Renault magnum dxi руководство

• #1

1. Каталог

2. Грузовые импортные

3. Renault

Andrew Burrows Post-treatment circuit / Operation 04/02/16

Operating principle
Introduction
The 2005 pollution control standards and beyond relate more especially to the reduction of nitrogen oxides (NOx) and particulate matter.

A: Euro 5.
B: Euro 4.
C: Euro 3.
D: Euro 2.
x: NOx (g / kWh)
y: Particulate matter (g / kWh)
Evolution of European standards, Euro 2 (1997) to Euro 5 (2009)
To meet this goal, it has been necessary to innovate in exhaust gas post-treatment systems in order to treat nitrogen oxides and particulate matter, whence
the formulation of the SCR (Selective Catalytic Reduction) system.
NOx reduction principle
To reduce NOx, the SCR system employs an aqueous solution of urea, AdBlue, which consists of ammonia (32.5 %) and water (67.5 %).
The principal component of the SCR system is the catalytic converter. It contains the elements which, because of the injection of urea, serves to reduce the
NOx.
1/2

Andrew Burrows Post-treatment circuit / Operation 04/02/16

The exhaust gases are treated in the catalytic converter in 4 phases:
– Injection of AdBlue (1).
An injector is installed at the inlet of the catalytic converter. The injector is pilot-controlled by the ADS (AdBlue Dosing System). The ADS very accurately
calibrates the quantity of AdBlue to be injected on the basis of the different data that it has to process, such as quantity of NOx emitted by the engine and
temperature of the exhaust gases.
– AdBlue hydrolysis (2).
The AdBlue frees the ammonia (NH3) by means of a hydrolytic reaction.
– SCR catalytic converter (3).
The oxidating catalytic converter serves to reduce the NOx with the ammonia.
– Clean-up (4).
The clean-up catalytic converter serves to reduce the re-emission of ammonia into the atmosphere by getting rid of the residue.

2/2

Andrew Burrows Post-treatment circuit / Diagram 04/02/16

Schematic diagram

Key

1/2

Andrew Burrows Post-treatment circuit / Diagram 04/02/16
Component part

Item

Preliminary catalytic converter

(1)

Exhaust gas temperature sensor

(2)

Injector

(3)

SCR catalytic converter

(4)

NOx sensor

(5)

Engine CAN

(6)

Solenoid valve

(7)

Engine coolant pipes

(8)

Tank

(9)

Level and temperature sensor

(10)

Heater

(11)

Heated AdBlue pipes

(12)

Pump module (ADS)

(13)

Depending on equipment

2/2

Andrew Burrows Post-treatment circuit / Connection / use 04/02/16

AdBlue pipes connection diagram

AdBlue pump module (A).

1/2

Andrew Burrows Post-treatment circuit / Connection / use 04/02/16

AdBlue injector (B).

AdBlue tank (C).

(1 — 2)

Dia. 8

(3 — 4)

Dia. 9.5

(5)

Dia. 8

(6)

Dia. 9.5

(7)

Dia. 8

(8)

Dia. 9.5

2/2

Andrew Burrows Injectors / Features 04/02/16

AdBlue injector cooling principle

The AdBlue injector supports a maximum temperature of 120 °C.
To resist the exhaust heat, the injector is fitted with a heat shield and it is cooled by circulating AdBlue.
Tank capacities (l)

Non-injectable volume (l)

20

5

50

6.8

36

6.1

40

6.7

60

5.3

70

9

95

8

125

12

Each tank has a non-injectable volume. Failing full filling of the tank after the operation, it is crucial to ensure the presence of the minimum required
volume.
It is absolutely essential to fill the tanks with a minimum volume of 7 l, except for the 70, 95 and 125 l tanks, which must have a minimum content of 12 l.
When in operation, the tanks must preserve a minimum volume of AdBlue for cooling the injector. The SCR system then operates in fall-back mode and
cuts off the injection of AdBlue to favour its circulation in the injector.
1/2

Andrew Burrows Injectors / Features 04/02/16

2/2

Andrew Burrows AdBlue / Recommendations 04/02/16

AdBlue
Use only commercially available AdBlue for motor vehicles (DIN standard 70070).Agricultural grade urea is not suitable.
It is forbidden to replace AdBlue by any other product or add any other product to it or else vehicle pollution control will no longer be achieved
and you will run the risk of damaging the post-treatment system.
Do not reuse AdBlue that has been drained from the tank.
AdBlue must always be handled with care – it is a corrosive product.AdBlue must under no circumstance enter into contact with other chemical
products.If any AdBlue is spilt onto the vehicle or in the event of leakage, wipe it off with a cloth and rinse with plenty of water.
When working on AdBlue circuit components protect unplugged electrical connectors and disconnected pipes against possible splashing of
AdBlue with the blanking plugs kit available from the Spare Parts Department.If any AdBlue is splashed:
* Onto an in-place connector: rinse with water;
* Onto an unplugged connector: replace the connector.
If any AdBlue is splashed onto your skin or into your eyes, rinse away with plenty of water.If you inhale AdBlue, breathe in plenty of fresh
air.Consult a doctor, if necessary.

1/1

Andrew Burrows AdBlue / Inspection / testing 04/02/16

Inspection of AdBlue

Check that there is no oil or diesel fuel in the AdBlue.
Push locking tabs (1).
Remove insert (2).

1/5

Andrew Burrows AdBlue / Inspection / testing 04/02/16

Immerse the indicator paper in the AdBlue 3to 4 times.
A dark blue colour indicates that the AdBlue is not pure.
Use tool 0110 + 3065.
Wear gloves for protection.
If any AdBlue is splashed onto your skin or into your eyes, rinse away with plenty of water.If you inhale AdBlue, breathe in plenty of fresh
air.Consult a doctor, if necessary.
AdBlue must always be handled with care – it is a corrosive product.AdBlue must under no circumstance enter into contact with other chemical
products.If any AdBlue is spilt onto the vehicle or in the event of leakage, wipe it off with a cloth and rinse with plenty of water.

2/5

Andrew Burrows AdBlue / Inspection / testing 04/02/16

Check the concentration of urea in the AdBlue.
Thoroughly rinse the tools 0105 and 2918 with distilled water before using.
Apply a drop of AdBlue onto tool 0105.
Use tool 2918.
Wear gloves for protection.
The concentration is correct if the level showing on the tool 0105 is exactly on the mark.
Thoroughly rinse the tools 0105 and 2918 with distilled water.

3/5

Andrew Burrows AdBlue / Inspection / testing 04/02/16

Fit insert (1).
If the measures or controls are incorrect:
Drain the AdBlue tank.

Tools
General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

5021143065

FLEXIBLE
MECHANICAL FINGER

BL

BL

1

1

5021142918

SAMPLING TOOL

BL

BL

1

1

BL

OKELIA
99 route de Lyon

4/5

Andrew Burrows AdBlue / Inspection / testing 04/02/16
FRANCE
-BL

OKELIA
99 route de Lyon
FRANCE
—

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

7488890105

7488890110

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

REFRACTOMETER

1

1

INDICATING PAPER
(ADBLUE QUALITY)

1

1

5/5

Andrew Burrows Connectors / Precautions 04/02/16

Protection of connectors

When working on SCR system components and AdBlue are disconnected, protect electrical connectors against possible splashing of AdBlue.

If any AdBlue is splashed onto a closed connector: rinse with water.
If any AdBlue is splashed onto an open connector: replace the connector.

1/1

Andrew Burrows Quick release couplings / Removal / Fitting 04/02/16

Fast couplings

Disconnect hoses by pressing in the locking tabson the coupling.
Connect hoses ensuring that the coupling is secure (pull the coupling, locking tabs free).

1/1

Andrew Burrows Catalytic converter / Precautions 04/02/16

Catalytic converter(s)

Model A.
Weight

49 kg

1/5

Andrew Burrows Catalytic converter / Precautions 04/02/16
Model B.
Weight

58 kg

Weight

72 kg

Model C.

The weight of catalytic converters requires the use of lifting tackle.Depending on the vehicle configuration and the workshop tools, use a
suitable piece of lifting equipment.

2/5

Andrew Burrows Catalytic converter / Precautions 04/02/16

Use tool 9364 + 9804.

Use tool 9804.
Use lifting tackle.
3/5

Andrew Burrows Catalytic converter / Precautions 04/02/16

Use tools 9366 + 9364 + 9804.

Use tool 9364 + 9804.

Tools

4/5

Andrew Burrows Catalytic converter / Precautions 04/02/16

General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

9366

LIFTING RAM

9364

ANCHOR PLATE

Manufacturer’s code N°

Scale

Qty

BB

1

1

BB

1

1

BB

SEFAC S.A.
1 rue André Compain
BP 101
FRANCE
03.24.53.01.82 — 03.24.53.29.18 —

BB

SEFAC S.A.
1 rue André Compain
BP 101
FRANCE
03.24.53.01.82 — 03.24.53.29.18 —

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000269804

STRAP

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

1

1

5/5

Andrew Burrows Post-treatment circuit / Information 04/02/16

AdBlue circuit
Pressure values
Pump / Injector

5±0.2 bars

Pump return to tank

0.5 bar

Checking temperatures
AdBlue freezes at a temperature of -11 °C.
Operating temperatures

Hot running

At the pump inlet

— 7 -> + 70 °C

At the injector inlet

— 7 -> + 70 °C

Circuit temperature

+ 70 -> + 85 °C

1/1

Andrew Burrows AdBlue pump / Tightening torques 04/02/16

AdBlue pump, tightening torques

Item 1

5 Nm

1/1

Andrew Burrows Pump module / Tightening torques 04/02/16

AdBlue pump module

AdBlue pump module securing bolts
Top cover securing bolt

24±4 Nm
7.5±0.5 Nm

Pressure sensor securing bolts

3.3 Nm

Electrovalve securing bolts

5±0.5 Nm

1/1

Andrew Burrows Injectors / Tightening torques 04/02/16

AdBlue injector

AdBlue injector securing bolts

10±1.5 Nm

1/1

Andrew Burrows Exhaust gases temperature sensor / Tightening torques 04/02/16

Exhaust gas temperature sensor

Temperature sensor

45±5 Nm

1/2

Andrew Burrows Exhaust gases temperature sensor / Tightening torques 04/02/16

2/2

Andrew Burrows NOx sensor / Tightening torques 04/02/16

NOx sensor

Monitoring unit securing nut(s) (1)

10±2 Nm

NOx sensor (2)

50±10 Nm

1/1

Andrew Burrows AdBlue tanks / Tightening torques 04/02/16

36 litre, 40 litre and 60 litre tanks

(1): 36 litre tank
(2): 40 litre tank
(3): 60 litre tank
Tank drain plug

24±4 Nm

1/3

Andrew Burrows AdBlue tanks / Tightening torques 04/02/16

AdBlue level and temperature sensor securing bolts

10±1.5 Nm

AdBlue heater securing clamp

3 Nm

Tank securing bolts M6

10±1.5 Nm

Tank securing bolts M8

24±4 Nm

2/3

Andrew Burrows AdBlue tanks / Tightening torques 04/02/16
Tank securing bolts M10

35±5 Nm

3/3

Andrew Burrows Catalytic converter / Tightening torques 04/02/16

Catalytic converter model C
Identification
See pages .

Heat shield(s) securing bolts

6 Nm

Strap securing bolts

24±4 Nm

Clamps and nuts and bolts securing the exhaust pipe

40±8 Nm

1/1

Andrew Burrows AdBlue pump / Removal 04/02/16

Pumping element, removal

Fit new bolts M8*100.
Adjust the boltsso that the pump is stable.

1/8

Andrew Burrows AdBlue pump / Removal 04/02/16

Remove bolts (1).
Remove bottom cover cap (2).

Remove valve (1).
Use a screwdriver.

2/8

Andrew Burrows AdBlue pump / Removal 04/02/16
Remove electrovalve.
See page

Remove clamps (1).

Mark and unplug connectors (1).

3/8

Andrew Burrows AdBlue pump / Removal 04/02/16

Unplug connector (1).

Unplug connectors (1 — 2).

4/8

Andrew Burrows AdBlue pump / Removal 04/02/16

Unplug connector (1).

Remove filter (1).
Refer to the Workshop maintenance manual.
5/8

Andrew Burrows AdBlue pump / Removal 04/02/16

Disengage wiring harness.

Remove bolts (1).

6/8

Andrew Burrows AdBlue pump / Removal 04/02/16

Remove passenger’s seat unit.

Separate the elements (1 — 2).

7/8

Andrew Burrows AdBlue pump / Removal 04/02/16

Remove tube (1).

8/8

Andrew Burrows AdBlue pump / Fitting 04/02/16

Pumping element, fitting
Carefully clean all the parts.
Clean the joint faces.

Fit a new tube (1).

1/9

Andrew Burrows AdBlue pump / Fitting 04/02/16

Assemble the elements (1 — 2).

Fit the assembly .

2/9

Andrew Burrows AdBlue pump / Fitting 04/02/16

Fit bolts (1).
Tighten to torque.
See pages .

Install wiring harness.

3/9

Andrew Burrows AdBlue pump / Fitting 04/02/16

Fit a new filter (1).
Refer to the Workshop maintenance manual.

Plug in connector (1).
4/9

Andrew Burrows AdBlue pump / Fitting 04/02/16

Plug in connectors (1 — 2).

Plug in connector.

5/9

Andrew Burrows AdBlue pump / Fitting 04/02/16

Line up the marks made upon removal.
Plug in connectors (1).

Fit clamps (1).
Fit the solenoid valve.

6/9

Andrew Burrows AdBlue pump / Fitting 04/02/16
See page

Fit a new valve (1).

Fit cover (2).
Fit new bolts (1).

7/9

Andrew Burrows AdBlue pump / Fitting 04/02/16
Tighten to torque.
See pages .

Remove bolts M8*100.

AdBlue pump, tightening torques

8/9

Andrew Burrows AdBlue pump / Fitting 04/02/16
Item 1

5 Nm

9/9

Andrew Burrows Pump module / Removal 04/02/16

Removal of AdBlue pump module
Switch off the ignition, wait for approximately 5 minutes, then disconnect the batteries or work elsewhere on the vehicle until automatic
bleeding has finished.If you do not comply with this instruction, damage may be caused to the AdBlue injector and circuit.
Disconnect the batteries, starting with the negative (-) terminal.
(See Driving & Servicing handbook)
When the engine is hot, the AdBlue circuit reaches a high temperature that may lead to risks of burns: take all necessary precautions when
working on the vehicle.

Remove clamps (1).
Unplug connector (2).
Protect the connector (2).
See pages .
Mark
Unplug connectors (3).
Protect the connectors (3).
See pages .
1/5

Andrew Burrows Pump module / Removal 04/02/16

Mark the location of connectors (1) on support bracket (2).
Remove connectors (1).
Protect the connectors (1).
See pages .

2/5

Andrew Burrows Pump module / Removal 04/02/16
Put a drain pan into place.
Mark their positions.
Disconnect pipes (1).

Fit plugs (1).
Remove heater (2).
If necessary
Drain the filter element .
Refer to the Workshop maintenance manual.
Remove bolts (3).
Remove AdBlue pump module (4).

Exhaust pipe alignment

3/5

Andrew Burrows Pump module / Removal 04/02/16

Midlum

Family

DXi 5

44EL
44EL

Variant
20132

A (mm)

B (mm)

56

70

4/5

Andrew Burrows Pump module / Removal 04/02/16
44ML / LA / MA
DXi 7

53

70

47

59

47

58

44ML

20135

44LB / MB / HB

1CE01

44LB

20135

44LB / MB / HB

1CE02

44MB

20132

44XL / XM

20132

36

57

44XM

20165

35

57

5/5

Andrew Burrows AdBlue pump / Precautions 04/02/16

Precautions

It is possible to differentiate between the changes made to AdBlue pumps and injectors by means of a mark.

Assembly type (A)

1/2

Andrew Burrows AdBlue pump / Precautions 04/02/16
Assembly type (B)

When replacing a component, it is forbidden to mix assembly type (A) with assembly type (B).

2/2

Andrew Burrows Pump module / Fitting 04/02/16

Fitting of AdBlue pump module

Fit AdBlue pump module (4).
Fit bolts (3).
Tighten to torque.
See pages .
Fit heater (2).
Remove plugs (1).

1/6

Andrew Burrows Pump module / Fitting 04/02/16

Connect pipes (1).
Line up the marks made upon removal.
If necessary.
Clean after the operation.

2/6

Andrew Burrows Pump module / Fitting 04/02/16
Take the protections off the connectors (1)
Fit connectors (1) to support bracket (2).
Line up the marks made upon removal.

Take the protections off the connectors (1)
Plug in connectors (1).
The connectors (1) for AdBlue heating pipes are identified by a colour code (2).
Ensure the marking.

3/6

Andrew Burrows Pump module / Fitting 04/02/16

Take the protection off connector (2).
Plug in connector (2).
Fit new clamps (1).
Reconnect the batteries, starting with the positive (+) terminal.
(See Driving & Servicing handbook)
In the event of replacement of the AdBlue pump module, the parameters must be programmed. Use the RENAULT TRUCKS test tool.
Start the engine.
Check for leaks.

Exhaust pipe alignment

4/6

Andrew Burrows Pump module / Fitting 04/02/16

Midlum

Family

DXi 5

44EL
44EL

Variant
20132

A (mm)

B (mm)

56

70

5/6

Andrew Burrows Pump module / Fitting 04/02/16
44ML / LA / MA
DXi 7

53

70

47

59

47

58

44ML

20135

44LB / MB / HB

1CE01

44LB

20135

44LB / MB / HB

1CE02

44MB

20132

44XL / XM

20132

36

57

44XM

20165

35

57

6/6

Andrew Burrows Solenoid valves / Dismantling 04/02/16

Disassembly of electrovalve
Remove AdBlue pump module.
See pages .

Fit new bolts M8 x 100.
Adjust the boltsso that the pump is stable.

1/5

Andrew Burrows Solenoid valves / Dismantling 04/02/16

Clean the cover.
Remove bolts (1).
Remove bottom cover cap (2).

Remove valve (1).

2/5

Andrew Burrows Solenoid valves / Dismantling 04/02/16

Unplug connector (1).

Remove bolts (1).
Remove electrovalve (2).
3/5

Andrew Burrows Solenoid valves / Dismantling 04/02/16

Remove clips (1).

Disengage the heating resistors .
4/5

Andrew Burrows Solenoid valves / Dismantling 04/02/16

Remove gasket (1).

5/5

Andrew Burrows Solenoid valves / Assembly 04/02/16

Assembly of electrovalve

Carefully clean and inspect all the parts.

Fit a new lip seal (1).

1/4

Andrew Burrows Solenoid valves / Assembly 04/02/16
Install the heating resistors .

Fit new clips (1).

Fit the solenoid valve (2).
Fit bolts (1).

2/4

Andrew Burrows Solenoid valves / Assembly 04/02/16
Tighten to torque.
See pages .

Plug in connector (1).

Fit cover (2).

3/4

Andrew Burrows Solenoid valves / Assembly 04/02/16
Fit bolts (1).
Tighten to torque.
See pages .

Remove bolts M8 x 100.
Test for leaks.
See pages .
Fit AdBlue pump module.
See pages .

4/4

Andrew Burrows Sensors / Dismantling 04/02/16

Disassembly of pressure sensor
Remove AdBlue pump module.
See pages .

Fit new bolts M8 x 100.
Adjust the boltsso that the pump is stable.

1/3

Andrew Burrows Sensors / Dismantling 04/02/16

Clean the cover.
Remove bolts (1).
Remove bottom cover cap (2).

Remove valve (1).

2/3

Andrew Burrows Sensors / Dismantling 04/02/16

Unplug connector (1).

Remove bolts (1).
Remove sensor (2).
3/3

Andrew Burrows Sensors / Assembly 04/02/16

Assembly of pressure sensor
Carefully clean and inspect all the parts.

Fit sensor (2).
Fit bolts (1).
Tighten to torque.
See pages .

1/3

Andrew Burrows Sensors / Assembly 04/02/16

Plug in connector (1).

Fit cover (2).
Fit bolts (1).
Tighten to torque.

2/3

Andrew Burrows Sensors / Assembly 04/02/16
See pages .

Remove bolts M8 × 100.
Test for leaks.
See pages .
Fit AdBlue pump module.
See pages .

3/3

Andrew Burrows Sensors / Dismantling 04/02/16

Disassembly of temperature sensor
Remove AdBlue pump module.
See pages .

Fit new bolts M8 x 100.
Adjust the boltsso that the pump is stable.

1/4

Andrew Burrows Sensors / Dismantling 04/02/16

Clean the cover.
Remove bolts (1).
Remove bottom cover cap (2).

Remove valve (1).

2/4

Andrew Burrows Sensors / Dismantling 04/02/16

Unplug connector (1).

Remove bolts (1).
Mark.
Remove sensor (2).

3/4

Andrew Burrows Sensors / Dismantling 04/02/16

4/4

Andrew Burrows Sensors / Assembly 04/02/16

Assembly of temperature sensor
Carefully clean and inspect all the parts.

Line up the marks made upon removal.
Fit sensor (2).
Fit bolts (1).
Tighten to torque.
See pages .

1/3

Andrew Burrows Sensors / Assembly 04/02/16

Plug in connector (1).

Fit cover (2).
Fit bolts (1).
Tighten to torque.

2/3

Andrew Burrows Sensors / Assembly 04/02/16
See pages .

Remove bolts M8 × 100.
Test for leaks.
See pages .
Fit AdBlue pump module.
See pages .

3/3

Andrew Burrows Hermetic control box seal / Inspection / testing 04/02/16

Testing for leaks

Remove AdBlue pump module.
See pages .

Fit new bolts M8 x 100.
Adjust the boltsso that the pump is stable.

1/5

Andrew Burrows Hermetic control box seal / Inspection / testing 04/02/16

Clean the cover.
Remove bolts (1).
Remove bottom cover cap (2).

Remove valve (1).

2/5

Andrew Burrows Hermetic control box seal / Inspection / testing 04/02/16

Fit cover (2).
Fit bolts (1).
Tighten to torque.
See pages .

3/5

Andrew Burrows Hermetic control box seal / Inspection / testing 04/02/16
Remove bolts M8 × 100.

Install tool 0102 + 0104.
Adjust the pressure using tool 0104.
The pressure should be between 0.2 and 0.3 bars.
The pressure must not drop by any significant amount for 60 seconds.
Drop the pressure.
Remove tool 0104 + 0102.

4/5

Andrew Burrows Hermetic control box seal / Inspection / testing 04/02/16

Fit a new bush (1).
Fit AdBlue pump module.
See pages .

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

7488890102

7488890104

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

UNION (ADBLUE
PUMP SEALING)

1

1

PUMP

1

1

5/5

Andrew Burrows Heating pipe / Inspection / testing 04/02/16

Heating pipes
Checking for leaks
With the engine shut-down:
— Check on all the pipes and unions that there are no traces of crystallized AdBlue.
With the engine running:
— Inspect all the pipes and unions. During operation, the circuit is pressurized. Check for any leaks.

1/1

Andrew Burrows Solenoid valves / Removal 04/02/16

Removal of heating system solenoid valve

Disconnect the batteries, starting with the negative (-) terminal.
(See Driving & Servicing handbook)

Unplug connector (1).

1/3

Andrew Burrows Solenoid valves / Removal 04/02/16

Put a drain pan into place.
Remove clamps (1).
Disconnect pipes (2).

Tighten nuts (1).

2/3

Andrew Burrows Solenoid valves / Removal 04/02/16
Remove washers.
Remove solenoid valve (2).

3/3

Andrew Burrows Solenoid valves / Fitting 04/02/16

Fitting of heating system solenoid valve

Fit solenoid valve (2).
Fit washers.
Fit bolts (1).
Tighten to torque.
See pages .

1/4

Andrew Burrows Solenoid valves / Fitting 04/02/16

Connect pipes (2).
Fit clamps (1).

Plug in connector (1).
If necessary

2/4

Andrew Burrows Solenoid valves / Fitting 04/02/16
Check the coolant system level. Top up if necessary.
Refer to the Workshop maintenance manual.
Reconnect the batteries, starting with the positive (+) terminal.
(See Driving & Servicing handbook)
Start the engine.
Check for leaks.

Standard tightening torques
Definitions
There are several types of tightening:
* Tightening to torque (in Nm)
* Tightening to angle (in °)
* Tightening to torque-angle (in Nm + °)
Torques given in Nm are nominal torques (average value calculated on the basis of the minimum torque and the maximum torque).
The tightening precision class defines the tolerance of this torque in percent as a function of the nominal torque applied.
Tightening precision classes:
* Class I: Special threaded hardware (tolerances ± 10% of the final torque).
* Class II: Reserved for precise tightening (tolerance ± 10% of the nominal torque).
* Class III: Reserved for normal standard tightening (tolerance ± 20% of the nominal torque).
For standard threaded hardware indicated in the table below, use tightening class III.
For other torques, see the following page(s).
«FIH» type (Nylstop) locknuts must be replaced whenever removed. «DRH» type (oval) locknuts can be re-used. If locknuts (DRH, FIH or other)
are re-used, make absolutely certain that the screw-thread of the bolt protrudes least two threads above the top edge of the nut.
Standard nut and bolt tightening torques table
The tightening torque values given in the table are based on standard 01.50.4002 and apply to new nuts and bolts fitted dry and re-used nuts and
bolts with oil applied to the screw-threads. If any nuts and bolts are replaced, it is absolutely essential to use nuts and bolts recommended by the
RENAULT TRUCKS Spare Parts Department (coefficient of friction in compliance with standard 01.50.4002).
Tightening torque values in Nm for conventional «metric system» threaded
hardware based on standard 01.50.4002 (H: normal and HE: with flange)
Diameter and pitch of nuts and bolts

Quality class III
Quality class 8.8

Quality class 10.9

3/4

Andrew Burrows Solenoid valves / Fitting 04/02/16
6 x 1.007 x 1.008 x 1.008 x 1.2510
x 1.0010 x 1.2510 x 1.5012 x
1.2512 x 1.5012 x 1.7514 x 1.5014
x 2.0016 x 1.5016 x 2.0018 x
1.5018 x 2.5020 x 1.5020 x 2.5022
x 1.5022 x 2.5024 x 2.0024 x 3.00

7.5 ± 1.515 ± 320 ± 420 ± 440 ± 840
± 840 ± 870 ± 1465 ± 1360 ± 12105
± 21100 ± 20160 ± 32150 ± 30240
± 48210 ± 42330 ± 66300 ± 60450
± 90410 ± 82560 ± 112510 ± 102

11 ± 2.220 ± 430 ± 627 ± 5.460 ± 1260
± 1250 ± 10100 ± 2095 ± 1990 ± 18155
± 31145 ± 29220 ± 44220 ± 44340
± 68310 ± 62480 ± 96435 ± 87650
± 130595 ± 119820 ± 164750 ± 150

4/4

Andrew Burrows Heater / Removal 04/02/16

Removal of air heater
Switch off the ignition, wait for approximately 5 minutes, then disconnect the batteries or work elsewhere on the vehicle until automatic
bleeding has finished.If you do not comply with this instruction, damage may be caused to the AdBlue injector and circuit.
Disconnect the batteries, starting with the negative (-) terminal.
(See Driving & Servicing handbook)
When the engine is hot, the AdBlue circuit reaches a high temperature that may lead to risks of burns: take all necessary precautions when
working on the vehicle.

Remove clamps (1).
Mark and disconnect pipes (2).

1/5

Andrew Burrows Heater / Removal 04/02/16

Disconnect pipes (1).

Loosen clamp (1).
Remove heater (2).

36 litre, 40 litre and 60 litre tanks

2/5

Andrew Burrows Heater / Removal 04/02/16

(1): 36 litre tank
(2): 40 litre tank
(3): 60 litre tank
Tank drain plug

24±4 Nm

3/5

Andrew Burrows Heater / Removal 04/02/16

AdBlue level and temperature sensor securing bolts

10±1.5 Nm

AdBlue heater securing clamp

3 Nm

Tank securing bolts M6

10±1.5 Nm

Tank securing bolts M8

24±4 Nm

4/5

Andrew Burrows Heater / Removal 04/02/16
Tank securing bolts M10

35±5 Nm

5/5

Andrew Burrows Heater / Fitting 04/02/16

Fitting of air heater

Clean the contact faces (1) thoroughly.

Fit heater (2).
1/6

Andrew Burrows Heater / Fitting 04/02/16
Tighten shackle (1).
Tighten to torque.
20 litre and 50 litre tanks
See pages .
36 litre, 40 litre and 60 litre tanks
See pages .

Connect pipes (1).

2/6

Andrew Burrows Heater / Fitting 04/02/16

Connect pipes (2).
Line up the marks made upon removal.
Fit clamps (1).
Check the coolant system level. Top up if necessary.
Refer to the Workshop maintenance manual.
Reconnect the batteries, starting with the positive (+) terminal.
(See Driving & Servicing handbook)
Start the engine.
Check for leaks.

36 litre, 40 litre and 60 litre tanks

3/6

Andrew Burrows Heater / Fitting 04/02/16

(1): 36 litre tank
(2): 40 litre tank
(3): 60 litre tank
Tank drain plug

24±4 Nm

4/6

Andrew Burrows Heater / Fitting 04/02/16

AdBlue level and temperature sensor securing bolts

10±1.5 Nm

AdBlue heater securing clamp

3 Nm

Tank securing bolts M6

10±1.5 Nm

Tank securing bolts M8

24±4 Nm

5/6

Andrew Burrows Heater / Fitting 04/02/16
Tank securing bolts M10

35±5 Nm

6/6

Andrew Burrows NOx sensor / Removal 04/02/16

Removal of NOx sensor / exhaust gas temperature sensor
Disconnect the batteries, starting with the negative (-) terminal.
(See Driving & Servicing handbook)

Unplug connector (1).
Disengage wiring harness (2).

1/5

Andrew Burrows NOx sensor / Removal 04/02/16

Unscrew connector (1).
Remove sensor (2).

Remove nuts (1).
Remove control unit (2).

2/5

Andrew Burrows NOx sensor / Removal 04/02/16

Depending on equipment
Unplug connector (1).
Disengage wiring harness (2).

Unscrew union (1) while holding insert (2).

3/5

Andrew Burrows NOx sensor / Removal 04/02/16
Remove sensor.

So as to not damage the sensor, it must be removed and placed perfectly in the axis of its housing until it is taken out or fully installed.

4/5

Andrew Burrows NOx sensor / Removal 04/02/16
Remove insert (1).

NOx sensor

Monitoring unit securing nut(s) (1)

10±2 Nm

NOx sensor (2)

50±10 Nm

5/5

Andrew Burrows NOx sensor / Fitting 04/02/16

Fitting of NOx sensor / exhaust gas temperature sensor

Fit control unit (2).
Fit nuts (1).
Tighten to torque.
See pages .

1/6

Andrew Burrows NOx sensor / Fitting 04/02/16

Fit sensor (2).
Screw up union (1).
Tighten to torque.
See pages .

2/6

Andrew Burrows NOx sensor / Fitting 04/02/16
Install wiring harness (2).
Fit new clamps.
Plug in connector (1).

Depending on equipment
Fit insert (1).
Tighten to torque.
See pages .

3/6

Andrew Burrows NOx sensor / Fitting 04/02/16

Fit sensor.
Screw on union (1) while holding insert (2).
Tighten to torque.
See pages .

4/6

Andrew Burrows NOx sensor / Fitting 04/02/16

So as to not damage the sensor, it must be removed and placed perfectly in the axis of its housing until it is taken out or fully installed.

Install wiring harness (2).

5/6

Andrew Burrows NOx sensor / Fitting 04/02/16
Fit new clamps.
Plug in connector (1).
Reconnect the batteries, starting with the positive (+) terminal.
(See Driving & Servicing handbook)

NOx sensor

Monitoring unit securing nut(s) (1)

10±2 Nm

NOx sensor (2)

50±10 Nm

6/6

Andrew Burrows Exhaust gases temperature sensor / Removal 04/02/16

Removal of exhaust gas temperature sensor

Disconnect the batteries, starting with the negative (-) terminal.
(See Driving & Servicing handbook)
Unplug connector (1).
Follow the routing of the wiring harness, mark its position and cut the securing clamps.
Disengage wiring harness.

1/4

Andrew Burrows Exhaust gases temperature sensor / Removal 04/02/16

Unscrew connector (1).
Remove sensor (2).

2/4

Andrew Burrows Exhaust gases temperature sensor / Removal 04/02/16
So as to not damage the sensor, it must be removed and placed perfectly in the axis of its housing until it is taken out or fully installed.
Depending on equipment
Remove guard.
See pages .

Exhaust gas temperature sensor

Temperature sensor

45±5 Nm

3/4

Andrew Burrows Exhaust gases temperature sensor / Removal 04/02/16

4/4

Andrew Burrows Exhaust gases temperature sensor / Fitting 04/02/16

Fitting of exhaust gas temperature sensor

Depending on equipment
Withdraw heat shield.
See pages .
Fit sensor (2).
Screw up union (1).
Tighten to torque.
See pages .

1/4

Andrew Burrows Exhaust gases temperature sensor / Fitting 04/02/16

So as to not damage the sensor, it must be removed and placed perfectly in the axis of its housing until it is taken out or fully installed.

Fit the wiring harness.

2/4

Andrew Burrows Exhaust gases temperature sensor / Fitting 04/02/16
Line up the marks made upon removal.
Fit new clamps.
Plug in connector (1).
Reconnect the batteries, starting with the positive (+) terminal.
(See Driving & Servicing handbook)

Exhaust gas temperature sensor

Temperature sensor

45±5 Nm

3/4

Andrew Burrows Exhaust gases temperature sensor / Fitting 04/02/16

4/4

Andrew Burrows AdBlue pump / Precautions 04/02/16

Precautions

It is possible to differentiate between the changes made to AdBlue pumps and injectors by means of a mark.

