioning compressor. high speed relay (K13M) to energize the high speed
De-energizing the clutch’s electric coil disengages the fan relays (K2M, K3M, K5M, K6M, K8M, K9M,
clutch and removes power from the compressor. The K11M, & K12M). Energizing these relays individually
clutch will be engaged when in cooling and disengaged grounds each evaporator fan motor separately plac-
when the system is off, in heating or during high and low ing them in high speed operation.
pressure conditions.
c. With the thermostat calling for heating, power flows
The clutch coil will be de-energized if the discharge from the heat switch:
pressure rises to the 365 ±10 psig (19.42 bar) cutout
setting of the compressor mounted high pressure 1. Through line UH to energize the heat relay (K3A).
switch. The clutch coil will energize (Automatic Re--Set) With the heat realy energized, power flows from the
when the discharge pressure falls to 280 ± 10 psig battery (line B+) to start the water pump and open
(11.41 bar). the heat valve. The unit is now in the heat mode. Fan
speeds can be adjusted the same as in the cooling
The clutch coil will be de-energized (open) if the suction mode.
pressure (LP) decreases below 6 ± 3 psig (0.45 bar). d. With the Thermostat calling for Heating and the need
The clutch coil will energize (Automatic Re--Set) when for Dehumidification is required:
suction pressure rises (close) to 25 ± 3 psig (1.7 bar).
1. The override switch, located in the return air inlet is
2.4 SEQUENCE OF OPERATION (280P / 282P) switched to the ON position.
2. Power will flow through the ambient and humidity
2.4.1 Electronic Thermostat control switch, if closed, and energize the cooling cir-
With a signal from the Hydraulic Brake Module (or other cuits at the same time as heating.
12 VDC source) the A/C Power Relay is grounded, This will put the system in a Reheat Mode of operation.
sending 12 VDC to the K1A relay. K1A relay energizes The thermostat will only cycle the heat valve and pump.
sending battery power (Line B+) to the Dash Control The cooling circuit will stay energized as long as the
switches (S1A & S2A). override switch is in the ON position and both sensor
switches are closed.
Begining with the Fan Speed Switch (S1A) in the low
speed position (vent 1) the following actions take place:
CONTROL ACTION -- CYCLING CLUTCH
a. Power flows from the Fan Speed Switch (S1A)
through relay K4A normally closed contacts. Line U2 RISING
energizes evaporator fan motor low speed relays TEMPERATURE
(K1M, K4M, K7M & K10M). Closing these relays al-
lows power to flow from the battery (line B+) through
the fan motors with two motors in series, operating FULL-
the motors at low speed. +1.8° F ABOVE
COOL SETPOINT
b. The ON/OFF switch (S2A) is then placed in the ON
position. Power flows from the switch to energize the
Thermostat. With the Thermostat calling for cooling, SETPOINT
power also flows from the cooling switch:
VENT
1. Thorugh the Humidity Control Sensor and the Ambi- SETPOINT
ent Sensor Switches located in the return air and
condenser respectively. If both of these switches are
in the closed position the following sequence will
take place. --1.8° F ABOVE HEAT
SETPOINT
2. Power will flow to the Clutch Lockout Relays (CLR1
& CLR2) allowing power to energize the Clutch Re-
lays (CR1 & CR2). Relays CR1 & CR2 are powere-
don terminal 30 from an OEM breaker, (A/C Low
Voltage Breaker). Energizing these relays will send FALLING
power through the high and low pressure switches
and to both compressor clutches energizing the TEMPERATURE
clutch coils and starting the compressor.
Figure 2.2 280P / 282P Thermostat
3. To the liquid line solenoids (Y1A & Y2A) to start the
flow of refrigerant.
04/08 2--3 T--304

SECTION 3
OPERATION BT324 CONTROLLER
3.1 STARTING, STOPPING AND OPERATING Before starting, electrical power must be available from
INSTRUCTIONS the bus power supply (See Figure 3--1).
A 150 Amp @12 VDC or a125 Amp @ 24 VDC fuse in
The BT324 Carrier Sutrak Digital Display (CSDD) is the battery compartment passes power for the clutch,
marked with international symbols (See Figure 3--2). evaporator and condenser assemblies.
A/C
Figure 3--1 Bus Dash With A/C Switch & BT324 CSDD Controller
3.1.1 Starting Toggling the A/C key (Item 5 Figure 3--2) on the display
again will stop the system operation.
a. If the engine is not running, start the engine.
b. When the 12/24VDC power is applied, the driver dis- 3.2 PRE--TRIP INSPECTION
play will illuminate and show return air set point.
Press the A/C key (Item 5 Figure 3--2) on the display After starting system, allow system to stabilize for ten to
to trigger the start up sequence. fifteen minutes and check for the following:
c. After the pre--trip inspection is completed, the a. Listen for abnormal noises in compressor or fan mo-
switches may be set in accordance with the desired tors.
control modes. b. Check compressor oil level (05G Compressor only).
3.1.2 Stopping c. Check refrigerant charge. (Refer to section 5.8.1 )
04/08 3--1 T--304

1 6
2 3 4 5
7 8 9 10
Figure 3--2 BT324 CSDD Controller

KEYS LEDS
1. Plus Key 6. Display
2. Minus Key 7. Fresh Air Operation (Green)
3. Recirculate/Fresh Air Key 8. Manual Blower Control ’ON’ (Green)
4. Blower Control Key 9. Heating Mode (Green)
5. Automatic Climate Control (A/C) 10. Malfunction Light (Red)
3.3 SEQUENCE OF OPERATION BT324 CSDD NOTE

The following blower steps are disabled when
3.3.1 Function of Keys when “Engine On” and the automatic climate control is on:
controller active: 2--, 3--step blower: Off
Continuously adjustable blower: Off
a. Plus Key -- Increases interior temperature setpoint by
1° per stroke or increases manual blower speed, de- 3.3.2 Illuminating Indications (Display)
pending on displayed mode. With “Engine--On” and Controller active
b. Minus Key -- Decreases interior temperature setpoint 3.4 Operating Instructions BT324
by 1° per stroke or decreases manual blower speed, When the engine is running, toggle the A/C Switch to on
depending on displayed mode. to activate the Air Conditioning Unit.
3.4.1 Display
c. Recirculating Air/Fresh Air -- Switches from Recircu-
lating Air to Fresh Air and vice--versa. When the unit is ON, the display shows the interior
setpoint temperature. When selecting individual
d. Blower Control -- Switches on the manual blower con- functions, the display shows the corresponding
trol. information for a short period of time. The display is dark
when the engine and control unit are OFF.
e. Automatic Climate Control -- Switches on the Auto- 3.4.2 Interior Temperature Control
matic Temperature Control. Press the Plus (1) or Minus (2) keys to set the desired
interior temperature.
f. Temperature Indicator (Key 2 + Key 3) -- Shows the The temperature can be adjusted between 64° F (18° C)
inside temperature for 10 seconds. If pressed a sec- and 82° F (28° C).
ond time shows the outside temperature for 10 sec-
onds (optional). When the outside temperatures are below 35° F (2° C)
(adjustable parameter), the cooling function remains
g. Reheat (optional) (Key 3 + Key 5) -- Starts Reheat disabled.
mode for 3 minutes (duration adjustable). 3.4.3 Ventilation
When the unit is operating in Automatic Climate Control
h. Controller Off (A/C Switch To Off) -- Switches off all mode, the blower speed is controlled based on the room
control functions and the display. temperature.
T--304 3--2 04/08

However, the blowers may be switched to manual mode A sensor malfunction is displayed by “i ----” or “o ----”.
of operation by pressing the blower key.
3.5 CHANGING BETWEEN °F (FAHRENHEIT)
Press the Plus or Minus keys to define one of 5 different AND °C (CELCIUS )
blower steps. The blowers can not be switched OFF
when Automatic Climate Control is ON. Procedures for changing the BT324 Controller between
Fahrenheit and Celcius is as follows:
When Automatic Climate Control is OFF, the blowers
stop when the manual control is turned to zero. a. Engine “OFF” & Ignition “ON”.
3.4.4 Reheat (optional) b. Press Key 1 (plus) and Key 2 (minus) at the same
time until the display shows the word “Code”.
The Reheat mode is used to remove air humidity and to
help defog the windshield. Press Key 3 (Recirculating
Air/Fresh Air) and Key 5 (Automatic Climate Control) at NOTE
the same time to activate Reheat. Heating and cooling After the display shows the word “Code” you
will be energized on for 3 minutes (adjustable have 5 seconds to enter the correct access
parameter). In addition, the blowers are switched to code.
maximum speed and the fresh air flap is closed. At the
end of the pre--set duration of time, the functions return c. Press Key 1 (Plus Key) one time and release.
to the previously selected settings.
d. Press Key 3 (Recirculating Air/Fresh Air) one time
Reheat mode is disabled with the outside temperature is and release.
below 35° F (2° C) (adjustable parameter), when the
sensor is not installed, or when there is a sensor failure. e. Press Key 4 (blower control) one time and release.
3.4.5 Temperature Indication The display will show the mode “Fah” for temperatures
Press key 2 (minus) and key 3 (Recirculating Air/Fresh in °F or the mode “Cel” for temperatures in °C.
Air) at the same time to display the inside temperature f. Press Key 1 (plus) or Key 2 (minus) to change the
for 10 seconds. temperature mode.
Optionally, the outside temperature may be displayed g. Press Key 5 (automatic climate control) one time to
when pressing the keys a second time. end the program.
04/08 3--3 T--304

SECTION 4
TROUBLESHOOTING
Table 4--1 General System Troubleshooting Procedures
INDICATION -- REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
4.1 System Will Not Cool
Compressor will not run Drive--Belt loose or defective Check
Clutch coil defective Check/Replace
Clutch malfunction Check/Replace
Compressor malfunction See Table 1--3
Electrical malfunction Coach power source defective Check/Repair
Circuit Breaker/safety device open Check/Reset
4.2 System Runs But Has Insufficient Cooling
Compressor Drive-Belt loose or defective Check
Compressor valves defective See Table 1--3
Refrigeration system Abnormal pressures 4.3
No or restricted evaporator air flow 4.5
Expansion valve malfunction 4.6
Restricted refrigerant flow 5.11
Low refrigerant charge 5.8
Service valves partially closed Open
Safety device open 1.5
Liquid solenoid valve stuck closed 5.13
Restricted air flow No evaporator air flow or restriction 4.5
Heating system Heat valve stuck open 4.7
4.3 Abnormal Pressures
High discharge pressure Refrigerant overcharge 5.8.1
Noncondensable in system Check
Condenser motor failure Check
Condenser coil dirty Clean
Low discharge pressure Compressor valve(s) worn or broken See Table 1--3
High suction pressure Compressor valve(s) worn or broken See Table 1--3
Low suction pressure Suction service valve partially closed Open
Filter-drier inlet valve partially closed Check/Open
Filter-drier partially plugged 5.11
Expansion valve malfunction 4.6
Restricted air flow 4.5
Suction and discharge pressures Compressor valve defective See Table 1--3
tend to equalize when system is
operating
4.4 Abnormal Noise Or Vibrations
Compressor Loose mounting hardware Check/Tighten
Worn bearings See Table 1--3
Worn or broken valves SeeTable 1--3
Liquid slugging 4.6
Insufficient oil 1.3
Clutch loose, rubbing or is defective Repair/Replace
Drive-Belt cracked, worn or loose Adjust/Replace
Dirt or debris on fan blades Clean
04/08 4--1 T-304

Table 4--1 General System Troubleshooting Procedures -- Continued
INDICATION -- REFERENCE
TROUBLE POSSIBLE CAUSES SECTION
4.4 Abnormal Noise Or Vibrations -- Continued
Condenser or evaporator fans Loose mounting hardware Check/Tighten
Defective bearings Replace
Blade interference Check
Blade missing or broken Check/Replace
4.5 No Evaporator Air Flow Or Restricted Air Flow
Air flow through coil blocked Coil frosted over Defrost coil
Dirty coil Clean
Dirty filter Clean/Replace
No or partial evaporator air flow Motor(s) defective Repair/Replace
Motor brushes defective Replace
Evaporator fan loose or defective Repair/Replace
Fan damaged Repair/Replace
Return air filter dirty Clean/Replace
Icing of coil Clean/Defrost
Fan relay(s) defective Check/Replace
Fan rotation incorrect Check
4.6 Expansion Valve Malfunction
Low suction pressure with high Low refrigerant charge 5.8
superheat Wax, oil or dirt plugging valve orifice Check
Ice formation at valve seat 4.6
Power assembly failure Replace
Loss of bulb charge Replace
Broken capillary tube 5.16
Low superheat and liquid slugging Bulb is loose or not installed. 5.16
in the compressor Superheat setting too low 5.16
Ice or other foreign material holding valve open
Side to side temperature differ- Wax, oil or dirt plugging valve orifice Check
ence (Warm Coil) Ice formation at valve seat 5.7
Power assembly failure Replace
Loss of bulb charge Replace
Broken capillary 5.16
4.7 Heating Malfunction
Insufficient heating Dirty or plugged heater core Clean
Coolant solenoid valve(s) malfunctioning or plugged Check/Replace
Low coolant level Check
Strainer(s) plugged Clean
Hand valve(s) closed Open
Water pumps defective Repair/Replace
Auxiliary Heater malfunctioning. Repair/Replace
No Heating Coolant solenoid valve(s) malfunctioning or plugged Check/Replace
Controller malfunction Replace
Pump(s) malfunctioning Repair/Replace
Continuous Heating Coolant solenoid valve stuck open 5.12
T--304 4--2 04/08

SECTION 5
SERVICE
WARNING
Be sure to observe warnings listed in the safety summary in the front of this manual before perform-
ing maintenance on the hvac system
WARNING
Read the entire procedure before beginning work. Park the coach on a level surface, with parking
brake applied. Turn main electrical disconnect switch to the off position.
NOTE
To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removing refriger-
ant. The refrigerant recovery system is available from Carrier Transicold (Carrier Transicold P/N MVSII--115
or MVSII--240). When working with refrigerants you must comply with all local goverment environmental laws.
5.1 MAINTENANCE SCHEDULE
SYSTEM REFERENCE
SYSTEM
ON OFF SECTION
a. Daily Maintenance
X Pre-trip Inspection -- after starting 2.2
X Check tension and condition of drive belts. None
b. Weekly Inspection
X Perform daily inspection See above
X Check condenser, evaporator coils and air filters for cleanliness None
X Check refrigerant hoses, fittings and component connections for leaks 5.6
X Feel filter-drier for excessive temperature drop across drier 5.11
c. Monthly Inspection and Maintenance
X Perform weekly inspection and maintenance See above
X Clean evaporator drain pans and hoses None
X Check wire harnesses for chafing and loose terminals Replace/Tighten
X Check fan motor bearings None
X Check compressor mounting bolts for tightness None
5.2 REMOVING EVAPORATOR COVER 3. Place the condenser cover on top of the evaporator
section.
To remove the evaporator cover do the following:
1. Turn all the 1/4 turn cam locks counterclockwise. 5.4 INSTALLING MANIFOLD GAUGE SET
2. Using two people carefully grasp the cover under the
bottom edge and lift up. A manifold gauge set can be used to determine system
operating pressures, add charge, equalize or evacuate
3. Place the evaporator cover on top of the condenser system.
section.
When the suction pressure hand valve is frontseated
5.3 REMOVING CONDENSER COVER (turned all the way in), the suction (low) pressure can be
read. When the discharge pressure hand valve is
To remove the condenser cover do the following: frontseated, discharge (high) pressure can be read.
1. Turn all the 1/4 turn cam locks counterclockwise. When both valves are open (turned counterclockwise),
high pressure vapor will flow into the low side. When
2. Using two people carefully grasp the cover under the only the low pressure valve is open, the system can be
bottom edge and lift up. charged or evacuated.
04/08 5--1 T-304

SUCTION DISCHARGE
CAUTION PRESSURE 1. PRESSURE
GAUGE GAUGE
The AC310 & AC350 Rooftop Systems have
R134a service port couplings installed on
the compressor and 1/4 inch flare (Acme)
fittings installed on the unit piping.
5.4.1 Installing R--134a Manifold Gauge/Hose SET OPENED CLOSED

(Backseated ) (Frontseated)
An R--134a manifold gauge/hose set with self--sealing HAND VALVE HAND VALVE
hoses is pictured in Figure 5--1. The manifold
gauge/hose set is available from Carrier Transicold.
(Carrier Transicold P/N 07--00294--00, which includes To Low Side 2. To High Side
items 1 through 6, Figure 5--1). To perform service using Access Valve Access Valve
the manifold gauge/hose set, do the following:
a. Preparing Manifold Gauge/Hose Set for use. 3.
BLUE 3.
1. If the manifold gauge/hose set is new or was ex-
posed to the atmosphere it will need to be evacuated RED
to remove contaminants and air as follows:
2. Back--seat (turn counterclockwise) both field service 3.
couplers (see Figure 5--1) and mid--seat both hand 4. 2. YELLOW 4.
valves.
3. Connect the yellow hose to a vacuum pump and an 6. To Refrigerant Tank 5.
R--134a cylinder. Blue Knob or Vacuum Pump Red Knob
4. Evacuate to 10 inches of vacuum and then charge Figure 5--1 Manifold Gauge Set (R--134a)
with R134a to slightly positive pressure of 1.0 psig.
5. Front--seat both manifold gauge set hand valves and 1. Manifold Gauge Set
disconnect from cylinder. The gauge set is now 2.. Hose Fitting (0.5-16 Acme)
ready for use. 3.. Refrigeration and/or Evacuation Hose
. (SAE J2196/R-134a)
4.. Hose Fitting w/O-ring (M14 x 1.5)
5.. High Side Field Service Coupling
6.. Low Side Field Service Coupling
b. Connecting the Manifold Gauge Gauge/Hose Set.

To connect the manifold gauge/hose set for reading
pressures, do the following:
1. Connect the field service couplers (see Figure 5--1)
to the high and low in--line service ports.
2. Turn the field service coupling knobs clockwise,
which will open the system to the gauge set.
3. Read the system pressures.
c. Removing the Manifold Gauge Set.
1. While the compressor is still ON, mid--seat both
hand valves on the manifold gauge set and allow the
pressure in the manifold gauge set to be drawn down
to low side pressure. This returns any liquid that may
be in the high side hose to the system.
CAUTION
To prevent trapping liquid refrigerant in the
manifold gauge set be sure set is brought to
suction pressure before disconnecting.
2. Back--seat both field service couplers and front--seat
both manifold set hand valves. Remove the couplers
from the in--line access valves.
3. Install both in--line access valve caps.
T-304 5--2 04/08

5.5 PUMPING THE SYSTEM DOWN OR REMOV-
ING THE REFRIGERANT CHARGE 3.
1. D S
NOTE
To avoid damage to the earth’s ozone layer, use
a refrigerant recovery system whenever remov- 2.
ing refrigerant.
4.
5.5.1 System Pump Down For Low Side Repair

To service or replace the filter--drier, pump the To Compressor
refrigerant to the condenser and receiver as follows:
a. Remove evaporator and condenser covers.
b. Install manifold gauge/hose set. (Refer to Section
5.4.1). 5.
7.
c. Frontseat the filter--drier inlet service valve by turning
clockwise. It will be necessary to install a jumper 6.
across the low pressure switch (LPS) contacts at the
compressor in order to reach 0 PSIG.
Figure 5--2 In--Line Service Connections
d. Start the system and run in cooling. Stop the unit
when suction reaches 10 ”/hg (25.4 cm/hg) vacuum.
1. Discharge Service 4. Vacuum Pump
e. Frontseat filter/drier outlet service valve to trap refrig- Port 5. Reclaimer
erant in the high side of the system between the com- 2. Suction Service 6. Refrigerant Cylinder
pressor and the filter--drier inlet valve. Wait 5 minutes Port 7. Thermistor Vacuum
to verify that system remains in a vacuum.
3. Manifold Gauge Gauge
f. Service or replace filter--drier. Set
g. Leak check connections after replacing filter--drier. 5.6 REFRIGERANT LEAK CHECK
Refer to paragraph 5.6.
A refrigerant leak check should always be performed
h. Using refrigerant hoses designed for vacuum service, after the system has been opened to replace or repair a
evacuate and dehydrate the filter--drier by connecting component.
a vacuum pump to center connection of manifold To check for leaks in the refrigeration system, perform
gauge set. Evacuate system to 500 microns. Close the following procedure:
off pump valve, isolate vacuum gauge and stop
pump. Wait 5 minutes to verify that vacuum holds. NOTE
i. Read Micron Gauge again to verify that the pressure It must be emphasized that only the correct re-
did not rise more than 500 microns within that 5--min- frigerant should be used to pressurize the sys-
ute timeframe. tem. Use of any other refrigerant will contami-
nate the system, and require additional
If the Micron Gauge rises more than 500 microns (to
excede a gauge reading of 500 + 500 = 1000 microns) at evacuation.
the end of 5 minutes, either a leak is present or an
unacceptable level of moisture remains in the circuit. If a. Ensure filter drier service and solenoid valves are
the gauge reads a gain of less than 500 microns during open.
the 5--minute wait, the circuit is acceptably tight and dry. 1. Filter drier service valves should be back seated.
b. If system is without refrigerant, charge system with
j. Once vacuum is maintained, recharge system by ad- refrigerant vapor to build up pressure between 20 to
mitting vapor from the refrigerant cylinder. 30 psig (1.36 to 2.04 bar).
k. Remove manifold gauges. Backseat both filter drier c. Add sufficient nitrogen to raise system pressure to
service valves. 150 to 200 psig (10.21 to 13.61 bar).
5.5.2 Removing Entire System Charge d. Check for leaks. The recommended procedure for
finding leaks in a system is with an electronic leak de-
To remove the entire refrigerant charge, do the tector. Testing joints with soapsuds is satisfactory
following: only for locating large leaks.
a. Connect a manifold gauge set to the system as e. Remove test gas and replace filter--drier.
shown in Figure 5--2 . f. Evacuate and dehydrate the system. (Refer to para-
graph 5.7.)
b. Connect a reclaimer to the center manifold gauge set
connection. g. Charge the unit. (Refer to paragraph 5.8.)
5.7 EVACUATION AND DEHYDRATION
c. Recover refrigerant in accordance with reclaimer
manufacturers instructions. 5.7.1 General
04/08 5--3 T-304

The presence of moisture in a refrigeration system can d. Under the above conditions, the system is properly
have many undesirable effects. The most common are charged when the liquid line sight glase shows full (no
copper plating, acid sludge formation, “freezing-up” of bubbles present).
metering devices by free water, and formation of acids,
resulting in metal corrosion. An evacuation should take 5.8.2 Adding Full Charge
place after a system repair (replacement of filter drier. a. Install manifold gauge set at the in--line suction and
expansion valve, solenoid valve, etc). discharge service ports.
5.7.2 Preparation b. Evacuate and dehydrate system. (Refer to paragraph
5.7)
NOTE
Using a compound gauge (manifold gauge) for c. Place appropriate refrigerant cylinder on scales. Pre-
pare to charge liquid refrigerant by connecting charg-
determination of vacuum level is not recom- ing hose from container to center connection on gage
mended because of its inherent inaccuracy. manifold. Purge air from hoses.
a. Evacuate and dehydrate only after pressure leak test. d. Note weight of refrigerant and cylinder.
(Refer to paragraph 5.6) e. Open cylinder valve, backseat discharge valve on
b. Essential tools to properly evacuate and dehydrate gauge manifold and allow liquid refrigerant to flow into
any system include a good vacuum pump with a mini- the high side of the system
mum of 5 cfm (8.5 m 3/hr) volume displacement, (CTD f. When correct charge has been added (refer to para-
P/N 07-00176-11), and a good vacuum indicator graph 1.3, refrigerant specifications), close cylinder
(CTD P/N 07--00414--00). valve and frontseat manifold discharge valve.
c. Keep the ambient temperature above 60°F (15.6°C) g. Prepare the cylinder as required to allow vapor charg-
to speed evaporation of moisture. If ambient temper- ing. Backseat the manifold suction valve and charge
ature is lower than 60°F (15.6°C), ice may form be- vapor until the correct charge has been added. Close
fore moisture removal is complete. cylinder valve and frontseat suction manifold set.
5.7.3 Procedure for Evacuation and Dehydrating
System h. Check charge level in accordance with the proce-
dures of paragraph 5.8.1.
a. Remove refrigerant using a refrigerant recovery sys-
tem. Refer to paragraph 5.5.2 5.9 CHECKING FOR NONCONDENSIBLES
b. The recommended method is connecting 3/8” OD re-
frigerant hoses designed for vacuum service as To check for noncondensibles, proceed as follows:
shown in Figure 5--3. a. Stabilize system to equalize pressure between the
c. Make sure vacuum pump valve is open. suction and discharge side of the system.
d. Start vacuum pump. Slowly open valves halfway and b. Check temperature at the condenser and receiver.
then open vacuum gauge valve.
c. Check pressure at the discharge (in--line) service
e. Evacuate unit until vacuum gauge indicates 500 mi- port.
crons Hg vacuum. Close gauge valve, vacuum pump
valve, and stop vacuum pump. d. Check saturation pressure as it corresponds to the
condenser/receiver temperature. See temperature--
f. Close off pump valve, and stop pump. Wait five min- Pressure chart Table Table 5--1. for R134a.
utes to see if vacuum holds.
e. If gauge reading is 3 psig or more than the calculated
g. Charge system. Refer to paragraph 5.8.2 P/T pressure in step d., noncondensables are pres-
ent.
5.8 ADDING REFRIGERANT TO SYSTEM
f. Remove refrigerant using a refrigerant recovery sys-
5.8.1 Checking Refrigerant Charge tem.
The following conditions must be met to accurately g. Evacuate and dehydrate the system. (Refer to para-
check the refrigerant charge. graph 5.7.)
a. Bus engine operating at high idle. h. Charge the unit. (Refer to paragraph 5.8.2.)
b. Unit operating in cool mode for 15 minutes.
5.10 CHECKING AND REPLACING HIGH OR LOW-
c. Compressor discharge pressure at least 150 psig PRESSURE CUTOUT SWITCH
(10.21 bar). (It may be necessary to block condenser
air flow to raise discharge pressure.) 5.10.1 Replacing High Or Low Pressure Switches
NOTE a. The high and low pressure switches are equipped
with schrader valves to allow removal and installation
Ideal charging conditions are with ambient without recovering the refrigerant charge.
above 86°F (30°C) and interior vehicle temper-
ature above 77°F (25°C). Charging to a full b. Disconnect wiring from defective switch.
sight glass at lower temperatures may lead to c. Install new cutout switch after verifying switch set-
system overcharge. tings.
T-304 5--4 Change 07/09

5.10.2 Checking High Or Low Pressure Switches 5.11 FILTER-DRIER
WARNING
Do not use a nitrogen cylinder without a pres- 1. 2. 3. 4. 3. 2. 6. 5.
sure regulator
Figure 5--5 Filter--Drier Removal

1. Filter-Drier Inlet 5. Liquid Line
WARNING 2.
Service Valve
Valve Service Port 6.
Solenoid Valve
Filter-Drier Outlet
Do not use oxygen in or near a refrigeration sys- 3. Flare Nut Service Valve
tem as an explosion may occur. 4. Filter-Drier
5.11.1 To Check Filter--Drier
a. Disconnect wiring and remove switch from system. The filter--drier (See Figure 5--5) must be changed if the
system has been opened, (for any reason), or the filter
b. Connect an ohmmeter across switch terminals. If the drier is partially restricted. Restriction can be identified
switch is good, the ohmmeter will indicate no resist- by either the outlet frosting or a temperature difference
ance, indicating that the contacts are closed. between the inlet and outlet.
c. Connect switch to a cylinder of dry nitrogen. 5.11.2 To Replace Filter--Drier Assembly
(SeeFigure 5--4). Filter Drier replacement can be accomplished by
performing either one of the two procedures
1. recommended.
4. 1. System operating, low side pump down (refer to sec-
tion 3.4.1).
2. 5. 2. System not operating (see below).
a. Turn the driver’s A/C switch to “OFF” position.
6.
b. Frontseat the filter--drier service valves on both sides
of the filter drier.
3. c. Place a new filter-drier near the unit for immediate
installation.
WARNING
The filter-drier may contain liquid refriger-
ant. Slowly loosen the connecting nuts and
Figure 5--4 Checking High Pressure Switch avoid contact with exposed skin or eyes.
1. Cylinder Valve and Gauge
2. Pressure Regulator d. Using two open end wrenches, slowly crack open the
3. Nitrogen Cylinder connecting nuts on each side of the filter-drier as-
4. Pressure Gauge (0 to 400 psig = 0 to 27.22 bar) sembly. Remove the filter-drier assembly.
5. Bleed-Off Valve e. Remove seal caps from the new filter-drier. Apply a
6. 1/4 inch Connection light coat of mineral oil to the filter--drier connections.
d. Set nitrogen pressure regulator higher than switch f. Assemble the new filter-drier to lines ensuring that the
cutout setting. (refer to paragraph 1.3.) arrow on the body of the filter-drier points in the direc-
tion of the refrigerant flow (refrigerant flows from the
e. Open cylinder valve. Slowly open the regulator valve receiver to the evaporator). Finger tighten the con-
to increase the pressure until it reaches cutout point. necting nuts.
The switch should open, which is indicated by an infi-
nite reading on an ohmmeter (no continuity). g. Tighten filter-drier connecting nuts using two open
end wrenches.
f. Close cylinder valve and release pressure through h. Evacuate system (refer to section 5.7).
the bleed--off valve. As pressure drops to cut--in
point, the switch contacts should close, indicating no i. Backseat (fully close) both service valve ports and re-
resistance (continuity) on the ohmmeter. place valve caps.
j. Check refrigerant charge (refer to section 5.8.1).
g. Replace switch if it does not function as outlined
above. k. Remove Gauges.
04/08 5--5 T-304

5.12 SERVICING THE HEAT VALVE 1. Coil Retaining Screw 5. Kick-Off Spring
2. Nameplate 6. Plunger
The heat valve (Figure 5--6) requires no maintenance
unless a malfunction to the internal parts or coil occurs. 3. Coil Housing 7. Closing Spring
This may be caused by foreign material such as: dirt, Assembly 8. Diaphragm
scale, or sludge in the coolant system, or improper 4. Enclosing Tube & 9. O-Ring
voltage to the coil. Bonnet Assembly 10. Valve Body
NOTE 5.12.1 Coil Replacement

The OEM supplied heating (hot water) Solenoid a. It is not necessary to drain the coolant from the sys-
Valve is normally located outside of the tem.
AC310/350 rooftop air conditioning system. b. Place main battery disconnect switch in OFF position
and lock.
There are only three possible valve malfunctions: coil c. Disconnect wire leads to coil.
burnout, failure to open, or failure to close.
d. Remove coil retaining screw and nameplate.
Coil burnout may be caused by the following:
e. Lift burned-out coil from enclosing tube and replace.
1. Improper voltage
f. Connect wire leads and test operation.
2. Continuous over-voltage, more than 10% or Under-
voltage of more than 15%. 5.12.2 Internal Part Replacement
3. Incomplete magnetic circuit due to the omission of the a. Disconnect system from bus battery.
coil housing or plunger. b. Open the vent fitting at the top of the outlet header of
4. Mechanical interference with movement of plunger the heater coil.
which may be caused by a deformed enclosing tube. c. Drain coil by opening the drain-cock on the inlet tube.
Failure to open may be caused by the following: d. Disassemble valve and replace defective parts.
1.Coil burned out or an open circuit to coil connections. e. Assemble valve, refill and bleed coolant lines.
2. Improper voltage. 5.12.3 Replace Entire Valve
3. Torn diaphragm. a. Disconnect system from bus battery.
4. Defective plunger or deformed valve body assembly. b. Drain coolant from lines as previously described and
disconnect hoses to valve .
Failure to close may be caused by the following:
c. Disconnect wire leads to coil.
1. Defective plunger or deformed valve body assembly.
d. Remove valve assembly from bracket.
2. Foreign material in the valve.
e. Install new valve and re-connect hoses. It is not ne-
3. Torn diaphragm. cessary to disassemble the valve when installing.
1. f. Refill and bleed coolant lines.
2. g. Connect wire leads and test operation.
5.13 SERVICING THE LIQUID LINE SOLENOID

3. VALVE
The Liquid line solenoid valve (Figure 5--7) is very
4. similar to the heat valve. It requires no maintenance
unless a malfunction to the internal parts or coil occurs.
This may be caused by foreign material such as: dirt,
5. scale, or sludge in the refrigeration system, or improper
6. voltage to the coil.
7. There are only three possible valve malfunctions: coil
8. burnout, failure to open, or failure to close.
9. Coil burnout may be caused by the following:
1. Improper voltage.
2. Continuous over-voltage, more than 10% or under-
voltage of more than 15%.
10. 3. Incomplete magnet circuit due to the omission of the
coil hosing or plunger.
4. Mechanical interface with movement of plunger
Figure 5--6 Heat Valve which may be caused by a deformed enclosing tube.
T-304 5--6 04/08

Failure to open may be caused by the following:
1.
1. Coil burned out or an open circuit to coil connections. 2.
2. Improper voltage.
3. Defective plunger or deformed valve body assembly.

