IVECO 682 - Instruction Manual

PT.
CHAKRA JAWARA
NEW 682
PUBLICATION 603.95.397
NEW 682
PT. CHAKRA JAWARA GENERAL INFORMATION 1
SECTION 1
General information
Page
VEHICLE IDENTIFICATION DATA .................... 3
❏ Vehicle Identification Plate ........................... 4
❏ Vehicle identification number (V.I.N.) punched

on the chassis ............................................... 4
P.I.C. NUMBER CODING ................................... 5
COMPOSITION OF MODELS ............................ 9
CAPACITIES ....................................................... 10
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2 PT. CHAKRA JAWARA
GENERAL INFORMATION NEW 682
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NEW 682
VEHICLE IDENTIFICATION DATA

The type and number of engine, type and number of chassis and manufacturer's plate comprise the vehicle
identification data.
Figure 1
Manufacturer plate Engine

Plate on the left rear side of the
crankcase
17148
1
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4 PT. CHAKRA JAWARA
Vehicle Identification Plate (located on rear cross member)

Plate key
a) Vehicle model.
b) Engine model.
c) Engine serial number.
d) Engine maximum rating.
e) Vehicle maximum speed.
f) Total vehicle weight.
g) Maximum transportable weight.
h) Towable weight.
i) Vehicle identification code number.
j) Date of manufacture.
Figure 2
17148
2
Vehicle identification number (V.I.N.) punched on the chassis

The vehicle identification number (V.I.N.) punched on the chassis is made up of 17 alphanumeric characters
assigned by the manufacturer to the individual vehicle. This number definitively identifies each vehicle for a period
of 30 years.
Position
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Positions 1-2-3: Manufacturer identification

Positions 4-5-6-7-8-9: General vehicle characteristics (vehicle type, total weight, engine rating,
type-approval, engine type)
Position 10: Year of manufacture (conventionally 0)
Position 11: Chassis manufacturer
Positions 12-13-14-15-16-17: Progressive production number
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NEW 682
P.I.C. NUMBER CODING
COMFORT
A A A B B C C D
F NEW 682
AXLE CONFIGURATION - GROSS VEHICLE MASS
A A A B B C C D
2 Chassis cab 4x2 (18 ton)
4 Tractors 4x2 (18 ton)

7 Tractor 6x4 (25 ton)
9 Tipper 6x4 (25 ton)
A Tipper 8x4 (31 ton)
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6 PT. CHAKRA JAWARA
ENGINE
A A A B B C C D
A 290 HP
B 340 HP
C 380 HP
TYPE OF REAR AXLE - TYPE OF SUSPENSION
A A A B B C C D
A Mechanical parabolic - SR
B Mechanical parabolic - HR
C Mechanical semi-elliptical - HR
H.R. = Double reduction rear axle

S.R. = Single reduction rear axle
VERSION
A A A B B C C D
1 Cab
2 Tractor
3 Tipper
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NEW 682
WHEELBASE
A A A B B C C D
WHEEL WHEEL WHEEL

VERSION VERSION VERSION
BASE BASE BASE
 4x2 3650  6x4 3400 O 6x4 3225 1
 8x4 5100 O 6x4 3600 2

 8x4 6400 6x4 3825 3
O
 4x2 4325 O 6x4 4125 4
 5
 4x2 5000 6x4 4325
O
 6x4 6000 O 6x4 4600 6
 4x2 5600 7
 6x4 5925 8
 = Cabs
 = Tractors
O = Tipper
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8 PT. CHAKRA JAWARA
GEARBOXES
A A A B B C C D
9M A
12 M B
CAB TYPE - DRIVE - BRAKES COMBINATION
A A A B B C C D
BRAKES
Cab type DRIVE FRONT REAR
AS - C Right Drum Drum A
AS - C Left Drum Drum I
AS - L Right Drum Drum D
AS - L Left Drum Drum 4
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NEW 682
PT. CHAKRA JAWARA 9
GENERAL INFORMATION
COMPOSITION OF MODELS
MODELS TRACTOR CAB TIPPER
GROUPS
4x2
6x4
4x2
6x4
8x4
6x4
8x4
CURSOR 9 - 290 HP •
CURSOR 9 - 340 HP • • • • •
CURSOR 9 - 380 HP • • • • • •
Single-disc 17” • • • • • • •
9 JS 119 •
12 JSD 160 TA • • • • •
12 JSD 180 TA • • • • • •
12 JSD 220 TA • • • •
CF7140 • • • • • • •
Single reduction rear axle • • • • •

Double reduction rear axle • • • • •
ZF 8098 • • • • • • •
Front mechanical • • • • • • •
Parabolic • • • • • * *
Rear mechanical
Semi-elliptic * * * * * • •
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10 PT. CHAKRA JAWARA
CAPACITIES
IVECO RECOMMENDED LUBRICANTS PARTS TO BE REFILLED Quantity

Litres kg
Urania FE 5W30 (1) F2C Engine

Urania LD7
st
Total capacity of 1 filling 25 22.5
Gearbox
Tutela Transmission 9 JS 119 12.5 11.5
W90/M-DA 12 JSD 160 TA 17 16
12 JSD 180 TA 18.5 17.5
12 JSD 220 TA - -
Tutela Truck FE – Gear
Total power take-off - -
Tutela ZC 90
Single reduction intermediate rear axle 16.5 14.8
SR
Single reduction rear axle SR 12.5 11.5
Tutela Transmission
Intermediate and rear tandem HR
W140/M-DA (2)
(hub reduction) axle
- rear axle case 6 5.5
- wheel hubs (for each hub) 2 1.8
- transfer case-differential 2.3 2.1
(if mounted)
HYDRAULIC CAR
Power steering 5 4.6
32HVI
Tutela TRUCK DOT Clutch circuit - -

SPECIAL
Cooling system
11 F2C Engine Total capacity* 45 40.5
Water+Paraflu
* = Protective anti-freeze
(concentration 50% freezing point -35°C)
HYDRAULIC CAR
Cab tilting system 0.6 0.54
32HVI
Refer to
R134A Air conditioning system SECTION
Bodywork for
quantities
(1) IVECO recommends using these oils to obtain benefits in terms of ”fuel economy”. The new vehicle is
already equipped by IVECO with this type of lubricants (also adequate for cold climate min. temperature up
to -30°C).
(2) Suitable for hot or temperate climates
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NEW 682
PT. CHAKRA JAWARA 11
GENERAL INFORMATION
Lubricants and fuels international name Original products

Engine oil
Meets specifications:
❏ ACEA E4 with fully synthetic base SAE 5W 30 URANIA FE 5W30 (1)
Qualification IVECO STANDARD 18-1804
❏ Mineral based ACEA E7
SAE 15W 40 Urania LD7
Qualification IVECO STANDARD 18-1804 T2E7
Total power take-off
Contains non-EP wear resistant additives
Meets specification:
API GL3 with a mineral base
SAE 80W 90 Tutela ZC 90
Oil for differential and wheel hubs
API GL5 with a mineral base Tutela Transmission W140/M-DA
SAE 85W 140
Qualification IVECO STANDARD 18-1805 (hot or mild climates)
Oil for mechanical gearboxes
API GL5 with a mineral base SAE 80W 90 Tutela Transmission W90/M-DA
Qualification IVECO STANDARD 18-1805 Class RAM 1
Oil for power steering and hydrostatic transmission
Meets specifications: HYDRAULIC CAR 32 HVI
ISO VG32
Grease for general greasing
with lithium soap base, N.L.G.I. consistency no. 2 Tutela MR 2
Specific grease for wheel hubs and bearings
with base of lithium soap, consistency N.L.G.I. no. 3 Tutela MR 3
Fluid for clutch control
Compliant with N.H.T.S.A. standards N 116, ISO 4925, Std. SAEJ
Tutela TRUCK DOT SPECIAL
1703
Hydraulic cab tilting system oil
Meets specifications: HYDRAULIC CAR 32 HVI
ISO VG32
(continued)
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Lubricants and fuels international name Original products

Windscreen washer liquid
Tutela Professional SC 35
mixture of alcohol and surfactants CUNA NC 956-11
Grease for central lubrication systems
containing lithium soaps, with synthetic base, N.L.G.I. no. 2. Tutela COMAR 2
Working temperatures: from -30 °C to +140 °C
Concentrated protective fluid for radiators
based on ethylene glycol containing corrosion inhibitors in
conformity Paraflu11
to the norm IVECO STANDARD 18-1830
To be used diluted with water at 50%.
(1) IVECO recommends using these oils to obtain benefits in terms of ”fuel economy”. The new vehicle is
already equipped by IVECO with this type of lubricants (also adequate for cold climate min. temperature up
to -30°C).
Such quantities are not binding. The exact check depends on level check.
IVECO guarantees optimum engine performance when genuine lubricants are used.
! If non-original products are used, lubricants with minimum ACEA performance are acceptable for the
Diesel engines given in the table. The use of products with characteristics inferior to the ACEA
specifications could cause damage to the engine which would not be covered by the guarantee.
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NEW 682
PT. CHAKRA JAWARA ENGINES 1
SECTION 2
5401 Engines
Page
REPAIR OPERATIONS ON VEHICLE ............... 3
ENGINE............................................................... 35
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2 PT. CHAKRA JAWARA
ENGINES NEW 682
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NEW 682
PT. CHAKRA JAWARA 3
REPAIR OPERATIONS ON VEHICLE
Repair operations on vehicle
Page
MAIN REPAIR OPERATIONS ON VEHICLE ..... 5
❏ Introduction ................................................... 5
MAIN REPAIRS ON THE FUEL SUPPLY SYSTEM
❏ Replacement of injectors on vehicle ............. 5

❏ Replacement of rail on vehicle ..................... 5
❏ Replacement of EDC control unit on vehicle 7
❏ High pressure pump replacement on the vehicle
❏ Fuel pre-filter replacement on vehicle .......... 8
❏ Fuel pre-filter support replacement on vehicle
❏ Fuel filter replacement on vehicle ................. 8

❏ Replacing the fuel tank ................................. 9
MAIN REPAIR INTERVENTIONS ON
TURBOCHARGING SYSTEM ...................... 10
❏ Replace muffler on vehicle ........................... 10

❏ Replace engine brake device on vehicle ...... 10
❏ Replace engine brake cylinder on vehicle .... 10
❏ Replace turbocharger on vehicle .................. 11
❏ Exhaust manifold replacement on vehicle .... 12
❏ Air filter box replacement on vehicle............. 12
❏ Replace air filters and clean air filter box...... 13
LUBRICATION SYSTEM .............................. 14
❏ Replace oil sump on vehicle ......................... 14

❏ Replace engine oil on vehicle ....................... 14
❏ Replace engine oil filter on vehicle ............... 15
❏ Blow-by filter replacement on vehicle ........... 15
❏ Replace heat exchanger on vehicle ............. 15
COOLING SYSTEM ..................................... 16
❏ Replace fan on vehicle ................................. 16

❏ Replacement of viscous fan coupling on vehicle
❏ Replace radiator on vehicle .......................... 17
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4 PT. CHAKRA JAWARA
REPAIR OPERATIONS ON VEHICLE NEW 682
Page
❏ Replace intercooler on vehicle ..................... 17
❏ Replace condenser on vehicle ..................... 17

❏ Replace air duct on vehicle .......................... 17
❏ Replace thermostat on vehicle ..................... 20

MAIN REPAIR OPERATIONS ON BELTS AND
AUXILIARY GEARS ..................................... 20
❏ Air conditioner compressor drive belts

replacement on vehicle ................................ 20
❏ Change coolant pump and alternator drive
belts on vehicle ............................................. 21
❏ Replacing the automatic belt tensioner
on the vehicle ............................................... 21
❏ Replace air conditioning compressor on vehicle
❏ Replace alternator on vehicle ....................... 22
❏ Replacing the water pump on the vehicle .... 22
MAIN REPAIR OPERATIONS ON
TRANSMISSION GEARS ............................ 23
❏ Replacement of rocker cover on vehicle ...... 23

❏ Replacement of rocker-arm shaft on vehicle 23
❏ Replace cylinder head on vehicle................. 25
❏ Replace camshaft on vehicle ....................... 25
MAIN REPAIR OPERATIONS ON ENGINE
GEARS ......................................................... 29
❏ Replace rod-piston on vehicle ...................... 29

❏ Replace cylinder liners on vehicle ................ 31
MAIN REPAIR OPERATIONS ON SERVICE
GEARS ......................................................... 33
❏ Starter motor replacement on vehicle .......... 33

❏ Replacing the power steering pump
on the vehicle ............................................... 33
❏ Replace air compressor on vehicle .............. 34
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NEW 682
PT. CHAKRA JAWARA REPAIR OPERATIONS ON VEHICLE 5
MAIN REPAIR OPERATIONS ON VEHICLE Figure 1

Introduction
❏ Wash the engine, if necessary.
If washing the engine compartment, protect

! the electric/electrical components and their
connections appropriately.
❏ Disconnect the batteries removing the electric

wires or opening the main switch.
❏ Lift the radiator cowling and tilt up the cab.
MAIN REPAIRS ON THE FUEL SUPPLY

SYSTEM
173805
.775010. Replacement of injectors on vehicle
.774510. Replacement of rail on vehicle ❏ Remove the electric connections (1) from injectors.
❏ Remove the high-pressure fuel pipes:
- fuel delivery pipe (2) from high-pressure pump
to rail;
NOTE Before removing the injectors, discharge the - fuel return pipe (5)
fuel in the cylinder head ducts by loosing the - 6 fuel pipes (6) between rail and injectors.
delivery and return fittings on cylinder head. ❏ Remove the injection wiring (7) from the head. The
wiring has to be extracted from the front.
❏ Remove the unions (3) and the oil pipe (4) on the
Each time the high pressure fuel pipes are engine brake cylinders and engine brake solenoid
removed they must be replaced with new valve cylinder.
ones.
Figure 2
Removal
❏ Remove the rocker cover as described in the
relevant chapter (operation 540630).
173806
❏ Unscrew the fastening screws (1) and remove the

rail (2).
❏ Remove the rocker arm shaft as described in the
❏ Remove and mark the bridges on the valve stem.
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6 PT. CHAKRA JAWARA
Figure 3 Figure 6
11
173807
091572
❏ Place the injectors (2) so that the distance X
❏ Unscrew retaining screw (1) and remove the between injector and valve spring (1) is identical
injector fastening bracket (2). on both sides.
❏ Tighten the injector retaining screws (1, Figure 3)
Figure 4
to 26 Nm.
Figure 7
169826
❏ Unscrew retaining screw (1) and remove the

injector fastening bracket (2).
Refitting
Figure 5
173805
❏ Refit the rocker arm shaft as described in the

❏ Fasten the rail to the head by tightening the
fastening screws to the specified torque.
❏ Set the injector wiring (7).
❏ Refit the oil pipe (4) on the engine brake cylinders
and engine brake solenoid valve cylinder, then
tighten the unions to the specified torque.
169828
❏ Install the injectors (1) including brackets, into the
cylinder head housing.
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NEW 682
Each time the high pressure fuel pipes are

removed they must be replaced with new Refitting
ones.
For refitting, carry out the steps described for
removal in reverse order.
❏ Refit the high pressure fuel pipes (2, 5 and 6,

Figure 7) and tighten the unions to the specified
.771010. High pressure pump replacement
torque.
on the vehicle
❏ Reconnect the electrical connections (1, Figure 7)
to the electro-injectors and bind the wiring to the Removal
fuel pipes (6, Figure 7) with straps.
Figure 9
❏ Adjust intake and exhaust rockers clearance as
described in the relevant chapter (operation
541230);
❏ Refit the rocker cover as described in the relevant
chapter (operation 540630);
❏ Reprogram the control unit.
.766161. Replacement of EDC control unit

on vehicle
Removal
Figure 8 173598
To remove the high-pressure pump (1) proceed as

follows:
❏ Remove the fuel filter (2) by unscrewing it with tool
99363280.
❏ Remove the air sleeve (3) from the air filter pipe
(4) to the compressor (5).
❏ Disconnect the two fuel delivery and return pipes
by unscrewing the unions (6).
❏ Unplug the high-pressure pump (1) wiring
connector (7).
173596
❏ Take out the fastenings (8) of the high-pressure
pump (1) and remove it.
❏ Lift the cab.
❏ Remove the three electrical connectors (1) coming
into the EDC control unit (2).
❏ Remove the fuel delivery and return pipes (4) by
unscrewing the fastening unions (3). Refitting
❏ Remove the fastenings (5) of the EDC control unit For refitting, carry out the steps described for
(2) to the engine block (6). removal in reverse order.
❏ Remove the EDC control unit (2) from above the
vehicle.
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8 PT. CHAKRA JAWARA
.773110. Fuel pre-filter replacement on Refitting

vehicle For refitting, carry out the steps described for
Removal removal in reverse order observing the
following precautions:
Figure 10 ❏ Tighten screws and unions to the
specified torque.
❏ Refit the fuel pre-filter as described in the
❏ Bleed air from fuel system as described
in the relevant paragraph (operation
542011).
.542011. Fuel filter replacement on vehicle
Figure 11
173829
❏ Remove the electrical connection (3) of the water
presence sensor (4).
❏ Unscrew the pre-filter (8) with a suitable tool.
Refitting
removal in reverse order observing the
❏ Before refitting the new fuel pre-filter
119972
moisten the gasket with diesel or engine oil.
❏ Screw the new pre-filter on by hand, taking ❏ Unscrew the fuel filter (1) using a suitable tool.
care to check that the rubber seal and the ❏ Before refitting the new cartridge, moisten the seal
mating surface are clean and in a perfect with diesel or engine oil.
state of repair.
❏ Screw the new one on by hand, taking care to
Cartridge tightening torque 18 ± 2 Nm. check that the rubber seal and the mating surface
❏ Bleed air from fuel system as described are clean and in perfect state of repair.
in the relevant paragraph (operation ❏ Screw the cartridge on by hand until it is in contact
542011). with the mounting and then tighten by 3/4 of a turn
to the required tightening torque.
❏ Bleed air from fuel system as described in the
relevant paragraph (operation 542011).Lift the
cab.
.773114. Fuel pre-filter support
replacement on vehicle
Removal
❏ Remove the fuel pre-filter (8) as
described in the relevant chapter
(operation 773110).
❏ Remove the electrical connection (1) of
the fuel heater (2).
❏ Disconnect the two fuel delivery and
return pipes (5) by unscrewing the
fastenings (6).
❏ Remove the two fastenings (7), then
remove the fuel pre-filter support (9).
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NEW 682
.507220. Replacing the fuel tank

Removal
Figure 12
17360
3
❏ Remove the side guard (1) by operating on the

fastenings (2). Refitting
❏ Disconnect the fuel delivery and return pipe (3) For refitting, carry out the steps described for
unions from the tank (7) by unscrewing the removal in reverse order.
fastenings (5).
❏ Remove the electrical connection of the fuel level
sensor (4).
❏ Remove the tank (7) fastening straps (6)
unscrewing the fastenings (8).
❏ Remove the tank (7) from the vehicle.
Printed 603.95.397 Base - 10/2013

MAIN REPAIR INTERVENTIONS ON .543710. Replace engine brake device on

TURBOCHARGING SYSTEM vehicle
.542410. Replace muffler on vehicle .543730. Replace engine brake cylinder on
Removal vehicle
Removal
Figure 13
Figure 14
173809
173808
❏ Disconnect air duct (2) from actuating cylinder (3).
❏ Detach and remove the clip (7) from the ball joint
❏ Loosen the clamps (3) and remove the hose (4). (8).
❏ Support the muffler (2) appropriately and loosen ❏ Unscrew the nut (1) fastening the engine brake
the fastening clips (1). cylinder (3).
❏ Remove the muffler (2) from the vehicle. ❏ Undo the screws (4) so that the support plate can
turn and remove engine brake cylinder (3).
❏ Unscrew the fixing bolts (5) and separate the
exhaust pipe (6) from the engine brake device (9).
❏ Remove the engine brake device (9).
Refitting
For refitting, carry out the steps described for Refitting
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NEW 682
.542410. Replace turbocharger on vehicle Figure 17

Removal
Figure 15
173810 173812
Loosen the collar (3) and disconnect the exhaust pipe Disconnect oil delivery (3) and return (5) pipes from
(4) from the turbocharger (5). turbocharger (4).
Remove the fastening screws (1), disconnect the Support suitably the turbocharger (4), unscrew the
sleeves (2) and (6) and remove the air pipe (7). fastening screws (1) and remove it from the exhaust
manifold (6).
Figure 16
Refitting
removal in reverse order observing the
❏ tighten screws and unions to the
specified torque;
❏ replace the gasket (2) between
turbocharger (4) and exhaust manifold
(6);
❏ replace all gaskets removed during
173811
removal;
❏ check engine oil level and if needed top
Loosen the collar (1) and disconnect the intercooler
pipe (4) from the turbocharger (2). up;
Unscrew the screws and disconnect the intercooler ❏ check the conditions of the oil return pipe
pipe (4) from the bracket (3) fastening it to the chassis. (5) to the sump.
Printed 603.95.397 Base - 10/2013

.540720. Exhaust manifold replacement on .505110. Air filter box replacement on

vehicle vehicle
Removal Removal
❏ Remove the turbocharger as described in the
Figure 20
Figure 18
169821
174178
❏ Unscrew the fastening screws and remove the ❏ Remove the clamps (3) and disconnect the hose
exhaust manifold (1) with related gaskets. (6).
❏ Loosen the clamp (2), then disconnect the pipe (5)
from the air filter box.
Refitting ❏ Disconnect the electric connection from the air
filter clogging sensor (1).
Figure 19 ❏ Remove the screws (4) and disconnect the air pipe
(5).
8 1 4 5 8 1 2 5 8 1 4 5
Figure 21
6 3 2 7 6 3 4 7 6 3 2 7
45359
❏ Fit the exhaust manifolds with new gaskets and

tighten the fastening screws to specified torque in
the order shown in the figure:
- Pre-tightening: 35 ÷ 45 Nm;
- Tightening: 65 ÷ 75 Nm.
❏ Refit the turbocharger as described in the relevant
chapter (operation 542410). 174179
❏ Remove the screws (2) and disconnect the bracket

(1) from the filter box (3).
❏ Unscrew the fixing screws (4) and remove the filter
box (3).
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NEW 682
Refitting
.505111. Replace air filters and clean air filter

box
Figure 22
200104
❏ Drain water if present, then clean the filter box

❏ Remove the winged nuts and remove the cap.
from dust and dirt.
❏ Remove the nut (3) and take out the air filter (2)
❏ Refit carrying out the operations described in the
from the filter box (1).
removal process in reverse order.
Printed 603.95.397 Base - 10/2013

MAIN REPAIR INTERVENTIONS ON .543070. Replace engine oil on vehicle

LUBRICATION SYSTEM
.540430. Replace oil sump on vehicle Figure 24
Removal
❏ Pull out the engine oil level control rod.
❏ Remove the muffler (2) from the vehicle.
Figure 23
119975
We recommend draining the oil when the engine is

hot.
Attention: wear suitable protections since the

engine operating temperature is very high.
Engine oil can reach very high temperatures:
always wear protective gloves.
155857
❏ Loosen the screws (2) and remove the engine oil ❏ Place a suitable container under the sump drain
sump (1) with the spacer (3) and the gasket. plug (3) in order to collect oil.
❏ Unscrew plug (3) and take out the dipstick (1) and
the insertion plug (2) in order to facilitate the
Refitting
lubricant oil flow.
❏ Refit carrying out the operations
described in the removal process in
reverse order, tightening the nuts in the
specified sequence and at the specified Engine oil is highly pollutant and toxic.
torque. In case of contact, wash skin thoroughly with
water and detergent.
Protect skin and eyes appropriately; operate
NOTE Replace all gaskets removed in compliance with safety norms.
during dis sse bling. Dispose of the waste in an appropriate
manner and in compliance with regulations.
❏ Fill in engine oil in the specified quantity.

❏ Check the engine oil level using the level ❏ After draining, screw the plug (3) under the sump
control rod. and tighten it at the prescribed torque.
❏ Fill the engine with the prescribed oil quantity and
quality through the filler cap (2) of the tappet
cover.
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NEW 682
❏ Re-screw the plug under the pan and tighten it at

Only use recommended oil or oil with the the prescribed torque.
required characteristics for correct engine
operation. ❏ Through the filler cap, fill the engine with the
When topping up, do not mix oils with prescribed oil quantity and quality as described in
different characteristics. the relevant chapter.
Failure to observe these norms will void the
service warranty.
❏ Check the level with the dipstick until it is close to

the maximum level notch shown on the dipstick.
.543110. Replace heat exchanger on vehicle
Removal
❏ Drain the cooling system as described in the
relevant chapter.
.543070. Replace engine oil filter on vehicle
Figure 27
Figure 25
173602
119976 ❏ Remove the pipe (1) coming from the heater from
the water pump (2).
❏ Remove the oil filter (1). ❏ Remove the bracket (3) fastening the air
compressor pipe (4).
❏ Remove the fastening screws (5) of the heat
NOTE Attention: the oil filter contains approximately exchanger cover (6) and remove it.
1 kg of engine oil. ❏ Remove the inner body of the heat exchanger
Place a suitable container so as to collect the operating from underneath the vehicle.
fluid.
Attention: avoid contact of the engine oil with

the skin: in case of contact, wash skin with
running water.
Engine oil is highly pollutant: it must be
disposed of according to applicable laws.
❏ Before refitting the new cartridge, moisten the

gasket with engine oil.
❏ Screw the oil filter (1) on by hand until it is in
contact with the mounting and then tighten by 3/4
of a turn to the required tightening torque.
Printed 603.95.397 Base - 10/2013

Refitting Figure 29
❏ For refitting, carry out the steps
described for removal in reverse order.
❏ Fill up the engine cooling circuit and carry
out the bleeding procedure as described
in the relevant chapter (operation
543210).
MAIN REPAIR INTERVENTIONS ON COOLING

SYSTEM
.543420. Replace fan on vehicle
.543422. Replacement of viscous fan
coupling on vehicle
Removal
Figure 28 200105
❏ At the bench, separate the fan (3) from the viscous

fan coupling (1), unscrewing the fastening screws
(2).
NOTE The fan must be stored in vertical position.
Refitting
173822
❏ Remove the fastening screws of the brackets (2)

and (5), so that the pipes (3) of the air conditioning
system are free from pipe (4).
❏ Remove the left (6) and right intercooler hoses.
❏ Loosen the bolts fastening the radiator to the
chassis and move the radiator assembly forward.
❏ Remove the 4 screws (7) and remove the viscous
fan coupling together with the fan, disconnecting it
from the pulley (1).
Base - 10/2013 Printed 603.95.397

NEW 682
.506010. Replace radiator on vehicle

.506050. Replace intercooler on vehicle
.553232. Replace condenser on vehicle
.506017. Replace air duct on vehicle
Removal
Figure 30
17382
4
❏ Drain the engine coolant. ❏ Unscrew the nut (12) fixing the pipe bracket (10).
❏ Drain the air-conditioning system with the specific ❏ Disconnect the intercooler air hose (5).
equipment. ❏ Unscrew the clamps and remove the coolant pipe
From the left side: (1).
❏ Remove the screws form brackets (3), (4) and (6) ❏ Disconnect the breather pipes (7) from the
fastening the pipes (2) of the air conditioning radiator.
system. ❏ Undo the screws (9) and disconnect the pipe
❏ Unscrew the nut (11) and remove the pipes (13) support bracket (8), setting it to one side
from the condenser.
Printed 603.95.397 Base - 10/2013

Figure 31
17417
2
From the right hand: ❏ Remove the viscous fan coupling and fan as
❏ Remove the screw (2) and the air conditioning described in the relevant chapter (operation
543422).
system pipe fastening bracket (1).
From underneath the vehicle:
❏ Unscrew the fittings (12) and disconnect the pipes
(1) from the air conditioning compressor (13). ❏ Remove the clamps (15) and remove the water
pipe (14).
❏ Remove the flexible unions and the intercooler
pipe (11). ❏ Remove the screws (14) securing the radiator
assembly (15) to the chassis both on the right and
❏ Lift the grille, unscrew the screw (5) and move
left side.
away the oil dipstick from the radiator assembly
(3). ❏ Fasten the radiator assembly (15) appropriately to
a hoist.
❏ Disconnect the water hoses (6) from the pipes (4).
❏ Lift and remove the radiator assembly (15) from the
❏ Remove the screw (7) and free the pipes (4) from
chassis, including:
the fastening bracket. - condenser;
❏ Remove the screws (8) and disconnect the pipe - intercooler (10);
(4) suport bracket (9) from the intercooler (10). - radiator;
❏ Move away the pipes (4) with bracket (9) from the - air duct.
radiator assembly.
Base - 10/2013 Printed 603.95.397

NEW 682
.553232. Condenser disassembly-assembly .506017. Air duct disassembly - assembly

Figure 32 Figure 34
174173 174176
❏ Unscrew screws (1), then remove bracket (2) and ❏ Undo the screws (2) and remove the outer part of
condenser (3) from the radiator assembly (4). the duct (1).
❏ Unscrew screws (3), then remove the air duct (4)
❏ For refitting, carry out the steps described for from the radiator (5).
❏ For refitting, carry out the steps described for
.506050. Disassembly-assembly of the Refitting

intercooler For refitting the radiator assembly, carry out
❏ Remove the condenser as described in the the steps described for removal in reverse
relevant chapter (operation 553232). order observing the following precautions:
Figure 33 ❏ check the auxiliary gear belts and the

climate control compressor drive belts
and replace them if worn or damaged;
❏ tighten the screws and/or nuts to the
prescribed torque;
❏ replace all gaskets removed during
removal with new gaskets.
❏ fill the cooling system, then bleed air out
of the cooling system as described in the
relevant chapter (operation 506010);
❏ recharge the air conditioning system as
(operation 553230).
174175
❏ Unscrew screws (2) and (3), then remove the

intercooler (3) from the radiator (1).
❏ For refitting, carry out the steps described for
Printed 603.95.397 Base - 10/2013

.543251. Replace thermostat on vehicle MAIN REPAIR OPERATIONS ON BELTS AND

Removal AUXILIARY GEARS
❏ Drain the cooling system as described in the .543910. Air conditioner compressor drive
relevant chapter. belts replacement on vehicle
❏ Remove the viscous fan coupling as described in
the relevant chapter (operation 543422).
Figure 35
Figure 36
174174
173819
❏ Cut the belt (1) driving the air conditioning

❏ Disconnect the hose (5) and pipe (1) from the
compressor as it must not be used again.
thermostat (2).
❏ Disconnect electrical connection (4) on the Figure 37
temperature sensor.
❏ Unscrew the five fixing screws (3) and remove the
thermostat body (2) together with the gasket.
Refitting
Thermostat fastening screws tightening
torque: 22 ÷27 Nm.
Fill up the engine cooling circuit and carry out
the bleeding procedure as described in the
178158
To fit the spring belt driving the climate

control compressor, you have to use tool
number 99360192 (4). Different methods
may cause tensions impairing spring belt.
❏ Apply the tool 99360341 to the gear case.