Assembly type (A)

1/2

Andrew Burrows AdBlue pump / Precautions 04/02/16
Assembly type (B)

When replacing a component, it is forbidden to mix assembly type (A) with assembly type (B).

2/2

Andrew Burrows Injectors / Removal 04/02/16

Removal of AdBlue injector
Switch off the ignition, wait for approximately 5 minutes, then disconnect the batteries or work elsewhere on the vehicle until automatic
bleeding has finished.If you do not comply with this instruction, damage may be caused to the AdBlue injector and circuit.
When the engine is hot, the AdBlue circuit reaches a high temperature that may lead to risks of burns: take all necessary precautions when
working on the vehicle.
Disconnect the batteries, starting with the negative (-) terminal.
(See Driving & Servicing handbook)

Put a drain pan into place.
Disconnect pipes (1).

1/4

Andrew Burrows Injectors / Removal 04/02/16

Fit plugs (1).
Clean after the operation.
Unplug connector (2).
Protect the connector.
See pages .
Depending on equipment
Remove sensor (3).
See pages .

2/4

Andrew Burrows Injectors / Removal 04/02/16

Remove bolts (1).
Remove injector (2).

Protect the injector (1).
Fit a plug (2)

3/4

Andrew Burrows Injectors / Removal 04/02/16

4/4

Andrew Burrows Injectors / Fitting 04/02/16

Fitting of AdBlue injector

Remove plug (1).

Fit injector (2).
1/3

Andrew Burrows Injectors / Fitting 04/02/16
Fit bolts (1).
Tighten to torque.
See pages .

Depending on equipment
Fit sensor (3).
See pages .
Take the protection off connector (2).
Plug in connector (2).
Remove plugs (1).

2/3

Andrew Burrows Injectors / Fitting 04/02/16

Connect pipes (1).
The diameters of the pipe unions are different. There is no possibility for inversion.
Reconnect the batteries, starting with the positive (+) terminal.
(See Driving & Servicing handbook)
Start the engine.
Check for leaks.

3/3

Andrew Burrows Heat protection / Removal 04/02/16

Removal of heat shield
Depending on the assembly, the AdBlue pipes and exhaust gas temperature wiring harness must be fitted with a heat shield.

Remove clamps (1).
Remove guard (2).

1/1

Andrew Burrows Heat protection / Fitting 04/02/16

Fitting of heat shield
Depending on the assembly, the AdBlue pipes and exhaust gas temperature wiring harness must be fitted with a heat shield.

Fit guard (2).
Fit new clamps (1).
Fit heat-resistant clamps (1).

1/1

Andrew Burrows Crankshaft seal / Removal 28/03/16

Crankshaft rear seal, removal
Remove flywheel.
See pages .

Remove lip seal.
Use tool 6400 + 0192.
Take care to not damage the crankshaft contact face of the seal during extraction.

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

7409990192

7409996400

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

PULLER

2

1

PULLER

2

1

1/2

Andrew Burrows Crankshaft seal / Removal 28/03/16

2/2

Andrew Burrows Crankshaft seal / Fitting 28/03/16

Crankshaft rear seal, fitting

Clean and carefully inspect the contact faces of seal.
Mount tool 0166.
Check that the tool is correctly placed on the locating dowel before tightening the bolts.

1/3

Andrew Burrows Crankshaft seal / Fitting 28/03/16

The seal is supplied fitted to a protective ring that is placed on the assembly tool. It is essential to hold the seal to the ring until it is finally
installed in the case.Do not apply grease to the lips.Any gasket that has been removed from its ring must not be re-used.

Fit protective ring (1) to tool 0166.

2/3

Andrew Burrows Crankshaft seal / Fitting 28/03/16
Match the direction of orientation.

Drive in seal as far as abutment.
Withdraw tool 0166.
Fit flywheel.
See pages .

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

7409990166

PUSHER

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

1

1

3/3

Andrew Burrows Engine flywheel / Removal 28/03/16

Engine flywheel, removal

Removal
Unplug connector (1).
Remove engine speed sensor (2).

1/5

Andrew Burrows Engine flywheel / Removal 28/03/16

Remove pilot bearing (1).
Use tool 2740.

Retain the flywheel against motion using tool 1380.
2/5

Andrew Burrows Engine flywheel / Removal 28/03/16

Loosen bolts (1) proceeding in the reverse sequence to tightening.
See pages .
Withdraw tool 1380.

Mount tool 1207.

3/5

Andrew Burrows Engine flywheel / Removal 28/03/16
Use a spacer (A) length: 50 mm thickness: 5 mm.
Remove bolts (1).
Remove flywheel (2).
Use lifting tackle.

Ring gear
Disassembly
Remove ring gear.

4/5

Andrew Burrows Engine flywheel / Removal 28/03/16

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000261207

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

HOOK (ENGINE
FLYWHEEL)

1

1

5000261380

CONTROL

1

1

5000262740

PULLER

1

1

5/5

Andrew Burrows Engine flywheel / Fitting 28/03/16

Engine flywheel, fitting

Ring gear
Assembly
Wear heat-resistant gloves for protection.
Heat at 200°C.

1/9

Andrew Burrows Engine flywheel / Fitting 28/03/16

If a welding torch is used, take a sheet metal plate and heat it to distribute the heat evenly. Check the temperature at 3 points (A).
Use tool 9675.

Wear heat-resistant gloves for protection.

2/9

Andrew Burrows Engine flywheel / Fitting 28/03/16
Fit ring gear.

Fitting
Clean the contact faces thoroughly.

To fit, proceed in the reverse sequence to removal.

3/9

Andrew Burrows Engine flywheel / Fitting 28/03/16
Retain the flywheel against motion using tool 1380.

Tighten bolts (1) to torque following the tightening sequence.
See pages .
Use tool 9776.

4/9

Andrew Burrows Engine flywheel / Fitting 28/03/16
Fit engine speed sensor (2).
Tighten to torque.
See pages .
Check the air gap.
See pages .
Plug in connector (1).

Fit pilot bearing (1).
Make pilot bearing (1) flush with its housing.
Use tool 2363 + 3016.

5/9

Andrew Burrows Engine flywheel / Fitting 28/03/16

Inspection of the flywheel run-out
Check the buckle.
Use tool 3241 + 9661.
Note down the value.
If the measured value is higher than the Manufacturer’s value, see page(s) .
Remove the engine flywheel.
Clean the contact faces thoroughly.

Tools
General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

9675

THERMOMETER

AL

APPA 51 + 80110

1

1

9661

MEASURING TOOL
(DIAL GAUGE AND
MAGNETIC FOOT)

AQ

2

1

6/9

Andrew Burrows Engine flywheel / Fitting 28/03/16

AL

CHAUVIN ARNOUX
190 rue Championnet
FRANCE
01 44 85 44 85 — 01 46 27 73 89 —

AQ

BROWN & SHARP ROCH
13-15 avenue Georges de la Tour
BP 45
FRANCE
03 83 76 83 76 — 03 83 74 13 16 —

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000261380

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

CONTROL

1

1

5000263016

HANDLE

2

1

5000262363

PUSHER

2

1

5000269776

INDICATOR DISC

1

1

7/9

Andrew Burrows Engine flywheel / Fitting 28/03/16

Locally manufactured tool
Illustration

RENAULT
TRUCKS part N°

Designation

OFL3241

HOOK

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

2

1

Engine flywheel, tightening torques

8/9

Andrew Burrows Engine flywheel / Fitting 28/03/16
The bolts can be re-used no more than 4 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.

The item numbers indicate the tightening sequence.
Stage1

60±5 Nm

Stage2

120±10 °

Control torque

270 › 410 Nm

9/9

Andrew Burrows Crankshaft seal / Removal 28/03/16

Crankshaft front seal, removal

There are 2 crankcase models:
Model A.
Model B.
See illustration opposite.
Models A and B.
Remove damper.
See pages .
Remove the oil sump.
See pages .

1/3

Andrew Burrows Crankshaft seal / Removal 28/03/16

Remove lip seal(1).
Use tool 0192 + 6400.

Remove securing nuts and bolts (1).
Remove casing (2).

2/3

Andrew Burrows Crankshaft seal / Removal 28/03/16

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

7409990192

7409996400

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

PULLER

2

1

PULLER

2

1

3/3

Andrew Burrows Crankshaft seal / Fitting 28/03/16

Crankshaft front seal, fitting

There are 2 crankcase models:
Model A.
Model B.
See illustration opposite.
Model: A
If it has, it is essential to replace the seal and the crankcase.
The seal is supplied fitted to a protective ring. It is essential to hold the seal to the ring until it is finally installed in the case.Do not apply grease
to the lips.Any seal that has been removed from its ring must not be re-used.

1 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16

Install tool 6401.
Tighten bolts to torque.
See pages .
Fit bolts (1) in locations (A).
Use 2 headless screws (1) diameter: M8 mm, length: 50 mm.
Clean the contact faces thoroughly.
Apply a bead of sealing compound to the gearbox casing joint face.
Apply »
«.
See pages .

SILICONE 7091

2 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16

Position the casing (1) / gasket (2) / protection ring (3) assembly on the crankshaft (4).
Push the casing (1) as far as abutment.

Withdraw protective ring (1).
3 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16

Fit bolts (1).
Start bolts (1).
Remove headless bolts (2).

Fit bolts (1).

4 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16
Tighten bolts (1 — 2) to torque.
See pages .
Withdraw tool 6401.
Fit the oil sump.
See pages .
Fit damper.
See pages .

Model: B
Install tool 6401.
Tighten bolts to torque.
See pages .
Fit bolts (1) in locations (A).
Use 2 headless screws (1) diameter: M8 mm, length: 50 mm.
Clean the contact faces thoroughly.
Apply a bead of sealing compound to the gearbox casing joint face.
Apply »
«.
See pages .

SILICONE 7091
5 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16

Fit casing (1).
Fit bolts (2).
Start bolts (2).
Remove headless bolts (3).

6 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16
Fit bolts (1).
Tighten bolts (1 — 2) to torque.
See pages .
Withdraw tool 6401.

Clean and carefully inspect the contact faces of seal (1).
The seal is supplied fitted to a protective ring. It is essential to hold the seal to the ring until it is finally installed in the case.Do not apply grease
to the lips.Any seal that has been removed from its ring must not be re-used.
Position protective ring (2) on crankshaft (3).

7 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16

Slide seal (1) onto crankshaft (2).
Withdraw protective ring (3).

Mount tool 2625.
8 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16

Mount tool 0021.
Using tool 2625, bring tool 0021 into abutment against the crankshaft so as to position seal (1) correctly in its housing.
Withdraw tool 0021 + 2625.
When fitting a model B casing already fitted with a gasket, follow the same procedure as for fitting a model A casing.
See pages .
Fit the oil sump.
See pages .
Fit damper.
See pages .

Consumables
Automotive part N°

Industrial reference N°

56 89 501 292

Silicon adhesive 7091

Tools
Specific tools
9 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

7409996401

7488800021

5000262625

Crankshaft sealed casing, tightening torques

10 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16

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 »
ADHESIF SILICONE 7091
«.

11 / 12

Andrew Burrows Crankshaft seal / Fitting 28/03/16

The item numbers indicate the tightening sequence.
Stage 1: bolts (2 — 7)

24±4 Nm

Stage 2: bolts (1 ›

24±4 Nm

Follow the tightening sequence.

12 / 12

Andrew Burrows Mobile hitch / Detailed view 28/03/16

Mobile hitch, exploded view

1/1

Andrew Burrows Mobile hitch / Dismantling 28/03/16

Mobile hitch, dismantling

The item numbers indicated in the text refer to the drawing on page .
Remove the cylinder head.
See pages .

Install tool 1462.
Remove the oil sump.
See pages .
During the reciprocating gear removal operation, carefully mark the position of installation of each part, and more particularly the connecting rod bearing
half-shells and caps.

1 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16

Cylinder block stiffener
Turn the engine over.
Remove bolts (A).
Remove oil strainer (B).
Remove tube (C).
Loosen bolts (1) proceeding in the reverse sequence to tightening.
See pages .

2 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16

Remove pipes (A).

Remove seals (A).
Remove bolts (1).
Remove cylinder block stiffener (2).

3 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16
Wear gloves for protection.
Oil jets
Remove bolts (3).
Remove oil jets (4).

Connecting rods
Precautions
Split connecting rodSo as to not have to loosen a connecting rod during operation, it is crucial to not bump, nor apply oil to the part and keep
the contact faces (A — B), which correspond to the relief of the connecting rod cap / connecting rod parting line, immaculately clean.

4 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16

Turn the crankshaft so as to be able to gain access to the connecting rod cap to be removed.
Check for the presence of marks on the connecting rod.
Identification marking
The connecting rod and its cap are paired and marked with a 3-figure identification number (*).
(*) With the identification markings opposite one another.

5 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16

Remove bolts (5).
Remove connecting rod caps (6).
Remove bearing half-shells (7).

If necessary, remove the scale from the top of the liner.

6 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16
Take out the connecting rod/piston assembly through the top of the cylinder block by pushing with the handle of a hammer.

Piston rings
Adjust the gap of grips on tool A according to the diameter of piston.
See pages .
A = 0083
Remove piston rings (8- 9 — 10).
To avoid breakage of the piston rings during operation and during assembly / dismantling of the fire and compression rings, it is vital to not
exceed the spacing distance X.Fire ring (8): X = 37.6 mmCompression ring (9): X = 38 mmOil scraper ring (10): X = 34.1 mm
Pistons
Remove circlips (11).
Remove spigot (12).
Remove piston (13).
Liners
The O-rings for cylinder liners are made from fluoride rubber. When the fluoride rubber is subjected to elevated temperatures (more than 300°C),
hydrofluoric acid may be formed. Hydrofluoric acid is highly corrosive!
* Contact with the skin may cause ulcers.
7 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16
* Splashing into the eyes may cause serious burns.
* Breathing in the vapours may cause lesions in the respiratory tracts.
Pay utmost attention when working on engines that may have been subjected to elevated temperatures, e.g. overheating caused by seizing or
fire.Under no circumstances should cylinder liner O-rings be burnt after disassembly or incinerated under non-controlled conditions.
* Always wear chloroprene gloves (gloves for handling chemical products) and safety goggles for protection.
* Handle removed O-rings as if they were an acid.
* Never use compressed air to clean off residue. Even the ashes may still be extremely corrosive.
* Put all the remains in a plastic box TO WHICH a label with a warning text is to be affixed.
* Before taking off the gloves, wash them in running water.

Withdraw tool 1462.

8 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16

Withdraw liners (15).
Use tool 1230 + 2955.
Remove gaskets (16 — 17 — 18).
Crankshaft
Remove crankshaft front seal casing.
See pages .
Remove flywheel.
See pages .
Remove oil pump.
See pages .

9 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16

Remove bolts (19).
Remove bearing caps (20 — 27).
Use tool 0114 + 0013.
Remove bearing half-shells (21).

10 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16
Remove half-rings (23).

Remove half-rings (24).

Remove crankshaft (25).
Use tool 9804.

11 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16
Use lifting tackle.
Remove bearing half-shells (22).

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000261230

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

PULLER

2

1

5000269804

STRAP

2

1

7409992955

PLATE

2

1

7409990013

SLIDE HAMMER

2

1

7409990114

PULLER

2

1

7488800083

PULLER
(PISTON RINGS)

2

1

Scale

Qty

Locally manufactured tool
Illustration

Designation

Manufacturer’s code N°

12 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16
RENAULT
TRUCKS part N°
OFL1462

Manufacturer’s
reference N°
SPACER

2

1

Mobile hitch, exploded view

13 / 14

Andrew Burrows Mobile hitch / Dismantling 28/03/16

14 / 14

Andrew Burrows Mobile hitch / Assembly 28/03/16

Mobile hitch, assembly

The item numbers indicated in the text refer to the drawing on page .
Liners
Clean the contact faces thoroughly.
Install the liners without seals.

Immobilize liners.
Use tool 1462.
Check the protrusion of the liners.
Use tool 1141 + 9661.
* Make 2 diagonally opposed measurements on the highest point of the sealing face of the liner. Calculate the average value of the 2 readings.
* Mark the positioning of the liners in the cylinder block with a felt pen so as to obtain the same positioning during assembly.
For values, see «Technical data» chapter.
See pages .

1 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Withdraw tool 1462.

Install seals (16 — 17 — 18).
Ensure the position
2 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16
Place the violet seal (16) in position in the lower groove.
O-rings (16 — 17 — 18) are to be fitted dry and the exposed part then greased.
Lubricate the seals with the product supplied.

Fit liners (15).
Use a cylinder head bolt (A).
Use tools 6599 + 6454 + 8511.

3 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Immobilize liners (15).
Use tool 1462.
Crankshaft
Clean the contact faces thoroughly.
Fit bearing half-shells (22).
Match the direction of orientation.
Line up the lubrication holes.
Apply oil (engine oil) to the inner faces of bearing half-shells (22) when installing them. Do not apply oil to the support face.

4 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Apply oil to the crankpins.
Fit crankshaft (25).
Use tool 9804.
Use lifting tackle.

5 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16
Clean the contact faces thoroughly.
Fit bearing half-shells (21).
Match the direction of orientation.
Apply oil (engine oil) to the inner faces of bearing half-shells (21) when installing them. Do not apply oil to the support face.
Lubricate thrust half-rings (24).
Use engine oil.
Install thrust half-rings (24).
Match the direction of orientation.
Check for the presence of dowel (26).

Lubricate thrust half-rings (23).
Use engine oil.
Position thrust half-rings (23) on bearing cap (27).
Match the direction of orientation.
Fit bearing cap (27) complete with thrust half-rings (23).
Check that dowel (26) is properly engaged in its housing.

6 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Fit bearing caps (20).
The numbers marked on the bearing caps must be positioned at the oil cooler casing end.
The bearing caps are marked from 1 to 7, N° 1 bearing at the engine front end.

7 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Fit bolts (19).
Tighten to torque.
See pages .
Use tool 9776.
Check that the crankshaft rotates freely by turning it by hand.

8 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Crankshaft end play
Gauge the crankshaft end play .
Use tool 9661 + 8511.
Correct, if necessary.
For values, see «Technical data» chapter.
See pages .
Fit flywheel.
See pages .
Fit crankshaft front seal casing varref vrefid=»1″ idpos=»1″>.
See pages .
Reaction rod

9 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Preparing a new connecting rod
* Immobilize the connecting rod (14) in a vice; use protections.
* Remove bolts (5).
* Free connecting rod cap (6) using a plastic mallet.
* Blow compressed air over the contact faces (A — B) of the connecting rod and of the connecting rod cap.

10 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Split connecting rodSo as to not have to loosen a connecting rod during operation, it is crucial to not bump, nor apply oil to the part and keep
the contact faces (A — B), which correspond to the relief of the connecting rod cap / connecting rod parting line, immaculately clean.

Piston

11 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16
Lubricate gudgeon pin, piston and small end bush.
Assemble pistons (13) and connecting rods (14) with gudgeon pins (12).
When assembling the connecting rod / piston assembly, take care to position the marks correctly.
Install circlips (11).

Adjust the gap of grips on tool A according to the diameter of piston.
See pages .
A = 0083
To avoid breakage of the piston rings during operation and during assembly / dismantling of the fire and compression rings, it is vital to not
exceed the spacing distance X.Fire ring : X = 37.6 mmCompression ring : X = 38 mmOil scraper ring : X = 34.1 mm

12 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Fit piston rings (10 — 9 — so that the «TOP» marks are facing upwards.
Use tool A.
A = 0083
For the oil scraper ring (10), the spring gap must be diametrically opposed to the joint gap.
The piston ring joint gaps must be staggered in relation to one another.

13 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

In a vice.
Use a protective device.
Apply oil to piston (13) (engine oil).
Compress rings (8 — 9 — 10).
Use tool A.
A = 8531
Mount tool B.
B = 2935

14 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Withdraw tool 1462.

Install connecting rod/piston assemblies.
Use tool A.
A = 8531

15 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16
The marking (›) must be directed towards the front of the engine (N° 1 cylinder).

Immobilize liners.
Use tool 1462.

Withdraw tool 2935.

16 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Clean the contact faces thoroughly.
Fit bearing half-shells (7).
Match the direction of orientation.
Apply oil (engine oil) to the inner faces of bearing half-shells (7) when installing them. Do not apply oil to the support face.
Fit connecting rod caps (6).
Ensure the marking.

17 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Fit securing bolts (5).
Tighten to torque.
See pages .
Use tool 9776.
Check that the crankshaft rotates freely by turning it by hand.

18 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Oil jets
Fit oil jets (4).
Fit securing bolts (3).
Tighten to torque.
See pages .
Check that jet (4) is right in front of the oilway port (A) under piston head (13).
Fit the oil pump.
See pages .
Cylinder block stiffener

19 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Clean the contact faces thoroughly.
Replace the seals (A — B — C).
See pages .

20 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16
Fit cylinder block stiffener (2).
Wear gloves for protection.
Fit pipes (A).
Fit bolts (1).

Tighten bolts (1) to torque.
Follow the tightening sequence.
See pages .
Use tool 9776.

21 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

Fit pipe (C).
Fit the oil strainer (B).
Tighten bolts (A) to torque.
See pages .
Fit the oil sump.
See pages .
Fit the cylinder head.
See pages .

Tools
General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

9661

MEASURING TOOL
(DIAL GAUGE AND
MAGNETIC FOOT)

AQ

Manufacturer’s code N°

Scale

Qty

2

1

22 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16
AQ

BROWN & SHARP ROCH
13-15 avenue Georges de la Tour
BP 45
FRANCE
03 83 76 83 76 — 03 83 74 13 16 —

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000269804

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

STRAP

3

1

5000269776

INDICATOR DISC

2

1

7409998511

CONTROL LEVER

2

1

7409996454

PUSHER

2

1

7409996599

PUSHER

2

1

5000261141

SUPPORT
(DIAL GAUGE)

2

1

5000262935

PROTECTION (SPLIT
CONNECTING ROD)

3

1

23 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

7409998531

INSTALLATION
TOOL (PISTON)

2

1

7488800083

PULLER
(PISTON RINGS)

2

1

Scale

Qty

3

1

Locally manufactured tool
Illustration

RENAULT
TRUCKS part N°

Designation

OFL1462

SPACER

Manufacturer’s
reference N°

Manufacturer’s code N°

Big end caps, tightening torques
Tighten in diagonally opposed sequence.
Stage1

20±3 Nm

Stage2

60±3 Nm

Stage3

90±5 °

Control torque

115 › 195 Nm

Mobile hitch, exploded view
24 / 25

Andrew Burrows Mobile hitch / Assembly 28/03/16

25 / 25

Andrew Burrows Cylinder head / Removal 13/02/16

Cylinder head, removal
Remove the camshaft.
See pages .
Remove the injectors.
See pages .

Unplug connector (1).
Disconnect wire (2).
Remove clamps (3).

1 / 12

Andrew Burrows Cylinder head / Removal 13/02/16

Unplug connector (1).
Remove clamp (2).
Disengage wiring harnesses (3).
Disconnect pipes (4).

2 / 12

Andrew Burrows Cylinder head / Removal 13/02/16
Remove bolt (1).
Withdraw stuffing box (2) and the wiring harness.
Disconnect pipes (3).

Depending on the vehicle’s equipment.
With hydraulic retarder
Remove bolt (1).
Remove lock plate (2).
Remove bolt (3).
Remove tube (4).

3 / 12

Andrew Burrows Cylinder head / Removal 13/02/16

Remove bolts (1 — 2).
Remove thermostat casing (3).

Without hydraulic retarder
Loosen clamp.

4 / 12

Andrew Burrows Cylinder head / Removal 13/02/16
Disconnect hose (1).
Remove bolt (2).
Remove lock plate (3).
Remove tube (4).
Remove bolts (5).
Remove manifold (6).

Unplug connector (1).
Remove sensor (2).

5 / 12

Andrew Burrows Cylinder head / Removal 13/02/16

Assembly type A
Remove bolts (1 — 2).
Align an orifice of the pinion (3) with a bolt (4).
Place a cloth in position to prevent the bolts from dropping into the timing gear.

6 / 12

Andrew Burrows Cylinder head / Removal 13/02/16
Use tool 1380.

Remove bolts (1 — 2).

Assembly type B
Remove bolts (1).

7 / 12

Andrew Burrows Cylinder head / Removal 13/02/16
Align hole in pinion (2) with bolt (3).
Place a cloth in position to prevent the bolts from dropping into the timing gear.

Use tool 1380.

Remove bolts (1 — 2).

8 / 12

Andrew Burrows Cylinder head / Removal 13/02/16

Remove sun gear thrust washer (1).

Remove the cylinder head bolts in the reverse sequence to tightening.
See pages .
Dislodge the cylinder head from the timing plate.

9 / 12

Andrew Burrows Cylinder head / Removal 13/02/16
Use tool 8511.

Remove the cylinder head.
Use tool 3241.
Use lifting tackle.

10 / 12

Andrew Burrows Cylinder head / Removal 13/02/16
Remove planet wheel thrust washers (1).

Remove cylinder head gasket.
Immobilize liners.
Use tool 1462.

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000261380

7409998511

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

CONTROL

1

1

CONTROL LEVER

1

1

11 / 12

Andrew Burrows Cylinder head / Removal 13/02/16

Locally manufactured tool
Illustration

RENAULT
TRUCKS part N°

Designation

OFL1462

OFL3241

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

SPACER

2

1

HOOK

2

1

12 / 12

Andrew Burrows Cylinder head / Fitting 13/02/16

Cylinder head, fitting

Withdraw tool 1462.
Clean the joint faces.
Tap the screw-threads in the cylinder block then blow through with compressed air.
See pages .
If necessary, clean the copper sleeves on the unit pump injectors before positioning the cylinder head on the cylinder block.
See pages .

1 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Fit the stops (1).
Tighten to torque.
See pages .
Fit a new cylinder head gasket.

2 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16
Mount tool 3241.

Depending on the assembly.
Apply a bead of silicone (E).
See pages , .

3 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16
Place the cylinder head delicately on the bosses on the cylinder head gasket , leave a space (C) of approximately 10 mm between the rear joint face of
the cylinder head and the timing plate.
The bosses serve to slide the cylinder head without damaging the cylinder head gasket. They are crushed down when the cylinder head is tightened.

Withdraw tool 3241.

4 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Flatten the cylinder head against the stops (1).
Fit sun gear thrust washer (2).
Tighten to torque.
See pages .
Flatten the cylinder head against the timing plate (3).

5 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Fit bolt (1).
Tighten to a torque of 85±15 Nm.
Fit bolts (2).
Screw up but do not tighten.

6 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Fit bolts (24 — 26 — 28 — 30).
Tighten to a torque of 35±5 Nm.

7 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Loosen bolts (1).

Fit the cylinder head securing bolts (1).
Tighten to torque.
Follow the tightening sequence.

8 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16
See pages .
Use tool 9777.

Assembly type A
Fit bolts (1 — 2 — 3).
Tighten to torque.
See pages .
Tighten bolts (4) to torque.
See pages .

9 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Assembly type B
Fit bolts (1 — 2).
Tighten to torque.
See pages .
Tighten bolts (3) to torque.
See pages .

10 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Use tool 9776.

Replace gasket.
Fit sensor (2).
Tighten to torque.

11 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16
See pages .
Plug in connector (1).

Depending on the vehicle’s equipment.
With hydraulic retarder
Clean the contact faces thoroughly.
Replace the seals.
Fit thermostat casing (3).
Tighten bolts (1 — 2) to torque.
See pages .

12 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Replace gasket.
For assembly of the rectangular section gasket.
See pages .
Fit pipe (4).
Fit lock plate (2).
Tighten bolts (1 — 3) to torque.
See pages .

13 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Without hydraulic retarder
Clean the contact faces thoroughly.
Replace the seals.
For assembly of the rectangular section gasket.
See pages .
Fit manifold (6).
Fit bolts (5).
Tighten to torque.
See pages .
Fit pipe (4).
Fit lock plate (3).
Tighten bolts (2) to torque.
See pages .
Connect hose (1).
Tighten shackle.
Tighten to torque.
See pages .
14 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Replace O-ring with a new O-ring.
Fit the wiring harness and stuffing box (2).
Fit bolt (1).
Tighten to torque.
See pages .
Replace the seals.
Connect up pipes (3).
Tighten to torque.
See pages .

15 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Replace the seals.
Connect pipe (4).
Tighten to torque.
See pages .
Install wiring harnesses (3).
Fit clamp (2).
Tighten to torque.
See pages .
Plug in connector (1).

16 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

Fit the clamps (3).
Tighten to torque.
See pages .
Connect wire (2).
Tighten to torque.
See pages .
Plug in connector (1).
Fit the injectors.
See pages .
Fit the camshaft.
See pages .

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000269776

INDICATOR DISC

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

2

1

17 / 18

Andrew Burrows Cylinder head / Fitting 13/02/16

5000269777

INDICATOR DISC

2

1

Scale

Qty

Locally manufactured tool
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

Manufacturer’s code N°

OFL1462

SPACER

2

1

OFL3241

HOOK

2

1

18 / 18

Andrew Burrows Cylinder head / Detailed view 13/02/16

Cylinder head, exploded view

*: with hydraulic retarder

1/2

Andrew Burrows Cylinder head / Detailed view 13/02/16

2/2

Andrew Burrows Oil pump / Tightening torques 13/02/16

Oil filler pipes, tightening torques
Oil filler pipes
Plastic lock

27±2 Nm

Dipstick guide bolts

20±4 Nm

1/1

Andrew Burrows Cylinder head cover / Tightening torques 13/02/16

Cylinder head cover, tightening torques

The item numbers indicate the tightening sequence.
Cylinder head cover securing bolts

24±4 Nm

1/1

Andrew Burrows Rocker arms / Tightening torques 13/02/16

Rocker arms, tightening torques

Without «Optibrake» / «Optibrake +»

With «Optibrake»

1/2

Andrew Burrows Rocker arms / Tightening torques 13/02/16

With «Optibrake +»

2/2

Andrew Burrows Camshaft / Tightening torques 13/02/16

Rocker shaft and camshaft bearing caps, tightening torques

Camshaft

1/2

Andrew Burrows Camshaft / Tightening torques 13/02/16
Stage 1: bolts (1 › 7)

40±3 Nm

Stage 2: bolts (8 › 13 — 20)

60±5 Nm

For the 2th stage, tighten bolts gradually in the following order: 11 — 10 — 12 — 9 — 13 — 8 — 20, so that the rocker shaft can be lowered without being
damaged.
Stage 3: bolts (1 › 7)

90±5 °

Stage 4: bolts (8 › 13 — 20)

Loosen the bolts

Stage 5: bolts (8 › 13 — 20)

60±5 Nm

Rocker shaft

For the 5th stage, tighten bolts gradually in the following order: 11 — 10 — 12 — 9 — 13 — 8 — 20, so that the rocker shaft can be lowered without being
damaged.
Stage 6: bolts (14 › 19)

40±3 Nm

Stage 7: bolts (14 › 19)

120±5 °

Stage 8: bolts (8 › 13)

Loosen the bolts

Stage 9: bolts (8 › 13)

40±3 Nm

Stage 10: bolts (8 › 13 — 20)

120±5 °

2/2

Andrew Burrows Retarders / Tightening torques 13/02/16

«Optibrake/Optibrake +» retarder, tightening torques
Control solenoid valve

24±4 Nm

Rocker arms elastic blades securing bolts

25±3 Nm

1/1

Andrew Burrows Injectors / Tightening torques 13/02/16

Pump injector mounting flange, tightening torques

Assembly type A
A = Socket with boss.
Tightening procedure for already used copper injector sleeves
Stage1

20+5 Nm

Stage2

60±5 °

1/3

Andrew Burrows Injectors / Tightening torques 13/02/16

Assembly type B
A = Double groove flat socket with washer.
Tightening procedure for new copper injector sleeves
Stage1

20+5 Nm

Stage2

180±5 °

Stage3

20+5 Nm

Stage4

90±5 °

Fully loosen the yoke securing bolt before proceeding with stage 3.

At each disassembly operation, change the washer.
Tightening procedure for a used injector socket or removing an injector.
Stage1

20+5 Nm

Stage2

180±5 °

Stage3

20+5 Nm

Stage4

90±5 °

Fully loosen the yoke securing bolt before proceeding with stage 3.

At each disassembly operation, change the washer.

2/3

Andrew Burrows Injectors / Tightening torques 13/02/16
Retightening at valve maintenance
Injector flange attachment bolts

45+5 Nm

3/3

Andrew Burrows Cylinder head / Tightening torques 13/02/16

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.

1/3

Andrew Burrows Cylinder head / Tightening torques 13/02/16

Tap the screw-threads in the cylinder block then blow through with compressed air.

2/3

Andrew Burrows Cylinder head / Tightening torques 13/02/16

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

100±5 Nm

Stage2 (check tightening)

100±5 Nm

Stage3

120±5 °

Stage4

90±5 °

3/3

Andrew Burrows Blanking plug / cap / Tightening torques 13/02/16

Cylinder head plugs, tightening torques
Plug M10 x 1.00

25±3 Nm

Plug M16 x 1.50

50±3 Nm

1/1

Andrew Burrows Exhaust manifold / Tightening torques 13/02/16

Exhaust manifold, tightening torques

Stage 1: bolts (1 › 12)

5±1.5 Nm

Stage 2: bolts (1 — 4 — 5 — 8 — 9 — 12)

10±1.5 Nm

Stage 3: bolts (3 — 2 — 7 — 6 — 11 — 10 — 1 — 4 — 5 — 8 — 9 — 12)

48±8 Nm

1/1

Andrew Burrows Intake manifold / Tightening torques 13/02/16

Intake manifold, tightening torques

Apply a fine coat of sealing compound in the gasket housing (A).
Apply »
ADHESIF SILICONE 7091
«.
Install seal.
Carry out the assembly work within 20 minutes following application of the sealing compound.