3.
Failure to close may be caused by the following:
1. Defective plunger or deformed valve body assembly. 4.

5.
2. Foreign material in the valve.
6.
5.13.1 Coil Replacement
7.
a. It is not necessary to remove the refrigerant charge 8.
from the system.
b. Disconnect system from bus battery.

Figure 5--7 Liquid Line Solenoid Valve
1. Snap Cap 5. Gasket
d. Remove coil retaining clip and nameplate. 2. Coil Assembly 6. Piston Assembly
3. Enclosing Tube 7. Body
e. Lift failed coil from enclosing tube and replace. Assembly 8. Bracket Adapter
4. Plunger Assembly
f. Connect wire leads and test operation
5.14 SERVICE VALVES
5.13.2 Internal Part Replacement
The filter/drier (High Side) service valves (Figure 5--8)
are provided with a double seat and a gauge port, which
a. Disconnect system from bus battery. allows servicing of the filter drier assembly.
b. Recover and recycle system refrigerant. Turning the valve stem counterclockwise (all the way
out) will backseat the valve to open the line to the
system and close off the gauge port. In normal
c. Slowly loosen enclosing tube assembly to bleed any operation, the valve is backseated to allow full flow
remaining pressure from the valve. Disassemble through the valve. The valve should always be
valve and replace defective parts. backseated before removing the gauge port cap.
d. Assemble valve and leak check. Turning the valve stem clockwise (all the way forward)
will frontseat the valve to isolate the system and open
the gauge port.
e. Evacuate and recharge system.
TO DISCHARG LINE VALVE CAP
5.13.3 Replace Entire Valve
a. Recover and recycle system refrigerant.
b. Remove valve assembly from bracket.

Port To SERVICE VALVE
d. Disassemble new valve, to protect internal parts, and Compressor PORT STEM
solder to lines.
Service Valve Service Valve
e. Assemble and leak check valve. Frontseated Backseated
(clockwise) (counterclockwise)
f. Evacuate and recharge.system.
g. Connect wire leads and test operation. Figure 5--8 Service Valve R134a (High Side)
04/08 5--7 T-304

5.15 REPLACING RETURN AIR FILTERS f. Pull filter element approximately 1/4 inch over ends of
the diffuser.
The return air filters are located behind the return air
grill, inside the vehicle. Diffuser
The filters should be checked for cleanliness
periodically depending on operating conditions. A dirty
filter will restrict air flow over the evaporator coil which
may cause insufficient cooling or heating and possible
frost buildup on the coil. To remove the filters, do the
following. Air Filter
a. Insure air conditioning system is in the off position.
b. Remove the return air grille with the filter--diffuser as-
sembly, by turning the six 1/4 turn fasteners counter-
clockwise.
Composit Frame
Composit Frame
Figure 5--11
Filter, Diffuser and Composit Frame
g. Place filter and diffuser into composit frame, with filter
element down (See Figure 5--11).
Return Air Filter

Captive 1/4 Fastners
Figure 5--9 Return Air Grill Assembly

With Air Filter Showing
c. Remove diffuser from the bus composit frame.
Diffuser
Figure 5--12 Return Air Grill Assembly

With Diffuser And Composit Frame Showing
h. Insert filter--diffuser assembly into composit frame on
bus with the six captive 1/4 fasteners. (See
Figure 5--12)
i. Lock the six captive 1/4 turns in place by rotating
clockwise.
5.16 THERMOSTATIC EXPANSION VALVE
Return Air Filter The thermostat expansion valve (Figure 5--13) is an
automatic device which maintains constant superheat
of the refrigerant gas leaving the evaporator regardless
of suction pressure. The valve functions are: (a)
Figure 5--10 Diffuser and Filter Element automatic control of refrigerant flow to match the
d. Remove and replace the filter element. evaporator load and (b) prevention of liquid refrigerant
entering the compressor. Unless the valve is defective,
e. Center diffuser on filter element. it seldom requires any maintenance.
T-304 5--8 04/08

1.
2.
3.
3. 4.
4.
2.
5. 5.
1.
4.
6.
Figure 5--14 Thermostatic Expansion Valve Bulb
7. and Thermocouple
1.. Suction Line 4.. Thermocouple
Figure 5--13 Thermostatic Expansion Valve (section view) 5.. TXV Bulb (Shown
1.. Power Head 4.. Gasket 2.. TXV Bulb Clamp in the 4’clock
Assembly 5.. Cage Assembly 3.. Nut & Bolt (clamp) position)
2.. Equalizer Connection 6.. Body Flange
3.. Bulb 7.. Cap screw
a. Open top cover.
5.16.1 Valve Replacement
a. If compressor is operative perform low side pump b. Remove Presstite insulation from expansion valve
down to replace expansion valve. (refer to 5.5.1) If bulb and suction line.
compressor is inoperative recover and recycle refrig-
erant from the system.(refer to 5.5.2) c. Loosen one TXV bulb clamp and make sure area un-
der clamp is clean.
b. Remove insulation from expansion valve bulb. (See
Figure 5--13 and Figure 5--14.)
d. Place temperature thermocouple in contact with the
c. Loosen retaining straps holding bulb to suction line suction tube and parallel to the TXV bulb, and then
and detach bulb from the suction line. secure loosened clamp making sure both bulb and
d. Loosen flare nuts on equalizer line and disconnect thermocouple are firmly secured to suction line. (See
equalizer line from the expansion valve. Figure 5--14). Reinstall insulation around the bulb.
e. Check, clean and remove any foreign material from
the valve body, valve seat and mating surfaces. If re- e. Connect an accurate low pressure gauge to the low
quired, replace valve body. pressure port.
NOTE f. Close top cover being careful to route thermocouple

R--134a valves are adjustable. Valves are pre- sensing wire and gauge hose outside the unit.
set at the factory.
g. Start bus and run on fast idle until unit has stabilized,
f. Leak check the new valve and evacuate and dehy- about 20 to 30 minutes.
drate the system. (Refer to paragraph 5.7.)
g. The thermal bulb is installed below the center of the
suction line (four or eight o’clock position). This area NOTE
must be clean to ensure positive bulb contact. Strap When conducting this test, the suction pressure
thermal bulb to suction line. Ensure that retaining
straps are tight and renew insulation. must be at least 6 psig (0.41 bar) below the ex-
pansion valve maximum operating pressure
h. Fasten equalizer line to the expansion valve. (MOP). Refer to paragraph 1.3 for MOP.
i. Evacuate and recharge the system.
j. Run the coach for approximately 30 minutes on fast
idle. h. From the temperature/pressure chart, determine the
k.Check refrigerant charge. (Refer to 5.8.1) saturation temperature corresponding to the evapo-
rator outlet pressure.
5.16.2 Superheat Measurement
NOTE i. Note the temperature of the suction gas at the expan-

sion valve bulb. Subtract the saturation temperature
All readings must be taken from the TXV bulb from this temperature. The difference is the super-
location and out of the direct air stream. heat of the suction gas.
04/08 5--9 T-304

j. The superheat may cycle from a low to high reading. readings taken to determine average superheat. The
Monitor the superheat taking readings every 3--5 min- superheat should be 18 ± 3°F.
utes for a total of 5--6 readings. Calculate the super-
heats, add the readings and divide by the number of k. If superheat is not within tolerance, replace the valve.
T-304 5--10 04/08

Table 5--1. R-134a Temperature - Pressure Chart
Temperature Vacuum Temperature Pressure
°F °C “/hg cm/hg kg/cm@ bar °F °C psig kPa kg/cm@ bar
--40 --40 14.6 49.4 37.08 0.49 28 --2 24.5 168.9 1.72 1.69
.35 .37 12.3 41.6 31.25 0.42 30 --1 26.1 180.0 1.84 1.80
--30 --34 9.7 32.8 24.64 0.33 32 0 27.8 191.7 1.95 1.92
--25 --32 6.7 22.7 17.00 0.23 34 1 29.6 204.1 2.08 2.04
--20 --29 3.5 11.9 8.89 0.12 36 2 31.3 215.8 2.20 2.16
--18 --28 2.1 7.1 5.33 0.07 38 3 33.2 228.9 2.33 2.29
40 4 35.1 242.0 2.47 2.42
--16 --27 0.6 2.0 1.52 0.02
45 7 40.1 276.5 2.82 2.76
Temperature Pressure 50 10 45.5 313.7 3.20 3.14
°F °C psig kPa kg/cm@ bar 55 13 51.2 353.0 3.60 3.53
--14 --26 0.4 1.1 0.03 0.03 60 16 57.4 395.8 4.04 3.96
--12 --24 1.2 8.3 0.08 0.08 65 18 64.1 441.0 4.51 4.42
--10 --23 2.0 13.8 0.14 0.14 70 21 71.1 490.2 5.00 4.90
--8 --22 2.9 20.0 0.20 0.20 75 24 78.7 542.6 5.53 5.43
--6 --21 3.7 25.5 0.26 0.26 80 27 86.7 597.8 6.10 5.98
--4 --20 4.6 31.7 0.32 0.32 85 29 95.3 657.1 6.70 6.57
--2 --19 5.6 36.6 0.39 0.39 90 32 104.3 719.1 7.33 7.19
0 --18 6.5 44.8 0.46 0.45 95 35 114.0 786.0 8.01 7.86
2 --17 7.6 52.4 0.53 0.52 100 38 124.2 856.4 8.73 8.56
4 --16 8.6 59.3 0.60 0.59 105 41 135.0 930.8 9.49 9.31
6 --14 9.7 66.9 0.68 0.67 110 43 146.4 1009 10.29 10.09
8 --13 10.8 74.5 0.76 0.74 115 46 158.4 1092 11.14 10.92
10 --12 12.0 82.7 0.84 0.83 120 49 171.2 1180 12.04 11.80
12 --11 13.2 91.0 0.93 0.91 125 52 184.6 1273 12.98 12.73
14 --10 14.5 100.0 1.02 1.00 130 54 198.7 1370 13.97 13.70
16 --9 15.8 108.9 1.11 1.09 135 57 213.6 1473 15.02 14.73
18 --8 17.1 117.9 1.20 1.18 140 60 229.2 1580 16.11 15.80
20 --7 18.5 127.6 1.30 1.28 145 63 245.6 1693 17.27 16.93
22 --6 19.9 137.2 1.40 1.37 150 66 262.9 1813 18.48 18.13
24 --4 21.4 147.6 1.50 1.48 155 68 281.1 1938 19.76 19.37
26 --3 22.9 157.9 1.61 1.58
04/08 5--11 T-304

SECTION 6
ELECTRICAL
6.1 INTRODUCTION (6) condenser fan motors. Figure 6--1 through
This section includes electrical wiring schematics. The Figure 6--6 shows the Thermostat with manual re--heat.
schematics shown in this section provides information Figure 6--7 thru Figure 6--13 shows the CSDD BT324
for the AC310 and AC350 model rooftop air conditioning controller used with the AC310 single and dual systems
units which are fitted with eight (8) and twelve (12) and the AC350 single loop with transit compressors.
single--shafted or four (4) and six (6) double--shafted Figure 6--14 thru Figure 6--18 shows Thermostat
evaporator blower/motor assemblies and four (4) or six control with one or two compressors.
UNIT CONTROLLER FIGURE NUMBERS

AC 310 Thermostat With Manual Reheat Figure 6--1 Thru Figure 6--6
AC 350 BT324 Figure 6--7 Thru Figure 6--13
AC 310/AC350 Thermostat One/Two Compressors Figure 6--14 To Figure 6--18
04/08 6--1 T--304

T--304
CONDENSER EVAPORATOR
CONTROL PANEL
Convection Heating Connection
R2N R1N
S1A
S2A S1A
S3A
6--2
Operation Board Operation Board
VERSION A VERSION B
AC 310 100A @ 24VDC LP Switch

FOM AC 350 125A @ 24VDC
AC310 OPTION 150A @12VDC
M31M
G Y31A
ALTERNATOR HEATING VALVE HP Switch

WATER PUMP HEATING Compressor Clutch
Battery 24 VDC
04/08
Figure 6--1 System Controls (Typical)
B+ B+
04/08
Battery
RD
Evap. High U5 BKYE
1 810 11 OR
F1A 15A
BKBU ---- 12V 24V UR
Evap. Low U2 REL 1 REL 2 Sensors
Thermostat
Cooling Heating
OGRD Poti. Sensor
Cond. Mtrs. U3
7 1 9162435
WHRD
LL
85 30 87a 87 85
K1A K4A
86 87a 87 30 86
WH BKGY
UH
OGRD
UK
V1
WH
WH
Clutch
V5
BKRD
WH
BN
RDWH
Inside sensor
V2 V3
6--3
V4
B1N
WHYE
WHOG
WHBU
X3 12 34 5 91011
X20
WH
1 2
Vent 1 Vent 2
or
swor
Low High Y1A Y2A

F01A 7
Climate
1
5A R1N
S1A S2A Dash Control
Liquid Line Valve
3
Temperature setting
Operation Board Operation Board

A/C Power
Breaker 10 30 A Relay
87
5A 30 Wire 393
87A
* T---- Splice Into Freightliner Other Signal Indicating
Wire 393 At Hydraulic OR Vehicle Electrical System OEM SUPPLIED
85 86 Brake Module Is Ready To Operate AC
*
System
REF: 98--62--62668--00
T--304
*
Figure 6--2 Manual Controls With Manual Reheat Control (Sheet 1)
B+
T--304
RD
12VDC * OEM SUPPLIED
Over-- -- Ride Switch
RD
60F 25F F2A 10A

OR
T-- --Stat Note A

86 30
BU
K2A
85 87a 87
NOTE A
60 Switch ---- Closes On Temperature Rise
25 Switch ---- Opens On Temperature Decrease
LL
LL Solenoids
BK
85 86 30
85
K3A
30 CLR2 30 CLR1
85 87a 87
UH 87a 87 86 87a 87 86
UK BKGY
BK
6--4
A/C Low Voltage
OGRD F3A F4A
10A 10A Breaker
BK
85 85
8
15A
30 CR2 30
* CR1
* *
87a 87 86 87a 87 86
B10F B20F
P HP -- -- switch P HP -- -- switch
B11F B21F
P LP -- -- switch P LP -- -- switch
M
= M31M
Y31A
Y7M Y8M
Compressor clutch Heating valve Waterpump heating

Compressor clutch
REF: 98--62668--00
04/08
Figure 6--3 Manual Controls With Manual Reheat Control (Sheet 2)
B+
04/08
15A 15A 15A 15A
F1M F2M F3M F4M
U2
BK
GN
85 30 85 30
K2M K5M
86 87 86 87
U4
BKBU
GN
BKBU
GN
BKGN
BKYE
BKRD
BKOG
BN
BN
85 87 85 87 85 87 85 87
86 30 86 30 86 30 86 30
K1M K3M K4M K6M
6--5
BKBU
BKWH
F01M
150 AMP
X2
BLACK 1 2 3 4 5 6
SAO
BN
WHRD
WHYE
+
WHOG
BN
WHGN
M M MM
----
(OPTIONAL)
M1M M2M M3M M4M
BATTERY 12 VDC
REF: 98--62668--00
T--304
Figure 6--4 Evaporator Motors 1 -- 4
T--304
B+ B+
F5M 15A F6M 15A 15A 15A

F7M F8M
U2 U2
BU
GY
85 30 85 30
K8M K11M
86 87 86 87
U4
87a 87 85
WHRD
BKBU
GN
WHOG
BKBU
GN K13M
WHYE
30 86
WHGN
U5
BN
BN
85 87 85 87 85 87 85 87
6--6
86 30 86 30 86 30 86 30
K7M K9M K10M K12M

WHBK
WHBU
10 11 12 13 14 15
X2
BKRD
BN
BKYE
BKOG
BN
BKGN
M M M M
M5M M6M M7M M8M
(Optional)
REF: 98--62668--00
04/08
Figure 6--5 Evaporator Motors 5 -- 8
04/08
B+ B+
BKBU
U2 U2
BKYE
U5 U5
OGRD
U3
30 86 30 86
K14M K15M
87 85 87 85
6--7
F13M 15A F14M 15A F15M 15A F16M 15A
X1 10 13 14 15
WHITE
GNOG
GNWH
GNBU
GNYE
M MMM
(Optional)
M21M M22M M23M M24M
REF: 98--62668--00
T--304
Figure 6--6 Condenser Motors
T--304
CONDENSER EVAPORATOR
CONTROL PANEL
BT 324 Convection Heating Connection
6--8
UNLOADER
LP Switch
ALT
UL SWITCHES
M31M
ALTERNATOR WITH Y31A
DASH SWITCH
HEATING VALVE HP Switch

WATER PUMP HEATING
Y7M Compressor Clutch
04/08
Figure 6--7 BT324 Controls With (1) Compressor (AC350)
REF: 98--62668--00
04/08
CONTROL PANEL
(RAS)
INSIDE SENSOR
6--9
WP
HSV
BT324
CONTROLLER
Compressor
Clutch
05G
5A 5A 5A
05G -- 05K OPTION WP -- WATER PUMP

OPTION HSV -- HEATING SOLENOID VALVE
OUTSIDE SENSOR
U2 -- EVAPORATOR RELAY -- COIL
UReg -- SPEED CONTROL POWER
(ATS) U4 -- EVAPORATOR RELAY -- COIL
T--304
Figure 6--8 BT324 Control Circuit (AC350)
2xRD 16 CONTROL PANEL
T--304
U1
U2
U3
Fma Ureg
BN U3a
3A U4
30 86 30 86 30 86 30 86 30 86 30 86
K1M K2M K3M K4M K5M K6M
87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85
15A 15A 15A 15A 15A 15A

F1M F2M F3M F4M F5M F6M F7M F8M F9M F10M F11M F11M
1 4 7 10 13 14 11 15 12 9 6 3 Ureg
6--10
+ X2
RDBU
+
FOM
125A -- AC350 X10.1 X10.1 X10.1 X10.1 X10.1 X10.1
100A -- AC310 X10 X10 X10 X10 X10 X10
X10.2 X10.2 X10.2 X10.2 X10.2 X10.2
INSTALLED BLOWERS
M M M M M M AC310 M1M -- M4M
AC350 M1M -- M6M
ALT
M1M M2M M3M M4M M5M M6M
EVAPORATOR MOTORS
REF: 98--62668--00
04/08
Figure 6--9 BT324 Evaporator Motors (AC350)
WHRD
+U4A
04/08
15A X1
U1 U4A
6 BU
U2 UVd
X2
8 RDBU
Ureg Ureg
9
U4 7 WHGN UKo
30 85 30 85 30 85 BUWH
UFri
K7M K8M K9M
87a 87 86 87a 87 86 87a 87 86
CONTROL PANEL
15A 15A 15A 15A 15A 15A

F13M F14M F15M F16M F17M F18M
6--11
1pol. 1pol.
10 13 14 15 12 11
X1
X10.1
1 2 1 2 X10 GY(GN)
X20 X21
LIQUID LINE VALVE FRESH AIR FLAP

(OPTIONAL) GY(OG) GY(BN)
CONDENSER MOTORS
AC310 M21 -- M24M
M M M M M M X10.2
AC350 M21 -- M26M
M21M M22M M23M M24M M25M M26M M

CONDENSER BLOWER MOTORS
SPEED CONTROLLER CONNECTION
REF: 98--62668--00
T--304
Figure 6--10 CSDD BT324 Condenser Motors
T--304
1....K1A = Compressor Clutch -- Liquid Line
+ Solenoid -- Condenser Fans
K1M
-- 2....K2A = Heat Valve -- Boost Pump
F1M 10A 3....K3A = Evaporator Fans
F2M 10A 4....K1M -- K6M = Individual Evaporator Fans
F3M 10A
K2M
(M1M -- M6M)
5....K7M -- K9M = Individual Condenser Fans
K3M
(M21M -- M26M)
F4M 10A
6....Fuse = Boost Pump & Heat Valve
F5M 10A
X2 7....F13M -- F18M = Individual Condenser
F6M 10A
Contact arrangement K4M Fans
Connect X1 -- X2 F7M 10A
8....F1M -- F12M = Individual Evaporator
F8M 10A
Fans
K5M 9....U Reg = Evaporator Speed Regulation
U3 F9M 10A
10...X1 = Condenser Fans
F10M 10A
11...X2 = Evaporator Fans
F11M 10A K6M 12...X3 -- X4 (Not Shown On Drawing) =
K1A
Top View F12M 10A Dash To Unit Interface Plug
U3A
F13M 15A
K7M
6--12
Ureg
K2A
F14M 15A
F15M 15A K8M
X1
F16M 15A
F17M 15A K3A
F18M 15A
K9M
Part Number
26.38.08.001
+ +
GND
SUTRAK SCHMATIC #65, 01, 28, 056--01--3

UNIT RELAYS FOR EVAP. MOTORS RELAYS FOR COND. MOTORS
AC310 K1m -- K4M K7M -- K8M

AC350 K1M -- K6M K7M -- K9M
Relay Board
04/08
Figure 6--11 AC350 With BT324 Control
X3 PLUG
04/08
(FROM)
1
(FROM)
(FROM)
AC--310/350 ELECTRICAL PANEL 24 V

SUTRAC PT.# 60--01--28--126
SCHEMATIC 65--01--28--056--01--3
X4 PLUG
6--13
100 Amp 24 VDC AC310
125 Amp 24 VDC AC 350
05G -- 05K OPTION

LEGEND
HPS -- HIGH PRESSURE SWITCH

HSV -- HEATING SOLENOID VALVE
LPS -- LOW PRESSURE SWITCH
WP -- WATER PUMP
UPS1 -- UNLOADER PRESSURE SWITCH #1
UV1 -- UNLOADER VALVE #1
UV2 -- UNLOADER VALVE #2
T--304
Figure 6--12 CSDD BT324 Control Circuit
T--304
Input Power 5A
1 BT--324
Ground
2
12 or 24 Night Light 5A
VDC 5
Alternator 5A
9
Compressor Failure Signal (Optional)
13
24 V (15) 6
or 12 V
a) Blower ON
b) Blower Speed 1 4
<P >P 8
Compressor Load
Clutch Pressure Relay Fresh Air
Free Switches Valve 12
Wheeling
Diode 16
20
Blower Motor Blower Speed Signal
M DRM 17
Blower Speed 2 18
Outside Sensor 3
6--14
(Optional) NTC
7
11
Inside Sensor
NTC
15
19
23
RS232 RxD 21
(Optional)
Blower Control Options a) Speed Controller RS232 TxD 22
(Software Selectable) b) Steps
10
Reat
Speed Blower Speed 2 Blower Speed 1 Relay Reserve 14
0 Off Off Not Used 24
1 Off On
2 On Off
3 On All Outputs 0.5 A Max.
On
Digital Controller
CSDD BT324
04/08
Figure 6--13 CSDD BT324
+
04/08
+
U1
U2
BN6
Ureg
--
U4
86 86 86 86 86 86
30 30 30 30 30 30
K1M K2M K3M K4M K5M K6M
87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85 87a 87 85
F1M F2M F3M F4M F5M F6M F7M F8M F9M F10M F11M F12M
10A 10A 10A 10A 10A 10A 10A 10A 10A 10A 10A 10A
Ureg
6--15
1 4 7 10 13 14 11 15 12 9 6 3
X2
X10.1 X10.1 X10.1 X10.1 X10.1 X10.1 X10.1 X10.1 X10.1 X10.1 X10.1 X10.1
X10 X10 X10 X10 X10 X10 X10 X10 X10 X10 X10 X10
FOM
X10.2 X10.2 X10.2 X10.2 X10.2 X10.2 X10.2 X10.2 X10.2 X10.2 X10.2 X10.2
M M M M M M M M M M M M
--
M1M M2M M3M M4M M5M M6M M7M M8M M9M M10M M11M M12M
BATTERY
24 VDC EVAPORATOR MOTORS INSTALLED BLOWERS
AC310 M1M -- M8M
AC350 M1M -- M12M
T--304
Figure 6--14 Thermostat (One/Two Compressors)
+ +
T--304
6--16
+
Yellow X10.1
X10
Red Grey
X10.2
M Green Brown
M M M M M
Installed Motors M
AC310 M21M -- M24M
AC350 M21M -- M26M
CONDENSER MOTORS
04/08
RD6
U1 Installed In Units With Heating
+
04/08
F1A 15A
X10
WHBU U2 B1N
U2
TEMP. SENSOR
K6A
Ureg WHYE UR
F2 F1
WHGN U3 D5
U3 U3
BN6 GND
V6
1 11 1 9
3
87 87a 85
A1P 7
K2A
30
280P/282P
85 1 86 COOLING HEATING
1
K1A 4 *
2 THERMOSTAT 3
86 87a 87 2 10 6 4 5
1 2
3
X3.4
1 3 2
6--17
V2 V4 B1
BKRD
V7
V1 4 2
86 30 86 30 86 30
B2N
V3 1 BKYE K3A K4A K5A
V5
B5 A1 85 87a 85 87a 87 85 87a 87
1 2 6 3 4 7 5 8 9 10 11 8 9 6 4 1 2 3
X4 X5
2 3
R1N
YM3
Operation Panels
Fresh Air Flap
D+61 OPTION
Alternator
T--304
UNIT WITH 1 COMPRESSOR
T--304
UNIT WITH 2 COMPRESSORS
3/B15 3/B15
U3 U3
F3A 10A F2A 10A F3A 10A

F2A 10A
3 1 2 3 1 2
X3.5 X3.5
GN GN
86 30 86 30
K7A K7A
Option 85 87a 87 Option 85 87a 87
1 2
X20
11 10 7 5 11 10 7 5
X5 X5
6--18
B1F 1 B2F 1 B1F 1
LP Switch LP-- Switch LP Switch
+ 4 2 4 2 + - 4 2
1
Y6A Y7A
B11F B21F 1 B11F 1
HP Switch HP-- Switch
Y7A HP Switch
+ 2 4 4 - + 2 4
2
Liquid Line Valve
Liquid Line Valves Compressor Unloader
B11N 1
+ 4 2
OPTION
Y7M Y8M Y7N Y8A
Compressor Clutch Compressor Clutch Compressor Clutch Unloader Valve
04/08
04/08
CONTROL PANEL CONTROL PANEL
(OPTION 1) (OPTION 2)
1
2
V1 V5
2 3 4 7 5 8 9 2 3 4 7 5 8 9
X4 X4
Speed Setting
R1
6--19
Evaporator Blowers S3A 1
Evaporator Blowers S3A 1 Fresh Air Flap
Ventilation: Stepless 7 1
7 1 S2A 1 Fresh Air Flap S1A OPTION
5
Clima Operation:
Ventilation -- 2 Steps S1A Clima 5 Stepless, depending 3
OPTION
3 5 on temperature
VERSION A VERSION B
T--304
INDEX
A M
Air Filters, 5--7 Maintenance Schedule, 5--1
Apex Unit, 1--2 Manifold Gauge Set, 5--1
Modes Of Operation, 2--2
C
N
Circuit Breaker, 1--8
Noncondensibles, 5--4
Clutch, 2--3
Compressor, 1--6, 1--7
Compressor Clutch Control, 2--3 O
Condenser Fan, 1--8 Operating Controls, 1--7
Condensing Section, 1--2 Operating Instructions, 2--1, 3--1
Cooling Mode, 2--2 OPERATION, 2--1, 3--1
D P
Pre--Trip Inspection, 2--1, 3--1
DESCRIPTION, 1--1
Pump Down, 5--2
E R
ELECTRICAL, 6--1 Refrigerant Charge, 1--7, 5--2, 5--3, 5--4
Evacuation, 5--3 Refrigerant Removal, 5--3
Evaporator, 1--4, 1--6 Refrigeration Cycle, 1--8
Evaporator Fan, 1--7, 2--2
Evaporator Fan Speed Selection, 2--3
S
SAFETY, Safety--1
F SERVICE, 5--1
Filter--Drier, 5--5 Starting, 2--1, 3--1
Fuse, 1--8 Stopping, 2--1, 3--1
Superheat, 5--9
H
T
Heat Valve, 5--5
Temperature Control, 2--2
Heating Cycle, 1--8
Temperature Pressure Chart, 5--10
Heating Mode, 2--2
Temperature Sensor, 1--8
High Pressure Switch, 1--7, 1--8
Thermostatic Expansion Valve, 1--7, 5--8
TROUBLESHOOTING, 4--1
L
Liquid Line Solenoid, 5--6 W
Low Pressure Switch, 1--7, 1--8 Water Temperature Switch, 1--7
T--304 Index --1 04/08

Carrier Transport Air Conditioning
50 Grumbacher Road
York PA 17406 USA Carrier Transicold Division,
Tel: 1--800--673--2431 Carrier Corporation
Fax: 1--717--764--0401 Transport Air Conditioning Group
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A
www.carrier.transicold.com
A member of the United Technologies Corporation family. Stock symbol UTX

©2008 Carrier Corporation D Printed in U. S. A. 0408
Ideas taking shape - worldwide
Dokumentnr. 049200091-en HÜBNER GmbH · Werk Waldau

Document No.
Erstell Datum Heinrich-Hertz-Straße 2 · D-34123 Kassel
2010-04-08
Date Postfach 10 19 20 · D-34019 Kassel
Änderungsstand E Tel. +49 (0)561 998-0 Fax +49 (0)561 998-1543
Revision
Mounting Instructions
HÜBNER Folding bellows for the articulated buses general
Ersteller Ritter
Author
Geprüft Mosaner
Checked
Freigegeben Mosaner
Approved
HW2.KE.STR.001.0.0306.Rit 049200091_E_en.doc page 1/26

Summary
Suspension frames Direction of travel
Folding bellows
Center hoop
Roof covering
Folding bellows
serial number
marked outside at the
Floor covering Insert floor middle bordering frame
at half height
Head covering Roof cover

Inner covering
Belt floor Insert floor
page 2/26 049200091_E_en.doc HW2.KE.STR.001.0.0306.Rit

Index
Safety Information
In order to ensure vehicles security and prevent failures pay attention to the following safety in-
formation:
– Prior to mounting the folding belows system please read this information carefully.
– We emphasise explicitly that the mounting of the articulation system has to be exe-
cuted well-informed and professionally in order to ensure the safety of the passen-
gers and the vehicle.
– For all screws, the given tightening torques must be observed.
– Modifications on components supplied will only be allowed after consultation and ap-
proval of HÜBNER.
1. Installing the suspension and fastening frames and the center hoop .................................. 4
1.1. Riveting the suspension frame ................................................................................................ 4
1.2. Welding the suspension frame ................................................................................................ 4
1.3. Installing the fastening frame for the roof and floor covering .................................................. 5
1.4. Mounting the center hoop ........................................................................................................ 6
1.4.1. Mounting the center hoop with supporting rolls to the main shaft..................................... 6
1.4.2. Mounting the center hoop on the bellow support .............................................................. 7
1.4.3. Mounting the center hoop stabilisation (telescope) ........................................................... 8
1.4.4. Mounting the center hoop stabilisation .............................................................................. 9
2. Installation of the folding bellows............................................................................................ 10
2.1. Pulling up the rubber profile ................................................................................................... 10
2.2. Mounting the folding bellows ................................................................................................. 10
2.3. Tightening the wire rope ........................................................................................................ 10
2.3.1. Wire rope tightener........................................................................................................... 10
2.3.2. Quick fastener .................................................................................................................. 11
2.4. Mounting the insert floor ........................................................................................................ 11
2.5. Closing the belt floor .............................................................................................................. 13
2.5.1. Pulling through the belt .................................................................................................... 13
2.5.2. Mounting the floor plate ................................................................................................... 14
2.6. Mounting the floor covering.................................................................................................... 15
2.6.1. Floor covering onto bordering tape (variant 1) ................................................................ 15
2.6.2. Floor covering with quick locking device (variant 2) ........................................................ 15
2.6.3. Floor covering with suspension device (variant 3) .......................................................... 16
2.7. Mounting the roof covering .................................................................................................... 16
2.8. Sealing profile for the floor flaps ............................................................................................ 17
2.9. Mounting the inner covering................................................................................................... 18
2.9.1. Mounting the inner covering onto suspension profiles .................................................... 19
2.10. Mounting the top covering...................................................................................................... 20
2.11. Mounting the roof cover ......................................................................................................... 22
3. Appendix ..................................................................................................................................... 24
3.1. Mounting dimensions the suspension frames, fastening frames and the guiding profile ..... 24
3.2. Check List............................................................................................................................... 25

