Page 1
Andrew Burrows Rocker arms / Adjustment 03/02/16
Rocker arms, adjustment
Position the marks on the camshaft which indicate the number of the cylinder to adjust between the marks on the camshaft front bearing cap.
Use tool A.
A = 6956
Direction of rotation of engine: anticlockwise.
See pages .
Camshaft marks
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Page 2
Andrew Burrows Rocker arms / Adjustment 03/02/16
Without "Optibrake" exhaust brake
The marks (B) 1 - 5 - 3 - 6 - 2 - 4 correspond to the recommended inlet valve clearances , to the recommended exhaust valve clearances and to the
recommended pump injector pre-travel distances for each relative cylinder.
Mark (B) must be positioned in the centre of marks (A) when carrying out the adjustment.
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Page 3
Andrew Burrows Rocker arms / Adjustment 03/02/16
With "Optibrake" exhaust brake
The marks (B) 1 - 5 - 3 - 6 - 2 - 4 correspond to the recommended inlet valve clearances and to the recommended pump injector pre-travel distances for
each relative cylinder.
The marks (C) V1 - V5 - V3 - V6 - V2 - V4 correspond to the recommended exhaust valve clearances for each relative cylinder.
The marks (B) or (C) must be positioned between the marks (A) to make the correct adjustment.
Adjustment of inlet valves
Measure the valve clearances using feeler gauges.
See pages .
Loosen the locknut and the adjuster.
Adjust the clearance between the rocker arm and the valve yoke by means of screw.
Tighten the locknut to torque while holding the adjuster.
See pages .
Make a mark on the rocker arm when adjustment is finished.
Perform the same operation on all the other cylinders.
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Page 4
Andrew Burrows Rocker arms / Adjustment 03/02/16
Adjustment of unit pump injectors pre-travel
Check the torque of the injector flange attachment bolts without removing the rocker arm assembly.
Use tool A.
A = 0162
Tighten to torque.
See pages .
This operation is to be performed at each valve adjustment maintenance.
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Page 5
Andrew Burrows Rocker arms / Adjustment 03/02/16
Loosen the locknut and the adjuster.
Screw up the adjuster by hand until contact is made with the pump injector.
Tighten the adjuster through 2/3 of a turn to obtain a unit pump injector preload.
Tighten the locknut to torque while holding the adjuster.
See pages .
Make a mark on the rocker arm when adjustment is finished.
Perform the same operation on all the other cylinders.
Exhaust valve adjustment
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Page 6
Andrew Burrows Rocker arms / Adjustment 03/02/16
Without "Optibrake" exhaust brake
Measure the valve clearances using feeler gauges.
See pages .
Loosen the locknut and the adjuster.
Adjust the clearance between the rocker arm and the valve yoke by means of screw.
Tighten the locknut to torque while holding the adjuster.
See pages .
Make a mark on the rocker arm when adjustment is finished.
Perform the same operation on all the other cylinders.
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Page 7
Andrew Burrows Rocker arms / Adjustment 03/02/16
With "Optibrake" exhaust brake
Before making the adjustment, press rocker arm (1).
Compress valve spring (2) to free the oil in the rocker arm.
Use a piece of rigid iron wire to make a hook (A).
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Page 8
Andrew Burrows Rocker arms / Adjustment 03/02/16
Check the clearance between the valve yoke and the exhaust rocker arm piston. Turn the piston to ensure that it is properly seated in its housing.
Use a feeler gauge corresponding to the recommended clearance.
See pages .
In the event of rocker arm play or sticking, make the check with a thicker or thinner feeler gauge in order to determine the thickness of the new adjusting
shim.
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Page 9
Andrew Burrows Rocker arms / Adjustment 03/02/16
In the event of incorrect clearances.
Remove bolt.
Remove adjusting shim .
Hold the caliper in place when unbolting.
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Page 10
Andrew Burrows Rocker arms / Adjustment 03/02/16
Note down the thickness X engraved on adjusting shim.
Determine the thickness of the new adjustment shim, in order to obtain the recommended clearance.
See pages .
You can superimpose a maximum of 2 adjusting shims, provided that they have the same thickness. Adjusting shims are available with thicknesses of
0.05 by0.05 mm.
10 / 12
Page 11
Andrew Burrows Rocker arms / Adjustment 03/02/16
Fit shim.
Fit bolt.
Tighten to torque.
See pages .
Hold the caliper in place when tightening.
Again check the clearance between the valve yoke and the arm piston.
Make a mark on the rocker arm when adjustment is finished.
Perform the same operation on all the other cylinders.
11 / 12
Page 12
Andrew Burrows Rocker arms / Adjustment 03/02/16
Remove tool A.
A = 6956
Tools
Specific tools
Illustration RENAULT
Designation Manufacturer's
TRUCKS part N°
7409996956 CONTROL 1 1
7488840162 WRENCH 2 1
reference N°
Manufacturer's code N° Scale Qty
12 / 12
Page 13
Andrew Burrows Key / Diagram 02/02/16
Group 0 - Electronics
Polarity N° Designation
0010 Communication bus J1587-1 (+ signal)
0011 Communication bus J1587-1 (- signal)
0012 Communication bus J1939-1 (+ signal)
0013 Communication bus J1939-1 (- signal)
0014 Not assigned
0015 Radio remote control
0016 Radio remote control
0017 Radio remote control
0018 Radio remote control
0019 Radio remote control
0020 Radio remote control
0021 “ZF” communication bus (+ signal)
0022 “ZF” communication bus (- signal)
0023 Power supply relay control by vehicle management ECU
0024 Injection pump and camshaft speed sensor information (electronic injection / - signal)
0025 Injection pump and camshaft speed sensor information (electronic injection / + signal)
0026 Gear lever communication bus (+ signal)
0027 Hydraulic retarder proportional solenoid valve control
0029 Hydraulic retarder oil boosting solenoid valve control
0031 Hydraulic retarder coolant temperature information
0032 Hydraulic retarder coolant temperature information
0038 Retarder manual control (analogue signal)
0039 Alarm siren activation and/or disabling encoded line
0045 Communication bus for EBS trailer socket (+ signal)
0046 Communication bus for EBS trailer socket (- signal)
0056 Vehicle speed sensor encrypted data line
0057 Information display pull-down menu sequence change signal
0058 Information display pull-down menu sequence change signal
0061 Gearbox input shaft speed information (+ signal)
0062 Gearbox input shaft speed information (- signal)
0063 Automatic gearbox casing oil level sensor power supply
0064 Automatic gearbox identification line
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Page 14
Andrew Burrows Key / Diagram 02/02/16
0065 Automatic gearbox casing oil temperature sensor information
0066 Automatic gearbox casing oil level sensor information
0067 Communication bus J1587 for gearbox diagnostic socket (+ signal)
0068 Communication bus J1587 for gearbox diagnostic socket (- signal)
0069 Gearbox speed selector data bit 1
007 Accelerator pedal potentiometer power supply
0070 Gearbox speed selector data bit 2
0071 Gearbox speed selector data bit 4
0072 Gearbox speed selector data bit 8
0073 Gearbox speed selector data parity bit
0074 Link between gearbox ECU and gear lever display
0075 Automatic gearbox gear lever information in input mode on gearbox ECU
0076 Automatic gearbox hydraulic pressure sensor information
0084 Automatic gearbox output speed sensor information (- signal)
0086 Automatic gearbox temperature sensor information
0087 Automatic gearbox turbine speed sensor information
0088 Automatic gearbox output speed sensor information (+ signal)
0089 Retarder coolant temperature sensor information
0100 Onboard management data transmission bus (+ signal)
0101 Onboard management data transmission bus (- signal)
0102 Onboard management data reception bus (+ signal)
0103 Onboard management data reception bus (- signal)
0104 Communication bus J1587-2 (+ signal)
0105 Communication bus J1587-2 (- signal)
0107 RH front brake pads wear analogue sensor earth
0108 RH front brake pads wear analogue sensor information
0109 RH front brake pads wear analogue sensor power supply (+5V)
011 Humidity sensor information
0114 Temperature sensor analogue signal for adjusting exhaust gases (EGR)
0116 Coolant temperature sensor analogue signal
0117 Pusher or follower rear axle angle sensor minimum voltage
0118 Pusher or follower rear axle angle sensor maximum voltage
0119 Front axle angle sensor minimum voltage
0120 Front axle angle sensor minimum voltage
0123 Red LED indicating that vehicle alarm is set (+) power supply
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Page 15
Andrew Burrows Key / Diagram 02/02/16
0127 Alarm ultrasonic reception (RX+ signal)
0128 Alarm ultrasonic reception (RX- signal)
0129 Alarm ultrasonic transmission (RX+ signal)
0130 Alarm ultrasonic transmission (RX- signal)
0143 Engine crankcase pressure sensor information
0144 Fuel pressure sensor information
0145 Available power supply (earth delivered by ECU for on-chassis engine stop control)
0146 Available power supply (Information requested by for on-chassis engine stop control)
0147 Communication bus between EBS ECU and front module (- signal)
0148 Communication bus between EBS ECU and front module (+ signal)
0149 Communication bus between EBS ECU and first additional module (- signal)
0150 Communication bus between EBS ECU and first additional module (- signal)
0151 Engine coolant level sensor information
0160 LH front brake pads wear analogue sensor earth
0161 LH front brake pads wear analogue sensor information
0162 LH front brake pads wear analogue sensor power supply (+5V)
0163 First axle RH rear brake pads wear analogue sensor earth