1/3

Andrew Burrows Intake manifold / Tightening torques 13/02/16

The item numbers indicate the tightening sequence.
Intake manifold securing bolts

24±4 Nm

Plug M10

20±3 Nm

Boost air pressure / temperature sensor

12±2 Nm

2/3

Andrew Burrows Intake manifold / Tightening torques 13/02/16

The item numbers indicate the tightening sequence.
Stage1

10±2 Nm

Stage2

24±4 Nm

Intake air heater supply cable securing nut

10±1.5 Nm

Consumables
Automotive part N°

Industrial reference N°

56 89 501 292

Silicon adhesive 7091

3/3

Andrew Burrows Air compressor / Tightening torques 13/02/16

Air compressor, tightening torques
Air compressor 636 cm³ drive pinion securing nut

200+ 50 Nm

Air compressor 636 cm³ securing nut

85±15 Nm

Lubrication union

25±4 Nm

1/1

Andrew Burrows Distribution / Tightening torques 13/02/16

Timing system, tightening torques
Assembly type A

1 / 10

Andrew Burrows Distribution / Tightening torques 13/02/16
Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091
«.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091
«.

2 / 10

Andrew Burrows Distribution / Tightening torques 13/02/16

The item numbers indicate the tightening sequence.
Timing plate securing bolts

28±4 Nm

3 / 10

Andrew Burrows Distribution / Tightening torques 13/02/16
The bolts must not be re-used. Use new bolts.
Assembly type B

4 / 10

Andrew Burrows Distribution / Tightening torques 13/02/16

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091

5 / 10

Andrew Burrows Distribution / Tightening torques 13/02/16
«.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091
«.

6 / 10

Andrew Burrows Distribution / Tightening torques 13/02/16

The item numbers indicate the tightening sequence.
Timing plate securing bolts

28±4 Nm

7 / 10

Andrew Burrows Distribution / Tightening torques 13/02/16
The bolts must not be re-used. Use new bolts.

8 / 10

Andrew Burrows Distribution / Tightening torques 13/02/16
The item numbers indicate the tightening sequence.
Crankshaft pinion securing bolt (A)

24±4 Nm

Idler gear hub securing bolt (B)

25±3 Nm + 110±5 °

The bolts must not be re-used. Use new bolts.
Adjustable idler gear hub securing bolt (C)

35±4 Nm + 120±5 °

Camshaft pinion securing bolt (D)

45±5 Nm + 90±5 °

Idler pinion shaft securing bolts

140±10 Nm

(*)Depending on the assembly.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Proceed with assembly within 20 minutes following application of the silicone.

9 / 10

Andrew Burrows Distribution / Tightening torques 13/02/16
Use a sealing product

ADHESIF SILICONE 7091

.

The item numbers indicate the tightening sequence.
Timing case to cylinder head securing bolts

24±4 Nm

Consumables
Automotive part N°

Industrial reference N°

56 89 501 292

Silicon adhesive 7091

10 / 10

Andrew Burrows Casing / Tightening torques 13/02/16

Oil pan, tightening torques

The item numbers indicate the tightening sequence.
Oil sump securing bolts

24±4 Nm

Oil sump drain plug

60±10 Nm

1/2

Andrew Burrows Casing / Tightening torques 13/02/16

2/2

Andrew Burrows Oil filter bracket / Tightening torques 13/02/16

Oil filter head, tightening torques
Oil filter

25+5 Nm

Euro 3 / 4

The item numbers indicate the tightening sequence.
Oil filter bracket unit securing bolts

24±4 Nm

1/4

Andrew Burrows Oil filter bracket / Tightening torques 13/02/16

Plug (1)

55±5 Nm

Plug (2)

12±2 Nm

Plug (3)

55±5 Nm

Bolt (4) dia. M6

10±2 Nm

Euro 5

2/4

Andrew Burrows Oil filter bracket / Tightening torques 13/02/16

The item numbers indicate the tightening sequence.
Oil filter bracket unit securing bolts

24±4 Nm

3/4

Andrew Burrows Oil filter bracket / Tightening torques 13/02/16

4/4

Andrew Burrows / Tightening torques 13/02/16

Oil filter nipple, tightening torque
Assembly A.

Assembly B.

Union

48 Nm

1/2

Andrew Burrows / Tightening torques 13/02/16

Union

60 Nm

2/2

Andrew Burrows Oil pump / Tightening torques 13/02/16

Lubrication components, tightening torques
Oil pump
Oil pump securing bolts

24±4 Nm

Oil strainer securing bolts

27±4 Nm

Oil jet securing bolts

24±4 Nm

Oil jets

The bolts must not be re-used. Use new bolts.

Safety valve (pressure limiter)

1/1

Andrew Burrows Sensors / Tightening torques 13/02/16

Sensors, tightening torques

Coolant temperature sensor (1)

22.5± 2.5 Nm

Crankcase pressure sensor (2)

25±5 Nm

Oil pressure and temperature sensor (3)

25±5 Nm

1/1

Andrew Burrows Water pump / Tightening torques 13/02/16

Cooling system, tightening torques
Water pump

1/4

Andrew Burrows Water pump / Tightening torques 13/02/16
The item numbers indicate the tightening sequence.

Stage 1: tighten bolts (2 — 5 — 6 — 4 — 3 — 1)

48±8 Nm

Stage2 (check tightening)

48±8 Nm

2/4

Andrew Burrows Water pump / Tightening torques 13/02/16
Oil cooler

The item numbers indicate the tightening sequence.
Stage 1: tighten bolts (1 — 2 — 3 — 4)

5±1 Nm

Stage 2: tighten bolts (1 — 2 — 3 — 4 — 1)

27±4 Nm

3/4

Andrew Burrows Water pump / Tightening torques 13/02/16

Begin by tightening bolts (13 — 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

55±8 Nm

Oil cooler casing water circuit drainage union

40±4 Nm

4/4

Andrew Burrows Engine block stiffener / Tightening torques 13/02/16

Cylinder block reinforcement, tightening torques

The item numbers indicate the tightening sequence.
The bolts must not be re-used. Use new bolts.
Stage1

45±5 Nm

Stage2

60±5 °

1/1

Andrew Burrows Connecting rods / pistons / Tightening torques 13/02/16

Big end caps, tightening torques
Tighten in diagonally opposed sequence.
Stage1

20±3 Nm

Stage2

60±3 Nm

Stage3

90±5 °

Control torque

115 › 195 Nm

1/1

Andrew Burrows Crankshaft / Tightening torques 13/02/16

Crankshaft bearing caps, tightening torques

The bolts can be re-used no more than 4 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 °

1/1

Andrew Burrows Casing / Tightening torques 13/02/16

Engine flywheel housing, tightening torques
Assembly type A

1/7

Andrew Burrows Casing / Tightening torques 13/02/16
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 »
ADHESIF SILICONE 7091
«.

2/7

Andrew Burrows Casing / Tightening torques 13/02/16

The item numbers indicate the tightening sequence.
Bolt M14

140±20 Nm

Bolt M10

48±8 Nm

3/7

Andrew Burrows Casing / Tightening torques 13/02/16
Bolt M8

24±4 Nm

Assembly type B

4/7

Andrew Burrows Casing / Tightening torques 13/02/16
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 »
ADHESIF SILICONE 7091
«.

5/7

Andrew Burrows Casing / Tightening torques 13/02/16

The item numbers indicate the tightening sequence.
Bolt M14

140±20 Nm

Bolt M10

48±8 Nm

6/7

Andrew Burrows Casing / Tightening torques 13/02/16
Bolt M8

24±4 Nm

Plug

40±4 Nm

(*)Depending on the assembly.

Consumables
Automotive part N°

Industrial reference N°

56 89 501 292

Silicon adhesive 7091

7/7

Andrew Burrows Casing / Tightening torques 13/02/16

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 »
ADHESIF SILICONE 7091
«.

1/2

Andrew Burrows Casing / Tightening torques 13/02/16

The item numbers indicate the tightening sequence.
Stage 1: bolts (2 — 7)

24±4 Nm

Stage 2: bolts (1 ›

24±4 Nm

Follow the tightening sequence.

Consumables
Automotive part N°

Industrial reference N°

56 89 501 292

Silicon adhesive 7091

2/2

Andrew Burrows Engine flywheel / Tightening torques 13/02/16

Engine flywheel, tightening torques

The bolts can be re-used no more than 4 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

Andrew Burrows Engine flywheel / Tightening torques 13/02/16

The item numbers indicate the tightening sequence.
Stage1

60±5 Nm

Stage2

120±10 °

Control torque

270 › 410 Nm

2/2

Andrew Burrows Damper / Tightening torques 13/02/16

Damper, tightening torques

The item numbers indicate the tightening sequence.
The bolts must not be re-used. Use new bolts.
Stage1

35±5 Nm

Stage2

90±10 Nm

1/1

Andrew Burrows Starter / Tightening torques 13/02/16

Starter, tightening torques

Mounting studs

24±4 Nm

1/1

Andrew Burrows Alternator / Tightening torques 13/02/16

Alternator, tensioners, tightening torques
Pulley to hub securing bolt

95±5 Nm

Tensioner roller securing bolts M10

48±8 Nm

Item A

12±2 Nm

Item B

40±8 Nm

Item C

100±20 Nm

Item D

10±2 Nm

1/1

Andrew Burrows Viscous coupling / Tightening torques 13/02/16

Viscous coupling, tightening torques
Viscous coupling fan / hub securing nuts

20±4 Nm

1/1

Andrew Burrows Fuel circuit / Tightening torques 13/02/16

Low-pressure fuel circuit, tightening torques
Banjo union(s) M10

25±3 Nm

Banjo union(s) M14

35±5 Nm

Banjo union(s) M16

48±5 Nm

Bolt dia. M8x1.25

24±4 Nm

1/4

Andrew Burrows Fuel circuit / Tightening torques 13/02/16

Item A

24±4 Nm

Item B

30±5 Nm

Item C

48±5 Nm

2/4

Andrew Burrows Fuel circuit / Tightening torques 13/02/16
Item D

35±5 Nm

Item E

10±1 Nm

Item F

35±5 Nm

Item G

48±4 Nm

Item H

35±5 Nm

Item A

55±5 Nm

Item B

10±1.5 Nm

Item C

25±1.5 Nm

3/4

Andrew Burrows Fuel circuit / Tightening torques 13/02/16
Item D

25±3 Nm

Item E

1.5±0.5 Nm

Item F

55±5 Nm

4/4

Andrew Burrows Steering pump / Tightening torques 13/02/16

Steering pump, tightening torques
Steering pump drive pinion securing nut
Steering pump securing bolts

100±10 Nm
24±2 Nm

Assembly type A

Assembly type B

1/2

Andrew Burrows Steering pump / Tightening torques 13/02/16

Item A

90 Nm

Item B

55±5.5 Nm

Item C

80±10 Nm

2/2

Andrew Burrows Fuses on distribution box / Detailed view 13/02/16

Table of fuses on electrical distribution box

1/2

Andrew Burrows Fuses on distribution box / Detailed view 13/02/16

2/2

Andrew Burrows Fuses on distribution box / Table 13/02/16

Table of fuses on electrical distribution box
Code

Function

Folio (code)

Fuse

Amperage

Folio (fuse)

M050

Front passenger’s sun visor motor

I01

F02

10

A42

M051

Driver’s sun visor motor

I01

F02

10

A42

M052

Front sun visor motor

I01

F02

10

A42

D001

Principal information display

B20

F03

7.5

A40

G001

Vehicle management ECU

B03

F03

7.5

A40

S300

Cab tilting safety and authorization relay

A40

F03

7.5

A40

S600

Cab tilting motor power supply relay

B01

F03

7.5

A40

D001

Principal information display

B20

F04

5

A44

D004

Tachograph

B40

F04

5

A44

M022

Headlamps wash pump motor

H05

F05

30

A43

D001

Principal information display

B20

F06

5

A40

D004

Tachograph

B40

F07

5

A41

G001

Vehicle management ECU

B03

F07

5

A41

D001

Principal information display

B20

F08

5

A41

G025

Engine immobilizer ECU

G01

F08

5

A41

G026

Alarm ECU

G20

F08

5

A41

G028

Doors central locking ECU

G01

F08

5

A41

G051

Air production management ECU

F40

F08

5

A41

G003

Bodybuilder pre-arrangement
management ECU

J01

F09

5

A41

B131

Air conditioner control

I70

F10

20

A40

G017

Cab temperature regulation ECU

I42

F10

20

A40

S452

Air conditioning fan piloting relay

I70

F10

20

A40

G021

Hydraulic retarder ECU

D30/D31

F11

10

A41

G012

Lighting and signalling management ECU

H05

F13

20

A41

M020

Windscreen wipers drive motor

H05

F13

20

A41

S400

Windscreen wipers motor time-delay relay

A41

F13

20

A41

J001

Cigar lighter

I03

F14

15

A42

X913

Vehicle diagnostic socket

K01

F15

5

A45

G005

EBS braking management ECU

E01/E03

F16

10

A41

V010

PTO engagement electrovalve N° 1

B01

F16

10

A41

V018

PTO engagement electrovalve N° 2

J01

F16

10

A41

1 / 10

Andrew Burrows Fuses on distribution box / Table 13/02/16
E502

RH main beam headlight

H04

F17

10

A42

L008

Electric horn

H06

F18

10

A43

V107

Air horn

H06

F18

10

A43

G001

Vehicle management ECU

B03

F19

5

A40

K003

Air conditioning ECU

I70

F19

5

A40

M200

Air conditioning compressor electric clutch

I70

F19

5

A40

G028

Doors central locking ECU

G01

F20

10

A40

G026

Alarm ECU

G20

F20

10

A40

X906

ABS/EBS trailer socket

J40

F21

20

A45

E007

Bunk lower RH overhead light

H06

F22

10

A43

E008

Driver’s side single overhead light

H06

F22

10

A43

E009

Bunk lower LH overhead light

H06

F22

10

A43

E010

Front passenger’s side single overhead light

H06

F22

10

A43

E012

RH upper overhead lighting (door)

H06

F22

10

A43

E025

Driver’s reading spotlight

H06

F22

10

A43

E026

Front passenger’s reading spotlight

H06

F22

10

A43

E033

LH upper overhead lighting (door)

H06

F22

10

A43

E034

LH overhead lighting (ambience)

H06

F22

10

A43

E035

RH overhead lighting (ambience)

H06

F22

10

A43

E038

Row 1 lighting

H06

F22

10

A43

E039

Row 2 lighting

H06

F22

10

A43

E040

Row 3 lighting

H06

F22

10

A43

E041

Row 4 lighting

H06

F22

10

A43

E042

Upper left-hand side overhead lamp lighting

H06

F22

10

A43

E043

Upper right-hand side overhead lamp lighting

H06

F22

10

A43

E102

Driver’s side stepwell lighting

H06

F22

10

A43

E103

Front passenger’s side stepwell lighting

H06

F22

10

A43

G004

Air suspension ECU

F01/F02/F03

F23

5

A41

G027

Piloted axle ECU

F20

F23

5

A41

G104

Tyre pressures monitoring ECU

G60

F23

5

A41

N001

Fuel heater resistor N° 2

C01

F24

20

A41

A230

Available power supply (equipment in
«road» position warning pictogram)

J20

F25

10

A45

A240

Available power supply (lighting)

J20

F25

10

A45

D001

Principal information display

B20

F25

10

A45

2 / 10

Andrew Burrows Fuses on distribution box / Table 13/02/16
X900

15-pin trailer socket

J40

F25

10

A45

A205

Available power supply (after ignition)

J21

F26

15

A41

M056

Driver’s door window winder motor

I01

F27

20

A42

M057

Front passenger’s door window winder motor

I01

F27

20

A42

G005

EBS braking management ECU

E01/E03

F28

20

A42

G018

Onboard management interface ECU

B60

F29

10

A40

G100

Datamax gateway ECU

B61

F29

10

A40

G103

Positioning module ECU

B61

F29

10

A40

G012

Lighting and signalling management ECU

H05

F30

30

A43

D001

Principal information display

B20

F31

20

A43

G017

Cab temperature regulation ECU

I42

F31

20

A43

K001

Air/water add-on heater

I42

F31

20

A43

K002

Air/air add-on heater

I40

F31

20

A43

A204

Available power supply (after master switch)

J21

F32

10

A42

M102

Cab tilting motor

B01

F33

30

A45

G018

Onboard management interface ECU

B60

F34

3

A40

G100

Datamax gateway ECU

B61

F34

3

A40

A308

Pre-arrangement for onboard
management (screen and keyboard)

J21

F35

20

A42

G012

Lighting and signalling management ECU

H04

F36

10

A40

A013

Voltage converter (24V / 12V — 15A)
for audio communication system

I20

F37

10

A42

B207

Emergency flashing lights control

B63

F37

10

A42

G018

Onboard management interface ECU

B63

F37

10

A42

D001

Principal information display

B20

F38

10

A43

E510

Working spotlight

H06

F38

10

A43

G001

Vehicle management ECU

B03

F39

15

A41

M080

RH rearview mirror
horizontal swivelling motor

I02

F39

15

A41

M081

RH rearview mirror vertical swivelling motor

I02

F39

15

A41

M082

LH rearview mirror
horizontal swivelling motor

I02

F39

15

A41

M083

LH rearview mirror vertical swivelling motor

I02

F39

15

A41

N008

LH defrosting rearview mirror resistor

I02

F39

15

A41

N009

RH defrosting rearview mirror resistor

I02

F39

15

A41

S500

Heated and swivelling rearview
mirror power supply relay

A41

F39

15

A41

3 / 10

Andrew Burrows Fuses on distribution box / Table 13/02/16
Nitrogen oxides gases concentration sensor

C30

F40

30

A41

G002

Engine management ECU

C01

F40

30

A41

G030

AdBlue supply management pump module

C30

F40

30

A41

M002

Starter

A01/A20

F40

30

A41

M205

Water pump electromagnetic clutch

C02

F40

30

A41

S020

Starting relay

A41

F40

30

A41

S501

Air preheating relay

C01

F40

30

A41

V020

Exhaust brake solenoid valve unit

C01

F40

30

A41

V021

Engine brake N° 1 solenoid valve

C01

F40

30

A41

V023

Exhaust brake solenoid valve

C01

F40

30

A41

V052

Range change electrovalve

C01

F40

30

A41

V053

Splitter control electrovalve

C01

F40

30

A41

V108

Air dryer bleeding solenoid valve

C01

F40

30

A41

V109

Engine cooling fan speed
regulation solenoid valve

C01

F40

30

A41

V126

Pistons cooling solenoid valve

C01

F40

30

A41

V127

Engine oil cooling solenoid valve

C01

F40

30

A41

M002

Starter

A01/A20

F41

15

A41

M205

Water pump electromagnetic clutch

C02

F41

15

A41

S020

Starting relay

A41

F41

15

A41

V020

Exhaust brake solenoid valve unit

C01

F41

15

A41

V021

Engine brake N° 1 solenoid valve

C01

F41

15

A41

V023

Exhaust brake solenoid valve

C01

F41

15

A41

V052

Range change electrovalve

C01

F41

15

A41

V053

Splitter control electrovalve

C01

F41

15

A41

V108

Air dryer bleeding solenoid valve

C01

F41

15

A41

V126

Pistons cooling solenoid valve

C01

F41

15

A41

V127

Engine oil cooling solenoid valve

C01

F41

15

A41

S501

Air preheating relay

C01

F42

10

A41

V109

Engine cooling fan speed
regulation solenoid valve

C01

F42

10

A41

A013

Voltage converter (24V / 12V — 15A)
for audio communication system

I20

F43

15

A43

X902

24 Volts power supply socket

I03

F43

15

A43

A240

Available power supply (lighting)

H30

F46

20

A45

D001

Principal information display

B20

F46

20

A45

C077

4 / 10

Andrew Burrows Fuses on distribution box / Table 13/02/16
G051

Air production management ECU

F40

F47

7,5

A40

B186

Brake holding enabling control

E01/E03

F48

3

A40

G005

EBS braking management ECU

E01/E03

F48

3

A40

G004

Air suspension ECU

F01/F02/F03

F49

5

A43

G027

Piloted axle ECU

F20

F51

5

A45

G104

Tyre pressures monitoring ECU

G60

F51

5

A45

G001

Vehicle management ECU

B03

F52

10

A40

G025

Engine immobilizer ECU

G01

F52

10

A40

S001

After ignition power supply relay N°1

A40

F52

10

A40

S004

Accessories power supply relay N° 1

A42

F52

10

A40

X913

Vehicle diagnostic socket

K01

F52

10

A40

A303

Pre-arrangement for
onboard management (ECU)

B60

F54

10

A40

G018

Onboard management interface ECU

B63

F54

10

A40

G102

Onboard management ECU

B61/B63

F54

10

A40

G021

Hydraulic retarder ECU

D30/D31

F57

10

A40

B170

Cab emergency stop control

A21

F58

3

A40

S021

Alternator circuit earthing relay (ADR)

A40

F58

3

A40

A303

Pre-arrangement for
onboard management (ECU)

B60

F59

10

A41

G018

Onboard management interface ECU

B63

F59

10

A41

G102

Onboard management ECU

B61

F59

10

A41

S104

Reversing lights power supply relay

A41

F59

10

A41

M023

LH headlamp ride correction motor

H04

F61

15

A42

M024

RH headlamp ride correction motor

H04

F61

15

A42

X909

Extra 24 Volts power supply socket

I03

F63

15

A42

X900

15-pin trailer socket

J40

F64

10

A41

M023

LH headlamp ride correction motor

H04

F66

10

A42

M024

RH headlamp ride correction motor

H04

F66

10

A42

M060

Electric roof air vent motor

I01

F66

10

A42

G019

Gear selector ECU

D01

F67

10

A41

A011

Voltage converter (24V / 12V)
for information technology pack

I03

F68

20

A45

A021

Voltage converter (24 / 12V — 15A)

I03

F68

20

A45

J007

Refrigerator

I03

F68

20

A45

X906

ABS/EBS trailer socket

J40

F70

10

A41

5 / 10

Andrew Burrows Fuses on distribution box / Table 13/02/16
A205

Available power supply (after ignition)

J20

F71

15

A41

E503

LH dipped beam headlight

H04

F72

10

A42

D001

Principal information display

B20

F72

10

A42

A247

Available power supply (alternator
information, engine running)

J20

F75

15

A40

J002

RH heated seat unit

I03

F75

15

A40

J003

LH heated seat unit

I03

F75

15

A40

J006

Refrigerated compartment

I03

F75

15

A40

K002

Air/air add-on heater

I40

F76

10

A40

S021

Alternator circuit earthing relay (ADR)

A40

F76

10

A40

A204

Available power supply (after master switch)

J20/J21

F77

15

A43

G012

Lighting and signalling management ECU

H04/H05

F90

3

A45

S101

Rear fog lights power supply relay

A42

F90

3

A45

S102

Main beam headlights power supply relay

A42

F90

3

A45

S103

Fog driving lights power supply relay

A42

F90

3

A45

S106

Switches night lighting power supply relay

A45

F90

3

A45

E124

LH front side/parking lights

H04

F91

10

A44

E128

LH clearance lights N° 3

H04

F91

10

A44

E129

LH clearance lights N° 4

H04

F91

10

A44

E133

LH clearance lights N° 1

H04

F91

10

A44

E134

LH clearance lights N° 2

H04

F91

10

A44

E138

LH rear side/parking lights

H04

F91

10

A44

E144

Roof LH side/parking lights

H04/H30

F91

10

A44

E150

Anti-glare strip-mounted RH marker lights

H30

F91

10

A44

E152

Left-hand side marker lamp N° 5

H04

F91

10

A44

A245

Available power supply (lighting
and side/parking lights)

H30

F92

10

A44

E122

RH clearance light N° 1

H04

F92

10

A44

E123

RH clearance light N° 2

H04

F92

10

A44

E125

RH front side/parking lights

H04

F92

10

A44

E131

RH clearance lights N° 3

H04

F92

10

A44

E132

RH clearance lights N° 4

H04

F92

10

A44

E137

RH rear side/parking lights

H04

F92

10

A44

E145

Roof LH side/parking lights

H04/H30

F92

10

A44

E149

Anti-glare strip-mounted LH marker lights

H30

F92

10

A44

E151

Right-hand side marker lamp N° 5

H04

F92

10

A44

6 / 10

Andrew Burrows Fuses on distribution box / Table 13/02/16
A295

Available power supply
(RH rear marker light(s)

J21

F93

15

A44

X900

15-pin trailer socket

J40

F93

15

A44

A294

Available power supply
(LH rear marker light(s)

J21

F94

15

A44

X900

15-pin trailer socket

J40

F94

15

A44

O000

Instruments and controls night lighting

—

F96

3

A45

A297

Available power supply (night lighting)

J21

F97

5

A45

D001

Principal information display

B20

F100

15

A42

E502

RH main beam headlight

H04

F100

15

A42

E503

LH dipped beam headlight

H04

F100

15

A42

E506

LH fog driving light

H05

F100

15

A42

E507

RH fog driving light

H05

F100

15

A42

D001

Principal information display

B20

F101

10

A42

E116

RH rear fog light

H04

F101

10

A42

E117

LH rear fog light

H04

F101

10

A42

X900

15-pin trailer socket

J40

F101

10

A42

G019

Gear selector ECU

D01

F102

10

A42

G020

Automatic transmission ECU

D01

F102

10

A42

A253

Available power supply
(reversing information)

J20

F103

10

A41

B151

Reversing buzzer inhibition control

H04

F103

10

A41

E141

LH reversing lights

H04

F103

10

A41

E142

RH reversing lights

H04

F103

10

A41

L004

External horn

H04

F103

10

A41

X900

15-pin trailer socket

J40

F103

10

A41

E119

LH stop lights

H04

F104

10

A40

E120

RH stop lights

H04

F104

10

A40

X900

15-pin trailer socket

J40

F104

10

A40

C077

Nitrogen oxides gases concentration sensor

C30

F107

10

A41

G030

AdBlue supply management pump module

C30

F107

10

A41

K001

Air/water add-on heater

I42

F108

20

A40

K002

Air/air add-on heater

I40

F108

20

A40

7 / 10

Andrew Burrows Fuses on distribution box / Table 13/02/16

Table of fuses on electrical distribution box

8 / 10

Andrew Burrows Fuses on distribution box / Table 13/02/16

9 / 10

Andrew Burrows Fuses on distribution box / Table 13/02/16

10 / 10

Andrew Burrows Fuses on distribution box / Detailed view 13/02/16

Table of relays on distribution box

1/1

Andrew Burrows Relays on distribution box / Table 13/02/16

Table of relays on distribution box
Code

Function

Relay Amperage Diagram page N°
item N°

S001

After ignition power supply relay N°1

R01

50

A40

S002

After ignition power supply relay N°2

R02

50

A41

S003

After ignition power supply relay N° 3

R03

50

A41

S500

Heated and swivelling rearview mirror power supply relay

R04

10

A41

S022

Alternator controlled power supply relay (engine running)

R05

20

A40

S105

RH and LH side/parking and marker lights power supply relay

R06

20

A44

S106

Switches night lighting power supply relay

R07

10

A45

S104

Reversing lights power supply relay

R08

10

A41

S102

Main beam headlights power supply relay

R09

10

A42

S021

Alternator circuit earthing relay (ADR)

R10

10

A40

S453

Add-on heater power supply relay

R10

10

A43

S300

Cab tilting safety and authorization relay

R11

10

A40

S107

RH and LH side/parking and marker lights
power supply relay (trailer and bodybuilder)

R12

10

A44

S100

Stop lights power supply relay

R13

10

A40

S200

Automatic transmission management ECU power supply relay

R14

10

A42

S400

Windscreen wipers motor time-delay relay

R15

20

A41

S451

Air conditioning compressor clutch power supply relay

R16

10

A43

S020

Starting relay

R17

10

A41

S101

Rear fog lights power supply relay

R18

10

A42

S202

Air suspension power supply relay

R19

10

A43

S201

Vehicle and engine ECUs power supply relay

R20

50

A41

S004

Accessories power supply relay N° 1

R21

50

A42

S005

Accessories power supply relay N° 2

R22

50

A42

S103

Fog driving lights power supply relay

R23

10

A42

Table of relays on distribution box

1/2

Andrew Burrows Relays on distribution box / Table 13/02/16

2/2

Andrew Burrows Distribution box / Detailed view 13/02/16

Electrical distribution box -Face A connectors

1/2

Andrew Burrows Distribution box / Detailed view 13/02/16

2/2

Andrew Burrows Distribution box / Electrics — Electrical distribution box 13/02/16

Electrical distribution box -Face A connectors
Connector
item N°

Function name

Colour

Number
of ways

XJC40

Not used

—

—

XJH50

Dashboard wiring harness

Y

24

XJH51

Cab rear wiring harness

GN

24

XJH52

+ 24 Volts power supply wiring harness

NL

6

XJR32

Central console wiring harness

NL

12

XJR33

Not used

—

—

XJR61

Independent heating equipment

LBL

12

XJR62

ADR-specific independent heating equipment

GR

03

XJR64

Refrigerator or pack equipment wiring harness

BL

03

XJR65

Heated seats equipment wiring harness

Y

09

XJR73

Not used

—

—

XJR80

Independent heating equipment

BL

06

Electrical distribution box -Face A connectors

1/3

Andrew Burrows Distribution box / Electrics — Electrical distribution box 13/02/16

2/3

Andrew Burrows Distribution box / Electrics — Electrical distribution box 13/02/16

3/3

Andrew Burrows Distribution box / Detailed view 13/02/16

Electrical distribution box -Face B connectors

1/4

Andrew Burrows Distribution box / Detailed view 13/02/16

2/4

Andrew Burrows Distribution box / Detailed view 13/02/16

3/4

Andrew Burrows Distribution box / Detailed view 13/02/16

4/4

Andrew Burrows Distribution box / Electrics — Electrical distribution box 13/02/16

Electrical distribution box -Face B connectors
Connector
item N°

Function name

Colour

Number
of ways

XJB15

Battery compartment wiring harness

VO

15

XJC01_01

Dashboard wiring harness

Y

24

XJC01_02

Dashboard wiring harness

GN

24

XJC01_03

Dashboard wiring harness

Y

24

XJC01_04

Dashboard wiring harness

GN

24

XJC01_05

Dashboard wiring harness

Y

09

XJC01_06

Dashboard wiring harness

NL

12

XJC01_07

Dashboard wiring harness

VO

15

XJC01_08

Dashboard wiring harness

VO

15

XJC01_09

Dashboard wiring harness

LBL

15

XJC01_10

Dashboard wiring harness

NL

15

XJC01_11

Dashboard wiring harness

LVO

15

XJC01_12

Dashboard wiring harness

BL

15

XJC01_14

Dashboard wiring harness

NL

09

XJC01_15

Dashboard wiring harness

LVO

12

XJC01_16

Dashboard wiring harness

LBL

09

XJC01_17

Dashboard wiring harness

LBL

12

XJC01_18

Dashboard wiring harness

Y

09

XJE21

Power unit equipment wiring harness

GN

12

XJF01

Front signalling and lighting wiring harness

Y

09

XJR11

Rear line wiring harness

NL

12

XJR13

Trailer sockets wiring harness

NL

09

XJR14

Trailer sockets wiring harness

SB

02

Electrical distribution box -Face B connectors

1/5

Andrew Burrows Distribution box / Electrics — Electrical distribution box 13/02/16

2/5

Andrew Burrows Distribution box / Electrics — Electrical distribution box 13/02/16

3/5

Andrew Burrows Distribution box / Electrics — Electrical distribution box 13/02/16

4/5

Andrew Burrows Distribution box / Electrics — Electrical distribution box 13/02/16

5/5

Andrew Burrows Bulkhead grommet / Detailed view 13/02/16

Chassis / cab connection

1/3

Andrew Burrows Bulkhead grommet / Detailed view 13/02/16

2/3

Andrew Burrows Bulkhead grommet / Detailed view 13/02/16

3/3

Andrew Burrows Bulkhead grommet / Electrics — Electrical distribution box 13/02/16

Chassis / cab connection
Connector
item N°

Function name

Colour

Number
of ways

A34

Air conditioning equipment wiring harness

R

24

XT01

Front end equipment wiring harness

BL

24

XT12

Rear line wiring harness

GN

24

XT13

Piloted axles equipment wiring harness

W

15

XT15

Trailer sockets wiring harness

GR

24

XT16

Trailer sockets wiring harness

SB

2

XT21

Power unit equipment wiring harness

NL

24

XT22

Rear line wiring harness

W

12

XT33

Hydraulic retarder equipment

Y

24

XT41

RH front module equipment wiring harness

Y

24

XT53

«EBS — ESP» equipment wiring harness

BL

24

XT55

Air suspension equipment wiring harness

NL

24

XT63

Independent heating equipment

Y

12

XT65

Front end equipment wiring harness

R

24

XT70

Front end equipment wiring harness

GR

24

XT71

Front end equipment wiring harness

VO

15

XT72

Cab tilting equipment

SB

2

Chassis / cab connection

1/4

Andrew Burrows Bulkhead grommet / Electrics — Electrical distribution box 13/02/16

2/4

Andrew Burrows Bulkhead grommet / Electrics — Electrical distribution box 13/02/16

3/4

Andrew Burrows Bulkhead grommet / Electrics — Electrical distribution box 13/02/16

4/4

Andrew Burrows Available power supply / Generalities; General features 13/02/16

Available power supplies

All electrical connections must be made, without fail, to the available power supplies made available by RENAULT TRUCKS.
It is strictly forbidden to make an electrical tapping on any of the different wiring harnesses on the vehicle.
It is compulsory to use and adapt connectors and wiring harnesses officially approved and distributed by RENAULT TRUCKS.
Cable sections should be adapted to the required use. RENAULT TRUCKS recommends a value of 7 Amps per mm2 for calculating the cross-section of
the conductor.
Make use of the circuit protections recommended by RENAULT TRUCKS.
It is forbidden to change fuse ratings.
There is a high risk of irreparable damage being caused to the ECUs if electrical loads are applied without integrated protection.