1. Installing the suspension and fastening frames and the center hoop
The suspension frames are delivered with an exact contour. If the contour of the suspension frame is
modified, we cannot guarantee for the accuracy in fitting anymore.
The required mounting height for the suspension frames to front and rear car is indicated in the
HÜBNER drawing “Set of folding bellows, compl.” or in the appendix, paragraph 3.1
Box-type Suspension
profile profile
34
42,5
12,5
14,5
25 26,1
Centre of wire rope
Figure 1: Suspension profiles Centre of wire rope
1.1. Riveting the suspension frame

The side parts of the suspension frame shall be fixed by blind rivets 5 mm (Figure 2/1) to front and
rear car by starting exactly from the middle of the car body. Distance between the rivets:
Roof area 150 mm
Radii area 50...100 mm
Side area 200 mm
Middle mark
2
1 1
suspension frame 2parts suspension frame 3 parts

Figure 2: Installing the suspension frame to front and rear car
1.2. Welding the suspension frame

For welding the suspension frame halves we
a2 n x 15(50)
recommend the following welding joints:
On both sides of the leg with an interrupted,
circumferential weld a = 2 mm, single welds
at a length of 15 mm each, and welded joint
distance 50 mm (Figure 3)
a2 n x 15(50)
Figure 3

After having completed the riveting or welding the suspension frames shall be sealed towards
HINWEIS the vehicle with an appropriate sealing agent (e.g. Sikaflex).
Seal the suspension frames at the joint by means of the aluminium adhesive foil (Figure. 2/2)
enclosed in order to prevent the ingress of moisture.
1.3. Installing the fastening frame for the roof and floor covering
See the required mounting height for the fas-
tening frame (Figure 4) of the roof and floor
covering to front and rear car indicated on the Middle mark
1
HÜBNER drawing “Set of folding bellows,
compl.” or in the appendix, paragraph 3.1 2
 The fastening frame (Figure 4/1) for the roof
covering shall be mounted with blind rivets 3
5 mm (Figure 4/2) to front and rear car by
starting exactly from the middle of the car 2 4
body.
 Fasten the fastening frame for the floor
covering (Figure 4/3;4) precisely fitting to
40
the connecting plate to the front and rear

car by means of blind rivets 5 mm (Figure
4/2).
12,8
Fastening profile
Drilling distance approx. 100 mm
Figure 4

1.4. Mounting the center hoop

The center hoop is delivered completely pre-mounted. The fastening of the center hoop may vary
corresponding with the version for low floor or high floor busses.
1.4.1. Mounting the center hoop with supporting rolls to the main shaft
 Prior to the final assembly of the articulation system to the front car, insert the closed center hoop
and adjust to the centre of the articulation system.
 Fasten the center hoop with the center hoop floor (Figure 5/1) to the main shaft (Figure 5/2) by
means of 8 cylinder screws M8x40 and washers (Figure 5/3;4). Tightening torque M8 = 21Nm
 If the center hoop floor (Figure 5/1) is premounted below the articulation system and to the main
shaft (Figure 5/2), the center hoop left and right needs to be fastened to the center hoop floor (Figure
5/1) by means of 3 cylinder screws M10x80 and washers (Figure 5/5;6).
Tightening torque M10 = 43Nm
 After the mounting of the platform and the set of folding bellows it is necessary to adjust the support-
ing rolls (Figure 5/7) right and left onto the platform. For doing this both supporting rolls (Figure 5/7)
need to be loosened at the axle by using a wrench of size 17 (Figure 5/8). Fix the supporting rolls
right and left in a way that they fit loosely onto the platform (Figure 5/9) and still can be turned by
hand. Tightening torque M8 = 21Nm
Please pay attention that the fastening frame (Figure 5) of the floor covering shall not contact the
platform, keep a distance of at least 5mm (see Figure 5) before adjusting the rollers.
If the support rollers (Figure 5/5) are fixed onto the platform under tension, this will cause
damage to the rollers and the platform!
Center hoop
8
7
9 Fastening frame
1
min. 5 mm 6
5
7 7 3
Articulation system 4
1
with platform 2
2
1
Figure 5

1.4.2. Mounting the center hoop on the bellow support

 Assemble / close the centre hoop around the articulation.
 Mount the bellow support (Figure 6/3) onto the articulation system.
 Loosen and remove the safety ropes (Figure 6/4) right/ left at the center hoop fastenings (Figure
6/2) by releasing the corresponding stud screw M4 (Figure 6/8).
 Fix the center hoop with center hoop fastenings (Figure 6/2) onto the tube of the bellow support
(Figure 6/3) right and left and screw by means of 2 hexagon screws M8x…, washers and nuts M8.
 The safety ropes (Figure 6/4) right/left shall be laid through the tube of the bellow support and
the center hoop fastening and stretched, then tighten the stud screw (Figure 6/8).
Center hoop
3
2
Articulation system
Figure 6

1.4.3. Mounting the center hoop stabilisation (telescope)

The mounting position of the center hoop stabilisation (telescope) is depending on the pitching axis of
the articulation system. The telescope has always to be mounted on the vehicle at the opposite side to
the pitching axis of the articulation system. Where the pitching axis of the articulation system is placed
exactly in the centre, the telescope can be mounted on front or rear car.
 Fasten the telescope (Figure 6a/1) to the center hoop and lock with counter nut.
 Align the telescope (Figure 6a/1) to the center of the bus (front or rear car)( the center hoop needs
to be in vertical position). Mark the 2 mounting holes through the flange plate at the telescope.
 Drill 2 holes for the fastening screws M8.
 Fix the telescope by means of 2 screws M8 at least property class 8.8 (Figure 6a/2) (fastening
screws not included in the delivery).
Tightening torque: Hexagon nut M10 (Figure 6a/3) = 21Nm
Direction of travel
1
Font car
M8
Rear car
Center hoop
Figure 6a

1.4.4. Mounting the center hoop stabilisation

Please see the required mounting height of the center hoop stabilisation (Figure 6b/1) from the
HÜBNER drawing “Set of folding bellows, complete” or Appendix 3.1.
 Please consider that the center hoop stabilisation and the rods have to be straightened in paral-
lel to the platform’s surface.
 Push the 2 tenon block (Figure 6b/2) on the right and left side to the center hoop.
 Fix the center hoop stabilisation (fig. 6b/1) by means of 8 cylinder screws M8 each (Figure 6b/3)
on the right and left side to the center hoop.
After having mounted the folding bellows fix the center hoop stabilisation (Figure 6b/1) wit h
hexagon screws M8, washer and nuts to the vehicle front and rear car.
Fastening material (Figure 6b/4;5;6) is not included in the delivery.
Modifications of the mounting height may cause the destruction of the center hoop stabilisa-
NOTICE tion and of the folding bellows. Necessary modifications of the height can just be made after
consultation and approval of HÜBNER.
Center hoop
Vehicle
14
2m
m
Center hoop
Mounting height
Figure 6b

2. Installation of the folding bellows
2.1. Pulling up the rubber profile

Push the rubber profile (Figure 7/1) onto the
Connection fabric
connection fabric of the folding bellows.
Wire rope
Folding bellows
Figure 7
2.2. Mounting the folding bellows

 Spray the suspension frames with soapy
water for easier mounting.
 Attach the folding bellows into the sus-
pension frames at front and rear car. Align
them exactly in the middle (pay attention to
the middle mark).
The folding bellows weighs approx. 50kg
 Hit the rubber profile into the suspension
frames by means of a hammer and a
wooden or plastic block (Figure 8).
When using folding bellows with a different
HINWEIS
number of frames pay attention to the marking
“front” and “rear”. Normally the folding bellows
with less folds are mounted to the front car. Figure 8
2.3. Tightening the wire rope

2.3.1. Wire rope tightener approx. 35kg
 The turnbuckles (Figure 9/1) premounted
onto the wire rope have to be pushed onto
the suspension profiles (Figure 9/2).
 Tighten the wire rope right and left
equally by means of the 1st nut M8 (Figure
9/3) at the turnbuckles (Figure 9/1) so that
the folding bellows (Figure 9/4) cannot be
manually pulled out of the suspension
frames. Check whether withstand a tensile
force of approx. 35kg if pulled at half vehi-
cle height. Then save by means of the 2nd
counter nut M8 (Figure 9/5).
Tightening torque: Counter nut M8 10 Nm
Figure 9

2.3.2. Quick fastener

 Attach the quick fastener (Figure 10/1)
into the loops of the wire rope (Figure 10/2)
right and left. 2 (5 0
70 0)
 Tighten the quick fastener by making one
4
0
clockwise rotation of the hexagon screw
1
(use wrench of size 32, Figure 10/3). If the
tension is low, reopen the quick fastener. 4
2
 Adjust the quick fastener by means of the
cylinder screw M10 (Figure 10/4).
 If the tension is not sufficient, shorten the 3
loops of the wire rope (Figure 10/2) right or
left.
Figure 10
2.4. Mounting the insert floor

There are used 2 variants, one-part or two-part insert floor
 Drill holes (Figure 11/1) for the tapping
Center hoop floor
screws 5,5x25 into the vehicle’s floor of Vehicle
front and rear car to fasten the retaining
pins. Distance of holes according to the ten-
sion band (Figure 11/5).
 Fasten the retaining pins (Figure 11/2)
with the tapping screws 5,5x25 (Figure
11/3) to the vehicle’s floor of front and rear
car.
 For connection to front and rear car, the
insert floor’s end fabric has to be provided
with cross shaped cuts (Figure 11/4) ac- Insert floor
cording to the distances between the retain- Figure 11
ing pins at the vehicle.
 When using the one-part insert floor, Center hoop floor
press the rubber profile into the groove of
the center hoop floor (Figure12).
 When using two-part insert floor, attach
the special rubber profile at the insert floor
fabric into the clamping profile of the center
One-part insert floor Rubber profile
hoop (Figure 13) and clamp tightly with
hexagon screws M6 (Figure 13/1). Figure 12
Tightening torque M6 = 9Nm
 Push all clamping profiles (Figure 11/6) Clamping profile
Special
into the straps at the insert floor. rubber profile
 Fit the insert floor with the tension bands
(Figure 11/5) at front and rear car over the
retaining pins (Figure 11/2).
1
Two-part insert floor
Figure 13

 Push the clamping profiles (figure 14/1) in the insert floor onto the border frames (figure
14/2) of the folding bellows so that the drilled holes are congruent.
 See variant A Figure 14 – for each connection (clamping profile/border frame Figure
14/1..2) insert 1 clamp (Figure 14/3) by means of a Seeger ring pliers 19 – 60mm 
(Figure 14/4).
 See variant B Figure 14 – each clamping profile (Figure 14/1) is fastened with 4 clips
(Figure 14/5) at each side to the border frame (Figure 14/2) of the folding bellows.
 See variant C Figure 14 – each clamping profile (Figure 14/1) is fastened with 2 pins
(Figure 14/6) and a clamping device to the border frame right and left of the folding bel-
lows. Here pay attention that the clamping safety device (Figure 14/7) fits with an audi-
ble „click“ into the groove at the pin.
 When closing the insert floor (hook tape onto coating tape), pay attention that the cuts
on the hook tape of the insert floor (see Figure 14) always are situated at the deepest
point of the folds.
B C
2
2
5 7
5 6
1 1
A 2
3 Center hoop
4
1
Folding bellows
2 cm cuts on the
hook tape Coating tape
2
Hook tape
Insert floor
Figure 14

2.5. Closing the belt floor

2.5.1. Pulling through the belt
 The plastic frame of the inner fabric (Figure
15/1) shall be put through the eye of the
outer fabric (Figure 15/2) of the belt floor.
 After this the belt (Figure 15/3) shall be 1
pulled through the free frame as locking
piece to close the belt floor.
 The ends of the belt (Figure 15/3) shall be
3
put back through the second last frame, see
Figure 15.
Figure 15

2.5.2. Mounting the floor plate

 For mounting the floor plate (Figure 16/1) drill 2 threaded holes M8 for the eccentric screws (Figure
16/2) to the centre in the lower side of front and rear car (for dimensions refer to figure 16/magnifying
glass A).
 For fastening of the two protection fabrics (Figure 16/3) front and rear to the belt floor, additionally
drill 3 holes right and left to the centre into the lower side of front and rear car for the tapping screws
5,5x25 (Fig. 16/4) required for the fastening of the retaining pins (Figure 16/5) and the tension bands
(Figure 16/10), drilling distance according to tension band, see also figure 16/magnifying glass B.
 Fit the retaining pins (Figure 16/5) by means of the tapping screws (Figure 16/4) to the lower side of
front and rear car.
 There are 2 tenon blocks M8 (Figure 16/6) provided for the fastening of the floor plate as well as
3 tenon blocks M6 (Figure 16/7) for the fastening of the retaining pins right and left (Figure 16/5).
Press those tenon blocks into the profile of the center hoop floor by means of a screwdriver (Fig.16/
magnifying glass C).
 Fasten 3 retaining pins (Figure 16/5) by means of the hexagon screws M6x20 (Figure 16/8) below
the center hoop floor. Distance between the retaining pins according to the holes of the tension band
(Figure 16/10).
 The protection fabrics (Figure 16/3) front and rear at the belt floor and in the center hoop area are cut
by means of a knife to provide small cross shaped cuttings (Figure 16/9) according to the distance
of the retaining pins and the screws of the floor plate.
 Then the protection fabrics (Figure 16/3) with the tension bands (Figure 16/10) are fastened to the
lower side of front and rear car as well as the tension bands with the belt floor below the center hoop
by fitting them over the retaining pins.
 Screw the eccentric screws (Figure 16/2) into the thread holes in the lower side of front and rear car,
the position as shown in Figure 16.
 Fit the floor plate (Figure 16/1) to the center hoop by means of 2 hexagon screws M8x25 (Figure
16/11) (Tightening torque 21 Nm) and under tension into the eccentric screws to front an rear car
lower side.
Center hoop
Vehicle 6/7
Vehicle
20
2
7 1
5
8 12
20 0
B 10 6
5 A
9
4 20
3 M8
10 2
11
5
Centre vehicle
4
10
Figure 16
2.6. Mounting the floor covering

2.6.1. Floor covering onto bordering tape (variant 1)
 Copy the fitting dimension for the floor covering from the HÜBNER drawing „Set of folding bellows,
compl.“ onto the bordering tape (Figure 17/2) provided at the inner fold of the folding bellows.
 Attach the connecting profile (Figure 17/1) of the floor covering sequentially to the previously marked
points of the bordering tape (Figure 17/2) and crimp each connecting profile 5x onto the bordering tape
by means of a universal crimping tool (part no. 04550000200) (Figure 17/3)
Folding bellows
Floor covering
Figure 17
2.6.2. Floor covering with quick locking device (variant 2)
 Insert the floor covering into the lower
caps (see magnifying glass A), do not
Center hoop
screw.
 Fasten the folding bellow profiles and
the floor covering profiles with the upper
caps (Figure18/1) and 2 tapping screws
(Figure 18/4).
Tightening torque: 3,4 Nm
 Attach the connecting profiles (Figure
18/3) located at the floor covering’s connec-
tion fabric to the fastening frames (Figure
18/4) located at the vehicle and the center
hoop and close with the clamping profile
(Figure 18/5). Floor
covering
For easier mounting spray the clamping pro-
files with soapsuds.
Platform
Figure 18

2.6.3. Floor covering with suspension device (variant 3)

 Suspend the floor covering into the upper
and lower fitting provided (Figure 19/A,B). Center hoop
 Attach the connecting profiles (Figure
19/1) located at the floor covering’s connec-
tion fabric to the fastening frames (Figure
19/2) located at the vehicle and the center
hoop. Close them by means of the clamping
profile (Figure 19/3).
For easier mounting spray the clamping pro-
files with soapsuds.
Floor
covering
Platform
Figure 19
2.7. Mounting the roof covering

 Insert the roof covering (figure 2/A) into
the premounted caps (figure 20/1).located
at the folding bellows and fasten them by A
means of 1 tapping screw (figure 20/2).
Tightening torque: 3,4 Nm
 Hinge the connection profiles (figure
20/3) located at the roof covering’s connec-
tion fabric into the fastening frames (figure
20/4) located at the vehicle and into the
center hoop. Close them by means of the
clamping profile (figure 20/5).
 For easier mounting spray the clamping
profiles with soapsuds.
Figure 20

2.8. Sealing profile for the floor flaps

 Prior to installing the sealing profiles (Figure 21/1) to the center hoop le/ri shorten the floor flaps
(Figure 21/2) at front and rear folding bellows respectively to the groove of the center hoop (please
see section A-A).
 Close the floor flaps with the sealing profiles (Figure 21/1).
 Seal the upper end of the sealing profile with Sikaflex 221.
Section A - A
Figure 21

2.9. Mounting the inner covering

 Fasten the turning lock (Figure 22/1) to front and rear car by means of 2 rivets and to the center hoop
by means of a clamping plate (Figure 22/2) and 2 countersunk screws M4x12 (Figure 22/3).
Refer for the mounting dimensions to the HÜBNER drawing „Set of folding bellows, compl.“
The corresponding turning lock plates are mounted at the border of the inner covering.
 Normally the clamping holders are premounted to the folding bellows, otherwise they need to be
mounted by means of special pliers (Figure 23) according to the HÜBNER drawing „Set of folding bel-
lows, compl.“.
There are various types of clamping holders (see Figure 22) depending on the position where mounted,
e.g. at the bordering frame, the connecting profile or the bordering tape.
 The support loops premounted to the heading tape of the inner covering have to be mounted to the
clamping holders by means of special pliers (best from the roof centre top-down), see also Figure 22 and
24.
 The turning lock plates may be inserted into the turning lock and fastened by means of quarter-turn.
Clamping holder
Clamping holder Clamping holder
Part no. 04480005500
Part no. 04480005400 Part no. 04480041800
Bordering frame Connecting profile

Bordering tape
Inner covering
Clamping holder
Support loop
Part no. 04480005200
Turning lock plate
1 2
Center hoop
Figure 22

Figure 23 Figure 24
2.9.1. Mounting the inner covering onto suspension profiles

 Fasten the turning lock (Figure 25/1) to front and rear car by means of 2 rivets and to the center hoop
by means of a clamping plate (Figure 52/2) and 2 countersunk screws M4x12 (Figure 25/3). Refer for the
mounting dimensions to the HÜBNER drawing „Set of folding bellows, compl.“
The corresponding turning lock plates are mounted at the border of the inner covering.
 Attach the suspension profiles (Figure 25/4) in the premounted caps (Figure 25/5) and fasten with a tap-
ping screw 3,9x16 (Figure 25/6).
 Fasten the clamping holders (Figure 25/7) to the suspension profile by means of special pliers according
to the distance of the support loops of the inner covering.
 The support loops (Figure 25/8) premounted to the heading tape of the inner covering have to be mounted
to the clamping holders by means of special pliers (best from the roof centre top-down), see also Figure
25.
 The turning lock plates may be inserted into the turning lock and fastened by means of quarter-turn.
4
5
7
6
8
Turning lock plate
1 2
Inner covering 3
Center hoop
Figure 25

2.10. Mounting the top covering

When mounting the top cover please refer for all dimensions to the HÜBNER drawing
“Set of folding bellows, compl.”
 Figure 1 Premount the parts (item 1 to 7): For doing this fasten the plug socket (Figure
26/2) to the supporting frame (Figure 26/1) right and left with 2 cylinder screws M6x20 Figure
26/7). Then push the T-connector (Figure 26/4) onto the rod (Figure 26/3) and insert into the
plug sockets (Figure 26/2) right and left. The mounting is completed by putting the socket
(Figure 26/6) with rod (Figure 26/5) into the T-connecter already connected with the afore-
mentioned rods (Figure 26/3).
The items 2 to 9 are optional to item 1 (Figure 26)
 Insert 3 tenon blocks M8 (Figure 26/10) into the center hoop (magnifying glass X) to fasten
the supporting frame (Figure 26/1) right and left, if necessary insert also 2 tenon blocks M6
(Figure 26/8) into the center hoop (see magnifying glass X) to fasten the supporting rod (Fig.
26/ 4…6).
 Position the premounted parts (item 1 to 7) onto the center hoop and align.
 Fix the supporting frame (Figure 26/1) right, left to the center hoop with 3 hexagon screws
M8x20 and washers (Figure 26/11;12).
 Fasten the supporting frame Figure 26/4…6) to the center hoop with 2 hexagon screws
M6x20 (Figure 26/9).
 Install the individual roof covers (item 26/13) to the center hoop support (item 26/1) by
means of 3 hexagon screws M6x20, washers (item 26/15;16) and fasten to the vehicle, to
front and rear car, by means of 3 hexagon screws M6x…, washers (item 26/17;18 >not in-
cluded in the delivery).
 Align the lower edges of the connecting profiles horizontally according to the roof covers
(item 26/13) by starting from the center hoop towards the vehicle and mark the folding bel-
low frames. Put the connecting profiles of the roof covers onto the folding bellow frames
all the way till the stop and make sure that the folding fabric of the roof cover is also in-
serted into the connecting profile (see magnifying glass Z in figure 1 > sequence A,B,C).
 Use an angle drilling machine to drill 3 drilled holes  6 mm at the marked points of the
connecting profiles (see magnifying glass Z/B in figure 26).
 Fix the connecting profiles by means of 6 clips (item 26/14) to the folding bellow frame
(see magnifying glass Z/C in figure 26).

2
7
1
18
17
3 7
15
11 16
2
4 12 13
5 9
16
15
6
8
1
14
10
14
13
Marking for
the drilled holes
Vehicle
frames of the Vehicle

folding bellows
Z Center hoop
Folding bellows
Drill  6mm
14
X 8
14
10
13
C
Connecting profiles
Figure 26

2.11. Mounting the roof cover

When mounting the roof cover please refer for all dimensions to the HÜBNER drawing
“Set of folding bellows, compl.”
 Insert 3 tenon blocks M8 (Figure 27/2) in order to fasten the frame (Figure 27/1) right and
left to the center hoop (see Figure 27/magnifying glass X).
 Fasten the frame (Figure 27/1)on to the center hoop right and left by means of 3 hexagon
screws M8x20 and washers (Figure 27/3;4).
 Place the connecting profiles fastened to the roof cover (Figure 27/5) onto the frames of
the folding bellows and align (see Figure 27/magnifying glass Z > sequence A,B,C).
 Use an angle drilling machine to drill 3 drilled holes  6 mm at the marked points of the
connecting profiles (see Figure 27/magnifying glass Z/B).
 Fasten the connecting profiles of the roof cover to the folding bellows by means of 6 clips
(Figure 27/6) (see Figure 27/magnifying glass Z/C).
 Fasten the roof cover (Figure 27/5) to the center hoop (Figure 27/1) by means of
3 hexagon screws M6x20, washers (Figure 27/7;8) and to the vehicle by means of
3 hexagon screws M6x…, washers (Figure 27/9;10 >not included in the delivery).

7
8
10
9
8
7
5
3
4
1
6
6
2
5
Vehicle
Vehicle
Folding bellows
Z Center hoop
Folding bellows
Drill  6mm
6 6
X 2
Figure 27

3. Appendix
3.1. Mounting dimensions the suspension frames, fastening frames and the guiding profile
for the folding bellows set P/N 0421 _ _ _ _ _ 00
Centre vehicle FB contour outside
1
2
3 4
3
B
C
FB contour inside
D
E
5
4
6
5
C
D
Top edge
Articulation platform
Articulation
Pos. Description P/N Qty Dimension

mm
1 Suspension frame 2 A=
side part left B=
2 Suspension frame 2 A=
side part right B=
3 Fastening frame 2 C=
for roof covering
4 Guiding profile 1 C=
5 Fastening frame 2 D=
for floor covering left E=
6 Fastening frame 2 D=
for floor covering right E=
Figure 28

3.2. Check List

Please use the following check list in order to ensure that the steering system has been correctly as-
sembled.
The step by step procedure aids a logical analysis of the assembly process of the steering system, ist
serves as an aid and support for the assembly team.
Simultaneously this check list gives us, as manufacturer, the chance to offer a speedy support to our
customers.
In particular the information concerning joint/folding bellows series numbers facilitates identification for
the case of a repair at our works.

Vehicle-Type:____________________ Vehicle Number:____________________
Date the vehicle was brought into service:______________ Kilometer reading:__________
Articulation Series number: _______________

Bellows-Series number – Forward Vehicle: _____________ Rear Vehicle: _____________
Component Criterion Comments tested

Suspension frame Assembly corresponds to dimen- s. Appendix _ _
sional drawing
Mounted in centre of chassis see page_ _ , Paragraph. _ _
Suspension frame sealed see page_ _ _ (instruction)

Attachment frame(s)
Floor covering / Assembly corresponds to dimen-
see. Appendix _ _ , Paragraph. _ _
Roof covering sional drawing
Center hoop
Mounted on the upright shaft
see page_ _ , Paragraph. _ _
Mounted on bellows support
Safety rope correctly mounted see page_ _ , Paragraph. _ _

Correct Assembly Forward and. see page_ _ , Paragraph. _ _/ Appen-
Centre hoop stabiliser
Rear Vehicle, center frame dix _ _
Telescope Mounting parallel to vehicle longti- see page_ _ , Paragraph. _ _
tudinal axle.
On Forward Vehicle
Note down position of the tele-
scope! On Rear Vehicle
Folding bellows
Mounted centre of vehicle (Sus-
pension frame) and center hoop
Correct Position of rubber profile

in suspension frame
Correct tension of cable see page_ _ , Paragraph. _ _
Insert floor Correct Assembly Forward and
Rear Vehicle, right and left side, see page_ _ , Paragraph. _ _
center hoop
Fastener profile mounted see page_ _ , Paragraph. _ _
Floor covering Correct Position and mounting in
the clamps on folding bellows as see page_ _ , Paragraph. _ _
well as center hoop and vehicle
Roof covering Correct Position and mounting in
the clamps on folding bellows as see page_ _ , Paragraph. _ _
well as center hoop and vehicle
Support rollers Correct Adjustment see page_ _ , Paragraph. _ _
Tested by:_______________ on (date):_______________

Logic inputs - outputs of multiplex control units
3 + various services available
Various services 2
Various services 1
Lighting
ECAS, Ralla HUBNER, ECU hydro fan BOSCH
Engine
Transmission
Doors
Controls and Signals
CAN-BUS communication and diagnostics
Power supply - starting and charging
Legend codes and mass points
functional electrical
scheme 360 DSL
STEP-C (general)
+(30) Gearbox power supply unit MPX Panel “G”
Description Location Description Location Description Location
battery compartment Solenoid valve for engine oil filling Engine compartment “B” Case Additional stop request indicator Front/Rear dashboard C6 +(30) Fuel filter resistance relay 30 for power supply MPX Panel “G”
Battery A
battery compartment Park brake release solenoid valve Axle 3 area “B” Case Door open warning light 1 Front/Rear dashboard C36 +(30) ECAS B control unit power supply (X1*7) MPX Panel “G”
Battery B
Solenoid valve for steering column unlocking Front - Left Door open warning light 2-3 (std) 2 (opt) Front/Rear dashboard C37 +(30) Door glass resistance power supply MPX Panel “D” case “A”
ECAS solenoid valve group "B" case Case “B” Door open warning light 4 (std) 3 (opt) Front/Rear dashboard C38 +(30) Driver’s window glass resistance power supply MPX Panel “D” case “A”
Description Location
engine compartment ECAS solenoid valve group "A" case Case “A” Door open warning light 4 (opt) Front/Rear dashboard C39 DOC/SCR/Nox power supply MPX Panel “G”
Alternator A
engine compartment Water supply solenoid valve Engine Compartment Case “B” External preheat insertion indicator Front area under calender + Direct general bodywork Battery compartment
Alternator B
Preheater solenoid valve Engine Compartment Case “B” Driver A.C. enabled indicator Area above driver +(30) Passenger A.C. case “A” Fuse panel case "A"
Driver AC Front Area Driver A.C. connected indicator Area above driver +(30) Passenger A.C. case “B” MPX Panel “F”
power socket for outdoor use battery compartment E.V. Dispenser UREA Engine exhaust area Disabled location light enabled indicator Wheelchair station +(30) Grid heater circuit Engine compartment
driver's seat power socket driver's back panel E.V. H2O heating tank UREA Rear Left under frame “B” Case Disabled rear stop request warning Wheelchair station +(30) Alternatore “A” Battery compartment
back current central power socket driver's back control panel Proportional solenoid valve Under frame defroster zone Cooling tank H2O max. level indicator Rear area above engine +(30) Alternatore “B” Battery compartment
engine compartment dashboardpower socket engine compartment dashboard Redundancy solenoid valve Engine compartment rear area +(30) General bodywork Battery compartment
+ Direct case “A” general Fuse panel case "A"