❏ Fit the spring belt (3) on the crankshaft pulley. Fit
the tool 99360192 (2) onto the pulley of climate
control compressor (1). Position the spring belt (3)
in the opening of tool 99360192.
❏ Using tool 99360341 rotate the crankshaft in the
direction of the arrow (→) until the spring belt (3) is
correctly positioned on compressor pulley (1).
Base - 10/2013 Printed 603.95.397

NEW 682
.543417. Replacing the automatic belt

NOTE While operating, keep tool 99360192 (4, tensioner on the vehicle
Figure 37) in contact to pulley and at the
same time guide the spring belt (3, Figure
37) as to prevent it from twisting. Figure 39
The flexible belt must be replaced with a new

one every time it is removed from the
vehicle.
❏ Refit the viscous fan coupling as described in the

.543411. Change coolant pump and

alternator drive belts on vehicle
173820
❏ Remove the air conditioning compressor belt as
❏ Remove the water pump/alternator drive belt (1) as
543910).
553411).
❏ Undo the fastening screw of the automatic
Figure 38 tensioner (2) using a spanner (3) and replace it
(Tightening torque: 40÷50 Nm).
❏ Refit the water pump/alternator drive belt as
553411).
.553239. Replace air conditioning

compressor on vehicle
Removal
106223 ❏ Bleed air conditioning system by means of a
suitable tool.
❏ Using a suitable tool (3), operate on the automatic
tensioner (4) in the direction of the arrow (→), and Figure 40
remove the belt (2) driving the water pump,
alternator and fan and replace it with a new belt.
NOTE Belt tensioner is automatic; therefore, no

further adjustments are to be made after
mounting.
❏ Refit the air conditioning compressor belt as

543910).
173597
❏ Remove the bracket (2) fastening the air

conditioning system pipes (1).
❏ Disconnect the pipes (1) from the compressor by
operating on the fastenings (3).
Printed 603.95.397 Base - 10/2013
❏ To refit, repeat the operations described for the

removal process in reverse order, tightening the
❏ Remove the electrical connection (6, Figure 40) fastening nuts to a torque of 67 ÷ 76 Nm.
driving the compressor (5, Figure 40).
❏ Cut the belt (4, Figure 40) driving the air
conditioning compressor as it must not be used .543210. Replacing the water pump on the
again. vehicle
❏ Remove fastenings (7, Figure 40) of the
Removal
compressor (5, Figure 40) and remove the
compressor. ❏ Drain the cooling system as described in the
relevant chapter.
Refitting
❏ Remove the water pump/alternator drive belt as
❏ Refit the compressor (5, Figure 40) and described in the relevant chapter (operation
tighten the fixing screws (7, Figure 40) to 553411).
a torque of 22÷27 Nm.
❏ Connect the pipes (1, Figure 40) of the
air conditioning system to the
compressor (5, Figure 40), tightening the
fastenings (3).
❏ Refit the bracket (2, Figure 40) fastening
the pipes (1, Figure 40) Figure 42
❏ Refit the belt (4, Figure 40) of the air
conditioning compressor belt as
(operation 543910).
❏ Recharge the air conditioning system as
described in the relevant chapter.
.760310. Replace alternator on vehicle

❏ Remove the water pump/alternator drive belt (1,
Figure 38) as described in the relevant chapter 125702
(operation 553411). ❏ Unscrew the screws (1) and remove the water
pump (2) and pulley (3).
Figure 41
Refitting
Water pump fastening screw tightening
torque:
20 ÷ 24 Nm.
❏ Replace all gaskets removed during
removal.
❏ Fill up the engine cooling circuit and carry
out the bleeding procedure as described
in the relevant chapter (operation
543210).
❏ Check for coolant leaks during the first
few hours of operation.
173821
❏ Disconnect the electrical connections.
❏ Unscrew the fixing nuts and remove the alternator
(1) from the support.
Base - 10/2013 Printed 603.95.397

NEW 682
MAIN REPAIR OPERATIONS ON Figure 44

TRANSMISSION GEARS
.540630. Replacement of rocker cover on
vehicle
Removal
Figure 43
173802
❏ Unscrew the fastening screws and remove the

thermostat (3) from the cylinder head.
❏ Remove the oil vapour breather pipe (2) from the
Blow-by cover (1) loosening the fastening clamp.
❏ Unscrew the fastening screws and remove the
173801
Blow-by cover (1).
❏ Unscrew the fastening screws (3) and remove the
rocker cover (1).
❏ Replace the rubber gasket removing it from the
tappet cover.
Figure 45
Refitting
Refit carrying out the operations described in
the removal process in reverse order,
tightening the nuts in the specified sequence
and at the specified torque.
.541230. Replacement of rocker-arm shaft on

vehicle
Removal
❏ Drain the engine coolant.
❏ To facilitate operations, remove the suction duct 173803
(3) after disconnecting it from turbocharger and air

filter. ❏ Remove the check springs (2) of the engine brake
❏ Remove the rocker cover as described in the lever.
relevant chapter (operation 540630). ❏ Unscrew the fastening screws (1) of the rocker-
arm shaft.
Printed 603.95.397 Base - 10/2013

Figure 46 Figure 48
0050320t
155847 ❏ Lock the screws (2) fixing the rocker-arm shaft as

❏ Apply tool 99360558 (1) to the rocker arm shaft (2) follows:
st
- 1 stage: tightening to a torque of 80 Nm (8
and remove the shaft from the cylinder head.
kgm) with the torque wrench (1);
nd
- 2 stage: closing with an angle of 60º using
tool 99395216 (3).
❏ Fit the engine brake lever retainer springs.
Refitting ❏ Adjust intake and exhaust rockers clearance as
well as pump injector control rocker pre-load as
541230).
NOTE Before refitting the rocker-arm shaft

assembly, make sure that all the adjustment Figure 49
screws have been fully unscrewed.
NOTE Replace all gaskets removed during removal.
❏ Apply the tool 99360558 (1) to the rocker

arm shaft (2) and mount the shaft on the
cylinder head.
Figure 47 173802
❏ Refit the Blow-by cover (1), tightening fastening

screws to the prescribed torque.
❏ Refit the thermostat (3) following the sequence
indicated in the figure and the prescribed
tightening torque of the screws.
❏ Connect the oil vapour breather pipe (2) to the
70567A Blow-by cover (1).
LAYOUT OF TIGHTENING SEQUENCE ❏ Refit the rocker cover as described in the relevant
FOR ROCKER SHAFT FASTENING SCREWS chapter (operation 540630).
❏ Screw screws (1 - 2 - 3) until rocker arms are ❏ Fasten the intake duct (3, Figure 43) connecting it
brought to contact relating seats on cylinder head, to turbocharger and to air filter and tightening the
tighten the screws according to sequence fastening screws.
indicated in figure operating in two steps as
indicated in successive figure.
Base - 10/2013 Printed 603.95.397

NEW 682
❏ Fill up the engine cooling circuit and carry out the ❏ Unscrew the fastening screws and remove the fuel
bleeding procedure as described in the relevant filter mount (16) from the cylinder head.
chapter (operation 543210).
.540610. Replace cylinder head on vehicle

.541210. Replace camshaft on vehicle
Removal
Figure 50

❏ Remove the compressor air intake pipe (12).
❏ Disconnect air pipe (14).
❏ Remove the EDC control unit as described in the
❏ Partially disconnect the engine wiring (1), by
disconnecting the electrical connections and
freeing the wiring from clips
❏ Remove the fuel filter (15).
❏ Disconnect the fuel pipes from the fuel filter mount
(16) and from the high pressure pump (13).
Printed 603.95.397 Base - 10/2013

❏ Disconnect the rail fuel delivery pipe (2) from

the cylinder head.
❏ Disconnect the air delivery pipe (3) from the Figure 52
compressor (11) and disconnect it from the support
brackets (4) by unscrewing the fastening
screws.
❏ Separate the power steering oil tank (6) from the
intake manifold (8), unscrewing the fastening
screws (5).
❏ Disconnect the engine ignition pushbutton panel
(10).
❏ Disconnect the intake manifold (8) from the
intercooler by removing the flexible sleeve.
❏ Remove fastening screws (7) and disconnect
intake manifold (8).
❏ Disconnect the fuel return pipe (9).
200106
Figure 51
❏ Unscrew the screws (2) and remove the Blow-by
cover (1).
Figure 53
173814
❏ Remove the air conditioning compressor as

553239). 173815
❏ Detach the air conditioning compressor mount (5) ❏ Unscrew the screws (1) and remove the gear (3)
from the cylinder head. fitted with pulser ring (2).
❏ Disconnect the pipe (2) from the Blow-by cover.
❏ Disconnect the hose (6) and breather pipe (3) from Figure 54
the thermostat (4).
❏ Remove the fastening screws and remove the
thermostat (4) from the cylinder head.
❏ Disconnect the breather pipe (1).
❏ Remove the turbocharger as described in the
❏ Remove the exhaust manifold as described in the
❏ Remove the rocker cover as described in the
❏ Remove the rocker arm shaft as described in the
relevant chapter (operation 541230). 173816
❏ Remove the electro-injectors as described in the ❏ Loosen the screws (1); drive one of them into the
relevant chapter (operation 775010). reaction hole and remove the shoulder plate (2),
❏ Remove the rail as described in the relevant then remove the gasket.
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 55 Figure 56
61270
❏ Diagram showing the cylinder head fixing screws

tightening order.
60515
❏ Unscrew the cylinder head fastening screws and Figure 57

remove the cylinder head (1).
❏ Remove the gasket (2).
❏ Place the cylinder head on the bench.
❏ Withdraw the cam shaft.
❏ Overhaul the cylinder head as described in the
Refitting
❏ Fit the camshaft it its seat.
50565
❏ Check that pistons 1-6 are exactly at
T.D.C. and insert tool 99360612 through ❏ Preliminary tightening by means of a torque
the engine speed sensor seat into the wrench (1):
st
hole of the engine flywheel. - 1 stage: 50 Nm (5 kgm);
nd
❏ Clean thoroughly the bearing surfaces - 2 stage: 100 Nm (10 kgm).
both on the cylinder head and on the
crankcase.
Figure 58
❏ Put the gasket (2) on the crankcase.
Replace all gaskets removed during

removal. α
❏ Place the cylinder head on the engine and tighten

the fastening screws in the specified sequence and
torque.
The cylinder head fastening screws are to be

50566
replaced each time you remove them.
❏ Angle tightening with tool 99395216 (1):
rd
- 3 stage: angle of 120°;
rd
- 4 stage: angle of 60°.
Lubricate the thread of the screws with
engine oil before assembly.
Printed 603.95.397 Base - 10/2013

Figure 59 Figure 61
117691
❏ Position the gear (1) on the camshaft so that the 4

114267 slots are centred with the holes for fixing the
❏ Fit the camshaft (3), positioning it with the camshaft, without fully locking the screws (5).
reference marks (→) as shown in the figure. ❏ Fit the spokes (4) of gear (1) as shown in the
❏ Lubricate the seal (2) and fit it on the thrust plate figure.
(1). This operation is needed to ensure correct fitting
of the pulser ring, which can be fitted only in one
❏ Clean the contact surfaces between the head and
position with respect to the gear.
the thrust plate (1).
❏ Tighten the bolts (3) to a torque of
❏ Apply LOCTITE 5970 IVECO (6) sealant on the st
thrust plate (1) as shown in the figure. - 1 stage: 25 Nm (2.5 kgm);
nd
- 2 stage: 45°.
Do not apply sealant inside the gasket (5). Figure 62
❏ Mount the thrust plate (1) with the gasket (5) within
10 minutes of applying the sealant and tighten the
screws (4) to a torque of 16 ÷ 22 Nm.
Figure 60
173817
❏ Fit the pulser ring (4) so that the notch marked by

the arrow (→) is aligned with the sensor (2).
❏ To check that the position is correct, insert tool (1)
99360613 into the sensor housing (2).
❏ Proceed by tightening the bolts (3) to a torque of
116053 st
- 1 stage: 10 Nm (1 kgm);
❏ Fit tool (1) 99395223 on the camshaft using 2 -
nd
2 stage: 25 ÷ 32 Nm (2.5 ÷ 3.2 kgm).
M8x1.25 screws (2) and place the pin (3) into the
❏ Refit the electro-injectors as described in the
matching hole on the head.
Base - 10/2013 Printed 603.95.397

NEW 682
❏ Refit the rocker arm shaft as described in the Figure 64

❏ Adjust intake and exhaust rockers clearance as
541230).
❏ Adjust clearance between gears (5 and 6) as
described in the relevant chapter.
❏ Check and put in timing phase as described in the
❏ Check the pulser ring timing as described in the
❏ Fit again the timing gear cover after replacing the
gasket. 155859
❏ Refit the rocker cover as described in the relevant ❏ Unscrew the fastening screws (1) of the rod caps
chapter (operation 540630). (2) and remove them.
❏ Refit the exhaust manifold as described in the ❏ Remove the cylinder head as described in the
relevant chapter (operation 540720). relevant chapter (operation 540610).
❏ Refit the turbocharger as described in the relevant
Figure 65
MAIN REPAIR OPERATIONS ON ENGINE

GEARS
.540840. Replace rod-piston on vehicle
Removal
155860
❏ Drain engine oil in a suitable container.
❏ Clean the upper part of the liner form carbon
❏ Remove the oil sump as described in the relevant
deposits as to facilitate the piston way out.
❏ Apply the cylinder liner fastening pins (2)
(99360703).
❏ Remove the connecting rod-piston assembly from
Figure 63 the upper side (1).
❏ Repeat these operations for the other pistons.
❏ Mark the rod bearing shells position when
removing them as to reassemble them in the same
position, should you not have to replace them.
129709
❏ Unscrew the screws (1) and remove the oil suction

strainer (2).
❏ Fit the 99360341 tool to rotate the engine flywheel.
Printed 603.95.397 Base - 10/2013
Figure 66 Figure 69
49024
❏ Remove the piston pin Seeger-rings (2) using 74052
round tipped pliers (1). ❏ Lubricate with engine oil the piston pin (2) and the
relevant seats.
Figure 67
❏ Fit the pin (2) and fasten it on the piston (1) with
the piston rings (3).
Figure 70
49025
❏ Disassemble the piston pin (1) as to release the

rod from the piston.
NOTE If removal is difficult use the appropriate

beater.
74053
Refitting ❏ Use pliers 99360184 (3) to fit the piston rings (1)
on the piston (2).
Figure 68
Piston rings must be assembled with the marking
"TOP" (4) facing upwards and their openings must
be offset to each other by 120°.
❏ Repeat these operations for the other pistons.
❏ Remove the cylinder liner fastening pins
99360703.
❏ Check the assembly clearance of crankpins as
540831).
❏ Fit the bearing shells on the connecting rod and on
the cap after lubricating them with engine oil.
73536
❏ The piston (1) has to be fitted on the connecting

rod (2) so that the graphic symbol (4), showing the
assembly position in the cylinder liner, and the
punch marks (3) on the connecting rod face each
other as shown in the figure.
Base - 10/2013 Printed 603.95.397
NEW 682
Figure 71 Figure 72
155861
❏ Clean and oil the cylinder linings (3).

❏ Using 99360603 clamp (2), fit the connecting rod- 155862
piston assembly (1) in the cylinder liners and ❏ Connect the connecting rods to the relevant
check following items: crankpins, assembly the connection rod caps (2)
- the openings of the piston rings are offset by with half bearings; tighten the fixing screws (1) of
120°; the connecting rod caps to a torque of 50 Nm (5
kgm). Using tool 99395216 (3), further tighten
- the pistons belong all to the same class;
screws with 90° angle.
- the ideogram punched on the piston crown
faces the engine flywheel, or the recess in the ❏ Clean the surface of the underblock.
piston skirt matches the position of oil nozzles. ❏ Refit the oil sump as described in the relevant
❏ Refit the cylinder head as described in the relevant
NOTE The pistons are supplied as spares in class chapter (operation 540610).
A and can also be fitted in class B cylinder
liners. ❏ Fill up the engine cooling circuit and carry out the
bleeding procedure as described in the relevant
Before reusing the screws fixing the ❏ Check the engine oil level using the level
connection rod caps, measure the diameter control rod.
of the thread; it must not be less than 11.4
mm, otherwise replace the screw.
.540420. Replace cylinder liners on vehicle
Removal
❏ Drain engine oil in a suitable container.
❏ Remove the oil sump as described in the relevant
❏ Remove the cylinder head as described in the
❏ Remove the connecting rods and the pistons as
540840).
Printed 603.95.397 Base - 10/2013

Figure 73 Figure 75
47577
60520
❏ Place tool 99360706 (2) and plate 99360724 (4) as
❏ Check cylinder liner protrusion using tool
shown in the figure and make sure the plate (4)
99360334 (2) and tightening the screw (1) to a
touches the cylinder liner correctly. Tighten the
torque of 170 Nm. Using a dial gauge (3),
screw nut (1) and pull out the cylinder liner (3)
measure that the cylinder liner protrusion as to
from the crankcase.
cylinder head supporting surface is 0.035÷0.065
mm (Figure 76); otherwise, replace the adjusting
Refitting shim (1, Figure 74) supplied as spare part in
different thicknesses.
Figure 74
Figure 76
114041
16798
CYLINDER LINER PROTRUSION
❏ Always replace the water sealing rings (4 and 5 ❏ Refit the connecting rods and the pistons as
black, 3 gray or purple). Install the adjustment ring described in the relevant chapter (operation
(1) on the cylinder liner (2); lubricate the lower part 540840).
of the liner and install it in the cylinder unit using ❏ Refit the cylinder head as described in the relevant
the proper tool. chapter (operation 540610).
❏ Refit the oil sump as described in the relevant
NOTE The adjusting ring (1) is equipped with a
spare part having the following thickness: ❏ Fill up the engine cooling circuit and carry out the
0.08 mm - 0.10 mm - 0.12 mm - 0.14 mm. bleeding procedure as described in the relevant
❏ Check the engine oil level using the level control
rod.
Base - 10/2013 Printed 603.95.397

NEW 682
MAIN REPAIR OPERATIONS ON SERVICE Figure 79

GEARS
.760810. Starter motor replacement on
vehicle
Figure 77
173601
❏ To facilitate the removal of the power steering

pump (4), disconnect the compressor (2) air
delivery pipe (7) by operating on union (1).
❏ Loosen the strap (9) and disconnect the oil
delivery hose (8) from the power steering pump (4)
by freeing it from the clamps.
❏ Disconnect the oil delivery hydraulic pipe (6) from
173818 the power steering pump (4) by operating on union
(3).
Unscrew the nuts (2) and disconnect the electrical ❏ Remove the fastening screws (5) of the power
connections (1). steering pump (4) and remove it from the vehicle.
Loosen nuts (4) and remove starter motor.
To refit, repeat the operations described for the
removal process in reverse order, tightening the
fastening nuts to a torque of 40 ÷ 48 Nm.
Refitting
.501450. Replacing the power steering pump
on the vehicle For refitting, carry out the steps described for
Removal removal in reverse order.
Fill up the steering hydraulic circuit and carry
Figure 78 out the air bleeding procedure as described
in the relevant chapter (operation 501462).
173600
❏ Unscrew the power steering oil tank (3) cap (2)

and disconnect the oil delivery and return pipes
(1).
Printed 603.95.397 Base - 10/2013

.790510. Replace air compressor on vehicle

Removal
❏ Remove the power steering pump as described in
❏ Drain the engine cooling circuit.
Figure 80
173599
❏ Remove the fuel filter (5) as described in the

❏ To facilitate removal of the air compressor (3),
remove the engine ignition pushbutton panel (7)
by operating on the fastening screws (6).
❏ Disconnect the air pipe (2) and the pipes (8) from
the compressor (3).
❏ Disconnect the water pipe (1) from the compressor
(3).
❏ Disconnect the air delivery pipe from the fastening
brackets on the engine head.
❏ Unscrew the fastening screws (4) and disconnect
the air compressor (3).
Refitting
Fill up the engine cooling circuit and carry out
the bleeding procedure as described in the
Base - 10/2013 Printed 603.95.397

NEW 682
PT. CHAKRA JAWARA ENGINE 35
Engine
Page
ENGINE VIEWS ................................................. 39
TECHNICAL NAME ............................................ 42

CHARACTERISTIC CURVES ............................ 43
FUEL SUPPLY ................................................... 46
SUPPLY DIAGRAM ............................................ 47
❏ Mechanical feed pump ................................. 48

❏ CP3 high pressure pump ............................. 49
❏ Rail (pressure accumulator) ......................... 53
❏ Electro-injector ............................................. 53
LUBRICATION SYSTEM LAYOUT .................... 54
❏ Oil pump ....................................................... 55

❏ Safety valve .................................................. 55
❏ Oil pressure regulator valve ......................... 56
❏ Heat exchanger ............................................ 56
❏ Engine oil filter .............................................. 57
❏ Filter by-pass valve ...................................... 57
❏ Oil vapour recirculation (Blow-by) ................ 58
COOLING ........................................................... 59
❏ Description ................................................... 59
❏ Water pump .................................................. 60
❏ Thermostat ................................................... 60
❏ TURBOCHARGING ..................................... 61
❏ Description ................................................... 61
❏ Turbocharge ................................................. 62
ENGINE BRAKE DEVICE CEB
(Combined Engine Brake) ............................ 62
ENGINE CHARACTERISTICS ........................... 63

ASSEMBLY DATA - CLEARANCES .................. 65
TIGHTENING TORQUES ................................... 71
❏ Layouts of tightening sequence for engine
main parts..................................................... 74
TOOLS ................................................................ 82
EQUIPMENT MODIFIED TO BE SUITED TO
CURSOR 9 ENGINE .................................... 89
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Page Page
ENGINE REMOVAL - REFITTING ..................... 93 ❏ Oil nozzle removal ........................................ 107
❏ Removal ..................................................... 93 REPAIR OPERATIONS CYLINDER BLOCK ..... 107
❏ Refitting ...................................................... 99 ❏ Crankcase checks ........................................ 107

ENGINE DISASSEMBLY ON BENCH ................ 100 ❏ Cylinder liner checks and measurements .... 107
❏ Heat exchanger removal .............................. 100 ❏ Cylinder liners ............................................... 109
❏ Electrical components disassembly ............. 100 ❏ Cylinder liners replacement .......................... 111
❏ Starter motor replacement ............................ 100 ❏ Disassembly ................................................. 111
❏ Air conditioner compressor drive belt removal ❏ Refitting and protrusion check ...................... 111
❏ Alternator removal ........................................ 101 ❏ Crankshaft measurements ........................... 112

❏ Water pump removal .................................... 101 ❏ Main Journal measurement .......................... 113
❏ Thermostat case removal ............................. 101 ❏ Crank pin measurement ............................... 113
❏ Oil filter removal............................................ 102 ❏ Preliminary measurement for main half-bearing
selection ....................................................... 114
❏ Turbocharger removal .................................. 102
❏ Preliminary measurement for connecting rod
❏ Exhaust manifold removal ............................ 102 half-bearing selection ................................... 114
❏ Intake manifold removal ............................... 102 ❏ Main half-bearing selection .......................... 115
❏ Fuel filter removal ......................................... 102 ❏ Main connecting rod half-bearing selection .. 115
❏ ECU removal ................................................ 102 ❏ Definition of the diameter class of the main
journals (nominal diameter) .......................... 116
❏ Blow-by case removal .................................. 102
❏ Definition of the diameter class of the main
❏ Blow-by filter removal ................................... 102 crankpins (nominal diameter) ....................... 116
❏ High pressure pump removal ....................... 103 ❏ Replacing timing and oil pump control gear . 121
❏ Engine flywheel removal .............................. 103 ❏ Checking main journal assembly clearance . 121
❏ Oil sump removal.......................................... 104 ❏ Crankshaft thrust clearance check ............... 122
❏ Suction strainer removal ............................... 104 PISTON CONNECTING ROD ASSEMBLY
OVERHAUL .................................................. 123
❏ Flywheel case removal ................................. 104
❏ Piston ring removal ....................................... 123
❏ Oil pump removal ......................................... 104
❏ Piston diameter measurement ..................... 123
❏ Rocker arm shaft removal ............................ 105
❏ Measuring the piston pin diameter ............... 124
❏ Rail removal .................................................. 105
❏ Measuring circlips ......................................... 125
❏ Injector removal ............................................ 105
❏ Connecting rod checks ................................. 126
❏ Camshaft removal ........................................ 105
❏ Installing the connecting rod-piston assembly
❏ Cylinder head removal ................................. 105
❏ Installing the piston rings .............................. 129
❏ Conrod-piston unit removal ......................... 106
❏ Assembling connecting rod-piston assemblies
❏ Crankshaft removal ...................................... 107 in the cylinder liners ...................................... 130
❏ Main bearings removal ................................. 107 ❏ Checking crankpin assembly clearance ....... 131
Base - 10/2013 Printed 603.95.397

NEW 682
Page Page
CYLINDER HEAD OVERHAUL .......................... 131 ❏ Injector assembly ......................................... 149
❏ Valve removal............................................... 131 ❏ Pulser ring timing ......................................... 150

❏ Checking cylinder block head contact surface ❏ Fitting the blow-by filter ................................ 150
❏ Valve descale and check ............................. 132 ❏ Adjusting intake and exhaust rocker
arm clearance .............................................. 151
❏ Replacing the valve guides .......................... 132
❏ Fitting the blow-by box ................................. 151
❏ Replacing - Regrinding valve seats ............. 133
❏ Tappet cover assembly ................................ 152
❏ Injector holder replacement.......................... 133
❏ Suction strainer assembly ............................ 153
❏ Disassembly ................................................. 133
❏ Oil sump assembly ....................................... 153
❏ Injector holder assembly .............................. 134
❏ Water pump assembly ................................. 153
❏ Valve spring check ....................................... 136
❏ Thermostat box assembly ............................ 153
❏ Valve assembly ............................................ 136
❏ Alternator assembly ..................................... 153
❏ Mounting the oil seal ring ............................. 136
❏ Water pump drive belt assembly .................. 154
COMPLETE TIMING SYSTEM OVERHAUL...... 137
❏ Climate control compressor drive belt
❏ Timing system drive ..................................... 137 disassembly ................................................. 154
❏ Idler gear pin ................................................ 137 ❏ ECU assembly ............................................. 154
❏ Idler gear ...................................................... 137 ❏ Intake manifold assembly............................. 154
❏ Twin idler gear .............................................. 137 ❏ Fuel filter installation .................................... 154
❏ Bushing replacement ................................... 137 ❏ Oil filter assembly ......................................... 155

❏ Checking camshaft, cam lift and journal ❏ Turbocharger assembly ............................... 155
alignment ...................................................... 138
❏ Exhaust manifold assembly ......................... 155
❏ Camshaft bushes check ............................... 139
❏ Alternator assembly ..................................... 155
❏ Replacing camshaft bushes using tool
99360505 ..................................................... 140 ❏ Water pump assembly ................................. 155
❏ Valve assembly ............................................ 140 ❏ Thermostat assembly ................................... 155
❏ Mounting the oil seal ring ............................. 140 ❏ Heat exchanger ............................................ 155
❏ Rocker arm shaft check ............................... 141 ❏ Electrical components assembly .................. 156
❏ Shaft ............................................................. 141 ❏ Replace oil filter cartridge............................. 157
ENGINE ASSEMBLY.......................................... 142
❏ Cylinder head assembly ............................... 142

❏ High pressure pump assembly..................... 144
❏ Engine flywheel assembly ............................ 144
❏ Camshaft assembly ...................................... 146
❏ Pulser ring and camshaft timing ................... 147
❏ Rocker arm shaft assembly.......................... 148
❏ Rail installation ............................................. 149
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Base - 10/2013 Printed 603.95.397

NEW 682
ENGINE VIEWS
Figure 1
12569
LEFT SIDE VIEW
Figure 2
12569
RIGHT SIDE VIEW
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Figure 3
11304
FRONT VIEW (without fan)
Figure 4
12569
REAR VIEW
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 5
12569
TOP SIDE VIEW
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
TECHNICAL NAME
TYPE
F 2 C E 0 6 8 1 B * B 0 5 2
Variant number in D.B.
Level of gas emissions
Power level
B Euro 3
Use (1 truck)
Fuel system + injection (TCA, direct injection diesel
Number of cylinders
A 290 HP
B 340 HP
Stroke and cylinder position
Engine F 380 HP
Engine family evolution (also irrespective of the
Engine family indication
Base - 10/2013 Printed 603.95.397