1/1

Andrew Burrows Available power supply / Detailed view 13/02/16

Available power supplies

1/1

Andrew Burrows Available power supply / Identification 13/02/16

Available power supplies
Location 1

Key to appliances
Function

Polarity N° Fuse item N° Amperage

Available power supply (vehicle earth)

1

—

—

Available power supply (radio-telephone +)

4460

—

—

Location 1′
Key to appliances
Function
Telephone set antenna

Polarity N° Fuse item N° Amperage
—

—

—

Location 2
Key to appliances
Function

Polarity N° Fuse item N° Amperage

Available power supply (vehicle earth)

1

—

—

Available power supply (night lighting)

2128

F97

5

Available power supply (after master switch)

2311

F32

10

Location 3
Key to appliances
Function

Polarity N° Fuse item N° Amperage

Available power supply (vehicle earth)

1

—

—

Pre-arrangement for onboard management (screen and keyboard)

4310

F35

20

Location 4
Key to appliances
Function

Polarity N° Fuse item N° Amperage

Available power supply (vehicle earth)

1

—

—

Available power supply (CB +)

4000

—

—

1/3

Andrew Burrows Available power supply / Identification 13/02/16
Location 5
Key to appliances
Function

Polarity N° Fuse item N° Amperage

Available power supply (vehicle earth)

1

—

—

Available power supply (lighting)

612

F46

20

Available power supply (lighting and side/parking lights)

304

F92

10

A passage for the bodybuilder’s wiring harness is reserved for that purpose on the chassis-cab connection.
It is forbidden to use the other connectors fitted to the chassis-cab connection.

Available power supplies

2/3

Andrew Burrows Available power supply / Identification 13/02/16

3/3

Andrew Burrows Available power supply / Identification 13/02/16

Supply feeds available inside the cab

Location PB1
Key to appliances
Function

Polarity N° Fuse item N° Amperage

Available power supply (vehicle earth)

1

—

—

Available power supply (vehicle earth)

1

—

—

Available power supply (alternator information, engine speed)

7

—

—

Available power supply (gearbox neutral information)

12

—

—

Available power supply (after master switch)

208

F77

15

Available power supply (reversing information)

608

F103

10

Available power supply (low speed)

1025

—

—

Available power supply (selection of engine speed N°1)

1026

—

—

Available power supply (PTO N°1 control)

1140

—

—

Available power supply (selection of engine speed N°2)

1141

—

—

Available power supply (after ignition)

2234

F71

15

1/3

Andrew Burrows Available power supply / Identification 13/02/16
Available power supply (alternator information, engine running)

4306

F75

15

Available power supply (tachograph corrected speed information)

5108

—

—

Available power supply (chassis-mounted
engine speed control actuation demand)

8067

—

—

Available power supply (PTO N°1 control)

8093

—

—

Available power supply (engine stop control)

8110

—

—

Available power supply (parking brake information)

8118

—

—

Available power supply (engine speed deceleration demand)

8119

—

—

Available power supply (engine speed acceleration demand)

8120

—

—

Available power supply (main engine speed automatic return)

8121

—

—

Available power supply (PTO 1 engaged information)

8169

—

—

Location PB2
Key to appliances
Function

Polarity N° Fuse item N° Amperage

Available power supply (independent heating cut-off)

89

—

—

Available power supply (equipment in
«road» position warning pictogram)

618

F25

10

Available power supply (equipment in
«working» position warning pictogram)

651

—

—

Available power supply (lighting)

8083

F25

10

Available power supply (alarm stop)

8084

—

—

Available power supply (6 km/h limitation)

8095

—

—

Available power supply (equipment in dangerous position)

8116

—

—

Available power supply (suspension level actuation control)

8137

—

—

Available power supply (suspension level control)

8138

—

—

Location PB4
It is strictly forbidden to use the connector in position PB4. Only RENAULT TRUCKS service points or dealers are qualified to upgrade vehicles
by adding «expert» functions managed by the bodybuilder pre-arrangements management box.
Location PB5
Key to appliances
Function

Polarity N° Fuse item N° Amperage

2/3

Andrew Burrows Available power supply / Identification 13/02/16
Available power supply (engine speed)

0384

—

—

Available power supply (high level CAN bus J1939)

0413

—

—

Available power supply (low level CAN bus J1939)

0414

—

—

Available power supply (engine start control)

8100

—

—

Available power supply (engine alert)

8104

—

—

Available power supply (engine starting information)

8108

—

—

Available power supply (PTO 2 control)

8113

—

—

Available power supply (PLC 2 min. output)

8122

—

—

Available power supply (PLC 1 min. output)

8123

—

—

Available power supply (PLC 1 min. input)

8131

—

—

Available power supply (PLC 2 min. input)

8132

—

—

Available power supply (CAN bus disabling)

8133

—

—

Available power supply (PTO 2 warning light)

8134

—

—

Available power supply (engine speed set-point validation)

8136

—

—

Available power supply (PTO 2 solenoid valve piloting)

8161

—

—

Available power supply (parameter definable frequency-related output)

8170

—

—

3/3

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (1/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (1/14)
Code

Function

Connectors

Colour

Number
of tracks

D001

Principal information display

A03.B

BL

26

D001

Principal information display

A03.C

SB

18

D001

Principal information display

A03.J

Y

26

G004

Air suspension ECU

A16.X1

GN

30

Dashboard wiring harness (1/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (2/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (2/14)
Code

Function

Connectors

Colour

Number
of tracks

G004

Air suspension ECU

A16.X2

GN

22

G003

Bodybuilder pre-arrangement management ECU

A17.BA

OR

30

G003

Bodybuilder pre-arrangement management ECU

A17.BB

W

30

G003

Bodybuilder pre-arrangement management ECU

A17.BC

GN

5

Dashboard wiring harness (2/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (3/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (3/14)
Code

Function

Connectors

Colour

Number
of tracks

G001

Vehicle management ECU

A17.PA

GN

30

G001

Vehicle management ECU

A17.PB

BL

30

G001

Vehicle management ECU

A17.PC

GN

5

G005

EBS braking management ECU

A21.X1

SB

18

G005

EBS braking management ECU

A21.X2

GR

21

G005

EBS braking management ECU

A21.X3

LVO

15

G005

EBS braking management ECU

A21.X4

GN

12

D004

Tachograph

A33.A

W

8

Dashboard wiring harness (3/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (4/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (4/14)
Code

Function

Connectors

Colour

Number
of tracks

D004

Tachograph

A33.B

Y

8

D004

Tachograph

A33.D

BN

8

B131

Air conditioner control

A34B.A

VO

8

B131

Air conditioner control

A34B.B

W

8

B131

Air conditioner control

A34B.C

BN

8

G012

Lighting and signalling management ECU

A64.X1

GN

12

G012

Lighting and signalling management ECU

A64.X2

VO

15

G012

Lighting and signalling management ECU

A64.X3

LVO

6

Dashboard wiring harness (4/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (5/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (5/14)
Code

Function

Connectors

Colour

Number
of tracks

G021

Hydraulic retarder ECU

A65A

SB

88

G018

Onboard management interface ECU

A94_B

GN

16

G019

Gear selector ECU

A95

GN

22

G100

Datamax gateway ECU

A107

GN

16

G018

Onboard management interface ECU

A125_S.DK

GN

16

Dashboard wiring harness (5/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (6/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (6/14)
Code

Function

Connectors

Colour

Number
of tracks

C114

Accelerator pedal sensor unit

B25

SB

6

C013

Driver’s door open position information sensor

B107DS.A

NL

1

C013

Driver’s door open position information sensor

B107DS.B

NL

1

C086

Steering lockover angle sensor

B205

SB

7

S600

Cab tilting motor power supply relay

K23

SB

4

S401

Headlamps wash pump motor power supply relay

K54

SB

9

X200

Available power supplies connector

PB1

BN

21

X200

Available power supplies connector

PB2

NL

21

X200

Available power supplies connector

PB4

VO

15

X200

Available power supplies connector

PB5

BL

21

Dashboard wiring harness (6/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (7/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (7/14)
Code

Function

Connectors

Colour

Number
of tracks

X204

Link-up connector between 2 wiring harnesses

PB4

BN

15

B148

Working lights control

S03

SB

10

B178

Cab interior lighting control (on dashboard)

S05D

SB

10

B164

Rear wheels diff lock control

S08

SB

10

B165

Second rear axle lift-up control

S11

SB

10

B167

Cab add-on heater control

S21D

SB

10

B177

PTO 1 engagement request control (in cab)

S28A

SB

10

B168

Traction control enabling control

S31A

SB

10

B186

Brake holding enabling control

S32A

SB

10

B169

Trailer brake holding enabling control

S33

SB

10

B170

Cab emergency stop control

S38

SB

10

Dashboard wiring harness (7/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (8/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (8/14)
Code

Function

Connectors

Colour

Number
of tracks

C130

Clutch pedal position sensor

S58

SB

2

B151

Reversing buzzer inhibition control

S73

SB

10

B182

Auto/manual selection control

S102

SB

10

B106

Hazard lights control

S105

SB

10

B122

Front curtain motor control (driver side)

S110

SB

10

B116

Doors locking control

S115

SB

10

B176

Pre-arrangement for bodybuilder N° 2 control

S125

SB

10

B175

Pre-arrangement for bodybuilder N° 1 control

S126

SB

10

B184

Axle load-shedding activation control

S136

SB

10

B185

PTO 2 engagement request control (in cab)

S137A

SB

10

B194

Overhead lighting control (ambience)

S145

SB

10

B199

Fast idling adjustment control

S146

SB

10

Dashboard wiring harness (8/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (9/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (9/14)
Code

Function

Connectors

Colour

Number
of tracks

B198

Fast idling actuation control

S147A

SB

10

B151

Reversing buzzer inhibition control

S223

SB

3

X902

24 Volts power supply socket

X22

SB

18

X203

CAN bus grouping connector

X36

BL

21

X913

Vehicle diagnostic socket

X43

SB

18

X204

Link-up connector between 2 wiring harnesses

XACC1

SB

3

X204

Link-up connector between 2 wiring harnesses

XACD1

GR

8

X204

Link-up connector between 2 wiring harnesses

XACD4

NL

9

X204

Link-up connector between 2 wiring harnesses

XAHC1_F

Y

9

X204

Link-up connector between 2 wiring harnesses

XAHC2_F

VO

8

Dashboard wiring harness (9/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (10/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (10/14)
Code

Function

Connectors

Colour

Number
of tracks

X204

Link-up connector between 2 wiring harnesses

XAHC3_F

BN

8

X204

Link-up connector between 2 wiring harnesses

XAHC7

Y

8

X204

Link-up connector between 2 wiring harnesses

XARC1

GN

12

X204

Link-up connector between 2 wiring harnesses

XARC2

Y

9

X204

Link-up connector between 2 wiring harnesses

XARC3

NL

9

X204

Link-up connector between 2 wiring harnesses

XASC1

W

8

X204

Link-up connector between 2 wiring harnesses

XASC3

VO

8

X204

Link-up connector between 2 wiring harnesses

XASC4

VO

8

X204

Link-up connector between 2 wiring harnesses

XASC5

W

8

X204

Link-up connector between 2 wiring harnesses

XASC6

R

8

X204

Link-up connector between 2 wiring harnesses

XASC7

R

8

A001

Cab electrical distribution box

XJB15

VO

15

Dashboard wiring harness (10/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (11/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (11/14)
Code

Function

Connectors

Colour

Number
of tracks

A001

Cab electrical distribution box

XJC01-01

Y

24

A001

Cab electrical distribution box

XJC01-02

GN

24

A001

Cab electrical distribution box

XJC01-03

Y

24

A001

Cab electrical distribution box

XJC01-04

GN

24

A001

Cab electrical distribution box

XJC01-05

Y

9

A001

Cab electrical distribution box

XJC01-06

NL

12

A001

Cab electrical distribution box

XJC01-07

VO

15

A001

Cab electrical distribution box

XJC01-08

VO

15

A001

Cab electrical distribution box

XJC01-09

BL

15

A001

Cab electrical distribution box

XJC01-10

NL

15

Dashboard wiring harness (11/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (12/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (12/14)
Code

Function

Connectors

Colour

Number
of tracks

A001

Cab electrical distribution box

XJC01-11

BN

15

A001

Cab electrical distribution box

XJC01-12

BL

15

A001

Cab electrical distribution box

XJC01-14

NL

9

A001

Cab electrical distribution box

XJC01-15

BN

12

A001

Cab electrical distribution box

XJC01-16

BL

9

A001

Cab electrical distribution box

XJC01-17

BL

12

A001

Cab electrical distribution box

XJC01-18

Y

9

A001

Cab electrical distribution box

XJE21

GN

12

A001

Cab electrical distribution box

XJF01

Y

9

A001

Cab electrical distribution box

XJR11

NL

12

A001

Cab electrical distribution box

XJR13

NL

9

A001

Cab electrical distribution box

XJR14

SB

2

Dashboard wiring harness (12/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (13/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (13/14)
Code

Function

Connectors

Colour

Number
of tracks

A002

Chassis-cab connection box

XT01

BL

24

A002

Chassis-cab connection box

XT12

GN

24

A002

Chassis-cab connection box

XT13

NL

15

A002

Chassis-cab connection box

XT15

GR

24

A002

Chassis-cab connection box

XT16

SB

2

A002

Chassis-cab connection box

XT21

NL

24

A002

Chassis-cab connection box

XT22

BL

12

A002

Chassis-cab connection box

XT33

Y

24

A002

Chassis-cab connection box

XT41

Y

24

A002

Chassis-cab connection box

XT53

BL

24

A002

Chassis-cab connection box

XT55

NL

24

A002

Chassis-cab connection box

XT63

GN

12

Dashboard wiring harness (13/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Dashboard wiring harness (14/14)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Dashboard wiring harness (14/14)
Code

Function

Connectors

Colour

Number
of tracks

A002

Chassis-cab connection box

XT65

R

24

A002

Chassis-cab connection box

XT70

GR

24

A002

Chassis-cab connection box

XT71

VO

15

A002

Chassis-cab connection box

XT72

SB

2

Dashboard wiring harness (14/14)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Steering column wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Steering column wiring harness
Code

Function

Connectors

Colour

Number
of tracks

B143

Steering wheel fingertip controls N° 1

S214.6V

SB

6

B143

Steering wheel fingertip controls N° 1

S214.10V

SB

10

B155

Electric or hydraulic retarder control

S215

SB

3

B125

Radio set control

S216

SB

6

B136

Cruise control and engine speed
regulator adjustment control

X68

SB

8

Steering column wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Cab rear wiring harness (1/4)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Cab rear wiring harness (1/4)
Code

Function

Connectors

Colour

Number
of tracks

J007

Refrigerator

A04A

SB

2

J002

RH heated seat unit

A06L

SB

2

J003

LH heated seat unit

A06R

SB

2

K002

Air/air add-on heater

A32D

NL

15

K002

Air/air add-on heater

A32E

VO

15

G017

Cab temperature regulation ECU

A68.A

R

8

G017

Cab temperature regulation ECU

A68.B

GR

8

G017

Cab temperature regulation ECU

A68.C

W

8

J006

Refrigerated compartment

A70

SB

2

J001

Cigar lighter

A76

W

3

J007

Refrigerator

A134

SB

2

C090

Add-on heater temperature sensor

B02A

SB

5

Cab rear wiring harness (1/4)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Cab rear wiring harness (2/4)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Cab rear wiring harness (2/4)
Code

Function

Connectors

Colour

Number
of tracks

C045

Internal temperature sensor

B59

SB

2

C110

Parking brake indicator pressure sensor

B149

BL

2

E102

Driver’s side stepwell lighting

E16DS

SB

2

E103

Front passenger’s side stepwell lighting

E16PS

SB

2

E025

Driver’s reading spotlight

E18L

W

2

E026

Front passenger’s reading spotlight

E18R

W

2

E007

Bunk lower RH overhead light

E76L

SB

3

E009

Bunk lower LH overhead light

E76R

SB

3

S452

Air conditioning fan piloting relay

K65

N

4

B142

Headlamps ride corrector control

S01

Y

4

B179

Cab interior lighting control (in cab)

S05R

SB

10

C149

Driver’s seatbelt not buckled sensor

S61

GR

2

Cab rear wiring harness (2/4)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Cab rear wiring harness (3/4)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Cab rear wiring harness (3/4)
Code

Function

Connectors

Colour

Number
of tracks

C149

Driver’s seatbelt not buckled sensor

S61P

GR

2

B001

Air suspension remote control

S67B

Y

9

B180

Sun-roof opening / closing control
(on cab rear control console)

S153C

SB

10

B001

Air suspension remote control

S199

Y

9

A011

Voltage converter (24V / 12V)
for information technology pack

U06

W

8

A021

Voltage converter (24 / 12V — 15A)

U19

SB

10

X908

12 Volts power supply socket

X07A

W

3

X908

12 Volts power supply socket

X50

SB

3

X204

Link-up connector between 2 wiring harnesses

XARC1

GN

12

X204

Link-up connector between 2 wiring harnesses

XARC2

Y

9

X204

Link-up connector between 2 wiring harnesses

XARC3

NL

9

Cab rear wiring harness (3/4)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Cab rear wiring harness (4/4)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Cab rear wiring harness (4/4)
Code

Function

Connectors

Colour

Number
of tracks

A001

Cab electrical distribution box

XJR32

NL

12

A001

Cab electrical distribution box

XJR61

BL

12

A001

Cab electrical distribution box

XJR62

GR

3

A001

Cab electrical distribution box

XJR64

BL

3

A001

Cab electrical distribution box

XJR65

Y

9

A001

Cab electrical distribution box

XJR80

LVO

6

Cab rear wiring harness (4/4)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Independent heating wiring harness THERMO 90ST

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Independent heating wiring harness THERMO 90ST
Code

Function

Connectors

Colour

Number
of tracks

K001

Air/water add-on heater

A32.X8

SB

12

K001

Air/water add-on heater

A32.X11

SB

2

A002

Chassis-cab connection box

XT63

GN

12

Independent heating wiring harness THERMO 90ST

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Cab top ledge wiring harness (1/3)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Cab top ledge wiring harness (1/3)
Code

Function

Connectors

Colour

Number
of tracks

H014

Radio set

A07V12.A

SB

8

H014

Radio set

A07V12.B

W

8

G028

Doors central locking ECU

A11

GN

16

G026

Alarm ECU

A31

GN

30

C014

Passenger’s front door open
position information sensor

B107PS.A

NL

1

C014

Passenger’s front door open
position information sensor

B107PS.B

NL

1

H020

Sharp loudspeaker, LH side

B163L

WH

2

Cab top ledge wiring harness (1/3)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Cab top ledge wiring harness (2/3)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Cab top ledge wiring harness (2/3)
Code

Function

Connectors

Colour

Number
of tracks

H021

Sharp loudspeaker, RH side

B163R

WH

2

S109

Long range driving lights power supply relay

K68

SB

9

M052

Front sun visor motor

M22

WH

2

Z008

Driver’s swivelling defrosting rearview mirror

R02L

WH

5

Z009

Passenger’s swivelling defrosting rearview mirror

R02R

WH

5

B117

Sun-roof opening / closing control (on dashboard)

S23

SB

10

B207

Emergency flashing lights control

S77

SB

10

B144

Long range driving lights control

S114B

SB

10

B172

Alarm siren sound level reduction control

S207

SB

10

B163

Alarm anti-panic control

S208

SB

10

A013

Voltage converter (24V / 12V — 15A)
for audio communication system

U06R15

SB

10

X909

Extra 24 Volts power supply socket

X23

SB

3

Cab top ledge wiring harness (2/3)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Cab top ledge wiring harness (3/3)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Cab top ledge wiring harness (3/3)
Code

Function

Connectors

Colour

Number
of tracks

X204

Link-up connector between 2 wiring harnesses

XAHC1_F

Y

9

X204

Link-up connector between 2 wiring harnesses

XAHC2_F

VO

8

X204

Link-up connector between 2 wiring harnesses

XAHC3_F

BN

8

X204

Link-up connector between 2 wiring harnesses

XAHC7

Y

8

X204

Link-up connector between 2 wiring harnesses

XAHD1

WH

8

X204

Link-up connector between 2 wiring harnesses

XAHD2

Y

8

X204

Link-up connector between 2 wiring harnesses

XAHH1_F

VO

15

X204

Link-up connector between 2 wiring harnesses

XAHH3_F

SB

3

A001

Cab electrical distribution box

XJH52

NL

6

A001

Cab electrical distribution box

XJH50

Y

24

A001

Cab electrical distribution box

XJH51_F

GN

24

Cab top ledge wiring harness (3/3)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Sun-roof wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Sun-roof wiring harness
Code

Function

Connectors

Colour

Number
of tracks

M060

Electric roof air vent motor

M10

GR

2

X204

Link-up connector between 2 wiring harnesses

XAHH1

GR

6

Sun-roof wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Roof wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Roof wiring harness
Code

Function

Connectors

Colour

Number
of tracks

H011

LH front loudspeaker

B164L

W

2

H012

RH front loudspeaker

B164R

W

2

E033

LH upper overhead lighting (door)

E17ML

SB

3

E012

RH upper overhead lighting (door)

E17MR

SB

3

E034

LH overhead lighting (ambience)

E53L

SB

3

E035

RH overhead lighting (ambience)

E53R

SB

3

E042

Upper left-hand side overhead lamp lighting

E78ML

SB

3

E043

Upper right-hand side overhead lamp lighting

E78MR

SB

3

M060

Electric roof air vent motor

M10A

GR

2

X204

Link-up connector between 2 wiring harnesses

XAHH1_F

VO

15

X204

Link-up connector between 2 wiring harnesses

XAHH4

SB

4

X204

Link-up connector between 2 wiring harnesses

XAHH5

NL

7

Roof wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Anti-glare strip wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Anti-glare strip wiring harness
Code

Function

Connectors

Colour

Number
of tracks

E149

Anti-glare strip-mounted LH marker lights

E58L

SB

2

E150

Anti-glare strip-mounted RH marker lights

E58R

SB

2

X204

Link-up connector between 2 wiring harnesses

XAHH5

NL

7

Anti-glare strip wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Front end wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Front end wiring harness
Code

Function

Connectors

Colour

Number
of tracks

C046

External temperature sensor

B22A

SB

2

C122

Piloted axle lockover angle sensor

B49F

SB

7

E506

LH fog driving light

E07L

SB

2

E507

RH fog driving light

E07R

SB

2

E505

LH headlamp insert

E26L.A

SB

7

E505

LH headlamp insert

E26L.B

SB

3

E504

RH headlamp insert

E26R.A

SB

7

E504

RH headlamp insert

E26R.B

SB

3

L008

Electric horn

H09

SB

4

A002

Chassis-cab connection box

XT01

BL

24

Front end wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Under-cab wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Under-cab wiring harness
Code

Function

Connectors

Colour

Number
of tracks

M020

Windscreen wipers drive motor

M01

SB

7

C088

Engine coolant level sensor

S68

GN

2

A002

Chassis-cab connection box

XT65

R

24

Under-cab wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Driver’s door wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Driver’s door wiring harness
Code

Function

Connectors

Colour

Number
of tracks

Z011

Driver’s door locking striker unit

M09DS

SB

6

M051

Driver’s sun visor motor

M21A

SB

2

B118

Swivelling rearview mirrors and
alarm siren adjustment control

S103

SB

10

B130

Front passenger window winder
motor control (driver side)

S106DS

SB

10

B126

Driver’s window winder motor control (driver side)

S107

SB

10

B121

Passenger’s electric curtain
motor control (driver side)

S108DS

SB

10

B120

Passenger’s electric curtain
motor control (passenger side)

S109

SB

10

B119

Rearview mirrors and windscreen defrosting control

S123

SB

10

X204

Link-up connector between 2 wiring harnesses

XACD1

GR

8

X204

Link-up connector between 2 wiring harnesses

XAHD1

W

8

X204

Link-up connector between 2 wiring harnesses

XAHD2

Y

8

Driver’s door wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Passenger’s door wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Passenger’s door wiring harness
Code

Function

Connectors

Colour

Number
of tracks

Z011

Driver’s door locking striker unit

M06PS

SB

2

M051

Driver’s sun visor motor

M09PS

SB

6

B118

Swivelling rearview mirrors and
alarm siren adjustment control

M20A

SB

2

B130

Front passenger window winder
motor control (driver side)

S106PS

SB

10

B126

Driver’s window winder motor control (driver side)

S108PS

SB

10

B121

Passenger’s electric curtain
motor control (driver side)

XACD4

NL

9

Passenger’s door wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Chassis main wiring harness (1/4)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Chassis main wiring harness (1/4)
Code

Function

Connectors

Colour

Number
of tracks

G027

Piloted axle ECU

A59

SB

68

G104

Tyre pressures monitoring ECU

A77

SB

7

C051

Fuel level sensor

B07B

SB

3

C115

Lift-up air spring pressure sensor

B24A

SB

4

C039

Drive axle suspension LH position sensor

B29

SB

4

C121

Piloted axle lockover angle sensor

B49R

SB

4

C087

Chassis lateral acceleration sensor

B50

GR

4

C116

Middle axle suspension air pressure sensor

B55

SB

4

C118

Drive axle suspension LH pressure sensor

B57

SB

4

C038

Drive axle suspension RH position sensor

B175

SB

4

Chassis main wiring harness (1/4)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Chassis main wiring harness (2/4)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Chassis main wiring harness (2/4)
Code

Function

Connectors

Colour

Number
of tracks

C119

Drive axle suspension RH pressure sensor

B177

SB

4

E133

LH clearance lights N° 1

E11LC

SB

2

E134

LH clearance lights N° 2

E11LF

SB

2

E128

LH clearance lights N° 3

E11LR

SB

2

E129

LH clearance lights N° 4

E11LW

SB

2

E122

RH clearance light N° 1

E11RC

SB

2

E123

RH clearance light N° 2

E11RF

SB

2

E131

RH clearance lights N° 3

E11RR

SB

2

E132

RH clearance lights N° 4

E11RW

SB

2

E135

LH tail lights unit

E27L

SB

7

E136

RH tail lights unit

E27R

SB

7

C030

Rear inter-axle diff lock engaged sensor

S45

SB

2

Chassis main wiring harness (2/4)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Chassis main wiring harness (3/4)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Chassis main wiring harness (3/4)
Code

Function

Connectors

Colour

Number
of tracks

C172

Fifth wheel position sensors

S152

SB

7

G008

Drive axle braking assistance modulator unit

U03_1C

SB

4

G016

Second rear axle braking assistance modulator unit

U21.3A

SB

4

V002

Rear wheels diff lock electrovalve

Y02

SB

4

V034

Rear axle suspension control solenoid valve unit

Y05

SB

4

M203

Add-on heater fuel pump motor

Y32

SB

2

V038

Front suspension electrovalve

Y40A

SB

4

V030

Drive axle suspension control solenoid valve unit

Y40R

SB

4

V005

Axle piloting solenoid valve unit

Y53

SB

7

V030

Drive axle suspension control solenoid valve unit

Y97

SB

4

X204

Link-up connector between 2 wiring harnesses

XHRR3

SB

7

Chassis main wiring harness (3/4)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Chassis main wiring harness (4/4)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Chassis main wiring harness (4/4)
Code

Function

Connectors

Colour

Number
of tracks

A002

Chassis-cab connection box

XT12

SB

24

A002

Chassis-cab connection box

XT13

NL

15

A002

Chassis-cab connection box

XT15

GR

24

A002

Chassis-cab connection box

XT16

SB

2

A002

Chassis-cab connection box

XT53

BL

24

A002

Chassis-cab connection box

XT55

NL

24

Chassis main wiring harness (4/4)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Cab / engine link-up wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Cab / engine link-up wiring harness
Code

Function

Connectors

Colour

Number
of tracks

Z014

Trailer brake control EBS modulator unit

A69

SB

7

X204

Link-up connector between 2 wiring harnesses

EI

GR

39

A002

Chassis-cab connection box

XT21

NL

24

A002

Chassis-cab connection box

XT22

BL

12

Cab / engine link-up wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Gearbox wiring harness (1/2)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Gearbox wiring harness (1/2)
Code

Function

Connectors

Colour

Number
of tracks

G020

Automatic transmission ECU

A13D.A

SB

20

V018

PTO engagement electrovalve N° 2

Y18

SB

4

V010

PTO engagement electrovalve N° 1

Y18A

SB

4

V018

PTO engagement electrovalve N° 2

Y18B

SB

4

V010

PTO engagement electrovalve N° 1

Y18G

SB

4

X204

Link-up connector between 2 wiring harnesses

XGH01

SB

23

X204

Link-up connector between 2 wiring harnesses

XHG02

SB

7

A002

Chassis-cab connection box

XT33

Y

24

AD: with automatic gearbox
AY: with manual gearbox

Gearbox wiring harness (1/2)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Gearbox wiring harness (2/2)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Gearbox wiring harness (2/2)
Code

Function

Connectors

Colour

Number
of tracks

C056

Tachograph speed sensor

B12B

SB

4

C035

PTO 1 engaged position information sensor

S124C

SB

4

X204

Link-up connector between 2 wiring harnesses

XHG02

SB

7

Gearbox wiring harness (2/2)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

AdBlue wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

AdBlue wiring harness
Code

Function

Connectors

Colour

Number
of tracks

G030

AdBlue supply management pump module

A108

SB

35

C077

Nitrogen oxides gases concentration sensor

B96

SB

4

C075

AdBlue tank temperature and level sensors

B158

SB

4

N019

AdBlue heating resistor (in filter on pump)

R38

SB

4

V056

AdBlue supply metering solenoid valve

Y89

SB

2

V055

Engine water circuit by-pass solenoid valve

Y90

SB

4

AdBlue wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Cab / battery tray link-up wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Cab / battery tray link-up wiring harness
Code

Function

Connectors

Colour

Number
of tracks

G006

Vehicle power supply management ECU (ADR)

A28B.X1

SB

7

G006

Vehicle power supply management ECU (ADR)

A28B.X2

BL

4

G051

Air production management ECU

A63

SB

7

F1

Fuse

F1

—

2

F1

Fuse

F1_ADR

—

2

F89

Fuse

F89

—

2

F89

Fuse

F89_ADR

—

2

F109

Fuse

F109

—

2

A006

Electrically controlled master switch

K51.A

SB

4

X200

Available power supplies connector

PB3_socket

SB

7

X204

Link-up connector between 2 wiring harnesses

XHRR3

SB

7

A002

Chassis-cab connection box

XT41

Y

24

Cab / battery tray link-up wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Front chassis wiring harness (1/2)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Front chassis wiring harness (1/2)
Code

Function

Connectors

Colour

Number
of tracks

C120

Piloted axle oil level sensor

B10B

SB

2

C061

Front axle suspension position sensor

B28

SB

4

C117

Front air spring pressure sensor

B56

SB

4

E152

Left-hand side marker lamp N° 5

E11LFP

SB

2

E151

Right-hand side marker lamp N° 5

E11RFP

SB

2

L006

Horn — Alarm siren

H06

SB

3

M027

Windscreen wash motor /
headlamps wash motor unit

M03

SB

4

M102

Cab tilting motor

M11

GR

2

B162

Cab tilting control

S26_L

SB

2

B171

Chassis emergency stop control

S39

SB

4

C054

Air filter clogging sensor

S154

SB

3

G007

Front axle braking assistance modulator unit

U11

GR

4

Front chassis wiring harness (1/2)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Front chassis wiring harness (2/2)

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Front chassis wiring harness (2/2)
Code

Function

Connectors

Colour

Number
of tracks

V003

LH roadwheel ABS electrovalve

Y58B

SB

3

V004

Front RH wheel ABS solenoid valve

Y59B

SB

3

A002

Chassis-cab connection box

XT71

VO

15

A002

Chassis-cab connection box

XT70

GR

24

A002

Chassis-cab connection box

XT72

SB

2

Front chassis wiring harness (2/2)

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Wear sensors wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Wear sensors wiring harness
Code

Function

Connectors

Colour

Number
of tracks

C001

LH front wheel brake linings wear sensor

B40B

SB

4

C002

RH front wheel brake linings wear sensor

B41B

GN

3

C003

LH rear wheel brake linings wear sensor

B178

SB

4

C004

RH rear wheel brake linings wear sensor

B179

SB

3

Wear sensors wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Connectors / Detailed view 13/02/16

Trailer sockets wiring harness

1/1

Andrew Burrows Connectors / Diagram 13/02/16

Trailer sockets wiring harness
Code

Function

Connectors

Colour

Number
of tracks

C120

Piloted axle oil level sensor

E04

GR

2

A002

Chassis-cab connection box

XT15

GR

24

A002

Chassis-cab connection box

XT16

SB

2

Trailer sockets wiring harness

1/2

Andrew Burrows Connectors / Diagram 13/02/16

2/2

Andrew Burrows Rocker arms / Adjustment 13/02/16

Rocker arms, adjustment

Remove the blanking plug.
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 = 1380
Engine rotation: anti-clockwise, from the engine flywheel end.
Camshaft marks

1 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Without «Optibrake» / «Optibrake +»
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.
For values, see «Technical data» chapter.
See pages .

2 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Engine equipped with «Optibrake»
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.
For values, see «Technical data» chapter.
See pages .

3 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Engine equipped with «Optibrake +»
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) E1 — E5 — E3 — E6 — E2 — E4 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.
For values, see «Technical data» chapter.
See pages .