0164 First axle RH rear brake pads wear analogue sensor information
0165 First axle RH rear brake pads wear analogue sensor power supply (+5V)
0166 First axle LH rear brake pads wear analogue sensor earth
0167 First axle LH rear brake pads wear analogue sensor information
0168 First axle LH rear brake pads wear analogue sensor power supply (+5V)
0169 Second axle RH rear brake pads wear analogue sensor earth
017 Accelerator pedal position potentiometer information
0170 Second axle RH rear brake pads wear analogue sensor information
0171 Second axle LH rear brake pads wear analogue sensor power supply (+5V)
0172 Second axle LH rear brake pads wear analogue sensor earth
0173 Second axle LH rear brake pads wear analogue sensor information
0174 Second axle LH rear brake pads wear analogue sensor power supply (+5V)
0175 First rear axle RH speed sensor information
0176 First rear axle RH speed sensor information
0177 First rear axle LH speed sensor information
0178 First rear axle LH speed sensor information
0180 RH rear brake pads wear analogue sensor earth on PUSHER additional module
0181 RH rear brake pads wear analogue sensor information on PUSHER additional module
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Page 16
Andrew Burrows Key / Diagram 02/02/16
0182 RH rear brake pads wear analogue sensor power supply (+5V) on PUSHER additional module
0183 LH rear brake pads wear analogue sensor earth on PUSHER additional module
0184 LH rear brake pads wear analogue sensor information on PUSHER additional module
0185 LH rear brake pads wear analogue sensor power supply (+5V) on PUSHER additional module
0186 LH rear brake pads wear analogue sensor earth on PUSHER additional module
0187 RH rear brake pads wear sensor information (follower axle module)
0188 RH rear brake pads wear sensor power supply (+5V) (follower axle module)
0189 LH brake pads wear sensor earth (follower axle module)
0190 LH brake pads wear sensor information (follower axle module)
0191 LH brake pads wear sensor power supply (+5V) (follower axle module)
0192 “Driver’s side hand presence” door sensor information (+ signal)
0193 “Driver’s side hand presence” door sensor power supply
0194 “Driver’s side hand presence” door sensor information (- signal)
0195 “Driver’s side hand presence” door sensor information (+ signal)
0196 “Passenger’s side hand presence” door sensor power supply
0197 “Passenger’s side hand presence” door sensor information (- signal)
0198 Driver’s side door antenna (+ signal)
0199 Driver’s side door antenna (- signal)
0200 Passenger’s side door antenna (+ signal)
0201 Passenger’s side door antenna (- signal)
0202 Cab antenna 1 (+ signal)
0203 Cab antenna 1 (- signal)
0204 Cab antenna 2 (+ signal)
0205 Cab antenna 2 (- signal)
0206 Communication bus J1939-6 (+ signal)
0207 Communication bus J1939-6 (- signal)
0208 Communication bus J1587 (+ signal)
0209 Communication bus J1587 (- signal)
0212 Cruise control analogue sensor power supply
022 Accelerator pedal position potentiometer information
028 Cruise control ON/OFF control
029 Cruise control ON/OFF control
03 Rear stop lights power supply (12N socket)
030 RH rear direction indicator light power supply (12N socket)
0307 Rear fog lights power supply (12N socket)
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Page 17
Andrew Burrows Key / Diagram 02/02/16
0308 LH rear direction indicator light power supply (12N socket)
031 Cruise control signal
032 Engine oil temperature information with electronic fuel-injection system
033 Intake air temperature information with electronic fuel-injection system
034 Intake air temperature information (P2) with electronic fuel-injection system
0374 Encoded link between radio frequency receiver and alarm
0375 Hazard lights control by radio frequency receiver and/or alarm
0376 EBS module pressure sensor power supply for trailer control
0377 EBS module pressure sensor information for trailer control
0380 EBS module pressure sensor earth for trailer control
0381 Communication bus between EBS ECU and second additional module (- signal)
0382 Communication bus between EBS ECU and second additional module (+ signal)
0384 "PTO" control signal input for engine speed control (customer’s pre-arrangement)
039 Brake pedal position sensor information with EBS system
040 Brake pedal position sensor information with EBS system
0403 Encoded tractor/trailer link between alarm and freight protection module
0405 Tachograph serial data bus for fleet management
041 Line K information for diagnostic socket
0411 Communication bus J1939-2 (+ signal)
0412 Communication bus J1939-2 (- signal)
0413 Communication bus for bodybuilding or fleet management (- signal)
0414 Communication bus for bodybuilding or fleet management (+ signal)
0415 Communication bus between EBS ECU and on-chassis acceleration sensor (+ signal)
0416 Communication bus between EBS ECU and on-chassis acceleration sensor (- signal)
0424 Communication bus J1939 for docking radar (+ signal)
0425 Communication bus J1939 for docking radar (- signal)
045 Cruise control deceleration control
0460 Switch-operated control (bodybuilder’s pre-arrangement)
0461 Switch-operated control (bodybuilder’s pre-arrangement)
0462 Communication bus for vehicle OBD data socket (+ signal)
0463 Communication bus for vehicle OBD data socket (- signal)
0464 Diesel fuel particulate filter temperature sensor power supply
0465 Diesel fuel particulate filter temperature sensor power supply
047 Cruise control acceleration control
052 Flywheel engine speed sensor information (+ signal)
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Page 18
Andrew Burrows Key / Diagram 02/02/16
055 Flywheel engine speed sensor information (- signal)
056 Brake pedal position sensor power supply (+5V)
057 EBS system load sensor information
0608 Reversing lights power supply (12N socket)
0632 Rear marker lights power supply (12N socket)
064 Communication bus between EBS ECU and double rear module (- signal)
066 Communication bus between EBS ECU and double rear module (+ signal)
071 EBS system load sensor earth
072 EBS ECU earth for brake valve
073 EBS system load sensor power supply (+5V)
077 Accelerator pedal position sensor information (rest position)
079 Variable-drive fan power supply
080 Engine oil pressure sensor earth
081 Engine oil pressure sensor power supply
082 Communication bus between gear selector and automatic gearbox ECU (+ signal)
083 Communication bus between gear selector and automatic gearbox ECU (- signal)
084 Shunt between gearbox ECU terminal 66 and 26
0801 Communication bus J1587 for adaptive cruise control system (+ signal)
0802 Communication bus J1587 for adaptive cruise control system (- signal)
0803 Information from cruise control system
0804 Information from cruise control system
0805 Information from cruise control system
0806 Information from cruise control system
0807 Information from cruise control system
0808 Information from cruise control system
0809 Information from cruise control system
0810 Gearbox output speed information (+ signal)
0811 Gearbox output speed information (- signal)
0812 First front axle RH roadwheel speed sensor information (+ signal)
0813 First front axle RH roadwheel speed sensor information (- signal)
0814 Second front axle RH roadwheel speed sensor information (+ signal)
0815 Second front axle RH roadwheel speed sensor information (- signal)
0816 First front axle LH wheel speed sensor information (+ signal)
0817 First front axle LH wheel speed sensor information (- signal)
0818 Second front axle LH wheel speed sensor information (+ signal)
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Page 19
Andrew Burrows Key / Diagram 02/02/16
0819 Second front axle LH wheel speed sensor information (- signal)
0820 First front axle RH wheel speed sensor information (+ signal)
0821 First front axle RH wheel speed sensor information (- signal)
0822 First front axle LH wheel speed sensor information (+ signal)
0823 First front axle LH wheel speed sensor information (- signal)
0833 Inclination sensor power supply (+)
0834 Inclination sensor information
0835 Inclination sensor power supply (-)
0836 Clutch position sensor power supply (+)
0837 Clutch position sensor information
0838 Clutch position sensor power supply (-)
0839 Parking brake control power supply (-)
0840 Parking brake control potentiometers N° 1 & 2 power supply
0841 Parking brake wake-up contact power supply
0842 Parking brake control potentiometer N° 1 information
0843 Parking brake control potentiometer N° 2 information
0844 Parking brake unlocking switch N° 1 information
0845 Parking brake unlocking switch N° 2 information
0846 Parking brake module air pressure sensor power supply (+)
0847 Parking brake module air pressure sensor power supply (-)
0848 Parking brake module air pressure sensor information
085 Rail pressure sensor information
087 Engine oil pressure sensor information
088 Retarder torque sensor information
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Page 20
Andrew Burrows Key / Diagram 02/02/16
Group 1 - Earths and negative power supplies
Polarity N° Designation
1 Vehicle general earth
11 Microphone (- signal)
12 Gearbox neutral position sensor information
13 Engine water circuit by-pass solenoid valve control
14 AdBlue heating resistor control (in circuit from tank to pump module)
15 AdBlue heating resistor control (in circuit from pump module to dosing solenoid valve)
16 AdBlue heating resistor control (in circuit from dosing solenoid valve to pump module)
17 AdBlue heating resistor control (in circuit from pump module to tank)
18 12 Volts socket earth (multi-pass cab option)
19 AdBlue heating resistor control (in filter, on pump)
101 Humidity sensor power supply (-)
104 Two-tone horn power supply (-)
106 Assistance control information
119 "Front door open" position sensor information for lighting
(overhead light, stepwell light, locker lights, ambient lighting...)