NEW 682
CHARACTERISTIC CURVES
Figure 6
300
250
200
150
100
50
0
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
1700
1500
1300
1100
900
700
500
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
17196
CHARACTERISTIC CURVES F2CE0681A
Maximum POWER 213 kW 290 HP at 2100 rpm
Maximum TORQUE 1200 Nm 122 kgm at 1000 ÷ 1780 rpm
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Figure 7
300
250
200
150
100
50
0
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
1700
1500
1300
1100
900
700
500
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
17197
CHARACTERISTIC CURVES F2CE0681B
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 8
300
250
200
150
100
50
0
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
1700
1500
1300
1100
900
700
500
500 700 900 1100 1300 1500 1700 1900 2100 2300
Speed [rpm]
17197
CHARACTERISTIC CURVES F2CE0681F
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
5420 FUEL SUPPLY

The Common Rail supply system has a special pump that continuously keeps fuel at high pressure, independently
from stroke and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors.
At the electro-injector inlet therefore, there is always fuel at the injection pressure calculated by the control unit.
When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from
rail takes place in the related cylinder.
Figure 9
12630
9
A. Return circuit
B. Delivery circuit
Base - 10/2013 Printed 603.95.397
NEW 682
5420 SUPPLY DIAGRAM
Figure 10
200108
1. High pressure pump - 2. Fuel filter - 3. Tank – 4. Water/fuel separator – 5. Water sensor presence -
6. Fuel pre-filter - 7. Control unit - 8. Electro-injectors - 9. Overpressure sensor – 10. Common Rail -
11. Pressure sensor
After fitting the high pressure pipes, check frequently the engine oil level for the following 20 hours of
operation. (IT MUST NOT INCREASE).
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
773010 Mechanical feed pump Normal operating conditions

Gear pump, fitted on the rear side of the high pressure
pump and used to supply it. It is driven by the high Figure 13
pressure pump shaft.
Normal operating conditions

Figure 11
72594
The by-pass valve (2) cuts in when, with engine off,

the fuel system shall be filled through the priming
pump. In this situation the by-pass valve (1) stays
closed whereas by-pass valve (2) opens due to inlet
72592 pressure, and fuel is drained out through B.
A Fuel inlet from tank, B Fuel outlet to filter, 1 - 2 by-
pass valves in close position.
NOTE The mechanical supply pump cannot be

replaced individually, therefore it cannot be
removed from the high pressure pump.
Overpressure condition at outlet

Figure 12
72593
By-pass valve (1) opens in the presence of

overpressure at the outlet B. The pressure of the fuel
overcomes the force exerted by the spring of the valve
(1), thereby placing the pump outlet in communication
with the inlet by way of passage (2).
Base - 10/2013 Printed 603.95.397

NEW 682
771010 CP3 high pressure pump

Pump with 3 radial pistons controlled by the timing
gear, without needing any setting. The mechanical
supply pump controlled by the high pressure pump
shaft is fitted on the rear side of the high pressure
pump.
The following work must be carried out on the feed pump - high-pressure pump assembly
❏ replacing the drive gear;
❏ replacing the pressure regulator.
Figure 14
72595
1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Pressure regulator - 4. Control gear
5. Fuel inlet fitting from filter - 6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit
heat exchanger - 8. Fuel outlet fitting from supply pump to filter - 9. Mechanical feed pump.
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
High-pressure pump - internal structure
Figure 15
B-B sect ion
C-C sect ion
70498
1. Cylinder. - 2. Three-lobe element - 3. Cap intake valve. - 4. Ball delivery valve. - 5. Piston. - 6. Pump
shaft. -
7. Low-pressure fuel inlet. - 8. Plungers supplying fuel ducts.
Every plunger unit is composed of: ❏ cap intake valve (3);

❏ a piston (5) actuated by a three-lobe element (2) ❏ ball delivery valve (4).
floating on the pump shaft (6). The element (2), as
it floats on a misaligned part of the shaft (6), when
the shaft rotates, does not rotate with it but is only
translated in a circular movement along a wider
radius, with the result of alternatively activating the
three pumping elements;
Base - 10/2013 Printed 603.95.397

NEW 682
Operating principle
Figure 16
B-B sect ion
72597
D-D sect ion
1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Plunger - 4. Pump shaft - 5. Plunger supply
duct -
The plunger (3) is oriented to pump shaft (4) cam. l d pressure
6 P l t t 7 P regulator (7). l t The pressure regulator,
During intake, the plunger is supplied through supply according to the PWM command received from the
duct (5). control unit, chokes the flow of fuel to the plunger.
The fuel amount to be sent to the plunger is set by the
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Figure 17 Figure 18
72598
C-C section A-A sect ion
72601
1. Plunger inlet - 2. Pump lubrication ducts - 3. Plunger 1. Fuel outlet duct - 2. Fuel outlet duct - 3. Fuel outlet
inlet - 4. Main plunger supply duct - 5. Pressure from pump with high pressure pipe fitting for common
regulator - rail.
6. Plunger inlet - 7. Regulator exhaust duct - 8. 5 bar
pressure relief valve - 9. Fuel drain from regulator inlet. Figure 18 shows high pressure fuel flow through
A Fuel inlet from tank, B Fuel outlet to filter, 1 - 2 by- plunger outlet ducts.
pass valves in close position.
Figure 17 shows low pressure fuel paths inside the

pump and highlights: main plunger supply duct (4),
plungers supply ducts (1 - 3 - 6), pump lubrication
ducts (2), pressure regulator (5), 5 bar pressure relief
valve (8) and fuel return duct (7).
Pump shaft is lubricated by fuel through delivery and
return ducts (2).
The pressure regulator (5) establishes the quantity of
fuel with which to feed the pumping elements; The
excess fuel flows out through the duct (9).
5 bar pressure relief valve acts as fuel return collector
and keeps 5 bar constant pressure at regulator inlet.
Base - 10/2013 Printed 603.95.397

NEW 682
Operation 774510 Rail (pressure accumulator)

The cylinder is filled through the cap intake valve only
if the supply pressure is suitable to open the delivery
Figure 19
valves set on the plungers (about 2 bars).
The amount of fuel feeding the high-pressure pump is
metered by the pressure regulator on the low-pressure
system; the pressure regulator is governed by the
control unit EDC 7 via a PWM signal.
When fuel is sent to a plunger, the related piston is
moving downwards (suction stroke). When the piston
stroke is reversed, the intake valve closes and the
remaining fuel in the plunger chamber, not being able
to come out, is compressed above the supply pressure
value existing in the rail.
The thereby-generated pressure makes the exhaust 114254
valve open and the compressed fuel reaches the high-
pressure circuit. 1. Rail - 2. Fuel return - 3. Pipes to injectors - 4. Fuel
The plunger compresses the fuel till the top dead inletfrom high-pressure pump - 5. Pressure sensor -
center (delivery stroke) is reached. Afterwards, the 6. Overpressure valve.
pressure decreases till the exhaust valve is closed. The rail volume is of reduced size to allow a quick
The plunger piston goes back towards the bottom pressurisation at start-up, at idle and in case of high
dead center and the remaining fuel is decompressed. flow-rates.
When the plunger chamber pressure becomes less It anyway has enough volume as to minimise
than the supply pressure, the intake valve is again pulsations caused by injectors openings and closings
opened and the cycle is repeated. and by the high-pressure pump operation. This
The delivery valves must always be free in their function is further enabled by a calibrated hole being
movements, free from impurities and oxidation. set downstream of the high-pressure pump.
The pressure delivered to the rail is modulated by the A fuel pressure sensor (5) is screwed to the rail. The
control unit by means of the pressure regulator signal sent by this sensor to the electronic control unit
solenoid valve. is a feed-back information, depending on which the rail
The pump is lubricated and cooled by the fuel. pressure value is checked and, if necessary,
The radialjet pump removal - refitting time on the corrected.
engine is highly reduced in comparison with traditional
injection pumps, because it does not require setting.
If the pipe between fuel filter and high-pressure pump 775010 Electro-injector
is to be removed - refitted, be sure that hands and
components are absolutely clean.
Figure 20
114255
1. Fuel return hole - 2. Fuel delivery
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
5430 LUBRICATION SYSTEM LAYOUT
Figure 21
Oil dropping
Oil under pressure
17197
3
Base - 10/2013 Printed 603.95.397

NEW 682
543010 Oil pump 543076 Safety valve

Figure 22 Figure 24
190 + 6N
324 + 9N
43.65
33.5
25.5
22.95
117716
114245
The oil pump (1) shall not be overhauled. If you find

MAIN DATA TO CHECK THE SAFETY
any damage, replace the entire oil pump.
VALVE SPRING
To change the gearing (2) of the crankshaft, see the
relevant section.
Figure 23
11232
7
OIL PUMP SECTION

1. Safety valve - Start of opening pressure 10.1 ± 0.7 bar
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
543075 Oil pressure regulator valve Figure 27

Figure 25
168 ± 9
308 ± 15
63
51
36.4
73542
88819
The oil pressure relief valve is located on the left-hand MAIN DATA TO CHECK THE OIL PRESSURE
side of the crankcase. ADJUSTMENT VALVE SPRING
Start of opening pressure 5 bar.
543110 Heat exchanger
Figure 26
11424
6
1. Exchanger gasket - 2. Heat exchanger internal element - 3. Cover -

4. Oil filter - 5. Oil filter gasket
Base - 10/2013 Printed 603.95.397

NEW 682
543070 Engine oil filter
Figure 28
1. Closing cap - 2. Cartridge - 3. Spring - 4. Support O-ring - 5. Tub O-ring - 6. Washer - 7. Washer - 200109
8. Support - 9. M14x1.5 plug - 10. By-pass valve 3.4 bar
Characteristics
543077 Filter by-pass valve
1. Maximum operating pressure: 13 bar
2. Operating temperature: -30 °C ÷ +120 °C Figure 29
3. Bypass valve opening pressure: 3.4 ± 0.3 bar
Tightening torques
Cap (detail 1): 60 ± 5 Nm
Plug (detail 9): 30 ± 5 Nm
Plug (detail 10): 90 ± 5 Nm
Assembly standard
Use thread-lock adhesive for the plug (detail 10).
73545
The valve quickly opens at a pressure of: 3.4 + 0.3

bar.
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
5404 Oil vapour recirculation (Blow-by)

Part of the gas produced by combustion leaks out of the piston gaskets into the sump and mixes with the oil vapour
it contains.
This mixture is conveyed upwards and is partially separated from the oil by a device located at the top of the timing
system cover and sent into the air intake circuit.
The device basically comprises a rotating filter keyed onto the camshaft and by a front cover housing the normally
closed valves which control the mixture flow.
Figure 30
11424
Gas with oil content greater than 10 g/hOil 8
Gas with oil content greater than ~ 0.2 g/h

Condensed oil returning to the oil sump
Base - 10/2013 Printed 603.95.397

NEW 682
5432 COOLING
Description
The engine cooling system is forced-circulation closed-circuit type.
It mainly consists of the following components:
❏ expansion tank;
❏ a heat exchanger to cool the lubricating oil;
❏ a centrifugal water pump incorporated in the crankcase;
❏ fan not supplied;
❏ a 2-way thermostat regulating the circulation of the coolant.
Operation
The water pump driven by a poly-V belt by the crankshaft sends coolant into the crankcase and with a greater head
into the cylinder head.
When the coolant temperature reaches and exceeds the working temperature, it causes the thermostat to open
and the fluid is channelled from here to the radiator and cooled by the fan.
Pressure inside the system, due to temperature change, is properly adjusted through expansion tank.
Figure 31
17197
4
Water leaving the thermostat
Water circulating in the engine
Water coming into pump
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
543210 Water pump

Figure 32 Figure 34
45358
Check that the thermostat works properly, replace it if

114250 there is any doubt.
SECTION ON WATER PUMP Travel start temperature 84 ºC ± 2 ºC.
Minimum travel 15 mm and 94 ºC ± 2 ºC
The water pump is composed of: impeller, shaft with
bearing, T gasket and control pulley with dust guard.
NOTE Check that the pump casing shows no sign

of cracking or water leakage; replace the
water pump assembly if it does.
543250 Thermostat
Thermostat operation view
Figure 33
45357
Base - 10/2013 Printed 603.95.397

NEW 682
5424 TURBOCHARGING
The turbocharging system is composed of: ❏ a turbocharger;
❏ an air filter; ❏ an intercooler radiator
Figure 35
Exhaust gas
Hot compressed air
Intake air
Intake compressed air
17197
5
543077 Filter by-pass valve
Description
The turbocharger comprises the following main parts: The turbocharger is fitted with a pressure regulator
a turbine, a turbocharged pressure regulator valve, a valve places on the exhaust manifold before the
central body and a compressor. turbine, and connected to the intake manifold by
During engine operation, the exhaust gases pass means of a pipe.
through the turbine body spinning the turbine rotor. Its purpose is to choke the exhaust gas outlet, by
The compressor rotor is connected by a shaft to the conveying part of the gas directly into the exhaust
turbine rotor, which it spins and in doing so pipe, when the boosting pressure downstream the
compresses the air taken in through the air filter. compressor reaches the prescribed bar value.
The air coming out of the compressor is sent through Cooling and lubrication of the turbocharger and the
the intake manifold directly to the pistons. bearing brass is performed by means of the engine oil.
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
542410 Turbocharger 5437 ENGINE BRAKE DEVICE CEB

(Combined Engine Brake)
Figure 36
Figure 38
71766
Holset HX 40
125814
Figure 37
In engines with fixed a geometry turbine and
wastegate, to improve the performance of the
decompression exhaust brake Iveco Turbo Brake
(ITB), the CEB (Combined Engine Brake) has also
been added.
For this purpose, a throttle valve activated by a
pneumatic cylinder is located in the engine's exhaust
manifold.
When the driver activates the engine brake, the throttle
valve actuates, blocking the exhaust gas outlet.
The exhaust gas thus returns to the cylinder where it
provides resistance to the up stroke of the piston.
This resistance extends throughout the entire
kinematic chain, applying a braking effect on the
driving wheels.
166358
Holset HX 52W
The turbocharger is fitted with pressure relief valve.

Essentially it consists of:
❏ a central body in which a shaft is housed,
supported by bushings, the ends of which are
connected to: the turbine rotor and the compressor
rotor;
❏ a turbine casing and a compressor casing mounted
on the end of the central body;
❏ a pressure limiter valve fitted on the turbine casing.
Its function is to choke the exhaust gas outlet,
conveying a portion of it straight into the exhaust
pipe when the turbocharging pressure downstream
from the compressor reaches the setting value.
Base - 10/2013 Printed 603.95.397

NEW 682
ENGINE CHARACTERISTICS
F2CE0681A F2CE0681B3 F2CE0681F

Type
290 HP 340HP 380 HP
Cycle Diesel 4-stroke

Supply Turbocharged with intercooler
Injection Direct
Number of cylinders 6 in line

Bore mm 117
Stroke mm 135
3
+ + +.. = Total displacement cm 8710
Ratio of compression 1 : 15.9 ± 0.8

Max. power kW
213(290) 250(340) 279(380)
(HP)
rpm 2100 2100 2100
Maximum torque Nm
1200(122) 1200(122) 1500(153)
(kgm)
rpm 1500 1500 1500
Low idle speed

rpm 600
of engine with no load
Maximum running
speed rpm 2420
of engine with no load
TURBOCHARGING Intercooler
Direct injection
Turbocharger type HX40 HX52W HX52W
LUBRICATION
Oil pressure with engine
Forced by gear pump, pressure relief valve, oil filter
warmed up
bar
at idle speed bar 2
at max speed bar 5
COOLING
Water pump drive: Belt driven
Thermostat: Fluid
initial opening °C 85°
FILLINGS
Urania Total capacity
st
FE5W30 1 filling
Urania LD7 litres 25
kg 22,5
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Type F2C
A
TIMING SYSTEM
Start before T.D.C. A 17°

End after B.D.C. B 31°
B
Start before B.D.C. D 48°
End after T.D.C. C 9°
mm -
For timing check X
mm -
X
mm 0.35 ÷ 0.45
For operation X
mm 0.55 ÷ 0.65
High pressure fuel feed system BOSCH EDC7.

Composed of CP 3.3 high-pressure pump, electro-
POWER SUPPLY
injectors,hydraulic accumulator (rail), EDC7 control
unit, pressure and temperature sensors
Electro-injectors type CRIN3
Firing order 1-4-2-6-3-5
bar
Injection pressure bar
1600
Injector calibration bar
Base - 10/2013 Printed 603.95.397

NEW 682
ASSEMBLY DATA - CLEARANCES
Type F2C
CYLINDER ASSEMBLY AND CRANK GEARS mm

∅1 Cylinder liner housing:
upper 130.500 ÷ 30.525
∅1
lower 129.510 ÷ 129.535
* Cylinder liners:
outer diameter:
L upper 130.461 ÷ 130.486
∅2
lower 129.475 ÷ 129.500
∅2 length L 226.15
Cylinder liners -
crankcase seats
upper 0.014 ÷ 0.064
lower 0.010 ÷ 0.060
Outer diameter ∅2 _
∅3 Cylinder liners:
A* 117.000 ÷ 117.012
X inner diameter ∅3
B* 117.010 ÷ 117.022
Overhang
X* 0.035 ÷ 0.065
(with load of 6,000 kg)
Piston - cylinder liners
A* 0.094 ÷ 0.118
B* 0.094 ÷ 0.118
Piston diameter ∅1 _
∅3 Piston pin ∅3 51.994 ÷ 52.000
Piston pin - pin seat 0.010 ÷ 0.022

* It indicates the selection class
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
F2C
Type
mm
X1 X1 3.120 ÷ 3.140
X 2 Piston ring slots X2 2.550 ÷ 2.570
X 3 X3 4.020 ÷ 4.040
S1 Piston rings:
S2 Trapezoidal sealing S1 3000
S3 Bevelled S2 2.470 ÷ 2.500
Scraper ring S3 3.970 ÷ 3.990
1 -
Piston rings - slots 2 0.050 ÷ 0.100
3 0.030 ÷ 0.070
Piston rings -
X1 Piston ring end gap inside the

X2 cylinder liner:
X3 X1 0.30 ÷ 0.40
X2 0.60 ÷ 0.75
X3 0.5 ÷ 0.65
∅1 Small end bushing seat Ø 1 55.700 ÷ 55.730
Connecting rod bearing

Ø2 85.987 ÷ 86.013
seat
∅2
1 85.987 ÷ 85.996
Ø selection classes 2 85.997 ÷ 86.005
3 86.006 ÷ 86.013
∅4 Bushing diameter at connecting
rod small end
∅3 external ∅4 55.780 ÷ 55.820
internal ∅3 52.015 ÷ 52.030
S Connecting rod
half-bearings S
Red colour 1.994 ÷ 2.002
Green colour 2.002 ÷ 2.010
Yellow colour* 2.010 ÷ 2.018
Small end bushing - housing 0.05 ÷ 0.08
Piston pin - bushing 0.015 ÷ 0.036
Connecting rod half-bearings 0.127 - 0.254 - 0.508
Connecting rod weight

A g. 3450 ÷ 3470
Class B g. 3471 ÷ 3490
C g. 3491 ÷ 3510
* Factory-assembled only, and not provided with spare parts
Base - 10/2013 Printed 603.95.397

NEW 682
F2C
Type mm
X Measuring point X 125
Maximum error on = 0.08

alignmentof connecting rod
center lines
Main journals
- rated 92.970 ÷ 93.000
- class 1 Ø1 92.970 ÷ 92.980
- class 2 92.980 ÷ 92.990
- class 3 92.990 ÷ 93.000
∅1 ∅2 Crankpins
- rated 81.915 ÷ 81.945
- class 1 Ø2 81.915 ÷ 81.925
- class 2 81.925 ÷ 81.935
- class 3 81.935 ÷ 81.845
S1 S2 Main half-bearings
Red colour 2.968 ÷ 2.978
S1
Green colour 2.978 ÷ 2.988
Yellow colour* 2.988 ÷ 2.998
Connecting rod half-
bearings
1.994 ÷ 2.002
Red colour S2
2.002 ÷ 2.010
Green colour
2.010 ÷ 2.018
Yellow colour*
Main housing
99.000 ÷ 99.030
- rated
99.000 ÷ 99.009
3 - class 1 Ø3
99.010 ÷ 99.019
- class 2
99.020 ÷ 99.030
- class 3
Main journals - half-bearings 0.050 ÷ 0.090
Crankpin half - bearings 0.040 ÷ 0.080
Main half-bearings 0.127 * - 0.254 - 0.508
Connecting rod half-bearings 0.127 * - 0.254 - 0.508
Thrust main journal X1 39.96 ÷ 40.04

X1
Thrust main housing X2 38.94 ÷ 38.99

X2
X3
Thrust washer halves X3 3.38 ÷ 3.43
Crankshaft thrust 0.10 ÷ 0.30
1 2
Alignmen // 1-2 -
t
Centring 1-2 0.04
Taper 1-2 -
* Factory-assembled only, and not provided with spare parts
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Type F2C
CYLINDER HEAD - TIMING SYSTEM mm

∅1 Valve guide housing on cylinder
head
∅1 12.980 ÷ 12.997
∅2 Valve guides
Inner diameter ∅2 8.023 ÷ 8.038
Outer diameter ∅3 13.012 ÷ 13.025

∅3
Valve guide outer diameter -

0.015 ÷ 0.045
seats on head
Valve guide oversizes 0.2 ÷ 0.4
∅4 Valves:
∅2 7.970 ÷ 7.985
α 60° 30′ ± 7° 30″
∅2 7.970 ÷ 7.985
+ 15’
α 45° - 0°
α
Valve stem and associated guide
Housing on head for valve seat:
∅1 41.985 ÷ 42.020
∅1 40.985 ÷ 41.020
∅1
Valve housing outer diameter;

∅2 valve housing inclination on
cylinder head:
∅2 42.060 ÷ 42.075
α
+ 15’
°60° - 30’ -0
∅2 41.060 ÷ 41.075
α 0’- 0.5’
α 45° - 30’
X 0.5 ÷ 0.8
Recess
X X 1.6 ÷ 1.9
Between valve seat

0.040 ÷ 0.090
and cylinder head
Base - 10/2013 Printed 603.95.397

NEW 682
Type F2C
mm
Valve spring height:
H 71.34
under a load of:
N 460 ± 22 H1 51
N 731.4 ± 42 H2 39
Camshaft bush housing fitted
in the cylinder head:
1⇒7 Ø 69.00 ÷ 69.030

  
∅ 2 Camshaft journals:
1⇒7 Ø 64.924 ÷ 64.940

∅ 1 ∅3
Camshaft bushing outer

diameter:

Ø 69.090 ÷ 69.130
Bushing inner diameter

 ∅ 65.080 ÷ 65.116
Bushings and seats in cylinder

0.060 ÷ 0.130
head
Bushings and supporting pins 0.100 ÷ 0.192
Useful cam height:
7.4034
H
8.2108
∅ 1 Rocker-arm shaft
∅1 31.964 ÷ 91.980
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
F2CE0641A F2CE0641B F2CE0641F

Type
mm mm mm
Bushing housing in rocker

arms:
32.025 ÷ 32.041
 32.025 ÷ 32.041
Bushes and housings:

0.045 ÷ 0.077
0.045 ÷ 0.077
Engine brake control

lever
Eccentric pin outer
∅2 32.03 ÷ 32.04
diameter
Rocker arm shaft seat ∅1 43.98 ÷ 44.00
0.04 ÷ 0.076
TURBOCHARGER
Type HX40 HX52W
End play 0.025 ÷ 0.127 0.025 ÷ 0.127
Radial play 0.330 ÷ 0.508 0.406 ÷ 0.610
Base - 10/2013 Printed 603.95.397

NEW 682
TIGHTENING TORQUES
PART TORQUE
Nm (Kgm)
Union for piston cooling nozzle M12x1.5 35 ± 2 (3.5 ± 0.2)
Screws securing heat exchanger M12x1.75 63 ± 7 (6.3 ± 0.7)
Cap M42x1.5 125 ± 15 (12.5 ± 1.5)
Spacer and oil sump fastening screws M10x1.5 41.5 ± 3.5 (4.1 ± 0.3)
Screws fixing gearbox to crankcase:
M10x1.25 41.5 ± 3.5 (4.1 ± 0.3)
M12x1.75 63 ± 7 (6.3 ± 0.7)
M8x1.25 23.5 ± 1.5 (2.3 ± 1.5)
Screw fixing cylinder head ♦
First stage pre-tightening 50 (5)
Second stage pre-tightening 100 (10)
Third stage closing to angle 90°
Fourth stage closing to angle 75°
M12x1.75x13
Screw fixing rocker arm shaft 104.5 ± 10.5 (10.4 ± 1)
0
Locknut for rocker arm adjusting screw ♦ 39 ± 5 (3.9 ± 5)
Screws for electro-injector fastening brackets ♦ M10x45 41 ± 3 (4.1 ± 0.3)
Shoulder plate fastening screws to head ♦ 23.5 ± 3.5 (2.3 ± 0.3)
Screws fixing engine support bracket to cylinder head 74 ± 8 (7.4 ± 0.8)
Screws fixing timing gear • M10x1.5x45
First stage pre-tightening 25 (2.5)
Second stage closing to angle 45°
Screws fixing pulser ring to timing gear M8
pre-tightening 10 (1.0)
tightening 28.5 ± 3.5 (2.8 ± 0.3)
Exhaust manifold fastening screws •
pre-tightening 32.5 ± 7.5 (3.2 ± 0.7)
tightening 47.5 ± 2.5 (4.7 ± 0.2)
Screws fixing connecting rod cap ♦ M12x1.25x69
Screws fixing engine flywheel ♦ M18x1.5x72
First stage pre-tightening 120 ± 6 (12 ± 0.6)
Second stage closing to angle 90° ± 4.5°
Screws fixing pulley flywheel to engine shaft ♦
Screws fixing connecting main bearing cap ♦ M16x2
Second stage closing to angle 60° + 60°
Flywheel guard fastening screws M10x1.5 41.5 ± 3.5 (4.1 ± 0.3)
Flywheel guard fastening screws M12x1.75 63 ± 7 (6.3 ± 0.3)
♦ Lubricate with MOLYKOTE oil before assembly
• Before assembly, lubricate with graphitized oil
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
PART TORQUE
Nm (Kgm)
Screws fixing damper flywheel ♦ 115 ± 15 (11.5 ± 1.5)
Screws securing middle gear pins ♦ M12x1.75x90
Screw fixing link rod for idler gear ♦ 24.5 ± 2.5 (2.4 ± 0.2)
Screw fixing oil pump 24.5 ± 2.5 (2.4 ± 0.2)
Screw fixing oil pump suction strainer 24.5 ± 2.5 (2.4 ± 0.2)
Screw fastening front cover to crankcase 19 ± 3 (1.9 ± 0.3)
Screw fastening control unit 19 ± 3 (1.9 ± 0.3)
Screw fastening fuel filter support to cylinder head ♦ M8x1.25x60 24.5 ± 2.5 (2.4 ± 2.5)
Screw securing the engine support to the gear case ♦
Turbocharger fastening screws and nuts •
pre-tightening 35 ± 5 (3.5 ± 0.5)
tightening 46 ± 2 (4.6 ± 0.2)
Front and rear engine suspensions fastening screws M16 268.5 ± 21.5 (26.85 ± 2.15)
Screw fixing water pump to crankcase 24.5 ± 2.5 (2.4 ± 0.2)
Screw fixing pulley to hub 55 ± 5 (5.5 ± 0.5)
Rocker arm cover fastening screws 8.5 ± 1.5 (0.8 ± 0.1)
Screws fixing thermostat box to cylinder head 24.5 ± 2.5 (2.4 ± 0.2)
Screws fixing automatic tensioner to crankcase 45 ± 5 (4.5 ± 0.5)
Screws fixing fixed tensioner to crankcase 105 ± 5 (10.5 ± 0.5)
Screws fixing fan support to crankcase 24.5 ± 2.5 (2.4 ± 0.2)
Screws fixing starter motor 44 ± 4 (4 ± 0.4)
Screws fixing air heater box to cylinder head 50 ± 5 (5 ± 0.5)
Nut for fastening high pressure pump gear 105 ± 5 (10.5 ± 0.5)
Screw fixing air-conditioner compressor to support 24.5 ± 2.5 (2.4 ± 2.5)
Screw securing upper alternator support 71.5 ± 3.5 (7.1 ± 0.4)
Screw fixing alternator bracket to crankcase 24.5 ± 2.5 (2.4 ± 0.2)
Water pipe fittings 24.5 ± 2.5 (2.4 ± 0.2)
Water temperature sensor 32.5 ± 2.5 (3.2 ± 0.2)
♦ Lubricate with MOLYKOTE oil before assembly
• Before assembly, lubricate with graphitized oil
Base - 10/2013 Printed 603.95.397