4 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

5 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

6 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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

7 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Without «Optibrake» / «Optibrake +»
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.

8 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Engine equipped with «Optibrake»
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).

9 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

10 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

In the event of incorrect clearances.
Remove bolt.
Remove adjusting shim .
Hold the caliper in place when unbolting.

11 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

12 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

13 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Engine equipped with «Optibrake +»
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.

14 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

In the event of incorrect clearances.
Remove bolt.
Remove adjusting shim .
Hold the caliper in place when unbolting.

15 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

16 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.
For adjusting the brake rocker arm, leave the feeler gauge in place.

17 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Adjustment of brake rocker arm
Loosen bolts.

For adjusting the brake rocker arm, leave the feeler gauge in place.

18 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16
The feeler gauge in place eliminates play in the exhaust valve.

Check the play in the brake rocker arm.
Use the 2.85 mm feeler gauge from tool A.
A = 0232
The checking feeler gauge should move without resistance.

19 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

In the event of incorrect clearances.
Loosen locknut (1).
Loosen bolt (2).
Fit the 3.20 mm feeler gauge from tool A.
A = 0232
Tighten bolt (2) until the exhaust valve just starts to open.
Unscrew bolt (2) until feeler gauge A can be withdrawn with slight resistance.
Tighten the locknut (1) to torque while holding the adjuster (2).
See pages .

20 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Check the play in the brake rocker arm.
Use the 2.85 mm feeler gauge from tool A.
A = 0232
The checking feeler gauge should move without resistance.

21 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16
Tighten the bolts to torque.
See pages .
Make a mark on the rocker arm when adjustment is finished.
Perform the same operation on all the other cylinders.

Remove tool A.
A = 1380
Fit blanking plug.

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000261380

7488840162

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

CONTROL

1

1

WRENCH

2

1

22 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

88800232

null

1

1

Rocker arms, tightening torques

Without «Optibrake» / «Optibrake +»

23 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

With «Optibrake»

With «Optibrake +»
24 / 24

Andrew Burrows Rocker shaft / Removal 13/02/16

Rocker shaft, removal

Remove the cylinder head cover.
See pages .

Remove brackets (1).
Depending on equipment
Unplug connector (2).
Remove bolts (3).
Remove control valve (4).
Remove tube (5).

1/7

Andrew Burrows Rocker shaft / Removal 13/02/16

Engine equipped with «Optibrake»
Remove bolts (1).
Remove elastic blades (2).

Engine equipped with «Optibrake +»

2/7

Andrew Burrows Rocker shaft / Removal 13/02/16
Remove bolts (2).
Remove elastic blades (1).

Remove bolts (14 › 19).

3/7

Andrew Burrows Rocker shaft / Removal 13/02/16
Loosen bolts (8 › 13 — 20) progressively so as to not distort the rocker shaft.
Remove bolts (8 › 13 — 20).

Mount tool 0185.
Remove the rocker assembly (1).
Use lifting tackle.
Engine equipped with «Optibrake»

4/7

Andrew Burrows Rocker shaft / Removal 13/02/16

Mount tool 0185.
For an engine equipped with «Optibrake», immobilize the piston (1) of each exhaust rocker arm (2) with a plastic clamp (3).
Blank off the openings in the cylinder head to prevent the ingress of foreign matter.
Remove the rocker assembly (4).
Use lifting tackle.
Engine equipped with «Optibrake +»

5/7

Andrew Burrows Rocker shaft / Removal 13/02/16

Mount tool 0185.
For an engine equipped with «Optibrake +», immobilize the piston (1) of each exhaust rocker arm (2) with a plastic clamp (3).
Blank off the openings in the cylinder head to prevent the ingress of foreign matter.
Remove the rocker assembly (4).
Use lifting tackle.

6/7

Andrew Burrows Rocker shaft / Removal 13/02/16

Mark.
Remove clips (1 — 2).

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

7409990185

LIFTING TOOL (ROCKER
ARM ASSEMBLY)

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

2

1

7/7

Andrew Burrows Rocker shaft / Fitting 13/02/16

Rocker shaft, fitting

Fit yokes (1 — 2).
Line up the marks made upon removal.

1 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16
When fitting new yokes, line up the marks.

Oil all moving parts.
Use engine oil.
Fit the rocker shaft (1).
Use tool 0185.
Use lifting tackle.
Engine equipped with «Optibrake»

2 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16

Oil all moving parts.
Use engine oil.
Fit the rocker shaft (4).
Use tool 0185.
Use lifting tackle.
Cut clamps (3) to free the pistons (1) of rocker arms (2).
Withdraw tool 0185.
Engine equipped with «Optibrake +»

3 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16

Oil all moving parts.
Use engine oil.
Fit the rocker shaft (4).
Use tool 0185.
Use lifting tackle.
Cut clamps (3) to free the pistons (1) of rocker arms (2).
Withdraw tool 0185.

4 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16

Tighten the camshaft and rocker shaft securing bolts to torque, following the tightening sequence (see page ).
Use tool 9776.
Inspect the rocker arms.
See pages .
Adjust the valve rocker clearances.
See pages .

5 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16

Engine equipped with «Optibrake»
Fit elastic blades (2).
Fit bolts (1).
Tighten to torque.
See pages .

6 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16

Engine equipped with «Optibrake +»
Fit elastic blades (1).
Fit bolts (2).
Tighten to torque.
See pages .

7 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16

Clean the contact faces thoroughly.
Fit new seals (1 — 2).
For assembly of the rectangular section gasket.
See pages .
Clean the pipes.

8 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16

Fit pipe (5).
Fit control valve (4).
Fit bolts (3).
Tighten to torque.
See pages .
Depending on equipment
Plug in connector (2).
Fit new clamps (1).
Fit the rocker cover.
See pages .

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000269776

INDICATOR DISC

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

1

1

9 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16
7409990185

LIFTING TOOL (ROCKER
ARM ASSEMBLY)

2

1

Rocker shaft and camshaft bearing caps, tightening torques

10 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16

Camshaft
Stage 1: bolts (1 › 7)

40±3 Nm

11 / 12

Andrew Burrows Rocker shaft / Fitting 13/02/16
Stage 2: bolts (8 › 13 — 20)

60±5 Nm

For the 2th stage, tighten bolts gradually in the following order: 11 — 10 — 12 — 9 — 13 — 8 — 20, so that the rocker shaft can be lowered without being
damaged.
Stage 3: bolts (1 › 7)

90±5 °

Stage 4: bolts (8 › 13 — 20)

Loosen the bolts

Stage 5: bolts (8 › 13 — 20)

60±5 Nm

Rocker shaft

For the 5th stage, tighten bolts gradually in the following order: 11 — 10 — 12 — 9 — 13 — 8 — 20, so that the rocker shaft can be lowered without being
damaged.
Stage 6: bolts (14 › 19)

40±3 Nm

Stage 7: bolts (14 › 19)

120±5 °

Stage 8: bolts (8 › 13)

Loosen the bolts

Stage 9: bolts (8 › 13)

40±3 Nm

Stage 10: bolts (8 › 13 — 20)

120±5 °

12 / 12

Andrew Burrows Rocker arms / Inspection / testing 13/02/16

Rocker arms, inspection

Turn the roller to eliminate the film of oil.
Check that the roller rotates freely.

1/6

Andrew Burrows Rocker arms / Inspection / testing 13/02/16
Checking the roller play
With the rocker shaft bolts loosened, using a screw clamp (A), immobilize rocker shaft (1).

Position the stylus of the dial gauge in the horizontal axis of the rocker arm roller.
Push roller (1) in the horizontal axis to eliminate the clearances.
Reset the dial gauge to zero.
Use tool 9661.

2/6

Andrew Burrows Rocker arms / Inspection / testing 13/02/16

Using a screwdriver (A), measure the roller clearance while holding rocker arm (1) in a horizontal position.
For values, see «Technical data» chapter.
See pages .

Checking the rocker arm bearing clearance

3/6

Andrew Burrows Rocker arms / Inspection / testing 13/02/16
With the rocker shaft bolts loosened, using a screw clamp (A), immobilize rocker shaft (1).

Position the stylus of the dial gauge at the end of the rocker shaft in the horizontal axis.
Use tool 9661.
Reset the dial gauge to zero.
Push rocker arm (1) back in the opposite direction to measure the clearance.
See pages .

4/6

Andrew Burrows Rocker arms / Inspection / testing 13/02/16

When replacing a rocker arm, use an oil can to squirt engine oil through the lubrication hole in the rocker arm to lubricate the roller shaft.
Upon removal, mark the position of the rocker arms on their shafts.

Check the torque of the injector flange attachment bolts without removing the rocker arm assembly.

5/6

Andrew Burrows Rocker arms / Inspection / testing 13/02/16
Use tool A.
A = 0162
Tighten to torque.
See page(s) .
This operation is to be performed at each valve adjustment maintenance.

Tools
General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

9661

MEASURING TOOL
(DIAL GAUGE AND
MAGNETIC FOOT)

AQ

AQ

Manufacturer’s code N°

Scale

Qty

1

1

BROWN & SHARP ROCH
13-15 avenue Georges de la Tour
BP 45
FRANCE
03 83 76 83 76 — 03 83 74 13 16 —

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

7488840162

WRENCH

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

2

1

6/6

Andrew Burrows Rocker arms / Adjustment 13/02/16

Rocker arms, adjustment

Remove the blanking plug.
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 = 1380
Engine rotation: anti-clockwise, from the engine flywheel end.
Camshaft marks

1 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Without «Optibrake» / «Optibrake +»
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.
For values, see «Technical data» chapter.
See pages .

2 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Engine equipped with «Optibrake»
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.
For values, see «Technical data» chapter.
See pages .

3 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Engine equipped with «Optibrake +»
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) E1 — E5 — E3 — E6 — E2 — E4 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.
For values, see «Technical data» chapter.
See pages .

4 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

5 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

6 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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

7 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Without «Optibrake» / «Optibrake +»
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.

8 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Engine equipped with «Optibrake»
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).

9 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

10 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

In the event of incorrect clearances.
Remove bolt.
Remove adjusting shim .
Hold the caliper in place when unbolting.

11 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

12 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

13 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Engine equipped with «Optibrake +»
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.

14 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

In the event of incorrect clearances.
Remove bolt.
Remove adjusting shim .
Hold the caliper in place when unbolting.

15 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.

16 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

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.
For adjusting the brake rocker arm, leave the feeler gauge in place.

17 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Adjustment of brake rocker arm
Loosen bolts.

For adjusting the brake rocker arm, leave the feeler gauge in place.

18 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16
The feeler gauge in place eliminates play in the exhaust valve.

Check the play in the brake rocker arm.
Use the 2.85 mm feeler gauge from tool A.
A = 0232
The checking feeler gauge should move without resistance.

19 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

In the event of incorrect clearances.
Loosen locknut (1).
Loosen bolt (2).
Fit the 3.20 mm feeler gauge from tool A.
A = 0232
Tighten bolt (2) until the exhaust valve just starts to open.
Unscrew bolt (2) until feeler gauge A can be withdrawn with slight resistance.
Tighten the locknut (1) to torque while holding the adjuster (2).
See pages .

20 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

Check the play in the brake rocker arm.
Use the 2.85 mm feeler gauge from tool A.
A = 0232
The checking feeler gauge should move without resistance.

21 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16
Tighten the bolts to torque.
See pages .
Make a mark on the rocker arm when adjustment is finished.
Perform the same operation on all the other cylinders.

Remove tool A.
A = 1380
Fit blanking plug.

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000261380

7488840162

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

CONTROL

1

1

WRENCH

2

1

22 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

88800232

null

1

1

Rocker arms, tightening torques

Without «Optibrake» / «Optibrake +»

23 / 24

Andrew Burrows Rocker arms / Adjustment 13/02/16

With «Optibrake»

With «Optibrake +»
24 / 24

Andrew Burrows Casing / Removal 13/02/16

Upper timing cover, removal
Remove the cylinder head cover.
See pages .

Unplug connector (1).
Remove bolt.
Remove sensor (2).

1/5

Andrew Burrows Casing / Removal 13/02/16

Remove clamps (1).
Disengage wiring harness (2).

Remove clamps (1).
2/5

Andrew Burrows Casing / Removal 13/02/16

Remove clamps (1 — 2).
Disengage pipes (3 — 4).

Loosen clamp.
Disconnect hose (1).

3/5

Andrew Burrows Casing / Removal 13/02/16
Remove tube (2).

Remove gasket (1).

Remove piping bracket (1).
Remove casing (2).

4/5

Andrew Burrows Casing / Removal 13/02/16

5/5

Andrew Burrows Casing / Fitting 13/02/16

Upper timing cover, fitting

Clean the contact faces thoroughly.
Install seals (2 — 3).
Apply sealing compound to the timing case joint face (1).
See pages .
Apply »
«.
Fit casing (1).

ADHESIF SILICONE 7091

1 / 20

Andrew Burrows Casing / Fitting 13/02/16

Fit bolts (1 — 2).
Bring the bolts into contact without tightening.

2 / 20

Andrew Burrows Casing / Fitting 13/02/16

Align the timing case joint face with the upper joint face of the cylinder head to ± 0.1 mm.
Use tool 8601 + 8628.

3 / 20

Andrew Burrows Casing / Fitting 13/02/16

Fit bolts (3 — 4 — 5).
Tighten bolts (1 › 5) to torque.
Follow the tightening sequence.
See pages .

4 / 20

Andrew Burrows Casing / Fitting 13/02/16

Remove tool 8601 + 8628.

Fit piping bracket (3).
Tighten to torque.
See pages .

5 / 20

Andrew Burrows Casing / Fitting 13/02/16
Replace gasket.
See pages .
Fit pipe (2).
Tighten to torque.
See pages .
Connect hose (1).
Tighten shackle.
Tighten to torque.
See pages .

Fit pipes (3 — 4).
Fit clamps (1 — 2).
Tighten to torque.
See pages .

6 / 20

Andrew Burrows Casing / Fitting 13/02/16

Fit clamps (1).
Tighten to torque.
See pages .

Fit sensor (2).

7 / 20

Andrew Burrows Casing / Fitting 13/02/16
Fit bolt.
Tighten to torque.
See pages .
Plug in connector (1).

Turn the engine to position a camshaft pulse wheel magnetic pole opposite the speed sensor housing.
Check the air gap.
* (A) = Clearance (mm)
* (B) = Adjusting shim
* (C) = Pulse wheel
* (D) = Camshaft speed sensor
See pages .

8 / 20

Andrew Burrows Casing / Fitting 13/02/16

Install wiring harness (2).
Fit clamps (1).
Tighten to torque.
See pages .
Fit the rocker cover.
See pages .

Consumables
Automotive part N°

Industrial reference N°

56 89 501 292

Silicon adhesive 7091

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

7409998628

9 / 20

Andrew Burrows Casing / Fitting 13/02/16

7409998601

Timing system, tightening torques
Assembly type A

10 / 20

Andrew Burrows Casing / Fitting 13/02/16

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091

11 / 20

Andrew Burrows Casing / Fitting 13/02/16
«.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091
«.

12 / 20

Andrew Burrows Casing / Fitting 13/02/16

The item numbers indicate the tightening sequence.
Timing plate securing bolts

28±4 Nm

13 / 20

Andrew Burrows Casing / Fitting 13/02/16
The bolts must not be re-used. Use new bolts.
Assembly type B

14 / 20

Andrew Burrows Casing / Fitting 13/02/16

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091

15 / 20

Andrew Burrows Casing / Fitting 13/02/16
«.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091
«.

16 / 20

Andrew Burrows Casing / Fitting 13/02/16

The item numbers indicate the tightening sequence.
Timing plate securing bolts

28±4 Nm

17 / 20

Andrew Burrows Casing / Fitting 13/02/16
The bolts must not be re-used. Use new bolts.

18 / 20

Andrew Burrows Casing / Fitting 13/02/16
The item numbers indicate the tightening sequence.
Crankshaft pinion securing bolt (A)

24±4 Nm

Idler gear hub securing bolt (B)

25±3 Nm + 110±5 °

The bolts must not be re-used. Use new bolts.
Adjustable idler gear hub securing bolt (C)

35±4 Nm + 120±5 °

Camshaft pinion securing bolt (D)

45±5 Nm + 90±5 °

Idler pinion shaft securing bolts

140±10 Nm

(*)Depending on the assembly.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Proceed with assembly within 20 minutes following application of the silicone.

19 / 20

Andrew Burrows Casing / Fitting 13/02/16
Use a sealing product
.

ADHESIF SILICONE 7091

The item numbers indicate the tightening sequence.
Timing case to cylinder head securing bolts

24±4 Nm

20 / 20

Andrew Burrows Camshaft / Removal 13/02/16

Camshaft, removal

Remove upper timing casing .
See pages .

Turn the engine in the direction of normal running, as far as compression TDC of N° 1 cylinder (valves of cylinder in balance with valves of N° 6 cylinder).
See pages .
The camshaft top dead centre mark (TDC) must be positioned between the marks (A) on the camshaft front bearing cap.

1/6

Andrew Burrows Camshaft / Removal 13/02/16

Use tool 1380.

Check that the flywheel TDC mark is in line with pointer (1).
Remove the rocker assembly.
See pages .

2/6

Andrew Burrows Camshaft / Removal 13/02/16

Remove bolts (1) proceeding in the reverse sequence of tightening.
See pages .
Remove washer (2).
Remove vibration damper (3) and camshaft pinion (4).

3/6

Andrew Burrows Camshaft / Removal 13/02/16
Remove bolts (1 › 7).

Remove upper half-bearings (1).
Use tool 0834 + 0857.
Remove bearing half-shells.

4/6

Andrew Burrows Camshaft / Removal 13/02/16
Remove the camshaft (1).
Use tool 8264.
Use lifting tackle.

Remove bearing half-shells.
Remove lower half-bearings (1).

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000261380

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

CONTROL

1

1

5000260834

PULLER

2

1

5000260857

PULLER

2

1

5/6

Andrew Burrows Camshaft / Removal 13/02/16

7409998264

LIFTING TOOL
(CAMSHAFT)

2

1

6/6

Andrew Burrows Camshaft / Inspection / testing 13/02/16

Camshaft, inspection

On the camshaft, inspect:
* Coaxiality,
* Cam lift,
* Bearings out-of-round diameter,
* Bearing half-shells.
For values, see «Technical data» chapter.
See pages .

1/1

Andrew Burrows Camshaft bearings / Replacement 13/02/16

Camshaft bearings, replacement
Remove the camshaft.
See pages .

If one of the bearings is damaged, all bearings must be replaced.

Locate new bearings in pairs.

1/3

Andrew Burrows Camshaft bearings / Replacement 13/02/16

Clean the cylinder head joint faces.
Fit locating dowels.
Use a mallet.

Fit new lower half-shell bearings.

2/3

Andrew Burrows Camshaft bearings / Replacement 13/02/16
Ensure that half-shell bearings numbers 1 — 7 can rotate around pin.
Ensure that half-shell bearings numbers 2 › 6 can be moved laterally.
Fit the camshaft.
See pages .

3/3

Andrew Burrows Camshaft / Fitting 13/02/16

Camshaft, fitting

Oil all moving parts.
Fit camshaft lower half-bearings (1) on the cylinder head.
Marks positioned on exhaust manifold end.
Apply oil (engine oil) to the inner faces of bearing half-shells (2 — 3) when installing them. Do not apply oil to the support face.
Fit bearing half-shells (2 — 3).
The half-shell (3) of N° 7 bearing determine the camshaft end float.

1 / 12

Andrew Burrows Camshaft / Fitting 13/02/16

Fit the camshaft (1).
Use tool 8264.
Use lifting tackle.

Fit half-bearing (item N° 7).

2 / 12

Andrew Burrows Camshaft / Fitting 13/02/16

Temporarily fit a bolt (1) complete with spacer (2) to N° 7 bearing.
Fit bolt (3).
Tighten to a torque of 25 Nm.

Fit half-bearing (A) (item N° 1).

3 / 12

Andrew Burrows Camshaft / Fitting 13/02/16
Fit bolt (B).
Tighten to a torque of 25 Nm.

Position the crankshaft with N° 1 cylinder at TDC.
Check that the flywheel TDC mark is in line with pointer (1).

4 / 12

Andrew Burrows Camshaft / Fitting 13/02/16
Use tool 1380.

The camshaft top dead centre mark (TDC) must be positioned between the marks (A) on the camshaft front bearing cap.

5 / 12

Andrew Burrows Camshaft / Fitting 13/02/16
Fit pinion (1) ensuring the position of marks.
Fit vibration damper (2).
Fit washer (3).
Fit securing bolts (4).
Tighten to torque.
See pages .

If necessary.
Immobilize crankshaft.
Use tool 1380.

6 / 12

Andrew Burrows Camshaft / Fitting 13/02/16

Fit upper half-bearings (1) in their original locations.
Ensure the marking.
Fit bolts (2).
Tighten to a torque of 25 Nm.

7 / 12

Andrew Burrows Camshaft / Fitting 13/02/16
Inspect the end play.
Use tool 8511 + 9661.
For values, see «Technical data» chapter.
See pages .

8 / 12

Andrew Burrows Camshaft / Fitting 13/02/16
Check the backlash .
See pages .
If necessary.
Adjust the camshaft bearing backlash.
See pages .
Remove bolt (1).
Remove shim (2).
Fit the rocker shaft.
See pages .
Fit upper timing casing .
See pages .

Tools
General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

9661

MEASURING TOOL
(DIAL GAUGE AND
MAGNETIC FOOT)

AQ

AQ

Manufacturer’s code N°

Scale

Qty

1

1

BROWN & SHARP ROCH
13-15 avenue Georges de la Tour
BP 45
FRANCE
03 83 76 83 76 — 03 83 74 13 16 —

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000261380

CONTROL

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

1

1

9 / 12

Andrew Burrows Camshaft / Fitting 13/02/16

7409998264

LIFTING TOOL
(CAMSHAFT)

2

1

7409998511

CONTROL LEVER

1

1

Rocker shaft and camshaft bearing caps, tightening torques

10 / 12

Andrew Burrows Camshaft / Fitting 13/02/16

Camshaft
Stage 1: bolts (1 › 7)

40±3 Nm

11 / 12

Andrew Burrows Camshaft / Fitting 13/02/16
Stage 2: bolts (8 › 13 — 20)

60±5 Nm

For the 2th stage, tighten bolts gradually in the following order: 11 — 10 — 12 — 9 — 13 — 8 — 20, so that the rocker shaft can be lowered without being
damaged.
Stage 3: bolts (1 › 7)

90±5 °

Stage 4: bolts (8 › 13 — 20)

Loosen the bolts

Stage 5: bolts (8 › 13 — 20)

60±5 Nm

Rocker shaft

For the 5th stage, tighten bolts gradually in the following order: 11 — 10 — 12 — 9 — 13 — 8 — 20, so that the rocker shaft can be lowered without being
damaged.
Stage 6: bolts (14 › 19)

40±3 Nm

Stage 7: bolts (14 › 19)

120±5 °

Stage 8: bolts (8 › 13)

Loosen the bolts

Stage 9: bolts (8 › 13)

40±3 Nm

Stage 10: bolts (8 › 13 — 20)

120±5 °

12 / 12

Andrew Burrows Running clearance / Adjustment 13/02/16

Camshaft, adjustment of tooth backlash

Loosen bolts (1).

Slide a feeler gauge (A) with a thickness of 0.1 mm between the teeth contact faces of pinions (1 — 2).
1 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16

Tighten bolts (1) to a torque of 10 Nm.

Check the backlash.
Use tool 9661.
For values, see «Technical data» chapter.

2 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16
See pages .

If the backlash is correct, tighten bolts (1) to torque (see page(s) ).
Use tool 9776.

Tools
General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

9661

MEASURING TOOL
(DIAL GAUGE AND
MAGNETIC FOOT)

AQ

AQ

Manufacturer’s code N°

Scale

Qty

2

1

BROWN & SHARP ROCH
13-15 avenue Georges de la Tour
BP 45
FRANCE
03 83 76 83 76 — 03 83 74 13 16 —

3 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000269776

INDICATOR DISC

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

2

1

Timing system, tightening torques
Assembly type A

4 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091

5 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16
«.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091
«.

6 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16

The item numbers indicate the tightening sequence.
Timing plate securing bolts

28±4 Nm

7 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16
The bolts must not be re-used. Use new bolts.
Assembly type B

8 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091

9 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16
«.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091
«.

10 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16

The item numbers indicate the tightening sequence.
Timing plate securing bolts

28±4 Nm

11 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16
The bolts must not be re-used. Use new bolts.

12 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16
The item numbers indicate the tightening sequence.
Crankshaft pinion securing bolt (A)

24±4 Nm

Idler gear hub securing bolt (B)

25±3 Nm + 110±5 °

The bolts must not be re-used. Use new bolts.
Adjustable idler gear hub securing bolt (C)

35±4 Nm + 120±5 °

Camshaft pinion securing bolt (D)

45±5 Nm + 90±5 °

Idler pinion shaft securing bolts

140±10 Nm

(*)Depending on the assembly.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Proceed with assembly within 20 minutes following application of the silicone.

13 / 14

Andrew Burrows Running clearance / Adjustment 13/02/16
Use a sealing product
.

ADHESIF SILICONE 7091

The item numbers indicate the tightening sequence.
Timing case to cylinder head securing bolts

24±4 Nm

14 / 14

Andrew Burrows Distribution / Detailed view 13/02/16

Timing assembly, exploded view

1/1

Andrew Burrows Distribution / Removal 13/02/16

Timing assembly, removal

The item numbers indicated in the text refer to the drawing on page .
Remove starter motor.
See pages .
Remove compressor.
See pages .
Remove steering pump.
See pages .
Remove flywheel.
See pages .
Remove the crankshaft rear seal.
See pages .
Remove the oil sump.
See pages .
Remove upper timing casing (1).
See pages .
Remove brackets (2 — 3).

Remove clamp (A).

1/7

Andrew Burrows Distribution / Removal 13/02/16
Disengage wiring harnesses (B).

Remove clamp (A).
Remove pipes (B).

Cut cable tie (A).

2/7

Andrew Burrows Distribution / Removal 13/02/16
Remove flange (B).
Remove bracket (C).

Remove bolts (A — B) M8.

Remove bolts (A) M8.

3/7

Andrew Burrows Distribution / Removal 13/02/16
Depending on the assembly.
Remove bolts (4) M10 — (5) M14 by loosening them in the reverse sequence to tightening.
See pages , .
Remove flywheel (6).
Depending on the assembly.
Assembly type A
Remove pinion (7).
Assembly type B
Remove bolt.
Remove pinion (7).
Remove gasket (8).
Loosen bolts (9 — 10 — 11) proceeding in the reverse sequence to tightening.
See pages .
Remove vibration damper (12) and camshaft pinion (13).
Remove washer (14).
Remove pinions (15 — 16).
Remove half-rings (17 — 18).
Remove hub (19).

4/7

Andrew Burrows Distribution / Removal 13/02/16
Remove bolts (20).
Remove pinion (21).
Use tool 0843.
Remove gasket (22).

Place locating tools 8267 in position and tighten them to 60 Nm.
Remove stud holder unit (A).
Remove gasket (B).
Depending on the assembly.
Remove bolts (23) by loosening them in the reverse sequence to tightening.
See pages , .
Remove timing plate (24).

Tools
Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000260843

PULLER

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

2

1

5/7

Andrew Burrows Distribution / Removal 13/02/16

7409998267

GUIDE

2

1

Timing assembly, exploded view

6/7

Andrew Burrows Distribution / Removal 13/02/16

7/7

Andrew Burrows Distribution / Fitting 13/02/16

Timing assembly, fitting

The item numbers indicated in the text refer to the drawing on page .
Clean the joint faces.
Depending on the assembly.
Apply a bead of silicone.
See pages , .
Fit timing plate (24).

Replace O-ring (B) with a new O-ring.
Fit stud holder unit (A).
Depending on the assembly.
Fit bolts (23).
Tighten to torque.
Follow the tightening sequence.
See pages , .
Withdraw the locating tools 8267.

1 / 24

Andrew Burrows Distribution / Fitting 13/02/16

The camshaft top dead centre mark (TDC) must be positioned between the marks (A) on the camshaft front bearing cap.

Fit pinion (13).

2 / 24

Andrew Burrows Distribution / Fitting 13/02/16
Check the position of marks.
Fit vibration damper (12).
Fit the washer (14).
Fit bolts (9).

Tighten to torque.
See pages .
Use tool 9776.
Lubricate hub (19).
Use engine oil.
Position hub (19) in pinion (16).
Install thrust half-rings (17 — 18).
Fit pinion (16).
Start bolts (10) but do not tighten.

3 / 24

Andrew Burrows Distribution / Fitting 13/02/16

Slide a feeler gauge (A) with a thickness of 0.1 mm between the teeth contact faces of pinions (13 — 16).
Preliminary tighten bolts (10) to a torque of 10 Nm.

Check the backlash .
Use tool 9661.

4 / 24

Andrew Burrows Distribution / Fitting 13/02/16
For values, see «Technical data» chapter.
See pages .
If the backlash is correct, tighten bolts (10) to torque (see page(s) ).
Use tool 9776.

Lightly oil a new O-ring (22) and install.
Fit pinion (21).
Tighten bolts (20) to torque.
See pages .

5 / 24

Andrew Burrows Distribution / Fitting 13/02/16

Fit pinion (15) ensuring the position of marks (A — B) / (C — D).
Tighten bolts (11) to torque following the tightening sequence.
See pages .

6 / 24

Andrew Burrows Distribution / Fitting 13/02/16

Use tool 9776.

Replace O-ring (8) with a new O-ring.
Depending on the assembly.
Assembly type A

7 / 24

Andrew Burrows Distribution / Fitting 13/02/16
Fit pinion (7).
Assembly type B
Fit pinion (7).
Fit bolt.
Tighten to torque.
See pages .
Check the timing.
See pages .
Inspect the backlash of pinions (7 / 21) — (15 / 21) — (16 / 15).
For values, see «Technical data» chapter.
See pages .
In the event of non-conforming play, adjust timing plate (24).
See pages .
Clean the flywheel casing (6).
Clean the joint faces.
Place the engine in a vertical position.
Depending on the assembly.
Apply a bead of silicone.
Apply »

ADHESIF SILICONE 7091
«.
See pages , .
Fit flywheel (6).
Depending on the assembly.
Tighten bolts (4) M10 — (5) M14 to torque, following the tightening sequence.
See pages , .

8 / 24

Andrew Burrows Distribution / Fitting 13/02/16

Fit bolts (A) M8.
Tighten to torque.
See pages , .

Fit bolts (A — B) M8.

9 / 24

Andrew Burrows Distribution / Fitting 13/02/16
Tighten to torque.
See pages , .

Fit bracket (C).
Tighten to torque.
See pages .
Fit clamp (B).
Tighten to torque.
See pages .
Fit clamp (A).

10 / 24

Andrew Burrows Distribution / Fitting 13/02/16

Fit pipes (B).
Fit clamp (A).
Tighten to torque.
See pages .

11 / 24

Andrew Burrows Distribution / Fitting 13/02/16
Install wiring harnesses (B).
Fit clamp (A).
Tighten to torque.
See pages .
Fit brackets (2 — 3).
Tighten to torque.
See pages .
Fit upper timing casing (1).
See pages .
Fit the oil sump.
See pages .
Fit the crankshaft rear seal.
See pages .
Fit flywheel.
See pages .
Fit the steering pump.
See pages .
Fit air compressor.
See pages .
Fit starter motor.
See pages .

Consumables
Automotive part N°

Industrial reference N°

56 89 501 292

Silicon adhesive 7091

Tools
General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

9661

12 / 24

Andrew Burrows Distribution / Fitting 13/02/16

AQ

BROWN & SHARP ROCH
13-15 avenue Georges de la Tour
BP 45
FRANCE
03 83 76 83 76 — 03 83 74 13 16 —

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

5000269776

7409998267

Timing system, tightening torques
Assembly type A

13 / 24

Andrew Burrows Distribution / Fitting 13/02/16

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091

14 / 24

Andrew Burrows Distribution / Fitting 13/02/16
«.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091
«.

15 / 24

Andrew Burrows Distribution / Fitting 13/02/16

The item numbers indicate the tightening sequence.
Timing plate securing bolts

28±4 Nm

16 / 24

Andrew Burrows Distribution / Fitting 13/02/16
The bolts must not be re-used. Use new bolts.
Assembly type B

17 / 24

Andrew Burrows Distribution / Fitting 13/02/16

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091

18 / 24

Andrew Burrows Distribution / Fitting 13/02/16
«.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Perform assembly within 20 minutes of application of the silicone.
Use a silicone sealant »
ADHESIF SILICONE 7091
«.

19 / 24

Andrew Burrows Distribution / Fitting 13/02/16

The item numbers indicate the tightening sequence.
Timing plate securing bolts

28±4 Nm

20 / 24

Andrew Burrows Distribution / Fitting 13/02/16
The bolts must not be re-used. Use new bolts.

21 / 24

Andrew Burrows Distribution / Fitting 13/02/16
The item numbers indicate the tightening sequence.
Crankshaft pinion securing bolt (A)

24±4 Nm

Idler gear hub securing bolt (B)

25±3 Nm + 110±5 °

The bolts must not be re-used. Use new bolts.
Adjustable idler gear hub securing bolt (C)

35±4 Nm + 120±5 °

Camshaft pinion securing bolt (D)

45±5 Nm + 90±5 °

Idler pinion shaft securing bolts

140±10 Nm

(*)Depending on the assembly.

Apply a bead of silicone dia. 2 mm (A) as shown in the drawing. Proceed with assembly within 20 minutes following application of the silicone.

22 / 24

Andrew Burrows Distribution / Fitting 13/02/16
Use a sealing product
.