123 Clutch pedal position sensor information
124 12 volts power socket earth
130 Overhead lights lighting earth (after master switch)
131 Communication bus between gear selector and ECU (- signal)
132 Communication bus between gear selector and ECU (+ signal)
141 Tachograph speed sensor information
142 Tachograph speed sensor information
144 Voltage converter earth for CB power supply
147 Master switch coil control
148 Master switch control
151 Available power supply (rear compartment open warning light)
152 Overhead lights earth
155 Voltage converter earth for radiotelephone power supply
156 Transfer box "low speed" information
157 Front wheels diff lock information
158 Transfer box PTO engaged information
159 Transfer box diff lock information
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Page 21
Andrew Burrows Key / Diagram 02/02/16
169 Doors central locking electronic box inhibition earth (presence of key in ignition switch)
173 N° 1/2/3 cylinder injectors earth (line 1)
174 N° 4/5/6 cylinder injectors earth (line 1)
183 Hydraulic retarder proportional solenoid valve earth
184 Hydraulic retarder charge accumulator solenoid valve earth
193 Earth between A/C ECU and fan management ECU
197 Master switch relay earth
198 Battery charging receptacle earth
1001 Front spotlight earth
1006 Exhaust brake solenoid valve N° 2 control earth
1007 Exhaust brake solenoid valve N° 2 control earth
1008 Exhaust brake electrovalve power supply (-)
1010 Fan electric clutch pilot-control earth
1012 EBS system solenoid valve earth
1018 Reversing lights relay control earth
1019 12 volts socket voltage converter earth
1020 Rear, doors opening/closing information
1021 Rear overhead lights power supply (-)
1025 Corrected vehicle speed information
1026 Engine speed regulation control (first selection)
1029 Automatic gearbox solenoid valve earth
1030 Automatic gearbox solenoid valve earth
1031 Automatic gearbox solenoid valve earth
1032 Automatic gearbox solenoid valve earth
1033 Automatic gearbox solenoid valve earth
1034 Automatic gearbox solenoid valve earth
1035 Automatic gearbox solenoid valve earth
1036 Automatic gearbox solenoid valve earth
1037 Automatic gearbox solenoid valve earth
1038 Automatic gearbox solenoid valve earth
1039 Automatic gearbox neutral earth
1043 Automatic gearbox solenoid valve earth
1045 Retarder control selector interface earth
1046 Automatic gearbox solenoid valve earth
1051 Air conditioning cut-out upon engine power loss control
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Page 22
Andrew Burrows Key / Diagram 02/02/16
1058 Fuel preheating relay control
1077 Earth delivered by engine management ECU for starting relay control
1081 Piloted axle control sensor earth
1084 Piloted axle control solenoid valve earth
1119 Alarm diode earth
1124 Roadwheels anti-slip sensor earth (ESP)
1140 PTO N° 1 engagement request
1141 Engine speed regulation control (second selection)
1147 Master switch closing control (ADR)
1148 Master switch closing control (ADR)
1149 Master switch warning light earth (ADR)
1150 Alternator earthing relay (-) control (ADR)
1151 N° 1/2/3 cylinder injectors earth (line 2)
1152 Cruise control operating control
1153 N° 4/5/6 cylinder injectors earth (line 2)
1154 Fuel pump control
1155 Air suspension ECU relay control
1156 Water/fuel separator bleeding solenoid valve control
1157 Alarm sound volume reduction control
1159 "Door open" information
1160 Engine retarder VGT2 solenoid valve earth
1161 Information feedback for "difficult terrain" warning light
1162 Turbocharger speed sensor earth
1163 Master switch diode earthing (ADR)
1164 Electrical master switch relay earthing (ADR)
1165 Single "H" solenoid valve N° 1 earthing
1166 Single "H" solenoid valve N° 2 earthing
1167 AdBlue tank level and temperature sensor earth
1168 AdBlue tank level and temperature sensor power supply (+5V)
1180 Driver presence in seat sensor power supply (-)
1200 Gearbox neutral position sensor information (after diode)
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Page 23
Andrew Burrows Key / Diagram 02/02/16
Group 2 - Positive power supplies
Polarity N° Designation
2 (+) power supply capable of being cut by master switch
20 Microphone (+ signal)
21 Urea heating resistor N° 1 (+) power supply
22 Key switch relay excitation (after ignition position)
23 Urea heating resistor N° 2 (+) power supply
24 (+) power supply after ignition (air management ECU, information
display, alarm, engine immobilizer, doors central locking)
25 Battery charge, alternator terminal A+, engine running warning light
26 Charging socket (+) power supply
28 Hydraulic pump power supply
200 Radio antenna power supply (+12V)
201 (+) power supply not cut by master switch
202 Full-time (+) power supply (headlights and hazard lights management ECU)
203 (+) power supply not cut by master switch (tachograph)
205 Starter relay control
206 (+) power supply after relay (fan-coil heaters)
208 (+) power supply capable of being cut by master switch (available power supply)
209 Radio antenna coaxial cable signal
210 Radio antenna coaxial cable earth
211 (+) power supply after ignition (ABS/EBS trailer socket)
212 (+) power supply after vehicle management ECU power supply relay
214 Accessories (+) power supply (ignition key position 1)
215 (+) power supply after ignition (rearview mirror
defrosting relay, swivelling rearview mirrors control)
216 GPS antenna coaxial cable signal
217 GPS antenna coaxial cable earth
218 GSM antenna coaxial cable signal
219 GSM antenna coaxial cable earth
220 GSM antenna coaxial cable signal (radiotelephone pre-arrangement)
221 GSM antenna coaxial cable earth (radiotelephone pre-arrangement)
229 (+) power supply after ignition (vehicle management ECU, tachograph)
238 (+) power supply after master switch (heated windscreen)
240 Brake pedal position sensor information
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Page 24
Andrew Burrows Key / Diagram 02/02/16
243 (+) power supply after ignition (cab tilt relay)
247 (+) power supply capable of being cut by master switch (cab tilting)
260 (+) power supply after air suspension ECU power supply relay
263 Full-time (+) power supply for central locking of electrical locks and electrical master switch
control or network isolation relay power supply and electronic master switch if FPT type vehicle
268 Intermediate conductor between battery banks
270 (+) power supply capable of being cut by master switch (automatic gearbox)
273 (+) power supply after ignition (hydraulic retarder)
274 (+) power supply after ignition (air suspension management ECU)
275 (+) power supply after ignition (available power supply)
291 Engine management and vehicle management ECUs
electronic fuel-injection function power supply
292 Engine ECU electronic fuel-injection function digital power supply
293 N° 1 cylinder injector control (line 1)
294 N° 3 cylinder injector control (line 1)
295 N° 2 cylinder injector control (line 1)
296 N° 5 cylinder injector control (line 1)
297 N° 6 cylinder injector control (line 1)
298 N° 4 cylinder injector control (line 1)
2000 (+) power supply after heated windscreen resistor fuse
2005 Brake pedal position sensor information
2014 (+) power supply after ignition (air conditioning/heating)