NEW 682
PART TORQUE
Nm (Kgm)
Flywheel rev sensor fastening screw 8±4 (0.8 ± 0.4)
Camshaft rev sensor fastening screw 8±4 (0.8 ± 0.4)
Electro-injector solenoid valve connector fastening screw 1.62 ± 0.3 (0.1 ± 0.3)
Overboost pressure sensor fastening screw 8±2 (0.8 ± 0.2)
Absolute pressure sensor fastening screw 22.5 ± 2.5 (2.2 ± 0.2)
P.W.M. control valve fastening screw/nut 8±2 (0.8 ± 0.2)
Fuel/coolant temperature sensor 35 ± 3.5 (3.5 ± 0.3)
Coolant temperature indicator 23.5 ± 2.5 (2.3 ± 0.2)
Filter clogging sensor 10 ± 1 (1 ± 0.1)
Oil temperature switch 25 ± 1 (2.5 ± 0.1)
Oil pressure sensor 25 ± 1 (2.5 ± 0.1)
Electric wire fastening screw 8±2 (0.8 ± 0.2)
Screws fixing engine suspensions M12x1.75x70
Oil filter body fastening screw M8 24.5 ± 2.5 (2.5 ± 0.2)
Alternator positive fastening nut M8x1.25 12.5 ± 2.5 (1.3 ± 0.3)
Starter motor terminal 30 nut M10x1.5 21 ± 3.4 (2.1 ± 0.3)
Starter motor terminal 50 nut M5x0.8 3.6 ± 1 (0.4 ± 0.1)
Sump fastening screw M10x1.5x45 41.5 ± 3.5 (4.2 ± 0.4)
Screws fixing engine suspension (R8.8) M14x2x50
Screw fixing engine suspension (R10.9) M14x2x50 167 ± 17 (16.7 ± 1.7)
Electro-injector bracket fastening screw M10x1.5x40 41 ± 2 (4.1 ± 0.2)
Screw securing upper alternator support 71.5 ± 3.5 (7.2 ± 0.4)
Screw fastening reinforcement plate to crankcase M10x1.25x20 49.25 ± 2.75 (4.91 ± 0.3)
Screw fastening SUCTION STRAINER/REINFORCEMENT
M10x1.25x25 49.25 ± 2.75 (4.91 ± 0.3)
PLATE to crankcase
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Layouts of tightening sequence for engine main parts
Figure 39
LAYOUT OF TIGHTENING SEQUENCE FOR LOWER CRANKCASE FASTENING SCREWS
SCREWS 1 SEQUENCE:
1st Step 140 + 6 Nm

2nd Step 600
3rd Step 600
SCREWS 2: 50 Nm
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 40
44900
CYLINDER HEAD FASTENING SCREW TIGHTENING DIAGRAM
Figure 41
136518
LAYOUT OF TIGHTENING SEQUENCE FOR ROCKER ARM SHAFTS FASTENING SCREWS
Figure 42
8 1 4 5 8 1 2 5 8 1 4 5
6 3 2 7 6 3 4 7 6 3 2 7
45359
LAYOUT OF TIGHTENING SEQUENCE FOR EXHAUST MANIFOLD FASTENING SCREWS
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Figure 43
DIAGRAM SHOWING THE TURBOCHARGER FIXING SCREWS AND NUTS TIGHTENING ORDER
45360
SEQUENCE: Pre-tightening 4–3–1–2
Tightening 1–4–2–3
Figure 44
45361
LAYOUT OF TIGHTENING SEQUENCE FOR HEAT EXCHANGER FIXING SCREWS

Figure 45
200110
LAYOUT OF TIGHTENING SEQUENCE FOR OIL SUMP FASTENING SCREWS
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 46
45363
LAYOUT OF TIGHTENING SEQUENCE FOR ROCKER ARM COVER FIXING SCREWS
Figure 47
151833
LAYOUT OF TIGHTENING SEQUENCE FOR SCREWS FASTENING THRUST PLATE TO CYLINDER HEAD
Figure 48
124510
LAYOUT OF TIGHTENING SEQUENCE FOR INTAKE MANIFOLD FASTENING SCREWS
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Figure 49
161259
LAYOUT OF TIGHTENING SEQUENCE FOR SCREWS FASTENING FLYWHEEL CASE TO CRANKCASE
Figure 50
151832
LAYOUT OF TIGHTENING SEQUENCE FOR THERMOSTAT FASTENING SCREWS
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 51
1365238
LAYOUT OF TIGHTENING SEQUENCE FOR AIR CONDITIONING COMPRESSOR FASTENING SCREWS
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Figure 52
136521
LAYOUT OF TIGHTENING SEQUENCE FOR ALTERNATOR FASTENING SCREWS
Figure 53
136519
LAYOUT OF TIGHTENING SEQUENCE FOR P.T.O. FASTENING SCREWS
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 54
169808
LAYOUT OF TIGHTENING SEQUENCE FOR PULSER RING FASTENING SCREWS
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
TOOLS
TOOL No. NAME
99322230 Rotary telescopic stand
99340051 Puller for crankshaft front gasket
99340054 Extraction tool for crankshaft rear gasket
99342149 Injector housing puller
99342157 Extraction tool for injectors
99346245 Key to fit crankshaft front gasket
Base - 10/2013 Printed 603.95.397

NEW 682
TOOL No. NAME
99346260 Key to fit crankshaft rear gasket
Pliers for piston ring removal and refitting

99360184 (105-160 mm)
99360264 Tool for engine valves removal and refitting
99360288 Punch for valve guide removal
99360292 Adjuster for gasket assembly on valve guide
99360294 Tool to drive valve guide

(use with 99360288)
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
TOOL No. NAME
Tool for checking cylinder liner protrusion

99360334 (to be used with 99370415 - 99395603 and special plates)
Cap for cylinder liners compression

99360335 (to be used with 99360334)
Tool for rotating the flywheel

99360341
99360500 Tool for lifting the crankshaft
99360505 Tool for camshaft bush assembly/disassembly
99360558 Tool to lift and transport rocker arm shaft
Base - 10/2013 Printed 603.95.397

NEW 682
TOOL No. NAME
99360585 Arm for engine removal and refitting
Belt to insert piston in cylinder liner

99360605 (60 - 125 mm)
99360612 Tool for engine T.D.C. positioning
99360613 Tool for timing of phonic wheel on timing

gear
99360703 Tool for cylinder liner fastening
99360706 Tool to extract cylinder liners
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
TOOL No. NAME
99360724 Ring (115 mm) (to be used with 99360706)
Brackets for fastening engine to 99322230 rotary stand

99361042
99365054 Tool for injector housing cold-heading
Set of 8 spanners with insert 14x18 (13-17-18-19-21-22-24-27-30

99368542 mm)
99370415 Tool for measuring cylinder liner protrusion

(to be used with 99395603)
99389833 14x18 coupling torque wrench (20-120 Nm)
Base - 10/2013 Printed 603.95.397

NEW 682
TOOL No. NAME
Dynamometric screwdriver (1-6 Nm) to calibrate screws

99389834 for injector solenoid valve
99390310 Sleeker for valve guide
99390772 Tool for removing injector holder deposits
99390804 Tool to thread injector housing to extract

(use with 99390805)
Reamer to rectify injector holder lower side

99394043 (to be used with 99394015)
Cutter to rectify injector holder housing (to be used

99394044 with 99394045)
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
TOOL No. NAME
Guide bush (to be used with 99394043 or 99394044)

99394045
Pair of gauges for angular tightening with 1/2” and 3/4”

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

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

99395222 camshaft and timing gear
99395223 Gauge for timing the camshaft
99395603 Dial gauge (0 - 5 mm)
Base - 10/2013 Printed 603.95.397

NEW 682
EQUIPMENT MODIFIED TO BE SUITED TO CURSOR 9 ENGINE
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Base - 10/2013 Printed 603.95.397

NEW 682
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Base - 10/2013 Printed 603.95.397

NEW 682
.540110. ENGINE REMOVAL – REFITTING

Removal
Figure 55
10
3 4
7 5
6 2
171961
Operations on the bottom:

❏ Drain the coolant in a suitable container by removing plug (8) from under the radiator.
❏ Drain the R134 A refrigerating gas from the climate control system by means of tool 99305146, connecting it to
the unions (9) on the evaporator pipes (10).
❏ Remove the piping (2) between radiator and water pump by operating on the metal clamps (1).
❏ Drain the power steering oil in a suitable container, disconnecting the oil delivery and return pipes (7); open the
power steering oil container plug (11, Figure 58) and remove the oil filter from inside the container.
❏ Remove the clamps from the cable bundle coming from the chassis to the starter motor (6) and disconnect the
electrical connection (3) of the starter motor (6).
❏ Disconnect the ground cable (5) and free the collar (4) holding the electrical cables on the crankcase in order
to be able to free the cable bundle.
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Operations on the top:

Figure 56
4
6
7
5
171962
❏ Disconnect the metal clamp (5) of the exhaust pipe (4) on the exhaust side.
❏ Disconnect the metal clamp (5) of the exhaust pipe (4) on the turbine side.
❏ Disconnect engine brake air delivery pipe (1).
❏ Unscrew the two screws (3) fastening the engine brake assembly to the bracket (2) on the chassis and remove
the air pipe of the engine brake by operating on fastening (1).
❏ Disconnect the compressor air delivery pipe (7) by operating on fastening (6).
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 57
171963
❏ Disconnect the pipe (7) coming from the water pump (6).
❏ Disconnect the air delivery intercooler sleeve (3) by operating on the metal clamps.
❏ Disconnect the air conditioning R134 A refrigerant gas delivery and return pipes (1) by unscrewing the
fastenings (2).
❏ Disconnect the intercooler (5) intake pipe (4).
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Figure 58
171964
❏ Disconnect the radiator breather pipe (1) from the engine side.
❏ Disconnect the sleeve (2) delivering water from the thermostat body to the radiator, by operating on the metal
clamps.
❏ Remove the bracket fastening the dipstick (4) to the radiator, operating on fastening (5).
❏ Remove the clamps and disconnect the alternator (8) positive cable (10) and its connector (9).
❏ Disconnect the electric connection (7) of the air conditioning compressor (6).
❏ Disconnect the electric connection (12) of the power steering oil level.
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 59
11 1
2
10
12
8
3
7
6 5
171965
❏ Disconnect the connectors (4) for start-up on the engine.
❏ Disconnect the diesel pipe (5) going from the tank to the union on the base of the high pressure pump.
❏ Disconnect the diesel pipe (12) going to the engine control unit (2).
❏ Disconnect the air intake pipe (8) going from the air filter to the engine, by operating on the fastenings (3-6).
❏ Disconnect the connection (1) going from the chassis to the engine control unit (2).
❏ Free the bracket (11) fastening the cab tilting pipes from the central bracket (9) supporting the cab.
❏ Unscrew the screws (10-7) from the central bracket (9) supporting the cab and remove it.
Printed 603.95.397 Base - 10/2013

ENGINE NEW 682
Figure 60
10
6 2
171966
❏ Unscrew the eight screws (1-3-6) fastening the engine mounts to the chassis from the support brackets (4-2-5).
❏ Fit tool 99360585 (10) to the eyelets located on the engine and lift the engine from the vehicle.
Base - 10/2013 Printed 603.95.397

NEW 682
❏ Reconnect the pipe (7, Figure 57) coming

from the water pump (6, Figure 57).
Refitting
❏ Reconnect the compressor air delivery pipe
(7, Figure 56) by operating on fastenings
Operations on the top: (6, Figure 56).
❏ Lower the engine in the chassis. ❏ Screw in the two fastening screws (3,
❏ Screw the eight screws fastening the Figure 56) of the engine brake assembly to
engine mounts (1-3-6, Figure 60) to the the bracket (2, Figure 56) on the chassis.
chassis at a torque of 167±17 Nm. ❏ Reconnect engine brake air delivery pipe
❏ Replace the central bracket (9, Figure 59) (1, Figure 56).
supporting the cab and screw in the ❏ Reconnect the metal clamp (5, Figure 56)
fastening screws. of the exhaust pipe (4, Figure 56) on the
❏ Replace and fasten the cab tilting pipe to turbine side.
the central bracket (9, Figure 59) ❏ Reconnect the metal clamp (5, Figure 56)
supporting the cab with bracket (11, Figure of the exhaust pipe (4, Figure 56) on the
59). exhaust side.
❏ Reconnect the diesel delivery pipe (12,
Figure 59) to the engine control unit (2, Operations on the bottom:
Figure 59). ❏ Apply clamps to the cable bundle going
❏ Reconnect the cable/connection (1, Figure from the chassis to the starter motor (6,
59) going from the chassis to the engine Figure 55).
control unit (2, Figure 59). ❏ Reconnect the electrical connection (3,
❏ Reconnect the air intake pipe (8, Figure 59) Figure 55) and the ground cable (5, Figure
going from the air filter to the engine, by 55) to the starter motor (6, Figure 55).
operating on the fastenings (3-6, Figure ❏ Tie the sealing collar (4, Figure 55) of the
59). electrical cable to the crankcase.
❏ Reconnect the diesel pipe (5, Figure 59) ❏ Reconnect the power steering oil delivery
going from the tank to the union on the and return pipes (7, Figure 55).
base of the high pressure pump.
❏ Reconnect the piping (2, Figure 55)
❏ Reconnect the connectors (4, Figure 59) for between radiator and water pump by
start-up on the engine. operating on the metal clamps (1, Figure
❏ Reconnect the electric connection (12, 55).
Figure 58) of the power steering oil level. ❏ Fit the radiator cap (8, Figure 55).
❏ Reconnect the electric connection (7, ❏ Fit the power steering oil container cap (11,
Figure 58) of the air conditioning Figure 55) with the filter inside it.
compressor.
❏ Fit caps to the air conditioning system
❏ Reconnect and place clamps on the evaporator pipes (9, Figure 55).
positive cable (10, Figure 58) of the
❏ Top up the power steering oil, coolant fluid
alternator (8, Figure 58) and on its
and R134 gas of the air conditioning
connector (9, Figure 58).
system.
❏ Reconnect the intercooler (5, Figure 57)
intake pipe (4, Figure 57).
❏ Reconnect the dipstick (4, Figure 58) to the
radiator, operating on fastening (5, Figure
58).
❏ Reconnect the sleeve (2, Figure 58)
delivering water from the thermostat body
to the radiator, by tightening the metal
clamps.
❏ Reconnect the radiator breather pipe (1,
Figure 58) from the engine side.
❏ Reconnect the air conditioning R134 A gas
delivery and return pipes (1, Figure 57) by
unscrewing the fastenings (2, Figure 57).
❏ Reconnect the intercooler air delivery
sleeve (3, Figure 57).
Printed 603.95.397 Base - 10/2013

100 ENGINE PT. CHAKRA JAWARA
NEW 682
.540110. ENGINE DISASSEMBLY ON BENCH . 760810. Starter motor replacement
Figure 62
NOTE Before fitting the engine on the 99322230
rotary stand, disassemble the parts which
could interfere with the assembly of the
brackets 99361042. Therefore, remove the
heat exchanger and the oil pipe as shown
below.
.543110. Heat exchanger removal
Figure 61
1
172609
Before assembling the engine on the rotating stand

99322230, remove the following elements:
❏ starter motor (1);
Figure 63
125700
Place a container to collect the coolant fluid under the

heat exchanger (2).
Slacken the fastening screws and remove the heat
exchanger assembly (2).
Remove the oil outlet pipe (1).
Fit the engine onto the revolving stand 99322230.
Drain off the oil from the sump into a special container.
Electrical components disassembly

114016
Disconnect the electrical components (see Figure 232).
Unscrew the fastening screws (2) and remove the

head cover (1) in order to access the rail and injector
wiring.
Base - 10/2013 Printed 603.95.397

NEW 682
.543910. Air conditioner compressor drive Figure 66

belt removal
Figure 64
125703
Remove the following parts:

❏ alternator (6);
❏ tensioner (5);
❏ air conditioner compressor (1);
125701
❏ flanged pipe (3);
Remove the fan. Cut the belt of the air conditioning
compressor (1), as it must not be used again. ❏ fixed belt tensioner (4);
Using a suitable tool (4), operate in the direction of the ❏ thermostat unit (2).
arrow, and remove the belt (5) driving water pump and
alternator.
Remove the screws and disassemble the pulley (2)
with the damper flywheel (3).
Figure 67
.760310. Alternator removal

.543210. Water pump removal
.543251. Thermostat case removal
Figure 65
114551
Fit puller 99340051 (2) and take off the seal (1).
Undo the screws and take off the front cover (3).
125702
Remove the water pump (2) and pulley (3) operating

on screws (1).
Printed 603.95.397 Base - 10/2013

NEW 682
.543070. Oil filter removal .766161. ECU removal

.542410. Turbocharger removal Figure 70
.540720. Exhaust manifold removal
Figure 68
5 1 125705
Disconnect the pipe (2) from the high pressure pump
171976
mount and remove the control unit (1) with its
Remove the following parts: underlying support.
❏ oil filter (1);
❏ oil inlet pipe (5); .540452. Blow-by case removal
❏ oil outlet pipe (2)
Figure 71
❏ turbocharger (4) and exhaust manifold (3).
Remove the starter motor from the other side of the
engine.
.540710. Intake manifold removal

.542011. Fuel filter removal
Figure 69
114015
Take off the screws (1) and remove the blow-by case
(2).
.540486. Blow-by filter removal
Figure 72
125704
Remove the following parts:

❏ fuel filter (1);
❏ oil level rod (2); 200106
❏ intake manifold (3). Loosen the screws (1) and remove the cover (2).
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 73 Figure 75
114019
114020
Use the appropriate wrench to loosen the screws (2) Undo the screws (1) and remove the thrust plate (2).
and remove the gear (3) with the pulser ring. Use the appropriate wrench to loosen the screws (4)
Undo the nut (4) and remove the control gear (5) of the and remove the idle gear (5).
high pressure pump. Remove the high pressure pump connection flange (3).
Remove the rpm sensor (1).
.540850. Engine flywheel removal
NOTE If it is difficult to remove gear (5), slacken the Figure 76

high pressure pump screws and tap lightly
with a drift on the drive shaft, then slide out
the gear (5).
.771010. High pressure pump removal
Figure 74
114009
Stop the flywheel (2) rotation by means of a suitable

tool, unscrew the fixing screws (1) and remove the
engine flywheel.).
114014
Disconnect the fuel pipes (2), undo the fastening

screws and remove the high pressure pump (1).
Remove the fuel filter support (3) with pipes.
Printed 603.95.397 Base - 10/2013

NEW 682
Figure 77 .540463. Flywheel case removal

Figure 80
45257
Fit puller 99340054 (2) and take off the seal (1). 114022
.540460. Oil sump removal Loosen the screws (1) and remove the flywheel box
(2).
Figure 78
.543010. Oil pump removal

Figure 81
125706
Loosen the screws (2) and remove the engine oil

sump (1) with the spacer (3) and the gasket.
.543060. Suction strainer removal 114023

Remove the screws (2) and disassemble the double
Figure 79
gear (3).
Remove securing screw (5) and disassemble the link
rod (4).
Disassemble the oil pump (1).
129709
Undo the screws (1) and remove the strainer (2).
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NEW 682
.541230. Rocker arm shaft removal Unscrew the fastening screws (1) and remove the rail
(2).
Figure 82
Figure 85
114024
❏ Disconnect the fuel pipes (3).
❏ Remove the check springs (2) of the exhaust
brake lever; 169826
❏ Unscrew the fixing screws (1) of rocker arm shaft.
Place tool 99342157 (1) and the hook on the injectors.
Figure 83
.541210. Camshaft removal
.540610. Cylinder head removal
Figure 86
114025
Apply tool 99360558 (1) to the rocker holder shaft and
remove the shaft and braces (3) from the cylinder
head.
.774510. Rail removal 45266
.775010. Injector removal

Extract the camshaft and loosen the cylinder head
Figure 84 fastening screws.
Use metal ropes to lift the cylinder head (1) and
remove the gasket (2).
172927
Remove the fastening brackets (3).
Printed 603.95.397 Base - 10/2013
NEW 682
Figure 87 Figure 89
117690 115882
Undo the screws (2) fixing the connecting rod cap (3)
Clean the mating surfaces to remove dirt and oil
and remove it.
residues. Apply silicone LOCTITE 5970 (1) to the cover
Remove the connecting rod-piston assembly from the
(2) as shown in the figure.
upper side (1).
The diameter of the bead of sealant must be approx.
Repeat these operations for the other pistons.
1.5 mm.
Keep the big end bearing shells in their

Mount the front cover within 10 minutes of
respective housings and/or note down their
applying the sealant.
assembly position since, if reusing them,
they will need to be fitted in the position
found upon removal.
.540840. Conrod-piston unit removal

Figure 90
Figure 88
114615
Using a suitable wrench and a hex socket wrench

undo screws (1 and 3) and remove the strengthening
115881 plate (2) and the main bearing caps (4).
Turn the crankcase (1) into vertical position.
NOTE Note down the assembly position of the top

and bottom main bearing shells since, if
reusing them, they will need to be fitted in
the position found upon removal.
Base - 10/2013 Printed 603.95.397

NEW 682
. 540810. Crankshaft removal REPAIR OPERATIONS CYLINDER BLOCK

Figure 91
.540410. Crankcase checks
.540420. Cylinder liner checks and
measurements
Figure 93 (For reference purposes)
114035
Using tool 99360500 (1), remove the crankshaft (2).

34994
.540416. Main bearings removal In order to check the inner diameter of cylinder liners
.540414. Oil nozzle removal and identify the degree of ovalization, taper and wear,
use gauge (2) fitted with a centesimal dial gauge (1)
previously reset on the 117 mm ring gauge (3).
Figure 92
NOTE If the 117 mm ring gauge is not available,

use a micrometer.
Figure 94
47571
Extract the main half-bearing (1), loosen the screws

and take out the oil nozzles (2).
Remove the cylinder liners as described in the related
section on page 111.
Once the engine disassembly is complete,

clean accurately the removed parts and
114035
check their integrity.
1 = 1st measuring
Instructions for main checks and
2 = 2nd measuring
measurements are given in the following
3 = 3rd measuring
pages, in order to determine whether the
parts can be re-used. Measurements should be carried out for every single
cylinder liner at three different heights and on two (A-
B) perpendicular plane levels as illustrated in Figure.
Printed 603.95.397 Base - 10/2013

NEW 682
Figure 95
114036
A = Selection class Ø 117 to 117.012 mm

B = Selection class Ø 117.010 to 117.022 mm
X = Selection class marking area
When wear is over 0.150 mm or maximum ovalization

is 0.100 mm compared to the values shown in the
figure, replace the cylinder barrel since it is not
possible to adjust, lap or dress it.
NOTE Cylinder liners are equipped with spare parts

belonging to selection class "A".
Figure 96
114037
A = Ø 130.500 ÷ 130.525 mm
B = Ø 129.510 ÷ 129.535 mm
C = Ø 130.461 ÷ 130.486 mm
D = Ø 129.475 ÷ 129.500 mm
The illustrated diagram refers to the cylinder liner outer
diameters and their housing inner diameters.
Cylinder liners can be removed and fitted several
times into different housings, if needed.
Base - 10/2013 Printed 603.95.397

NEW 682
Cylinder liners
Figure 97
114038
CRANKCASE ASSEMBLY WITH CHROME-PLATED CYLINDER LINERS
Figure 98
114039
CYLINDER LINER MAIN DATA

A 117.000 to 117.012 mm
Selection class
B 117.010 to 117.022 mm
Printed 603.95.397 Base - 10/2013

NEW 682
Figure 99
114040
PART "X"
"A" = Selection class marking area
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NEW 682
.540420. Cylinder liners replacement

Figure 102
Disassembly
Figure 100
77812
Check cylinder liner protrusion using tool 99360334 (1-

2-3-4) and tighten screw (1) to 170 Nm.
With dial gauge 99395603 (5) placed on base
47577
99370415 (6).
Measure the cylinder liner protrusion compared to the
Position parts 99360706 (1 and 2) and plate 99360724
cylinder head supporting face.This must be 0.035 to
(4) as shown in the figure, making sure that the plate
0.065 mm (Figure 103); otherwise replace the
(4) is properly resting on the cylinder liner.
adjusting shim (1, Figure 101) provided as spare parts
Tighten the screw nut (1) and remove the cylinder liner having different thicknesses.
(3) from the block.
Figure 103
.540420. Refitting and protrusion check

Figure 101
114041
CYLINDER LINER PROTRUSION
16798
Always replace the water sealing rings (3, 4 and 5).

Install the adjustment ring (1) on the cylinder liner (2);
lubricate the lower part of the liner and install it in the
cylinder unit using the proper tool.
NOTE The adjusting ring (1) is equipped with a

spare part having the following thickness:
0.08 mm - 0.10 mm - 0.12 mm - 0.14 mm.
16798
Once assembly is complete, block the cylinder liners

(1) on the crankcase (2) with stud bolts 99360703 (3).
Printed 603.95.397 Base - 10/2013
NEW 682
.540810. Crankshaft measurements

Figure 105
Upper main half-bearings
Lower main half-

bearings 114042
CRANKSHAFT MAIN DATA AND HALF-BEARINGS FOR MAIN SUPPORT

Check the condition of the journals and the big end pins; there must no be signs of scoring, ovalization or
excessive wear. The values shown refer to pin regular diameter.
Figure 106 Figure 107
114043
114044
X. Journal fillet detail Y. Crankpin fillet detail
Base - 10/2013 Printed 603.95.397

NEW 682
.540811. Main Journal measurement Figure 109

.540812. Crank pin measurement
Before grinding the crank pins, measure the main
journals and the crank pins (2) with a micrometer (1)
and on the basis of the undersizing of the bearings
determine the final diameter to which the pins are to
be ground.
Figure 108
47536
MEASURING CRANKPINS
During grinding, pay attention to journal and crank

pins values specified in figures 68 and 69.
NOTE All the main journals and crankpins must

47535
also be ground to the same undersizing
class, in order to avoid any alteration to
MEASURING MAIN JOURNALS shaft balance.
NOTE It is advisable to enter the values found in a

table (Figure 31).
Fill in this table with the measurements of the main journals and the crankpins of crankshaft.
Figure 110
Main journals
∅ MINIMUM
∅ MAXIMUM
∅ MINIMUM
∅ MAXIMUM
Crankpins
114045
Printed 603.95.397 Base - 10/2013

NEW 682
.540816. Preliminary measurement for main half-bearing selection

.540831. Preliminary measurement for connecting rod half-bearing selection
For each of the journals of the crankshaft, it is necessary to carry out the following operations:
Main journals: Crankpins:

❏ determination of the diameter class of the seat in ❏ determination of the diameter class of the seat in
the crankcase; the connecting rod;
❏ determination of the diameter class of the main ❏ determination of the diameter class of the
journal; crankpin;
❏ selection of the class of the half-bearings to ❏ selection of the class of the half-bearings to
mount. mount.
DEFINING THE DIAMETER CLASS OF THE SEATS FOR HALF BEARINGS ON THE CRANKCASE
On the front of the crankcase, two sets of numbers are marked in the position shown (Figure 111 at top):
❏ the first set of digits (four) is the coupling number of the crankcase with relative cap;
❏ the following seven digits, taken individually, are the diameter class of each of the seats referred to (Figure 111
at bottom);
❏ each of these digits may be 1, 2 or 3.
Figure 111
MAIN BEARING HOUSING

CLASS
NOMINAL DIAMETER
1 99.000 ÷ 99.009
2 99.010 ÷ 99.019
99.020 ÷ 99.030
3
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NEW 682
.540816. Main half-bearing selection

.540831. Main connecting rod half-bearing selection
NOTE To obtain the specified assembly clearances, the main and connecting rod half-bearings need to be
selected as follows.
This operation makes it possible to identify the most suitable half-bearings for each of the journals (the half-
bearings, if necessary, can have different classes from one journal to another).
Depending on the thickness, the half-bearings are The following tables give the specifications of the
selected in classes of tolerance marked by a main and big end half-bearings available as spares in
coloured sign (red-green - red/black - green/black). the standard sizes (STD) and in the allowed oversizes
(+0.127, +0.254, +0.508).
Figure 112
114046
* Fitted in production only and not supplied as spare part
Printed 603.95.397 Base - 10/2013

NEW 682
.540816. Definition of the diameter class of the main journals (nominal diameter)
.540831. Definition of the diameter class of the main crankpins (nominal diameter)
Main journals and crankpins: determining the diameter class of the journals.
Three sets of numbers are marked on the crankshaft in the position shown by the arrow (Figure 113 at top):
❏ the first number, of five digits, is the part number of the shaft;
❏ under this number, on the left, a set of six digits refers to the crankpins and is preceded by a single digit
showing the status of the journals (1 = STD, 2 = -0.127), the other six digits, taken individually, give the
diameter class of each of the crankpins they refer to (Figure 113 at top);
❏ the set of seven digits, on the right, refers to the main journals and is preceded by a single digit: the single digit
shows the status of the journals (1 = STD, 2 = -0.127), the other seven digits, taken singly, give the diameter
class of each of the main journals they refer to (Figure 113 at bottom).
Figure 113
92.980 ÷ 92.990
92.990 ÷ 93.000
Base - 10/2013 Printed 603.95.397

NEW 682
.540816. Main half-bearings selection (nominal diameter)

After detecting, for each main journal, the necessary data on crankcase and crankshaft, select the type of half-
bearings to be used, according to the following table:
Figure 114
STD.
114048
1 2 3
green green green
1
green green green
red green green
2
red green green
red red green
3
red red green
114055
Printed 603.95.397 Base - 10/2013

NEW 682
Main half-bearings selection (rectified)

If the journals have been rectified, the procedure described cannot be applied.
In this case, ascertain that the new diameter of the journals is as shown in the table and fit the only type of half-
bearings suitable for the undersizing.
Figure 115
red/black =
mm 3.031 ÷ 3.041
green/black =
mm 3.041 ÷ 3.051 -0.127
green/black =
mm 3.051 ÷ 3.061
1 2 3
92.843 green/black green/black green/black
1 green/black
92.853 green/black green/black
92.853 red/black green/black green/black

2
92.863 red/black red/black green/black

3
Base - 10/2013 Printed 603.95.397

NEW 682
.540831. Connecting rod half bearing Figure 116

selection (nominal diameter pins)
There are 3 markings on the body of the connecting
rod in the positions indicated in the figure:
1. Coloured mark to identify weight
2. Coloured mark to identify diameter class
3. Progressive number to identify connecting
rod
NOTE The mark identification colours are shown in

the table on page 127.
The number indicating the diameter class of the seat

for half bearings can be: 1, 2 or 3.
Determine the type of crankpin half-bearing to fit on
each crankpin by following the indications in the table
(Figure 117).
Figure 117
STD.
1 2 3
Class
yellow green blue
green green green

1
green green green
red green green

2
red green green
red red green

3
red red green
Printed 603.95.397 Base - 10/2013

NEW 682
Connecting rod half-bearings selection (rectified)