ADHESIF SILICONE 7091

The item numbers indicate the tightening sequence.
Timing case to cylinder head securing bolts

24±4 Nm

Timing assembly, exploded view

23 / 24

Andrew Burrows Distribution / Fitting 13/02/16

24 / 24

Andrew Burrows Distribution / Adjustment 13/02/16

Timing assembly, adjusting the timing plate
It is necessary to adjust the timing plate if the timing idler gears backlash is incorrect.
The item numbers indicated in the text refer to the drawing on page .

Mount tool 6401.
Ensure that tools 6401 are smooth and free from burrs so as to not damage the oil sump face on the cylinder block.

1/9

Andrew Burrows Distribution / Adjustment 13/02/16

The joint faces of the timing plate and of the cylinder block must be meticulously cleaned of all traces of sealing compound.
Place timing plate (24) in position on tools 6401.
Fit 3 securing bolts; 2 on the lower edge and 1 on the upper edge of the timing plate.
See illustration opposite.
Bring the bolts into contact without tightening.

2/9

Andrew Burrows Distribution / Adjustment 13/02/16

Fit pinion (21).
Fit pinion (7).
Depending on the assembly.
Assembly type A
Install one bolt (A) M 14×100 with a wide washer (B).
Assembly type B
Fit bolt (A).
Bring bolt (A) into contact without tightening.
Fit pinion (15) with 2 bolts (11).
Bring the bolts into contact without tightening.
Check that the timing plate can always be moved sideways.

3/9

Andrew Burrows Distribution / Adjustment 13/02/16

Insert two 0.10 mm feeler gauges between the teeth of the idler gears and the teeth of the crankshaft pinion.
Using a plastic mallet, tap on the side of the timing plate until the feeler gauges are a tight fit between the gear teeth.
Both feeler gauges must be as tight a fit as one another.
Tighten the 3 timing plate securing bolts (24).
Tighten the bolts with enough torque to prevent the position of the timing plate (24) from being modified.
Tighten the setscrews (11).

4/9

Andrew Burrows Distribution / Adjustment 13/02/16

Tighten bolt (A).
Take out the feeler gauges.
Inspect the backlash of pinions (7 / 21).
Use tool 9661.
For values, see «Technical data» chapter.
See page(s) .

5/9

Andrew Burrows Distribution / Adjustment 13/02/16

Check alignment of timing plate in relation to the bottom of the engine block. Correct distance 0±0.25 mm.
Use tool 9661 + 1141.

Place locating tools 8267 in position and tighten them to 60 Nm.
Withdraw positioning tools 6401.

6/9

Andrew Burrows Distribution / Adjustment 13/02/16
Remove idler gears (7 — 15 — 21).
Remove timing plate (24).
Take out timing plate (24) in a straight line, so as to not damage locating tools 8267.

Tools
General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

9661

MEASURING TOOL
(DIAL GAUGE AND
MAGNETIC FOOT)

AQ

AQ

Manufacturer’s code N°

Scale

Qty

2

1

BROWN & SHARP ROCH
13-15 avenue Georges de la Tour
BP 45
FRANCE
03 83 76 83 76 — 03 83 74 13 16 —

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

7409996401

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

CLAMP

2

1

7409998267

GUIDE

2

1

5000261141

SUPPORT
(DIAL GAUGE)

2

1

7/9

Andrew Burrows Distribution / Adjustment 13/02/16

Timing assembly, exploded view

8/9

Andrew Burrows Distribution / Adjustment 13/02/16

9/9

Andrew Burrows Casing / Inspection / testing 13/02/16

Engine flywheel housing, checking for deformation
Check the run-out of the flywheel casing.
See pages .

Clean the flywheel casing.
Place the dial gauge stylus on the outer face of the flywheel.
Use tool 9661.
Note down the value.
Place the magnetic foot on the opposite side.
Check that the readings are inside the tolerances.
See pages .
Repeat the reading at 4 points.

1/4

Andrew Burrows Casing / Inspection / testing 13/02/16

Mount tool 1380.

Place the dial gauge stylus on the inner face of the flywheel.
Use tool 9661.
Turn the flywheel using tool 1380.

2/4

Andrew Burrows Casing / Inspection / testing 13/02/16
Note down the value.
Check that the readings are inside the tolerances.
See pages .
If one or several readings are outside the tolerances, check the contact face between the flywheel and the cylinder block before replacing the casing.

Withdraw tool 1380.

Tools
General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

9661

MEASURING TOOL
(DIAL GAUGE AND
MAGNETIC FOOT)

AQ

AQ

Manufacturer’s code N°

Scale

Qty

2

1

BROWN & SHARP ROCH
13-15 avenue Georges de la Tour

3/4

Andrew Burrows Casing / Inspection / testing 13/02/16
BP 45
FRANCE
03 83 76 83 76 — 03 83 74 13 16 —

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000261380

CONTROL

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

1

1

4/4

Andrew Burrows Distribution / Inspection / testing 13/02/16

Timing assembly, checking the shimming

Turn the flywheel using tool 1380.

Align the mark (1) between the marks (A).
1/3

Andrew Burrows Distribution / Inspection / testing 13/02/16

Adjust the inlet valve rocker arm clearance of (1) N° 1 cylinder to nil.
Install a dial gauge.
Use tool 9661.
Set the dial gauge to zero and mark the measuring point.

2/3

Andrew Burrows Distribution / Inspection / testing 13/02/16
Turn the engine in the normal direction of rotation as far as mark 6 after TDC (about 1 1/4 of a revolution ), N° 6 cylinder compression.
The inlet valve of N° 1 cylinder opens by 1.6± 0.3 mm when the flywheel is positioned at 6° after top dead centre.
After making the check, do not forget to adjust the N° 1 cylinder inlet valve rocker arm clearance.
See pages .

Tools
General purpose tools
Illustration

RENAULT
TRUCKS part N°

Designation

Manufacturer’s
reference N°

9661

MEASURING TOOL
(DIAL GAUGE AND
MAGNETIC FOOT)

AQ

AQ

Manufacturer’s code N°

Scale

Qty

1

1

BROWN & SHARP ROCH
13-15 avenue Georges de la Tour
BP 45
FRANCE
03 83 76 83 76 — 03 83 74 13 16 —

Specific tools
Illustration

RENAULT
TRUCKS part N°

Designation

5000261380

CONTROL

Manufacturer’s
reference N°

Manufacturer’s code N°

Scale

Qty

2

1

3/3

Andrew Burrows Diagram / Diagram 28/03/16

List of «equipment» codes
Key to appliances
Code

Function name

Location

A001

Cab electrical distribution box

—

A002

Chassis-cab connection box

—

A004

Batteries

A01 / A20

A006

Electrically controlled master switch

A01

A009

Alternator

A01 / A20

A011

Voltage converter (24V / 12V) for information technology pack

I03

A013

Voltage converter (24V / 12V — 15A) for audio communication system

I20

A014

Power fuse box unit (FM1 to FM4)

A01 / A20

A021

Voltage converter (24 / 12V — 15A)

I03

A200

Available power supply (insulated cut wires)

J21

A201

Available power supply (vehicle earth)

H30 / J20 / J21

A204

Available power supply (after master switch)

J20 / J21

A205

Available power supply (after ignition)

J20 / J21

A206

Available power supply (CB +)

I20

A212

Available power supply (engine speed)

J21

A213

Available power supply (PTO N°1)

J20

A219

Available power supply (radio-telephone +)

I20

A220

Available power supply (radio-telephone -)

I20

A230

Available power supply (equipment in
«road» position warning pictogram)

J20

A231

Available power supply (equipment in
«working» position warning pictogram)

J20

A240

Available power supply (lighting)

H30 / J20

A245

Available power supply (lighting and side/parking lights)

H30

A246

Available power supply (PTO N°1 control)

J20

A247

Available power supply (alternator information, engine running)

J20

A248

Available power supply (alternator information, engine speed)

J20

A249

Available power supply (tachograph corrected speed information)

J20

A250

Available power supply (PTO 2 control)

J21

A251

Available power supply (PTO 2 warning light)

J21

A252

Available power supply (PTO 2 solenoid valve piloting)

J21

1 / 14

Andrew Burrows Diagram / Diagram 28/03/16
Available power supply (reversing information)

J20

A254

Available power supply (parking brake information)

J20

A255

Available power supply (gearbox neutral information)

J20

A256

Available power supply (chassis-mounted
engine speed control actuation demand)

J20

A257

Available power supply (selection of engine speed N°1)

J20

A258

Available power supply (selection of engine speed N°2)

J20

A259

Available power supply (engine speed acceleration demand)

J20

A260

Available power supply (engine speed deceleration demand)

J20

A270

Available power supply (main engine speed automatic return)

J20

A280

Available power supply (low speed)

J20

A281

Available power supply (engine stop control)

J20

A282

Available power supply (engine start control)

J21

A283

Available power supply (engine starting information)

J21

A284

Available power supply (engine alert)

J21

A285

Available power supply (parameter definable frequency-related output)

J21

A286

Available power supply (PLC 2 min. output)

J21

A287

Available power supply (PLC 1 min. output)

J21

A288

Available power supply (PLC 1 min. input)

J21

A289

Available power supply (PLC 2 min. input)

J21

A290

Available power supply (high level CAN bus J1939)

J21

A291

Available power supply (low level CAN bus J1939)

J21

A294

Available power supply (LH rear marker light(s)

J21

A295

Available power supply (RH rear marker light(s)

J21

A297

Available power supply (night lighting)

J21

A303

Pre-arrangement for onboard management (ECU)

B60

A308

Pre-arrangement for onboard management (screen and keyboard)

J21

A311

Available power supply (PTO 1 engaged information)

J20

A312

Available power supply (equipment in dangerous position)

J20

A313

Available power supply (CAN bus disabling)

J21

A314

Available power supply (engine speed set-point validation)

J21

A319

Available power supply (suspension level control)

J20

A320

Available power supply (suspension level actuation control)

J20

A321

Available power supply (6 km/h limitation)

J20

A323

Available power supply (alarm stop)

J20

A253

2 / 14

Andrew Burrows Diagram / Diagram 28/03/16
Available power supply (rigid perimetric protection module)

J21

B001

Air suspension remote control

F01 / F02 / F03

B026

Automatic transmission gear selector

D01

B103

Key switch unit

A01 / A20

B105

Engine stop control

C02

B106

Hazard lights control

H04

A324

B111

Horn control

H06

B113

Side/parking lights control

H05

B116

Doors locking control

G01

B117

Sun-roof opening / closing control (on dashboard)

I01

B118

Swivelling rearview mirrors and alarm siren adjustment control

I02

B119

Rearview mirrors and windscreen defrosting control

I02

B120

Passenger’s electric curtain motor control (passenger side)

I01

B121

Passenger’s electric curtain motor control (driver side)

I01

B122

Front curtain motor control (driver side)

I01

B125

Radio set control

B20

B126

Driver’s window winder motor control (driver side)

I01

B127

Front passenger window winder motor control (front passenger side)

I01

B130

Front passenger window winder motor control (driver side)

I01

B131

Air conditioner control

I70

B136

Cruise control and engine speed regulator adjustment control

B03

B137

Windscreen wash control

H05

B138

Windscreen wipers control

H05

B139

Windscreen / headlamps wash/wipe control

H05

B140

Dipped beam headlights control

H05

B141

Main beam headlights control

H05

B142

Headlamps ride corrector control

H04

B143

Steering wheel fingertip controls N° 1

H04 / H05 / H06

B144

Long range driving lights control

H30

B145

Fog driving lights control

H05

B146

Fog lights control

H05

B148

Working lights control

H06

B151

Reversing buzzer inhibition control

H04

B155

Electric or hydraulic retarder control

B01

B162

Cab tilting control

B01

3 / 14

Andrew Burrows Diagram / Diagram 28/03/16
Alarm anti-panic control

G20

B164

Rear wheels diff lock control

E01 / E03

B165

Second rear axle lift-up control

F02 / F03

B167

Cab add-on heater control

I40 / I42

B168

Traction control enabling control

E01 / E03

B169

Trailer brake holding enabling control

E01 / E03

B170

Cab emergency stop control

A21

B171

Chassis emergency stop control

A21

B172

Alarm siren sound level reduction control

G20

B175

Pre-arrangement for bodybuilder N° 1 control

J20

B176

Pre-arrangement for bodybuilder N° 2 control

J20

B177

PTO 1 engagement request control (in cab)

B01

B178

Cab interior lighting control (on dashboard)

H06

B179

Cab interior lighting control (in cab)

H06

B180

Sun-roof opening / closing control (on cab rear control console)

I01

B181

Direction indicator control

H04

B163

B182

Auto/manual selection control

B01

B184

Axle load-shedding activation control

F02 / F03

B185

PTO 2 engagement request control (in cab)

J01

B186

Brake holding enabling control

E01

B194

Overhead lighting control (ambience)

H06

B199

Fast idling adjustment control

B03

B200

Cruise control / engine speed adjustment controls

B03

B207

Emergency flashing lights control

B63

B219

Driver’s side electric curtain motor control

I01

B220

Optiroll control

B01

C001

LH front wheel brake linings wear sensor

E01 / E03

C002

RH front wheel brake linings wear sensor

E01 / E03

C003

LH rear wheel brake linings wear sensor

E01 / E03

C004

RH rear wheel brake linings wear sensor

E01 / E03

C005

Lift-up axle or second rear axle LH wheel brake linings wear sensor

E01

C006

Lift-up axle or second rear axle RH wheel brake linings wear sensor

E01

C007

LH front wheel speed sensor

E01 / E03

C008

RH front wheel speed sensor

E01 / E03

C009

LH rear wheel speed sensor

E01 / E03

4 / 14

Andrew Burrows Diagram / Diagram 28/03/16
C010

RH rear wheel speed sensor

E01 / E03

C011

Lift-up axle or second rear axle LH wheel speed sensor

E01

C012

Lift-up axle or second rear axle RH wheel speed sensor

E01

C013

Driver’s door open position information sensor

H05

C014

Passenger’s front door open position information sensor

H05

C019

Boost air pressure and temperature sensor

C02

C020

Boost air temperature sensor

C02

C021

Boost air pressure sensor

C02

C022

Engine oil level sensor

C02

C023

Engine oil pressure sensor

C01

C024

Engine oil level and temperature sensor unit

C02

C025

3-level air conditioning pressure sensor

I70

C027

Low level air conditioning pressure sensor

I70

C028

High level air conditioning pressure sensor

I70

C029

Intermediate level air conditioning pressure sensor

I70

C030

Rear inter-axle diff lock engaged sensor

E01 / E03

C035

PTO 1 engaged position information sensor

B03

C036

PTO 2 engaged position information sensor

J01

C038

Drive axle suspension RH position sensor

F01 / F02 / F03

C039

Drive axle suspension LH position sensor

F02 / F03

C045

Internal temperature sensor

I42

C046

External temperature sensor

B20

C048

Engine cooling circuit temperature sensor

C01

C051

Fuel level sensor

B20

C053

Stop lights switch

E01 / E03

C054

Air filter clogging sensor

B20

C056

Tachograph speed sensor

B40

C057

Neutral position sensor

B03

C058

Reverse gear engaged position sensor

B03

C059

Retarder oil temperature sensor

D01 / D31

C060

Retarder coolant temperature sensor

D30 / D31

C061

Front axle suspension position sensor

F03

C062

Clutch position sensor

D01

C064

Retarder air pressure sensor

D01

C066

Retarder coolant temperature sensor

D01

5 / 14

Andrew Burrows Diagram / Diagram 28/03/16
C067

Flywheel speed sensor

C02

C068

Camshaft engine speed sensor

C02

C071

Alarm ultra-sonic transmitter sensor

G20

C072

Alarm ultra-sonic receiver sensor

G20

C075

AdBlue tank temperature and level sensors

C30

C076

Exhaust gases temperature sensor

C30

C077

Nitrogen oxides gases concentration sensor

C30

C078

Exhaust gases after catalytic converter temperature sensor

C30

C079

Trailer braking assistance pressure system sensor

E01 / E03

C084

Engine oil temperature sensor

C02

C086

Steering lockover angle sensor

E01 / E03

C087

Chassis lateral acceleration sensor

E01 / E03

C088

Engine coolant level sensor

C01

C090

Add-on heater temperature sensor

I40 / I42

C096

Range change selector pressure sensor

C02

C109

Water in fuel sensor

C01

C110

Parking brake indicator pressure sensor

E01 / E03

C111

Accelerator pedal position sensor

B01

C112

Accelerator pedal «rest» position sensor N° 2

B01

C113

Accelerator pedal rest position sensor

B01

C114

Accelerator pedal sensor unit

B01

C115

Lift-up air spring pressure sensor

F02 / F03

C116

Middle axle suspension air pressure sensor

F02 / F03

C117

Front air spring pressure sensor

F03

C118

Drive axle suspension LH pressure sensor

F02 / F03

C119

Drive axle suspension RH pressure sensor

F01 / F02 / F03

C120

Piloted axle oil level sensor

F20

C121

Piloted axle lockover angle sensor

F20

C122

Piloted axle lockover angle sensor

F20

C130

Clutch pedal position sensor

B01

C132

Engine boost pressure sensor

C01

C133

Engine cooling fan speed sensor

C02

C134

Brake pedal sensor unit

E01 / E03

C135

Brake pedal position copying sensor

E01 / E03

C149

Driver’s seatbelt not buckled sensor

B20

6 / 14

Andrew Burrows Diagram / Diagram 28/03/16
Engine block inside pressure sensor

C01

C172

Fifth wheel position sensors

B20

C227

Pistons cooling oil pressure sensor

C01

C250

Blown air temperature sensor

I70

C260

Evaporator temperature sensor

I70

C261

Air conditioning outside air temperature sensor

I70

C263

AdBlue internal temperature sensor

C30

C264

AdBlue internal pressure sensor

C30

C268

Hydraulic retarder oil pressure sensor

D31

C269

Temperature sensor on the autonomous heating system

I40 / I42

C270

Flame presence detector

I42

C150

C271

Overheating sensor

I42

C273

Exhaust backpressure sensor

C01

D001

Principal information display

B20

D004

Tachograph

B40

E007

Bunk lower RH overhead light

H06

E008

Driver’s side single overhead light

H06

E009

Bunk lower LH overhead light

H06

E010

Front passenger’s side single overhead light

H06

E012

RH upper overhead lighting (door)

H06

E025

Driver’s reading spotlight

H06

E026

Front passenger’s reading spotlight

H06

E027

Cigar lighter light

I03

E033

LH upper overhead lighting (door)

H06

E034

LH overhead lighting (ambience)

H06

E035

RH overhead lighting (ambience)

H06

E038

Row 1 lighting

H06

E039

Row 2 lighting

H06

E040

Row 3 lighting

H06

E041

Row 4 lighting

H06

E042

Upper left-hand side overhead lamp lighting

H06

E043

Upper right-hand side overhead lamp lighting

H06

E100

RH front direction change indicator lights

H04

E101

LH front direction change indicator lights

H04

E102

Driver’s side stepwell lighting

H06

7 / 14

Andrew Burrows Diagram / Diagram 28/03/16
E103

Front passenger’s side stepwell lighting

H06

E104

Roof RH front direction change indicator lights

H04

E105

Roof LH front direction change indicator lights

H04

E109

RH rear direction change indicator lights

H04

E110

LH rear direction change indicator lights

H04

E116

RH rear fog light

H04

E117

LH rear fog light

H04

E119

LH stop lights

H04

E120

RH stop lights

H04

E122

RH clearance light N° 1

H04

E123

RH clearance light N° 2

H04

E124

LH front side/parking lights

H04

E125

RH front side/parking lights

H04

E128

LH clearance lights N° 3

H04

E129

LH clearance lights N° 4

H04

E131

RH clearance lights N° 3

H04

E132

RH clearance lights N° 4

H04

E133

LH clearance lights N° 1

H04

E134

LH clearance lights N° 2

H04

E135

LH tail lights unit

H04

E136

RH tail lights unit

H04

E137

RH rear side/parking lights

H04

E138

LH rear side/parking lights

H04

E141

LH reversing lights

H04

E142

RH reversing lights

H04

E144

Roof LH side/parking lights

H04 / H30

E145

Roof LH side/parking lights

H04 / H30

E149

Anti-glare strip-mounted LH marker lights

H30

E150

Anti-glare strip-mounted RH marker lights

H30

E151

Right-hand side marker lamp N° 5

H04

E152

Left-hand side marker lamp N° 5

H04

E500

RH dipped beam headlight

H04

E501

LH dipped beam headlight

H04

E502

RH main beam headlight

H04

E503

LH dipped beam headlight

H04

8 / 14

Andrew Burrows Diagram / Diagram 28/03/16
E504

RH headlamp insert

H04

E505

LH headlamp insert

H04

E506

LH fog driving light

H05

E507

RH fog driving light

H05

E510

Working spotlight

H06

G001

Vehicle management ECU

B01 / B03

G002

Engine management ECU

C01 / C02

G003

Bodybuilder pre-arrangement management ECU

J01

G004

Air suspension ECU

F01 / F02 / F03

G005

EBS braking management ECU

E01 / E03

G006

Vehicle power supply management ECU (ADR)

A21

G007

Front axle braking assistance modulator unit

E01 / E03

G008

Drive axle braking assistance modulator unit

E01 / E03

G012

Lighting and signalling management ECU

H04 / H05 / H06

G016

Second rear axle braking assistance modulator unit

E01

G017

Cab temperature regulation ECU

I42

G018

Onboard management interface ECU

B60 / B63

G019

Gear selector ECU

D01

G020

Automatic transmission ECU

D01

G021

Hydraulic retarder ECU

D30 / D31

G025

Engine immobilizer ECU

G01

G026

Alarm ECU

G20

G027

Piloted axle ECU

F20

G028

Doors central locking ECU

G01

G030

AdBlue supply management pump module

C30

G051

Air production management ECU

F40

G053

Air/air autonomous heating ECU

I40

G100

Datamax gateway ECU

B61

G102

Onboard management ECU

B61 / B63

G103

Positioning module ECU

B61

G104

Tyre pressures monitoring ECU

G60

H001

Engine immobilizer antenna

G01

H005

GPS satellite antenna

I20

H011

LH front loudspeaker

I20

H012

RH front loudspeaker

I20

9 / 14

Andrew Burrows Diagram / Diagram 28/03/16
Radio set

I20

H019

Microphone

I20

H020

Sharp loudspeaker, LH side

I20

H021

Sharp loudspeaker, RH side

I20

J001

Cigar lighter

I03

J002

RH heated seat unit

I03

J003

LH heated seat unit

I03

J006

Refrigerated compartment

I03

J007

Refrigerator

I03

K001

Air/water add-on heater

I42

K002

Air/air add-on heater

I40

K003

Air conditioning ECU

I70

L004

External horn

H04

L006

Horn — Alarm siren

G20

L008

Electric horn

H06

M002

Starter

A01 / A20

M020

Windscreen wipers drive motor

H05

M021

Windscreen wash pump motor

H05

M022

Headlamps wash pump motor

H05

M023

LH headlamp ride correction motor

H04

M024

RH headlamp ride correction motor

H04

M027

Windscreen wash motor / headlamps wash motor unit

H05

M050

Front passenger’s sun visor motor

I01

M051

Driver’s sun visor motor

I01

M052

Front sun visor motor

I01

M056

Driver’s door window winder motor

I01

M057

Front passenger’s door window winder motor

I01

M060

Electric roof air vent motor

I01

M061

Air recycling motor

I70

M064

Air mixing flap motor

I70

M080

RH rearview mirror horizontal swivelling motor

I02

M081

RH rearview mirror vertical swivelling motor

I02

M082

LH rearview mirror horizontal swivelling motor

I02

M083

LH rearview mirror vertical swivelling motor

I02

M101

Add-on heater fan motor

I40 / I42

H014

10 / 14

Andrew Burrows Diagram / Diagram 28/03/16
Cab tilting motor

B01

M107

Air/water autonomous heating water pump

I42

M200

Air conditioning compressor electric clutch

I70

M202

Driving position fan-coil heater motor

I70

M203

Add-on heater fuel pump motor

I40 / I42

M205

Water pump electromagnetic clutch

C02

N001

Fuel heater resistor N° 2

C01

N004

Air preheating resistor

C01

N008

LH defrosting rearview mirror resistor

I02

N009

RH defrosting rearview mirror resistor

I02

N015

AdBlue heating resistor (in tank to pump module circuit)

C30

N016

AdBlue heating resistor (in pump module to tank circuit)

C30

N017

AdBlue heating resistor (in pump module
to metering solenoid valve circuit)

C30

N018

AdBlue heating resistor (in metering
solenoid valve to pump module circuit)

C30

N019

AdBlue heating resistor (in filter on pump)

C30

N027

Fan/coil heater pilot-control resistors assembly

I70

N034

Autonomous heating system heating element

I40 / I42

S001

After ignition power supply relay N°1

A40

S002

After ignition power supply relay N°2

A41

S003

After ignition power supply relay N° 3

A41

S004

Accessories power supply relay N° 1

A42

S005

Accessories power supply relay N° 2

A42

S020

Starting relay

A41

S021

Alternator circuit earthing relay (ADR)

A20 / A40

S022

Alternator controlled power supply relay (engine running)

A20 / A40

S100

Stop lights power supply relay

A40

S101

Rear fog lights power supply relay

A42

S102

Main beam headlights power supply relay

A42

S103

Fog driving lights power supply relay

A42

S104

Reversing lights power supply relay

A41

S105

RH and LH side/parking and marker lights power supply relay

A44

S106

Switches night lighting power supply relay

A45

S107

RH and LH side/parking and marker lights
power supply relay (trailer and bodybuilder)

A44

M102

11 / 14

Andrew Burrows Diagram / Diagram 28/03/16
S109

Long range driving lights power supply relay

H30

S200

Automatic transmission management ECU power supply relay

A42

S201

Vehicle and engine ECUs power supply relay

A41

S202

Air suspension power supply relay

A43

S300

Cab tilting safety and authorization relay

A40

S400

Windscreen wipers motor time-delay relay

A41

S401

Headlamps wash pump motor power supply relay

H05

S451

Air conditioning compressor clutch power supply relay

A43

S452

Air conditioning fan piloting relay

I70

S453

Add-on heater power supply relay

A43

S500

Heated and swivelling rearview mirror power supply relay

A41

S501

Air preheating relay

C01

S600

Cab tilting motor power supply relay

B01

V002

Rear wheels diff lock electrovalve

E01 / E03

V003

LH roadwheel ABS electrovalve

E01 / E03

V004

Front RH wheel ABS solenoid valve

E01 / E03

V005

Axle piloting solenoid valve unit

F20

V006

Locking solenoid valve

F20

V007

LH steer control solenoid valve

F20

V008

RH steer control solenoid valve

F20

V010

PTO engagement electrovalve N° 1

B01 / D01

V011

High speed disengagement solenoid valve

D01

V012

High speed engagement solenoid valve

D01

V013

Low speed engagement solenoid valve

D01

V014

Low speed disengagement solenoid valve

D01

V015

Retarder proportional electrovalve

D01 / D30

V016

Retarder accumulation electrovalve

D30

V018

PTO engagement electrovalve N° 2

D01 / J01

V020

Exhaust brake solenoid valve unit

C01

V021

Engine brake N° 1 solenoid valve

C01

V023

Exhaust brake solenoid valve

C01

V030

Drive axle suspension control solenoid valve unit

F01 / F02 / F03

V031

Drive axle rear suspension main electrovalve

F01 / F02 / F03

V032

Drive axle rear suspension (RH side) electrovalve

F01 / F02 / F03

V033

Drive axle rear suspension (LH side) electrovalve

F02 / F03

12 / 14

Andrew Burrows Diagram / Diagram 28/03/16
V034

Rear axle suspension control solenoid valve unit

F02 / F03

V035

Rear axle suspension main electrovalve

F02 / F03

V036

Rear axle suspension electrovalve

F02 / F03

V037

Lift-up air spring control electrovalve

F02 / F03

V038

Front suspension electrovalve

F03

V050

Braking auxiliary electrovalve

E01 / E03

V051

Trailer braking inlet/exhaust electrovalve

E01 / E03

V052

Range change electrovalve

C01

V053

Splitter control electrovalve

C01

V054

Splitter and range change control unit

C01

V055

Engine water circuit by-pass solenoid valve

C30

V056

AdBlue supply metering solenoid valve

C30

V101

Cylinder injector solenoid valve N° 1

C02

V102

Cylinder injector solenoid valve N° 2

C02

V103

Cylinder injector solenoid valve N° 3

C02

V104

Cylinder injector solenoid valve N° 4

C02

V105

Cylinder injector solenoid valve N° 5

C02

V106

Cylinder injector solenoid valve N° 6

C02

V107

Air horn

H06

V108

Air dryer bleeding solenoid valve

C01

V109

Engine cooling fan speed regulation solenoid valve

C01

V126

Pistons cooling solenoid valve

C01

V127

Engine oil cooling solenoid valve

C01

V140

Cab heating engine coolant circuit by-pass solenoid valve

I70

V141

AdBlue cooling electrovalve

C30

V142

Hydraulic retarder oil pump control solenoid valve

D31

V143

Hydraulic retarder main oil flow circuit control solenoid valve

D31

W100

Alternator circuit draw resistor

A40

W500

Diode(s)

A40 / A42 / A43 / A44 / H06

W502

Diode on after ignition information circuit for vehicle management box

A40 / B03

W503

Diode on engine running information relay power supply circuit

A01 / A20 / A40 / B20

W504

Diode on alternator earthing relay power supply circuit

A40

W505

Diode on alternator earthing relay power supply circuit

A40

W506

Doors central locking diode

A43

W507

Vehicle alarm sounding diode

G20

13 / 14

Andrew Burrows Diagram / Diagram 28/03/16
X001

Electrical connection terminal

A01 / A20

X200

Available power supplies connector

J20 / J21

X203

CAN bus grouping connector

K21

X207

Audio auxiliary connector

I20

X208

Audio USB connector

I20

X900

15-pin trailer socket

J40

X902

24 Volts power supply socket

I03

X906

ABS/EBS trailer socket

J40

X907

Ground receptacle

A01

X908

12 Volts power supply socket

I03

X909

Extra 24 Volts power supply socket

I03

X913

Vehicle diagnostic socket

K01

Z001

Fuel heating unit

C01

Z003

Fan speed regulator unit

C01 / C02

Z004

Retarder unit

D01

Z005

Automatic transmission unit

D01

Z008

Driver’s swivelling defrosting rearview mirror

I02

Z009

Passenger’s swivelling defrosting rearview mirror

I02

Z010

Front passenger’s door locking striker unit

G01

Z011

Driver’s door locking striker unit

G01

Z014

Trailer brake control EBS modulator unit

E01 / E03

Z021

Adblue pump module assembly

C30

14 / 14

Andrew Burrows List / Electrical diagram 28/03/16

Summary of diagrams
Energy production (except ADR)
Diagram plate: A01
See page
Energy production ADR
Diagram plate: A20
See page
Control ECU ADR
Diagram plate: A21
See page
Electrical distribution (1/6)
Diagram plate: A40
See page
Electrical distribution (2/6)
Diagram plate: A41
See page
Electrical distribution (3/6)
Diagram plate: A42
See page
Electrical distribution (4/6)
Diagram plate: A43
See page
Electrical distribution (5/6)
Diagram plate: A44
See page
Electrical distribution (6/6)
Diagram plate: A45
See page
Vehicle electronic management (1/2)
Diagram plate: B01
See page

1/6

Andrew Burrows List / Electrical diagram 28/03/16
Vehicle electronic management (2/2)
Diagram plate: B03
See page
Principal information display
Diagram plate: B20
See page
Tachograph
Diagram plate: B40
See page
Onboard management FMS
Diagram plate: B60
See page
Onboard management DATAMAX
Diagram plate: B61
See page
Onboard management OPTIFLEET
Diagram plate: B63
See page
Engine electronic management (1/2)
Diagram plate: C01
See page
Engine electronic management (2/2)
Diagram plate: C02
See page
Urea inflow management
Diagram plate: C30
See page
Automatic gearbox
Diagram plate: D01
See page
Hydraulic retarder ECOSPLIT 2

2/6

Andrew Burrows List / Electrical diagram 28/03/16
Diagram plate: D30
See page
Hydraulic retarder ECOSPLIT 4
Diagram plate: D31
See page
EBS 6×2 equipment
Diagram plate: E01
See page
EBS 4×2 equipment
Diagram plate: E03
See page
Electronic air suspension — Tractors4x2 (1 sensor)
Diagram plate: F01
See page
Rear air suspension — 4×2 / 6×2 (2 sensors)
Diagram plate: F02
See page
Integral electronic air suspension — 4×2 / 6×2 (2 sensors)
Diagram plate: F03
See page
Steered axle
Diagram plate: F20
See page
Air production management
Diagram plate: F40
See page
Doors / engine immobilizer controls
Diagram plate: G01
See page
Alarm
Diagram plate: G20
3/6

Andrew Burrows List / Electrical diagram 28/03/16
See page
Checking tyre pressures
Diagram plate: G60
See page
Lighting and signalling management (1/3)
Diagram plate: H04
See page
Lighting and signalling management (2/3)
Diagram plate: H05
See page
Lighting and signalling management (3/3)
Diagram plate: H06
See page
Side, marker, identification and parking lights
Diagram plate: H30
See page
Electric window winder, sun-roof
Diagram plate: I01
See page
Swivelling defrosting rearview mirrors
Diagram plate: I02
See page
Comfort accessories
Diagram plate: I03
See page
Radio
Diagram plate: I20
See page
Independent (add-on) heating AT2000 ST
Diagram plate: I40
See page
4/6