2016 Information between air conditioning control and ventilation control ECU.
2017 Information between air conditioning control and ventilation control ECU.
2018 Information between air conditioning control and ventilation control ECU.
2023 (+) power supply after master switch for retarder
2025 (+) power supply after ignition for ABS and/or EBS system
2050 Auto/manual retarder mode request
2056 (+) power supply capable of being cut by master switch
2057 on-chassis (+) power supply (bodybuilder’s pre-arrangement)
2069 Automatic gearbox solenoid valve (+) power supply
2070 Automatic gearbox solenoid valve (+) power supply
2071 Automatic gearbox solenoid valve (+) power supply
2072 Automatic gearbox solenoid valve (+) power supply
2088 Automatic gearbox solenoid valve (+) power supply
2093 Power supply after master switch
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Page 25
Andrew Burrows Key / Diagram 02/02/16
2109 Air suspension ECU remote control electrical socket (+) power supply
2117 (+) power supply after ignition
2119 Master switch opening condition (ADR)
2120 (+) power supply after master switch (available power supply)
2121 (+) power supply after ignition (diff lock control, PTO electrovalves)
2122 (+) power supply after ignition (vehicle management ECU)
2123 (+) power supply after ignition (engine speed regulation adjustment,
water/fuel separator bleed solenoid valve, auto/manual selection)
2124 Accelerator and clutch pedals position sensor power supply
2125 (+) power supply after bodybuilder’s pre-arrangements ECU relay
2126 Alternator earthing relay (+) power supply (ADR)
2127 (+) power supply after automatic gearbox ECU relay
2128 Night lighting power supply (available power supply)
2132 Batteries DC (+) power supply (independent heating)
2220 Winch power supply
2221 (+) power supply after master switch (available for bodybuilding and/or parking socket)
2222 (+) power supply for all power fuses (alternator output B+)
2223 (+) power supply before master switch (flasher unit and power fuses box)
2224 (+) power supply after master switch (air preheating)
2226 Alternator excitation earthing upon opening of master switch
2227 (+) power supply before master switch (engine
immobilizer electronic box, automatic gearbox ECUs)
2229 Alternator-controlled (+) power supply (engine running)
2230 (+) power supply after master switch (air production management ECU)
2231 Accessories (+) power supply (sun-roof and headlamps ride corrector)
2232 Accessories (+) power supply (electrically-operated windows)
2233 (+) power supply after master switch
2234 (+) power supply after ignition (in-cab bodybuilder’s pre-arrangements)
2235 Vehicle management ECU “wake-up” (+) power supply
2302 (+) power supply after master switch (refrigerator and voltage dropper)
2303 Alarm siren and piloted axle ECU power supply
2304 (+) power supply after master switch (independent heating)
2306 (+) power supply after master switch (independent heating)
2307 "Batteries being charged" information (engine running)
2309 (+) power supply after master switch (EBS electronic box ECU)
2310 (+) power supply after ignition (onboard management ECU and doors management ECU)
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Andrew Burrows Key / Diagram 02/02/16
2311 (+) power supply after ignition (available power supply)
2312 (+) power supply after ignition (onboard management ECU)
2315 Accessories power supply (bodybuilder’s pre-arrangement)
2316 (+) power supply after master switch (lighting and signalling management ECU)
2317 (+) power supply after ignition (reversing lights and bodybuilder’s pre-arrangements relay)
2318 "Panic / alarm" system control
2319 Alarm sound volume reduction information
2320 Automatic gearbox ECU power supply relay control
2323 Engine coolant fan motor power supply
2325 Power supply after ignition (gear selector)
2327 (+) power supply after master switch (onboard management system)
2328 Batteries DC power supply
2328 Alimentation (+) directe batterie après interrupteur général de l'équiment ADR
2329 (+) power supply vehicle management ECU relay
2330 Jake brake relay power supply
2331 24 Volts dashboard socket and 24V/12V voltage converter power supply
2332 Air conditioning electronic management power supply
2334 Driver presence in seat sensor power supply power supply (+)
2930 N° 1 cylinder injector control (line 2)
2940 N° 3 cylinder injector control (line 2)
2950 N° 2 cylinder injector control (line 2)
2960 N° 5 cylinder injector control (line 2)
2970 N° 6 cylinder injector control (line 2)
2980 N° 4 cylinder injector control (line 2)
2981 Optiroll mode request
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Andrew Burrows Key / Diagram 02/02/16
Group 3 - Signalling
Polarity N° Designation
3 Stop lights power supply
30 Trailer RH side direction change indicator lights power supply
31 Hazard lights control
32 Vehicle RH side direction change indicator lights control
33 Vehicle LH side direction change indicator lights control
34 Day/night function tell-tale light power supply
36 Hazard lights warning light control
37 RH front direction change indicator lights and side repeaters power supply
38 RH rear direction change indicator lights power supply
39 LH front direction change indicator lights and side repeaters power supply
301 LH rear direction change indicator lights power supply
302 LH front direction change indicator lights and side repeaters power supply
303 Parking lights lighting relay control
304 RH side parking lights and marker lights power supply
305 LH side parking lights and marker lights power supply
306 (+) power supply before rear fog lights fuse
307 Rear fog lights power supply
310 (+) power supply after master switch (horn)
311 Horn power supply
312 Horn relay control
313 Parking lights lighting control
320 Day/night function relay control
321 (+) power supply after master switch (illuminated warning)
322 Illuminated warning relay control (revolving beacons, illuminated "D" signs...)
323 Illuminated warning power supply
352 Trailer EBS system state of activation information
370 Rear fog lights lighting relay control
373 (+) power supply after master switch (steering wheel
fingertip controls – main beam headlights lighting)
374 Encoded line between alarm ECU and doors central locking ECU
386 “Heated rearview mirrors" function activation request
388 12 Volts power supply coming from voltage converter for headlamps ride correctors
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Andrew Burrows Key / Diagram 02/02/16
389 Penetration lights pre-arrangement and front grille identification lights power supply
390 Two-tone horn power supply
2 / 2
Page 29
Andrew Burrows Key / Diagram 02/02/16
Group 4 - Comfort accessories
Polarity N° Designation
4 Heated rearview mirrors resistors and windscreen defrosting controls power supply
41 12V power supply for 12 Volts socket (multi-pass cab option)
43 Air conditioning fan power supply relay control
45 (+) power supply after master switch (overhead lights)
46 12V power supply after 24V/12V converter for radiotelephone
47 Accessories power supply (headlamps ride correctors motor)
402 Driver’s side window winder motor power supply
403 Driver’s side window winder motor power supply
404 Auxiliary audio input, LH side
405 Auxiliary audio input, RH side
406 Auxiliary audio inputs earth
407 Auxiliary audio inputs diagnostic line
413 Independent heating fuel pump motor (-) power supply
414 Independent heating fuel pump motor (+) power supply
428 Swivelling rearview mirrors motors (-) power supply
429 Swivelling rearview mirrors motors (+) power supply
430 RH swivelling rearview mirror vertical movement motor (+) power supply
431 LH swivelling rearview mirror horizontal movement (+) power supply
432 RH swivelling rearview mirror horizontal movement (+) power supply
433 Passenger’s side electrically-operated front curtains motor control
434 Link between passenger’s side switch and driver’s side curtains control switch
435 Link between passenger’s side switch and driver’s side curtains control switch
436 Switch-operated order for locking electric door strikers
437 Headlamps ride adjustment
443 Passenger’s side electrically-operated front curtains motor control
444 LH front loudspeaker earth
445 Rear loudspeaker power supply (+), RH side
446 Rear loudspeaker power supply (-), RH side
447 LH front loudspeaker power supply
448 RH front loudspeaker power supply
449 Rear loudspeaker power supply (+), LH side
450 Rear loudspeaker power supply (-), LH side
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Andrew Burrows Key / Diagram 02/02/16
451 LH front loudspeaker power supply
452 (+) power supply after master switch (diagnostic and data extraction sockets)
454 Windscreen electrically-operated curtains motor control
455 Windscreen electrically-operated curtains motor control
456 Accessories power supply (electrically-operated curtains)
462 Power supply after air conditioning compressor "pressure sensor" block fuse
463 (+) power supply after air conditioning compressor "pressure sensor"
block fuse (hydraulic retarder, automatic gearbox, horn, fan-coil heater)
469 Link between passenger’s side and driver’s side window winder motor control switch
470 Link between passenger’s side and driver’s side window winder motor control switch
476 Independent heating control
484 Switch-controlled doors electric strikers unlocking order
485 Cab tilt pump motor power supply
489 Fan-coil heater pressure sensor power supply
491 Air/water independent heater water distribution solenoid valve control
496 Passenger’s side front window winder motor power supply
497 Passenger’s side front window winder motor power supply
4000 Passenger’s side front window winder motor 12V power supply output for CB radio
4002 Independent heating rheostat adjustment (level 1)
4003 Independent heating timer diagnostic information
4004 Independent heating rheostat adjustment (level 2)
4005 Driver’s side electrically-operated curtains motor control
4006 Driver’s side electrically-operated curtains motor control
4010 24 Volts dashboard socket power supply
4014 Sun-roof motor control