Left low beam headlight Front - Left Engine compartment lighting lamp Engine compartment + Under TGC, case “A” general Fuse panel case "A"
engine compartment Right low beam headlight Front - Right + Direct case “B” general MPX Panel “F”
Starter Motor
Left high beam headlight Front - Left + Under TGC, case “B” general MPX Panel “F”
Right high beam headlight Front - Right Digital tachograph Dashboard above driver
Defroster Fan front area Fog lamp / daylight module Front - Left Tachograph transmitter On transmission output
driver heater fan support front area Fog lamp / daylight module Front - Right 1a series indoor lights button Front Dashboard Pos C41
passenger heater fan support 1 front area Left reversing light Rear 2a series indoor lights button Front Dashboard Pos C41
passenger heater fan support 2 under frame left side case "A" Right reversing light Rear Air pressure transmitter, brake reservoir, axle 1 Rear area case “B” 3a series indoor lights button (blue) Front Dashboard Pos C42
passenger heater fan support 3 under front left side case "A" Air pressure transmitter, brake reservoir, axle 2 Rear left roof case “A” Obliterator switch Front Dashboard Pos C29
passenger heater fan support 4 rear engine compartment casing "A" Front Left Position Light Front - Left Air pressure transmitter, brake reservoir, axle 3 Rear area case “B” Radio telephone switch Side Dashboard Pos 102
Front Right Position Light Front - Right Suspension air pressure transmitter Center left roof case “A” Rearview mirrors defrost button Side Dashboard Pos 104
Front Left Direction Light Front - Left Driver’s light button Front Dashboard Pos C42
Rearview Mirror Adjuster Left front left stand "A" case Front Right Direction Light Front - Right Indicator sign system button Front Dashboard Pos C10
Rearview Mirror Adjuster Right front right stand "A" case Left Side Direction Light Front Panel Case "A" Left Side Suspension air pressure transmitter Carburetor tank case “A” Door window / window defrost button Side Dashboard Pos 103
Recirculation deflector control motor front area defrost Right Side Direction Light Front Panel Case "A" Right Side Communication emergency control unit switch Side Dashboard Pos 107
Interior retractable mirror motor front right stand "A" case Front Left Clearance Light Front Panel Case "A" Retarder by-pass button Front Dashboard Pos C28
Front hatch 2 center left stand "A" case Front Right Clearance Light Front Panel Case "A" + Direct Open Carburetor tank case “A” Vehicle doors unlocking switch MPX “D” panel area
Front hatch 1 center left stand "A" case Side Marker Lights Case "A" 1˚ on the left + Direct Hatch “A” Handling MPX Panel “D” case “A” Additional vehicle doors unlocking switch Area above driver
Rear hatch 2 center left stand "B" case Side Marker Lights Case "A" 2˚ on the left + (Dir) pin 8 predisposition connector 9104B(V.Sorv) MPX Panel “D” case “A” Engine compartment starting by-pass switch Engine compartment dashboard
Rear hatch 1 center left stand "B" case Side Marker Lights Case "A" 3˚ on the left + (30) pin 7 predisposition connector 9104B(V.Sorv) MPX Panel “D” case “A” Key switch services Side Dashboard Pos 106
Side Marker Lights Case "A" 4˚ on the left + (30) pin 6 predisposition connector 9104B(V.Sorv) MPX Panel “D” case “A” Emitter switch Front Dashboard Pos C29
Side Marker Lights Case "B" 5˚ on the left + (15) Open MPX Panel “D” case “A” CCTV door activation buttun Front Dashboard Pos C1
washer motor Front Area Side Marker Lights Case "B" 6˚ on the left + Direct Hatch “B” Handling MPX Panel “G” case “B” Engine compartment light by-pass switch On engine compartment dashboard
UREA electric pump cooling upper back area Side Marker Lights Case "B" 7˚ on the left + Direct Radio Telephone Power Supply Driver rear panel Radio system button Front Dashboard Pos C10
Electric preheater pump pre-heater area Side Marker Lights Case "A" 1˚ on the right + Direct ECU I/O Dashboard Power Supply Driver rear panel Automatic heating switch Side Dashboard Pos 106B
Side Marker Lights Case "A" 2˚ on the right + (Dir) pin 5 predisposition connector 9104B (AVM) MPX Panel “D” case “A” Driver A.C. switch Area above driver
Side Marker Lights (footboard) Case "A" 3˚ on the right + (30) BOSCH ECU Hydraulic Pump Power Supply MPX Panel “G” Park brake unlock switch MPX “D” panel area
Side Marker Lights (footboard) Case "A" 4˚ on the right "RA" engine control unit Power Supply MPX Panel “G” Additional park brake unlock switch Area above driver
wiper motor front area
Side Marker Lights Case "A" 5˚ on the right + Direct Multiplex “B” power supply (PIN 17,18) Driver rear panel Ramp control enable switch Front Dashboard Pos C27
audible warning horns Front Area Side Marker Lights Case "B" 6˚ on the right + Direct Multiplex “C” power supply (PIN 1,2) Driver rear panel Front door 1 by-pass switch Front Dashboard Pos C33
single-tone ringer for stop request “E” MPX panel case “A” Side Marker Lights Case "B" 7˚ on the right + Direct Multiplex “C” power supply (PIN 17,18) Driver rear panel Reverse gear buzzer by-pass button Front Dashboard Pos C2
ramp in motion ringer the central door case "A" Side Marker Lights Case "B" 8˚ on the right +(30) Direct Multiplex “B” power supply (PIN 1,2) Driver rear panel Reverse gear buzzer by-pass switch On engine compartment dashboard
Reverse gear buzzer engine compartment dashboard area + Direct Multiplex “D” power supply (PIN 1,2) MPX Panel “D” case “A” Stop brake switch (opt) Front Dashboard Pos C24
front door "A" open buzzer Above Door +(30) Direct Multiplex “D” power supply (PIN 17,18) MPX Panel “D” case “A” Recirculation switch interior-exterior Side Dashboard Pos 106C
Center door "A" open buzzer Above Door -Stop- Direction Position Light Rear - Left + Direct Multiplex “E” power supply (PIN 1,2) MPX Panel “D” case “A” Door opening buzzers by-pass button Front Dashboard Pos C2
Center door "B" open buzzer Above Door -Stop- Direction Position Light Rear - Right + Direct Multiplex “E” power supply (PIN 17,18) MPX Panel “D” case “A” B.T. Revolution limiter block by-pass switch Area above driver
Rear door "B" open buzzer Above Door Left Rear Fog Light Rear - Left + Direct Multiplex “G” power supply (PIN 1,2) MPX Panel “G” case “B”
Right Rear Fog Light Rear - Left +(30) Direct Multiplex “G” power supply (PIN 17,18) MPX Panel “G” case “B”
Left Licence Plate Light Rear + (Dir) Pre-heater system power supply MPX Panel “G” case “B”
general current contactor battery compartment Right Licence Plate Light Rear + (Dir) Power supply relay 2502 for emer. WEBASTO MPX Panel “G” case “B”
emergency preheating relay aux “G” MPX panel case “B” Rear Left Light Rear Left Mask +(30) Engine control unit power supply MPX Panel “G” case “B”
ecu mpx starter power supply relay “G” MPX panel case “B” Rear Right Light Rear Right Mask +(30) Engine control unit power supply 30 relay MPX Panel “G” case “B”
ecu engine starter power supply relay “G” MPX panel case “B” + Direct Multiplex “F” power supply (PIN 1,2) MPX Panel “G” case “B”
air intake preheating relay engine compartment +(30) Direct Multiplex “F” power supply (PIN 17,18) MPX Panel “G” case “B”
1˚ wiper speed relay Driver’s back control unit Driver Light Driver Area +(30) Contact 50 start power supply MPX Panel “G”
2˚ wiper speed relay Driver’s back control unit Interior light left side Light channel lodge + Direct Slave Display Driver rear panel
door defrost control relay “D” MPX panel case “A” Interior light right side Light channel lodge + Direct Tachograph (Opt) Driver rear panel
driver window defrost control relay “D” MPX panel case “A” Front side articulation light Front area + Direct GPS - GSM module power supply MPX Panel “D” case “A”
ramp output control relay Driver’s back control unit Rear side articulation light Front area + Direct Power supply for FM radio system MPX Panel “D” case “A”
ramp return command relay Driver’s back control unit + (15) BOSCH fan control unit MPX Panel “G” case “B”
power supply relay “D” MPX panel case “A” + (30) BOSCH proportional solenoid valve supply MPX Panel “G” case “B”
motor control unit power relay “G” MPX panel case “B” Stop booked light Roof center case “A” + (15) Locked-up alternators MPX Panel “G” case “B”
fuel filter resistance command relay “G” MPX panel case “B” Alternate stop booked light Center door area case “A” + Direct ERAR Fire System MPX Panel “G” case “B”
fire control relay “G” MPX panel case “B” Stop booked light Roof center case “B” + (30) Master display power supply Driver rear panel
Alternate stop booked light Center door area case “B” + (30) Power supply of correct rear guide Driver rear panel
Exit Light Roof center case “A” + (30) OBD socket power supply Driver rear panel
E.V. On/Off BOSCH radiator fan area Exit Light Roof center case “B” + (30) Open Driver rear panel
E.V. Proportional BOSCH radiator fan area Front door opening case “A” light Door area 1 + (30) Power supply of motor compartment MPX Panel “G”
E.V. pneumatic horn front area Center door opening case “A” light Door area 2 + (30) Power supply of diagonal A ECU EBS Driver rear panel
E.V. pneumatic horn front area Center door opening case “B” light Door area 3 + (30) Power supply of diagonal B ECU EBS Driver rear panel
Functional electrical scheme "Legend Code"
E.V. ABS 1˚ Left Axle left wheel compartment axle 1 Rear door opening case “B” light Door area 4 + (30) Power supply of 30 relays indicating signs MPX Panel “D” case “A” "and mass points" TAV "0"
E.V. ABS 1˚ Right Axle right wheel compartment axle 1 Ceiling lamp in motion Right door 2 area lodge + (30) ECAS A power supply unit
Hatch button case "A" handling Front Dashboard pos C7 Water presence sensor, fuel tank Sub-frame of the diesel tank area Wiring “D” <> Left lighting network “A” case Front roof area “A” case
TCG closing button Front Dashboard pos C35 Hatch button case "B" handling Front Dashboard pos C8 Water presence sensor, fuel filter Engine area Wiring “D” <> Right lighting network “A” case Front roof area “A” case
TCG opening button Front Dashboard pos C35 Retarder control lever switch Front Dashboard pos C81 Pt 500 ambient temperature sensor Front Left Area Wiring “F” <> Left lighting network “B” case Front roof area “B” case
Stop button for door opening Engine Compartment Dashboard Speaker switch Dashboard above the driver ECU ECAS “A” case MPX “D” panel “A” case Wiring “F” <> Right lighting network “B” case Front roof area “B” case
Loud stop request button Headliner Case “A” 1st Left ECU ECAS “B” case MPX “F” panel “B” case Connection arrangement in the engine compartment dashboard Engine compartment dashboard
Loud stop request button Headliner Case “A” 2nd Left Engine cooling H2O tank low level Rear area above engine Front left level sensor 1st axle left wheel compartment Predisposition signals connection Dashboard above driver’s head
Loud stop request button Headliner Case “A” 3rd Left UREA cooling H2O tank low level Rear area above engine Front right level sensor 1st axle right wheel compartment AVM - Video surveillance power supply connection Dashboard above driver’s head
Loud stop request button Headliner Case “A” 4th Left 2nd axle stationary B.P. pressure tank 2nd Axis under frame area 2nd axle left level sensor 2nd axle left wheel compartment Disabled ramp connection Underframe “A” case
Loud stop request button Headliner Case “B” 1st Left 3rd axle stationary B.P. pressure tank Engine under frame area 2nd axle right level sensor 2nd axle right wheel compartment Wiring harness “D” <> EBS wiring Driver’s back, middle area
Loud stop request button Headliner Case “B” 2nd Left Pt 500 Internal temperature sensor Front Left Headliner Case “A” 3rd axle left level sensor 3rd axle left wheel compartment Wiring harness “D” <> “E” wiring MPX “E” roof panel area
Loud stop request button Headliner Case “B” 3rd Left Pt 500 Internal temperature sensor Rear Left Headliner Case “A” 3rd axle right level sensor 3rd axle right wheel compartment Side dashboard harness <> Control panel dashboard intervention Driver’s back, middle area
Loud stop request button Headliner Case “B” 4th Left Pt 500 Internal temperature sensor Left Headliner Case “B” Steering angle sensor Driver’s back, middle area Connection with door 2 Right door 2 headliner
Loud stop request button Headliner Case “A” 1st Right Engine oil tank filling min. level sensor Rear Area Engine ECU Engine compartment Dashboard harness <> Control panel dashboard intervention Side dashboard
Loud stop request button Headliner Case “A” 2nd Right Power steering pump oil tank min. level sensor Engine Area Accelerator Pedal Pedal area Connection with door 3 Right door 3 headliner
Loud stop request button Headliner Case “A” 3rd Right Clogged air filter pressure Air Filter Inlet Area Fuel temperature sensor Engine compartment Connection with door 4 Right door 4 headliner
Loud stop request button Headliner Case “A” 4th Right Hydraulic pump oil tank low level Engine Area MULTIPLEX Display A/B /KAS Front dashboard Connection with door 1 Right door 1 headliner
Loud stop request button Headliner Case “A” 5th Right Pt 500 Internal temperature sensor X driver A.C. Area Above Driver MULTIPLEX “B” input connector Driver’s back, middle area Dashboard harness <> Control panel dashboard intervention Side dashboard
Loud stop request button Headliner Case “B” 1st Right 2nd axle parking break pressure release 2nd Axis under frame area MULTIPLEX “B” output connector Driver’s back, middle area Wiring harness “D” <> HUBNER articulation Rear left roof “A” case
Loud stop request button Headliner Case “B” 2nd Right 2nd axle parking break pressure release Engine under frame area MULTIPLEX “C” input connector Driver’s back, middle area Wiring harness “F” <> HUBNER articulation MPX “F” panel “B” case
Loud stop request button Headliner Case “B” 3rd Right MULTIPLEX “C” output connector Driver’s back, middle area Wiring harness “B” <> Control panel dashboard intervention Driver’s back, middle area
Loud stop request button Headliner Case “B” 4th Right Pushbutton Automatic Gearbox Front Dashboard pos C43 MULTIPLEX “D” input connector MPX “D” panel “A” case Wiring harness “C” <> Control panel dashboard intervention Driver’s back, middle area
Loud stop request button Headliner Case “B” 5th Right Automatic Gearbox ECU Engine compartment MULTIPLEX “D” output connector MPX “D” panel “A” case Wiring harness “D” <> Control panel dashboard intervention Driver’s back, middle area
Silent stop request button Side Panel “A” 1st Left VOITH Automatic Gearbox ECU Left Headliner Case “B” MULTIPLEX “E” input connector MPX “E” panel “A” case Wiring harness “D” <> Control panel dashboard intervention Driver’s back, middle area
Silent stop request button Side Panel “A” 2nd Left VOITH Automatic Gearbox ECU Left Headliner Case “B” MULTIPLEX “E” output connector MPX “E” panel “A” case Wiring harness “D” <> “E” wiring MPX “E” roof panel area
Silent stop request button Side Panel “A” 1st Right MULTIPLEX “F” input connector MPX “F” panel “B” case Wiring harness “G” <> Engine compartment FAN. WEB. MPX “G” panel “B” case
Silent stop request button Side Panel “A” 2nd Right OB front case “A” on the left Left headliner at driver’s back area MULTIPLEX “F” output connector MPX “F” panel “B” case Side dashboard harness <> Control panel dashboard intervention Driver’s back, middle area
Door opening button from the outside Right windshield wiper area OB front case “A” on the right Headliner on front right wheel arch MULTIPLEX “G” input connector MPX “G” panel “B” case Wiring harness “G” <> Engine compartment FAN. WEB. MPX “G” panel “B” case
Door opening button 1 Front Dashboard pos C36 OB rear case “B” on the left Headliner on rear left wheel arch MULTIPLEX “G” output connector MPX “G” panel “B” case Wiring harness “G” <> Engine compartment FAN. WEB. MPX “G” panel “B” case
Door opening button 2-3 (Std) 2 (Opt) Front Dashboard pos C37 OB rear case “B” on the right Headliner on rear right wheel arch Clogged fuel filter sensor Engine compartment Wiring harness “G” <> Engine wiring SCR-UDS MPX “G” panel “B” case
Door opening button 4 (Std) 3 (Opt) Front Dashboard pos C38 Ticket Issuer Left headliner at driver’s back area Pt 500 engine compartment temperature sensor Engine compartment Dashboard harness <> Control panel dashboard intervention Side dashboard
Door opening button 4 (Opt) Front Dashboard pos C39 OB Controller Driver Area GPS-GSM board module MPX “D” panel “A” case Wiring harness “G” <> Engine wiring SCR-UDS MPX “G” panel “B” case
Fuel cap limit switch Front Right Dashboard case “A” DOC upstream temperature sensor Engine exhaust area Wiring harness “G” <> “F” wiring MPX “F” panel “B” case
Radiator rear side door limit switch Rear left radiator area Radiotelephone power supply Area Above Driver DPF upstream temperature sensor Engine exhaust area Wiring harness “G” <> “F” wiring MPX “F” panel “B” case
Engine rear side door limit switch Rear left engine area Casette / CD Player Area Above Driver SCR upstream temperature sensor Engine exhaust area Wiring harness “F” <> Underbody “B” case MPX “F” panel “B” case
Limit switch for engine compartment hatch Engine compartment upper door Speaker sound system connector Area Above Driver SCR downstream temperature sensor Engine exhaust area Wiring harness “D” <> HUBNER articulation Rear left roof “A” case
Limit switch for engine compartment hatch Engine compartment lower door Front driver speaker Area Above Driver ECU fire system (fire extinguisher) Front Left Headliner Case “B” Wiring harness “F” <> HUBNER articulation MPX “F” panel “B” case
Limit switch for preheater door Rear right engine area Rear driver speaker Area Above Driver Fire detection sensor Front Left Headliner Case “B”
Limit switch for battery compartment door Front Left Dashboard case “B” "A" case 1st left passenger speaker Left Headliner Case “A” DEF ADBLUE Module UREA Tank Area Driver’s back panel clamp connections Driver’s back panel
Limit switch for UREA refill door Front Right Dashboard case “B” "A" case 2nd left passenger speaker Left Headliner Case “A” UREA quality level and temperature module (UQS) UREA Tank Area Driver’s back panel (+dir) clamp connections Driver’s back panel
Unlocking gear button MPX “D” Panel Area "A" case 3rd left passenger speaker Left Headliner Case “A” NOX DOC upstream sensor Engine exhaust area MPX “D” (+dir) clamp connections MPX “D” panel “A” case
Limit switch for parking brake Side Dashboard "B" case 1st left passenger speaker Left Headliner Case “B” NOX SCR upstream sensor Engine exhaust area MPX “G” (+dir) clamp connections MPX “G” panel “B” case
Start button from engine compartment Engine compartment dashboard "B" case 2nd left passenger speaker Left Headliner Case “B” NH3 sensor Engine exhaust area Driver’s back panel (+30) clamp connections Driver’s back panel
External preheating ignition Front area under grille "A" case 1st right passenger speaker Left Headliner Case “A” MP (particle) sensor Engine exhaust area MPX “D” (+30) clamp connections MPX “D” panel “A” case
Forced / self-inhibited regeneration button Side Dashboard Pos 101 "A" case 2nd right passenger speaker Right Headliner Case “A” Air temperature and humidity sensor Engine area MPX “G” (+30) clamp connections MPX “G” panel “B” case
Stop request button from the rear disabled area Wheelchair station "A" case 3rd right passenger speaker Right Headliner Case “A” Filter pressure difference sensor FAP Engine exhaust area “RA” engine coupling Engine compartment
Disabled assistance button Wheelchair station "B" case 1st right passenger speaker Right Headliner Case “B” Diagnostic socket “OBD” Front dashboard
External assistance request button Right side panel “A” "B" case 2nd right passenger speaker Right Headliner Case “B” ECU system EBS - ABS - ASR Driver’s back, middle area CD / Casette Player Antenna Roof over the driver
Disabled seat activation button Front Dashboard pos C27 Microphone Area Above Driver Braking signal transmitter (61)(62) Under brake pedal MTS “Door opening” Solenoid valve A Center door
Central unit emergency button Front Dashboard pos C9 2nd axle module “A” case Sub-frame 2nd axis area Front door, leaf 1 lock solenoid valve Center door
ASR by-pass button Front Dashboard pos C28 Control Unit for Destination Plates Area Above Driver 3rd axle module “B” engine case Sub-frame 3rd axis area Door sensitive edge left/right On door leaves
Lift / level button 1-2 ECAS Front Dashboard pos C25 Front Destination Plate Front dome case “A” Hydraulic pump ECU diagnosis outlet MPX “G” panel “B” case MTS “Door closing” Solenoid valve B Center door
Movement enabling button for the rear disabled area Wheelchair Area Rear Destination Plate Rear Right Headliner Case “B” RS232 MPX pass connector Inner dashboard
“Halt Brake” Button Front Dashboard pos C30 Side Destination Plate Case “A” Headliner on front right wheel arch Air intake preheating resistance Engine area Power supply + CAN conditioner output Left Headliner Case “A” / “B”
Climb assist “Hill Holder” Button Front Dashboard pos C30 Side Destination Plate Case “B” Front Right Headliner Case “B” Left rearview mirror resistance Front Left Headliner Case “A” CAN line conditioner output Left Headliner Case “A” / “B”
Programming Connector Front Dashboard pos C31 Inside Destination Plate Case “A” Headliner on front right wheel arch Right rearview mirror resistance Front Right Headliner Case “A” MTS “Balance/Cush” Solenoid valve C Center door
Steering column unlock button Front Dashboard pos C32 Air resistance resistance Engine compartment Bulb signal NC 2bar for door in emergency Center door on EV MCS
Display management button “+” / “M” Front Dashboard pos C3 Pre-heater Engine Compartment Door window heating resistance Front Right Headliner Case “A” Emergency reset solenoid valve 5km/h Center door
Display management button “-” / “0” Front Dashboard pos C4 Fuel filter resistance Engine area Door obstruction detection left/right Center door
Display management button page change / select range Front Dashboard pos C5 1st Axle left brake wear sensor 1st Axle left wheel compartment Resistance charging ventilation adjustment Front defroster area Bulb signal NC 4bar for open door Center door on EV MCS
Start / Stop Button Side Dashboard Pos 108 1st Axle right brake wear sensor 1st Axle right wheel compartment Door 1 leaf 1 potentiometer (front) Right door 1 headliner DB9 serial poles MPX connector Under the dashboard on the left
Defroster speed increase / decrease button Side Dashboard Pos 106E 2nd Axle left brake wear sensor 2nd Axle left wheel compartment Door 1 leaf 2 potentiometer (rear) Right door 1 headliner Bulb signal NC 4bar for door leaf locked Center door on EV BA
2nd Axle right brake wear sensor 2nd Axle right wheel compartment Door 2 leaf 1 potentiometer (front) Right door 2 headliner Connector for the CCTV system Dashboard above the driver
Power off switch Battery Compartment 3rd Axle left brake wear sensor 3rd Axle left wheel compartment Door 2 leaf 2 potentiometer (rear) Right door 2 headliner
Front door switch Front Dashboard pos C34 3rd Axle right brake wear sensor 3rd Axle right wheel compartment Door 3 leaf 1 potentiometer (front) Right door 3 headliner
Front lights direction lever switch Front Dashboard pos C80 1st Axle left rpm sensor 1st Axle left wheel compartment Door 3 leaf 2 potentiometer (rear) Right door 3 headliner
Lever switch : Horn Front Dashboard pos C80 1st Axle right rpm sensor 1st Axle right wheel compartment Door 4 leaf 1 potentiometer (front) Right door 4 headliner
flash and brights lever switch Front Dashboard pos C80 2nd Axle left rpm sensor 2nd Axle left wheel compartment Door 4 leaf 2 potentiometer (rear) Right door 4 headliner
Horn button Front Dashboard pos C1 2nd Axle right rpm sensor 2nd Axle right wheel compartment Driver window heating resistance Driver left side area
Direction lights control - stationary vehicle Front Dashboard pos C11 3rd Axle left rpm sensor 3rd Axle left wheel compartment CAN MPX termination resistance MPX “G” panel “B” case
ECAS/Kneeling Reset Button Front Dashboard pos C26 3rd Axle right rpm sensor 3rd Axle right wheel compartment CAN LINEA 2 termination resistance MPX “G” panel “B” case
BOSCH Hydraulic Pump ECU MPX “G” panello “B” case CAN LINEA OBD termination resistance Side dashboard
Windscreen heating / ventilation Side Dashboard pos 106D ECU TEQ management of topping up engine oil in sump MPX “G” panello “B” case
Additional driver’s area heater Side Dashboard pos 106A ECU Wheel control connector A Rear left roof “A” case Electric motor body connection Engine compartment
External light switch Front Dashboard pos C40 ECU Wheel control connector B Rear left roof “A” case
Functional electrical scheme "Legend Code"
Wiper switch Front Dashboard pos C80 Passenger condition panel Area above driver "IBS" setting in the battery compartment Battery compartment case “B”
"and mass points" TAV "0"
Mirror adjuster controller Side Dashboard pos 109 Passenger AC case “A” ECU In the roof group “A” Provision of battery compartment lighting Battery compartment case “B”
Fog light and rear fog light switch Front Dashboard pos C40 Passenger AC case “B” ECU In the roof group “B” Wiring harness “D” <> Left speaker line Rear Left Headliner Case “A”
passenger heating Side Dashboard pos 105 Control of pneumatic horns ECU Driver’s back, middle area Wiring harness “D” <> Right speaker line Rear Left Headliner Case “A”
FRONT DIRECTION
FRON
T DI
RECT
ION
Body crossing the case “B”
Body crossing the case “A”

UNDERBODY
Right roof wiring “F” body “B”
Right roof wiring “F” body “C”

Underbody wiring “C” body “B”
Right roof wiring “E” body “C”
Underbody wiring “B” body “A”
Body frame - batteries

Right roof wiring “E” body “B”
Right roof wiring “E” body “A”
FR
ON LEGEND
Left roof wiring “D” body “A” TD
IR
EC
TIO
N
reference: it is composed of a letter and a number,
the letter refers to the table in the number and refers
to the position in which the reference is referred
Left roof wiring “D” body “B”
Cuna Code:
present on the cable.
identifies the particular connection
Left roof wiring “D” body “C”
TEQ dashboard body
Body code:
Front light wiring “B” Body “B”
code that allows to identify
Body for Driver’s back, center area the position on the vehicle
Air Conditioner Body “B”
NOTE
Right roof wiring “F” body “C”
Left roof wiring “G” body “A”
the data contained in this publication may not be updated as a result of changes made by the manufacturer at any
time for technical or commercial reasons as well as for adaptation to the legal requirements of the various countries.
Motor interface wiring harness
Front light wiring “B” Body “A”

Under frame wiring “C” Body “A”
Central interface control wiring harness - Dashboard
Wiring harness EBS
Electric Motor Body
Body Frame - Engine
Engine compartment wiring “B” - Lights - WEBASTO - Body “A” Functional electrical scheme "Legend Code"
"and mass points" TAV "0"
Engine compartment wiring - Lights - WEBASTO - Body “B”
Under frame wiring “B” Body “B”
Engine compartment wiring - Lights - WEBASTO - Body “Dashboard”
POWER SUPPLY AND DISTRIBUTION STARTING AND CHARING STARTING AND CHARING
START UP FROM OUTSIDE
BATTERY GENERAL CURRENT RELAY “TGC” DIESEL VEHICLE RECHARGE CIRCUIT ENGINE STARTING
SERVICE CURRENT SOCKETS
DIVERTER GENERAL CURRENT SWITCH SWITCH TGC (5527) EMERGENCY CENTRAL CONTROL (5212) MEGAVAL MEGAVAL STARTING ENGINE START KEY ENGINE BY-PASS EXT. SWITCH POWER SUPPLY POWER SUPPLY DRIVER SEAT CONTROL ENGINE COMP.
BODY CASE “B” ALTERNATOR FUSE 1 ALTERNATOR MOTOR STARTING STOP CONTACT COMPARTMENT SWITCH FOR STOPING KEY PANEL KEY PANEL UNIT
HEADLINER LEFT SIDE FUSE 2 RELAY BUTTON FOR STARTING FROM MPX "G" MPX "G"
FROM ENGINE COMP.
ENGINE COMP.
ELECTRIC
MOTOR BODY EMERGENCY
MUSHROOM HEAD BUTTON
FOR BLOCK OF CONTCTS
FUSES IN THE BATTERY CASE IN POSITION 3 EMERGENCY EMERGENCY
MUSHROOM HEAD BUTTON MUSHROOM HEAD BUTTON
FUSE ON MPX PANEL "F" LEFT SIDE FOR BLOCK OF CONTCTS FOR BLOCK OF CONTCTS
FUSE ON PANEL CASE “A” LEFT SIDE IN POSITION 1 IN POSITION 2
POWER SUPPLY AND DISTRIBUTION POWER SUPPLY AND DISTRIBUTION POWER SUPPLY AND DISTRIBUTION
MULTIPLEX DISPLAY UNIT "A" (in the dashboard)
MULTIPLEX "B" CONTROL UNIT MULTIPLEX "C" CONTROL UNIT MULTIPLEX "E" CONTROL UNIT MULTIPLEX "D" CONTROL UNIT MULTIPLEX "F" CONTROL UNIT MULTIPLEX "G" CONTROL UNIT
POWER SUPPLY BUTTON +DIR POW. SUP. +DIR POW. SUP. +DIR POW. SUP. MULTIPLEX CAN MULTIPLEX central control central control right headliner CASE “A” left headliner CASE “A” right headliner CASE “A” left headliner CASE “A”
KAS DISPLAY SLAVE DISPLAY MASTER CONTROL UNIT
color
light blue
white
yellow
grey
blue
brown
black
red
green
white - blue
white - black
white - red
white - green
Functional electrical
yellow - black Scheme -A- “Supply”
“Starting and charging”
yellow - green
CAN-BUS COMMUNICATION AND DIAGNOSTICS CAN-BUS COMMUNICATION AND DIAGNOSTICS CAN-BUS COMMUNICATION AND DIAGNOSTICS
Summary diagram of MULTIPLEX centerline serial connections Screen summary of the links SAE CAN-BUS J1939 LINE 1 Summary diagram connecting the SAE CAN-BUS J1939 OBD
JUMPER ONLY WITH GEARBOX
CAN-BUS COMMUNICATION AND DIAGNOSTICS CAN-BUS COMMUNICATION AND DIAGNOSTICS CAN-BUS COMMUNICATION AND DIAGNOSTICS
OBD DIAGNOSTIC
+(30) POWER SUPPLY +(15) POWER SUPPLY
SOCKET MULTIPLEX PROMISATION / DIAGNOSIS SOCKET
PREDISPOSITON OBD SOCKET OBD SOCKET
Diagnosis Button and Display Management

Diagnosis Button and Display Management - / BUTTON LINE 2 LINE 1 LINE 2 TERMINATION OBD LINE
CHANGE PAGE / RANGE SELECTION
+ / BUTTON M ‘K’
OBD DIAGNOSTIC
SOCKET
COLOR
light blue
white
yellow
grey
blue
brown
black
red
green
white - blue
white - black
white - red
white - green
yellow - black
yellow - green FUNCTIONAL ELECTRIC SCHEME
-B- 'CAN-BUS' AND DIAGNOSTICS
CHECKS AND REPORTS CHECKS AND REPORTS CHECKS AND REPORTS
WARNING LIGHTS / SYMBOLS - SIGNALLING
ENGINE RADIATOR PREHEATER BATTERY AdBlue FUEL PARKING BRAKE STORAGE TANK B.P. STORAGE TANK B.P. AIR FILTER CONDENSER SUSPENSION FUEL LEVEL 2nd AXLE 1st AXLE 3rd AXLE
COMPARTMENT DOOR DOOR DOOR DOOR DOOR LIMIT SWITCH PRESSURE SWITCH PRESSURE SWITCH PRES. SWITCH SEPARATOR AIR PRES. TRANSMITTER BRAKE AIR PRES. BRAKE AIR PRES. BRAKE AIR PRES.
ACTIVE FRONT FOG LAMPS ACTIVE REAR FOG LAMPS
DOOR LIMIT LIMIT LIMIT LIMIT LIMIT INSERTED II AXLE III AXLE CLOGGED SOLENOID VALVE TRANSMITTER TRANSMITTER TRANSMITTER TRANSMITTER
ACTIVE WATER yellow ACTIVE yellow green yellow
LIMIT SWITCH SWITCH SWITCH SWITCH SWITCH SWITCH
CIRCUIT VALVE SPEED LEVEL LEFT SIGNAL LAMP
ACTIVE yellow ACTIVE yellow yellow red

ABS ACTIVE OR
DRIVER HEATER PASSENGER HEATER BRAKE SYS. FAILURE
ABS MALFUNCTION
ESP ACTIVE OR ESP MALFUNCTION yellow
DEACTIVE WITH CROSSED SYMBOL
ACTIVE yellow yellow red green
PREHEATER
PREHEATER ACTIVE PARK. BRAKE ACTIVE RETARDER
ACTIVE yellow ACTIVE yellow yellow red

DOOR DEFROST WINDOW DEFROST WATER IN FUEL HIGH COOLANT TEMP.
ACTIVE yellow yellow

MIRRORS DEFROST
yellow
red
REPEATER DOORS OPEN

PASSENGER STOP yellow
red BUTTON PRESSED
ACTIVE POSITION LAMPS ACTIVE HIGH BEAM BRAKE PAD WEAR DETECTED
green blue green yellow red
RIGHT SIGNAL LAMP EBS MULFUCTION
BATTERY
red red yellow
ENGINE OIL PRESSURE ASR ACTIVE OR DISABLED
yellow yellow
ACT. DISABLED PAS. BUT. DIS. RAMP NOT
COMPLETELY RETURNED
yellow yellow
LOW FUEL LEVEL ADBLUE TANK
yellow MAXIMUM ENGINE SPEED

ENGINE MALFUCTION MULFUCTION ON DEF THRESHOLD EXCEEDED
INDUCEMENT: LIGHT LEVEL yellow yellow
LONG LAMP, MEDIUM LAMP red
SPEED FIXED SEVERE LEVEL red
yellow
red
WARNING
(MESSAGE OF MISERS
ON THE DISPLAY)
CONTACT CLOSED
Y=MODERATE R=SEVERE
CONTACT CLOSED CONTACT CLOSED CONTACT CLOSED CONTACT CLOSED WITH ACTIVATED
AT CLOSED DOOR AT CLOSED DOOR AT CLOSED DOOR AT CLOSED DOOR LEVER
CONTACT CLOSED CONTACT CLOSED CONTACT CLOSED