If the journals have been rectified, the procedure described cannot be applied.
In this case, it is necessary to check (for each of the undersizings) which field of tolerance includes the new
diameter of the crankpins and to mount the bearing shells identified according to the relevant table.
Figure 118
red/black =
mm 2.057 ÷ 2.065
green/black =
mm 2.065 ÷ 2.073 -0.127
green/black =
mm 2.073 ÷ 2.081
1 2 3
81.789 green/black green/black green/black
1 green/black
81.799 green/black green/black

2

3
Base - 10/2013 Printed 603.95.397

NEW 682
.540815. Replacing timing and oil pump

control gear Place the half-bearings (1) and thrust half-rings on the
main journals as shown in the figure.
Check that the teeth of the gears are not damaged or
worn, otherwise remove them using the appropriate
extractor.
Figure 121
Figure 119
114034
Using the hoist and hook 99360500 (1) mount the

115883
crankshaft (2).
NOTE Before fitting the gear, spread a bead of

Loctite type 603, approx. 5 mm wide, on the
engine shaft, 30 mm from the contact
surface.
After fitting the gear (1) on the crankshaft (2), heat it for
~15 minutes in an oven at temperature not exceeding
180 °C.
Let it cool down after pressing.
If replacing the pin (3), after fitting it on, check it
protrudes from the crankshaft as shown in the figure.
.540811. Checking main journal assembly

clearance
200114
114049
Place the half bearings (1) on the main caps (2).
Fit the oil spray nozzles (2), so that the dowel Check the assembly clearance between the main
coincides with the crankcase hole (3). journals of the crankshaft and their bearings as shown.
Printed 603.95.397 Base - 10/2013

NEW 682
Figure 125
114615
❏ Position the main caps (4) and fit the strengthening

plate (2) observing the following procedure:
❏ hand tighten the internal screws, then the external
screws starting from bench "7" and proceeding to
bench "1";
❏ tighten screws by means of a torque wrench, still
starting from bench "7" and proceeding up to
bench "1":
1st stage: 140 Nm
2nd stage 60°+60°
.540817. Crankshaft thrust clearance check
Figure 126
47588
End float is checked by placing a magnetic dial gauge

(1) on the crankshaft (2), as shown in the figure. If the
value obtained is higher than specified, replace the
rear thrust half-bearings and repeat this check.
Base - 10/2013 Printed 603.95.397

NEW 682
5408 PISTON CONNECTING ROD ASSEMBLY OVERHAUL

Figure 127
47580
PISTON-CONNECTING ROD ASSEMBLY

1. Connecting rod body - 2. Half bearings - 3. Connecting rod cap - 4. Cap fixing screws - 5. Circlip - 6. Slotted oil
scraper ring with spiral spring - 7. Claw piston ring - 8. Trapezoidal piston ring - 9. Piston pin - 10. Piston
Make sure the pistons have no signs of seizing, Pistons are equipped with three piston rings: a sealing
scoring, cracking; otherwise replace them. ring, with trapezoidal section; a sealing ring with
chamfer cut and a scraper ring.
Pistons are grouped into classes A and B for diameter.
.540842. Engine flywheel removal .540840. Piston diameter measurement

126311 126312
Removal of the piston rings (2) using pliers 99360184 Removal of piston pin Seeger ring (2) using the round
(1). tipped pliers (1).
Printed 603.95.397 Base - 10/2013

NEW 682
Figure 130 Conditions for correct piston pin-piston

coupling
Figure 132
49026
Remove the piston pin (1).
If removal is difficult use the appropriate beater.
49026
Lubricate the pin (1) and the relevant housing on the

.540841. Measuring the piston pin diameter piston hubs with engine oil; piston must be inserted
with a slight finger pressure and it should not come out
Figure 131 by gravity.
32618
Measure piston pin diameter (1) with a micrometer (2).
Figure 133
MAIN DATA ON PISTON, CIRCLIPS AND PIN

X = 0.6 ± 0.15
• The measurement is made on the ∅ of 113 mm
114053
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NEW 682
.540842. Measuring circlips Figure 136

Figure 134
16552
Check the thickness of the piston ring (2) using a

micrometer (1).
3513
Figure 135 The sealing ring (2) of the 1st seat is trapezoidal.
Clearance "X" between the sealing ring and its housing
is measured by placing the piston (1) with its ring in the
cylinder liner (3), so that the sealing ring is half-
projected out of the cylinder liner.
Figure 137
16553
Check the clearance between the sealing rings (2) and

the relative piston housings (1) using a thickness
gauge (3).
36134
Check the end gap of the sealing rings (1), using a

thickness gauge (2), entered in the cylinder liner (3).
If the distance between ends is lower or higher than the
value required, replace split rings.
Printed 603.95.397 Base - 10/2013

NEW 682
.540830 Connecting rod checks
When installing connecting rods, make sure they all belong to the same weight class and same supplier.
The cap/connecting road is of the "stretched" type, check that the connecting rod is not damaged before
fitting it.
Each connecting rod can be fitted only with the relative cap. If the cap is fitted upside down, the
connecting rod must be refused.
Figure 138
114054
MAIN DATA OF BUSH, CONNECTING ROD, PIN AND HALF-BEARINGS

* Dimension to be obtained after driving the bushing
1. A distance higher than 0.4 mm must exist between the connecting rod bush and the connecting rod profile.
2. A missing area of less than 5 mm2 is permitted on the external fracture line.
3. Cracks are not permitted in the threaded area.
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 139
200115
1. Coloured mark to identify weight - 2. Coloured mark to identify diameter class - 3. Progressive number for
connecting rod identification
WEIGHT DIAMETER
∅ 85.987-85.996 Yellow
CLASS A
3450 g – 3470 g ∅ 85.997-86.005 Green
Yellow
∅ 86.006-86.013 Blue
∅ 85.987-85.996 Yellow
CLASS B
3471 g – 3490 g ∅ 85.997-86.005 Green
Green
∅ 86.006-86.013 Blue
∅ 85.987-85.996 Yellow
CLASS C
3491 g – 3510 g ∅ 85.997-86.005 Green
Blue
∅ 86.006-86.013 Blue
Printed 603.95.397 Base - 10/2013

NEW 682
Connecting rod check Torsion check
Figure 140 (For reference purposes) Figure 141 (For reference purposes)
61694
Check the torsion of the connecting rod (5) by

comparing two points (A and B) of the pin (3) on the
61696 horizontal plane of the axis of the connecting rod.
Position the dial gauge (2) support (1) to obtain a
Checking axis alignment preload of ∼ 0.5 mm on the pin (3) in point A and then
Check the alignment of the axes of the connecting set the dial gauge (2) to zero. Shift the spindle (4) with
rods (1) using the device (5), proceeding as follows: the connecting rod (5) and compare any deviation on
❏ fit the connecting rod (1) on the tool (5) spindle the opposite side B of the pin (3): the difference
and lock it with the screw (4); between A and B must not exceed 0.08 mm.
❏ set the spindle (3) on the "V"-prisms, resting the
connecting rod (1) on the stop bar (2).
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NEW 682
Bending check .540840. Installing the connecting rod-

piston assembly
Carry out the steps for removal described on pages
123 and 124 in reverse order.
Figure 143
117694
61695
NOTE The connecting rod screws can be reused as
long as the diameter of the thread (d)
Check the bend of the connecting rod (5) by measured in area (L) is not less than 11.4
comparing two points C and D of the pin (3) on the mm.
vertical plane of the connecting rod axis.
Position the vertical support (1) of the dial gauge (2) so
that this rests on the pin (3) at point C.
Swing the connecting rod to and fro, seeking the
highest position of the pin and reset the dial gauge (2)
in this condition.
Move the spindle (4) with the connecting rod (5) and .540842. Installing the piston rings
repeat the check on the highest point on the opposite
side D of the pin (3). The difference between points C Figure 144
and D must not exceed 0.08 mm.
126313
Use pliers 99360184 (3) to fit the piston rings (1) on the
piston (2).
Piston rings shall be fitted with the marking "TOP" (4)
facing upwards and their openings shall be displaced
with each other by 120°.
Printed 603.95.397 Base - 10/2013

NEW 682
.540840. Assembling connecting rod-piston Figure 146

assemblies in the cylinder liners
Figure 145
47593
❏ all pistons belong to the same class, A or B;

115885
❏ the symbol stamped on the crown of the pistons
Fit the half-bearings (1), selected as described on faces the engine flywheel; or the recess in the
pages 115 to 120, both on the connecting rod and on piston skirt matches the position of the oil nozzles.
the stand.
If the cap (1) is fitted upside down, the

connecting rod must be refused.
NOTE The pistons are supplied as spares in class

A and can also be fitted in class B cylinder
liners.
Fit the connecting rod-piston assemblies (2) into the

piston liners using band 99360605 (1, Figure 146);
check the following:
❏ the openings of the piston rings are offset by 120º;
Figure 147
1 Connecting rod-piston assembly
2 Marking area on the piston crown of

ideogram specifying the assembly
position and the selection class
3 Connecting rod marking area 61831
Base - 10/2013 Printed 603.95.397

NEW 682
.540831. Checking crankpin assembly Figure 149

clearance
To check the clearance proceed as follows
Connect the connecting rods to the relative
crankpins, place a length of calibrated wire on the
latter.
Figure 148
47583
Install and fix tool 99360264 (2) with bracket (4);

tighten with lever (1) until cotters can be removed (3);
remove the tool (2) and the upper plate (5), the spring
(6) and the lower plate (7).
115886
Repeat this operation for all the valves.
Install the connecting rod caps (1) with half-bearings; Overturn the cylinder head and withdraw the valves
tighten the connecting rod cap fixing screws (2) to a (8).
torque of 50±2.5 Nm (5 ± 0.2 kgm). Using tool
99395216 (3), further tighten the screws with a 90°
angle.
Remove the caps and check the clearance by .540610. Checking cylinder block head
comparing the width of the calibrated wire with the contact surface
scale calibration on the envelope containing the wire.
.540610. CYLINDER HEAD OVERHAUL

Before disassembling cylinder head, check cylinder
head for hydraulic seal using a suitable tool; in case of
leaks not caused by cup plugs or threaded plugs,
replace cylinder head.
NOTE In case of plugs dismounting/replacement, 36159
on mounting, apply sealant Loctite 270 on

plugs. Check the supporting surface (1) of the head on the
cylinder block with a rule (2) and a feeler gauge (3).
If you find any deformation, level the head on a
surface grinder; maximum amount of stock removal is
.540662. Valve removal 0.2 mm.
NOTE Before removing cylinder head valves,

number them in view of their remounting in
the same position should they not have to
be overhauled or replaced. NOTE After levelling, make sure that valve sinking
Intake valves are different from exhaust and injector protrusion are as described in
valves in that they have a notch placed at the relative paragraph.
valve head centre.
Printed 603.95.397 Base - 10/2013

NEW 682
.540610. Checking cylinder block head Figure 152

contact surface
Figure 151
92841
MAIN DATA OF VALVES AND VALVE GUIDES

* Measurement obtained after fitting the valve
guides
48625
Clean the valves using a proper metal brush.
Check that the valves show no signs of seizure or
cracking and check with a micrometer that the valve Check, by means of a micrometer, that valve stem
stem diameter comes within the required values (see diameters are as specified; if necessary, grind the
Figure 152); replace the valves if it does not.) valves seat with a grinder, removing the minimum
quantity of material.
.540667. Replacing the valve guides

Figure 153
47509
INSTALLATION DIAGRAM FOR VALVE GUIDES AND VALVES

* Using a bore meter, ascertain that the new diameter of the journals is as shown.
Base - 10/2013 Printed 603.95.397
NEW 682
Remove valve guides by means of tool 99360288. .540613. Injector holder replacement
They are fitted with the drift 99360288 equipped with Disassembly
part 99360294.
Part 99360294 determines the exact valve guide fitting Figure 155
position in cylinder head; if not available, fit valve
guide in cylinder head so that they protrude from it by
16.3 ÷ 16.7 (Figure 153).
After driving in the valve guides, rebore their holes with
the smoother 99390310.
.540661. Replacing - Regrinding valve seat

To replace the valve seats, remove them using the
appropriate tool.
Figure 154
115887
41032
To replace the injector holder (2), act as follows:
Using tool (1) regrind the valve seats (2) on the ❏ thread the holder (2) with tool 99390804 (1);
cylinder head. The steps described in the following figures need to be
carried out by fixing the tools, with the bracket A, to the
cylinder head.
NOTE Valve seats must be reamed whenever

valves or valve guides are replaced or
ground.
After regrinding the valve seats, use tool 99370415, to

make sure that the valve position, referred to the
cylinder head surface, is the following:
❏ -0.5 ÷ -0.8 mm (recessing) of intake valves;
❏ -1.6 ÷ -1.9 mm (recessing) of exhaust valves.
Printed 603.95.397 Base - 10/2013

NEW 682
Figure 156 .540613. Injector holder assembly

Figure 158
115889
❏ Lubricate sealing rings (3) and fit them to the case

115888 (4); fix tool 99365054 (2) to the cylinder head by
means of bracket A, install the new holder, tighten
❏ fasten puller 99342149 (2) to the holder (3), by
the screw (1), upsetting the holder lower part.
tightening the nut (1), and pull out the holder from
cylinder head.
Figure 159
Figure 157
45633
115890
❏ Remove any residue (1), with tool 99390772 (2),

❏ Re-machine the housing bore (3) by means of
from the cylinder head groove.
borer 99394043 (1) and guide bushing 99394045
(2).
Base - 10/2013 Printed 603.95.397
NEW 682
115891 114056
❏ Using the milling cutter 99394044 (1) and bushing INSTALLATION LAYOUT FOR INJECTOR HOLDER
99394045 (2), regrind the injector seat in the
sleeve (3).
Printed 603.95.397 Base - 10/2013

NEW 682
.540665. Valve spring check .540662. Valve assembly

.540668. Mounting the oil seal ring
Figure 164
70000
Before assembly, check the valve spring flexibility

using a suitable tool.
Compare the load and elastic deformation data with
those of the new springs given in the following figure.
87051
Lubricate the valve stem and insert the valves in the

Figure 163 respective valve guides; fit the lower caps (1). Use tool
99360329 to fit the oil seal (2) on the valve guides (3)
of the exhaust valves; then fit the valves as follows.
Free spring
Valve closed
NOTE If the valves have not been overhauled or
replaced, reassemble them according to the
number sequence adopted during
disassembly.
Intake valves are different form exhaust
valves in that they have a notch placed at
Valve open valve head centre.
Figure 165
109107
MAIN DATA TO CHECK THE SPRING FOR INTAKE

AND EXHAUST VALVES
86290
❏ fit springs (6) and the upper plate (5);
❏ apply tool 99360264 (2) and block it with bracket
(4); tighten the lever (1) until cotters are installed
(3), remove tool (2).
Base - 10/2013 Printed 603.95.397

NEW 682
5412 COMPLETE TIMING SYSTEM

OVERHAUL
541252 Idler gear
Timing system drive
Figure 168
Figure 166
114211
114210
TIMING CONTROL COMPONENT PARTS

1. Camshaft - 2. Bushing - 3. Pin - 4. Articulated rod -
5. Camshaft control gear - 6. Idler gear - 7. Twin idler
gear - 8. Crankshaft driving gear. 541252 Twin idler gear
Figure 169
541253 Idler gear pin

Figure 167
114212
.541254. Bushing replacement

Bushings (1, Figure 167 and Figure 168), can be
replaced when they are worn. Put up the bushing, then
86926 grind it so as to bring it to a dimension of Ø 65.010 ±
0.10 mm.
Rated assembly play between idler gear bushings and
pins: 0.040 ÷ 0.080 mm.
NOTE The bush fitting in the gears (2, Figure 167
and Figure 168) shall be carried out
following the direction of the arrows and
with the value shown in the figures.
Printed 603.95.397 Base - 10/2013

NEW 682
.541211. Checking camshaft, cam lift and journal alignment

Figure 170
47506
Set the camshaft (4) on the tailstocks (1) and check the lift of the cams (3) using the dial gauge (2); the values are
given in the table on page 69.
Figure 171
47507
With camshaft (4) on tailstocks (1) use a centesimal gauge (2) to check pin alignment (3); it must not exceed 0.030
mm. If the misalignment is greater than this value, replace the camshaft.
Figure 172
47505
To check the assembly clearance, measure the inside diameter of the bushings and the diameter of camshaft
journals (1). The difference will give the actual clearance.
If you find any clearances over 0.150 mm, replace the bushings and, if necessary, the camshaft as well.
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 173
MAIN DATA AND TOLERANCES OF THE CAMSHAFT 114213
The surfaces of shaft supporting pin and cams must be extremely smooth; if you see any sign of seizing or scoring,
replace the shaft and the relative bushes.
TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL

ORIENTATION Perpendicularity ⊥
POSITION Concentricity or coaxiality
OSCILLATION Circular oscillation ↗
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL
CRITICAL 
IMPORTANT ⊕
SECONDARY ⊝
.541213. Camshaft bushes check
Figure 174
114214
MAIN DATA OF THE BUSHINGS FOR THE CAMSHAFT AND SEATS ON THE CYLINDER HEAD
* Bushing inner diameter after fitting
The bush surfaces must not show any sign of seizing value.
or scoring; if they do replace them. To remove and fit the bushings, use the appropriate
Measure the bushes inner diameters with a bore meter drift 99360487.
and replace them, if the value measured exceeds the
tolerance
Printed 603.95.397 Base - 10/2013

NEW 682
.541213. Replacing camshaft bushes using .540662. Valve assembly

tool 99360505
.540668. Mounting the oil seal ring
Disassembly
Figure 177
Figure 175
114280
Remove the bushings (2) with tool 99360505 (3) fitted

as shown in the figure.
Position the drift accurately during the phase of
removal.
87051
Assembly Lubricate the valve stem and insert the valves in the
For refitting, reverse removal operations respective valve guides; fit the lower caps (1). Use tool
taking care to match the lubrication hole (1) 99360329 to fit the oil seal (2) on the valve guides (3)
on the bushing with the hole on the seat. of the exhaust valves; then fit the valves as follows.
NOTE Should valves not have been overhauled or

replaced, remount them according to the
numbering performed on dismounting.
Intake valves are different form exhaust
Figure 176 valves in that they have a notch placed at
valve head centre
Valve closed
Figure 178
Valve open
114215
MAIN DATA TO CHECK THE SPRING FOR INTAKE

AND EXHAUST VALVES
86290
❏ fit springs (6) and the upper plate (5);
❏ apply tool 99360264 (2) and block it with bracket
(4); tighten the lever (1) until cotters are installed
(3), remove tool (2).
Base - 10/2013 Printed 603.95.397

NEW 682
.541233. Rocker arm shaft check

Figure 179
126315
The camshaft cams control the 12 valve rockers directly. The intake valve control rocker arms are keyed on rocker
arms shaft directly. Exhaust valves control rocker arms are keyed on rocker arms shaft putting in between the
levers with engine brake control eccentric pin. Rockers slide directly on the cam profiles via rollers. The other end
acts on a bar directly supported by the two valves stems. A pad is placed between the rocker adjusting screw and
the bar. Two lubrication holes are obtained inside the rockers. The rocker shaft practically covers the whole
cylinder head; remove it to have access to all underlying components.
Shaft
Figure 180
114217
MAIN DATA OF THE ROCKER ARM SHAFT

Check that the surface of the shaft shows no scoring or signs of seizure; if it does, replace it.
.541233. Pump injector rocker arms check .541231. Pump injector rocker arms check
114219 114218
EXHAUST VALVE ROCKER ARM INTAKE VALVES ROCKER ARMS
Printed 603.95.397 Base - 07/2012

NEW 682
.543751. Lever with engine brake control .540610. Cylinder head assembly
eccentric pin check
Figure 186
Figure 183
42566
126316 Check that the pistons 1-6 are exactly at the T.D.C.
The bush surfaces must not show any trace of scoring Put the gasket (2) on the crankcase.
of excessive wear; otherwise, replace bushes or the Mount the cylinder head (1) and tighten the screws as
whole rocker. shown in the following figures.
.540110. ENGINE ASSEMBLY The screws that have been removed must
not be reused.
Figure 184 Use new screws.
Figure 187
44900
Diagram showing the cylinder head fixing screws

114257
tightening order.
Mount the front cover (1) and tighten the fixing screws
to torque.
Figure 188
Figure 185
45267
114258 ❏ Preliminary tightening by means of a torque

wrench (1): 1st stage: 50 ± 2.5 Nm (5 ± 0.2
Fit the oil seal (1), install the fitting tool 99346260 (2) and
kgm);
drive the seal (1) by screwing nut (3).
2nd stage:100 ± 5 Nm (10 ± 0.5 kgm).
Base - 07/2012 Printed 603.95.397
NEW 682
Figure 189
NOTE Fit the gear housing within 10 minutes after
the sealant application.
Figure 192
α
45268
❏ Closing to angle with tool 99395216 (1):
3rd stage: angle of 90° ± 4.5°
4th stage: angle of 75° ± 3.5°
Figure 190
114262
Tighten up bolts (1) using a torque wrench to the
required torque setting.
114023 Figure 193
Fit the oil pump (1), double gear (3) complete with
connecting rod (4) and lock the screws (2) to a torque
of 24.5 ± 2.5 Nm (2.4 ± 0.2 kgm).
Figure 191
114263
Clean the mating surfaces to remove dirt and oil
114261 residues. Apply silicone LOCTITE 5970 to the flange
(1) of the high pressure pump as shown in the figure.
Clean the mating surfaces to remove dirt and oil residues. The diameter of the bead of sealant must be approx.
Apply LOCTITE 5970 silicone on the gear case (1) as shown 1.5 mm.
in the Figure.
The diameter of the bead of sealant must be approx. 1.5
mm. NOTE Mount the flange within 10 minutes of
applying the sealant.
Printed 603.95.397 Base - 07/2012

NEW 682
.540850. Engine flywheel assembly

Figure 194
NOTE If the teeth of the ring gear mounted on the

engine flywheel used for starting the engine
are very damaged, replace the ring gear.
It must be fitted after heating the ring gear
to a temperature of ~200 ºC.
Figure 196
114264
Apply gauge 99395221 (1) to check and record the

flange position (2) connecting the high pressure pump.
Fasten the flange screws (2) to the prescribed torque.
.771010. High pressure pump assembly

Figure 195
45258
Adjust the seal (1), fit the adjusting device 99346260

(2), drive in the seal by screwing the nut (3).
NOTE The crankshaft has a centring pin that has

to couple with the relevant seat on the
flywheel.
114272
Mount high pressure pump (1) on the flange (2).
Base - 07/2012 Printed 603.95.397

NEW 682
Figure 197
114265
DETAIL OF PUNCH MARKS ON ENGINE FLYWHEEL FOR PISTON POSITIONS

A. Hole on flywheel with reference mark, corresponding to TDC of pistons 3-4. - B. Hole on flywheel with reference
mark, corresponding to the TDC of pistons 1-6. - C. Hole on flywheel with reference mark, corresponding to the
TDC of pistons 2-5. - D. Hole on flywheel with two reference marks, corresponding to 545.
α α
49037
Position the flywheel (1) on the crankshaft, lubricate

49036
the thread of the screws (2) with engine oil and screw
them down. Second stage: closing with an angle of 90° ± 4.5°
Lock rotation by means of a suitable tool.
with tool 99395216 (1).
Lock the screws (2) in three stages.
First stage: pre-tightening with torque wrench (4) to a
torque of 120 ± 6 Nm (12 ± 0.6 kgm).
Printed 603.95.397 Base - 07/2012

NEW 682
.541210. Camshaft assembly

NOTE Take care NOT to place sealant in the inner
Figure 200 groove (5).
The diameter of the bead of sealant must be approx.

1.5 mm.
Mount the plate (1) with the gasket (2) within 10
minutes of applying the sealant and tighten the screws
(4) to the prescribed torque.
Figure 202
72436
Position the crankshaft with the pistons 1 and 6 at the

top dead centre (T.D.C.).
This situation occurs when:
1. the hole with a reference mark (5) of the engine
flywheel (4) can be seen through the inspection
window;
2. the tool 99360612 (1) inserted in the hole (3) in the 114269
engine flywheel (4) through the seat (2) of the

Apply gauge 99395222 (1), check and adjust the position of
engine speed sensor. the rod (3) for the transmission gear, tighten the screw (2) to
If this condition does not occur, turn the engine the prescribed torque.
flywheel (4) appropriately. Remove tool 99360612 (1).
114270
Refit the idle gear (2) and tighten the screws (1) to the
specified torque using a suitable six spline wrench.
114267
NOTE Replace the idle gear bushing (1) when
Fit the camshaft (3), positioning it with the reference wear is detected.
marks (→) as shown in the figure. Put up the bushing, then grind it so as to
Clean the mating surfaces of the plate (1) to remove bring it to a dimension of 58.010 ± 0.10 mm.
dirt and oil residues.
Apply LOCTITE 5970 silicone (6) on the plate (1) as
shown in the Figure.
Base - 07/2012 Printed 603.95.397

NEW 682
.541210. Pulser ring and camshaft timing Figure 206

Figure 204
16053
Turn tool (1) 99395223 so that pin (3) can be inserted in the
hole (2, Figure 203) of the head.
115061
Fit tool (1) 99395223 by means of two screws (2) M8x1.25.
Turn the engine shaft with tool 99360341 so that the

hole marked by two notches (5) can be seen from the
Figure 207
lower inspection window of the flywheel case.
In this condition, insert the tool 99360612 (1) through
the seat (2) of the engine speed sensor in the hole (3)
located on the engine flywheel (4).
Figure 205
117691
Fit the gear (1) controlling the camshaft so that it

matches with the fastening holes on the shaft and with
the slots (2) of the control gear.
Fit the gear (1), placing the spokes (4) as shown in the
figure.
This operation is needed to fit the pulser ring correctly,
since it has only one fitting position with respect to the
gear.
116052 Tighten the fixing screws (3).
Apply the tool (1) 99395223 to the front side of the

camshaft.
Printed 603.95.397 Base - 07/2012

NEW 682
Figure 208
116055
Install the braces (1) on the valve rod.
NOTE Before refitting the rocker-arm shaft

assembly, make sure that all the
adjustment screws have been fully
unscrewed.
.541230. Rocker arm shaft assembly

Figure 209
114025
Apply the tool 99360558 (1) to the rocker arm shaft (2)
and mount the shaft on the cylinder head.
Tighten the fixing screws to the prescribed torque.
Fit the engine brake retainer springs.
Base - 07/2012 Printed 603.95.397

NEW 682
.774510. Rail installation

.775010. Injector assembly
Figure 210
125708
Check that injectors (2) are at the same

Previously removed pipes cannot be refitted ! distance from springs (1). Distance "X" must
and must be replaced. remain unchanged.
1. Fit the oil delivery pipe to the engine brake on the 5. Fit the pipes on the rail, tightening the unions by
cylinder head and on the engine brake cylinders, hand.
tightening the fastening screws by hand. 6. Tighten the rail fixing screws to the cylinder head
2. Tighten the fixing screws to the prescribed torque at the prescribed torque.
7. Fit the pipes on the injectors and on the head,
tightening the unions by hand.
Lubricate the injector fastening O-Rings with 8. Tighten the unions on the rail (A, C) to specified
lubricants PDE SILIKONFETT 22, NLG 12, torque.
PDE LUBRICOMET GR 220 NLG12. 9. Tighten to the specified torque the unions on the
injectors and the head (B, C).
TYPE DESCRIPTION TIGHTENING
3. Fit the rail on the cylinder head, tightening the
TORQUE
fastening screws by hand.
4. Fit the injectors in the correct position and tighten
A M18 x 1.5 40 ± 2 Nm
them to the prescribed torque. B M14 x 1.5 35 ± 2 Nm
C M16 x 1.5 40 ± 2 Nm
Printed 603.95.397 Base - 10/2013

NEW 682
After fitting the high pressure pipes, check

frequently the engine oil level for the Figure 212
following 20 hours of operation.
(IT MUST NOT INCREASE).
.541215. Pulser ring timing

Figure 211
114275
NOTE Previously removed pipes cannot be

refitted and must be replaced.
Fit the pipe (1) delivering fuel from the high pressure pump
to the rail.
Tighten the nuts to the prescribed torque.
After fitting the high pressure pipes, check

frequently the engine oil level for the
following 20 hours of operation.
(IT MUST NOT INCREASE).
114284
Fit the high pressure pump gear (7) tightening the nut
(8) to torque.
Use a flat washer (PN 17095914) together with nut (8)
to replace that provided with the Bosch CP3 pump.
Place the cylinders 1-6 in combustion phase. Verify
that the cylinder 1 is in combustion phase. Rotate the
flywheel till the two marks are in the correspondence
of slot mount lower
Fit the pulser ring (4) so that the tooth marked by the
arrow (→) matches the sensor seat (6). Insert tool
99360613 in the timing sensor seat (6) to check
correct positioning.
Tighten the screws (5).
Remove tools 99395223, 99360612 and 99360613.
Base - 10/2013 Printed 603.95.397

NEW 682
.540486. Fitting the blow-by cover

FIRING ORDER 1-4-2-6-3-5
Figure 214
CLOCKWISE BALANCING ADJUST
START-UP AND CYLINDER CLEARANCE
ROTATION VALVES NO. OF CYLINDER
VALVE NO.
1 and 6 at 6 1
T.D.C.
120° 3 4
120° 5 2
120° 1 6
120° 4 3
120° 2 5
NOTE To correctly perform the above

adjustments, the sequence shown in the
114286
table must be followed, checking that the
Fit the timing cover (1) and tighten the fixing screws positioning is correct for each stage of
(2) to the prescribed torque. rotation by means of pin 99360612.
.541230. Adjusting intake and exhaust
rocker arm clearance
Figure 215 .540452. Fitting the blow-by box
Figure 216
114287
The adjustment of clearance between the rocker arms

114288
and bridges controlling intake and exhaust valves must Fit the blow-by body (1) and its gasket and then
be done very carefully. Take the cylinder where tighten the screws (2) to the prescribed torque.
clearance must be adjusted to the bursting phase; its
valves are closed while balancing the symmetric
cylinder valves. Symmetric cylinders are 1-6, 2-5 and
3-4.
The blow-by body must be fitted perfectly in
In order to properly operate, follow these instructions
line with the camshaft in order not to damage
and data specified on the table.
the gasket
- Using a ratchet spanner slacken the locking nut (1)
of the rocker arm adjusting screw (2);
- Insert the thickness gauge blade (3) with a value
equal to the operating clearance shown in the
"Characteristics and data" table; Mount the cover (3) and tighten the screws (4) to the
- Screw or unscrew the adjustment screw with the prescribed torque.
appropriate wrench;
- Make sure that the gauge blade (3) can slide with
a slight friction;
- Lock the nut (1) while holding the adjustment
screw/
Printed 603.95.397 Base - 10/2013

NEW 682
Figure 217 .540630. Tappet cover assembly

Figure 218
115880
Fit the electrical cable inside the head 114016
(injectors+pressure sensor) passing it through the hole

Fit the cover (1) of the cylinder head and tighten the
(5, Figure 217) and fastening it by means of clamps as
screws (2) to the prescribed torque according to the
shown in the figure (↓).
order shown in Figure 217.
Figure 219
Figure 220
114265
Before fitting the strainer, apply LOCTITE sealant to the mating surface (1) between crankcase, flywheel case and
front cover, observing the following instructions. Clean the mating surfaces to remove dirt and oil residues. Apply
silicone LOCTITE 275 (1) as shown in the figure. The diameter of the bead of sealant must be 1.5±0.5/0.2 mm.
Base - 10/2013 Printed 603.95.397

NEW 682
.543060. Suction strainer assembly .543210. Water pump assembly

Figure 221
.543251. Thermostat box assembly
.700310. Alternator assembly
Figure 223
125709
Fit the strainer (2), tightening the screws (1) on the

crankcase to the specified torque.
125703
Refit the following parts:
❏ alternator (6);
.540460. Oil sump assembly ❏ tensioner (5);
Figure 222 ❏ air conditioner compressor (1);
❏ flanged pipe (3);
❏ fixed belt tensioner (4);
❏ thermostat unit (2).
Figure 224
125706
Turn the engine.