4015 Sun-roof motor control
4016 Air conditioning compressor clutch relay control
4017 Air conditioning compressor clutch earth
4019 Air conditioning fresh air recycling control (position 3)
4020 Air conditioning fresh air recycling control (position 2)
4021 Air conditioning fresh air recycling control (position 1)
4022 Air conditioning air recycling control position transcription
4023 Information between air conditioning control and fan control ECU
4024 Information between air conditioning control and fan control ECU
4025 Information between air conditioning control and fan control ECU
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Andrew Burrows Key / Diagram 02/02/16
4026 Air conditioner air outlet setting control
4028 Ventilation unit fresh air recycling control (speed 1)
4029 Link between engine heating switch and engine heating electrovalve pilot-control relay contact
4030 Ventilation unit fresh air recycling control (speed 2)
4050 Ventilation unit fresh air recycling control (speed 3)
4051 12V socket power supply after le 24V/12V voltage converter
4052 Air conditioning pressure sensor information (intermediate level)
4053 Overhead lamps lighting earth (before switch)
4055 Passenger’s side electrically-operated curtains motor control
4056 Passenger’s side electrically-operated curtains motor control
4057 Cab rear electrically-operated curtains motor control
4058 Cab rear electrically-operated curtains motor control
4060 Rearview mirrors defrosting relay control by vehicle management ECU
4065 External loudspeaker power supply (+) (available power supply)
4066 External loudspeaker power supply (-) (available power supply)
4067 External loudspeaker earth braid (available power supply)
4068 Radio "mute" mode control by hands free telephone
4069 Hands free telephone kit input (+ signal)
4070 Hands free telephone kit input (- signal)
4306 Alternator-controlled power supply (engine running)
4308 Cigar lighter power supply
4309 24V/12V voltage converter and onboard radio power supply
4310 Accessories power supply (electrically-operated seats)
4311 Rear doors electric striker locking / unlocking control
4312 Rear doors electric striker locking / unlocking control
4313 Passenger’s side front door electric striker locking/unlocking control
4314 Passenger’s side front door electric striker locking/unlocking control
4315 Passenger’s side front door unlocked information
4316 Driver’s side front door electric striker locking/unlocking control
4317 Driver’s side front door electric striker locking/unlocking control
4318 Driver’s side front door unlocked information
4320 Air conditioning compressor information feedback
4321 Interior lighting control
4322 Stepwells lighting control
4323 CD player control ("CD in" information)
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Andrew Burrows Key / Diagram 02/02/16
4324 CD player control ("CD out" information)
4325 CD player control ("CD on" information)
4326 CD player control (“CD AF GND" information)
4327 CD player control (“CD AF IN left" information)
4328 CD player control ("CD AF IN right" information)
4440 Interior lighting control two-way switch line
4441 Interior lighting control two-way switch line
4442 Link between dashboard and cab rear switches for sun-roof control
4443 Link between dashboard and cab rear switches for sun-roof control
4460 12V radiotelephone power supply
4461 12V accessories power supply
4462 Independent heating control (ADR)
4463 Air conditioning compressor control
4466 Ambient lighting lamps power supply
4467 Independent heating switch-operated control
4469 Independent heating switch-on
4470 Independent heating control from information display (air/water)
4 / 4
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Andrew Burrows Key / Diagram 02/02/16
Group 5 - Safety accessories
Polarity N° Designation
54 Electromagnetic retarder power supply (level 1)
55 Electromagnetic retarder power supply (level 2)
56 Electromagnetic retarder power supply (level 3)
57 Electromagnetic retarder power supply (level 4)
59 Corrected speed information given by tachograph
500 Electronically pilot-controlled electromagnetic retarder switches box relay N° 1 control
501 (+) power supply after fuse (windscreen wiper)
502 Windscreen wiper motor power supply (high speed) after fuse (windscreen wiper)
503 Relay control time-delayed via vehicle management ECU
504 Windscreen wiper motor power supply (low speed)
506 Windscreen wash pump motor power supply
507 Windscreen wiper motor fixed stop power supply
508 Windscreen wiper speed controller power supply
509 Windscreen wiper motor fixed return power supply
510 Headlamps wash pump time-delayed power supply
522 (+) power supply after ignition for trailer socket
539 ABS system LH front inlet electrovalve control
540 ABS system LH front outlet electrovalve control
556 ABS system RH front inlet electrovalve control
557 ABS system RH front outlet electrovalve control
566 Speed limitation system intermediate speed memorization line
588 Electronically pilot-controlled electromagnetic retarder switches box relay N° 2 control
589 Electronically pilot-controlled electromagnetic retarder switches box relay N° 3 control
5021 Gearbox sensor information for superimposition of speeds
5024 Electronically pilot-controlled electromagnetic retarder switches box relay N° 4 control
5025 Electronically pilot-controlled electromagnetic retarder terminal V control
5028 Stop lights relay control by vehicle management ECU
5031 Automatic gearbox ECU power supply (after power relay)
5048 Acceleration module and lockover angle sensor power supply
5050 Trailer EBS module power supply (+24V)
5064 Water in fuel bleeding request
5065 Airbag triggered warning light information
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Page 34
Andrew Burrows Key / Diagram 02/02/16
5066 Key presence in ignition switch information (ADR)
5067 Emergency stop switch (ADR)
5068 Emergency stop switch (ADR)
5069 On-chassis emergency stop switch
5070 On-chassis emergency stop switch
5071 Key presence in ignition switch information (ADR)
5072 IVS information
5073 Changeover to difficult terrain mode request
5074 Vehicle immobilization request
5075 Accelerator pedal second rest position sensor information
5077 Brake pedal position sensor information (EBS)
5079 EBS front module power supply (battery voltage)
5080 EBS front module power supply (earth)
5081 EBS rear module power supply (battery voltage)
5082 EBS rear module power supply (earth)
5083 EBS first additional module power supply (battery voltage)
5084 EBS second additional module power supply (earth)
5085 Brake holding authorization control
5086 Brake holding authorization information
5087 EBS second additional module power supply (battery voltage)
5088 EBS second additional module power supply (battery voltage)
5089 Trailer brake EBS information
5091 Air inlet electrovalve control for trailer EBS
5092 Air outlet electrovalve control for trailer EBS
5093 EBS load solenoid valve control for trailer
5094 Headlamps wash pump power supply
5095 Headlamps wash pump relay power supply
5096 High pressure pump power supply
5097 High pressure pump power supply
5098 Fuel heating resistors power supply
5099 Power supply after master switch (battery voltage)
5100 (+) power supply after master switch for airbag ECU
5101 Engine starting relay power supply
5102 Engine starting relay earthing
5108 Road speed information
2 / 3
Page 35
Andrew Burrows Key / Diagram 02/02/16
5109 Link between gear selector and automatic gearbox ECU (information redundancy)
3 / 3
Page 36
Andrew Burrows Key / Diagram 02/02/16
Group 6 - Lighting
Polarity N° Designation
6 Instrument panel and customer extra lighting fuses (+) power supply
60 (+) power supply after RH and LH side fog driving lights fuse
and multi-function information display in service warning light
62 Main beam headlights power supply relay control
64 Switches night lighting and other vehicle controls power supply
65 (+) power supply after fog driving lights fuse
68 Fog driving lights control
69 Fog driving lights control
602 RH main beam headlight (+) power supply after fuse
603 LH main beam headlight (+) power supply after fuse and
multi-function information display in service warning light
604 RH dipped beam headlight (+) power supply after fuse
605 LH dipped beam headlight (+) power supply after fuse and
multi-function information display in service warning light
606 Working spotlight, valves lighting, trailer sockets lighting... power supply
607 Multi-function information display working spotlight in service warning light
608 Reversing lights power supply
609 Long range driving lights power supply relay control and/or automatic gearbox ECU power supply
610 Main beam headlights relay power supply control
611 RH and LH side long range driving lights (+) power supply
after fuse and/or automatic gearbox ECU power supply
612 Long range headlights power supply
613 RH and LH side long range driving lights (+) power supply before fuse
615 Front searchlight (+) power supply after fuse
618 24-way ADR socket power supply for authorization of use of
power circuit, valves lighting or van interior lighting power supply
621 (+) power supply after Main beam headlights and van interior lighting relay
623 (+) power supply after fuse (power supply for fire vehicle pre-arrangement)
632 Lighting power supply (+24V) available for customer
634 Trailer sockets power supply (terminal 2 and 6 on 24N socket or 5 and 6 on 15-way socket)
635 Reversing buzzer power supply
640 (+) power supply after rear searchlight fuse
641 Front searchlight 12 Volts power supply
643 Rear searchlight control
1 / 2
Page 37
Andrew Burrows Key / Diagram 02/02/16
644 Rear searchlight 12 Volts power supply
646 Extra lighting control
647 Extra lighting power supply
651 Bodybuilding system in work position information
655 Door open warning light power supply (-)
659 Day/night warning light power supply (+)
661 Reverse gear engaged position sensor information
662 Rear fog lights cut-off
663 Main beam headlights and fog driving lights common power supply
665 Dipped beam headlights power supply relay control