WITH AIR IN WITH AIR IN WITH AIR IN
CHECKS AND REPORTS CHECKS AND REPORTS DISCHARGE DISCHARGE DISCHARGE CHECKS AND REPORTS
CHECK AND REFILL ENGINE OIL Pt 500 TEMPERATURE
SENSOR
BODY WATER IN FUEL SENSOR
DIGITAL TACHOGRAPH TACHOGRAPH
TRANSMITTER
ENGINE COOLANT LEVEL LEVEL SWITCH AND WARNING LIGHT ENGINE OIL LEVEL TEQ CONTROL UNIT ENGINE OIL LOW LEVEL SWITCH LOW LEVEL SWITCH ENGINE WEBASTO SUPPORT DASHBOARD SELENOID VALVE BRAKE PRESSURE SWITCH
LOW MAX WATER TANK LEVEL LOW SOLENOID TO REFILL ENGINE OIL LEVEL SENSOR FOR FOR COMP. COMP. CONTROL SWITCH (OPT.) UNLOCKED
UREA VALVE FOR IN SUMP IN SUMP HYDRAULIC PUMP HYDRAULIC
ENGINE OIL FILLING OIL TANK STEERING WHEEL
ISOLATED JUMPERS IN THE CASE OF A DIGITAL TACHOGRAPH

COLOR
light blue
white
yellow
grey
blue
brown
black
red
green
white - blue
white - black
white - red
white - green
yellow - black
-C- 'CHECKS AND REPORTS'
VEHICLE HANDLING VEHICLE HANDLING DOOR CONTROL 2-3(STD) DOOR CONTROL 4(STD)
DOOR CONTROL 2(OPT) DOOR CONTROL 3(OPT) DOOR CONTROL 4(STD)
DOOR COMMAND 1
POTENTIOMETER POTENTIOMETER
EXTERNAL INTERNAL DIVERTER DOOR 1 ELECTROPNEUMATIC VENTURA DOOR 2 ELECTROPNEUMATIC VENTURA
OPEN DOOR
EXTERNAL SEMI-DOOR LOCK SWITCH (OPT) LIGHT DOOR “1” DOOR “2” DOOR LEAF DOOR LEAF
ON-OFF BUTTON ON-OFF FRONT REAR “1” FRONT “2” REAR ON-OFF OPEN DOOR ON-OFF OPEN DOOR ON-OFF OPEN DOOR
BUTTON BUTTON LIGHT BUTTON LIGHT BUTTON LIGHT
VEHICLE HANDLING VEHICLE HANDLING

POTENTIOMETER POTENTIOMETER WHEEL RELEASE
DOOR 3 ELECTROPNEUMATIC VENTURA
DOOR “1” DOOR “2” DOOR “1” DOOR “2” VEHICLE LOCK STOP BY-PASS ENGINE ENGINE COMP. BUTTON SOLENOID VALVE
FRONT REAR FRONT REAR WITH OPEN BRAKE REVOLUTIONS REVERSE GEAR DOOR/REVERSE GEAR BUZZER EXCLUSION BUTTON
DOORS BY-PASS SWITCH LIMITING BLOCK BUZZER BY-PASS SIGNALING BUZZERS OPEN DOOR FOR
SWITCH AT LOW TEMP. SWITCH CASE “A” DISABLED PASSENGERS
FRONT CENTER”A” CENTER”A” REAR
Functional
electrical scheme -D1- “Doors”
VEHICLE HANDLING VEHICLE HANDLING VEHICLE HANDLING
AUTOMATIC TRANSMISSION ZF - ECOLIFE
BUTTON
SWITCH GEAR ENGAGEMENT +24V T.G.C. +24V KEY CAN BUS SAE J1939 LINE 1 CAN BUS SAE J1939 LINE 1 ASR OFF ROAD RETARDER BY-PASS GEAR ENGAGEMENT POWER POWER GEAR NEUTRAL ISO K-LINE CAN BUS SAE J1939 LINEA 1 OPTIONAL RETARDER CONTROL LEVER SWITCH DOOR GEAR BREAK
SUPPLY ECONOMY RELEASE GEAR UNLOCK RELEASE RELEASE
SUPPLY PUSHBUTTON PUSHBUTTON
BUTTON BUTTON BUTTON
VEHICLE HANDLING EBS3 WABCO 3 AXLES 4S/4M

VEHICLE HANDLING
ACTIVATION
CAN J1939 LINE 1 BRAKING SIGNAL TRANSMITTER EBS3 WABCO 3 AXLES 6S/6M OPTIONAL BUTTON
+(15) +(30)A +(30)B

BRAKE STOP
AXLE 2 MODULE CASE “A” AXLE 3 MODULE CASE “A”
VEHICLE HANDLING
STEERING ANGLE SENSOR HILL HOLDER
PREPARATION 1st AXLE RIGHT WHEEL 1st AXLE LEFT WHEEL FRONT RIGHT 1st AXLE RPM SENSOR FRONT RIGHT BRAKE WEAR RPM RPM SENSOR BRAKE WEAR BRAKE WEAR RPM RPM SENSOR BRAKE WEAR
ABS SOLENOİD VALVE ABS SOLENOİD VALVE WHEEL BRAKE RIGHT WHEEL LEFT WHEEL WHEEL BRAKE SENSOR LEFT SENSOR LEFT RIGHT SENSOR RIGHT SENSOR LEFT SENSOR LEFT RIGHT SENSOR RIGHT HALT BRAKE
WEAR SENSOR WEAR SENSOR
color
light blue
white
CABLE COLORS
yellow
grey
blue
brown
black
red
green
white - blue
white - black
white - red
white - green
yellow - black
yellow - green Functional electrical scheme
-D2- “Gearbox”
EXTERNAL
VEHICLE HANDLING FORCED FILTER HEAT RESISTANT RELAY-SUCTION
BRAKE
PEDAL
ENGINE CONTROL
UNIT POWER POWER ENGINE CONTROL UNIT FUEL FILTER
VEHICLE HANDLING
REGENERATION BUTTON FAB OIL FILTER SWITCH SUPPLY RELAY RESISTANCE RELAY
TEMPERATURE PROBE PREHEAT RESISTANCE SUPPLY POWER SUPPLY
POWER
CAN J1939 LINEA 1 DOC/SCR/Nox
RELAY
ENGINE STARTING RELAY
ACCELERATOR PEDAL ADBLUE COOLING AUTOMATIC REGENERATION ENGINE CONTROL UNIT POWER SUPPLY KEY 50 FOR
ECU/RA OIL HEATING
SYSTEM INHIBITION FAB ENGINE START
MOTOR POWER FILTER RELAY(OPT.)
ELECTROPUMP SUPPLY
CONNECTION

ADBLUE TANK
WATER PRESENCE WATER HEATER
NOX DOC UPSTREAM SENSOR NOX DOC DOWNSTREAM SENSOR NH3 SENSOR PM SENSOR(PARTICULATE) HUMIDITY AND AIR POWER SUPPLY SENSOR SOLENOID VALVE INJECTOR
TEMPERATURE SENSOR +24V. SWITCH ADDITIONAL ADBLUE MODULE DOSER EXHAUST GAS TEMPERATURE SENSORS
MOTOR FUEL CLOGGED SENSOR ECU SENSOR ECU SENSOR ECU SENSOR ECU LINEA PRESSURE PRESSURE SENSOR SOLENOID VALVE PUMP DOC UPSTREAM DPF UPSTREAM SCR UPSTREAM SCR DOWNSTREAM
COUPLING TEMPERATURE FUEL UQS ADBLUE QUALITY ISO K DIFFERENCE
SENSOR FILTER SENSOR LEVEL AND TEMP. CAN J1939 LINEA OBD SENSOR (P)
SENSOR MODULE
color
light blue
white
yellow
grey
blue
brown
black
red
green
white - blue
white - black
white - red
white - green
yellow - black
-D3- “Motor”
ELECTRONIC SUSPENSION CONTROL WABCO (ECAS) CASE “A” ELECTRONIC SUSPENSION CONTROL WABCO (ECAS) CASE “B” LIFTING / LEVEL 1-2 ECAS
BUTTON KNEELING / RESET ECAS BUTTON
SOLENOID VALVE GROUP CASE “A” LEVEL SENSORS
REAR REAR FRONT FRONT +24V +24V KEY CAN J1939 LINE 1 CAN J1939 LINE 1 +24V +24V KEY SOLENOID VALVE GROUP CASE “B” REAR REAR
LEFT RIGHT LEFT RIGHT T.G.C. T.G.C. LEFT RIGHT
LIFTING
LEVEL 1-2 KNEELING
WABCO CONTROL UNIT ECAS BUS CAN 4 CHANNELS ELECTRONIC SUSPENSION CONTROL WABCO CONTROL UNIT ECAS BUS CAN 2 CHANNELS ELECTRONIC SUSPENSION CONTROL

PROPORTIONAL ENGINE COOLING FAN SYSTEM BOSCH ELECTRONIC CONTROL UNIT
SOLENOID VALVE
ELECTRONIC CONTROL UNIT FOR STABILIZATION BELLOWS CONTROL +24 POWER SUPPLY BRAKE SWITCH
+24V KEY
ISO K-LINE CAN J1939 LINE 1 BELLOWS CONTROL UNIT EMERGENCY BUTTON SOLENOID VALVE ON/OFF DIAGNOSIS SOCKET CAN LINE
ECU GEARBOX ECOLIFE
DIAGNOSIS SOCKET
color
light blue
white
yellow
grey
blue
brown
black
red
green
white - blue
white - black
Functional electrical scheme
white - red
white - green -D4- “ECAS” “WHEEL”
yellow - black “ECU BOSCH” HYRAULIC PUMP

yellow - green
LIGHTING LIGHTING LIGHTING
EXTERNAL LIGHTING LEFT FRONT LAMPS RIGHT FRONT LAMPS LEFT REAR LAMPS RIGHT REAR LAMPS
MODULE SIDE MARKER LAMPS
BRIGHTS MODULE TRIPLE MODULE TRIPLE MODULE
SIGNAL LAMPS SWITCH FIXED FLASHING LOW BEAM POSITION POSITION LOW BRIGHTS FOG PARK SIGNAL POSITION LOW BRIGHTS FOG PARK SIGNAL LEFT-RIGHT STOP POSITION SIGNAL REVERSE REAR STOP POSITION SIGNAL REVERSE REAR EMERGENCY LIGHT SWITCH
LEFT HIGH BEAM LIGHT SWITCH BEAM LAMPS LAMPS BEAM LAMPS LAMPS GEAR FOG GEAR FOG
SIGNAL
REAR FOG LAMPS
RIGHT FLASHING
SIGNAL
LEFT RIGHT
POSITION FOG LAMPS
BRIGHTS REAR FOG
+24V REAR FOG LAMP
LIGHTING INTERNAL LIGHTING BUTTON 3a SERIES LIGHTING

3a SERIES/DRIVER LIGHT PREDISPOSITION ARTICULATION INTERIOR LIGHTING
FRONT SIDE LAMPS SIDE MARKER 1a SERIES 2a SERIES 1a SERIES 2a SERIES
REAR SIDE LAMPS LIGHTS
LAMPS PLATE LAMPS
CASE “A” CASE “B” DOOR LIGHTING REAR LIGHT SWITCH ON DASHBOARD
RAMP SIDE
LEFT RIGHT LEFT CASE “A” RIGHT CASE “A” MARKER LIGHTS LEFT RIGHT LEFT RIGHT INTERNAL LIGHTING BUTTON DRIVER LIGHTS LEFT RIGHT BLUE LIGHTS FRONT REAR LEFT RIGHT FRONT CENTER A CENTAR B REAR
LEFT CASE “B” RIGHT CASE “B” 1a/2a SERIES RIGHT ENGINE COMPARTMENT
LIGHTING BY-PASS SWITCH
REAR LIGHTNING
FRONT DASHBOARD CONTROLS
color
light blue
white
CABLE COLORS
yellow
grey
blue
brown
black
red
green
white - blue
white - black
white - red
white - green
yellow - black
-E- “Lighting”
AUTONOMOUS
HEATING BUTTON
VARIOUS SERVICES VARIOUS SERVICES DRIVER HEATING
ADDITIONAL ELECTRIC VARIOUS SERVICES
DEFROSTER DRIVING SEAT FAN BUTTON (106A) PASSENGER HEATING BUTTON (105)
DIESEL PREHEATER SYSTEM WEBASTO
INTERNAL IGNITION WINDSHIELD FAN ADJUSTMENT (106E) DUAL-CHAMBER AIR DRYER
ELECTRIC FAN ELECTRIC FAN
CASE “A” CASE “B”
PRE-HEATER SOLENOID EXTERNAL IGNITION

SWITCH INDICATOR WK MPX EMERGENCY RELAY HEATING DEFROSTER THERMOSTAT DEFROSTER EXTERNAL RECIRCULATION BUTTON (106C) RECIRCULATION 1st 2nd 3rd 4th PT 500 INTERNAL RESISTANCE SOLENOID VALVE
VALVE FAN A.C. DRIVER SOLENOID VALVE DEFLECTOR TEMPERATURE SENSORS
BUTTON CONTROL MOTOR
INTERNAL/EXTERNAL
VARIOUS SERVICES STOP REQUEST SYSTEM

VARIOUS SERVICES VARIOUS SERVICES
DEFROST SWITCH RELAY
STOP REQUEST BUTTONS CASE “A” 1st SPEED WIPER SYSTEM AND HORNS
EXTERNAL MIRRORS STOP REQUEST BUTTONS
MOTORIZED EXTERNAL / INTERNAL MIRRORS STOP REQUEST CASE “B” TRUMPETS BUTTON/TVCC PORTE PNEUMATIC HORNS
CASE “A” CASE “B”
RELAY
LEFT RIGHT LEFT RIGHT 2nd SPEED
LEFT MIRROR JOYSTICK RIGHT MIRROR INTERIOR MIRRORS SINGLE BEAT EXIT LIGHT ADDITIONAL SIGNS WIPER MOTOR WASHER MOTOR COMMUTATOR DEFLECT GUIDE HORN SOLENOID VALVES HORNS
REQUEST STATIONS
RINGER
color
light blue
white
yellow
grey
blue
brown
black
red
green
white - blue
white - black
white - red
white - green
yellow - black Functional electrical scheme
yellow - green -F1- “Various Services” 1
VARIOUS SERVICES VARIOUS SERVICES
TICKET VALIDATION SYSTEM
DRIVER SEAT AIR CONDITIONING "THERMO KING" PASSENGER AIR CONDITIONING SYSTEM CAN1 GPS-GSM BOARD MODULE HATCH BUTTON CASE “A” FRONT ELECTRIC HATCH CASE “A” REAR ELECTRIC HATCH CASE “B”
HANDLING OB/EMITTER ENABLING BUTTON
HATCH BUTTON CASE “B”
CASE “A” CASE “B” HANDLING
A/C SWITCH TEMP. A/C INSERT SOLENOID CAN MPX TEQ PREPARATION MOTOR 2 MOTOR 1 MOTOR 2 MOTOR 1 EMITTING OB. OB FRONT LEFT OB REAR LEFT
A / C ENABLED PROBE INDICATOR VALVE CAN LINEA 1 CONTROL OB FR. RIGHT OB REAR RIGHT
INDICATOR A.C. DRIVER
VARIOUS SERVICES VARIOUS SERVICES VARIOUS SERVICES

SOUND SYSTEM - RADIO
AVAILABLE CONNECTION FOR INTEGRATED SYSTEMS THERMAL VIDEO SIGNS/RADIO FM ENABLE BUTTON SPEAKER SWITCH
SURVEILLANCE POWER SUPPLY - AVM SIGN INDICATOR SYSTEM
SIGNS
DRIVER AND PASSENGER
AVAILABLE CONNECTOR FOR TVCC SYSTEM CONNECTOR A : SIGNALS / RS485 SIGNS CONNECTOR B : AVAILABLE CABLES ON THE AVM CONTROL POWER +(30) SIDE “A” INTERNAL SIDE “B” REAR “B” CD/CASSETTE MICROPHONE ANTENNA LEFT CHANNEL SPEAKERS RIGHT CHANNEL
COMPARTMENT AT THE BACK OF THE DRIVER UNIT SUPPLY FRONT PLAYER
RELAY
CAMERA - MONITOR POWER SUPPLY
ANOMALY VIDEO SURVEILLANCE
CENTER DOOR CASE “B”
CENTER DOOR CASE “B”

CENTER DOOR CASE “A”
CENTER DOOR CASE “A”

FRONT DOOR OPEN
MOTOR IN MOTION
AVAILABLE CABLES
AVAILABLE CABLES
AVAILABLE CABLES
AVAILABLE CABLES
AVAILABLE CABLES
REAR DOOR OPEN
REVERSE GEAR
SPEED SIGNAL
FRONT DOOR
DOOR OPEN
REAR DOOR
color
light blue
white
yellow
grey
blue
brown
black
red
green
white - blue
white - black
white - red
white - green
yellow - black
-F1- “Various Services” 2
VARIOUS SERVICES VARIOUS SERVICES VARIOUS SERVICES
RADIO-TELEPHONE SYSTEM
TRANSCEIVER SWITCH DISABLED PASS. ACCESS PLATFORM DISABLED PASS. WHEELCHAIR AREA CONTROLS (+15) FREE
PREPARATION
ENABLE BUTTON
DISABLED PAS. AREA / PLATFORM CONTROLS
SENSOR SENSOR SENSOR EDGE SENSITIVE PLATFORM PLATFORM EXIT ENGINE RETURN TO REPORTING POWER SUPPLY PORTS 3-4 ASSISTANCE MOVEMENT
BLOCK
STOP REQUEST WARNING LIGHT ON WARNING LIGHT ON (OPT.) ADDITIONAL STOP LIGHT
‘OUTSIDE’ ‘INSIDE’ ‘LOAD 15kg’ OBSTACLES ON EXIT CONTROL RELAY PLATFORM PLATFORM MOVING PLATFORM BUTTON CONSENT
ACTUATOR CONTROL RELAY CEILING RINGER BUTTON BUTTON INDICATION THE CONTROL PANEL THE CONTROL PANEL RESERVED WITH HALF-BRIGHTNESS
MANUAL PLATFORM
SENSOR ‘OUTSIDE’
1/2 STOP
REQUEST LIGHT
PLATFORM ‘BODE’
RADIO-TELEPHONE SYSTEM
(+30) FREE
TRANSCEIVER SWITCH VARIOUS SERVICES VARIOUS SERVICES VARIOUS SERVICES PREPARATION
PREDISPOSITION OF ERAR FIRE SYSTEM DEFROSTER SWITCH DEFROSTER SWITCH
DOOR GLASS WINDOW
SUPPLY
+DIR
ANTIFIRE FREE
COMMAND RELAY RESISTANCE COMMAND RELAY RESISTANCE PREPARATION (+DIR) AVALIABLE
PREPAR. PREPAR. PREPAR. AVAILABLE BELLOWS
ANTI FIRE DEFROSTER SWITCH PREPAR. PREPAR. GAS SUPPLY SUPPLY HOUSING PASSAGE 'F' CENTER-LEFT POWER SUPPLY LINE K CLUSTER INLET+/- WAKE UP
COMMAND DOOR GLASS / WINDOW +L +L SENSOR 5V +DIR FROM 9103G CONNECTOR AVAILABLE AVAILABLE INPUTS PREDISP. IN BATTERY IBS AVALIABLE AVALIABLE
RELAY MULTIPLEX MULTIPLEX FUSE 500917 IN THE ENGINE INSTRUMENT PANEL AVALIABLE BELLOWS PASSAGE COMPARTMENT
OUTPUTS AND INPUTS - PREPARED FOR VARIANTS COLOR

light blue
white
password control unlock button yellow
preheating ON grey
3A USB power outlet blue
sensitive edge exclusion switch brown
firefighting ERAR
black
low tank pressure I
red
low tank pressure / anti-fire command
green
low tank pressure II
white - blue
stop request buzzer - CASE B
white - black
stop request button
white - red
white - green
yellow - black
-F3- 'VARIOUS SERVICES' + AVALIABLE
Circuit 1 Circuit 2 Circuit 3 Circuit 4 Circuit 5
Suspension Suspension Suspension Pressure (bar)
Dynamic opening
Orifice 21 Orifice 22 Orifice 24 Orifice 25 Orifice 26
pressure
Dynamic
closing
pressure
Pressure
limitation
Test pressure
case “B”
Condensate drains
Test pressure
case “A”
Driver's seat
Bitonal horns
Parking Brake Parking Brake
Door case “A”
EBS modulator (Drive axle)

Steering wheel unlock
EBS modulator (Additional axle)
EBS modulator
Brake distributor
Air intake valve

Limiting valve
Solenoid valve ABS

5,7 bar pressure switch
Relay valve
Parking brake lever

Solenoid valve block
Air filter
Pressure transmitter
Solenoid valve ECAS
Solenoid valve ECAS

Air intake valve
Filling valve 1/2”
Non-return valve
Condensation separator
Air reservoir 1,6 lt

Distance sensor
Front Brake
2nd axle brake 3rd axle brake Double-chamber dryer
Protection valve
Air reservoir 30 lt
Air reservoir 4 way
Air reservoir 4 way
Air reservoir 4 way

Air reservoir 4 way
General scheme for pneumatic systems

Installation of the C24, D7, D29m and
X5-III-12CH, D9forMDVR etc. – SIBIU l
Installation of the C24, D7, D22m and X5-III-12CH, etc.
SIBIU
Summary
This document describes how to install a Thoreb vehicle system based on a C24, D7,
D29m (master), D29m (master) APC and a video surveillance system consisting of the
X5-III-12CH with cameras. The document also gives general information about how
to connect other peripherals.
Page 1
 THOREB 2018 D:\DOCUMENTE DESKTOP\PROIECTE\ROMANIA\SIBIU\2018\DOCUMENTATIE PE LIVRARE\INSTALLATION OF THE C22, D7 AND X5 FOR 8 CAMERAS, D22, ETC.DOC
Document no. 10xxxen Rev. 1 Type Thoreb H No. of pages 37 Approved date 2018-..- ...
Printed 18-07-17 17:31:00 Publisher Andreea Dobrin Examiner Claudiu Moiseanu Approved by
Contents
1. CONNECTOR OVERVIEW ......................................................................................................... 4
1.1 C24 ......................................................................................................................................... 4
1.2 D7........................................................................................................................................... 6
1.3 TRIPLE ANTENNA FOR 3G / GPS ............................................................................................. 7
1.4 X5-III-12CH VIDEO RECORDER ............................................................................................. 7
1.5 ETHERNET SWITCH FOR VIDEO RECORDER............................................................................. 8
1.6 D9 RECORDER DISPLAY ......................................................................................................... 9
1.7 PASSENGER COUNTING UNIT .................................................................................................. 9
1.8 NETWORK SWITCH................................................................................................................ 10
1.9 D29M .................................................................................................................................... 11
1.10 WIFI FOR PASSENGERS.......................................................................................................... 12
1.11 AMPLIFIER ............................................................................................................................ 13
1.12 RF-ID READER...................................................................................................................... 13
2. GROUND CONNECTIONS IN GENERAL .............................................................................. 15
3. THE C24 ........................................................................................................................................ 15

3.1 POWER SUPPLY, PASSENGER SPEAKERS AND SIGNALS TO THE C24...................................... 15
3.1.1 The Alert inputs......................................................................................................... 16
3.1.1.1 Main Switch................................................................................................................ 16
3.1.1.2 Door Signal ................................................................................................................. 16
3.1.2 Passenger Speakers .................................................................................................. 17
3.1.3 Outside Bus Speakers-not used in this project .......................................................... 17
3.1.4 Audio announcement schematics details................................................................... 17
3.1.5 FMS– or other CAN network .................................................................................... 18
3.1.6 Driver’s Microphone (including telephony) ............................................................. 18
3.2 3G......................................................................................................................................... 18
3.3 GPS ...................................................................................................................................... 18
3.4 WIFI - NOT USED ................................................................................................................... 19
3.5 ADDITIONAL UNIT, E.G. DIAGNOSTIC LAPTOP (OPTIONAL) .................................................... 19
4. D7 .................................................................................................................................................... 19
4.1 POWER SUPPLY TO THE D7 AND C24 COMMUNICATION ....................................................... 19
4.2 COMMUNICATION WITH DESTINATION SIGNS ....................................................................... 19
5. X5-III-12CH VIDEO RECORDER ............................................................................................. 20
5.1 VIDEO RECORDER AND MDVR SWITCH POWER SUPPLY ..................................................... 20
5.2 ETHERNET NETWORK CONNECTION ..................................................................................... 20
5.2.1 Hard Disc Drive (HDD) ........................................................................................... 20
5.3 CONNECTING CAMERAS........................................................................................................ 20
5.4 D9 RECORDER DISPLAY ....................................................................................................... 21
6. CONNECTING D29M INFOTAINMENT UNITS .................................................................... 22
6.1 POWER SUPPLY ..................................................................................................................... 22
6.2 ETHERNET COMMUNICATION ............................................................................................... 22
7. CONNECTING D29S INFOTAINMENT UNIT........................................................................ 22
7.1 POWER SUPPLY ..................................................................................................................... 22
7.2 DVI CABLE COMUNICATION TO THE D29M ........................................................................... 22
8. PASSENGER COUNTING UNITS ............................................................................................. 22
8.1 POWER SUPPLY AND DOOR SIGNAL ...................................................................................... 23
9. NETWORK SWITCH .................................................................................................................. 24
10. DIMENSIONS AND INSTALLATION ...................................................................................... 25
Page 2
10.1 C24 ....................................................................................................................................... 26
10.2 D7......................................................................................................................................... 27
10.3 NETWORK SWITCH................................................................................................................ 28
10.4 DOUBLE ANTENNA ............................................................................................................... 28
10.5 AUTOMATIC PASSENGER COUNTING UNIT............................................................................ 29
10.5.1 Installation Kit .......................................................................................................... 31
10.6 X5-III-12CH ........................................................................................................................ 32
10.6.1 LED Indicators ......................................................................................................... 32
10.7 MDVR SWITCH..................................................................................................................... 33
10.8 D9 RECORDER DISPLAY ....................................................................................................... 33
10.9 CAMERA ............................................................................................................................... 35
11. TESTS MADE TO VERIFY THE INSTALLATION ............................................................... 36
11.1 TEST OF THE 3G COMMUNICATION ....................................................................................... 36
11.2 TEST OF GPS RECEPTION ...................................................................................................... 36
12. OPERATING ROUTINES ........................................................................................................... 36
13. SUMMARY OF ARTICLE NUMBERS ..................................................................................... 37
Page 3
Introduction
This document describes how to install a Thoreb IT system based on a C24, D7, and a
video surveillance system consisting of the X5-III-12CH with cameras. The document
also gives general information about how to connect other peripherals to the Thoreb
system.
1. Connector Overview
1.1 C24 Connectors to the Triple antenna
for
3G GPS
WiFi
Opening for change of
SIM card
USB
P4
P3
P2
P1 Ethernet and
Power supply from the bus
adv. PoE
battery, input signals,
FMS, speakers, etc. to D7
to network
spare switch
The following connectors/cables are used together with the C24, art. no. 17823P-P03:
Connector Type
USB M12-4 A coded Cable M12-4 A code / USB type A connectors (optional)
pin housing
C22 USB
Page 4
P1 42 pos. AMP
socket housing
42 pos. AMP socket housing,

art. no. 17654A-P01
P1
Backshell, art. no. 17654B-P01
Socket DCS, art. no. 11399, 1-2.5 mm2
Socket Micro-Timer, art. no. 11440, 0.5-1 mm2
P2-P4 M12-8 A-coded Ethernet and Advanced PoE from the C24
pin housing Standard straight cable M12-8 A-coded to M12-8 A-coded, 24
AWG, shielded CAT5
Standard straight cable M12-8 A-coded to RJ45, 24

AWG, shielded CAT5
Eth
GPS SMA (m)

WAN (3G) SMA (m)
WiFi SMA (m)
Pinning
P1 Output Unit Supply P2-P4 aPoE
2. Lowside out 1.- amplifier actv. 28. +24 V supply in, red 1. +48 V
5. Lowside out 2 14. GND supply in, black 2. GND
15. High side out – 20A 3. GND
CAN 4. Eth TX-
Alert Inputs 3 CAN-H C 5. Eth RX+
6. Inp low 1, 4 CAN-L C 6. Eth TX+
10. Inp low 2 16. CAN H B - elsy 7. +48 V
19. Inp high 2 (door signal) 17. CAN B term. H - elsy 8. Eth RX-
22. Inp high 1 (Ignition) 18. CAN L B - elsy
30. CAN H A
Speaker 31. CAN A term. H
7. SPK1 + 32. CAN L A
8. SPK1 –
35. SPK2 for outside bus + SGND
36. SPK2 for outside bus– 25. SGND
29. SPK2 + driver - telephony 34. SGND
42. SPK2 – driver telephony 39. SGND
Driver’s Microphone 24. Odometer signal in

37. Driver mic. in
39. GND Inputs
1. Req. to talk 20. Inp 1, +, -
26. Inp 2, +, -
RS485
23. RS485-A
9. RS485-B
RS232
11. RS232 Tx, brown
12. RS232 Rx, white
25. SGND
GPS GPS antenna USB1 For software
Page 5
update/transfer
WAN 3G antenna
WLAN WiFi antenna - not used
Use
crimping tool art. no. 14432L-P00 for the JPT sockets
crimping tool art. no. 14432M-P00 for the Micro-Timer sockets
Do also see section 9.1.
1.2 D7
The D7 is designed to be waterproof. Therefore its connectors are selected with that in
mind. To facilitate installation the D7 unit is supplied with adapting cables.
P1 P2
P3
The following connectors/cables are used together with the D7, art. no. 17794B-P03:
Connector Type
P1 M12-4 A-
coded pin D7 P1 RS485
housing
P2 M12-8 A- Ethernet and Advanced PoE from the C24
coded pin Standard straight cable M12-8 A-coded to M12-8 A-coded, 24 AWG, shielded CAT5
housing
P3-not M12-4 D- 1 2
used in this coded pin
D7 P3 Vin 1
project housing
(not used in 4 3
this project)
Pinning
P1 RS485 P2 aPoE
1. RS485-A 1. +48 V 5. Eth RX+
2. RS485-B 2. GND 6. Eth TX+
3. GND 7. +48 V
4. Eth TX- 8. Eth RX-
P3 1. Vin 1
2. Vin 2
3. Vin 3
4. SGND
Page 6
1.3 Triple Antenna for 3G / GPS

Ø 70
15
Grounding
housing 4.5
Ø19
22
The following connectors are used together with the Triple antenna, art. no.
14207N-P00:
Connector Type
GLON (GPS), GSM (3G), SMA (f)
Each cable is labelled with its usage. Do also see section 9.4.
1.4 X5-III-12CH Video Recorder
AV
Rear
Supply Eth
The following connectors and cables are used together with the unit art. no. 17999B-
P01:
Connector Type
AV Din Jack 4 socket housing
AV-IN 1-8 (Video Input 1-8,
camera 1-8), NOT USED IN
THIS PROJECT
AV-OUT (for connecting the D9)
AV
AV-in Camera
Eth RJ45 Strait Ethernet Cable
Page 7
Supply Din Jack 9 socket housing
1.5 Ethernet Switch for Video Recorder
DVR switch art no 17931B-P01 is used to power feed video surveillance camera over
POE line.
Connector Type
Connection between DVR and DVR Ethernet Straight CAT 7 - RJ45
SWITCH(audio - video - signal)
Connection between DVR SWITCH and Ethernet Straight CAT 7 - RJ45
Cameras (audio - video - signal and
power)
Power connectors Common with DVR Power Connector
Page 8
1.6 D9 Recorder Display
AV/Supply
The following connectors and cables are used together with the unit art. no. 16199A-
P01:
Connector Type
AV
Din Jack 4
socket housing
AV-out Display
Supply 4 pos. socket See the illustration above

housing
(Do also see section 9.9.)
1.7 Passenger Counting Unit
The following connectors and sockets are used together with the unit, art. no. 17302E-P01.
Connector Name
Input signals & PwSupply 14 pos connector, art. no. 17304A-P01
Ethernet Comm M12-4 D coded
Page 9
1.8 Network Switch
Power
Power
V2- 4
V2+ 3
V1- 2
V1+ 1
The following connectors sockets are used together with the unit, art. no. 14739A-P00:
Connector Name Sockets
Ethernet RJ45
Power Included with the network switch AMP 0,5-1,0 mm2
art. no. 11440
Page 10
1.9 D29m
DVI
GPS antenna
3G
antenna
USB
SIM
card USB
Connectors Eth
underneath a
cover plate.
The following connectors are used together with the D29m, art. no. 16211A-P01:
Connector Name Pinning
P1 Socket housing Unit Supply IBIS (slave)
IL-AG5 30 pos. 1. +12-35 V supply 20. Aufruf – P1
art. no. 14163A-P00 2. GND supply 6. Aufruf +
25. Antwort – 1
Line Out 9. Antwort +
8. Line out R -
24. Line out R + IBIS (master) 15
10. Line out L - 13. Aufruf – 30
Socket IL-AG5 26. Line out L + 29. Aufruf +
0.35-0.5 mm² 14. Antwort –
art. no. 11203 Outputs 30. Antwort +
3. Output -
17. Output - Inputs
5. 12 V out (for 7. Input low
Thoreb use) 21. Input high
CAN GND Pins