Arrange the gasket on oil sump (1), position the spacer
(3) and fit the sump on crankcase screwing up the
screws (2) at prescribed torque.
125702
Refit the water pump (2) and pulley (3) operating on

screws (1).
Printed 603.95.397 Base - 10/2013

NEW 682
.543411. Water pump drive belt assembly .766161. ECU assembly

.543910. Climate control compressor drive Figure 226
belt disassembly
Figure 225
125705
Connect the pipe (2) from the high pressure pump

mount and install the control unit (1) with its underlying
support.
.540710. Intake manifold assembly

.542011. Fuel filter installation
125701 Figure 227
Refit the pulley (2) with the damper flywheel (3).

Using a suitable tool (4), operate in the direction of the
arrow, and refit the belt (5) driving water pump and
alternator.
Fit the spring belt (1) on the pulley.
Place the belt on the shaft of the air conditioning pulley.
With a suitable tool turn the crankshaft so as to fit the
belt on the air conditioning pulley.
NOTE During the operation, guide the belt

properly so as to avoid torsions/tensions
that could damage it.
If necessary place a rubber piece between
the pulley and belt.
125704
NOTE Install the following parts:

The flexible belt must be replaced with a
new one every time it is removed from the ❏ fuel filter (1);
vehicle. ❏ oil level rod (2);
❏ intake manifold (3).
Base - 10/2013 Printed 603.95.397

NEW 682
.543070. Oil filter assembly Figure 230

.542410. Turbocharger assembly Fi 208
.540720. Exhaust manifold assembly

Figure 228
Fi 208
4 125703
Install the following parts:

2 ❏ alternator (6);
5 1 ❏ tensioner (5);
❏ air conditioner compressor (1);
171976
Install the following parts: ❏ flanged pipe (3);
❏ oil filter (1); ❏ fixed belt tensioner (4);
❏ oil inlet pipe (5);
❏ thermostat unit (2).
❏ oil outlet pipe (2);
❏ turbocharger (4) and exhaust manifold (3).
Fit the starter motor from the other side of the engine. .543110. Heat exchange
Figure 231
NOTE The couplings of the pipes, cooling water
and lubricating oil of the turbocharger must
be locked to a torque of:
❏ 35 ± 5 Nm, water pipe fittings;
❏ 55 ± 5 Nm, oil pipe female fitting;
❏ 110 ± 5 Nm, oil pipe male fitting.
.760310. Alternator assembly

.543210. Water pump assembly
.543251. Thermostat assembly
Figure 229
Fi 208
125700
Place a container to collect the coolant fluid under the

heat exchanger (2).
Slacken the fastening screws and install the heat
exchanger assembly (2).
Install the oil outlet pipe (1).
125702
Install the water pump (2) and pulley (3) operating on

screws (1).
Printed 603.95.397 Base - 10/2013

NEW 682
Electrical components assembly

Figure 232
172610
A. Fuel temperature sensor - B. Camshaft timing sensor - C. EDC 7 control unit - D. Fuel regulator valve on high
pressure pump - E. Starter motor - F. Oil temperature/pressure transmitter - G. Alternator - H. Air
pressure/temperature sensor -
I. Air conditioning compressor - L. Water temperature sensor - M. Connector on engine head to connect with
electro-injectors - N. Engine speed sensor on flywheel
Connect the electrical components as shown in the figure.
Base - 10/2013 Printed 603.95.397

NEW 682
.543070. Replace oil filter cartridge Figure 235

Disassembly
Figure 233
115878
Bring the top part of the body thread to the first lower
thread of the support (the shaft of the cartridge cover
115876 enters the outlet duct of the oil on the support).
Remove the plug (2). Screw the cartridge-body assembly (1) on support (4).
Unscrew the body (1) of the filter by a couple of turns In this stage, both the sealing ring (3) of the cartridge-
and wait for a few minutes. oil outlet duct shaft and the sealing ring (2) of the
In this way, the oil left inside the body starts to drip and body-support progressively enter in their seats.
then flow freely outward. Tighten the filter body to a torque of 65 Nm.
Unscrew the body fully and replace the cartridge.
Assembly Figure 236
Figure 234
115877
Insert the cartridge in the body so that the centring fins

(2) located on the upper plate (1) match the respective
seats.
The cartridge is pushed into the container until it
115879
overcomes the action of the coupling system located
on the bottom of the body. Screw in the protection plug (1) on the filter body.
At the same time, the fins located on the upper plate
slide in their respective seats.
Printed 603.95.397 Base - 10/2013

NEW 682
Base - 10/2013 Printed 603.95.397

NEW 682
PT. CHAKRA JAWARA CLUTCH 1
SECTION 3
5052 Clutch
Page
DESCRIPTION .................................................... 3
HYDRAULIC CONTROL ..................................... 3
❏ Master cylinder ............................................. 3

❏ Clutch actuator without clutch wear indicator 4
CHARACTERISTICS AND DATA ....................... 5
TOOLS ................................................................ 6
CLUTCH REMOVAL AND REFITTING .............. 7
❏ Pressure plate removal ................................. 7

❏ Driven disc removal ...................................... 7
❏ Checks .......................................................... 7
❏ Driven disc refitting ....................................... 8
❏ Pressure plate refitting .................................. 8
THRUST BEARING REMOVAL-REFITTING ..... 9
REPLACING CLUTCH SHAFT SUPPORT
BEARING ...................................................... 9
PEDAL ASSEMBLY REMOVAL - REFITTING ... 9
❏ Removal ........................................................ 9
❏ Refitting ......................................................... 10
SPECIFICATIONS TO REPLACE THE MASTER
CYLINDER .................................................... 11
BLEEDING CLUTCH SYSTEM........................... 11

DIAGNOSTICS.................................................... 12
❏ Main mechanical malfunctions ..................... 12
Printed 603.95.397 Base - 07/2012

2 PT. CHAKRA JAWARA
CLUTCH NEW 682
Base - 07/2012 Printed 603.95.397

NEW 682
DESCRIPTION
Vehicles with mechanical gearboxes (Fuller 12 gear, manufactured by Shanxi Fast Gear C. Ltd, ) are hydro-
pneumatically controlled; hydro-pneumatic control includes master cylinder, with built-in oil tank and clutch actuator
HYDRAULIC CONTROL
The hydraulic control is composed of:
❏ master cylinder with built in oil tank;
❏ clutch actuator with full recovery of driven disc wear.
505271 Master cylinder
Figure 1
200117
1. Cylinder - 2. Sensor
Printed 603.95.397 Base - 10/2013

4 PT. CHAKRA JAWARA
CLUTCH NEW 682
505277 Clutch actuator without clutch wear indicator

Figure 2
106870
1. Inlet (compressed air)
3. Outlet (compressed air)
4. Drive (clutch liquid)
32. Purge screw
NOTE Clutch actuator can only be driven after mounting.
Clutch actuator view
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NEW 682
Figure 3 Functional diagram

1. Inlet (compressed air)
3. Outlet (compressed air)
4. Drive (clutch liquid)
Operating pressure:
❏ clutch fluid (P4) 40 bar
❏ air (P1) 7.5 bar
Max pressure:
❏ clutch fluid (P4) 120 bar
102608
Printed 603.95.397 Base - 10/2013

6 PT. CHAKRA JAWARA
CLUTCH NEW 682
Base - 10/2013 Printed 603.95.397

NEW 682
CHARACTERISTICS AND DATA
17” clutch Engine power > 280 HP
Type Dry single disc
Clutch mechanism Pull-type, with diaphragm spring
Driven disc Clutch disc
Driven disc hub With spring flexible coupling
Clutch disc gasket outer Ø mm 430
Clutch disc gasket inner Ø mm 240
+ 0.5
Disc thickness (new) mm 10 - 0.3
Max. driven disc off

mm ~0.3
centring
Load on pressure plate

N 25700
(new)
Disengagement load N 6000
Minimum pressure plate

mm 1.6
rise
+2
Disengagement stroke mm 12
Max. depression stroke mm 16.5
Clutch control: Master cylinder with built in oil reservoir - clutch

actuator and driven disc
Oil type Tutela TRUCK DOT SPECIAL
Printed 603.95.397 Base - 10/2013

6 PT. CHAKRA JAWARA
CLUTCH NEW 682
TIGHTENING TORQUES
PART TORQUE
Nm (kgm)
Flanged hex screw fixing pressure plate to flywheel M12 65 ± 7 (6.5 ± 0.7)
Nut for stud bolt fixing clutch housing to flywheel case 46 ± 5 (4.6 ± 5)
Stud bolt fixing clutch housing to crankcase 19 ± 2 (2 ± 0.2)
Stud bolt fixing clutch housing to crankcase (with PTO Multipower) 19 ± 2 (2 ± 0.2)
Hex nut to lock cylinder push rod adjustment for clutch and servo-clutch 37.5 ± 3.5 (3.7 ± 0.3)
Device to bleed air from brake and clutch systems 23.5 ± 2.5 (2,3 ± 0,2)
TOOLS
TOOL No. NAME
99370264 Guide pin for centering clutch plate
99370547 Support for removing and refitting the clutch unit (to be applied
to the hydraulic jack)
Base - 10/2013 Printed 603.95.397

NEW 682
.505210. CLUTCH REMOVAL AND REFITTING .505211. Driven disc removal

.505220. Pressure plate removal Figure 6
This operation consists of:
❏ propeller shaft removal/refitting (see section
505620)
❏ gearbox removal/installation (see relevant section
530210)
Figure 4
125703
Remove the clutch disk (2) together with the centring
pin 99370264 (1).
38438 Checks
Insert the clutch centring pin 99370264 (1) into the The checks to be made are as follows:
bearing for the gearbox input shaft. ❏ The contact surface, on the flywheel, of the driven
disc must not be excessively worn or scored;
❏ the teeth of the flywheel ring gear must not be
Figure 5 excessively deteriorated or worn.
Otherwise, remove the engine flywheel (operation
540850).
In addition, check there is not even the slightest
leakage of lubricant from the seal of the crankshaft
rear cover: if there are, remove the flywheel as
described in the relevant paragraph.
Remove the rear cover with the sealing ring and
replace as described at section 2.
Check bearing or bushing supporting the gearbox
input shaft mounted on the crankshaft for wear or
deterioration. If this is the case replace it.
Check the conditions of the pressure plate. The
supporting surface of the driven disc must have no
40194
deformation, wear or sign of overheating and its spring
or diaphragm must be sound.
Fit the mount 99370547 (1) on the hydraulic jack and
apply the mount to the pressure plate (3). Unscrew the
screws (2) and remove the clutch body with the
pressure plate from the engine flywheel.
Printed 603.95.397 Base - 10/2013

8 PT. CHAKRA JAWARA
CLUTCH NEW 682
Check the condition of the driven disc: Figure 8

❏ the wear gaskets must be neither very worn, nor
with signs of overheating or traces of oil or grease;
❏ there should be very little clearance between the
hub and input shaft;
❏ the hub flexible coupling springs must not be loose
or broken.
If you find any trouble at all, replace the part
concerned.
The clutch assembly is supplied as a spare in kit form.
The following are supplied individually:
❏ the driven disc and thrust bearing.
In this case it will be necessary to assemble the new
parts of the same supply as the pressure plate spring
that is to be reused. If the disc is off centre, use a fork wrench (1) acting as
shown in the figure.
.505211. Driven disc refitting

.505220. Pressure plate refitting
To install the clutch assembly, carry out the operations
Figure 7 described in the removal process in reverse order,
observing the following instructions:
❏ carefully clean the contact surface of the

flywheel using alcohol or petrol; if any
slight scratches are noted remove with
an abrasive cloth;
❏ position the driven disc, always using the guide
pin for perfect centring and to prevent harmful
stresses on the hub when refitting the gearbox;
❏ position the clutch body with pressure plate
matching the holes for the fastening screws with
the ones on the engine flywheel;
❏ assemble and lock the clutch body fixing screws to
Before fitting a new driven disc check that it is centred the specified torque;
as follows: ❏ re-fit the gearbox back on after overspreading the
Position the driven disc (1) on a lathe and, with the use splined shaft with Molikote molybdenum
of a magnetic stand dial gauge (2), check that the disulphide grease;
surface of the disc is not out of line at any point. ❏ adjust the push rod of the slave cylinder as
The maximum permissible eccentricity of the driven described in the relevant chapter (operation
disc is 0.20 mm. 505272).
Base - 10/2013 Printed 603.95.397

NEW 682
❏ gearbox removal/refitting (see relevant section

530210);
.505254. THRUST BEARING REMOVAL- ❏ clutch removal/refitting (operation 505210).
REFITTING
Using the appropriate pliers remove the split ring (3).
Figure 9 Using a suitable extractor (1) remove the bearing (2).
For refitting, use the appropriate beater.
Refit the circlip.
.502601. PEDAL ASSEMBLY REMOVAL -

REFITTING
Removal
Figure 11
36800
The operation consists of:
505620);
❏ gearbox removal/installation (see relevant section
530210).
By using the appropriate pliers open the split pin (1)
and extract the thrust bearing (2) from the pressure
plate. 171946
Reverse these steps when refitting.
Remove the heel rest (2) by unscrewing the fixing
screws (1), remove mat (3)
NOTE The new part must be from the same
supply as the pressure plate that is to be
reused.
.540852. REPLACING CLUTCH SHAFT

SUPPORT BEARING
Figure 12
Figure 10
1
2
2
3
171947
Remove the covering of the steering column on the

40196 lower side (2), by removing fastenings (1-3)
The operation consists of:
505620);
Printed 603.95.397 Base - 10/2013

CLUTCH NEW 682
Figure 13 Figure 15
72834
Disconnect the pipe (2).

Remove the screws (3) and disconnect the steering 99143
control mount (1) from the pedal unit (4). Remove the screws (4) securing the cover (5) of the control
valve (6).
Gradually lift the cover (5) to bleed pressurized air in the
system.
Remove the screws (1 and 3) securing the wiring clamps (2)
and the pedal unit to the cab.
Figure 16
Figure 14
72837
Remove the screw (2) securing the bracket (1)
supporting piping and wiring and disconnect the pedal
unit from the cab.
Refitting
Figure 17
99142
From outside the cab, lift the front casing, extract the
cable guide (1) with the wiring from the pedal unit (6).
Disconnect the piping (4) from the coupling (5).
Disconnect sensor (2) electric connection from
distributor (3).
72838
To refit, carry out the operations described in the
removal process in reverse order.
Then adjust the pedal stroke as described in the
relevant chapter.
Base - 10/2013 Printed 603.95.397

NEW 682
Figure 19
.505271. SPECIFICATIONS TO REPLACE
THE MASTER CYLINDER
NOTE Should you detect any oil leaks from the

main cylinder, replace the component
and bleed the hydraulic system.
The clutch fluid is toxic and corrosive: in

case of accidental contact, wash
immediately with water and mild soap.
40355
❏ attach a plastic tube to the bleed screw (2) of the

.505260. BLEEDING CLUTCH SYSTEM slave cylinder (1) and immerse the opposite end
of the tube in a container containing Tutela
Figure 18 (For reference purposes) TRUCK DOT SPECIAL fluid, unscrew the bleed
screw (1) by one full turn, open the cock (2) (see
Figure 21) until a pressure reading of 1 ÷ 1.2
bar is obtained on the pressure gauge (3);
❏ when the clutch fluid emerging from circuit is free
of bubbles, tighten the bleed screw and drain air
from the device reservoir (5) by means of valve
(6).
NOTE When clutch fluid is changed, bleed

master cylinder by loosening fitting (1,
Figure 21) before bleeding the servo
38438 clutch.
Bleed air from clutch control hydraulic circuit after
repairing control clutch assembly or following periodic
oil changes.
Use an air remover for this purpose as follows:
❏ supply the reservoir (5) with compressed air;
❏ fill reservoir (4) with Tutela TRUCK DOT
SPECIAL fluid;
Printed 603.95.397 Base - 10/2013

NEW 682
DIAGNOSTICS
Main mechanical malfunctions
Visible fault Possible cause Repair operation

Thrust bearing excessively worn, Replace the thrust bearing.
damaged or not properly lubricated.
Noise when the clutch is disengaged Excessive play between the splined Replace the shaft and, if necessary,
grooves on the gearbox input shaft the driven disc.
and the relevant housing on the hub
of the driven disc.
Driven disc springs are broken or Replace the driven disc.
weakened.
Transmission input shaft worn. Replace the shaft and, if necessary,
Noise when the clutch is engaged
the driven disc also.
Thrust bearing has excessive play Replace the thrust bearing.
in the joint.
Repair the oil or grease leaks, clean
Oil or grease on the flywheel, or on
the flywheel, and replace the driven
the linings of the driven disc.
disc.
Pressure plate deformed. Replace the clutch.
Clutch jerks
Lining worn due to driven disc run
Replace the driven disc.
out.
Clutch diaphragm spring weak or
Replace the driven disc.
broken.
Grooves on the gearbox input shaft Replace the shaft and, if necessary,
are worn and prevent the driven the driven disc.
disc movement.
The clutch does not release
Slave cylinder free play excessive. Check and adjust the slave cylinder
free play.
Air in the hydraulic circuit. Bleed the circuit.
Driven disc linings worn or burnt. Replace the driven disc.
Clutch diaphragm spring weak or
Replace the clutch.
The clutch slips broken.
Oil or grease on the seals of the Repair the oil or grease leaks and
driven disc. replace the driven disc.
The driver must break this habit and
The driver keeps the clutch pedal
use the clutch pedal only when
pressed while driving.
necessary.
Pressure plate deformed. Replace pressure plate.
Abnormal wear of driven disc linings
Clutch diaphragm spring blades Replace the clutch.
weakened or broken.
Insufficient operating cylinder free Check and adjust the slave cylinder
play. free play.
Printed 603.95.397 Base - 10/2013

NEW 682
PT. CHAKRA JAWARA GEARBOXES 1
SECTION 4
5302 Gearboxes
Page
GEARBOX 9JS119 ............................................. 3
GEARBOX 12JS ................................................. 27
Printed 603.95.397 Base - 07/2012

2 PT. CHAKRA JAWARA
GEARBOXES NEW 682
Base - 07/2012 Printed 603.95.397

NEW 682
PT. CHAKRA JAWARA GEARBOX 9JS119 3
5302 Gearbox 9JS119
Page
GENERAL INFORMATION ................................. 5
❏ Teeth alignment and procedures .................. 5

❏ Gearboxes .................................................... 6
❏ Control mechanism ....................................... 6
❏ Synchronizer structure and working principle
❏ Countershaft brake ....................................... 8

❏ Operation Requirements and Precautions ... 8
LONGITUDINAL SECTION................................. 9
❏ Gearbox name .............................................. 9

TOOLS ................................................................ 12
PRECAUTIONS FOR REMOVAL
AND REFITTING ....................................... 13
❏ Removal precautions and wearing part
inspections .................................................... 13
❏ Precautions for refitting ................................. 14

DIAGNOSTICS.................................................... 15
❏ Operation and faults diagnosis for gearbox
pneumatic system ......................................... 15
❏ Noisy transmission........................................ 16
❏ Transmission overheating ............................ 17
❏ Transmission gear disengagement (gear falling)
or hard gearshifting ....................................... 18
❏ Gear damage ................................................ 18

❏ Deformation and breakage of gearbox ......... 19
❏ Bearing faults ................................................ 19
❏ Fault diagnosis guide .................................... 20
Printed 603.95.397 Base - 07/2012

4 PT. CHAKRA JAWARA
GEARBOX 9JS119 NEW 682
Base - 07/2012 Printed 603.95.397

NEW 682
GENERAL INFORMATION
The main transmission and splitter of the FAST twin countershaft transmission comprise two countershafts with the
same structure. Each is staggered by 180 degrees. After being transferred via the input shaft, power will flow to
these two countershafts and then to the main shaft by means of the splitter.
Each countershaft can bear only half of the total torque. The twin countershaft structure allows decreasing the
transmission center distance, decreasing the volume and weight of the transmission.
Thanks to this floating gear structure, the traditional needle bearing is no longer necessary. This simplifies the
main shaft structure. During operation, the radial forces transmitted by the two middle gears to the gear of the main
shaft are equal but in opposite directions, therefore the main shaft only need to bear the torque. In this way the
loading capability of the main shaft and bearing are improved, with greater reliability and durability for the
transmission.
Teeth alignment and procedures

Figure 1
174278
Transmission assembly gear teeth alignment diagram

1. Left countershaft gear - 2. 1st shaft gear - 3. Right countershaft gear
Alignment of gear teeth

Apply paint mark on two adjacent gears of one shaft, then make the same mark on the other side at an angle of
180 degrees. The gears between these two marks should be equal.
Apply a unique paint mark on the upper part of the external tooth crest which is opposite to the two countershaft
constant mesh gear inner hole spline slot.
During assembly, make sure to insert the two marked gears of the two countershaft constant mesh gear into the
shaft gear marked teeth. Smoothly moving of 1st shaft means that the assembly is correct. If it is impossible or
hard to turn the shaft, check that the alignment marks of the gears are correct.
Splitter gear teeth alignment

Apply paint marks on two adjacent gears of splitter reducing gear, then make the same mark on the other side at
an angle of 180 degrees. The gears between these two marks should be equal.
Apply a unique paint mark on the upper part of the tooth crest with O mark of the splitter countershaft gear.
During assembly, make sure to insert the two marked gears of the splitter countershaft gear into the splitter
reducing gear marked teeth. During installation of the splitter assembly on the main transmission, take care to
ensure that the gear marks are aligned. If it is so, proceed with assembly.
Printed 603.95.397 Base - 10/2013

6 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682
Gearboxes
Gearboxes with twin countershafts are fitted with synchronizers.
The synchronizer is controlled by the lever gear shifting.
The synchronizer structure is as shown in the figure.
Figure 2
1 2
Gearbox diagram
1. Synchronizer - 2. 2nd shaft gear - 3. Main shaft
Control mechanism
The twin countershaft transmission control mechanism is direct (single H).
Direct control mechanism (single H superimposed)
Figure 3
174280
Shift lever knob diagram of single H gearshift
Base - 10/2013 Printed 603.95.397

NEW 682
Synchronizer structure and working principle

The splitter of twin countershaft gearbox is fitted with lock pin inertial synchronizer. The synchronizer is controlled
by the splitter gear shifting cylinder and only operates when switching between higher and lower gears. Its
operation is coordinated and controlled by the lateral shift lever and double H valve.
The synchronizer structure is as shown in the figure. Three locking pins 4 and 7 are riveted on each of the two
parts: high gear synchronizer ring 2 and lower gear cone ring 6. The shifting sleeve 3 is engaged with output shaft
via spline. The higher gear synchronizer ring and lower gear cone ring base material is sintering iron-base powder.
The non-metal materials with high friction property are attached onto higher gear synchronizer ring inner cone and
lower gear synchronizer ring outer cone. There are corresponding outer cone and inner cone on the splitter drive
gear and reducing gear.
Figure 4
174281
Splitter synchronizer assembly

1. Higher gear friction belt - 2. Higher gear synchronizer ring - 3. Sliding sleeve - 4. Higher gear locking pins -
5. Lower gear friction belt - 6 Lower gear cone ring - 7. Lower gear locking pins - 8. Spring
Printed 603.95.397 Base - 10/2013

8 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682
Operation Requirements and Precautions

Proper gearbox operation and regular maintenance are considerably important to the vehicle safe driving and
gearbox service life. Please observe the following operation requirements.
Lubricant SAE NO.
The transmission should be filled with Tutela Transmission W90/M-DA vehicle gear oil.
Correct oil level
Remove the tapered oil level inspection hole plug which is on the side of gearbox housing and add the oil until it
flows out of the hole. For the specific quantity, refer to the technical data.
Working temperature
During continuous running, the gearbox should have a temperature no higher than 120 °C. If the operating
temperature is higher than 120 °C, the lubricating oil will decompose and the transmission will have a shortened
service life.
If the gearbox operating temperature is higher than 120 °C, it may be due to one of the following reasons:
(1) Running at a speed lower than 32km/h for more than 1 hour continuously.
(2) The engine runs at a high speed.
(3) The ambient temperature is high.
(4) The transmission is surrounded by air turbulence.
(5) The exhaust system is too close to the transmission.
(6) Over-running at a high speed.
If the operating temperature is very high, the lubricant should be changed more frequently. If the conditions above
cannot be avoided, we recommend mounting a cooling system on the gearbox in order to decrease the operating
temperature.
Base - 10/2013 Printed 603.95.397

NEW 682
LONGITUDINAL SECTION
Figure 6
200119
Main section on the transmission assembly

1. PTO Shaft connection (right side)
Gearbox name
9 J S 119 A (B)
Forward gears Ratio code
Mechanical type X10 = nominal input torque (Nm)
Twin countershaft
Printed 603.95.397 Base - 10/2013

10 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682
GEAR CONTROL LEVER

Figure 5
R2 7 9 11
R1 1 3 5
L Front
N
8 10 12
2 4 6
172603
H = high gears - L= low gears

1. Power (Red colour) – 2. Output for lower gears (Black colour)
Base - 10/2013 Printed 603.95.397

NEW 682
GEARBOX 9JS119
Type Mechanical
Input torque Nm 1190
Pick-up gear 1
Forward gears 8
Reverse gear
1
Mechanical
Main four gears E.R.G.* control
Pneumatic
Power take-off Optional
Gear engagement:
Splitter and forward Synchronised
Pick up and reverse gears Rapid engagement
Gears Straight teeth
Printed 603.95.397 Base - 10/2013

12 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682
GEARBOX 9JS119
Gear ratio
Pick-up gear 12.11
st
1 8.08
nd
2 5.93
rd
3 4.42
th
4 3.36
th
5 2.41
th
6 1.76
th
7 1.32
th
8 1.00
Reverse 12.66
Oil type Tutela Transmission W90/M-DA
11.5
Kg
Quantity 12.5
itres
Main shaft and lay shaft bearings roller and balls
Base - 10/2013 Printed 603.95.397

NEW 682
TIGHTENING TORQUES
TORQUE
PART QUANTITY
Nm (kgm)
Clutch housing 6 M16×1.5 244÷271 (24,4÷27,1)
Clutch housing 4 M12 108÷135 (10.8÷13.5)
st
1 shaft bearing cap 6 M10 47.5÷61 (4.75÷6.1)
st
1 shaft gear M54×1.5 338÷406 (33.8÷40.6)
Double H control unit 8 M10×1 47.5÷61 (4.75÷6.1)
Top cover 16 M10 47.5÷61 (4.75÷6.1)
Fork lock screw 5 M12~1.2S 67.5÷88 (6.75÷8.8)
Splitter fork 2 M12×1.5 67.5÷88 (6.75÷8.8)
Air filter bracket 2 M6 13.5÷20.3 (1.35÷2.03)
Output shaft M50×1.5 609÷677 (60.9÷67.7)
Splitter rear cover 19 M10 47.5÷61 (4.75÷6.1)
Oil drain port Z3/4” 61÷74.5 (6.1÷7.45)
Oil filling port 21 81÷101.5 (8.1÷10.15)
Splitter drive gear positioning disk 6 6M10 47.5÷61 (4.75÷6.1)
Reverse gear shaft 2 M16×1.5 67.5÷81 (6.75÷8.1)
Splitter countershaft rear cover 8 M10 47.5÷61 (4.75÷6.1)
Lower power takeoff cover 8 M12 67.5÷81 (6.75÷8.1)
Countershaft brake 8 M10 47.5÷61 (4.75÷6.1)
Transmission side port cover 6 M10 24.5÷31 (2.45÷3.1)
Main shaft rear bearing cap 6 M10 47.5÷61 (4.75÷6.1)
Gear shifting cylinder housing 4 M10 47.5÷61 (4.75÷6.1)
Cylinder head (Splitter) 4 M10 47.5÷61 (4.75÷6.1)
Clutch housing bottom cover 4 M8 20÷27 (2.0÷2.7)
Countershaft leading face 2 M16×1.5 122÷162 (12.2÷16.2)
TOOLS
TOOL No. NAME
Stand for supporting the transmission unit during