666 (+) power supply after fuse (working spotlight)
2 / 2
Page 38
Andrew Burrows Key / Diagram 02/02/16
Group 7 - Onboard instruments
Polarity N° Designation
7 Engine speed information (alternator, terminal W information)
71 Pull-down menu 'Raise' request
72 Pull-down menu 'Extend' request
73 Pull-down menu 'Selection' request
74 Pull-down menu 'Lower' request
76 Fuel level sensor information (+ signal)
709 External temperature sensor information (+ signal)
710 External temperature sensor information (- signal)
711 Cab internal temperature sensor information (- signal)
712 Cab internal temperature sensor information (+ signal)
718 Fuel level sensor information (- signal)
719 Power supply after master switch (multi-function information display)
720 Air filter clogging information
766 Fifth wheel position N° 1 sensor digital output
767 Fifth wheel position N° 2 sensor digital output
768 Fifth wheel position N° 3 sensor digital output
775 Driver’s seat belt locking information
778 Bit 1 between fleet management ECU and information display information
779 Bit 2 between fleet management ECU and information display information
780 Bit 3 between fleet management ECU and information display information
781 Bit 4 between fleet management ECU and information display information
1 / 1
Page 39
Andrew Burrows Key / Diagram 02/02/16
Group 8 - Auxiliary equipment and monitoring
Polarity N° Designation
81 Coolant level probe power supply
82 Coolant level probe information
83 Parking brake engaged relay control
84 Construction site mode switch power supply
85 Construction site mode switch information
86 Inter-wheel diff lock control
87 Rear inter-wheel diff lock information
88 Gearbox-driven PTO in service information
89 Independent heating auxiliary pump
803 Air preheating resistors and/or preheating in service power supply
808 Fuel heating resistors power supply
813 Air suspension rear solenoid valve and 6x2 lift-up axle electrovalve control
814 Air suspension RH rear electrovalve control
815 Air suspension LH rear electrovalve control
816 Air suspension front electrovalve control
823 Exhaust brake solenoid valve power supply
824 Charge air pressure limitation control electrovalve power supply
825 (+) power supply for tachograph pulse generator sensors (Euro 2) or
(-) power supply for tachograph encryption sensor (as from Euro 3)
829 Servo steering sensors information
846 ASR system control
851 Diagnostic socket information (line K)
867 Brake pads wear sensor information
868 Brake pads wear sensor, RH/LH link on first front axle
869 Oil level probe information (+ signal)
870 Oil level probe information (- signal)
879 Vehicle front suspension level sensor information
880 Vehicle rear suspension level sensor information
881 Vehicle RH rear suspension level sensor information
899 Common point between air suspension RH and LH level and pressure sensors
8020 30 km/h speed limitation control
8040 Brake pads wear sensor, first/second front axle link
1 / 5
Page 40
Andrew Burrows Key / Diagram 02/02/16
8041 Brake pads wear sensor, RH/LH link on first rear axle
8044 Variable-drive fan motor speed sensor earth
8046 Variable-drive fan motor speed sensor power supply
8067 Chassis-mounted engine speed control
8077 Air suspension pressure sensors power supply
8079 Hub-piloted axle oil level sensor information
8080 Control solenoid valve control for LH cornering
8081 Control solenoid valve control for RH cornering
8082 Safety solenoid valve control
8083 Live equipment warning light power supply
8084 Alarm stop control
8085 Gearbox PTO activation information
8093 PTO N° 1 electrovalve control
8098 Rear inter-wheel diff lock information
8100 Available power supply (engine starting request)
8104 Available power supply (engine alert)
8108 Available power supply (engine starting information)
8109 Cab tilt relay control authorization
8110 On-chassis engine stop request
8111 Cab tilt relay control
8112 PTO N° 3 engagement request
8113 PTO N° 2 engagement request
8114 Transfer box neutral selection electrovalve control
8115 PTO N° 3 engagement electrovalve control
8116 Equipment in dangerous position information warning light power supply
8118 Parking brake engaged information
8119 On-chassis engine speed deceleration request
8120 On-chassis engine speed acceleration request
8121 Automatic return to rated engine speed request
8122 Available power supply (PLC min. output N° 1)
8123 Available power supply (PLC min. output N° 2)
8124 Transfer box changeover to low speed request
8125 Transfer box changeover to low speed control
8126 PTO electrovalves diff lock control
8127 Transfer box diff lock engagement request
2 / 5
Page 41
Andrew Burrows Key / Diagram 02/02/16
8128 Rear inter-wheel diff lock control
8129 Rear inter-wheel diff lock solenoid valve control
8131 Available power supply (analogue) or PTO N° 2 solenoid valve control
8132 Available power supply (PLC analogue input N° 2)
8133 CAN bus disabling control
8134 PTO N° 2 engaged information
8136 Engine speed setting control
8137 Suspension level control activation
8138 Suspension level control
8140 Air suspension rear drive axle level sensor earth
8142 Air suspension rear drive axle level sensor power supply
8143 Air suspension remote control (memory position)
8144 Air suspension remote control (lifting position)
8145 Air suspension remote control (lowering position)
8146 Air suspension remote control (memory 2 position)
8147 Air suspension remote control (return to normal position)
8148 Rear axle suspension air spring electrovalve control
8149 Rear axle lift-up air spring electrovalve control
8150 Rear drive axle air inlet/outlet electrovalve control
8151 Second rear axle lifting control
8152 Second rear axle raising control
8153 Load-shedding lift-up axle control
8154 Air suspension remote control (front axle control)
8155 Air suspension remote control (front axle control)
8156 Front axle air suspension pressure sensor information
8157 Lift-up rear axle air suspension pressure sensor information
8158 Rear axle LH side air suspension pressure sensor information
8159 Rear axle RH side air suspension pressure sensor information
8160 Rear axle LH side air suspension pressure sensor information
8161 Available power supply (PTO N° 2 solenoid valve pilot-control)
8165 PTOs N° 1 & 2 engagement electrovalve earth
8166 PTO N° 1 engagement electrovalve control
8167 PTO N° 2 engagement electrovalve control
8169 PTO N° 1 in service information
8170 Available power supply (parameter programmable frequency-related output)
3 / 5
Page 42
Andrew Burrows Key / Diagram 02/02/16
8172 Transfer box neutral position activation control
8173 Double H position sensor information
8174 Fogging pre-arrangement (+ signal)
8175 Fogging pre-arrangement (- signal)
8176 Tank low level pre-arrangement (- signal)
8177 Tank low level pre-arrangement (+ signal)
8178 Difficult terrain idling request
8179 Front axle inter-wheel diff lock solenoid valve control
8180 Brake pads wear sensor, RH/LH link on second front axle
8181 Brake pads wear sensor, first rear axle/second front axle link
8182 Brake pads wear sensor, first/second rear axle link
8183 Brake pads wear sensor, RH/LH rear link on second axle
8185 Automatic gearbox gear selector position information (position 1)
8186 Automatic gearbox gear selector position information (position 2)
8187 Automatic gearbox gear selector position information (position 3)
8188 Automatic gearbox gear selector position information (position 4)
8189 Automatic gearbox gear selector position information (position 5)
8190 Automatic gearbox gear selector position information (position 6)
8191 Retarder ON control
8192 Axle N° 4 brake air pressure switch
8207 AdBlue dosing solenoid valve control
8208 AdBlue dosing solenoid valve earth
8209 Exhaust gases temperature sensor earth
8210 Exhaust gases temperature sensor power supply
8211 AdBlue tank temperature sensor signal
8212 Exhaust gases temperature after catalytic converter sensor power supply
8213 AdBlue tank level sensor signal
8214 Exhaust gases temperature after catalytic converter sensor earth
8215 Engine cooling circuit by-pass solenoid valve power supply (+)
8216 Engine cooling circuit by-pass solenoid valve power supply (-)
8217 Diagnostic pressure sensor N° 1 information
8218 Diagnostic pressure sensor N° 2 information
8219 Diagnostic pressure sensor N° 3 information
8220 Diagnostic pressure sensor N° 4 information
8221 Gear selector position sensor information
4 / 5
Page 43
Andrew Burrows Key / Diagram 02/02/16
8222 Gear selector position sensor information
8223 Gear selector position sensor information
8224 Gear selector position sensor information
8225 Gear selector position sensor information
8226 60 tonnes safety electrovalve power supply
8227 Forbidden reversing inhibition control
8228 Electric winch winding electrovalve power supply (+)
8229 Electric winch winding electrovalve power supply (+)
8240 Electric parking brake 2-function electrovalve terminal N° 1 power supply
8241 Electric parking brake 2-function electrovalve terminal N° 2 power supply
8242 Trailer test electrovalve power supply (-)
8243 Trailer test electrovalve power supply (+)
8244 Parking brake holding electrovalve power supply (+)
8245 Parking brake holding electrovalve power supply (-)
5 / 5
Page 44
Andrew Burrows Key / Diagram 02/02/16
Group 9 - Free
Polarity N° Designation
971 Available wire N° 1 - From cab to chassis
972 Available wire N° 2 - From cab to chassis
973 Available wire N° 3 - From cab to chassis
974 Available wire N° 4 - From cab to chassis
975 Available wire N° 5 - From cab to chassis
977 Available wire N° 1 - From dashboard to ledge
978 Available wire N° 2 - From dashboard to ledge
979 Available wire N° 3 - From dashboard to ledge
980 Available wire N° 4 - From dashboard to ledge
981 Available wire N° 5 - From dashboard to ledge
982 Available wire N° 6 - From dashboard to ledge
983 Available wire N° 7 - From dashboard to ledge
1 / 1
Page 45
Andrew Burrows Oil pump / Tightening torques 03/02/16
Lubrication components, tightening torques
Oil pump
The item numbers indicate the tightening sequence.