12. CAN L 15. GND
27. CAN H* 16. GND
28 CAN term* 19. GND
4. SGND
* are joined for 18. SGND
termination
Ethernet RJ45 1. +12-48 V
2. GND
3. GND
4. Eth TX-
5. Eth RX+
6. Eth TX+
7. +12-48 V
8. Eth RX-
DVI DVI-D single link pin Standard pinning To D29s
housing
USB (2x) Type A (m) Standard pinning Not used in this project
GPS / 3G 2x SMA (m)
Not used in this project
anntenna
Page 11
Use crimp tool art no. 11204B-P00 for the IL-AG5 sockets.
Use tool art. no. 11216 for removing the IL-AG5 sockets.
Function Performance
ARM processor, 4 kernels
Operating system Linux
2 Gbyte flash
1 Gbyte RAM
Clock frequency 1.91GHz
Hardware graphics for 3D, 2D and vector graphics
acceleration
Supply voltage 12 to 35 V
Current consumption 1 A @ 24V
Operating temperature -20 to 70 C (display element 0 to +70 C)
Weight ~6.5 kg
Display dimension 29”
Display colors Full-color
TFT LCD
Active area 689.400(H) x 196.425(V)
Resolution 1920 x 540 pixels
Viewing angle
(horizontal) 70°/80° (right/left)
(vertical) 70°/80° (U/D)
Luminance of white 1000 cd/m2
Backlight operating life time 30 000 h
Light sensor
E-certified. Tested according to UN ECE Regulation No. 10, ver 3:2008
1.10 WiFi for passengers
Item Product specification

WIFI WIFI 802.11 b/g/n, 300Mbps
2G/3G GSM/GPRS: GSM850, EGSM900 DCS1800, EDGE GSM850,
900 UMTS:
GPS (optional) GPS/GLONASS, Protocol: NMEA
WIFI Frequency 2.4G
Power Supply DC 5~48V

Working current 2A (Max Current)
Temperature Operating Temperature -40~+75ºC Storage Temperature -45~+85ºC
Environment humidity 95%
Case Aluminum Alloy Shell
Size 115mm*73mm*20mm
Weight 160g
Page 12
1.11 Amplifier
The following connectors are used together with the amplifiers, art no. 16191A-P01.
Connector Name Sockets
P1 Socket housing Socket IL-AG5
IL-AG5 30 pos. 0.35-0.5 mm²
art. no. 14163A-P00 art. no. 11203
1.12 RF-ID reader
Card reader device is meant to be used as a driver ID input to the Multiplex system.
It can be used also as a security system for the bus.
For example: the data base of the vehicle computer (d7) contain the driver ID which
suppose to drive a specific bus during a specific day. In this situation only the owner
Page 13
of that driver card can log in to the system and open the ITC system and as an option,
start the engine (only in vehicles with Thoreb Multiplex).
In any situation the driver-computer, after the driver insert his card in the specific card
holder, the vehicle computer will inject in to the CAN system the driver ID according
with the J1939 specification.
Page 14
2. Ground Connections in General
Bad ground connections can cause interference and potential differences in ground
references. This unavoidably decreases the system’s interference margins, or at worst
causes (mostly intermittent) “inexplicable” malfunctions, which are difficult to locate.
Ring cable terminal
Self-locking nut
Spring washers
Lock washer Ground cables
to nodes
Chassis/body
Figure 1. Example of ground connection

Ground connections to chassis and body shall be clean. Screws in combination with a
nut, should be tightened with a moment of torsion according to your company
standard. Use tin-plated ring cable terminals (if possible zinc-plated), together with
zinc-plated locking washers and spring washers. When all ground cables are attached,
the entire ground connection shall be sprayed with wax or similar, as moisture
protection. If the surface of the ground connection has been treated against rust, a lock
washer is necessary in order to guarantee good conductivity.
3. The C24
3.1 Power Supply, Passenger Speakers and Signals to the C24
The C24 is connected to the bus battery via a 7.5 A fuse by using the cabling art. no.
17813B-P01, length 0.5 m.
Art. No. 16123F-P01,
C24 P1 L = 0.5 m
28. Power supply In 1. + 24 V supply (B+), red
14. Supply GND 3. GND supply, black
19. Door signal brown Optional
4. Door signal, brown
22. Main switch orange P1 CAN A H brown
6. Main switch, orange
30. CAN A H brown CAN A L white
8. CAN A H brown Included in Art.no.
32. CAN A L white 9. CAN A L white
31. CAN A H term. brown 17535X-P04, see section 3.1.3
10. Speaker in (-) yellow
7. Passenger speaker + green 11. Speaker In (+) green
8. Passenger speaker - yellow
13. Req. to talk blue (optional)
1. Req. to talk blue
14. Microphone violet (optional)
2.Lowside out – to activate amplifier
15. GND black (optional)
37. Microphone violet
16. activate amplifier
34. GND black
17. Outside bus speaker+
35. Outside bus speaker+
18. Outside bus speaker-
36. Outside bus speaker-
19. Driver speaker +(telephony)
29.Driver speaker +(telephony)
20. Driver speaker -(telephony)
42. Driver speaker -(telephony)
21. odometer
24. Odometer
22. elsy CAN H-to connect driver ID card reader
16.elsy CAN H
23. elsy CAN L -to connect driver ID card reader
17.elsy CAN L
24. elsy CAN T
18.elsy CAN T
Termination jumper that

can be cut away, see
section 3.1.3 for when to
use it.
Yellow text will indicate that pin is not used in this project.
Page 15
The C24 has two processors; a small processor that is always active and controls when to
turn on and off different parts of the C24 (i.e. the different parts of the powerful Linux
processor). Thereby the C24 only uses 0.5 mA in sleeping mode. Thus a bus can be long-term
parked for 70 days in a row and only use one Amp-hour from the bus's battery.
The C24 will not cut the power to the 3G modem while the C24 communicates with the
central system.
3.1.1 The Alert inputs

The C24 has four alert inputs
• Two inputs activated by a minus signal (P1:6 and P1:10)
• Two inputs activated by a plus signal (P1:19 and P1:22)
The alert inputs always have a voltage, when the C24 has voltage, and can be
used to wake up the C24 from sleeping mode. A switch connected to the inputs
shall normally be open. The alert inputs have a short response time
Examples of how to use an alert input:
• One alert input is connected to a fuel cap micro switch. The switch is open as
long as the fuel cap is closed. As soon as the cap is opened, this will result in a
small current that immediately will be detected by the C24. This means that the
alert inputs normally are not using any energy from the battery.
If someone opens the cap in the middle of the night, it is probably a diesel theft
going on. This activates the C24 to start the 3G communication and the C24
can give power to the DVR which starts recording and streaming of video
images to the control room.
• One alert input can be connected to the door button and an ordinary output to a
contactless card reader on the inside of the window, close to the door. When
the door button is pressed, the C24 will give instructions to activate the card
reader. In order to open the door, the driver needs to press the door button and
displays his driver card. If the card is valid the door is opened.
3.1.1.1 Main Switch

The main switch signal should be 24 V when active and open circuit, or GND when
not active. The main switch has to be connected to P1:22 to activate the C24, when it
is in sleeping mode.
3.1.1.2 Door Signal

The door switch signal should be 24 V when active and open circuit, or GND when
not active. The door switch has to be connected to P1:19 to activate the C24, when it is
in sleeping mode.
Page 16
3.1.2 Passenger Speakers
When connecting the passenger loud speakers to the Amplifier art number 16191A-
P01, the loudspeakers should be connected in such a way that the resulting impedance
is 4 .
+ +
Amplifier out+ - 4 - 4
Loudspeakers (example in a vehicle
Amplifier out- with 4 pieces of 4  loudspeakers)
+ +
- 4 - 4
3.1.3 Outside Bus Speakers-not used in this project
When connecting the passenger loud speakers to the C24, the loudspeakers should be
connected in such a way that the resulting impedance is 4 .
+
C24 - 4
+
- 4
3.1.4 Audio announcement schematics details
Page 17
3.1.5 FMS– or other CAN network
FMS is connected to the C24 CAN A channel.
Note! There must be one termination (is connected in the P1 connector). If there is
some other unit connected to FMS that has a termination resistance, one of the units
must have a termination connected, but only one of them is allowed to have it. In such
case it is possible to cut away the termination jumper in the P1 connector.
As an option the cable described below, can be connected to the WAGO connection
block.
WAGO connection block Optional
8. CAN A H brown 1. CAN H brown
9. CAN A L white FMS FMS
2. CAN L white
Art. No. 17830X-P04,
Length (m) X length, X m, see table 1
1 A
1.5 B
2 C
2.5 D
3 E
3.5 F
Table 1 .
3.1.6 Driver’s Microphone (including telephony)

A microphone can be connected to the C24:P1 together with a “request to speak”
button.
3.2 3G
The C24 supports mini SIM cards.
Connect the triple antenna cable, length 5 m, marked with GSM (3G) to the C24:3G
connector.
Note!
It is of utmost importance that the antenna is NOT installed behind a
metal surface, or is in contact with the bus ground plane, since this could
negatively affect the signal transmission, see section 6.3.
3.3 GPS
Connect the triple antenna cable, length 5 m, marked with GLON (GPS) to the
C24:GPS connector.
Position, velocity, time, and direction information are provided according to the
NMEA-0183 standard.
Note!
Page 18
3.4 WiFi - not used
Connect the triple antenna cable, length 3 m, marked with WiFi to the C24:WiFi
connector.
Note!
3.5 Additional unit, e.g. diagnostic laptop (optional)

It is possible to connect an additional unit to the C24 via the Ethernet port P2. Either
use an ordinary Ethernet straight cable M12-8 A-coded to M12-8 A-coded, 24 AWG,
shielded (thereby power supply will also be included), or the cable art. no. 17811C-
A01 (if the connected unit has RJ45 connector and no power supply should be
connected).
Art. no. 17811C-A01,
L=0.5 m
Optional unit
C24:P2 Eth
4. D7
4.1 Power Supply to the D7 and C24 Communication
The power supply and C24 communication via aPoE and the cable connected between
C24:P4 to D7:P2, art. no. 17738C-D04, length 2 m.
Art. no. 17738C-D04,
L=2 m
D7:P2 C24:P4
4.2 Communication with Destination Signs

Destination signs are connected to the D7:P1 via RS485 by using the cable, art. no.
17763C-P02, without IL-AG5 connector, length 2 m.
Art. no. 17675A-S04, IL-AG5

L=2 m socket housing
RS485-A brown
D7:P1 D7 P1 RS485 RS485-B, white
Not included in
–P02
Page 19
5. X5-III-12CH Video Recorder
5.1 Video Recorder and MDVR Switch Power Supply
Use the supply cable included with the video recorder. The supply should be
connected as below.
The X5-III-12CH has a built in DC/DC converter that enables 12 V camera power
supply, regardless of what power supply the unit has (8-36 V).
5.2 Ethernet Network Connection

The video recorder is connected to the mdvr switch by using an Ethernet CAT5.
See section 6 in the Thoreb X5-III-12CH Video Recording System Manual, for which
video recorder settings are needed when a vehicle computer is connected.
5.2.1 Hard Disc Drive (HDD)

The HDD can be removed when studying the recorded files in a PC. The HDD is
connected to a PC by using a USB cable, type B.
5.3 Connecting Cameras

The RJ45 connector at the back of the X5-III-12CH is used for connecting MDVR
switch. The D9 Recorder Display is connected to the MDVR over AV connector, as
per image below.
Page 20
All cameras required to be mounted in this project will have RJ45 connectors and it
will be connected to the MDVR switch. The RJ45 connection is an POE connection.
All AV connectors coming from the video recorder are Din Jack 4 pins connectors.
Additional Cameras can be connected to the Video recorder AV-IN by using the cable
art. no. 17161X-Q01 (X represents different cable lengths,), as extension cable
between the Video AV-IN connectors and the camera cable.

The cable below is included with the D9 recorder display.
Cut away the white supply connector and connect power supply (24 V to the red and
GND to the black conductors).
The cable 17161C-Q01, length 3 m is used for connecting the D7 Recorder Display.
Art. no. 17161C-Q01
To video recorder L= 3 m To D7:C1
AV-OUT, see recorder display
section 5.3 Page 21
6. Connecting D29m Infotainment Units
In this delivery it should be one D29 master and one D29 slave.
6.1 Power Supply

The power supply cable, art. no. 16121A-P01, cable length 1 m (front display). Mating
socket housings with sockets are included in the delivery.
Art. No. 16121A-P01 D22:P2
+24 V supply
L= 1 m
1. +24 V green
+24 V green/brown
+ P2 Display 24 V 2. +24 V brown
GND grey/white - 15. GND grey
16. GND white
6.2 Ethernet Communication

The D29m unit is connected to the network switch via Ethernet, by using a standard
CAT5e patch cables straight (shield), RJ45 art. no. 14526F-Q02, length 5 m (see
section 8). The cable between the network switch and the D29m should be connected
to Ethernet 1.
Length (m) X Length (m) X Length (m) X

1.0 A 7 G 13 N
2.0 B 8 H 14 Q
3.0 C 9 J 15 R
4.0 D 10 K 16 S
5.0 E 11 L
6.0 F 12 M
7. Connecting D29s infotainment unit

7.1 Power Supply
The power supply cable, cable length 1 m. Mating socket housings with sockets are
included in the delivery.
Art. No. 16121A-P01 D29:P1
+24 V supply
L= 1 m
1. +24 V green
+24 V green/brown
+ P2 Display 24 V 7. GND white
GND grey/white -
7.2 DVI cable comunication to the D29m

The D29s unit is connected to D29m via DVI dual link cable. The cable between the
D29s and the D29m should not excide 15m.
8. Passenger Counting Units

The APC units communicate with the C24 unit via Ethernet, see section 8.
Page 22
8.1 Power Supply and Door signal
Each passenger counting unit should get its power supply and door signal according to
the illustration below.
If the door signal is ground when active:
If the door signal is plus when active:
The connector for power supply and door signal is included with the delivery. No
sockets are needed.
Page 23
9. Network Switch
A network switch is connected between the units for the Ethernet communication
network. The switch has screws for connecting the power supply cables (not included
in the delivery).
Ethernet cable switch to C24

art. no. 17811C-D01, length 2 m
C24
Ethernet cable switch to D22m

art. no. 14526L-P02, length 5 m
D29m
Standard straight cable M12-4 D-coded

to RJ45, 24 AWG, shielded CAT5
APC art. no. 14526L-P04, length 5 m
1. 24 V blue Main switch
Standard straight cable M12-4 D-coded 2 GND brown
Standard straight cable M12-4 D-coded

Video Recorder
Standard CAT5e patch straight

cable (shield), RJ45
art. no. 14526F-Q01, length 2 m
Page 24
10. Dimensions and Installation
Do always regard this:
• All installation should be made by staff with proper technical education, e.g. in
vehicle electrical engineering, electrical installations, etc.
• All units shall be installed for convenient connector and service access, at
protected locations inside the vehicle’s body.
• All units shall be installed by using all fastening points and in such a way that
unnecessary vibrations are avoided.
• All sockets shall be crimped with a calibrated tool intended for the socket
and cable area in question, and according to the Thoreb document “Crimping
Cable Shoes”. Control the following after each crimping:
The conductor crimp should enclose the copper strands completely
1. No strands are allowed to be outside the crimp
2. No part of the insulation is allowed to be inside the conductor crimp
3. The strands should protrude somewhat through the conductor crimp
4. Both the strands and the insulation should be visible between the conductor
crimp and the insulation crimp
5. The insulation should be secured by the insulation crimp
6. The cable shoe should be undamaged and not bent or warped due to the
crimping
Contact part Strands Insulation crimp Insulation
Conductor crimp
• Make sure to use all locking devices on the connectors and that no parts of the
cable can come loose.
• Make sure, by pulling the cables, that no sockets are pushed out of the housings.
• Choose the length of the cables, in order to avoid tensile stress or prevent the
cable from folding.
• Use straps to fix the position of all cables.
• The units must never be exposed to water or other fluids, e.g. when washing the
inside of a bus.
• Condensed water shall NOT be able to run along any cable and into a unit.
• Do NOT locate the units close to sources of heat, e.g. auxiliary heater and hot air
units, or their outlets.
• All units shall be located to places with good ventilation. If there are ventilation
slots at the bottom and at the top of the location, the air could self-circulate
between the node’s location and the compartment. This will result in decrease in
temperature.
• The lifetime of electronic components is negatively affected by excessively high
ambient temperatures.
• All screws should be properly tightened.
Page 25
• The units may not be opened. If a unit is suspected of being out of order, it
should be replaced and sent for examination, or repair to Thoreb. All such units
shall be provided with a complaint report. On these, all errors should be
described as clear and as plain as possible.
10.1 C24
If possible, locate the C24 close to the ceiling above the driver’s seat.
Preferably use four ST4.8, or M5 screws together with lock washers.

294
>80
284
14
168,5
158,5
39
50
Features:
• Weight 2.1 kg
• Casing made of black aluminium
• Coated PCBs
• IP classification 66
• Supply voltage - 9-36 V
directly connected to the bus battery
• Maximum power 15 A if the 10 A output is < 15 A @ 24V
used < 7 A @ 12V
• Power consumption for a long-term parked 0.5 mA
bus (the C22 is in “sleeping mode”)
• Operating temperature -40 to +85 C
E-certified. Tested according to UN ECE Regulation No. 10, ver 3:200
• Processor 32 bit CPU

• RAM 256 Mbyte 1
(512 Mbyte optional)
• Flash 2 Gbyte
• EEPROM 1 Kbyte
• Operating system Linux
Page 26
10.2 D7
4
2
23.3
85
38.3
70
M5 (4x)
53.3
44
75.3 75.3
99.5
M12 connectors (3x)

For fastening the unit by using M5 screws (4x)
The D7 should be installed within reach of the driver, either flush mounted on the
dashboard, or by using the four holes at the rear for fastening a bracket. >80 mm space
needed for connectors and cables behind the display.
When installing it flush mounted:
1. Make a hole in the dashboard big enough for the connectors.
2. Drill Ø6 holes for the screws, see the illustration above.
3. Connect the cables before fastening the display.
4. Fasten the display by using four M5 screws and lock washers.
Features:
• Weight 1.7 kg
• Casing made of black aluminium (rear),
Acrylonitrile butadiene styrene Atech-5103 (front)
Vicat B/120, softening temperature 125C
• 4 mm hardened glass (display window) Double-sided UV-protection, Vicat B/120,
softening temperature 125C)
• Coated PCBs
• Four integrated keys
• IP classification 66
• Supply voltage Advanced Power over Ethernet (48 V) from C22
Bus Computer via one cable (M12-8 A-coded)
• Current consumption <20 Watts
• Operating temperature -30to +85 C
• Display dimension 7”
• Active area 152.4 x 91.44
• Display colours 262 k
• Viewing angle
• Contrast 600
• Resolution 800 x 480 dots
• Backlight 500 cd/m
• Processor 32 bit CPU
• RAM 256 Mbyte
• Flash 1 Gbyte
• EEPROM 1 Kbyte
Page 27
10.3 Network Switch
96,6
88,9
88,9
43,5
37,8
The network switch can be installed on a
standard 35 mm DIN rail
107,2
89,6
10.4 Double Antenna
A good location of the antenna is of utmost importance for the performance of the
system. With poor satellite and/or 3G coverage, the system will not function as
expected.
The antenna MUST NOT be in contact with the bus ground plane. If it is installed on a
metal roof, it is necessary to use insulation between the antenna and the roof.
If the front of the bus roof and ceiling is made of plastic, the optimal location of the
antenna, considering signal reception, is just underneath the ceiling.
The antenna can for instance be installed on the dashboard, as long as the windscreen
has no conductive material, which could prevent the signals.
The antenna is delivered with 5 m long cables.
Page 28
Make a square 15x15 mm mounting hole in the installation surface.
Features:
• Material Lid ABS/ Base Zamak, /Gasket TPE
• Weight 246 g
• Operating temperature -40to +85 C
• 3G frequencies UMTS 2.1 GHz
polarization Vertical
gain 2.2 dBi max.
VSWR <3:1
• GPS frequencies 1575.42 MHz / GLONASS 1592-1610 MHz
noice figure 1.15 dB
polarization RHCP
LNA gain 26 dB at 3V, 27 dB at 5 V
VSWR <1.2:1
voltage supply 2.5-5.5 V
current 15 – 25 mA
power 138 mW
• Impedance 50 Ω
10.5 Automatic Passenger Counting Unit

The passenger counting units art. no. 17302B-P01 should be installed above each
doorway.
170
160 38.5
142 36.5
80
30
40
Ø 23
90
Use these four holes to

fasten the unit to the
Hella installation kit
Page 29
Features:
• Supply voltage 9-32 V
• Power consump. 4W
• Operating temp. -25 to 70 C
• Weight About 450 g
• Camera lens horizontal opening angle 110
F 2.2 mm
• Fitted height 2.10-3.30 m
• Recording range 0.8-3.5 m
•
The passenger counting
Recorded area 1-2 munits
2 is installed by using the installation kit, see section
• 9.6.1.
Shock/vibation EN 61373
• Humidity EN 60068 (low temp., dry heat, damp cycle, average humidity
<75% but 95% allowed during 30 consecutive days)
• IP classification IP50 (DIN IEC 60529)
• E-certified with regard to Directive 72/245/EEC, last amended by directive 2009/19/EC
Type approval number e1*72/245*2009/19*5913*00
• EMC EN 50022, E1 (buses)
EN 50121-3-2 (trains)
• Reliability DIN EN 61078
prediction DIN IEC 61709
SN 29500
• Tested according to EN 50155
• Fire protection level 3 (according to DIN 5510/ISO 3795
• Flammable class UL94 (V0)/ISO 3795
Page 30
10.5.1 Installation Kit
When using the installation kit, art. no. 17698B-P01, follow the instructions below.
40-50 cm
>2 m
Ø5.5 (4x)
1.
1.
2.
2.
Spacers
2.
1. Make a hole centered above each doorway, with the location as in the illustration
above. Make the hole with the same size as the square shaped hole in the installation
kit (use it as a template). When using position 1 (see point 2
below) the hole needs to be a bit larger at the bottom part. Shape of
Do also make room for the four screws on the installation kit. the hole
2. Fasten the APC unit to the installation kit by using the four screws that are included,
and the spacers. There are two different positions/angles to select between, 1 and 2.
Select the position that result in the most horizontal position of the APC lenses.
3. Drill four Ø5.5 mm holes and use four screws (M5 x 20 T25), washers RB
M5.3x15x1.2 fzb for M5, DIN 9021) and self-locking nuts (M5) to fasten the installation
kit to the ceiling.
4. Connect all cables (see section 7).
5. When the installation is completed, the settings and calibration described in the
document “APC Settings during Installation” should be made.
Page 31
10.6 X5-III-12CH
Features:
• Casing black anodized aluminium
• Weight 2.6 kg
67
75
• Supply voltage 8 to 36 V DC
• Power consumption < 15 W (without loads)
• Power output 2A@12V
6.5 • Operating temp. -33 to +60 C
• Humidity 10 - 90%
•
•
• Video compression H.264 (8 input channels/
2 output channels)
• Audio compression ADPCM
• Image resolution PAL: 352x288, 704x288,
120
195
293
90
704x576
NTSC: 352x240, 704x240,
704x480
• Image quality 1- 8 levels (1 is the best)
• Storage 2.5” SATA HDD
500 Mbyte
175 • Backup mode USB, HDD, network
195
215
1. Remove all components provided in the package.

2. Locate a proper location for installation. There should be enough space for connectors
and removing the hard disc, etc. The locking device is located to the front of the recording
unit (with LEDs). This is turned when removing the HDD. The key has to be turned into
locking position, to start the system and record.
3. Disconnect any power supply or device.
4. Fasten the unit. Two angle brackets are included in the supply.
5. Locate a reliable electrical ground point in the vehicle (preferably use the same as the
other Thoreb units).
6. Connect the provided cables to the rear of the Video recorder.
7. Apply any information labels required by local statute for video surveillance.
10.6.1 LED Indicators

• [HDD] Blue, the hard disc drive status, LED flashing indicates that everything is OK.
• [SD] Green, (not applicable)
• [GPS] Green, (not applicable)
• [NET] Green, for displaying the network status.
• [PWR] Blue, input power status: LED ON confirms that the unit has power supply.
• [REC] Green, video recording status: LED ON indicates recording is on for at least one
channel.
• [VLOSS] Red, the LED is red when there is some video loss, e.g. the camera connection is
loose. If cameras are not connected to all channels, this should be defined in the video
recorder system settings, see section 4.6.4.2.3 in the Thoreb X5-III-12CH Video Recording
System Manual.
• [ALM] Yellow, alarm status. When the LED is flashing, the unit is responding to an alarm
event. An alarm can be caused by covered cameras, an external sensor trigger, hard disk
failure and video loss. When the cause is video loss, it is necessary to log in as
administrator to disable the alarm.
• [ERR] Red, error status. The LED is flashing if e.g. USB connection problem occur.
Page 32
10.7 MDVR switch
The MDVR switch should be instaled close to the MDVR instalation site for a good
aftersale maintenance.
Specifications

The D7 Recorder Display should be installed at the dashboard within sight of the
driver. The enclosed bracket can be used for this purpose.
Page 33
Bracket
Features:
• TFT LCD
• Supply voltage normal 11-32 V
operation
• Power consumption ~0.7 A @ 24 V active
mode
• Operating temperature -30 to +60 C
• Display dimension 9”
• Display colours Full-colour
• Contrast 500:1
• Viewable area 153.6 x 86.6
• Resolution 500 x 480 dots
• Viewing angle
• Backlight 450 cd/m2
• PAL/NTSC
• Supports two cameras
Page 34
10.9 Camera
Cable slot
Installation plate
Locking ring
Camera housing
parts
F F F F
2.8
3 (not 3 3
. use . .
6 d) 6 6
1. Unscrew the locking ring.

2. Remove the bottom part (installation plate)
of the camera housing parts.
3. Fasten the installation plate to the ceiling by
using the four enclosed M4 screws.
Make sure that the cable is routed in one of the cable slots.
4. Put the camera housing parts into position, adjust the angle of
the camera and tighten the locking ring.
The camera is provided as two version without (art. no. 17192J-Q01) and with
mirrored camera image (art. no. 17192K-P01).
Features:
• Casing black aluminium
• Weight 304 g
• Supply voltage 12 V DC
• Current consumpt. ~ 210 mA
• Operating temp. -20 to +55 C
• Built in IR LEDs
• Light sensitivity 0 lux (IR on)
• IR distance 10 m
• Fixed lens f = 3.6
• Picture sensor 1/3” Sony CCD
• Video standard PAL/NTSC
• Resolution 700 lines (PAL: 976x582,
NTSC: 976x494)
• SNR >52 dB (AGC off)
• Gain Control Auto
• AWB Auto
• Electronic Shutter Auto
• Video output 1.0 Vp-p, 75 Ω
• Gamma correction 0.45
• CCD NVP2010
• Audio On
Page 35
11. Tests Made to Verify the Installation
11.1 Test of the 3G Communication
The 3G symbol ( ) in the D7 indicates the 3G coverage quality. The vehicle
should be standing outdoors when testing this.
A triangle indicates that the vehicle has Internet access (via 3G).
The C24 has a green status indication LED, just above the P2 connector. The table
below describes how and when it is light.
LED Status Device status

Permanently off • Device off
Permanently on • Not registered
• Voice call active
Blinking 1 sec on + 2 sec • Registered in idle
off • Dial-up
Depends on the event that • Registered in idle +
triggers the wakeup power saving
11.2 Test of GPS Reception

The GPS ( ) symbol in the D7 indicates the quality of the GPS reception.
• The symbol is displayed all the time when the GPS receiver has contact with
more than 3 satellites.
• If the GPS symbol is flashing, the GPS does not get reliable information.
• If the GPS symbol is displayed with a question mark, the GPS antenna is not
connected.
The vehicle should be standing outdoors when testing this.
12. Operating Routines

Before the vehicle is put into service, there are some additional facts worth noting:
• When using an electrical weld, the weld’s ground connection should be located as
near to the welding spot as possible. Do also disconnect the positive battery pole
before welding.
• The Thoreb units may not be opened.
If a unit is suspected of being out of order, it should be replaced and sent for
examination, or repair to Thoreb. All such units shall be provided with a complaint
report, specifically for this purpose. On these, all errors should be described as clear
and as plain as possible.
Page 36
13. Summary of Article Numbers
The following units, cables, connectors and antenna can be used for the installation:
TBD
Copyright  2018 AB Thoreb, all rights reserved.
The content in this document belongs to AB Thoreb and is protected by copyright law. This document
is provided as a service to its customers and may only be used for informational purposes. No part of
this publication may be brought to the knowledge of any third party, reproduced, stored in a retrieval
system, or transmitted in any form or by any means, electronic, photocopying, or otherwise without
written permission from AB Thoreb.
You may not

(a) modify the document or use it for any public display
(b) remove any copyright or other proprietary notice from this document.
You agree to keep confidential and use your best efforts to prevent and protect the contents of the
document from unauthorised disclosure, use or copying.
For information please contact

AB Thoreb Phone +46 31-734 39 00
Gruvgatan 37 Facsimile +46 31-734 39 10
SE-421 30 VÄSTRA FRÖLUNDA E-mail thoreb@thoreb.com
SWEDEN
Page 37
A28
Communications Module
Technical Specification
Revision 01
TEQ SA
Index
1. About This Document 3
1.1. Scope 3
1.2. Complementary Documentation 3
1.3. Warning and Caution Messages 3
1.4. Other 3
2. Product Description 3
3. Specifications and Model Variants 4
Product Code 5
Model Variants 5
4. Signals and Interfaces 6

4.1. Pinout 6
4.2. Signal Description 7
4.3. Communication Interfaces 7
5. Wiring 9
5.1. Precautions 9
5.2. Connector Part Numbers 9
5.3. Power Supply 10
6. Mounting 11
6.1. Precautions 11
6.2. Physical Dimensions 11
7. Certifications 12
8. Warnings 12
9. Acronyms and Abbreviations 14
10. Revision Table 14
General Notes
TEQ pursues a policy of continuous improvement. The specifications in this document may therefore be changed without
notice. The content of the present document is not binding and it cannot be used in litigation case.
Copyright
Transmittal, reproduction, dissemination and/or editing of this document as well as utilization of its contents and
communication thereof to others without express authorization are prohibited. Offenders will be held liable for payment
of damages.
TEQMonitoring® and Bus Sapiens® are registered trademarks of TEQ SA, protected by law.
Other company and/or product names mentioned may be trademarks or registered trademarks of their respective owners.
TEQ SA
Via al Municipio 16
6917 Barbengo
Switzerland
www.teq.ch
TS_A28_01.docx 2 of 14
TEQ SA
1. About This Document

1.1. Scope
The scope of this document is to provide necessary and useful information for the integration of the A28 product
family.
1.2. Complementary Documentation

The following additional documentation is available on request from TEQ:
 Installation manual (.pdf)
 3D Drawings (.iges)
 2D Drawings (.pdf, .dwg or .dxf)
 Pinout tables (.xls)
 Copy of Compliance Certification documents (.pdf)
If additional documentation is desired, contact TEQ to enquire on its availability.
1.3. Warning and Caution Messages