Andrew Burrows List / Electrical diagram 28/03/16
Independent (add-on) heating THERMO 90ST
Diagram plate: I42
See page
Air conditioning
Diagram plate: I70
See page
Bodybuilder pre-arrangement management
Diagram plate: J01
See page
Available power supplies (1/2)
Diagram plate: J20
See page
Available power supplies (2/2)
Diagram plate: J21
See page
Trailer sockets
Diagram plate: J40
See page
Diagnostic socket
Diagram plate: K01
See page
BUS J1587-1 transfer zone
Diagram plate: K20
See page
CAN BUS transfer zone J1939-1
Diagram plate: K21
See page
CAN BUS transfer zone J1939-2
Diagram plate: K22
See page
CAN BUS transfer zone J1939-ENG

5/6

Andrew Burrows List / Electrical diagram 28/03/16
Diagram plate: K23
See page

6/6

Andrew Burrows

03/28/2016, 11:54:17 AM (CEST)

A001
F36
10A

F20
10A

2

F06
5A

2

F108
20A

2

F105
10A

2

S020

W506

W503

S022

R17
10A

2

W100

1

1

1

W506

R21
50A

1

1

S004

R05
20A

F52
10A
1

2

1

2

A002
XT41:14

XT41:12

X10

XT21:7

XT21:5

XT21:6

XT21:8
1

169
4

1

X907
0
2221

1
+

—

214

5

22

3
2

1S
FM3
125A

1

3S
FM1
125A

2S
FM2
200A

4S
FM4
40A

EI:11

F01
25A

EI:9

2227
6

1
2
3

EI:10

B103
A014

2
1P

2222

X001

A006
3

4

88a

M002
SW1
1

2

B+

88

A009
B+

BS

G

W

W/SB

M

E1

+

+-

Y/R
GN/R

E

A004

A004
201

B-

L
+15

268
—

+

+-

1
—

225785

A01

B

Andrew Burrows Energy production / Diagram 28/03/16

Energy production (except ADR)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

A004

Batteries

C4d

A006

Electrically controlled master switch

C4d

A009

Alternator

B3c

A014

Power fuse box unit (FM1 to FM4)

C4d

B103

Key switch unit

C2c

M002

Starter

A3c

S004

Accessories power supply relay N° 1

B2c

S020

Starting relay

B2c

S022

Alternator controlled power supply relay (engine running)

B2c

W100

Alternator circuit draw resistor

B2c

W503

Diode on engine running information relay power supply circuit

B2c

W506

Doors central locking diode

B2c

X001

Electrical connection terminal

B4d

X907

Ground receptacle

C5d

Energy production (except ADR)

1/2

Andrew Burrows Energy production / Diagram 28/03/16

2/2

Andrew Burrows

BO

BP

BO

03/28/2016, 11:56:24 AM (CEST)

BP

AN

AM

DE

BQ

AN

AM

AN

AM

BQ

DE

CO

2126

A001
W100

W505
F57
10A

F34
3A

2

2

1

1

W503

W504

S021
S001

R10
10A

F47
7.5A

W502

F58
3A

2
1

1

2

2

F54
10A

R01
50A

F104
10A

1

F36
10A

F20
10A

F06
5A

F108
20A

2

2

2

2

2

1

1

1

1

1

S022
R05
20A

F75
15A
1

F76
10A
1

F19
5A

S100
R13
10A

1

F10
20A

F48
3A

1

F29
10A

1

1

F52
10A

F03
7.5A
1

S300

W500

1

R11
10A
2

AN

2

2

2

2

2

2

2

AM
BS

DD

BQ

DE

AN

AM

AN

AM

225785

A40

B

Andrew Burrows Electrical distribution / Diagram 28/03/16

Electrical distribution (1/6)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

S001

After ignition power supply relay N°1

B2c

S021

Alternator circuit earthing relay (ADR)

B2c

S022

Alternator controlled power supply relay (engine running)

B2c

S100

Stop lights power supply relay

B2c

S300

Cab tilting safety and authorization relay

B2c

W100

Alternator circuit draw resistor

B2c

W500

Diode(s)

B2c

W502

Diode on after ignition information circuit for vehicle management box

B2c

W503

Diode on engine running information relay power supply circuit

B2c

W504

Diode on alternator earthing relay power supply circuit

B2c

W505

Diode on alternator earthing relay power supply circuit

B2c

AM: with ADR equipment
AN: without ADR equipment
BO: with ECOSPLIT 2 hydraulic retarder
BP: with ECOSPLIT 4 hydraulic retarder
BS: 4×2 vehicles
DD: 6×2 vehicles
BQ: with FMS equipment
CO: with OPTIFLEET equipment
DE: with DATAMAX equipment

Electrical distribution (1/6)

1/2

Andrew Burrows Electrical distribution / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 11:57:19 AM (CEST)

AN

AM

A001

S201
S002
F08
5A

F71
15A

2

2

F26
15A

S020

R02
50A

R20
50A

F64
10A

R03
50A

2

F07
5A

2

2

1

1

R17
10A

S003
1

1

F59
10A

F13
20A

F70
10A
1

1

2

2

1

F103
10A

F11
10A

F39
15A

F24
20A

F23
5A

F67
10A

F16
10A

F09
5A

F40
30A

F41
15A

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

1

S400

S500
R08
10A

R04
10A

F107
10A

F42
10A

20A
1

1

2

2

S104

DE

BQ

BO

BP

DF

EM

EN

DD

BS

225785

A41

B

Andrew Burrows Electrical distribution / Diagram 28/03/16

Electrical distribution (2/6)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

S002

After ignition power supply relay N°2

B2c

S003

After ignition power supply relay N° 3

B2c

S020

Starting relay

B2c

S104

Reversing lights power supply relay

B2c

S201

Vehicle and engine ECUs power supply relay

B2c

S400

Windscreen wipers motor time-delay relay

B2c

S500

Heated and swivelling rearview mirror power supply relay

B2c

AM: with ADR equipment
AN: without ADR equipment
BO: with ECOSPLIT 2 hydraulic retarder
BP: with ECOSPLIT 4 hydraulic retarder
BS: 4×2 vehicles
DD: 6×2 vehicles
BQ: with FMS equipment
DE: with DATAMAX equipment
DF: with electronic air suspension tractor vehicle 4×2
EM: with 4×2 — 6×2 vehicle rear electronic air suspension
EN: with 4×2 — 6×2 vehicle integral electronic air suspension

Electrical distribution (2/6)

1/2

Andrew Burrows Electrical distribution / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 11:58:54 AM (CEST)

AN

AM

DD

BS

DD

BS

A001
W500
F32
10A
2

F100
15A

S004

S005

R21
50A

F28
20A
2

S101

1

R22
50A

S200

R18
10A
1

R14
10A

1

2

S103
R23
10A

F37
10A
1

F61
15A
1

F27
20A
1

F14
15A
1

F63
15A
1

F02
10A
1

F35
20A
1

S102

R09
10A

F101
10A

F66
10A
1

F72
10A
1
2

2

2

2

2

2

2

1

1

2

2

F17
10A
1

2

2

F102
10A

2

225785

A42

B

Andrew Burrows Electrical distribution / Diagram 28/03/16

Electrical distribution (3/6)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

S004

Accessories power supply relay N° 1

B2c

S005

Accessories power supply relay N° 2

B2c

S101

Rear fog lights power supply relay

B2c

S102

Main beam headlights power supply relay

B2c

S103

Fog driving lights power supply relay

B2c

S200

Automatic transmission management ECU power supply relay

B2c

W500

Diode(s)

B2c

AM: with ADR equipment
AN: without ADR equipment
BS: 4×2 vehicles
DD: 6×2 vehicles

Electrical distribution (3/6)

1/2

Andrew Burrows Electrical distribution / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 11:59:50 AM (CEST)

DF

EM

EN

CY

CX

CY

CX

A001

F49
5A

F31
20A

F43
15A

F05
30A

F30
30A

F22
10A

1

2

2

2

2

2

2

1

1

1

1

1

W506
S202

S453

R19
10A

EN

EM

EN

R10
10A

EM

DF

EN

EM

W500

S451
F38
10A

F18
10A

R16
10A

F77
15A

1

1

1

2

2

2

DF

225785

A43

B

Andrew Burrows Electrical distribution / Diagram 28/03/16

Electrical distribution (4/6)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

S202

Air suspension power supply relay

B2c

S451

Air conditioning compressor clutch power supply relay

B2c

S453

Add-on heater power supply relay

B2c

W500

Diode(s)

B2c

W506

Doors central locking diode

B2c

CX: Without air / air independent heating
CY: Without air / water independent heating
DF: with electronic air suspension tractor vehicle 4×2
EM: with 4×2 — 6×2 vehicle rear electronic air suspension
EN: with 4×2 — 6×2 vehicle integral electronic air suspension

Electrical distribution (4/6)

1/2

Andrew Burrows Electrical distribution / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 12:00:41 PM (CEST)

DD

BS

DD

BS

A001

S107

S105

R12
10A

R06
20A

W500

W500
F91
10A

F92
10A

F93
15A

F04
5A

15A

1

1

1

1

1

2

2

2

2

2

225785

A44

B

Andrew Burrows Electrical distribution / Diagram 28/03/16

Electrical distribution (5/6)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

S105

RH and LH side/parking and marker lights power supply relay

B2c

S107

RH and LH side/parking and marker lights
power supply relay (trailer and bodybuilder)

B2c

W500

Diode(s)

B2c

BS: 4×2 vehicles
DD: 6×2 vehicles

Electrical distribution (5/6)

1/2

Andrew Burrows Electrical distribution / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 12:01:39 PM (CEST)

DD

BS

A001

F90
3A

F51
5A

2

2

F25
10A
2

F46
20A
2

F21
20A
2

F15
5A
2

F68
20A
2

F33
30A

S106

2

R07
10A

F97
5A
2

1

1

1

1

1

1

1

1

1

F96
3A
1

2

BO

BP

BS

DD

EM

EN

EM

EN

CX

CY

DD

BS

DD

BS

225785

A45

B

Andrew Burrows Electrical distribution / Diagram 28/03/16

Electrical distribution (6/6)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

S106

Switches night lighting power supply relay

B2c

BO: with ECOSPLIT 2 hydraulic retarder
BP: with ECOSPLIT 4 hydraulic retarder
BS: 4×2 vehicles
DD: 6×2 vehicles
CX: Without air / air independent heating
CY: Without air / water independent heating
EM: with 4×2 — 6×2 vehicle rear electronic air suspension
EN: with 4×2 — 6×2 vehicle integral electronic air suspension

Electrical distribution (6/6)

1/2

Andrew Burrows Electrical distribution / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 12:02:33 PM (CEST)

A001
S300
F16
10A

F03
7.5A

S500

R11
10A

F33
30A

S104

R04
10A

S100

R08
10A

S201

R13
10A

R20
50A

F96
3A

F96
3A

F96
3A

1

1

1

1

1

1

2

2

2

2

2

2

B177
2

7

B182
5

2

7

10
1

B220
5

2

7

10

3

1

5

10

3

1

3

G001

RE02
50A

16

S600

2

1

13

4

6

28

11

15

17

12

29

21

PB
18

23

24

10

8

22

5

21

2

1

4

5

PC

19

A002

C114
B155
3

6

2

5

4

3
2

1

C130
C111
C113

V010

1
2

M

2

1

2 C112

1

4
1

5
1

4

3

2

1
AD

M102
B162

225785

B01

B

Andrew Burrows Vehicle control ECU / Diagram 28/03/16

Vehicle electronic management (1/2)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B155

Electric or hydraulic retarder control

C2c

B162

Cab tilting control

A4d

B177

PTO 1 engagement request control (in cab)

C2b

B182

Auto/manual selection control

C2b

B220

Optiroll control

B2c

C111

Accelerator pedal position sensor

C1c

C112

Accelerator pedal «rest» position sensor N° 2

C1c

C113

Accelerator pedal rest position sensor

C1c

C114

Accelerator pedal sensor unit

C1c

C130

Clutch pedal position sensor

C1c

G001

Vehicle management ECU

B2b

M102

Cab tilting motor

A4c

S100

Stop lights power supply relay

B2c

S104

Reversing lights power supply relay

B2c

S201

Vehicle and engine ECUs power supply relay

B2c

S300

Cab tilting safety and authorization relay

B2c

S500

Heated and swivelling rearview mirror power supply relay

B2c

S600

Cab tilting motor power supply relay

B2b

V010

PTO engagement electrovalve N° 1

B4d

AD: with automatic gearbox

Vehicle electronic management (1/2)

1/2

Andrew Burrows Vehicle control ECU / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 12:03:27 PM (CEST)

A001
W502
F96
3A

F96
3A
1

1

2

2

2

B200

7

5

6

B199

8

R04
10A

F07
5A

1

2

S500

2

7

102

5

W500

R17
10A

B136

6

3

8

102

AN

1

S020

3

10

1

3

BK

G001

3

10

BK

9

6

5

AM

4

BK

1

2

10

12

13

14

6

19

29

11

27

28

24

PA
8

18

23

7

30

21

5

4

25

15

16

A002

XT33:6

XT33:8

XT33:7

1

1

1

2

2

2

C058

C035

XT33:13

C057
225785

B03

B

Andrew Burrows Vehicle control ECU / Diagram 28/03/16

Vehicle electronic management (2/2)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B136

Cruise control and engine speed regulator adjustment control

C2c

B199

Fast idling adjustment control

C2c

B200

Cruise control / engine speed adjustment controls

C2c

C035

PTO 1 engaged position information sensor

B4c

C057

Neutral position sensor

B4c

C058

Reverse gear engaged position sensor

B4c

G001

Vehicle management ECU

B2b

S020

Starting relay

B2c

S500

Heated and swivelling rearview mirror power supply relay

B2c

W500

Diode(s)

B2C

W502

Diode on after ignition information circuit for vehicle management box

B2c

AM: with ADR equipment
AN: without ADR equipment
BK: with engine speed regulation and steering wheel operated Cruise Control

Vehicle electronic management (2/2)

1/2

Andrew Burrows Vehicle control ECU / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 12:04:26 PM (CEST)

A001
S103

S453
R10
10A

F06
5A

F04
5A

W503

R23
10A

F08
5A

F72
10A

F101
10A

F03
7.5A

1

1

1

1

1

1

2

2

2

2

2

2

C149
B125
1
VOL+
VOL1

3

5

4

6

2

2
DD
AT

AS

AM

AN

AM

BS

AN

D001

1

C

2

3

4

10

5

9

6

7

17

8

11

13

12

15

11

6

12

J

8

23

1

24

21

19

10

18

22

2

13

17

20

24

B

26

26

23

20

4

13

19

17

16

15

14

25

12

6

8

7

A002

CX

CY
4

3

2

C051

2
1

2

1

°C

2

1

5

1

U

3

C046

C054

C172
225785

B20

B

Andrew Burrows Principal information display / Diagram 28/03/16

Principal information display
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B125

Radio set control

C2b

C046

External temperature sensor

C2c

C051

Fuel level sensor

A5d

C054

Air filter clogging sensor

C5d

C149

Driver’s seatbelt not buckled sensor

C3c

C172

Fifth wheel position sensors

B6c

D001

Principal information display

C2b

S103

Fog driving lights power supply relay

B2c

S453

Add-on heater power supply relay

B2c

W503

Diode on engine running information relay power supply circuit

B2c

AM: with ADR equipment
AN: without ADR equipment
AS: With air / air independent heating
AT: With air / water independent heating
BS: 4×2 vehicles
DD: 6×2 vehicles
CX: Without air / air independent heating
CY: Without air / water independent heating

Principal information display

1/2

Andrew Burrows Principal information display / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 12:05:20 PM (CEST)

A001

F07
5A
1

2

D004

3

6

5

7

A

B
8

4

D

1

1

3

2

4

6

8

A002

AN

AM

F89
5A

AY

AY

AY

AY

AD

AD

AD

AD

BQ

DE

BQ

DE

CO

F89
1A

2

2

1

1

C056

1

3

n

2

4

C056

1

3

2

4

n
225785

B40

B

Andrew Burrows Tachograph / Diagram 28/03/16

Tachograph
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

C056

Tachograph speed sensor

B3c

D004

Tachograph

C2c

AD: with automatic gearbox
AY: with manual gearbox
AM: with ADR equipment
AN: without ADR equipment
BQ: with FMS equipment
CO: with OPTIFLEET equipment
DE: with DATAMAX equipment

Tachograph

1/2

Andrew Burrows Tachograph / Diagram 28/03/16

2/2

Andrew Burrows Onboard management / Diagram 28/03/16

Onboard management DATAMAX
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

G100

Datamax gateway ECU

B2c

G102

Onboard management ECU

B2c

G103

Positioning module ECU

B2c

Onboard management DATAMAX

1/2

Andrew Burrows Onboard management / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 12:06:43 PM (CEST)

A001

F42
10A

AM

F40
30A

F24
20A

F41
15A

F42
10A

1

1

1

1

1

2

2

2

2

2

AN

A002

S501
RE03
50A

V021

V054

V023

V126

V127

V020

Z001
88n

84n

2

2
88a

GR/SB

1

1

N001

C109

84a

Z003

4

V108
3

C088

4

V053

1

V052

2

2

2

2

2

1

1

1

1

1

3

7

V109

3
2

G002

4

7

6

5

C02-9

7

25

57

60

15

23

10

8

33

34

26

30

41

53

38

50

58

59

61

49

B
27

32

18

28

11

12

19

16

17

29

52

56

51

55

3

4

1

1

2

4

2

2

P

1

4

2

P

1

4

2

P

1

4

2

P

1

4

P

1

AM

AN

2

N004
C048

C150

C023

C273

C227

C132
225785

C01

B

Andrew Burrows Engine control ECU / Diagram 28/03/16

Engine electronic management (1/2)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

C023

Engine oil pressure sensor

B3b

C048

Engine cooling circuit temperature sensor

B3b

C088

Engine coolant level sensor

B3b

C109

Water in fuel sensor

B3b

C132

Engine boost pressure sensor

B3b

C150

Engine block inside pressure sensor

B3b

C227

Pistons cooling oil pressure sensor

B3b

C273

Exhaust backpressure sensor

B3b

G002

Engine management ECU

B3b

N001

Fuel heater resistor N° 2

B3b

N004

Air preheating resistor

B3b

S501

Air preheating relay

C4d

V020

Exhaust brake solenoid valve unit

B3b

V021

Engine brake N° 1 solenoid valve

B3c

V023

Exhaust brake solenoid valve

B3c

V052

Range change electrovalve

B4c

V053

Splitter control electrovalve

B4c

V054

Splitter and range change control unit

B4c

V108

Air dryer bleeding solenoid valve

B3b

V109

Engine cooling fan speed regulation solenoid valve

B3c

V126

Pistons cooling solenoid valve

B3b

V127

Engine oil cooling solenoid valve

B3b

Z001

Fuel heating unit

B3b

Z003

Fan speed regulator unit

B3c

AM: with ADR equipment
AN: without ADR equipment
1/3

Andrew Burrows Engine control ECU / Diagram 28/03/16

Engine electronic management (1/2)

2/3

Andrew Burrows Engine control ECU / Diagram 28/03/16

3/3

Andrew Burrows

03/28/2016, 12:07:36 PM (CEST)

C096
C024

C019

1

4

1

C020

C084

C022

Z003

B105

1

C021

A002

2

C133

M205

P

1
1

2

2

3

4

5

3

2

2

2
1

G002

31

11

47

22

7

39

35

27

15

29

4

57

A
38

1

37

2

n

C067

46

1

45

59

62

20

24

12

16

28

32

60

61

52

56

44

48

36

40

2

4

2

4

2

4

2

4

2

4

2

4

1

3

1

3

1

3

1

3

1

3

1

3

34

33

3

2

n

C068

V101

V102

V103

V104

V105

V106
225785

C02

B

Andrew Burrows Engine control ECU / Diagram 28/03/16

Engine electronic management (2/2)
Key to appliances
Code

Function

Location

A002

Chassis-cab connection box

B2c

B105

Engine stop control

B3c

C019

Boost air pressure and temperature sensor

B3c

C020

Boost air temperature sensor

B3c

C021

Boost air pressure sensor

B3c

C022

Engine oil level sensor

B3c

C024

Engine oil level and temperature sensor unit

B3c

C067

Flywheel speed sensor

B2c

C068

Camshaft engine speed sensor

B3c

C084

Engine oil temperature sensor

B3c

C096

Range change selector pressure sensor

B4d

C133

Engine cooling fan speed sensor

B3c

G002

Engine management ECU

B3b

M205

Water pump electromagnetic clutch

B3c

V101

Cylinder injector solenoid valve N° 1

B3c

V102

Cylinder injector solenoid valve N° 2

B3c

V103

Cylinder injector solenoid valve N° 3

B3c

V104

Cylinder injector solenoid valve N° 4

B3c

V105

Cylinder injector solenoid valve N° 5

B3c

V106

Cylinder injector solenoid valve N° 6

B3c

Z003

Fan speed regulator unit

B3c

Engine electronic management (2/2)

1/2

Andrew Burrows Engine control ECU / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 12:08:59 PM (CEST)

A001
F107
10A
1

2

A002

V056
C075

C076

N015

N017

N019

N016

N018

V055

C078
1

1

1

1

1

2

°C

F109
25A

°C
U

2

1

2

3

U
4

1

1

°C
1

U
2

1

4

2
2

2

2

34

35

33

2

2

32

22

1

AM

AN

C077
3

4

Z021

G030
1

2

24

14

15

3

4

30

1

2

3

18

29

19

28

17

26

25

31

20

1

U
C264

6

11

12

2

1

23

2

2

°C

P

5

U

C263

1

V141

225785

C30

B

Andrew Burrows Urea input management / Diagram 28/03/16

Urea inflow management
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

C075

AdBlue tank temperature and level sensors

A4d

C076

Exhaust gases temperature sensor

C4d

C077

Nitrogen oxides gases concentration sensor

C4d

C078

Exhaust gases after catalytic converter temperature sensor

C4d

C263

AdBlue internal temperature sensor

C4d

C264

AdBlue internal pressure sensor

C4d

G030

AdBlue supply management pump module

C4d

N015

AdBlue heating resistor (in tank to pump module circuit)

A4d

N016

AdBlue heating resistor (in pump module to tank circuit)

A4d

N017

AdBlue heating resistor (in pump module
to metering solenoid valve circuit)

A4d

N018

AdBlue heating resistor (in metering
solenoid valve to pump module circuit)

A4d

N019

AdBlue heating resistor (in filter on pump)

A4d

V055

Engine water circuit by-pass solenoid valve

C4d

V056

AdBlue supply metering solenoid valve

C4d

V141

AdBlue cooling electrovalve

C4d

Z021

Adblue pump module assembly

C4d

AM: with ADR equipment
AN: without ADR equipment

Urea inflow management

1/2

Andrew Burrows Urea input management / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 4:49:32 PM (CEST)

A001
S200
F102
10A

R14
10A

F67
10A

1

1

2

2

A002
V010

V018

4

4

1

1

G020

A
B

G019

20

17

16

8

4

3

7

13

12

2

1

15

10

19

18
1

10

8

11

9

4

5

12

3

1

1

6

7

3

4

5

2

1

C

11

4

16

12

10

2

1

15

7

5
13

12

2
11

7

3
8

9

17

4

3

6

5

2

1

18

15

16

6

°C
U
2

°C
U

C066

C059

P

C064

Z004

V015

C062

V013

V014

V012

V011

Z005

OPTIDRIVER+

B026
225785

D01

B

Andrew Burrows Gearbox / Diagram 28/03/16

Automatic gearbox
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B026

Automatic transmission gear selector

B2b

C059

Retarder oil temperature sensor

B4d

C062

Clutch position sensor

B4d

C064

Retarder air pressure sensor

B4d

C066

Retarder coolant temperature sensor

B4d

G019

Gear selector ECU

B2b

G020

Automatic transmission ECU

B2b

S200

Automatic transmission management ECU power supply relay

B2b

V010

PTO engagement electrovalve N° 1

B4d

V011

High speed disengagement solenoid valve

B4d

V012

High speed engagement solenoid valve

B4d

V013

Low speed engagement solenoid valve

B4d

V014

Low speed disengagement solenoid valve

B4d

V015

Retarder proportional electrovalve

B4d

V018

PTO engagement electrovalve N° 2

B4d

Z004

Retarder unit

B4d

Z005

Automatic transmission unit

B4d

Automatic gearbox

1/2

Andrew Burrows Gearbox / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 4:50:41 PM (CEST)

A001
F96
3A

F16
10A

F28
20A

F48
3A

F96
3A

F96
3A

F96
3A

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

7

B186

5

2

9

7

B168

5

2

7

B169

5

1

3

1

10

10
1

2

3
10

B164

1

10

10
1

3

3

2

7

5

C110

10

G005

16

17

11

12

13

X1

13

14

9

8

X3
14

6

5

4

8

7

3

1

1

X2
10

4

7

6

3

9

10

X4

11

1

2

3

15

7

8

9

12

4

5

6

10

13

14

16

18

1

2

3

4

5

6

7

4

6

5

2

1

7

3

C086

1

2

4

3

A002

1

C005

3

2

1

C002

3

2

1

C004

3

2
1

2

1

C030

3

1

4

V002

6

4

1

C135

5

2

G016
2

1

4

3

4

A

6

5

1

B

2

3 1

1

2

A

3

4

B

2 1

2

G007

4

A

6

5

1

B

2

3 1

1

2

A

3

4

B

2 1

2

G008

4

A

6

5

1

B

2

3 1

1

2

A

3

B

2 1

2

4
2

1

V004

C053

C134

U

3

C135
2

C087

1

3

C006

4

1

2

1

2

C011 C012

1

3

C001

4

1

2

1

2

C008 C007

EBS 6X2

1

3

C003

4

1

2

1

2

C010 C009

P

C079

V051

V050

V003
Z014
225785

E01

B

Andrew Burrows EBS equipment / Diagram 28/03/16

EBS 6×2 equipment
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B164

Rear wheels diff lock control

C2b

B168

Traction control enabling control

C2c

B169

Trailer brake holding enabling control

C2c

B186

Brake holding enabling control

C2c

C001

LH front wheel brake linings wear sensor

C3d

C002

RH front wheel brake linings wear sensor

A3d

C003

LH rear wheel brake linings wear sensor

C7d

C004

RH rear wheel brake linings wear sensor

A7d

C005

Lift-up axle or second rear axle LH wheel brake linings wear sensor

C8d

C006

Lift-up axle or second rear axle RH wheel brake linings wear sensor

A8d

C007

LH front wheel speed sensor

C3d

C008

RH front wheel speed sensor

A3d

C009

LH rear wheel speed sensor

C7d

C010

RH rear wheel speed sensor

A7d

C011

Lift-up axle or second rear axle LH wheel speed sensor

C8d

C012

Lift-up axle or second rear axle RH wheel speed sensor

A8d

C030

Rear inter-axle diff lock engaged sensor

B7d

C053

Stop lights switch

C2c

C079

Trailer braking assistance pressure system sensor

B7d

C086

Steering lockover angle sensor

C2c

C087

Chassis lateral acceleration sensor

B6d

C110

Parking brake indicator pressure sensor

B6d

C134

Brake pedal sensor unit

C2c

C135

Brake pedal position copying sensor

C2c

G005

EBS braking management ECU

B2b

G007

Front axle braking assistance modulator unit

B3d

G008

Drive axle braking assistance modulator unit

B7d

G016

Second rear axle braking assistance modulator unit

B7d

V002

Rear wheels diff lock electrovalve

B7d

1/3

Andrew Burrows EBS equipment / Diagram 28/03/16
V003

LH roadwheel ABS electrovalve

C3d

V004

Front RH wheel ABS solenoid valve

A3d

V050

Braking auxiliary electrovalve

B7d

V051

Trailer braking inlet/exhaust electrovalve

B7d

Z014

Trailer brake control EBS modulator unit

B7d

EBS 6×2 equipment

2/3

Andrew Burrows EBS equipment / Diagram 28/03/16

3/3

Andrew Burrows

03/28/2016, 4:51:41 PM (CEST)

A001
S202

F23
5A

R19
10A

F96
3A

F96
3A

1

1

1

2

2

2

B184
2

7

B165

5

2

7

5

10
1

10

3

1

3

9

G004

4

3

22

6

11

1

16

5

2

12

17

18

X2
14

X1
13

8

7

9

15

10

4

5

12

1

15

13

17

26

11

28

30

21

7

1

2

4

20

22

23

B001
1

2

5

6

7

8

9

A002

1

2

3

1

2

3

1

V035

V037

4

V036

V031

V033

4

2

1

4

V032

2

1

2

4

1

2

4

1

2

P

P

P

P

C116

C115

C118

C119

4

4

V034

V030

C039

C038

225785

F02

B

Andrew Burrows Suspension ECU / Diagram 28/03/16

Rear air suspension — 4×2 / 6×2 (2 sensors)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B001

Air suspension remote control

C4c

B165

Second rear axle lift-up control

B2b

B184

Axle load-shedding activation control

B2b

C038

Drive axle suspension RH position sensor

A7d

C039

Drive axle suspension LH position sensor

C7d

C115

Lift-up air spring pressure sensor

A8d

C116

Middle axle suspension air pressure sensor

A8d

C118

Drive axle suspension LH pressure sensor

C7d

C119

Drive axle suspension RH pressure sensor

A7d

G004

Air suspension ECU

B2b

S202

Air suspension power supply relay

B2c

V030

Drive axle suspension control solenoid valve unit

B7d

V031

Drive axle rear suspension main electrovalve

B7d

V032

Drive axle rear suspension (RH side) electrovalve

B7d

V033

Drive axle rear suspension (LH side) electrovalve

B7d

V034

Rear axle suspension control solenoid valve unit

B7d

V035

Rear axle suspension main electrovalve

B7d

V036

Rear axle suspension electrovalve

B7d

V037

Lift-up air spring control electrovalve

B7d

Rear air suspension — 4×2 / 6×2 (2 sensors)

1/2

Andrew Burrows Suspension ECU / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 4:52:39 PM (CEST)

A001
F08
5A

F47
7.5A

1

1

2

2

00

EJ

A002
XT41:1

XT41:5

XT41:2

G051

1

2

3

4

7

5

00

EK

EK

6

EK

00

EK

J1587-1

225785

F40

B

Andrew Burrows Air supply / Diagram 28/03/16

Air production management
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

G051

Air production management ECU

C4d

EJ: with battery box on the right
EK: with rear steering axle
00: other cases of use

Air production management

1/2

Andrew Burrows Air supply / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 4:53:34 PM (CEST)

A001

W500

W506

F96
3A

F20
10A

F08
5A

F52
10A

F08
5A

1

1

1

1

1

2

2

2

2

2

B116
2

7

8

10
1

3

10

G028

G025

13
9

11
3

14

5

16

12

6
8

1
2

15

10

4

Z011

4316

6
4

5
3

1
1

2

1

2

Z010

4313

4317

1

4314

1

4318

2

4315

2

1 3
4

1 3
4

H001

225785

G01

B

Andrew Burrows Doors / Diagram 28/03/16

Doors / engine immobilizer controls
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

B116

Doors locking control

B2b

G025

Engine immobilizer ECU

C2c

G028

Doors central locking ECU

A2c

H001

Engine immobilizer antenna

C2c

W500

Diode(s)

B2c

W506

Doors central locking diode

B2c

Z010

Front passenger’s door locking striker unit

A3c

Z011

Driver’s door locking striker unit

C3c

Doors / engine immobilizer controls

1/2

Andrew Burrows Doors / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 4:57:41 PM (CEST)

A001

W500

W506

F96
3A

F20
10A

1

1

2

2

B172

1

B163

5

1

9

2

10

5

10
2

7

F08
5A

10
7

AN

G026

5
19

22
18

4

11

27
30

8
26

15

2
17

20

13

7
12

25

23

16
24

6
1

3

1

A002

1

1

2

1

2

4

W507

C071

C072
L006

2

225785

G20

B

Andrew Burrows Alarm / Freight monitoring / Diagram 28/03/16

Alarm
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B163

Alarm anti-panic control

B2b

B172

Alarm siren sound level reduction control

B2b

C071

Alarm ultra-sonic transmitter sensor

C2c

C072

Alarm ultra-sonic receiver sensor

A2c

G026

Alarm ECU

A2a

L006

Horn — Alarm siren

C2d

W500

Diode(s)

B2c

W506

Doors central locking diode

B2c

W507

Vehicle alarm sounding diode

B2a

AN: without ADR equipment

Alarm

1/2

Andrew Burrows Alarm / Freight monitoring / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 4:59:05 PM (CEST)

A001

F51
5A

F23
5A

1

1

2

2

A002

G104

3

7

1

5

6

225785

G60

B

Andrew Burrows Tyres pressure management / Diagram 28/03/16

Checking tyre pressures
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

G104

Tyre pressures monitoring ECU

B7d

Checking tyre pressures

1/2

Andrew Burrows Tyres pressure management / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:00:09 PM (CEST)

A001
S104
F96
3A

S100

R08
10A

F92
10A

R13
10A

F101
10A

F91
10A

F90
3A

F96
3A

F36
10A

F92
10A

F91
10A

F72
10A

F91
10A

F61
15A

F66
10A

F92
10A

F17
10A

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

B151

2

9

7

XASC4:5

B106

B143

XASC4:3

E145

5

B181

4

B3

9

7

E144

5

B142
2

2

5W

5W

1

1

A4

10
1

10

A1

3

B2

G012

1

3

10

A3

3

6

9

10

X1

4

A2

11
5

7

8

2

1

A002

E133
E135

03W
2
2

2

03W

03W

E128
03W
2

1

03W

1
2

21W

E110

5W

E138

5W

E138

21W

E109

2

L004

37

635

5W

5W

E138

1
5W

E138

5W

1
1

E122

E137

5W

E137

E117
E119

21W

E116

21W

2

3
21W

21W

E100

21W

E101

70W

E500

70W

E501

E502

1
1

1

1

E123

70W

E503

E132

3

603
3

E125

5W

E124

305
5

+V1

M
1

605
4

5

03W

5

1

5W
1
1

2

2

70W

602

47

3

E142

21W

3

307

E120

3
E141

1

03W

304

6
21W

5

E505

4

E131

1

6

608

2

E137

4
21W

604

03W

4

3

2

2

7

307

302

1

2

1

03W

21W

1

1

E504

38

E129
E151

1

2

2

E152

E105
21W

37

E134
1

E104

E136

1

+V2

M024
2

1

1

M023 +V1
2

47
1

M

+V2

3

03W
2

1

225785

H04

B

Andrew Burrows Tail lights / Diagram 28/03/16

Lighting and signalling management (1/3)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B106