99370629
removal and refitting
99360341 Tool for rotating the flywheel
Printed 603.95.397 Base - 10/2013

14 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682
PRECAUTIONS FOR REMOVAL AND REFITTING

Removal precautions and wearing part inspections
Removal precautions
1. Clean the bearings carefully. Check that the roller surface is not pitting and the roller is intact. Use special tools
when removing.
2. When removing the various assemblies, put all of the components on a clean bench according to the removal
sequence. As a result, the assembly will be more convenient and the possibility of missing components will be
reduced as well.
3. Remove the counters
haft, 2nd gear and 1nd shaft gears except the 1st shaft.
4. The repair should be done in a clean area. Do not let the dust or other foreign matters enter the gearbox.
Clean gearbox exterior carefully before the removal.
Wearing part inspections
Check every component carefully before the assembly. In order to avoid unnecessary damage, do not fit the
damaged parts.
Recommended inspection procedures are as follows:
A. Bearings
1. Wash all of the bearings in a clean solution. Check whether the steel ball, roller and roller race are pocked.
2. Wash the undamaged bearings and check the end and radial play. Replace the bearings with excessive
clearance.
3. Inspect the mating conditions of bearing and housing hole. If the external ring moves freely in the hole, replace
the housing.
B. Gears
1. Check if the gear teeth is pitting. If so, replace the pitted gears.
2. Check all of the meshing gears. Replace the gears which are worn into a conical shape or having a reduced
meshing length.
3. Check the gear end play. If there is a part with excessive clearance, check whether the gear split ring, washer,
adjustment shim and flange are worn excessively. The 2nd forward gear end play should remain between
0.13-0.30 mm, and the reverse gear should be between 0.30-0.90 mm.
C. Spline
Check the wear conditions for all of the shaft splines. If the sliding sleeve and output flange are lean to one side of
spline due to wear, replace the components.
D. Thrust washer
Check the surface conditions of all thrust washers. Replace scratched or thin washers.
E. Grey cast iron components
Check whether the grey cast iron components are cracked or damaged. As for large castings, fusion welding or
braze welding can be accepted. However, heat cracks should not extend to the bearing hole or bolt contact
surface.
F. Bearing cap
1. Check the bearing wear condition.
2. Check the oil seals in the 1st bearing cap and odometer case. If the lip is unsealed, replace the sealant.
G. Synchronizer
1. Check whether the lower and higher gears are burred or uneven and the wear conditions of contact surface.
2. Check if the lock pin is excessively worn.
3. Check whether the contact condition (wear) between the lower and higher gears and the conditions of the
synchronizer. Replace the burnt synchronizer or worn gears.
H. Sliding sleeve
1. Check if the fork slots of forks and sliding sleeves are worn excessively or discoloured due to overheating.
2. Check if the contact area of sliding sleeve meshing teeth is worn.
I. O-ring
Check the crack and deformation conditions of O-rings. Replace them if worn.
Base - 10/2013 Printed 603.95.397

NEW 682
Precautions for refitting

Observe the following precautions when refitting:
1. Gaskets: Make sure to use new gaskets when refitting the transmission.
2. Screws: In order to avoid leakage, apply thread sealant on all of the screws. As for the corresponding torques,
please see the sheet below.
3. O-rings: Lubricate all of the O-rings with silicone lubricant.
4. During the initial assembly, apply lubricant on all of the thrust washers to avoid scratching or damage.
5. End play: Ensure to maintain the 2nd shaft forward gears end play between 0.13-0.30 mm and reverse gears
between 0.30-0.90 mm.
6. Tighten the output shaft flange fastening nut. Make sure to tighten the nut to 610-680 Nm. Otherwise, serious
consequences may occur.
Printed 603.95.397 Base - 10/2013

16 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682
DIAGNOSTICS
Operation and faults diagnosis for gearbox pneumatic system
The splitter of twin countershaft gearbox is operated to raise or decrease gears by means of the pneumatic
system.
The pneumatic system consists of air filter regulator, double H valve, splitter gear shifting cylinder and junction
pipes.
It is helpful to discover and repair any faults in case you realized something during the operation of the air circuit
system and after performing simple inspections.
Operating principle
Air (7,5 bar) from compression cylinder is adjusted to a lower pressure (6,5 bar) by means of the air-filter regulator.
Air is brought into the inlet of the double H valve. When shifting to a lower gear, double H valve contact will eject
out to get through the air line for low gears. The air cylinder piston for shifting will be moved backward by
compressed air, which is brought into the inlet of the air cylinder for shifting from double H valve air tube for low
gears. The fork shaft of air cylinder for shifting drives the sliding sleeve of splitter synchronizer to engage with the
inner gear teeth of splitter release gear to achieve shifting of the transmission from higher to lower gears. When
shifting to a higher gear, double H valve contact will be pressed down to get through the air line for high gears.
Then air is brought into the inlet of double H valve to contact with the inner gear teeth of splitter drive gear to
achieve shifting of the transmission from lower to higher gears. When switching the gear shift from a high gear to a
low gear or vice versa, the air remaining in air cylinder will be exhausted through the outlet of double H valve via
air tube.
Figure 7
200120
Pneumatic shifting diagram for gearshift mechanism with double H valve

1. Double H valve - 2. Auxiliary gear cylinder - 3. Air filter and pressure regulator - 4. Compressed air inlet -
H. High gear - L. Low gear 5.consens valve
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NEW 682
1.Neutral switch for safety cab – 2. Reverse switch – 3.consent valve – 4. Selection valve – 5. Filter and pressure
reducer – 6.Red pipe – 7.Black pipe – H .High range – L. Low range.
Fault inspection of gearbox pneumatic system

(1) Inspection of pneumatic shifting system should be performed when engine is off and nominal air pressure is
largest.
(2) Check air tubes for proper installation and interference.
(3) Check the connection of air tubes for leakage.
(4) Check all the air tubes for cracks or being pinched by other parts, which may block air flow.
Inspection of the air filter regulator:
(1) Check components of the air filter regulator for defects or leakage.
(2) When the vehicle air pressure is 7,5 bar, install an air pressure gauge at the outlet, and then check if the air
pressure is adjusted to 6,5 bar. Please replace it if the reading does not meet the specification.
Inspection of the double H valve:
(1) Check for defects.
(2) Check if the cylindrical pin moves smoothly and has obvious signs of wearing.
(3) With the cylindrical pin being at initial position, check if the compressed air only flows out from the outlet 4
when the air is supplied; with the cylindrical pin being forced to the lowest position, check if the compressed air
only flows out from the outlet 2 when the air is supplied. The double H valve is normal when you see the above
results. If not, please replace it.
Inspection of the splitter gear shifting cylinder:
If there is any shifting problem after above inspections, please check that the O-ring or other sealing ring on the
cylinder piston is not defective. See the following diagram.
Figure 8
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18 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682
174285
Cylinder structural diagram (neutral gear)

H. High - L. Low
Fault analysis
1. Air hole for low gears: reverse gear, low gears (1 - 4 gears)
2. Air hole for high gears: 5 - 8 gears
3. Piston
4. O-ring leakage. It may cause a failure that prevents shifting to low gears and causes the pressure in
transmission to rise.
5. Fork rod
6. O-ring leakage. It may cause a failure that prevents shifting to high / low gears or causing continuous leakage
from double H valve vent plug.
7. Gaskets leakage and sliding may cause slowly shifting to high gears.
Noisy transmission
Transmission may present a little noise during normal operation. But if the noise is too loud or abnormal, such as
roaring or shrill, it indicates that there is fault in the gearbox. It is possible that the noise is conducted from other
noisy parts, and amplified by the gearbox.
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NEW 682
Internal noise of transmission

1. Knocking
(1) Gear teeth in transmission knocking against each other. It can be identified according by the evident spots
after performing grinding of gear teeth. Generally speaking, the noisy problem will be more obvious when the
gears are bearing a load. If noise only occurs when shifting to a certain gear, it indicates that the gear teeth of
this gear position are faulty. This kind of knocking problem can be resolved by abrasive stone or portable
grinding wheel.
(2) If there are pocks and peeling on the tracks due to damaged bearing balls or rollers, noise may occur when
performing gearshifting.
(3) If the gear has been struck or has cracks during assembly, it may have knocking at low gears and shrill at high
gears.
2. Shrill
(1) It may caused by normal wear of gears. These pocks produced in prolonged operation may present a shrill
noise before final damage of a gear.
(2) It may caused by improper gears engagement, which can be identified by the uneven wearing of gear surface.
(3) Small end and radial play may cause shrill after bearing pre-tightening.
3. Roaring
It may be the result of an error in teeth alignment. Roaring may occur because of the incorrect teeth alignment
when refitting transmission or improper teeth alignment caused by gear rotating on the lay shaft.
4. Clack
When turning the torque, clack noise may be heard due to large end play between lay shaft and main shaft. Large
radial clearance for lay shaft bearing will lead to excessive lay shaft center distance, and the gear may be broken
due to overloading of gear tips.
Transmission overheating
The transmission should have a temperature no higher than 120 °C in prolonged operation. If the operating
temperature is higher than 120 °C, the lubricant will deteriorate, and the gearbox will have a shortened service life.
The transmission will generate an amount of heat due to friction of moving parts. The normal operating
temperature is approximately 38 °C higher than the ambient temperature. Poor heat dissipation may cause
gearbox overheating.
To ensure correct reading of oil temperature gauge, be sure to check the gauge and oil temperature sensor before
performing troubleshooting. Overheating is generally caused by the following factors:
(1) Improper lubrication. The fluid level is too low/high, fluid with incorrect SAE NO, or the operating angle of
transmission is over 12°;
(2) Driving speed is generally under 32Km/h;
(3) Engine speed is high;
(4) Air flow is impeded since the gearbox is surrounded by vehicle frame, floor, fuel tank and bumper assembly;
(5) The engine exhaust system is too close to the gearbox;
(6) The ambient temperature is too high;
(7) Overload-driving and overspeed-driving.
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20 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682
Transmission gear disengagement (gear falling) or hard gearshifting

Main transmission gear disengagement
When the engaging gear seat (lay shaft sliding sleeve) and primary shaft gears are moved to be in mesh, the gear
teeth to be engaged must be parallel to each other. If the engaged gear teeth have a certain taper or wear, there
will be a trend to be disengaged for these gear teeth and gear disengagement may occur in given conditions.
Reason for gear disengagement:
(1) Transmission input shaft and pilot bearing in the engine flywheel are not concentric;
(2) The violent knocking of gears when shifting leads to wearing of the engaging teeth end surface;
(3) The engaging teeth are worn to a certain taper;
(4) The pressure applied to fork shaft positioning ball is not enough due to the weakened or damaged lock spring.
(5) Fork shaft locating slot is worn badly.
(6) The link of remote gearshift control mechanism is adjusted improperly, resulting in partial engagement of the
engaging teeth and the sliding sleeve.
(7) When the vehicle is operating in full tractive power or is driven under loading condition, gear disengagement
often occurs if it suddenly decelerates.
(8) Driving on a bumpy road, if the gear shift is very long and heavy, it may swing like a pendulum, which may
break through the pressure from lock spring, resulting in gear disengagement.
Splitter gear disengagement
Splitter gear disengagement may be caused by wear, taper or partial engagement of the engaging teeth between
the splitter drive gear and the synchronizer sliding sleeve.
These defects are the result of shifting knock and normal wear in prolonged operation.
Other factors for gear disengagement also include vibration resulting from improper propeller shaft assembly and
insufficient pressure in pneumatic shifting system.
Hard gearshifting
When performing transmission shifting, different gears require different efforts. However, it is not appropriate to
shift a gear with great efforts.
Hard gearshifting often appears on the remote control mechanism used by cab-over-engine vehicle model.
Therefore, when performing troubleshooting, please check the linkage of remote control mechanism. Furthermore,
the reasons for linkage fault are various, such as wear, improper engagement and adjustment of coupling fork or
bush, poor lubrication of joints, restricted movement of the link resulting from mechanical barriers.
To verify if the fault of hard gearshifting is caused by the transmission itself, you need to remove the gear shift
lever or link from the transmission, move the gearshift guide block by means of a pry bar or screwdriver in order to
make it engage into individual gear position. If the fork shaft can slide easily, it indicates that the fault is not in the
transmission. Otherwise, it indicates that the transmission is faulty.
If the fault is in the transmission, it may be caused by:
(1) The spline of lay shaft sliding sleeve is blocked on the main shaft, which is caused by distortion of main shaft,
fork or main shaft spline.
(2) Fork shaft is blocked in the transmission housing, which may be caused by fork shaft bending or knocking
resulting from housing cracking or applying too much tightening torque for the lock screw on the shift shaft.
(3) Lock screw on the shift shaft is loose.
Gear damage
The engaged gear teeth are damaged
It is a common defect for transmissions with a synchronizer; gears knocking may easily damage the engaged gear
teeth when performing shifting. Minor gear knocking may lead to light consequence of failure, but the violent
engaging knocking of gears before achieving synchronization will result in severe damage. In that case, the
engaging teeth end may crash and fall down.
The causes of engaged gear teeth damage are shown as follows:
(1) Improper gearshifting operation. The driver is not familiar with the gear positions, nor with the engine speed
range for different gears.
(2) When starting in first gear or reverse gear, knocking may occur due to inefficient clutch release clearance or
partial release.
Teeth damage
1. Normal wear
Since there is relative sliding during gear engaging, normal wear of gear teeth will occur. This kind of wear is slow
and stable. However, sometimes the teeth surface may wear rapidly, and shorten its service life under various
extremely adverse conditions.
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NEW 682
2. Gear teeth fracture

The fracture of gear teeth is a severe damage. Fragments of gear teeth often cause damage to other parts.
The reasons for most fractures of gear teeth are attributed to heavy-load impacts. If a gear is broken after a short
period of operation under heavy loading condition, it is known as "impact fracture". If the fracture occurs after
numerous operation cycles, it is called "fatigue fracture".
3. Pocks
A gear will show pocks generally after prolonged overloading operation, dirty lubricant or lubricant with unsuitable
SAE NO may also cause the above defects of the teeth surface. If these gears continue operating, fatigue
fractures may occur.
4. Scratching and bonding
Scratching and bonding may occur when the metal surfaces of gear teeth enter into direct contact.
Relative sliding of the metal surfaces may create a very high temperature which will soften the metal surface.
Bonding of soft metals in this condition may occur during gear engagement.
The key reason for scratching and bonding is inferior quality or lack of lubricating oil.
Deformation and breakage of gearbox

Shift deformation or breakage may occur when the torque movement applied to the shaft is larger than the
designed value. Possible causes of deformation or breakage are as follows:
1. Incorrect gearshifting methods
2. High transmission gear position when starting
3. Towing under non-compliant conditions
4. Attempt to drive the vehicle before releasing the brake
5. The service condition for the gearbox does not meet the design specification
6. The rear of vehicle bumps into other barriers
7. Fatigue or impact fracture
Bearing faults
Bearing wear features as the peeling of bearing track or roller with rough surface, which will be noisy and vibrating.
When a bearing comes to the end of its service life under normal loading and operation conditions, wear and
fatigue signs may occur.
When refitting the bushing for bearing bore inside the transmission, damage may occur if the bearing bore is too
small or out of roundness. A deformation for the bores on transmission housing may cause improper shaft
installation, resulting in early fatigue damage of bearings.
Poor lubrication
There are some features of bearing damage due to poor lubrication, such as bearing components discolouring,
bearing track peeling off, and bearing cage damage. Low lubrication level is just one of the factors of bearing
damage, and there are some other causes, such as dirty lubricant, different lubricant classifications, and mixture of
lubricants with different SAE NO.
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22 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682
Fault diagnosis guide

(1) Preliminary checks
❏ Visual check: Try to find signs of damage and pay attention to the key parts, such as mounts, connectors and
supports; check the pneumatic circuit.
❏ Collect information on working conditions and fault history of the gearbox.
❏ Create documentation including maintenance and lubricant intervals, faults occurring in the past, mileage and
days of use.
(2) Gearbox removal.
❏ Store an oil sample to check impurities when necessary.
❏ Check if the components are fitted correctly, whether there are any missing parts or non genuine components
during disassembly.
❏ Clean and check every component carefully.
(3) Identify the failure type
(4) Find the fault causes and resolve them
Internal gearbox structure – Main shaft
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NEW 682

Pressure-regulator valve defective Replace the components
Air pipe or connector loose Tighten the components
Air pipe or connector pinched Remove the components suffering
The splitter higher and lower gears interferences
are disengaged Gears disengage due to the teeth Replace the components
misalignment position caused by Identify the causes of damage
the distortion of shaft
Engaging tooth tapered Replace the components
Fork worn Replace the components
Lock spring weakened or missing Replace the components.
Gears disengage due to the teeth Replace the components
Engaging tooth tapered Replace the components
Main shaft gears are disengaged or Sliding sleeve fork groove worn Replace the components.
stepped across The sleeve resists movement Remove the components suffering
interferences
Wrong position of sleeve Replace the component
Engine support damaged Replace the components.
Engine and gearbox not centred Replace the components
Readjust according to the
requirements
Printed 603.95.397 Base - 10/2013

24 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682

Air pipe or connector loose Tighten the components
Air pipe pinched Remove the components suffering
interferences
Double H valve plug is stiff Clean the components
Shifting cylinder O-ring damaged Clean the components
Replace the components
Cylinder piston nut loose Tighten the components
Higher and lower gear shifting is Clean the components
sluggish or cannot shift Cylinder piston cracked Replace the components
Apply a thin layer of silicone lubricant
Synchronizer spring damaged Replace the components
Identify the causes of damage
Synchronizer damaged Replace the components
Cylinder O-ring lubricant inefficient Apply a thin layer of silicone
lubricant
Cylinder O-ring lubricant excessive Clean components.
Apply a thin layer of silicone
lubricant
Fork shaft bent Replace the components
Loosen the lock screw, then tighten
to proper torque.
Fork shaft burred Grind the surface with sand
Lock spring is stiff Replace the components
Gearshift housing cracked Replace the components
misalignment caused by the Identify the causes of damage
The main transmission gear shifting distortion of shaft
is difficult or cannot shift gear Main shaft deformed Replace the components
Wrong use of clutch Instruct the driver to drive correctly
The sliding sleeve resists Remove the components suffering
movement interferences
Improper clutch adjustment Readjust according to the
requirements
Engine support damaged Replace the components
Identify the causes of damage.
Interlock steel ball missing Replace the components
Interlocking is not possible
Interlock pin missing Replace the components
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NEW 682

Fork damaged Replace the components.
Gears disengage from the teeth Replace the components
alignment position due to the Identify the causes of damage
distortion of shaft
Countershaft brake not operating Replace the components
Tighten the components
Rattling sound when shifting gears Check the air pipe
The sleeve resists movement. Remove the component
Improper adjustment of connecting Readjust according to the
rod requirements
Gearshift housing sleeve worn Replace the components
Improper clutch adjustment Readjust according to the
requirements
Main shaft deformed Replace the components
The sleeve resists movement Remove the component
Cannot shift to the neutral gear
Improper adjustment of connecting Readjust according to the
rod requirements
Gears disengage from the teeth Replace the components
alignment position due to the Identify the causes of damage
distortion of shaft
Gear cracked or teeth burred Grind the surface with sand
Main shaft gear difference Replace the components
excessive
Splitter countershaft front bearing Install the missing components
Excessive noise inner race sliding
Damaged bearing Replace the components
Low oil level Identify the causes of damage
Insufficient lubricant quantity Top up lubricant
Oil change is not timely Replace components - Top up oil
level
Different oils mixed Replace the components
Main shaft gear difference Readjust according to the
excessive requirements
Gears noisy when idling
Unstable engine operation Readjust according to the
requirements
Insufficient output shaft nut Readjust according to the
tightening torque requirements
High vibration Improper propeller shaft mounting Readjust according to the
requirements
Suspension worn Replace the components
requirements
Printed 603.95.397 Base - 10/2013

26 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682

Low oil level Replace the components
requirements
The main shaft washer is burnt
Poor method of vehicle towing or Replace the components
sliding Identify the causes of damage
requirements
Starting from too high gears Instruct the driver to drive correctly
Replace the components.
Excessive loading Instruct the driver to drive correctly
Improper clutch adjustment Replace the components
requirements
The input spline is worn or
Clutch failed Replace the components
damaged
requirements
Engine and transmission not Readjust according to the
centred requirements
Improper propeller shaft mounting Readjust according to the
requirements
Engine and transmission not Replace the components
The clutch housing is damaged centred
Transmission auxiliary support Install the missing components
missing
Fork mounting reversed Replace the components
Perform mounting again
Synchronizer spring damaged Replace the components
The synchronizer is damaged
Insufficient lubricant quantity Top up lubricant
Different oils mixed Readjust according to the
requirements
Poor operation and usage Instruct the driver to drive correctly
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NEW 682

Damaged bearing Replace the components
Splitter lay shaft front bearing inner Replace the components
race sliding
Low oil level Identify the causes of damage.
Excessive oil level Check correct quantity of oil
Overheating Insufficient lubricant quantity Check correct quantity of oil
Excessive transmission working Replace damaged components
angle Readjust according to the
requirements
Oil change is not timely Replace damaged components
Top up oil again according to the
requirements
Different oils mixed Replace any damaged components
Top up with suitable oil
Starting from too high gears Instruct the driver to drive correctly
The main shaft is deformed
Excessive shock absorber loading Instruct the driver to drive correctly
Splitter lay shaft front bearing inner Replace the components
race sliding
Excessive oil level Replace the components
requirements
Housing cast defective Replace the components
The bearing is burnt
requirements
Rear flange oil sealing gasket Replace the components
damaged Identify the causes of damage
Fastening screw loose or missing Replace the components
requirements
Printed 603.95.397 Base - 10/2013

28 GEARBOX 9JS119
PT. CHAKRA JAWARA
NEW 682

Vent hole blocked Remove the components suffering
interferences
Excessive engine oil level Readjust according to the
requirements
Housing cast defective Replace the components
Leakage
Rear oil seal damaged Replace the components
Fastening screw loose or missing Readjust according to the
requirements
Install the missing components
Apply sealant
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NEW 682
PT. CHAKRA JAWARA GEARBOX 12JS 29
5302 Gearbox 12JS
Page
GENERAL INFORMATION ................................. 29
❏ Structure Features ........................................ 29

LOCATION OF GEARBOX DESCRIPTION PLATE
30
GEARBOX VIEW ................................................ 31
GEAR CONTROL LEVER ................................... 32
TOOLS ................................................................ 35
GEARBOX REMOVAL - REFITTING ................. 36
❏ Removal ........................................................ 36
❏ Refitting ......................................................... 40
BOWDEN CABLES ADJUSTMENT DIAGRAM .. 41
Printed 603.95.397 Base - 10/2013

GEARBOX 12JS NEW 682
Base - 10/2013 Printed 603.95.397

NEW 682
GENERAL INFORMATION
Structure Features
• The design combines main and auxiliary cases, small volume, light weight, high driving efficiency.
• Twin-countershaft, power distributed, unique structure.
• Fully-synchronized, easy and flexible shifts gears. Main case adopts double-cone lock-ring synchronizer, with
great capability.
Auxiliary case adopts enhanced lock-pin inertial synchronizer, with non-metal friction material, high reliability.
• Large first speed ratio (15.53), large loading capability, great climbing ability.
• Rational gear arrangement, small ratio difference, and economical fuel burning.
• Fine-teeth design, stable engagement and low noise.
• Various ways of power take-off, can fit PTO on any position of transmission.
• The gear control is single H type for a clear gear arrangement and an easy and flexible shifting.
Figure 1
172640
Gearbox name
Number (F) 12 J D S 160 T A (-B)

Description High N. Mechanic Unique Twin x10 = Input With Type of Modified
gears al structure countershaf torque Nm synchronizer ratio
t s
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32 GEARBOX 12JS
PT. CHAKRA JAWARA
NEW 682
LOCATION OF GEARBOX DESCRIPTION PLATE
Figure 2
A
E
D C
172605
A = Type of gearbox
B = Input nominal torque
C = N. drawing
D = P.T.O. gear ratio
E = Input nominal power
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NEW 682
GEARBOX VIEW
Figure 3
200124
1. Air hose to neutral position with PTO engaged – 2. Air supply tank
Figure 4
200125
1.Neutral switch for safety cab tilting - 2. Reverse switch

Printed 603.95.397 Base - 10/2013
34 GEARBOX 12JS
PT. CHAKRA JAWARA
NEW 682
GEAR CONTROL LEVER

Figure 5
R2 7 9 11
R1 1 3 5
L Front
N
8 10 12
2 4 6
172603
H = high gears - L= low gears

1. Power (Red colour) – 2. Output for lower gears (Black colour)
When engaging gears with super H, it is possible to change range using the lever switch on the gear selector.
If the lever switch is set to "Low" gears 1st to 6th are selected. If it is set to "High" gears 7th to 12th are selected.
The neutral position is at the centre of ¾ path.
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NEW 682
GEARBOX 12JS
Type Mechanical
Input torque Nm 1600
Forward gears 12
Reverse gear 2
Six main gear control Mechanical

ERG control * Pneumatic
Power take-off Optional
Gear engagement:
st nd rd th th th
1 - 2 - 3 - 4 - 5 - 6 and ERG* Free-ring synchronizer
Crawler gear and reverse Rapid engagement
Sliding sleeves locked by rollers and
Speed retention mechanism
springs.
Gears Straight toothing
E.R.G.* = Epicyclic Reduction gear Unit
Printed 603.95.397 Base - 10/2013

36 GEARBOX 12JS
PT. CHAKRA JAWARA
NEW 682
12JS160T 12JS180T
GEARBOXES 12JS160T 12JS180T
A A
Gear ratio
a
1 15.53 12.10 15.53 12.10
a
2 12.08 9.41 12.08 9.41
a
3 9.39 7.31 9.39 7.31
a
4 7.33 5.71 7.33 5.71
a
5 5.73 4.46 5.73 4.46
a
6 4.46 3.48 4.46 3.48
a
7 3.48 2.71 3.48 2.71
a
8 2.71 2.11 2.71 2.11
a
9 2.10 1.64 2.10 1.64
a
10 1.64 1.28 1.64 1.28
a
11 1.28 1.00 1.28 1.00
a
12 1.00 0.78 1.00 0.78
st
1 Reverse 14.86 11.56 14.86 11.56
nd
2 Reverse 3.33 2.59 3.33 2.59
Oil type Tutela Transmission W90/M-DA
Quantity
kg 16 16 17.85 17.5
litres 17 17 18.85 18.5
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NEW 682
TIGHTENING TORQUES
PART TORQUE
Nm (kgm)
Gearbox fastening screws M10 51 ± 5 (5.1 ± 0.5)
Bowden cables fastening M8 10 ± 1 (1 ± 0.5)
Bowden cables fastening M10 12 ± 2 (1.2 ± 0.2)
Self-locking nut M12 83.5 ± 8.5 (8.35 ± 0.8)
Self-locking nut M14 162 ± 16 (16.2 ± 1.6)
Self-locking nut M16 221 ± 22 (22.1 ± 2.2)
TOOLS
TOOL No. NAME
Stand for supporting the transmission unit during

99370629
removal and refitting
99360341 Tool for rotating the flywheel
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38 GEARBOX 12JS
PT. CHAKRA JAWARA
NEW 682
.530210. GEARBOX REMOVAL - REFITTING

Removal
In order to remove the gearbox, proceed as follows:
❏ Place the vehicle over a pit or on an auto lift.
❏ Disconnect the battery leads by means of the "battery disconnector" in order to avoid possible short circuits.
Operations from above the vehicle:

Figure 6
8 1 2
10 3
9
5
14
171941
❏ Disconnect the Bowden cables (2-7) by operating on the fastenings (6).