Some sections of this document present caution and warning messages to the reader. These messages are
presented in the following formats for visibility.
Caution
 A caution message presents an instruction or indication that aims to prevent damage to the unit or
compromise of its functionality.
Warning!
 A warning message presents an instruction that aims to prevent immediate harm to persons.
 Malfunctions of the system may cause indirect damage to persons due to failure of safety features. All
instructions and indications presented in this document must be carefully read, understood and followed
before installing or utilising the unit.
Ensure all warning and caution messages are read and understood before proceeding with integration or
installation of the product.
1.4. Other
Please note that where direct reference is not made, the illustrations and photographs included in this
document are included for reference purposes only, and as such are not intended to provide any specific
information on the product.
2. Product Description
This device includes all the required functionality for a variety of applications involving on board diagnostics
and blackbox functionality, gateway functionality, fleet management, passenger information management, and
other applications.
In its various configurations, it provides:
 Blackbox functionality, with internal memory and a USB port for easy data log download
 Triaxial accelerometer
 GPS compatibility, for location and speed tracking
 Data connectivity (GSM, UMTS and 3G) for real-time communication with Fleet Management systems
TEQ SA
 Up to 2 RS232 lines and 1 RS485 line
 Up to 3 CAN lines, SAE J1939 compliant
 PT100 temperature sensor support (3-line) on select variants
3. Specifications and Model Variants

The following table lists the unit’s technical specifications:
Table 1: Technical Specifications
Function Description
Microprocessor(s) 1 32-bit
Memory 8 MB flash for program backup(can be expanded on request)
8 kB FRAM
512 MB internal SD-card on select variants
USB 1 Host (for flash-drive reading)
1 Device (serial emulation)
Digital inputs 2 with frequency input capability
Speedometer input 1 (digital or sinusoidal)
Analogue inputs 3 can also be used to read digital inputs; software configurable
Digital outputs 3 negative, max 0.5A
Accelerometer 1
(triaxial)
Current consumption max 100 mA (logic) @ 24V
Operating conditions -40°C / +85°C
IP protection IP30
Software update Through CAN bus, RS232
TEQ SA
Product Code
The product code determines the characteristics of the A28 variant.
A28._ _ X.XXX
Software Code
Defined by TEQ when order is placed
Other characteristics
Defined by TEQ when order is placed
Interface Configuration
Version
0 Double CAN bus, IBIS
1 Triple CAN bus
2 Triple CAN bus, IBIS
3 Triple CAN bus, IBIS (No SD Card)
Connectivity
GPS Modem
A - -
B - HSDPA: data only
C • HSDPA: data only
D - HSDPA: data and voice
E • HSDPA: data and voice
F - LTE: data and voice
G • LTE: data and voice
Model Variants
Table 2: Interface Configuration
Function Version
0 1 2 3
CAN 2 3 3 3
CAN 3 Termination - • • •
RS232 • 2 2 2
IBIS • - • •
RS485 • • • •
512MB Flash • • • •
PT100 • - - -
K-line •
TEQ SA
4. Signals and Interfaces

4.1. Pinout
X1
Pin All Variants Pin All Variants
1 +B 11 GND
2 +Lin 12 K-line
3 Out0.25A- 13 RS232 1 Tx
4 Out0.25A- 14 Prg-
5 Out0.25A- 15 RS232 1 Rx
6 In- F 16 InAn
7 In- F 17 InAn
8 In- F / In Speed 18 InAn
9 GND Out 19 CAN 1 H
10 CAN 1 L 20 CAN 1 T
X2
Pin Variant 0 Variant 1 Variant 2, 3
1 GND Out GND Out GND Out

2 RS485 H RS485 H RS485 H
3 RS485 L RS485 L RS485 L
4 IBIS Tx CAN 3 H CAN 3 H
5 PT100 pwr+ RS232 2 Tx RS232 2 Tx
6 PT100- RS232 2 Rx RS232 2 Rx
7 CAN 2 T CAN 2 T CAN 2 T
8 CAN 2 L CAN 2 L CAN 2 L
9 CAN 2 H CAN 2 H CAN 2 H
10 IBIS Rx CAN 3 L CAN 3 L
11 reserved CAN 3 T IBIS Tx
12 PT100 pwr- reserved IBIS Rx
TEQ SA
4.2. Signal Description

Function Description
+B Electrical Power Supply
Wired directly to battery
+Lin Logic Power Supply
From mains switch
CAN x H CAN x: High line
CAN 1 H and CAN 2 H, for CAN line 1 and 2 respectively
CAN x L CAN x: Low line
CAN 1 L and CAN 2 L, for CAN line 1 and 2 respectively
CAN x T CAN x: Termination resistor
Connect to CAN x L to terminate with 120Ohm
GND Logic Ground (-31)
Reference ground for logic circuit components.
GND Out Ground Out
Ground output for communication lines
IBIS WBED IBIS data reception line
IBIS WBSD IBIS data transmission line
In- F / In Speed Frequency input capable of reading sinusoidal speed signal

Can only read frequency inputs (sinusoidal or digital)
In- Digital Input
Two states: open circuit and short to ground
In- F Digital Input capable of reading frequency signals
InAn Analogue input, software configurable

Voltage: 0-5V, 0-33V
Current: 4-20mA
Resistance: 0-1kOhm
+/- three-state input
K-line K-line
OutxA- Low side output, up to x Amperes

Out0.25A-. Short-circuit protected
Prg- Programming enable
When shorted to ground during start-up, enables board programming mode
PT100 pwr- PT100 Power Minus Line
PT100 pwr+ PT100 Power Plus Line
PT100- PT100 Measurement Line
reserved Not to be used
RS232 x Rx RS232 x: Reception line

RS232 1 Rx and RS232 2 Rx, for RS232 1 and 2 respectively
RS232 x Tx RS232 x: Transmission line
RS232 1 Tx and RS232 2 Tx, for RS232 1 and 2 respectively
RS485 H RS485 x: High line
RS485 1 H and RS485 2 H, for RS485 1 and 2 respectively
RS485 L RS485 x: Low line
RS485 1 L and RS485 2 L, for RS485 1 and 2 respectively
4.3. Communication Interfaces

The communication interfaces supported by this board are listed and described below.
CAN
CAN interface according to standard ISO 11898 (physical layer).
Connection must be carried out through a normal twisted cable.
RS232
TEQ SA
One of the two interfaces (RS232 1) can be used for module programming. Both interfaces can be used for
interfacing with the PC for diagnostics functionalities or according to user needs.
RS485
Can be used according to user needs.
K-Line
K-Line is a bidirectional single wire bus used for data transfer in automotive engineering and it is standardized
as ISO 9141 and ISO 14230-1.
In combination with L-line for vehicle diagnostics, K-line can run uni-directionally.
USB Host
The USB Host functionality allows reading and writing on external flash memory.
IBIS
IBIS interface according to VDV300D.
Often used to interface with passenger information devices.
TEQ SA
5. Wiring
5.1. Precautions
Caution
 Always use cables with a rating suitable for the maximum current drawn by the loads. If the cable cross-
sectional area is prescribed by TEQ SA, the use of cables with a cross-sectional area different to those
indicated is not permissible under any circumstances.
 Ensure the electrical wiring connection to the control unit is not crushed by metal parts and does not undergo
forces in the direction opposite to the insertion of the connector as this could cause damage to the unit or
wiring.
 Ensure both the logic ground and power ground of the control unit are firmly connected to ground.
 Do not connect the vehicle battery to the system without having ensured the correct polarity. A reversal of
polarity can cause serious damage to the unit and to the rest of the system.
 Do not connect or disconnect the unit without having first disconnected the vehicle battery from the system.
 Do not pull on cables when attempting to disconnect connectors from the unit. Detach the connector in
accordance with the instructions provided by the supplier of the connector.
 After the unit installation, before connecting the vehicle power supply, make sure the connectors are not
swapped or reversed.
 In case of positive outputs on the control unit, when specifying the thermal protection relays ensure that the
total consumption of all loads is considered. If the outputs are grouped, repeat the calculation for each group.
Always refer to the technical description of the product, as in some cases the current rating of each group is
lower than the sum of the ratings of each output.
 Do not separately supply the loads connected to the unit for any reason, as this may damage the unit.
 Before making modifications to the electrical system wiring, always disconnect the battery.
5.2. Connector Part Numbers
Figure 1: Device connectors for A28 variants
Table 3: Connector part numbers for A28 variants
Device connector Wire connector part

Ref Supplier part number number Wire gauge Crimp part number
X1 Molex 43045-2009 43025-2000

20-24 AWG 43030-0007
X2 Molex 43045-1209 43025-1200
U1 USB Mini-B Type
U2 USB Type A
A1* SMB-Fakra
A2* SMB-Fakra
*Only present on some variants
TEQ SA
5.3. Power Supply

The gateway has the following power supply connections:
 Permanent power supply from battery (+B), which feeds connected loads and the internal logic.
 Power supply from main switch contact (+Lin), to activate the system.
 Logic ground.
Warning!
 The ground line must be connected to the chassis using a dedicated short cable (1m max.). It may not be
shared with power loads.
 The same instruction applies to the elements connected to the signal inputs of all control units.
TS_A28_01.docx 10 of 14
TEQ SA
6. Mounting
6.1. Precautions
Caution
 The control unit must be mounted on a planar surface and all the fixing points shall be aligned in height
between them. Otherwise the control unit could suffer serious damage due to twisting.
6.2. Physical Dimensions

The diagrams below illustrate the physical dimensions of the unit. All measures are in mm.
Figure 2: Device dimensions, front view
TS_A28_01.docx 11 of 14
TEQ SA
Figure 3: Device dimensions, top view
7. Certifications
Description Certification
Electromagnetic Regulation 10 (Reg 10)
Compatibility
Radio Equipment RED (on variants with Data modem)
Directive
Protection Grade IP IP 30
8. Warnings
Caution
 Ignoring the instructions provided by TEQ SA in this document and other correspondence, or otherwise using
the product other than intended, will immediately void the warranty that TEQ provides with the product.
 The instructions provided in this document are intended for use by a qualified person.
 If any confusion should arise from the information provided herein, contact TEQ for clarification before
proceeding.
TS_A28_01.docx 12 of 14
TEQ SA
 Additional warnings are presented in other sections of this document, where relevant. Warnings must be read
and understood before proceeding with installation.
 The control unit must be used within the technical limits specified in the manufacturer’s documentation, with
particular care regarding the limits of the supply voltage and the specified temperature range. Refer to
relevant sections of this document for details of these limits.
 Always handle the unit with care. In particular:

◦ Do not drop the unit from a height exceeding 1m
◦ Do not expose the unit to direct heat, perforate it or put it in contact with any liquid
◦ Do not open the device under any circumstances.
 Do not clean the unit without having disconnected the batteries. Use a damp cloth for cleaning. Do not use
compressed air as this may damage the internal parts, or introduce metal powders which could lead to
damage. Do not use chemicals or other cleaning products. It is permissible to use a mild soap or
disinfectants.
 Do not use tools which can produce metal filings or metal powders of any kind nearby the control unit. If these
objects come into contact with the electronics, they may cause serious damage to the control unit.
Warning!
 Unauthorised modification or repair of the product assembly by the user may void the regulatory compliance
of the product and/or cause malfunction of the unit, potentially resulting in safety hazards for the user or other
persons depending on the application of the product. TEQ declines all responsibility for any anomalous
behaviour of the system and resulting damage if it the product has been modified in any way by the user
without prior written agreement with TEQ.
 Malfunction of this unit may cause anomalous behaviour of the system, which in turn can present severe
health and safety hazards during usage.
 Where it hasn’t been explicitly agreed with TEQ SA, the responsibility for functional testing and validation of
the product lies with the client or product owner, or in any case externally to TEQ SA.
 The control unit must not be used in a potentially explosive or flammable atmosphere, such as areas where
the air contains high levels of volatile chemicals, vapors or flammable particles. Ignoring this warning may
cause severe damage or harm to the control unit, property or persons.
 Do not weld on the vehicle without having ensured all electrical connections and cables have been carefully removed
from all connectors.
 Do not attempt to force the thermal overload protection relay if triggered. Inspect and carefully check the
wiring, the connections to the control unit, the battery voltages and the rest of the vehicle in case of triggering
of thermal protection on the group, as a wiring error is likely the cause.
 Do not replace the thermal with higher values, if they are triggered. Contact TEQ SA if the cause of the
unexpected thermal relay triggering cannot be identified.
 Do not use the unit if damaged. In case of unit failure or anomalous behaviour, do not attempt to open the unit
nor try to repair it; instead contact TEQ for support.
TS_A28_01.docx 13 of 14
TEQ SA
9. Acronyms and Abbreviations

Acronym/Abbrev. Definition
A Ampere
AWG American Wire Gauge

CAN Controller Area Network
GPS Global Positioning System
IDE Integrated Development Environment
IP Ingress Protection
MB Megabyte
mm Millimetres
PAL Phase Alternating Line
RTC Real Time Clock

SAE Society of Automotive Engineers
SRAM Static Random-Access Memory
USB Universal Serial Bus

V Volt
10. Revision Table

Rev. Date Changes
01 12.07.2018 Initial Release
TEQ SA
Via al Municipio 16
6917 Lugano Barbengo
Switzerland
www.teq.ch
TS_A28_01.docx 14 of 14
1 2 3 4 5 6 7 8
PART No. COMPUTER PRODUCED DRAWING
310_070_000_2 MUST NOT BE CHANGED MANUALLY
1. INLET: M22x1.5 1
2. DRAIN: n 18
A
3. ELECTRICAL CONNECTION: M24x1, (2x n 4mm PINS)
3
ELECTRIC POWER: 24VDC / 0.5A
2
MAX WORKING PRESSURE: 2.0MPa (20bar)
AIR CONSUMPTION: 50cc FREE AIR / OPERATION AT 0.8MPa
DRAINING CAPACITY: 1.3cc WATER / OPERATION AT 0.8MPa
INLET AIR TEMPERATURE: MAX +80 $ C

AMBIENT TEMPERATURE: -40 $ C TO +80 $ C
INSTALLATION: VERTICAL # 15 $ , VALVE DOWN

B
INSULATION CLASS: IP68
WEIGHT: ~0.65kg
RELAY (NOT INCLUDED)
87a
ELECTRCAL CONNECTION 87 30 IGNITION SWITCH (+15)
45 # 1
BRAKE LIGHT SWITCH (54) 86 85 GROUND
C
INLET
(8)
23 0.5
SW 30
(8)
(2x n4)
ELECTRICAL THIS DRAWING/SPECIFICATION USES

CONNECTION CLASSIFIED CHARACTERISTIC SYMBOLS DEFINED IN
D QUALITY PROCEDURE 4.17
6xM5
TO VIEW CHANGE INFORMATION, ACCESS THE
68.5 1 ENGINEERING DOCUMENT DATABASE (EDD) & INPUT
THE RELEVANT NUMBER BELOW. EXAMPLE 'C6500'.
DRAIN
82 1
E
93 1 106.5 2
1 C6945 LD 05/04/17
0 50 100
ORDER NO. 310 070 001
ISS CHANGE CHEC DATE ISS CHANGE CHEC DATE
THIS DRAWING/DOCUMENT IS ASSOC SPECS. TITLE

COPYRIGHT AND THE PROPERTY OF NOTE: UNLESS OTHERWISE STATED THE FO LLOWING APPLIES
HALDEX BRAKE PRODUCTS LIMITED. 1 ISO METHOD A PROJECTION .
RT
2 S.I. UNITS. MATERIAL MODEL: DATE: ADV

IT MUST NOT BE COPIED (IN WHOLE
PA
OR IN PART) USED FOR MANUFACTURE 3 SURFACE FINISH TO BS 308/BS 1134. DRAWN: LD DATE: 04/04/17 AUTOMATIC DRAIN VALVE
R
4 DIMS. APPLY AFTER CHEMICAL OR ELE CTRO-PLATED FINISH.

EE
OR OTHERWISE DISCLOSED WITHOUT HEAT TREATMENT CHECKED DATE

5 WELD SYMBOLS TO BS 499.
N
HALDEX BRAKE PRODUCTS LTD.

PRIOR WRITTEN CONSENT OF THE 06/04/17
GI
6 D DATUM DIMENSIONS. MIRA TECHNOLOGY PARK, LINDLEY, WARKS, CV13 6DE

COMPANY. ANY COPIES OF THIS
EN
7 METRIC THREADS TO BS 3643/DIN 13. FINISH APPROVED SPECIALIST DATE WAS PART No.
DRAWING/DOCUMENT MADE BY ANY
06/04/17
O
310_070_000_2
8 UNIFIED THREADS TO BS 1580.
PR
METHOD MUST ALSO INCLUDE A COPY 1:1

OF THIS LEGEND. FORM APPROVED FOR ISSUE DATE
C 2017 SHEET 1 OF 1
06/04/17 A2
Left Wing O/C Valve
10 5 Open/Close
1 (White)
13 4 4 4 13 4 Left Wing P.S.
0 V GND (-)
Tyco 350783-1 2 (Black) Door Close Side
1 (Pink)
Right Wing P.S.
0 V GND (-)
Door Close Side
2 (Black)
1 (Pink)
0 V GND (-) Edge Sensor
2 (Black)
Edge Sensor
1
m
m
mm
mm
Right Wing O/C Valve 13 (Blue)
m
50 m
Open/Close Door Close Side
300
200
200
1 (Color1) 9 2 (Pink)
L =3
L=
L=
L=
0 V GND (-)
2
Fonksiyonel değişiklikler ve pin dizilimi değişti.

(Black)
m
0 0m
L =3
1 4 7 10
2 5 8 11 L = 400 mm L = 50 mm A L = 700 mm 11
4
3 6 9 12
Out 5 Km/h
mm
Out 5 Km/h
1
m
50 m
(Brown)
600
0 V GND (-)
650
250
2
6
(Black)
L=
L=
L=
L=
08.02.16
Left Wing Sw.
Right Wing Sw. Emergency Emergency
Door Closed Condition 6 Unblock Valve
1 Sw. (Orange) Door Closed
4 Emergency
Emergency
0 V GND (-) 7 4 1 Sw. (Color2) 12 4 4 8 1 Cond. (Yellow) 1 Unblock(Grey)
2 (Black) 0 V GND (-) 0 V GND (-) 0 V GND (-)
2 (Black) 2 (Black)
2 (Black)
A: GND (Şase) kablo ek yeridir. Siyah kablo tüm soketlere buradan dağıtılacaktır.
NOT: Bütün tesisatta kablo demeti çapına uygun PVC makaron kullanılacaktır. Ek yerinde daralan makaron kullanılacaktır.
1 Boş
2 Boş
3 Boş
4 Black (-) GND 2.5 - 0.75
5 White Left Wing Open/Close Valve (+) 0.75 mm²
6 Grey Front Door Emergency Unblock (+) 0.75 mm²
7 Orange Front door Right Wing Limit Switch(-) 0.75 mm² 08.03.14 S.GUVERCIN
BREDA EURO 6
08.03.14 S.GUVERCIN
8 Yellow Front door emergency Cond. (-) 0.75 mm² ON KAPI TESISATI
9 Blue Front door edge sensor (-) 0.75 mm²
10 Color1 Right Wing Open/Close Valve (+) 0.75 mm²
11
12
Brown
Color2
Out 5 km/h (+)
Front door Left Wing Limit Switch(-)

0.75 mm²
0.75 mm²
300600216
Door O/C Valve
Right Wing Sw. 5 Open/Close
1 (White)
7 4 1
Door Closed 4 13 4 Door Valve P.S.
Sw. (Orange) 0 V GND (-)
Tyco 350783-1 2 (Black)
0 V GND (-) Door Close Side
2 (Black) 1 (Pink)
0 V GND (-)
2 (Black)
Edge Sensor
Edge Sensor
1
m
13 (Blue)
m
L=
Door Close Side
300
200
9 2 (Pink)
650
L=
L=
Fonksiyonel değişiklikler ve pin dizilimi değişti.

mm
mm
00
L =3
1 4 7 10
2 5 8 11 L = 400 mm L = 50 mm A L = 300 mm 11
4
3 6 9 12
Out 5 Km/h
m
Out 5 Km/h
1
mm
mm
50 m
(Brown)
0 V GND (-)
650
250
2
3
(Black)
L=
L=
L=
08.02.16
Left Wing Sw.
Emergency Emergency
Door Closed Condition 6 Unblock Valve
1 Sw. (Orange) 4 Emergency
Emergency
0 V GND (-) 7 4 4 8 1 Cond. (Yellow) 1 Unblock(Grey)
2 (Black)
0 V GND (-) 0 V GND (-)
2 (Black)
2 (Black)
A: GND (Şase) kablo ek yeridir. Siyah kablo tüm soketlere buradan dağıtılacaktır.
NOT: Bütün tesisatta kablo demeti çapına uygun PVC makaron kullanılacaktır. Ek yerinde daralan makaron kullanılacaktır.
1
2
3
4 Black (-) GND 2.5 - 0.75
5 White Door Open/Close Valve (+) 0.75 mm²
6 Grey Emergency Unblock (+) 0.75 mm²
7 Orange Door Closed Limit Switch(-) 0.75 mm² 08.03.14 S.GUVERCIN

BREDA EURO 6
08.03.14 S.GUVERCIN
8 Yellow Door emergency Cond. (-) 0.75 mm² ORTA-ARKA KAPI TESISATI
9 Blue Door edge sensor (-) 0.75 mm²
10 0.75 mm²
11
12
Brown Out 5 km/h (+) 0.75 mm²
0.75 mm²
300600217
MONTAGEANLEITUNG
90 MM LED L4060 FERNSCHEINWERFER
INSTALLATION INSTRUCTION
90 MM LED L4060 DRIVING LAMPS
INSTRUCTIONS DE MONTAGE
90 MM LED L4060 PROJECTEURS LONGUE PORTÉE
MONTERINGSANVISNING
90 MM LED L4060 FJÄRRSTRÅLKASTARE
MONTAGEHANDLEIDING
90 MM LED L4060 VÈRSTRALERS
INSTRUCCIONES DE MONTAJE
90 MM LED L4060 LED FAROS DE LARGO ALCANCE
INSTRUZIONI DI MONTAGGIO
90 MM LED L4060 LED MODULE PROIETTORI DI PROFONDITÀ
ASENNUSOHJE
90 MM LED L4060 LISÄKAUKOVALOT
Technische Änderungen vorbehalten. Das hier beschriebene System ist belüftet. In seltenen Fällen kann es
DE durch Umgebungsbedingungen zu geringer Kondensation von Luftfeuchtigkeit an der Streuscheibe kommen.
Dieses Kondensat löst sich jedoch rückstandfrei auf und hat keine schädigenden Einflüsse.
Subject to alteration without notice. The system described here is ventilated. In rare cases, environmental
EN conditions may cause slight condensation of humidity on the lens. This condensation nevertheless evaporates
without leaving behind any residue and has no damaging impact.
Sous réserve de modifications techniques. Le système décrit ici est ventilé. Dans de rares cas, il peut arriver
FR que le diffuseur soit soumis à une faible condensation par l’humidité de l’air dans des conditions ambiantes.
Toutefois, ce condensat se dissout sans résidu et n’a aucun effet nocif.
Vi reserverar oss för tekniska ändringar. Systemet som beskrivs här är ventilerat. I sällsynta fall kan omgivn-
SV ingsförhållanden leda till att fukt kondenseras på spridningslinsen. Kondensen försvinner utan att lämna spår
och har inga skadliga effekter.
2
Technische wijzigingen voorbehouden. Het hier omschreven systeem is geventileerd. In zeldzame gevallen kunnen
NL omgevingsfactoren ertoe leiden dat er, vanwege de luchtvochtigheid, lichte condensatie op de lichtverstrooiende
plaat ontstaat. Dit condensaat verdwijnt echter weer zonder sporen achter te laten en heeft geen schadelijke invloed.
Reservadas modificaciones técnicas. El sistema aquí descrito está ventilado. En raras ocasiones, las condi-
ES ciones ambientales pueden hacer que haya una baja condensación de humedad del aire en el cristal difusor.
Sin embargo, este líquido de condensación se disuelve sin generar residuos y no tiene efectos perjudiciales.
Con riserva di modifiche tecniche. Il sistema qui descritto è ventilato. In rari casi le condizioni ambientali pos-
IT sono comportare una bassa condensazione dell’umidità atmosferica sul diffusore di luce. Questa condensa si
scioglie tuttavia priva di residui e non ha alcuni influssi dannosi.
Oikeus teknisiin muutoksiin pidätetään. Tässä kuvailtu järjestelmä on tuulettuva. Joskus harvoin suuntauslin-
FI ssin pintaan voi tiivistyä hieman kosteutta ympäristöolojen vuoksi. Tämä tiivistynyt kosteus kuitenkin poistuu
jäämiä jättämättä eikä sillä ole haitallisia vaikutuksia.
Zeichenerklärung Symbolförklaring Legenda
Explanation symbols Legenda Piirroksen selitys
Explication des symboles Aclaración de símbolos
DE Richtig DE Falsch DE Positionspfeil DE Bewegungspfeil

EN Correct EN Incorrect EN Location/Position Arrow EN Movement Arrow
FR Correct FR Incorrect FR Flèche de Position FR Flèche indiquant
SV Rätt SV Fel SV Positionpil sens du vouvement
NL Goed NL Fout NL Lokatie/Positie pijl SV Rörelsepil
ES Correcto ES Erróneo ES Flecha de posición NL Richtingspijl
IT Giusto IT Sbagliato IT Freccia di posizione ES Flecha de moviemiento
3 FI Oikein FI Väärin FI Paikannusnuoli IT Freccia di movimentov
FI Liikesuuntanuoli
DE Achtung DE Abklemmen DE Verbinden DE Siehe

EN Warning EN Disconnect EN Connect EN Look/See
FR Attention FR Déconnecter FR Connecter FR Voir
SV Varning SV Koppla los SV Ansult SV Se
NL Let op NL Demonteren NL In elkaar NL Kikjken naar
ES Atención ES Desconectar ES Conectar ES Ver
IT Attenzione IT Staccare IT Collegare IT Vedere
FI Huomio FI Irrota FI Yhdistä FI Katso
DE Fernlicht DE Tagfahrlicht DE Positionslicht

EN High beam EN Daytime running light EN Position light
FR Feu de route FR Feu de jour FR Feu de position
4 SV Helljus SV Varselljus SV Positionsljus
NL Grootlicht NL Dagrijverlichting NL Positielicht
ES Luz de largo alcance ES Luz de conducción diurna ES Luz de posición
IT Luce abbagliante IT Luce di marcia diurna IT Luce di posizione
FI Kaukovalo FI Päiväajovalo FI Seisontavalo
Lieferumfang Leveransomfattning Contenuto della confezione
Scope of delivery Leveringsomvang Toimituksen sisältö
Fourniture Alcance de suministro
3x
3x
5
3x
1FO 011 988-021 1FO 011 988-121
1FO 011 988-031 1FO 011 988-131

Zubehör Tillbehör Accessori
Accessories Toebehoren Lisätarvikkeet
Accessories Accessorios
1FO 011 988-021/ -031 1FO 011 988-121/ -131

-121/ -131
8JA 202 231-002
6 8KW 863 933-013 (50x)

9AH 169 580-011
9GD 863 952-022

(0,35 - 0,5 mm)
1FO 011 988-121
9GD 863 952-012
(0,75 mm)
1FO 011 988-131
9GD 863 952-002 (50x) 9AH 254 228-001

Benötigte Montagewerkzeuge Nödvändiga monteringsverktyg Attrezzi necessari per il montaggio
Installation tools required Benodigde montagewerktuigen Tarvittavat asennustyökalut
Outillage de montage requis Herramientas de montaje necesarias
3,5 mm
5 mm
6,5 mm
7
14 mm
16 mm
17 mm
24 mm
Torx 20
SW 10
Montage Montering Montaggio
Mounting Montage Asennus
Montage Général Montaje
1FO 011 988-021/ -031 Ø110

Ø90 10 10
54.6
1.25
20 20
90.6
20 20
8
20
1FO 011 988-121/ -131

33.4
3
14.8
1FO 011 988-021/ -121
= =
9
≤ 1500 mm
1FO 011 988-031/ -131
≥ 250 mm
≤ 400 mm ≥ 600 mm
10
A 11 - 13 B 14 - 25
A
11
A
1 73,5 mm
12 4 Ø 5,5mm
73,5 mm
5
6
Ø 90 mm
7
A
13
B
14
B
9AH 169-580-011 9AH 254-228-001
B1 B3 B4
16-17 20-22 23-25
15
B2 B4
18-19 23-25
B1 85 mm
Ø14 mm
min. 3 mm
16
85 mm
Ø98 mm
3x
Ø 14 mm
B1
1
K
4 CLIC
max. 14,8 mm
CLIC
K 3
4
17
K
CLIC
1
4
CLIC
K 1 2
4
90º K
CLIC
B2 85 mm
Ø17 mm
min. 3 mm
18
85 mm
Ø98 mm
3x
Ø 17 mm
B2
4 K
CLIC
max. 14,8 mm
K 3
CLIC
19
4 4
K
CLIC
1
K
1 2
CLIC
4
90º K
CLIC
B3 50 mm
Ø6,5 mm
41 mm
min. 3 mm
20
71 mm
104 mm
Ø 6,5 mm
B3
SW 10
21
B3
4 K
CLIC
max. 14,8 mm
CLIC
3
4
22 K
CLIC
K
CLIC 4
1
4 1 2
K
CLIC
90º K
CLIC
B4 38 mm
Ø6,5 mm
41 mm
min. 3 mm
23
71 mm
112 mm
Ø 6,5 mm
B4
SW 10
24
B4
4 K
CLIC
max. 14,8 mm
3
4
25
4
K
CLIC
CLIC
K 1
1 2
K 90º
CLIC CLIC
K
4
Torx 20 Torx 20
26
Torx 20
Elektrischer Anschluss Elektrisk anslutning Collegamento elettrico
Electrical connection Elektrische aansluiting Osaluettelo
Branchement électrique Conexión eléctrica
1
4
3
5 4mm
2
27 6
1 = 56A
2 58
4 2
3 = 31
4 = 15 3 1
3A @ 12V
1A @ 24V
28
30 87
56A 86
85 86 85
87
30
4 2 PIN1
3 1
FR FRANÇAIS ES ESPAÑOL
Respecter les directives ¡Siempre deberán respetarse las
et les dispositions légales de disposiciones y directrices legales
chaque pays applicables aux propias de cada país relacionadas
véhicules automobiles lors du con el montaje de los faros en los
montage des projecteurs ! vehículos!
DE DEUTSCH SV SVENSKA IT ITALIANO

Die jeweiligen landesspezifischen De rådande landsspecifika l Al montaggio dei proiettori,
gesetzlichen Vorgaben und agstadgade föreskrifter och rispettare le relative prescrizioni
29 Richtlinien für Kraftfahrzeuge, sind riktlinjer för motorfordon måste e normative legali specifiche del
bei der Montage der Scheinwerfer följas när strålkastare monteras. Paese per autoveicoli!
zu beachten!
EN ENGLISH NL NEDERLANDS FI SUOMI

The relevant country-specific De toepasselijke landspecifieke Valoja asennettaessa on noudatet-
statutory specifications and wettelijke vereisten en richtlijnen tava moottoriajoneuvoja koskevia
regulations for motor vehicles voor motorvoertuigen moeten bij maakohtaisia lakimääräyksiä ja
must be observed when installing de montage van de schijnwerpers ohjeita.
headlamps! in acht worden genomen!
DE TECHNISCHE DATEN SV TEKNISKA DATA IT DATI TECNICI
Fernlicht max. 20W Helljus max 20W Luce abbagliante max. 20W
Tagfahrlicht max. 16W Varselljus max 16W Luce di marcia diurna max. 16W
Positionslicht max. 2W Positionsljus max 2W Luce di posizione max. 2W
Betriebsspannung 9-32V Drisspänning 9-32V/DC Tensione di esercizio 9-32 V/c.c.
Strom im Fehlerfall < 10mA Ström vid defekt < 10mA Corrente in caso di guasto < 10mA
Absicherung pro Funktion : 3A (12V) / 1A (24V) Avsäkring per funktion: 3A (12V) / 1A (24V) Fusibile per ogni funzione: 3A (12V) / 1A (24V)
EN TECHNICAL DATA NL TECHNISCHE GEGEVENS FI TEKNISET TIEDOT