Oil pump securing bolts 24±4 Nm
Oil filler pipes
Plastic lock 27±2 Nm
Dipstick guide bolts 20±4 Nm
Valve body
Valve body mounting bolts 48±8 Nm
Clamp screw 24±4 Nm
Oil strainer
1 / 2
Page 46
Andrew Burrows Oil pump / Tightening torques 03/02/16
Oil strainer securing bolts 24±4 Nm
2 / 2
Page 47
Andrew Burrows Engine block stiffener / Tightening torques 03/02/16
Cylinder block reinforcement, tightening torques
The item numbers indicate the tightening sequence.
Cylinder block stiffener securing bolts 48±8 Nm
1 / 1
Page 48
Andrew Burrows Cylinder head / Tightening torques 03/02/16
Cylinder head, tightening torques
The bolts can be re-used no more than 5 times maximum. Mark the bolt head with an indentation (A) after tightening each time using a centre punch. In
this case, apply engine oil to the screw-threads and under the bolt heads.Do not apply engine oil to new bolts, which are already pre-lubricated.
1 / 4
Page 49
Andrew Burrows Cylinder head / Tightening torques 03/02/16
Tap the screw-threads in the cylinder block then blow through with compressed air.
2 / 4
Page 50
Andrew Burrows Cylinder head / Tightening torques 03/02/16
The cylinder head must be positioned and tightened in accordance with the instructions given in the method (see page ).
The item numbers indicate the tightening sequence.
Stage1 65±5 Nm
Stage2 (check tightening) 65±5 Nm
Stage3 120±5 °
Stage4 90±5 °
Bolts M8 securing the unit pump injectors wiring harness bracket 24±4 Nm
3 / 4
Page 51
Andrew Burrows Cylinder head / Tightening torques 03/02/16
The bolts M8 can be re-used 5 times. If they are, do not apply any product to the screw-threads.Do not apply any product to new bolts, which
are already pre-coated.
4 / 4
Page 52
Andrew Burrows Blanking plug / cap / Tightening torques 03/02/16
Cylinder head plugs, tightening torques
Plug M10 x 1.00 20±4 Nm
Pre-coated plug M14 x 1.50 30±3 Nm
Pre-coated plug M10 x 1.00 10±2 Nm
Pre-coated straight union 10 Nm
1 / 1
Page 53
Andrew Burrows Camshaft / Tightening torques 03/02/16
Rocker shaft and camshaft bearing caps, tightening torques
The bolts can be re-used no more than 5 times maximum. Mark the bolt head with an indentation (A) after tightening each time using a centre punch. In
this case, apply engine oil to the screw-threads and under the bolt heads.Do not apply engine oil to new bolts, which are already pre-lubricated.
1 / 3
Page 54
Andrew Burrows Camshaft / Tightening torques 03/02/16
Stage 1: bolts (1 › 7) 25±3 Nm
Stage 2: bolts (9 - 11 - 13) 90±5 Nm
2 / 3
Page 55
Andrew Burrows Camshaft / Tightening torques 03/02/16
For the 2nd stage, tighten the bolts gradually, starting with bolt (11), so the rocker shaft descends without distorting.
Stage 3: bolts (8 - 10 - 12 - 14) 60±5 Nm
Stage 4: bolts (9 - 11 - 13) Loosen the bolts
Stage 5: bolts (9 - 11 - 13) 60±5 Nm
Stage 6: bolts (1 › 7) 90±5 °
Stage 7: bolts (8 › 14) 100±5 °
3 / 3
Page 56
Andrew Burrows Rocker arms / Tightening torques 03/02/16
Rocker arms, tightening torques
Valve play adjusting screw locknut 38±4 Nm
Exhaust valves play adjusting shim securing bolts (Optibrake retarder) 38±4 Nm
Unit pump injector pre-travel adjusting screw locknut 52±4 Nm
1 / 1
Page 57
Andrew Burrows Cylinder head cover / Tightening torques 03/02/16
Cylinder head cover, tightening torques
The item numbers indicate the tightening sequence.
Cylinder head cover securing bolts 24±4 Nm
1 / 1
Page 58
Andrew Burrows Exhaust manifold / Tightening torques 03/02/16
Exhaust manifold, tightening torques
Stage 1: bolts (1 - 8 - 3 - 10 - 5 - 12) 10±2 Nm
Stage 2: bolts (2 - 7 - 4 - 9 - 6 - 11 - 1 - 8 - 3 - 10 - 5 - 12) 48±8 Nm
1 / 1
Page 59
Andrew Burrows Intake manifold / Tightening torques 03/02/16
Intake manifold, tightening torques
Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Apply "
SILICONE 7091
".
1 / 2
Page 60
Andrew Burrows Intake manifold / Tightening torques 03/02/16
The item numbers indicate the tightening sequence.
Intake manifold securing bolts 24±4 Nm
Plug M10 20±3 Nm
Boost air pressure / temperature sensor 3.3 Nm
Consumables
Automotive part N° Industrial reference N°
56 89 501 292 Silicon adhesive 7091
2 / 2
Page 61
Andrew Burrows Heater / Tightening torques 03/02/16
Heater, tightening torques
The item numbers indicate the tightening sequence.
Stage1 10±2 Nm
Stage2 24±3 Nm
Intake air heater supply cable securing nut 10±1.5 Nm
1 / 1
Page 62
Andrew Burrows Engine flywheel / Tightening torques 03/02/16
Engine flywheel, tightening torques
The bolts can be re-used no more than 5 times maximum. Mark the bolt head with an indentation (A) after tightening each time using a centre punch. In
this case, apply engine oil to the screw-threads and under the bolt heads.Do not apply engine oil to new bolts, which are already pre-lubricated.
1 / 2
Page 63
Andrew Burrows Engine flywheel / Tightening torques 03/02/16
The item numbers indicate the tightening sequence.
Stage1 60±5 Nm
Stage2 135±10 °
2 / 2
Page 64
Andrew Burrows Damper / Tightening torques 03/02/16
Damper, tightening torques
The item numbers indicate the tightening sequence.
Stage1 40±4 Nm
Stage2 90±10 Nm
1 / 1
Page 65
Andrew Burrows Damper / Tightening torques 03/02/16
Damper, tightening torques
The item numbers indicate the tightening sequence.
Stage1 40±4 Nm
Stage2 90±10 Nm
1 / 1
Page 66
Andrew Burrows Water pump / Tightening torques 03/02/16
Cooling system, tightening torques
Water pump
The item numbers indicate the tightening sequence.
Water pump securing bolts 24±4 Nm
1 / 3
Page 67
Andrew Burrows Water pump / Tightening torques 03/02/16
The item numbers indicate the tightening sequence.
Casing securing bolts M10 48±8 Nm
Water pump pulley securing bolts 24±4 Nm
2 / 3
Page 68
Andrew Burrows Water pump / Tightening torques 03/02/16
Water pump drive belt tensioner bracket securing bolts M16 275±45 Nm
Water pump drive belt tensioner bracket securing bolts M10 48±8 Nm
Free pulley securing bolts M10 48±8 Nm
Tensioner roller securing bolts M10 48±8 Nm
Viscous coupling
Viscous coupling fan to hub securing nuts 24±4 Nm
Viscous coupling hub to water pump casing securing nut 48±8 Nm
3 / 3
Page 69
Andrew Burrows Crankshaft / Tightening torques 03/02/16
Crankshaft bearing caps, tightening torques
The bolts can be re-used no more than 5 times maximum. Mark the bolt head with an indentation (A) after tightening each time using a centre punch. In
this case, apply engine oil to the screw-threads and under the bolt heads.Do not apply engine oil to new bolts, which are already pre-lubricated.