Hazard lights control

C2b

B142

Headlamps ride corrector control

C2b

B143

Steering wheel fingertip controls N° 1

C2b

B151

Reversing buzzer inhibition control

C2b

B181

Direction indicator control

C2b

E100

RH front direction change indicator lights

A1d

E101

LH front direction change indicator lights

C1d

E104

Roof RH front direction change indicator lights

A2a

E105

Roof LH front direction change indicator lights

C2a

E109

RH rear direction change indicator lights

A9d

E110

LH rear direction change indicator lights

C9d

E116

RH rear fog light

A9d

E117

LH rear fog light

C9d

E119

LH stop lights

C9d

E120

RH stop lights

A9d

E122

RH clearance light N° 1

A2d

E123

RH clearance light N° 2

A4d

E124

LH front side/parking lights

C1d

E125

RH front side/parking lights

A1d

E128

LH clearance lights N° 3

C2d

E129

LH clearance lights N° 4

C4d

E131

RH clearance lights N° 3

A6d

E132

RH clearance lights N° 4

A8d

E133

LH clearance lights N° 1

C6d

E134

LH clearance lights N° 2

C8d

E135

LH tail lights unit

C9d

E136

RH tail lights unit

A9d

E137

RH rear side/parking lights

A9d

E138

LH rear side/parking lights

C9d

1/3

Andrew Burrows Tail lights / Diagram 28/03/16
LH reversing lights

C9d

E142

RH reversing lights

A9d

E144

Roof LH side/parking lights

C2a

E145

Roof LH side/parking lights

A2a

E151

Right-hand side marker lamp N° 5

A8d

E152

Left-hand side marker lamp N° 5

A8d

E500

RH dipped beam headlight

A1d

E501

LH dipped beam headlight

C1d

E502

RH main beam headlight

A1d

E503

LH dipped beam headlight

C1d

E504

RH headlamp insert

A1d

E141

E505

LH headlamp insert

C1d

G012

Lighting and signalling management ECU

B2c

L004

External horn

A9d

M023

LH headlamp ride correction motor

C1d

M024

RH headlamp ride correction motor

A1d

S100

Stop lights power supply relay

B2c

S104

Reversing lights power supply relay

B2c

Lighting and signalling management (1/3)

2/3

Andrew Burrows Tail lights / Diagram 28/03/16

3/3

Andrew Burrows

03/28/2016, 5:01:32 PM (CEST)

S103

S102

R23
10A

F90
3A

R09
10A

S101
R18
10A

S103
R23
10A

S106

S107

R07
10A

W500

R15
20A

F30 R12
30A 10A

1

1

F13
20A

A001

F05
30A

1

1

2

2

2

S400
1
2

2

B143
373

62
B3

B4

B141
373

370
A3

B1

B139

B146
1
373

S401

1

RE01
20A

69
A3

B1

A6
2

373

B137

2

313
A3

A1

B138

B145

B4

1

0

A2

2

3

MC PV GV

B113
373

A7

C013 C014

665
A4

A3

A2

A5

A4

A5

B140

11

G012

X2
6

A002

12

9

4

2

1

8

13

7

10

14

5

15

A002

M027
M020
1
2

2

70W

70W

506
1

502

2

3

M021

M

5094
3
M022

1
1

504
2

1

1

509
5

E506

4

501

E507

225785

H05

B

Andrew Burrows Main beam & extra headlamps / Diagram 28/03/16

Lighting and signalling management (2/3)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B113

Side/parking lights control

C2b

B137

Windscreen wash control

C2b

B138

Windscreen wipers control

C2b

B139

Windscreen / headlamps wash/wipe control

C2b

B140

Dipped beam headlights control

C2b

B141

Main beam headlights control

C2b

B143

Steering wheel fingertip controls N° 1

C2b

B145

Fog driving lights control

C2b

B146

Fog lights control

C2b

C013

Driver’s door open position information sensor

C2c

C014

Passenger’s front door open position information sensor

A2c

E506

LH fog driving light

C1d

E507

RH fog driving light

A1d

G012

Lighting and signalling management ECU

B2c

M020

Windscreen wipers drive motor

B1c

M021

Windscreen wash pump motor

B1c

M022

Headlamps wash pump motor

B1c

M027

Windscreen wash motor / headlamps wash motor unit

C4c

S101

Rear fog lights power supply relay

B2c

S102

Main beam headlights power supply relay

B2c

S103

Fog driving lights power supply relay

B2c

S106

Switches night lighting power supply relay

B2c

S107

RH and LH side/parking and marker lights
power supply relay (trailer and bodybuilder)

B2c

S400

Windscreen wipers motor time-delay relay

B2c

S401

Headlamps wash pump motor power supply relay

B2c

W500

Diode(s)

B2c

1/3

Andrew Burrows Main beam & extra headlamps / Diagram 28/03/16

Lighting and signalling management (2/3)

2/3

Andrew Burrows Main beam & extra headlamps / Diagram 28/03/16

3/3

Andrew Burrows

03/28/2016, 5:02:35 PM (CEST)

F18
10A

F96
3A

F38
10A

F22
10A

F96
3A

F96
3A

F22
10A

1

1

1

1

1

1

1

2

2

2

2

2

2

2

A001

XAHC3:3

B148

B143
B2

B111

2

7

E033

5

10

B5
1

E012

E042

2

7

E043

5

10

3

3

3

3

21W

21W

21W

21W

1

1

1

1

2

2

1

3

B194
5W

5W

5W

5W

E038

E039

E040

E041

10W

10W

3

W500

E008

E010

W500
1

1
3

3

05W

05W

1

1

B178
A002

5

7

2

G012

E034
9

3

1

E025

4
5

X3

2

1

B179
9
1

1

3

E035

7.5W

E026
1

7.5W

E007
1

E009
3

E102
3

21W

21W

E103
2

2

05W

05W

1

1

1

2
70W

2
2

2
1

5

7

2

2
1

2

1

2

L008
V107

E510

225785

H06

B

Andrew Burrows Specific trade spotlight / Diagram 28/03/16

Lighting and signalling management (3/3)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B111

Horn control

C2b

B143

Steering wheel fingertip controls N° 1

C2b

B148

Working lights control

C2b

B178

Cab interior lighting control (on dashboard)

C2b

B179

Cab interior lighting control (in cab)

B4b

B194

Overhead lighting control (ambience)

C2b

E007

Bunk lower RH overhead light

C4c

E008

Driver’s side single overhead light

C2a

E009

Bunk lower LH overhead light

C4c

E010

Front passenger’s side single overhead light

A2a

E012

RH upper overhead lighting (door)

A3a

E025

Driver’s reading spotlight

C2a

E026

Front passenger’s reading spotlight

A2a

E033

LH upper overhead lighting (door)

C3a

E034

LH overhead lighting (ambience)

C3a

E035

RH overhead lighting (ambience)

A3a

E038

Row 1 lighting

B2a

E039

Row 2 lighting

C2a

E040

Row 3 lighting

A2a

E041

Row 4 lighting

A2a

E042

Upper left-hand side overhead lamp lighting

C2a

E043

Upper right-hand side overhead lamp lighting

A2a

E102

Driver’s side stepwell lighting

C2d

E103

Front passenger’s side stepwell lighting

A2d

E510

Working spotlight

B4d

G012

Lighting and signalling management ECU

B2c

L008

Electric horn

C2d

V107

Air horn

C2d

W500

Diode(s)

B2c

1/3

Andrew Burrows Specific trade spotlight / Diagram 28/03/16

Lighting and signalling management (3/3)

2/3

Andrew Burrows Specific trade spotlight / Diagram 28/03/16

3/3

Andrew Burrows

03/28/2016, 5:03:35 PM (CEST)

F46
20A

F96
3A

F91
10A

F92
10A

F92
10A

F91
10A

1

1

1

1

1

1

2

2

2

2

2

2

A001

1

5

10
2

7

B144

S109
RE16
20A

XAHH5:1

2

2

2

2

3W

3W

5W

5W

1

1

1

1

E150

E149

E145

E144

5
A240

A201

A245
225785

H30

B

Andrew Burrows Side marker & identification lights / Diagram 28/03/16

Side, marker, identification and parking lights
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A201

Available power supply (vehicle earth)

B2a

A240

Available power supply (lighting)

B2a

A245

Available power supply (lighting and side/parking lights)

B2a

B144

Long range driving lights control

C2b

E144

Roof LH side/parking lights

C2a

E145

Roof LH side/parking lights

A2a

E149

Anti-glare strip-mounted LH marker lights

C2a

E150

Anti-glare strip-mounted RH marker lights

A2a

S109

Long range driving lights power supply relay

B2c

Side, marker, identification and parking lights

1/2

Andrew Burrows Side marker & identification lights / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:06:38 PM (CEST)

F27
20A

F66
10A

1

F96
3A

F02
10A

1

1

1

2

2

2

A001
2

B180
B130

XACD1:1

B126
3

10

6

8

3

5

10

6

8

3

9

4

10

B121

5

B219
3

9

4

10

B122
3

9

4

10

3

9

4

10

102
2
201
1

4

7

5

6

8

201
7

1

4

102
2

7

7

5

102
6

8

2

7

5

102
6

8

2

7

5

6

8

B117
B127

B120
7
10

6

8

3

3

4

5

3

9

4

10

102
201
1

4

1

5

102

6
2

7

7

5

6

8

1

1

2

1

1

1

M

M

M

M

M

M

2

2

1

2

2

2

M050

M051

M057

M056

M060

M052

225785

I01

B

Andrew Burrows Electric window winder / Sun-roof / Diagram 28/03/16

Electric window winder, sun-roof
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

B117

Sun-roof opening / closing control (on dashboard)

B2b

B120

Passenger’s electric curtain motor control (passenger side)

A3c

B121

Passenger’s electric curtain motor control (driver side)

C3c

B122

Front curtain motor control (driver side)

C3c

B126

Driver’s window winder motor control (driver side)

C2b

B127

Front passenger window winder motor control (front passenger side)

A2b

B130

Front passenger window winder motor control (driver side)

C2b

B180

Sun-roof opening / closing control (on cab rear control console)

B4b

B219

Driver’s side electric curtain motor control

C3c

M050

Front passenger’s sun visor motor

A3a

M051

Driver’s sun visor motor

C3a

M052

Front sun visor motor

C3a

M056

Driver’s door window winder motor

C3c

M057

Front passenger’s door window winder motor

A3c

M060

Electric roof air vent motor

B3a

Electric window winder, sun-roof

1/2

Andrew Burrows Electric window winder / Sun-roof / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:07:54 PM (CEST)

S500

R04
10A

F96
3A

F39
15A

1

1

2

2

A001

B119
2

7

5

10
1

3

B118
3

A

7

9

B

10

8

C

5

4
XAHD1:3
XAHD1:5

1

4
E

432
B

N009

M
M080

430
A

1

D

D

N008

E

428
C

431
C

A
M082
429

M

B

M081

M083

Z009

Z008
225785

I02

B

Andrew Burrows Rearview mirrors / Rearvision / Diagram 28/03/16

Swivelling defrosting rearview mirrors
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

B118

Swivelling rearview mirrors and alarm siren adjustment control

C2b

B119

Rearview mirrors and windscreen defrosting control

C2b

M080

RH rearview mirror horizontal swivelling motor

A2a

M081

RH rearview mirror vertical swivelling motor

A2a

M082

LH rearview mirror horizontal swivelling motor

C2a

M083

LH rearview mirror vertical swivelling motor

C2a

N008

LH defrosting rearview mirror resistor

C2a

N009

RH defrosting rearview mirror resistor

A2a

S500

Heated and swivelling rearview mirror power supply relay

B2c

Z008

Driver’s swivelling defrosting rearview mirror

C2a

Z009

Passenger’s swivelling defrosting rearview mirror

A2a

Swivelling defrosting rearview mirrors

1/2

Andrew Burrows Rearview mirrors / Rearvision / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:08:53 PM (CEST)

F63
15A

F75
15A

F68
20A

F43
15A

F14
15A

F96
03A

1

1

1

1

1

1

2

2

2

2

2

2

A001

EL

EL

00

A021
3

1

24V

5

6

8

9

2

00

A011
7

2

24V

12V
10

7

4

5

8

1

12V

6

3

4

2

2

+
2
—

2

2

-3

-3

+2

2

1

2
+
E027

3
1

1
1

+

2

+

2

—

3

1

—

3

3

X909
J002

J003

J006

X908

X908

X908

J007

X902

J001
225785

I03

B

Andrew Burrows Comfort accessories / Diagram 28/03/16

Comfort accessories
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A011

Voltage converter (24V / 12V) for information technology pack

C4c

A021

Voltage converter (24 / 12V — 15A)

C4c

E027

Cigar lighter light

B2b

J001

Cigar lighter

B2b

J002

RH heated seat unit

A3b

J003

LH heated seat unit

C3b

J006

Refrigerated compartment

B3c

J007

Refrigerator

B3c

X902

24 Volts power supply socket

B2b

X908

12 Volts power supply socket

B2b

X909

Extra 24 Volts power supply socket

B2a

EL: with MULTIPASS
00: other cases of use

Comfort accessories

1/2

Andrew Burrows Comfort accessories / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:10:55 PM (CEST)

F43
15A

A001

F37
10A

1

1

2

2

X207

X208

1

2

3

4

1

2

3

4

13

14

15

16

1

2

3

4

H019

1

2

A013
H014
1

2

3
8

24V

4

5

9

2

12V

4

6

1

A

7

F

5

1

2

3

4

B

5

6

A219

1
4000

4460

H005

1

5

H020

2

1

2

B1

B2

D1

D2

A220
C1

A220

1

A206
A1

1

3

E

8

H021

4

2

C

C2

1

H012

H011

447

448
1

2

451

444
1

2

225785

I20

B

Andrew Burrows Onboard radio / CB / Telephone / Diagram 28/03/16

Radio
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A013

Voltage converter (24V / 12V — 15A) for audio communication system

B2a

A206

Available power supply (CB +)

C2a

A219

Available power supply (radio-telephone +)

B2b

A220

Available power supply (radio-telephone -)

B2b

H005

GPS satellite antenna

C2a

H011

LH front loudspeaker

C2a

H012

RH front loudspeaker

A2a

H014

Radio set

C2a

H019

Microphone

C2a

H020

Sharp loudspeaker, LH side

C2a

H021

Sharp loudspeaker, RH side

A2a

X207

Audio auxiliary connector

C2a

X208

Audio USB connector

C2a

Radio

1/2

Andrew Burrows Onboard radio / CB / Telephone / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:12:18 PM (CEST)

A001

F96
3A

F31
20A

F76
10A

F108
20A

1

1

1

1

2

2

2

2

C090
2

7

5

1

2

3

9

10

11

3

6

10

11

14

10
1

3

B167

AN

AM

K002
2

1

7

15

AN

13

AM

AN

5

14

8

AM

G053

2

X4

1

X6
X1

2

3

1

2

X2

12

1

2

4

1

X3

1

2

A002

M

1

M

2

M101

N034

C269

M203
225785

I40

B

Andrew Burrows Independent heating; add-on heating / Diagram 28/03/16

Independent (add-on) heating AT2000 ST
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B167

Cab add-on heater control

C3a

C090

Add-on heater temperature sensor

B4b

C269

Temperature sensor on the autonomous heating system

B2b

G053

Air/air autonomous heating ECU

B2b

K002

Air/air add-on heater

B2b

M101

Add-on heater fan motor

B2b

M203

Add-on heater fuel pump motor

C4d

N034

Autonomous heating system heating element

B2b

AM: with ADR equipment
AN: without ADR equipment

Independent (add-on) heating AT2000 ST

1/2

Andrew Burrows Independent heating; add-on heating / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:26:18 PM (CEST)

A001
S451
F10
20A

1

F19
5A
1

2

2

2

CY

RE06
50A
2

R16
10A

1

AT

S452

F96
3A

1

B131

A7

8
2

1

6

C

3
2

7

8

CY

CY

CY

CY

1

B1

5

7

6

3

8

2

5

12

14

13

4

3

5
2014

CY
AT

AT

CY

AT

XARC3:4
2332

AT

A002

AT

AT

CY

AT

K003

1

25

3

M

12

3
5

11

19

4

9

6

1

10

SGB

8

31

22

30

31

27

8
25

34

26

35

36
1

4

Y/BL
1

6
1

2

°C
M202

15

SGA

2

2

GR

N027

1

2

°C
U

1

4

5

1

1

3

5

2

°C
U

3

M

U

4

6

1
1

C028
C027

2

M

2

Y/BL

3

2

4
C029

C250

C261

C260

M064

M061

V140

M200

C025
225785

I70

B

Andrew Burrows Air conditioning / Diagram 28/03/16

Air conditioning
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B131

Air conditioner control

B2b

C025

3-level air conditioning pressure sensor

B2b

C027

Low level air conditioning pressure sensor

B2b

C028

High level air conditioning pressure sensor

B2b

C029

Intermediate level air conditioning pressure sensor

B2b

C250

Blown air temperature sensor

B2b

C260

Evaporator temperature sensor

B2b

C261

Air conditioning outside air temperature sensor

B2b

K003

Air conditioning ECU

B2b

M061

Air recycling motor

B2b

M064

Air mixing flap motor

B2b

M200

Air conditioning compressor electric clutch

B3d

M202

Driving position fan-coil heater motor

B2b

N027

Fan/coil heater pilot-control resistors assembly

B2b

S451

Air conditioning compressor clutch power supply relay

B3c

S452

Air conditioning fan piloting relay

B2c

V140

Cab heating engine coolant circuit by-pass solenoid valve

B2b

AT: With air / water independent heating
CY: Without air / water independent heating

Air conditioning

1/2

Andrew Burrows Air conditioning / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:27:12 PM (CEST)

A001

F96
3A

F09
5A

F16
10A

1

1

1

2

2

2

2

7

5

B185
10
1

8

3

5

14

7

2

4

1

10

13

11

G003

24

A002

BBA

6

25
15

12
16

1

14
2

13

2

1

BBC

4

5

16

BBB
15

4

18

2

6

11

28

21

A002

1

V018

1

C036

4

2

225785

J01

B

Andrew Burrows CECU electronic control unit / Diagram 28/03/16

Bodybuilder pre-arrangement management
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

B185

PTO 2 engagement request control (in cab)

C2c

C036

PTO 2 engaged position information sensor

B4d

G003

Bodybuilder pre-arrangement management ECU

B2b

V018

PTO engagement electrovalve N° 2

B4d

Bodybuilder pre-arrangement management

1/2

Andrew Burrows CECU electronic control unit / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:28:15 PM (CEST)

A001

W500

W500

F77
15A

F71
15A

1

1

2

2

1

2

F75
15A
2

1

F96
3A

F25
10A

1

1

1

2

2

2

X200
PB1
A204
A254
A201
A205
A311
A247
A201
A248

20

208

6

8118

1

1

2

2234

7
3
21

X200
2

4306

A321

1

9

A255
A213
A246
A256
A258
A280
A257
A260
A259
A270
A281
A249

5
12
4
10
8
14
18
11
13

16

19

5

2

7

5

8169

7
7

A253

7

PB2

608
12
1140
8093
8067
1141
1025
1026
8119

8120

8121

17

8110

15

5108

AN
AM

7
7

A01-8
A20-8
A41-4
A44-9
B01-9

A240
A230
A231
A312
A323

11
6

10
8095

618

12

651

15

B01-6

EM
DF
EN

B01-3
B03-5

A320

16
EM
DF

B03-5

A259

18

89

3

B176

B20-8

17

B01-8

10
1

B20-9

8084

EN

A319

3

B20-9

8116

B01-4

1

B175

8083

9

3

B01-4

8138
8138
8138
8137
8137
8137

F03-1
F02-2
F01-4
F03-1
F02-1
F01-3
I40-9

B03-4

B03-4
B03-3
B40-9

225785

J20

B

Andrew Burrows Available power supply / Diagram 28/03/16

Available power supplies (1/2)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A201

Available power supply (vehicle earth)

B2c / C5d

A204

Available power supply (after master switch)

B2c / C5d

A205

Available power supply (after ignition)

C5d

A213

Available power supply (PTO N°1)

B2c

A230

Available power supply (equipment in
«road» position warning pictogram)

B2c

A231

Available power supply (equipment in
«working» position warning pictogram)

B2c

A240

Available power supply (lighting)

B2c

A246

Available power supply (PTO N°1 control)

B2c

A247

Available power supply (alternator information, engine running)

B2c

A248

Available power supply (alternator information, engine speed)

B2c

A249

Available power supply (tachograph corrected speed information)

B2c

A253

Available power supply (reversing information)

B2c

A254

Available power supply (parking brake information)

B2c

A255

Available power supply (gearbox neutral information)

B2c

A256

Available power supply (chassis-mounted
engine speed control actuation demand)

B2c

A257

Available power supply (selection of engine speed N°1)

B2c

A258

Available power supply (selection of engine speed N°2)

B2c

A259

Available power supply (engine speed acceleration demand)

B2c

A260

Available power supply (engine speed deceleration demand)

B2c

A270

Available power supply (main engine speed automatic return)

B2c

A280

Available power supply (low speed)

B2c

A281

Available power supply (engine stop control)

B2c

A311

Available power supply (PTO 1 engaged information)

B2c

A312

Available power supply (equipment in dangerous position)

B2c

A319

Available power supply (suspension level control)

B2c

A320

Available power supply (suspension level actuation control)

B2c

A321

Available power supply (6 km/h limitation)

B2c

A323

Available power supply (alarm stop)

B2c

1/3

Andrew Burrows Available power supply / Diagram 28/03/16
B175

Pre-arrangement for bodybuilder N° 1 control

C2b

B176

Pre-arrangement for bodybuilder N° 2 control

C2b

W500

Diode(s)

B2c

X200

Available power supplies connector

B2c

AM: with ADR equipment
AN: without ADR equipment
DF: with electronic air suspension tractor vehicle 4×2
EM: with 4×2 — 6×2 vehicle rear electronic air suspension
EN: with 4×2 — 6×2 vehicle integral electronic air suspension

Available power supplies (1/2)

2/3

Andrew Burrows Available power supply / Diagram 28/03/16

3/3

Andrew Burrows

03/28/2016, 5:29:20 PM (CEST)

A001
F26
15A

F77
15A

F94
15A

F93
15A

F97
5A

F32
10A

F35
20A

1

1

1

1

1

1

1

2

2

2

2

2

2

2

A200
A200

2
A201 A297

3

A201 A204

A201 A308

X200
A002

X200
PB3
A324
A205
A204
A294
A295
A201
A201

1

6

2

3

5
7
4

0403

275

208

632

634
1
1

1

PB5
A282
A291
A290
A313
A314
A250
A251
A252
A283
A284
A287
A288
A286
A289
A285
A212

3

8100

21
20

J1939-4

H

0414

L

0413

18

8133

17

8136

2

8113

5

8134

8

8161

6

8108

9

8104

11

8122

15

8131

12
14
10
16

8123
8132
8170
0384

J01-2
J01-4
J01-4
J01-6
J01-5
J01-4
J01-3
J01-9
J01-8
J01-9
J01-9
J01-9
J01-9
J01-9
J01-9
J01-9

225785

J21

B

Andrew Burrows Available power supply / Diagram 28/03/16

Available power supplies (2/2)
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

A200

Available power supply (insulated cut wires)

B2c

A201

Available power supply (vehicle earth)

B2c

A204

Available power supply (after master switch)

B2c

A205

Available power supply (after ignition)

C5d

A212

Available power supply (engine speed)

B2c

A250

Available power supply (PTO 2 control)

B2c

A251

Available power supply (PTO 2 warning light)

B2c

A252

Available power supply (PTO 2 solenoid valve piloting)

B2c

A282

Available power supply (engine start control)

B2c

A283

Available power supply (engine starting information)

B2c

A284

Available power supply (engine alert)

B2c

A285

Available power supply (parameter definable frequency-related output)

B2c

A286

Available power supply (PLC 2 min. output)

B2c

A287

Available power supply (PLC 1 min. output)

B2c

A288

Available power supply (PLC 1 min. input)

B2c

A289

Available power supply (PLC 2 min. input)

B2c

A290

Available power supply (high level CAN bus J1939)

B2c

A291

Available power supply (low level CAN bus J1939)

B2c

A294

Available power supply (LH rear marker light(s)

C5d

A295

Available power supply (RH rear marker light(s)

C5d

A297

Available power supply (night lighting)

B2c

A308

Pre-arrangement for onboard management (screen and keyboard)

C2a

A313

Available power supply (CAN bus disabling)

B2c

A314

Available power supply (engine speed set-point validation)

B2c

A324

Available power supply (rigid perimetric protection module)

C5d

X200

Available power supplies connector

B2c

1/3

Andrew Burrows Available power supply / Diagram 28/03/16

Available power supplies (2/2)

2/3

Andrew Burrows Available power supply / Diagram 28/03/16

3/3

Andrew Burrows

03/28/2016, 5:30:24 PM (CEST)

A001
S100
F21
20A

BS

DD

DD

F70
10A

F94
15A

F93
15A

R13
10A

S104
R08
10A

F64
10A

F101
10A

1

1

1

1

1

1

2

2

2

2

2

2

BS

A002

15

9

10

1

2
1

2

3
7

0046
7

8

8

3

7

3

7

6

4

6

15

634

4

5

5

5

X906

14

5

1
2

12
13

6

39

1

11

14

6

0045

11

10

9

3

30
2
307
3

4
13

4

12

X900
225785

J40

B

Andrew Burrows Trailer sockets / Diagram 28/03/16

Trailer sockets
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

S100

Stop lights power supply relay

B2c

S104

Reversing lights power supply relay

B2c

X900

15-pin trailer socket

B4b

X906

ABS/EBS trailer socket

B4b

BS: 4×2 vehicles
DD: 6×2 vehicles

Trailer sockets

1/2

Andrew Burrows Trailer sockets / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:31:28 PM (CEST)

A001

F15
5A
1

2

AN

AM

X913
7

1

12

13

16

4

5

8

17

6

14

18

225785

K01

B

Andrew Burrows Diagnostic socket / Diagram 28/03/16

Diagnostic socket
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

X913

Vehicle diagnostic socket

C3c

AM: with ADR equipment
AN: without ADR equipment

Diagnostic socket

1/2

Andrew Burrows Diagnostic socket / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:32:29 PM (CEST)

J1587-1
(+)

A001

EN

EM

DF

(-)

DD

BS

BQ

DE

CO

EN

EM

DF

DD

BS

BQ

DE

CO

A002

225785

K20

B

Andrew Burrows CAN J1587 bus architecture / Diagram 28/03/16

CAN BUS transfer zone J1587-1
Key to appliances
Code

Function

Location

A001

Cab electrical distribution box

B2c

A002

Chassis-cab connection box

B2c

D001

Principal information display

C2b

G001

Vehicle management ECU

B2c

G002

Engine management ECU

B3c

G003

Bodybuilder pre-arrangement management ECU

B2c

G004

Air suspension ECU

B2b

G005

EBS braking management ECU

B2b

G012

Lighting and signalling management ECU

B2c

G018

Onboard management interface ECU

B2b

G019

Gear selector ECU

C2b

G020

Automatic transmission ECU

C4d

G025

Engine immobilizer ECU

C2c

G026

Alarm ECU

C1a

G030

AdBlue supply management pump module

C4d

G051

Air production management ECU

C4d

G100

Datamax gateway ECU

C2b

H014

Radio set

C2a

X913

Vehicle diagnostic socket

C2c

BQ: with FMS equipment
CO: with OPTIFLEET equipment
DE: with DATAMAX equipment
BS: 4×2 vehicles
DD: 6×2 vehicles
DF: with electronic air suspension tractor vehicle 4×2
EM: with 4×2 — 6×2 vehicle rear electronic air suspension
EN: with 4×2 — 6×2 vehicle integral electronic air suspension

CAN BUS transfer zone J1587-1

1/2

Andrew Burrows CAN J1587 bus architecture / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:33:37 PM (CEST)

CAN J1939-1
H

X203

EN

EM

DF

BS

L

DD

BO

EN

EM

DF

BS

DD

BO

A002

BP

BP

225785

K21

B

Andrew Burrows CAN J1939 bus architecture / Diagram 28/03/16

CAN BUS transfer zone J1939-1
Key to appliances
Code

Function

Location

A002

Chassis-cab connection box

B2c

D001

Principal information display

C2b

G001

Vehicle management ECU

B2c

G002

Engine management ECU

B3c

G003

Bodybuilder pre-arrangement management ECU

B2c

G004

Air suspension ECU

B2b

G005

EBS braking management ECU

B2b

G018

Onboard management interface ECU

B2b

G019

Gear selector ECU

C2b

G020

Automatic transmission ECU

C4d

G021

Hydraulic retarder ECU

B2c

G051

Air production management ECU

C4d

X203

CAN bus grouping connector

B2c

BO: with ECOSPLIT 2 hydraulic retarder
BP: with ECOSPLIT 4 hydraulic retarder
BS: 4×2 vehicles
DD: 6×2 vehicles
DF: with electronic air suspension tractor vehicle 4×2
EM: with 4×2 — 6×2 vehicle rear electronic air suspension
EN: with 4×2 — 6×2 vehicle integral electronic air suspension

CAN BUS transfer zone J1939-1

1/2

Andrew Burrows CAN J1939 bus architecture / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:34:35 PM (CEST)

CAN J1939-2
H

L

DE

CO

DE

CO

A002

225785

K22

B

Andrew Burrows CAN J1939 bus architecture / Diagram 28/03/16

CAN BUS transfer zone J1939-2
Key to appliances
Code

Function

Location

A002

Chassis-cab connection box

B2c

D001

Principal information display

C2b

D004

Tachograph

C2b

G018

Onboard management interface ECU

B2b

G100

Datamax gateway ECU

C2b

G104

Tyre pressures monitoring ECU

B7d

H014

Radio set

C2a

CO: with OPTIFLEET equipment
DE: with DATAMAX equipment

CAN BUS transfer zone J1939-2

1/2

Andrew Burrows CAN J1939 bus architecture / Diagram 28/03/16

2/2

Andrew Burrows

03/28/2016, 5:35:34 PM (CEST)

CAN J1939-ENG
H

L

A002

225785

K23

B

Andrew Burrows CAN J1939 bus architecture / Diagram 28/03/16

CAN BUS transfer zone J1939-ENG
Key to appliances
Code

Function

Location

A002

Chassis-cab connection box

B2c

C077

Nitrogen oxides gases concentration sensor

C4d

G002

Engine management ECU

B3c

G020

Automatic transmission ECU

B3d

G030

AdBlue supply management pump module

C4d

X913

Vehicle diagnostic socket

C2c

CAN BUS transfer zone J1939-ENG

1/2

Andrew Burrows CAN J1939 bus architecture / Diagram 28/03/16

2/2

Andrew Burrows Key / Diagram 14/02/16

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

1/7

Andrew Burrows Key / Diagram 14/02/16
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

2/7

Andrew Burrows Key / Diagram 14/02/16
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

3/7

Andrew Burrows Key / Diagram 14/02/16
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)

4/7

Andrew Burrows Key / Diagram 14/02/16
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)

5/7

Andrew Burrows Key / Diagram 14/02/16
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)

6/7

Andrew Burrows Key / Diagram 14/02/16
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

7/7

Andrew Burrows Key / Diagram 14/02/16

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

1/3

Andrew Burrows Key / Diagram 14/02/16
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

2/3

Andrew Burrows Key / Diagram 14/02/16
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)

3/3

Andrew Burrows Key / Diagram 14/02/16

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

1/4

Andrew Burrows Key / Diagram 14/02/16
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

2/4

Andrew Burrows Key / Diagram 14/02/16
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)

3/4

Andrew Burrows Key / Diagram 14/02/16
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

4/4

Andrew Burrows Key / Diagram 14/02/16

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

1/2

Andrew Burrows Key / Diagram 14/02/16
389

Penetration lights pre-arrangement and front grille identification lights power supply

390

Two-tone horn power supply

2/2

Andrew Burrows Key / Diagram 14/02/16

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

1/4

Andrew Burrows Key / Diagram 14/02/16
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

2/4

Andrew Burrows Key / Diagram 14/02/16
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)

3/4

Andrew Burrows Key / Diagram 14/02/16
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

Andrew Burrows Key / Diagram 14/02/16

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

1/3

Andrew Burrows Key / Diagram 14/02/16
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

Andrew Burrows Key / Diagram 14/02/16
5109

Link between gear selector and automatic gearbox ECU (information redundancy)

3/3

Andrew Burrows Key / Diagram 14/02/16

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

Andrew Burrows Key / Diagram 14/02/16
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

Andrew Burrows Key / Diagram 14/02/16

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

Andrew Burrows Key / Diagram 14/02/16

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 6×2 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

Andrew Burrows Key / Diagram 14/02/16
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

Andrew Burrows Key / Diagram 14/02/16
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

Andrew Burrows Key / Diagram 14/02/16
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

Andrew Burrows Key / Diagram 14/02/16
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

Andrew Burrows Key / Diagram 14/02/16

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