High beam max. 20W Grootlicht max. 20 W Kaukovalo, maks. 20 W
Daytime running light max. 16W Dagrijverlichting max. 16 W Päiväajovalo, maks. 16 W
30 Position light max. 2W Positielicht max. 2 W Seisontavalo, maks. 2 W
Operating voltage 9-32 V/DC Bedrijfsspanning 9-32 V/DC Käyttöjännite 9–32 V/DC
Current in event of malfunction < 10mA Stroom in geval van een storing < 10 mA Virta vian ilmaantuessa < 10 mA
Fuse protection per function: 3A (12V) / 1A (24V) Beveiliging per functie: 3A (12V) / 1A (24V) Sulake per toiminto: 3A (12V) / 1A (24V)
FR DOCUMENT TECHNIQUE ES DATOS TÉCNICOS

Feu de route max. 20 W Luz de largo alcance máx. 20 W
Feu de jour max. 16 W Luz de conducción diurna máx. 16 W
Feu de position max. 2 W Luz de posición máx. 2 W
Tension de service 9-32 V/c.c. Tensión de trabajo 9-32 V/DC
Courant en cas de défaut < 10 mA Corriente en caso de fallo < 10 mA
Fusible par fonction : 3A (12V) / 1A (24V) Fusible para cada función : 3A (12V) / 1A (24V)
DE Beleuchtungsanlage auf einwandfreie Funktion hin prüfen
EN Check that the lighting system is working perfectly
FR Contrôler le bon fonctionnement de l’installation d’éclairage
SV Kontrollera att ljussystemet fungerar felfritt

31
NL Controleer of de verlichting goed functioneert
ES Comprobar que el sistema de iluminación funciona impecablemente
IT Controllare la perfetta funzionalità dell’impianto di illuminazione
FI Tarkasta valaistusjärjestelmän toiminta

DE Bei Fragen oder Einbauproblemen, rufen Sie bitte den HELLA Kundendienst, Großhändler an
oder wenden Sie sich an Ihre Werkstatt.
EN Ifturn
you have questions or installation problems, please call the HELLA Service, wholesaler, or
to your garage.
FR Pour toutes questions ou problèmes de montage, merci de contacter le service après-vente

HELLA, votre distributeur ou votre garage.
SV Vid frågor eller monteringsproblem, kontakta Hellas kundtjänst, återförsäljaren eller din verk-
stad.
32
NL In geval van vragen of montageproblemen verzoeken wij u contact met de HELLA-klantenser-
vice, de groothandel of uw dealer op te nemen.
ES En caso de dudas o problemas de montaje, por favor, llame al Servicio postventa de Hella o al
mayorista, o bien diríjase a su taller.
IT Per qualsiasi domanda o problemi di montaggio si prega di contattare il servizio assistenza o il

proprio grossista HELLA oppure di rivolgersi alla propria officina.
FI Jos sinulla on kysymyksiä tai asennusongelmia, soita HELLA-asiakaspalvelulle tai tukkuliik-

keelle tai käänny korjaamon puoleen.
HELLA KGaA Hueck & Co.
Rixbecker Straße 75
59552 Lippstadt /Germany
www.hella.com
© HELLA KGaA Hueck & Co., Lippstadt

460 942-04 /05.14
MONTAGEANLEITUNG
90 MM LED L40/60 NEBELSCHEINWERFER
INSTALLATION INSTRUCTION
90 MM LED L40/60 FOG LAMPS
INSTRUCTIONS DE MONTAGE
90 MM LED L40/60 PROJECTEUR ANTIBROUILLARD
MONTERINGSANVISNING
90 MM LED L40/60 DIMSRTRÅLKASTARE
MONTAGEHANDLEIDING
90 MM LED L40/60 MISTLAMPEN
INSTRUCCIONES DE MONTAJE
90 MM LED L40/60 FAROS ANTINIEBLA
INSTRUZIONI DI MONTAGGIO
90 MM LED L40/60 PROIETTORI FENDINEBBIA
ASENNUSOHJE
90 MM LED L40/60 SUMUVALONHEITTIMET
Technische Änderungen vorbehalten. Das hier beschriebene System ist belüftet. In seltenen Fällen kann es
DE durch Umgebungsbedingungen zu geringer Kondensation von Luftfeuchtigkeit an der Streuscheibe kommen.
Dieses Kondensat löst sich jedoch rückstandfrei auf und hat keine schädigenden Einflüsse.
Subject to alteration without notice. The system described here is ventilated. In rare cases, environmental
EN conditions may cause slight condensation of humidity on the lens. This condensation nevertheless evaporates
without leaving behind any residue and has no damaging impact.
Sous réserve de modifications techniques. Le système décrit ici est ventilé. Dans de rares cas, il peut arriver
FR que le diffuseur soit soumis à une faible condensation par l’humidité de l’air dans des conditions ambiantes.
Toutefois, ce condensat se dissout sans résidu et n’a aucun effet nocif.
Vi reserverar oss för tekniska ändringar. Systemet som beskrivs här är ventilerat. I sällsynta fall kan omgivn-
SV ingsförhållanden leda till att fukt kondenseras på spridningslinsen. Kondensen försvinner utan att lämna spår
och har inga skadliga effekter.
2
Technische wijzigingen voorbehouden. Het hier omschreven systeem is geventileerd. In zeldzame gevallen kunnen
NL omgevingsfactoren ertoe leiden dat er, vanwege de luchtvochtigheid, lichte condensatie op de lichtverstrooiende
plaat ontstaat. Dit condensaat verdwijnt echter weer zonder sporen achter te laten en heeft geen schadelijke invloed.
Reservadas modificaciones técnicas. El sistema aquí descrito está ventilado. En raras ocasiones, las condi-
ES ciones ambientales pueden hacer que haya una baja condensación de humedad del aire en el cristal difusor.
Sin embargo, este líquido de condensación se disuelve sin generar residuos y no tiene efectos perjudiciales.
Con riserva di modifiche tecniche. Il sistema qui descritto è ventilato. In rari casi le condizioni ambientali pos-
IT sono comportare una bassa condensazione dell’umidità atmosferica sul diffusore di luce. Questa condensa si
scioglie tuttavia priva di residui e non ha alcuni influssi dannosi.
Oikeus teknisiin muutoksiin pidätetään. Tässä kuvailtu järjestelmä on tuulettuva. Joskus harvoin suuntauslin-
FI ssin pintaan voi tiivistyä hieman kosteutta ympäristöolojen vuoksi. Tämä tiivistynyt kosteus kuitenkin poistuu
jäämiä jättämättä eikä sillä ole haitallisia vaikutuksia.
DE Richtig DE Falsch DE Positionspfeil DE Bewegungspfeil

EN Correct EN Incorrect EN Location/Position Arrow EN Movement Arrow
FR Correct FR Incorrect FR Flèche de Position FR Flèche indiquant
SV Rätt SV Fel SV Positionpil sens du vouvement
NL Goed NL Fout NL Lokatie/Positie pijl SV Rörelsepil
ES Correcto ES Erróneo ES Flecha de posición NL Richtingspijl
IT Giusto IT Sbagliato IT Freccia di posizione ES Flecha de moviemiento
3 FI Oikein FI Väärin FI Paikannusnuoli IT Freccia di movimentov
FI Liikesuuntanuoli
DE Achtung DE Abklemmen DE Verbinden DE Siehe

EN Warning EN Disconnect EN Connect EN Look/See
FR Attention FR Déconnecter FR Connecter FR Voir
SV Varning SV Koppla los SV Ansult SV Se
NL Let op NL Demonteren NL In elkaar NL Kikjken naar
ES Atención ES Desconectar ES Conectar ES Ver
IT Attenzione IT Staccare IT Collegare IT Vedere
FI Huomio FI Irrota FI Yhdistä FI Katso
DE Nebellicht DE Positionslicht
EN Fog light EN Position light
FR Feu de brouillard FR Feu de position
SV Dimljus SV Positionsljus
NL Mistlicht NL Positielicht
ES Luz antiniebla ES Luz de posición
4 IT Fendinebbia IT Luce di posizione
FI Sumuvalo FI Seisontavalo
DE Tagfahrlicht DE Abbiegelicht
EN Daytime running light EN Cornering light
FR Feu de jour FR Projecteur de virage
SV Varselljus SV Kurvljus
NL Dagrijverlichting NL Afbuiglicht
ES Luz de conducción diurna ES Luz de curvas
IT Luce di marcia diurna IT Luce di curva statica
FI Päiväajovalo FI Kaarrevalo
Lieferumfang Leveransomfattning Contenuto della confezione
Scope of delivery Leveringsomvang Toimituksen sisältö
Fourniture Alcance de suministro
1N0 011 988-001 1N0 011 988-051 1N0 011 988-061
1N0 011 988-011

Zubehör Tillbehör Accessori
Accessories Toebehoren Lisätarvikkeet
Accessories Accessorios
8JA 202 231-002
8KW 863 933-013 (50x)

6 8KW 163 160-011
9GD 863 952-022
(0,35 - 0,5 mm)
9GD 863 952-012
(0,75 mm)
5DF 009 244-007
9GD 863 952-002 (50x)
Benötigte Montagewerkzeuge Nödvändiga monteringsverktyg Attrezzi necessari per il montaggio
Installation tools required Benodigde montagewerktuigen Tarvittavat asennustyökalut
Outillage de montage requis Herramientas de montaje necesarias
3,5 mm
5 mm
6,5 mm
7
14 mm
16 mm
17 mm
24 mm
Torx 20
SW 10
Montage Montering Montaggio
Mounting Montage Asennus
Montage Général Montaje
Ø110
Ø90 10 10
54.6
1.25
20 20
90.6
20 20
20
9
1NO 010 988-001
max. 800 mm
M1 N1 max. 3,5t
1200 mm max. *
max. 3,5t
250 mm min.
9x
10
max. 1500 mm
N3G
400 mm max.
* Nicht höher als Abblendlicht

Not higher than low beam
1NO 010 988-051/061
900 mm max. *
250 mm min.
max. 800 mm
11
M1 N1 max. 3,5t
max. 3,5t
9x
400 mm max.
1NO 010 988-011
max. 800 mm
M1 N1 max. 3,5t
1200 mm max. *
max. 3,5t
250 mm min.
12 9x
max. 1500 mm
N3G
400 mm max. 600 mm min.

1NO 011 988-061
1NO 011 988-051
13
1NO 011 988-051
1NO 011 988-061

1 73,5 mm
14 4
max. Ø 5,5mm
73,5 mm
5
6
Ø 90 mm
7
15
Torx 20
16
1
4
3
5 4mm
2
17 6
1 = /
2 = 58
4 2
3 = 31
4 = 15 3 1
3A @ 12V
1A @ 24V
58
18 87
30
86
85 86 85
87
30
31
4 2 PIN1
3 1
FR FRANÇAIS ES ESPAÑOL
Respecter les directives ¡Siempre deberán respetarse las
et les dispositions légales de disposiciones y directrices legales
chaque pays applicables aux propias de cada país relacionadas
véhicules automobiles lors du con el montaje de los faros en los
montage des projecteurs ! vehículos!
DE DEUTSCH SV SVENSKA IT ITALIANO

Die jeweiligen landesspezifischen De rådande landsspecifika l Al montaggio dei proiettori,
gesetzlichen Vorgaben und agstadgade föreskrifter och rispettare le relative prescrizioni
19 Richtlinien für Kraftfahrzeuge, sind riktlinjer för motorfordon måste e normative legali specifiche del
bei der Montage der Scheinwerfer följas när strålkastare monteras. Paese per autoveicoli!
zu beachten!
EN ENGLISH NL NEDERLANDS FI SUOMI

The relevant country-specific De toepasselijke landspecifieke Valoja asennettaessa on noudatet-
statutory specifications and wettelijke vereisten en richtlijnen tava moottoriajoneuvoja koskevia
regulations for motor vehicles voor motorvoertuigen moeten bij maakohtaisia lakimääräyksiä ja
must be observed when installing de montage van de schijnwerpers ohjeita.
headlamps! in acht worden genomen!
DE TECHNISCHE DATEN SV TEKNISKA DATA IT DATI TECNICI
Nebellicht max. 12W Dimljus max 12W Fendinebbia max. 12W
Abbiegelicht max. 16W Kurvljus max 16W Luce di curva statica max. 16W
Tagfahrlicht max. 16W Varselljus max 16W Luce di marcia diurna max. 16W
Positionslicht max. 2W Positionsljus max 2W Luce di posizione max. 2W
Betriebsspannung 9-32 V/DC Drisspänning 9-32V/DC Tensione di esercizio 9-32 V/c.c.
Strom im Fehlerfall < 10mA Ström vid defekt < 10mA Corrente in caso di guasto < 10mA
Absicherung pro Funktion : 3A (12V) / 1A (24V) Avsäkring per funktion: 3A (12V) / 1A (24V) Fusibile per ogni funzione: 3A (12V) / 1A (24V)
EN TECHNICAL DATA NL TECHNISCHE GEGEVENS FI TEKNISET TIEDOT

Fog light max. 12W Mistlicht max. 12 W Sumuvalo, maks. 12 W
Cornering light max. 16W Afbuiglicht max. 16 W Kaarrevalo, maks. 16 W
Daytime running light max. 16W Dagrijverlichting max. 16 W Päiväajovalo, maks. 16 W
20 Position light max. 2W Positielicht max. 2 W Seisontavalo, maks. 2 W
Operating voltage 9-32 V/DC Bedrijfsspanning 9-32 V/DC Käyttöjännite 9–32 V/DC
Current in event of malfunction < 10mA Stroom in geval van een storing < 10 mA Virta vian ilmaantuessa < 10 mA
Fuse protection per function: 3A (12V) / 1A (24V) Beveiliging per functie: 3A (12V) / 1A (24V) Sulake per toiminto: 3A (12V) / 1A (24V)
FR DOCUMENT TECHNIQUE ES DATOS TÉCNICOS

Feu de brouillard max. 12 W Luz antiniebla máx. 12 W
Projecteur de virage max. 16 W Luz de curvas máx. 16 W
Feu de jour max. 16 W Luz de conducción diurna máx. 16 W
Feu de position max. 2 W Luz de posición máx. 2 W
Tension de service 9-32 V/c.c. Tensión de trabajo 9-32 V/DC
Courant en cas de défaut < 10 mA Corriente en caso de fallo < 10 mA
Fusible par fonction : 3A (12V) / 1A (24V) Fusible para cada función : 3A (12V) / 1A (24V)
DE Beleuchtungsanlage auf einwandfreie Funktion hin prüfen
EN Check that the lighting system is working perfectly
FR Contrôler le bon fonctionnement de l’installation d’éclairage
SV Kontrollera att ljussystemet fungerar felfritt

21
NL Controleer of de verlichting goed functioneert
ES Comprobar que el sistema de iluminación funciona impecablemente
IT Controllare la perfetta funzionalità dell’impianto di illuminazione
FI Tarkasta valaistusjärjestelmän toiminta

DE Bei Fragen oder Einbauproblemen, rufen Sie bitte den HELLA Kundendienst, Großhändler an
oder wenden Sie sich an Ihre Werkstatt.
EN Ifturn
you have questions or installation problems, please call the HELLA Service, wholesaler, or
to your garage.
FR Pour toutes questions ou problèmes de montage, merci de contacter le service après-vente

HELLA, votre distributeur ou votre garage.
SV Vid frågor eller monteringsproblem, kontakta Hellas kundtjänst, återförsäljaren eller din verk-
stad.
22
NL In geval van vragen of montageproblemen verzoeken wij u contact met de HELLA-klantenser-
vice, de groothandel of uw dealer op te nemen.
ES En caso de dudas o problemas de montaje, por favor, llame al Servicio postventa de Hella o al
mayorista, o bien diríjase a su taller.
IT Per qualsiasi domanda o problemi di montaggio si prega di contattare il servizio assistenza o il

proprio grossista HELLA oppure di rivolgersi alla propria officina.
FI Jos sinulla on kysymyksiä tai asennusongelmia, soita HELLA-asiakaspalvelulle tai tukkuliik-

keelle tai käänny korjaamon puoleen.
HELLA KGaA Hueck & Co.
Rixbecker Straße 75
59552 Lippstadt /Germany
www.hella.com
© HELLA KGaA Hueck & Co., Lippstadt

460 942-03 /02.14
Printed in Germany
15.8. The integrated system for electronic management and diagnosis (ISEMD) through
CAN
The buses must be provided with an Integrated system for electronic management and
diagnosis (ISEMD) through CAN, which will be compatible with FMS STANDARD, version
2.0 or a similar interface.
The main electric and electronic subsystems, the automation of mechanical systems of the
vehicle and auxiliary equipment will be integrated with ISEMD: dashboard, the vehicle on
board computer, on board computer for AVL (OBC-AVL), OBC-ITS, the engine, gear box,
brake system, suspension system, doors, heating/air conditioning systems, lighting system,
signalling system, passenger information systems, video surveillance system, passenger
counting system etc.. Integration will allow information exchange, commands or control
operations of certain parameters.
Connectivity: ISEMD will provide data transfer to OBC-ITS or other equipment. The Supplier
must provide the necessary interfaces (including CAN communication protocols and
conversion functions) and standardize connections for data transfer (special connectors,
RS232, USB, wireless etc.).
The Tenderer will present the overall IT system architecture. The tenderer will describe the
software and hardware functionality for all equipment installed on the vehicle, communication
mode for downloading data onto server, maintenance manual, user and operating manual.
The information transmitted from CAN through FMS Standard or a similar interface must be
downloaded to a dedicated back-office application which will be installed at RATBV
headquarters before the first buses arrival. Communication must be conducted via OBC-ITS,
using 3G/4G module for alerts/warnings and main monitored parameters, and also using the
depot WI-FI system for other data transfer. The back-office software application must allow
visualization of following parameters:
- main alerts/warnings and errors from vehicle subsystems (also speeding over 50km/h,
lower level of engine oil and cooling liquid, abnormal fuel consumption, rapid drop of
fuel level in the fuel tank, cooling liquid temperature is too high, low pressure of
engine oil, fire danger in engine compartment, low pressure in pneumatic system,
pressure dropping in brake circuit, overcoming maintenance period, high level of wear
for brake plates etc.), including also planned maintenance warnings.
- vehicle speed, engine rotations, cooling liquid temperature, engine oil pressure,
instant fuel consumption (L/100 km for moving status, L/hour for stationary status),
fuel level in fuel tank, AdBlue level, temperature in passenger area.
The software application must include an interface for querying the data base and an
interface for creating the following reports:
- Driving mode report
§ Selection of: period, vehicle type/all vehicles types, vehicle number/all
vehicles of the same type, driver/all drivers who worked with the selected
bus in the selected period
§ Date/hour/minute, GPS coordinates, route
§ Fast acceleration and braking which overcome a configurable comfort
value
§ Fuel consumption of the vehicle in the selected time period
- Top best driver during a selected period
Output of all drivers sorted by anticipation time interval (summing of time
intervals between each accelerator pedal pressing followed by brake
pedal pressing)
- Top worst driver during a selected period
§ Output of drivers who overcome the comfort values for acceleration and
braking with mention about the number of times the driver overcome
those values
- Fuel consumption report during a selected period
§ Fuel consumption value will be provide in: absolute values (e.g.: litters of
fuel consumed in a period of time, from date, hour …to date, hour…), in
average values (e.g.: litters/100 km or litters/hour)
- Distances covered by the bus (during a selected period) between each end of line
and between depot and the end of line (integration with OBC-ITS must be provided
for terminus/depot identification through GPS data: the report will use the terminus
names provided for passengers information system)
- Engine working hours of vehicle (during a selected period) counting also the non-
working time intervals less than 10 minutes
- Idle time of the bus (engine running / vehicle not moving) during a selected period,
working hours of the air conditioning system and passenger area heating system
- Number of wheelchair ramp utilization per each bus, during a selected period
- Doors operating report per vehicle during a selected period: manoeuvre type:
opening/closing doors, GPS coordinates, timestamp
- Speed Gear utilization report (percentage)
- The application will allow editing of others reports based on data structure saved on
server.
- The software application must include an interface for remote monitoring and control
of the air conditioning and heating system from the passengers compartment. This
interface will allow to RATBV staff to monitor in real time the functioning of air
conditioning or heating system in the passenger area and to start or stop the systems.
Nr. Crt. Name of alarm / parameters CAN - Karsan availibility parameter
Main alerts/warnings and errors from vehicle

subsystems, including also planned
1 maintenance warnings.
speeding over 50km/h EDC2BC / Speed limiter status
lower level of engine oil and cooling liquid We need to be included in Tell Tale - FMS1
abnormal fuel consumption LFE1 / Fuel Rate
rapid drop of fuel level in the fuel tank DD / Fuel level
Alarms cooling liquid temperature is too high We need to be included in Tell Tale - FMS1
low pressure of engine oil We need to be included in Tell Tale - FMS1
fire danger in engine compartment
low pressure in pneumatic system We need to be included in Tell Tale - FMS1
pressure dropping in brake circuit We need to be included in Tell Tale - FMS1
overcoming maintenance period SERV
high level of wear for brake plates
2 Parameters
vehicle speed CCVS-V / Wheel based vehicle speed
engine rotations EEC1 / Engine speed
cooling liquid temperature ET1 / Engine coolant temperature
EFL/P1 / Engine Oil Pressure
EFL/P1 / Engine Oil Level
engine oil pressure EFL/P1 / Coolant Level
instant fuel consumption (L/100 km for moving LFE1 / Fuel Rate
status, L/hour for stationary status) LFE1 / Instantaneous Fuel Economy
fuel level in fuel tank DD / Fuel level
AdBlue level
temperature in passenger area
accelerator pedal pressing EEC2 / Accelerator pedal position 1
Variable
Parameters brake pedal pressing CCVS-V / Status of brake switch
Total Fuel Used HRLFC / Engine Total Fuel Used
Total Vehicle Distance VHDR / High Resolution Total Vehicle Distance
Total Hours of Operation HOURS / Engine Total Hours of Operation
DC1 / Position of doors
Door Control 1 DC1 / Ramp / Wheel Chair Lift Position
Door Control 2 DC2 / Open Status
Electronic Transmission Controller 2 ETC2 / Current gear
AIR1V / Pneumatic Supply Pressure
Air Supply Pressure AIR1V / Service Brake Air Pressure Circuit
EDC2BC / Speed limiter status
EDC2BC / Engine over temperature
EDC2BC EDC2BC / Engine oil pressure low
Nr. Crt. Report Name CAN - Karsan availibility parameter
1 Driving mode report

Fast acceleration and braking which overcome a
CCVS-V / Status of brake switch
configurable comfort value
Fuel consumption of the vehicle in the selected time
HRLFC / Engine Total Fuel Used
period
2 Top best driver during a selected period

Output of all drivers sorted by anticipation time interval EEC2 / Accelerator pedal position 1
(summing of time intervals between each accelerator CCVS-V / Status of brake switch
pedal pressing followed by brake pedal pressing)
3 Top worst driver during a selected period
Output of drivers who overcome the comfort values for EEC2 / Accelerator pedal position 1
acceleration and braking with mention about the number CCVS-V / Status of brake switch
of times the driver overcome those values
4 Fuel consumption report during a selected period
Fuel consumption value will be provide in: absolute
HRLFC / Engine Total Fuel Used
values (e.g.: litters of fuel consumed in a period of time,
LFE1 / Engine Average Fuel Economy
from date, hour …to date, hour…), in average values
(e.g.: litters/100 km or litters/hour)
Distances covered by the bus (during a selected

period) between each end of line and between depot
and the end of line (integration with OBC-ITS must VHDR / High Resolution Total Vehicle Distance
be provided for terminus/depot identification
through GPS data: the report will use the terminus
5 names provided for passengers information system)
Engine working hours of vehicle (during a selected
period) counting also the non-working time intervals HOURS / Engine Total Hours of Operation
6 less than 10 minutes
Idle time of the bus (engine running / vehicle not CCVS-V / Wheel based vehicle speed
7 moving) during a selected period, HOURS / Engine Total Hours of Operation
working hours of the air conditioning system and
8 passenger area heating system
Number of wheelchair ramp utilization per each bus,
DC1 / Ramp / Wheel Chair Lift Position
9 during a selected period
Doors operating report per vehicle during a selected
DC1 / Position of doors
period: manoeuvre type: opening/closing doors,
DC2 / Open Status
10 GPS coordinates, timestamp
11 Speed Gear utilization report (percentage) ETC2 / Current gear
TC02 Instruction Manual
Chapter & Index

Session 01 Welcome to new user
Session 02 Product Operation Requirement
Session 03 Electrical Characteristic
Session 04 Operating Instruction
Session 05 Product Diagrams
Session 06 Communication Mythology
01 Welcome to new user

1.1 This product was design for vehicle with CAN bus harnessing and according to J1939 standard.
1.2 Please contact our company if you find any questions.
02. Operation Requirement
2.1 Operation Voltage DC12 ~ 24V
2.2 Operation Temperature -20℃ ~ 80℃
2.3 Storage Temperature -40℃ ~ 85℃
3. Electrical Characteristic
No. Item Range Unit
1 Standby current ﹤50 mA
consumption
2 Frequency 433.91 ~ 433.93 mHZ
3 Rx Sensitivity -118 ~ -110 dBm
4 Operating Instruction
4.1 LED status Lamp
a) Normal mode, LED flash once at three second interval
b) Learning mode: while waiting for manual tire ID entry, LED will flash at 250ms alternative
interval
4.2 Learning TPMS sensors ID
Under Normal mode (i.e. LED flash at three second interval), quick press button for FIVE times
will enter learning mode (i.e. long BEEP follow by LED flashing at 250mse alternative
interval) , operator can use handheld code reader to transfer the tire sensor IDs batch into TC02 .
Beep sound will tell successful tire code transfer in next 90 seconds and return to normal mode.
If code transfer was not successful, NO BEEP sound before reentering normal mode.
1
5. Product Diagrams
5.1 Wiring diagram
Wire Color Description

Green CAN-L
Yellow CAN-H
Red DC12-24V
Black GND for grounding
2
5.2 Product drawing
3
6. TPMS CAN BUS Transceiver Communication coding
Base on J1939 for large vehicle
CAN bus data rate 250Kps
Reference ID 0x18FEF433
Pgn65268—Wheel condition—TIRE
Transmission cycle: 10s

Data length; 8 bits
Data page; 0
PDU format: 254
PDU Spec: 244
Default Setting: 6
Reference Group Reference: 65268（00FEF416）
Bit Start Length SPN description SPN

position/session
1 8 bits Tire position
2 1 byte Tire pressure
3-4 2 bytes Tire temperature
5.1 2 bits CTI sensor status Not support
5.3 2 bits CTI tire status Not support
5.5 2 bits CTI terminal end Not support
electrical status
6-7 2 bytes Tire air pressure losing
speed
8.6 3 bits Tire pressure limit status
SPN929
High 4 bits indicate Wheel Axle number, begin from normal driving position and from front axle to rear
axle.
Low 4 bits indicate a single position, begin from normal driving position, begin from Left to Right.
SPN241 Tire pressure monitor

Define as pressure between wheel to internal tire surface.
Bit length: 1 byte
Differential step: 4kPa/Step, measurement starting from 0 kPa
Measurement range: 0 to +1,000kPa (i.e. 0 to 145 PSI)
SPN242 Tire temperature monitor

Define as temperature beside tire surface
Bit Length: 2 bytes
Differential Step: 0.03125℃／Step, start from －273℃
Measurement Range: From －273 to 1735℃（i.e. From －459.4 to 3155.0℉）
4
SPN2587 Tire Valve pressure monitor
Define as pressure reference level. Level standard will be subject to different tire designed by individual
tire manufacturer.
000 extreme high pressure – define as pressure level in dangerous to vehicle safety
001 over pressure – define as pressure level exist tire manufacturer’s specification
010 no alarm pressure – define as pressure level within tire manufacturer’s specification
011 low pressure - define as pressure level below tire manufacturer’s specification
100 extreme low pressure - define as pressure level in dangerous to vehicle safety
101 no definition
110 error massager
111 not in used
Example
Index Channel Time log TX/RX direction Frame ID Frame type Frame Format Data length Data (Hex)
00051 0 84.969248 Receiving 18FEF433 EXTENDED FRAME DATA FRAME 08 10 00 E0 1B 00 00 00 60


Example Data: 10 00 E0 1B 00 00 00 60
Tire pressure ： 0x00 à 0 kPa
Tire Temperature : 0x1BE0 à 0 °C
Remark:
Now TC02 new software send out status as below:
1）. Do not receive sensor signal while the TC02 initially power on, send 6;
2）. Sensor do not work or failure, send 6;
3）. Once the TC02 received sensor signal, low pressure send 3, high pressure send 1 and normal pressure
send 2.

Karsan 18M Repair Manual

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Citymood 18 StepC C9 E6 Diesel

1.2 Editorial Series.........................................................................................................................8

1.3 Purpose of This Manual...........................................................................................................8

1.4 Target Audience of This Manual..............................................................................................9

1.5 How to Read This Manual........................................................................................................9

1.6 Regulations and Certifications...............................................................................................10

2.2 Vehicle Repair Personnel Skills..............................................................................................11

2.3 Proper Use of the Vehicle........................................................................................................11

3.1.1 Tightening Class.............................................................................................................14

3.1.2 Tightening Torques of Important Chassis Components..................................................14

3.2 Thermal Switches.....................................................................................................................23

3.2.1 Comprehensive Retro-Driver Control Panel...................................................................23

3.2.2 Complex Control Panel “D”............................................................................................24

3.2.3 Complex Control Panel “F”.............................................................................................25

3.4 Warning and Information Labels.............................................................................................27

3.4.1 Warning and Information Labels Outside the Vehicle....................................................27

3.5 Technical Features...................................................................................................................28

3.5.1 Bus and Homologation...................................................................................................28

4.1.1 Remove the Axle............................................................................................................29

4.1.2 Mount the Axle................................................................................................................31

4.2 Check the Brakes.....................................................................................................................33

4.2.1 Locate Brake Faults.......................................................................................................33

4.2.2 Wear Limits....................................................................................................................35

4.3 Replace the Front Brake Cylinder...........................................................................................36

4.3.1 Remove the Front Brake Cylinder..................................................................................36

4.3.2 Fit the Front Brake Cylinder...........................................................................................36

4.4 Replace the Front Pneumatic Spring.....................................................................................37

4.4.1 Remove the Front Pneumatic Spring.............................................................................37

4.4.2 Mount the Front Pneumatic Spring................................................................................39

4.5 Check the Leveling of the Vehicle..........................................................................................40

4.6 Replace Brake Discs................................................................................................................42

4.7 Replace the Shock Absorbers.................................................................................................42

5.1.1 Remove the Full Rear Axle.............................................................................................43

5.1.2 Reinstall the Complete Rear Axle..................................................................................46

5.2 Replace the Rear Brake Cylinder...........................................................................................50

5.2.1 Remove the Rear Brake Cylinder...................................................................................50

5.2.2 Install the Rear Brake Cylinder.......................................................................................51

5.3 Replace the Rear Pneumatic Spring.......................................................................................51

5.3.1 Remove the Rear Pneumatic Spring..............................................................................52

5.3.2 Fit the Rear Pneumatic Spring.......................................................................................53

5.4 Checking Wheel Hub................................................................................................................54

5.5 Checking the Rear Side Gear Reducer...................................................................................54

5.6 Replace Brake Discs................................................................................................................55

5.7 Replace the Shock Absorbers.................................................................................................55

6.1.1 Remove the Drive Shaft.................................................................................................56

6.1.2 Mount the Transmission Shaft........................................................................................57

7 Automatic Speed Change................................................................................. 59

7.1.1 Remove the Automatic Gearbox....................................................................................59

7.1.2 Mount the Automatic Gearbox........................................................................................62

8.1.1 Remove the Engine........................................................................................................65

8.1.2 Mounting the Engine......................................................................................................69

8.2 Replace the Alternator.............................................................................................................72

8.3 Replace the Engine Oil Filling Tank........................................................................................72

8.3.1 Remove the Engine Oil Filling Tank...............................................................................72

8.3.2 Install the Engine Oil Filling Tank...................................................................................74

9 Door Control System......................................................................................... 76

9.2 Replace the Door Control Cylinder.........................................................................................76

9.3 Adjust the Doors.......................................................................................................................76

10.1.1 Remove the Right Rear-View Mirror............................................................................77

10.1.2 Fit the Right Rear-View Mirror.....................................................................................77

10.2 Replace the Left Rear-View Mirror.......................................................................................77

10.2.1 Remove the Left Rear-View Mirror...............................................................................77

10.2.2 Fit the Left Mirror..........................................................................................................78