Stage1 150±20 Nm
Stage2 120±5 °
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Page 70
Andrew Burrows Connecting rods / pistons / Tightening torques 03/02/16
Big end caps, tightening torques
The bolts can be re-used no more than 5 times maximum. Mark the bolt head with an indentation (A) after tightening each time using a centre punch. In
this case, apply
Molycote
grease to the screw-threads and under the bolt heads.Do not apply engine oil to new bolts, which are already pre-lubricated.
Tighten in diagonally opposed sequence.
Use a hexagon socket.
Stage1 30±3 Nm
Stage2 180±6 °
Consumables
Automotive part N° Industrial reference N°
50 00 336 962 Molykote lubricant
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Page 71
Andrew Burrows Connecting rods / pistons / Tightening torques 03/02/16
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Page 72
Andrew Burrows Engine block stiffener / Tightening torques 03/02/16
Cylinder block reinforcement, tightening torques
The item numbers indicate the tightening sequence.
Cylinder block stiffener securing bolts 48±8 Nm
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Page 73
Andrew Burrows Casing / Tightening torques 03/02/16
Engine flywheel housing, tightening torques
Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Apply "
SILICONE 7091
".
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Page 74
Andrew Burrows Casing / Tightening torques 03/02/16
The item numbers indicate the tightening sequence.
Stage 1: bolts M8 - M12 - M14 24±4 Nm
Stage 2: bolts M12 85±15 Nm
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Page 75
Andrew Burrows Casing / Tightening torques 03/02/16
Stage 3: bolts M14 140±15 Nm
Consumables
Automotive part N° Industrial reference N°
56 89 501 292 Silicon adhesive 7091
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Page 76
Andrew Burrows Casing / Tightening torques 03/02/16
Crankshaft sealed casing, tightening torques
Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Apply "
SILICONE 7091
".
1 / 2
Page 77
Andrew Burrows Casing / Tightening torques 03/02/16
The item numbers indicate the tightening sequence.
Sump attachment bolts
Stage 1: bolts (2 - 7) 24±4 Nm
Stage 2: bolts (1 › 8) 24±4 Nm
Consumables
Automotive part N° Industrial reference N°
56 89 501 292 Silicon adhesive 7091
2 / 2
Page 78
Andrew Burrows Distribution / Tightening torques 03/02/16
Timing system, tightening torques
Apply a bead of silicone dia. 2 mm (E) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
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Page 79
Andrew Burrows Distribution / Tightening torques 03/02/16
Apply "
".
SILICONE 7091
The item numbers indicate the tightening sequence.
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Page 80
Andrew Burrows Distribution / Tightening torques 03/02/16
The bolts can be re-used 5 times. If they are, do not apply any product to the screw-threads.Do not apply any product to new bolts, which are
already pre-coated.
Timing plate securing bolts 28±4 Nm
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Page 81
Andrew Burrows Distribution / Tightening torques 03/02/16
The item numbers indicate the tightening sequence.
Crankshaft pinion securing bolt (A) 24±4 Nm
Intermediate pinion hub securing bolts(B)Stage1Stage2 25±3 Nm110±5 °
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Page 82
Andrew Burrows Distribution / Tightening torques 03/02/16
Adjustable intermediate pinion hub securing bolts(C)Stage1Stage2 35±4 Nm120±5 °
Camshaft pinion securing bolts(D)Stage1Stage2 45±5 Nm90±5 °
Apply a bead of silicone dia. 2 mm (F) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Apply "
SILICONE 7091
".
5 / 6
Page 83
Andrew Burrows Distribution / Tightening torques 03/02/16
The item numbers indicate the tightening sequence.
Timing case bolts
Stage 1 12±2 Nm
Stage 2 24±4 Nm
Consumables
Automotive part N° Industrial reference N°
56 89 501 292 Silicon adhesive 7091
6 / 6
Page 84
Andrew Burrows Casing / Tightening torques 03/02/16
Oil pan, tightening torques
The item numbers indicate the tightening sequence.
Oil sump securing bolts 24±4 Nm
Oil sump drain plug 60±5 Nm
Oil dipstick securing bolt 10±1 Nm
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Page 85
Andrew Burrows Oil pump / Tightening torques 03/02/16
Lubrication components, tightening torques
Oil pump
The item numbers indicate the tightening sequence.
Oil pump securing bolts 24±4 Nm
Valve body
1 / 8
Page 86
Andrew Burrows Oil pump / Tightening torques 03/02/16
The item numbers indicate the tightening sequence.
Oil strainer bracket securing bolts 48±8 Nm
Oil strainer securing bolts 24±4 Nm
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Page 87
Andrew Burrows Oil pump / Tightening torques 03/02/16
Oil pressure safety valve cover securing bolts 10±2 Nm
Oil jets
Oil jet securing bolts 24±4 Nm
The bolts can be re-used 5 times. If they are, do not apply any product to the screw-threads.Do not apply any product to new bolts, which are
already pre-coated.
Oil cooler
Oil cooler securing bolts 27±4 Nm
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Page 88
Andrew Burrows Oil pump / Tightening torques 03/02/16
Begin by tightening bolts (11 - 14 - 3) to a torque of 24±4 Nm, then tighten all the bolts in the specified sequence.
Oil cooler casing securing bolts 24±4 Nm
Oil cooler casing plug 30±3 Nm
Oil cooler casing water circuit drainage union 40±4 Nm
Oil filter bracket
Euro 3 / 4
Oil filter 25±5 Nm
4 / 8
Page 89
Andrew Burrows Oil pump / Tightening torques 03/02/16
The item numbers indicate the tightening sequence.
Oil filter bracket unit securing bolts 25±5 Nm
5 / 8
Page 90
Andrew Burrows Oil pump / Tightening torques 03/02/16
Plugs (1) 55±5 Nm
Plug (2) 40±4 Nm
Plug (3) 50±5 Nm
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Page 91
Andrew Burrows Oil pump / Tightening torques 03/02/16
Plug (4) 55±5 Nm
Plugs (5) 55±5 Nm
Bolt (6) dia. M6 10±2 Nm
Euro 5
7 / 8
Page 92
Andrew Burrows Oil pump / Tightening torques 03/02/16
The item numbers indicate the tightening sequence.
Oil filter bracket unit securing bolts 25±5 Nm
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Page 93
Andrew Burrows / Tightening torques 03/02/16
Oil filter nipple, tightening torque
Assembly A.
Assembly B.
Union 48 Nm
1 / 2
Page 94
Andrew Burrows / Tightening torques 03/02/16
Union 60 Nm
2 / 2
Page 95
Andrew Burrows Turbocharger / Tightening torques 03/02/16
Turbocharger, tightening torques
Turbocharger to exhaust manifold securing bolts 48±8 Nm
Turbocharger oil supply pipe union 25±5 Nm
Turbocharger oil supply tube union (on oil filter bracket) 40±5 Nm
Turbine casing exhaust pressure regulator 24±2 Nm
Stage 1: bolts (1 - 3) 12 Nm
Stage 2: bolts (2 - 4 - 1 - 3) 24±2 Nm
1 / 1
Page 96
Andrew Burrows Air compressor / Tightening torques 03/02/16
Air compressor, tightening torques
Air compressor 636 cm³ drive pinion securing nut 200+50 Nm
Air compressor 636 cm³ securing nut 85±15 Nm
Union(s) 25±3 Nm
1 / 1
Page 97
Andrew Burrows Low pressure pump / Tightening torques 03/02/16
Fuel supply pump, tightening torques
Fuel feed pump securing bolt 8+2 Nm
Fuel feed pump banjo unions 40±5 Nm
1 / 1
Page 98
Andrew Burrows Steering pump / Tightening torques 03/02/16
Steering pump, tightening torques
Steering pump drive pinion securing nut 100±10 Nm
Steering pump securing bolts 24±4 Nm
1 / 1
Page 99
Andrew Burrows Exhaust brake solenoid valve / Tightening torques 03/02/16
"Optibrake" retarder, tightening torques
Control solenoid valve 24±4 Nm
Power supply wires securing nut 1.8±0.3 Nm
1 / 1
Page 100
Andrew Burrows Injectors / Tightening torques 03/02/16
Pump injector mounting stirrup, tightening torques
Assembly type A
A = Socket with boss.
Tightening procedure for already used copper injector sleeves
Stage1 20+5 Nm
Stage2 60±5 °
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