❏ Disconnect the plate (3) complete with support, by operating on fastenings (1).
❏ Disconnect the gear selection and engagement electrical connectors (10).
❏ Cut and remove the various cable bundle straps (4) coming from the chassis.
❏ Disconnect the pneumatic pipes (5) (red and black pipe) connected to Bowden cables.
❏ Loosen the upper screws (8) fastening the gearbox case to the engine.
❏ Remove the fastening bracket (9) on the gearbox by operating on fastenings (11).
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NEW 682
Operations from under the vehicle:

Figure 7
11
1
10 2
9 3
8 5
7
12
171942
❏ Remove the propeller shaft (1) with the support tool 99370618, see relative chapters in the section 5 on
camshafts.
❏ Remove the fastenings (2) securing the shaft to the gearbox.
❏ Remove the fastenings securing the shaft to the rear axle.
❏ Free the shaft (3) of the gearbox power take-off, operating on fastenings (4) and marking the assembly side on
the shaft (gearbox).
❏ Cut and remove the electrical cable straps (10) coming from the chassis to the gearbox.
❏ Disconnect the ground cable (7) from the chassis to the gearbox case by operating on fastening (8).
❏ Disconnect the speed sensor cable (11) from the speed sensor (9) and the pneumatic actuators (5-6-12)
❏ Check there are no interferences in the cabling.
❏ Disconnect the power take-off actuation sensor (6).
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40 GEARBOX 12JS
PT. CHAKRA JAWARA
NEW 682
Figure 8
6
1
3
4
171943
❏ Disconnect the chassis bracket (6) by operating on fastenings (7) and support it on a suitable hydraulic jack.
❏ Disconnect the clutch actuator (2) by operating on fastenings (1) and secure it to the chassis.
❏ Fit a hydraulic jack with support 99370629 (3) under the transmission.
❏ Remove the gearbox from the gearbox "suspension" (5) by removing the middle (4) and side fastenings (4).
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NEW 682
Figure 9
1 2
6 5
171944
❏ Unscrew the last fastenings (6) fixing the gearbox case to the engine.
❏ Remove the clutch inspection cover (8) and remove the thrust plate spring (2) using your hand inside the
inspection hole (5).
❏ Unscrew the plug and screw in the tool 99360341 (4) to allow the engine to turn, so it is possible to remove the
spring (2) of the thrust plate.
❏ Remove the fork lock (1) engaging the thrust plate by operating on the fastenings.
❏ Remove the gearbox from the vehicle, ensuring that the support tool 99370629 (3) and the hydraulic jack are
placed correctly in order to sustain the weight of the gearbox.
Printed 603.95.397 Base - 10/2013

42 GEARBOX 12JS
PT. CHAKRA JAWARA
NEW 682
Refitting
Operations from under the vehicle:

❏ Refit fork (1, Figure 9) engaging the thrust plate, then fit the clutch inspection cover (8, Figure 9).
❏ Place the gearbox under the vehicle and bring it near to the coupling on the engine, on the clutch side.
❏ Screw in the screws (6, Figure 9) fixing the gearbox case on the bottom side and tighten them to 50 Nm.
❏ Remove tool 99360341 (4, Figure 9) to turn the engine and screw in the plug.
❏ Refit the gearbox to the gearbox "suspension" (5, Figure 8), tightening the middle and side screws (4, Figure
8).
❏ Remove the gearbox support tool 99370629 (3, Figure 8).
❏ Refit the clutch actuator (2, Figure 8 ) by operating on fastenings (1, Figure 8).
❏ Reconnect the chassis fastening bracket (6, Figure 8), lifting it with the hydraulic jack and placing it under the
gearbox, then screw in the eight fastening screws (7, Figure 8).
❏ Reconnect the power take-off actuation sensor (6, Figure 7).
❏ Reconnect the speed sensor cable (11, Figure 7) to the speed sensor (9, Figure 7) and the various actuators
(5-6-12, Figure 7) checking that there are no interferences in the cabling.
❏ Reconnect the ground cable (7, Figure 7) going from the chassis to the gearbox case, by tightening fastenings
(8, Figure 7).
❏ Fit the straps to the electrical cables (10, Figure 7) going from the chassis to the gearbox.
❏ Reconnect the PTO shaft (3, Figure 7) to the gearbox, tightening fastenings (4, Figure 7) and taking care to fit
the shaft correctly on the gearbox side.
❏ Place the propeller shaft (1, Figure 7) in the seats on the gearbox side and rear axle side with tool 99370618,
tighten the fastenings (2, Figure 7) on the gearbox and rear axle sides, see the relative chapter in section 5,
camshafts.
Operations from above the vehicle:

❏ Screw in the screws (8, Figure 6) fastening the gearbox case on the top side and tighten them to 50 Nm.
❏ Bind the cable bundle (4, Figure 6) coming from the chassis with straps.
❏ Fasten the cable bundle to the stud bolt of the gearbox case by means of the support bracket.
❏ Reconnect the pneumatic pipes connected to Bowden cables (5, Figure 6) (red and black pipe).
❏ Reconnect the plate (3, Figure 6) of the Bowden cables (2-7, Figure 6) complete with support, by operating on
fastenings (1, Figure 6).
❏ Reconnect the selection and engagement electrical connectors (10, Figure 6) to their seats on the gearbox.
❏ Reconnect the Bowden cables (2-7, Figure 6) by operating on the fastenings (6, Figure 6).
❏ Top up the power steering oil, coolant fluid and R134 gas of the air conditioning system.
❏ Reconnect the battery cables and remove the vehicle from the lift.
Base - 10/2013 Printed 603.95.397

NEW 682
BOWDEN CABLES ADJUSTMENT DIAGRAM

Figure 10
177316
1. Gears selection Bowden cable - 2. Gears engagement Bowden cable - A. Cab side - B. Gearbox side
This diagram shows the dimensions for adjustment of the gear control Bowden cables.
Printed 603.95.397 Base - 10/2013

44 GEARBOX 12JS
PT. CHAKRA JAWARA
NEW 682
Base - 10/2013 Printed 603.95.397

NEW 682
PT. CHAKRA JAWARA STEERING SYSTEM 1
SECTION 10
5014 Steering system
Page
DESCRIPTION .................................................... 3
STEERING CONTROL DIAGRAMS ................... 5
❏ Steering control diagram for 4x2 - 6x4 vehicles

❏ General torques ............................................ 7
TOOLS ................................................................ 7
POWER STEERING SYSTEM REMOVAL -
REFITTING ................................................... 8
❏ Removal ........................................................ 8
❏ Refitting ......................................................... 9
BLEEDING THE POWER STEERING SYSTEM 9
CHECKING MAXIMUM PRESSURE OF POWER
STEERING SYSTEM.................................... 10
❏ Setting the automatic hydraulic steering limit
❏ Check ............................................................ 10
DIAGNOSTICS.................................................... 11
Printed 603.95.397 Base - 07/2012

2 PT. CHAKRA JAWARA
STEERING SYSTEM NEW 682
Base - 07/2012 Printed 603.95.397

NEW 682
DESCRIPTION
The power steering ZF 8098 is equipped with a ball recirculation control system; this basically consists of one
housing including the mechanism for manual steering, one hydraulic cylinder governed by a rotary control valve
and automatic valves for hydraulic limiting of steering and for safety.
Figure 1
142699
ZF 8098 POWER STEERING
A = Code ECC 200

B = Progressive production number
C = Date of manufacture
Printed 603.95.397 Base - 07/2012

4 PT. CHAKRA JAWARA

ZF 8098 ball circulation with integral
pressure relief valve (the hydraulic guide
Power steering
can be provided with a hydraulic device to
automatically adjust the steering angle limit)
Operating pressure variable 170 + 10 bar
Reduction ratio
variable:
- steering centre 22.2:1
- maximum steering 26.2:1
Power steering pump ZF
o
Minimum N of RPM rpm 500 500
o
Maximum N of RPM rpm 4700 3500
Maximum pressure
bar 180 180
(without pressure relief valve)
3
Capacity dm /min 22 16
Power steering oil
Oil type HIDRAULIC CAR 32 HVI
Quantity litres 5
Base - 07/2012 Printed 603.95.397

NEW 682
STEERING CONTROL DIAGRAMS

Steering control diagram for 4x2 - 6x4 vehicles
Figure 2
90645
Printed 603.95.397 Base - 07/2012

6 PT. CHAKRA JAWARA
TIGHTENING TORQUES
Figure 3
C-C section
A-A section
137224
TORQUE
PART
Nm (kgm)
1 Hexagonal nut with collar for steering support and idler arm 226 ± 22.5 (22.6 ± 2.3)
2 Castellated nut for steering linkage and hydraulic cylinder * 300 (30)
3 Fixing collar for track rod and drag link arm 80 ± 10 (8 ± 1)
4 Flanged hexagonal head screw for fixing steering gear stand 278 ± 28 (27.8 ± 2.8)
226.5 ±
5 Self-locking flanged hex nut for steering gear stand (22.6 ± 2.2)
22.5
527.5 ±
6 Hexagonal head screw for steering box (52.7 ± 5.3)
52.5
7 Hexagonal nut for lever on the steering box 575 ± 55 (57.5 ± 5.5)
527.5 ±
8 Calibrated hexagonal head screw for steering box (52.7 ± 5.3)
52.5
9 Self-locking nut for universal joint 55 ± 5 (5.5 ± 0.5)
10 Calibrated screw for universal joint 55 ± 5 (5.5 ± 0.5)
M16 310 ± 45 (31 ± 4.5)
11 Screws fastening steering case to chassis 447.5 ±
M18 (44.75 ± 6.25)
62.5
M24 265 ± 15 (26.5 ± 1.5)
12 Nuts fixing ball joints to steering tie-rods
M20 220 ± 10 (22 ± 1)
Single 80 ± 10 (8 ± 1)
13 Nuts fastening steering tie rod collars
Double 40 ± 5 (4 ± 0.5)
14 Nuts fastening universal joint to steering control shaft M10 55 ± 5 (5.5 ± 0.5)
* If the notch does not correspond to the hole when tightened at the prescribed torque, further tighten until the
split pin can be fitted.
Base - 07/2012 Printed 603.95.397

NEW 682
General torques
NOTE If not otherwise indicated, refer to the torques shown in this table:
Screw / Nut Torque (Nm)

M12 120
M16 350
M20 600
M22 900
M24 1100
M27 1650
TOOLS
TOOL No. NAME
99347068 Extractor for ball joint
Printed 603.95.397 Base - 07/2012

8 PT. CHAKRA JAWARA
.541430. POWER STEERING SYSTEM Figure 6

REMOVAL - REFITTING
Removal
Set the vehicle with its wheels straight. Lift up the
radiator cowling and tilt up the cab.
Remove the front bumper as described in the relevant
Figure 4
174276
Mark the assembly position of the universal joint (1) on

the power steering.
Remove the bolt (2) and disconnect the universal joint
(3) from the power steering case (3).
Figure 7
174274
Remove the screws (2) and detach the step (1).
Unscrew screws (4), remove the brackets (5) and
remove the cab access footboard (3).
Figure 5
174277
Unscrew the screws (6) and remove the power steering

system (2) from the vehicle, including the support
bracket (1) and steering lever (4).
174275 Secure the power steering system in a vice and hold
Undo the unions (3) and drain the power steering the lever (4) so as to prevent the power steering shaft
system oil into a suitable container. from turning, then unscrew the nut (5) by means of a
Disconnect unions (1) and (7) from the power steering suitable spanner and remove arm (4).
case (8) and remove the oil pipes (2). Unscrew the screws (3) and remove the power steering
Remove the split pin and undo the nut (6). (2) from the support bracket (1).
Using an extractor 99347068, disconnect the
longitudinal tie rod (5) from the steering lever (4).
Base - 07/2012 Printed 603.95.397

NEW 682
Refitting .501430. BLEEDING THE POWER STEERING

SYSTEM
Carry out the steps performed for removal To bleed the power steering system, proceed as
in reverse order. follows.
Lubricate the screws securing the hydraulic Fill the power steering fluid reservoir with the
power steering box with oil. prescribed fluid (HIDRAULIC CAR 32 HVI).
Replace the O-rings on the couplings of the Turn the engine over with the starter motor and top up
disconnected pipes. the fluid continually to prevent air being drawn into the
Tighten the screws to the recommended pump. Top up the fluid until the level remains constant
tightening torques. above the minimum mark on the dipstick.
Bleed system as directed in the relevant Start the engine and run at idle, checking that the oil
chapter (operation 501430). level does not drop below the minimum notch mark on
the dipstick.
Rotate the steering wheel several times from stop to
NOTE Since the power steering incorporates stop so that air cannot go out of the hydraulic power
automatic adjustment of the hydraulic steering cylinder, until no air bubbles can be seen
steering limit control, after refitting the coming into the tank.
power steering unit, set the automatic Fully accelerate the engine, stop it and check that the
adjustment as described in the relevant level of oil in the tank climbs no more than 1 to 3 cm.
chapter.
Printed 603.95.397 Base - 07/2012

CHECKING MAXIMUM PRESSURE OF POWER In this position, apply an additional force on the
STEERING SYSTEM steering wheel to determine the automatic setting.
Repeat the same operations in the other steering
Using a pair of suitable pressure testers previously
direction.
connected and the wheels locked on driver side, start
Should the range of the steering control lever be
the engine and run at idle; apply a steering force of 10
reduced, replace the faulty steering limiting bush with
÷ 20 kg to the steering wheel and record the pressure
a new one, or both bushes, if the defect also affects
reading on the 0÷160 bar gauge.
the range in the opposite direction.
Repeat the operation applying the same steering force
The steering angle can always be increased without
in the opposite direction; if the readings obtained are
replacing the bushes.
lower than specified, locate the source of the problem.
Check
NOTE The maximum pressure is given on the Carry out the check by fitting a pressure gauge
data plate attached to the ZF steering box. (minimum end of scale value 200 bar) to the pressure
test fitting on the supply line from the pump to the
hydraulic power steering and apply a steering force at
the steering wheel of 50 ± 20 Nm (corresponding to
Setting the automatic hydraulic steering
200 ± 80 N on a 500 mm diameter steering wheel),
limit turning the wheel to the full lock position.
The pressure reading should be within the range of 35
Figure 28 and 70 bar. In the case of excessively high pressure,
the adjustment bushes must be replaced with new
ones, and the adjustment operation must be repeated.
If the pressure is too low, check that the hydraulic
system is operating properly and that there are no
leaks.
60925
This adjustment is made after fitting the hydraulic

power steering system on the vehicle, with the vehicle
unladen and the front wheels raised or placed on
turntables. Adjustments shall be performed in both
steering directions as described below.
Make sure that the gearbox is in neutral.
The procedure must be carried out with the engine off
or on.
Turn the steering wheel slowly in one direction until the
stop bush (2) installed on the on the knuckle (3)
touches the axle (1).
NOTE Make sure that the limit stop of the axle is

reached effectively, otherwise the hydraulic
power steering would be considerably
reduced just before reaching the limit stop.
Base - 07/2012 Printed 603.95.397

NEW 682
DIAGNOSTICS

With engine running, check the level;
System oil level too low. top up oil to upper mark on the
dipstick and bleed the system.
Check the intake tube and pump
Air in the hydraulic system. shaft seal for leaks and top up the
oil. Bleed the system.
Pump regulating valve jammed or Remove the valve, wash and check.
blocked The opening should not be blocked.
Insufficient oil pump flow rate. Overhaul or replace the pump.
Free the joint by moving it back and
Steering stiff when turning right and Spider not sliding well. forth several times so that it can tilt
left under its own weight.
Poor lubrication of transmission
Grease the transmission lever
lever bearings (on vehicles with
bearings.
second steering axle).
Worn transmission lever bearings
Overhaul the transmission levers
(on vehicles with second steering
and replace worn parts.
axle)
Hydraulic cylinders not working (on
Replace the involved cylinders.
vehicles with second steering axle).
A hydraulic pump is not working Overhaul the hydraulic pump or
(8x4x4 vehicles). replace it.
Send hydraulic power steering to a
Inefficient internal gaskets.
ZF service centre.
Steering stiff only when turning left or Incorrect position of hydraulic centre
right (when wheel is released, the Have hydraulic power steering
steering returns to one end of travel adjusted by a ZF service centre.
by itself).
Limiter valve blocked Remove the valve, wash and clean.
Hydraulic pump flow rate is Overhaul the hydraulic pump or
Steering stiff when the wheel is inadequate (worn gears). replace it.
turned quickly
Air in the steering system. shaft seal for leaks and top up the
(Continued)
Printed 603.95.397 Base - 07/2012


Universal joint is slack. Replace the universal joint.
Hydraulic power steering internal Send hydraulic power steering to a
breakdown. ZF service centre.
System oil level too low. Top up oil and bleed the system.
Carry out the checks and
Incorrect wheel geometry.
adjustments.
Hard knocks on the steering wheel
when steering Balance in accordance with
Unbalanced wheels. instructions given in the section
”Wheels and tyres”.
Steering rods ball joint loose. Replace any worn parts.
Pump not operating correctly. Replace the pump.
Oil seepage from hydraulic power Check the efficiency of the coupling
steering circuit fittings. seals, replacing any which are worn.
Balance in accordance with
Unbalanced wheels. instructions given in the section
”Wheels and tyres”.
Perform checks and adjustments in
Torsional vibration of the steering
Incorrect front wheel geometry. accordance with characteristic data
wheel
found in the ”AXLE” section.
Air in the hydraulic system. shaft seal for leaks and top up the
Backlash in ball joints and/or flexible
Replace the ball joints.
mountings are slack.
Excessive steering wheel clearance Universal joint is slack. Replace the universal joint.
Hydraulic power steering internal Send hydraulic power steering to a
breakdown. ZF service centre.
Tank cover not secured. Secure the cover.
Replace the worn gaskets, top up
Seal gaskets worn.
fluid and bleed.
Loss of fluid
In any case it is necessary to determine the place and the reason the oil is
leaking, eliminate the cause and top up oil in the tank with the engine
started up to the upper mark of the dipstick.
Overhaul the hydraulic pump or
Pump not operating correctly.
replace it.
Check the efficiency of the seals
Fluid leaking from circuit connectors. and of the couplings, replacing any
Insufficient pressure in the circuit which are worn.
Top up the oil level and bleed the
Insufficient fluid level in the tank.
circuit.
Fluid leaking from couplings in
Replace the faulty cylinders.
power steering circuit (8x4x4).
Base - 07/2012 Printed 603.95.397

NEW 682
PT. CHAKRA JAWARA ELECTRIC/ELECTRONIC SYSTEM 1
SECTION 14
Electric/Electronic System
Page
GENERAL WARNINGS FOR ELECTRICAL/

ELECTRONIC COMPONENTS ................... 5
❏ Practical advice ............................................ 7
COMPONENT CODE ......................................... 8
CAN LINE ........................................................... 11
❏ CAN line efficiency tests .............................. 11
❏ VDB (Vehicle Data Bus) communication Line
POWER NETWORK ........................................... 13
❏ Power cable section: .................................... 13
❏ Negative network ......................................... 13
GROUNDING POINTS ....................................... 14
ELECTRICAL EQUIPOTENTIAL BRAID............ 15
MITSUBISHI 28V-90A ALTERNATOR [03000] .. 19
STARTER MOTOR "Nippondenso" 24V - 4.5kW
[08000] ......................................................... 21
JUNCTION CONNECTORS ............................... 23
❏ Junction connector location.......................... 23
❏ List of connectors ......................................... 24
❏ Junction connector ST01 (black) - ignition key
❏ ST02A (grey) - connection for steering column
❏ ST06A junction connector (yellow) - roof
panel wings devices on the driver side ........ 26
❏ ST06B junction connector (black) - tachograph
❏ Junction connector ST08A (blue) - driver
side door....................................................... 28
❏ Junction connector ST08B (blue) - driver
side door....................................................... 29
❏ Junction connector ST09A (blue) - passenger
side door....................................................... 30
❏ Junction connector ST09B (blue) - passenger
side door....................................................... 31
❏ ST15 junction connector (yellow) - Connection
for couplings in the high roof ........................ 32
Printed 603.95.397 Base - 07/2012

2 ELECTRIC/ELECTRONIC SYSTEM
PT. CHAKRA JAWARA
NEW 682
Page Page
❏ T16 junction connector- connection for LH DRIVE CONTROL [54033] ............................ 52

pneumatic horn ............................................. 32 RH DRIVE CONTROL [54030] ........................... 53
❏ ST31A junction connector (green) - Cab rear CRUISE CONTROL AND ENGINE BRAKE
❏ ST79A junction connector (yellow) - CONTROL .................................................... 54
external cab front .......................................... 34 INSTRUMENT CLUSTER [50005] ..................... 55
❏ Junction connector ST79B (yellow) - windshield
❏ Description.................................................... 55
washer and warning horn unit ...................... 35
❏ STY1 - STY2 junction connector .................. 36 ❏ Versions available ........................................ 57
❏ STY1 junction connector - right light ❏ Optical indicators on cluster ......................... 58

cluster cable ................................................. 36
❏ Indicators on display (failure) ....................... 61
❏ STY2 junction connector - left light
cluster cable ................................................. 36 ❏ Cluster (pin-out) ............................................ 63
❏ ST82000A - ST82000B junction connector .. 37 TACHOGRAPH [40011]...................................... 64
❏ ST82000A junction connector - manual VOLTAGE REDUCER [85031] ........................... 65
control air conditioning system ..................... 37
❏ ST82000B junction connector - manual CENTRAL INTERCONNECTING UNIT [75000]. 66
control air conditioning system ..................... 37 ❏ Contactor assembly ...................................... 67
❏ ST82000C junction connector - manual
❏ Supplementary relay switches...................... 68
control air conditioning system ..................... 38
❏ X56/3/A junction connector - rear ❏ Diagram of fuses .......................................... 69
chassis wiring ............................................... 39
❏ Connector assembly ..................................... 71
❏ X56/3/B junction connector - trailer prefitting
LOCATION OF CONTROL UNITS ..................... 78
❏ 7-poles current outlet for trailer electric
connection .................................................... 41 BODY CONTROLLER (IBC2) [86116] ................ 79
❏ 72000 - standard 7-poles current outlet for
❏ Connection connectors ................................. 79
trailer electric connection .............................. 41
REAR VIEW MIRROR CONTROL CONTROL
❏ 72001 - auxiliary 7-poles current outlet for
UNIT [86021] ................................................ 84
trailer electric connection .............................. 41
CENTRAL LOCKING CONTROL UNIT
❏ 72006 - 7-poles current outlet for trailer
[86029] .......................................................... 85
ABS electric connection ............................... 41
DIAGNOSIS SOCKETS ...................................... 86
BULKHEAD ......................................................... 42
❏ Diagnosis connector - [72021]...................... 86
❏ "A" connector pin-out (white) ........................ 43
❏ OBD diagnosis connector (blue) [72069] ..... 87
❏ "B" connector pin-out (brown) ...................... 44
❏ 7 pole diagnostics connector [72XXX] ......... 88
❏ "C" connector pin-out (yellow) ...................... 45
EDC SYSTEM FUNCTIONS............................... 89
❏ "D" connector pin-out (blue) ......................... 46 ❏ Components on engine ................................ 91
❏ "F" connector pin-out (green) ....................... 47 ❏ EDC 7 UC31 electronic control unit [85150] 92
INSTRUMENT PANEL ........................................ 48 ❏ Electro-injectors [78247] ............................... 97
CENTRAL DASHBOARD ................................... 49 ❏ Engine coolant temperature sensor [85153] 98
❏ Cab inside lights ........................................... 50 ❏ Fuel temperature sensor [47042] ................. 99
❏ Rearview mirror adjustment / power window ❏ High pressure pump (Pressure regulator)
control / tool compartment opening control......... 51 [78013] .......................................................... 100
Base - 07/2012 Printed 603.95.397

NEW 682
Page
❏ Flywheel pulse transmitter [48035] .............. 101

❏ Camshaft pulse transmitter [48042] ............. 102
❏ Oil pressure/temperature sensor
[42030]/[47032] ............................................ 103
❏ Air temperature and pressure sensor [85156]
❏ Fuel pressure sensor on rail [85157] ........... 105
❏ Engine brake solenoid valve [78050] .......... 105
ABS (ANTI-LOCK BRAKE SYSTEM) ................. 106

❏ ABS (Anti-Lock Brake System) .................... 106
❏ Operating logic ............................................. 107
❏ ABS electronic control unit [88000] .............. 107
❏ ABS control unit pin - out ............................. 108
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Base - 07/2012 Printed 603.95.397

NEW 682
PT. CHAKRA JAWARA 5
ELECTRIC/ELECTRONIC SYSTEM
GENERAL WARNINGS FOR ELECTRICAL/ELECTRONIC COMPONENTS
NOTE Never disconnect the system's batteries or open the cut-off switch with the engine running.
Do not start the engine without first having connected the batteries in a permanent manner.
❏ Before doing any work on the vehicle chock the wheels appropriately.
❏ Do not use fast chargers to start up the engine. Start up must only be performed with either separate batteries
or special truck.
❏ Incorrect polarisation of voltage supply to the electronic control units (for example, incorrect polarization of
batteries) may lead to their destruction.
❏ If you have to disconnect the batteries from the system, always disconnect the chassis ground cable from the
negative terminal of the batteries first.
❏ Before connecting the batteries to the system, make sure that the system is suitably insulated.
❏ Disconnect the batteries from the system during their recharging with an external apparatus.
❏ Disconnect the external recharging apparatus from the public utility network before removing the apparatus
pins from the battery terminals.
❏ With temperatures above 80 °C (drying ovens) remove the electronic control units.
❏ On connecting, only screw connector (temperature sensors, pressure sensors, etc.) nuts to the prescribed
tightening torque.
❏ Before working on the vehicle's electrical/electronic system, disconnect the positive pole of the battery.
❏ Isolate the circuit prior to disconnecting the junction connector from an electronic control unit.
❏ Do not cause sparks to verify the presence of voltage in a circuit.
❏ Do not use a test lamp to verify circuit continuity, but proper control equipment only.
❏ Do not directly supply current to components served by electronic control units with nominal vehicle voltage.
❏ Ensure that the wiring of electronic devices (length, lead type, location, strapping, connection to screening
braiding, grounding, etc,) complies with the IVECO system and are carefully restored after repair or
maintenance operations. To prevent malfunctions of the on-board electronic equipment, the cabling of
accessory equipment must be routed separately from that of the above-mentioned systems.
❏ Do not connect the negative poles of the accessory equipment to the negative poles of the electronic
equipment.
❏ In the event of electric welding on the vehicle, disconnect all the electronic control units and/or disconnect the
power cable from the battery positive terminal and connect it to the chassis ground.
❏ The connectors are viewed from cable side.
Key storage procedures are affected by electromagnetic disturbances such as cell phones and the like.
! Therefore, during key storage:
1. Take care that there are no such disturbances in the vicinity of the keys or in the cab.
2. Keys not inserted in the panel must be at least 1 metre away.
When working on electronic control units, plug connections and electrical connections to the
! components, measurements can be made only on suitable testing lines, by means of special plugs and
plug-type bushes.
Never use improvised equipment like metal wires, screwdrivers, pins or similar. In addition to the risk of
causing a short circuit, this might damage plug-type connections and this would then give rise to contact
problems.
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
NOTE The connectors are viewed fromcable side.Connector views contained in the manual are
representative of cable side.
Base - 07/2012 Printed 603.95.397

NEW 682
PT. CHAKRA JAWARA 7
In order to prevent damage or short-circuiting of the on-board electronic control units, the following
operations must
be always carried out before starting any welding operation on the chassis:
❏ If electric welding is to be carried out on the vehicle,
112514
isolate the electrical system as follows:

a) disconnect the power supply cable from battery positive terminal and connect the cable to chassis
ground;
b) disconnect the power supply cable from battery negative terminal;
c) disconnect the connectors from electronic control units and ward off touching control unit connector pins
with your hands.
❏ Moreover:
a) if the control unit is near the part to be welded, remove the control unit from its position;
b) where possible, connect the welding machine ground directly to the piece to be welded.
In the case of vehicles equipped with a DTCO digital tachograph, do not disconnect the battery
leads and then connect them by jumpers to reset the electronic systems.
This operation should be avoided, as it could cause permanent damage to the DTCO tachograph
CARD or other on-board electronic systems.
To reset the electronic system without running risks, disconnect the vehicle battery and wait for
10 minutes.
It is strictly forbidden to carry out any modifications or connections to the electronic control unit
wiring. In particular, the data line between the control units (CAN line) is to be considered
untouchable.
Diagnostic and maintenance operations can only be carried out by authorised personnel with
IVECO approved equipment.
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Practical advice
The negative conductors connected to a system grounding point must be as short as possible and connected in a
"star"pattern, as well as being tightened down correctly and as specified.
The following precautions must be observed regarding the electronic components:
❏ Control units must be connected to the system ground when equipped with metal housings.
❏ Electronic control unit negative cables must be connected to a system ground point, such as the dashboard
compartment ground (avoiding "serial" or "chain" connections), as well as to the negative terminal of the
battery/ies.
❏ Even if not connected to the circuit ground/battery negative terminal, analogue ground (sensors) should have
optimal isolation. Consequently, particular care should be given to terminal parasitic resistances: oxidation,
clinching defects, etc.
❏ The metal braid on shielded circuits must be in electrical contact at both ends with system components.
❏ Only one end of the braid should be connected to the system ground.
❏ In the case of junction connectors, the unshielded section d, near to the latter, must be as short as possible
(Figure 1).
❏ The cables must be routed in such a way as to be parallel to the reference plane, as close as possible to the
chassis/body.
❏ The additional electro-mechanical systems must be carefully connected to the system ground and must not be
set alongside the cables of the electronic components.
Figure 1
SHIELDING THROUGH METAL BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT -

C. CONNECTOR - d. DISTANCE → 0
Base - 07/2012 Printed 603.95.397

NEW 682
PT. CHAKRA JAWARA 9
COMPONENT CODE
03000 Self-rectifying alternator with built-in voltage regulator

08000 Starter motor
12010 Motor for locking or unlocking door on passenger side
12011 Motor for outside air intake door
12012 Window shade motor
12032 Cab hydraulic release pump motor
12034 Tool compartment opening motor
19005 Thermostarter
20000 Starter battery
22000 Horn
22047 Warning buzzer for ACC (Adaptive Cruise Control)
25003 Contactor for fog light
25007 Remote reversing light switch
25200 Start-up contactor
25213 Contactor for supply of users connected to ignition switch through battery positive
25222 Contactor for thermostarter activation consent
25326 Contactor for short activation of air-conditioning system
25327 Contactor for connection of air-conditioning system
25530 Contactor to turn on internal lights when front door opens
25705 Remote control switch for vehicle diagnosis
25722 Cab hydraulic release pump contactor (lowering)
25723 Cab hydraulic release pump contactor (raising)
25805 Horn control contactor
25810 Relay switch for diesel heating circuit control
25813 Contactor for heated rear view mirror activation
25819 Overhead reading light contactor
25825 Contactor for pre-filter heating control
25847 Contactor for cab tilting motor
25903 Contactor for EDC deactivation
25906 Contactor to turn off engine with power-pack failure
30001 Low beam and high beam with side light
30011 Fog light
32002 Front turn indicator light
32005 Front clearance light
33001 Side turn indicator light
34000 Multi-function rear light
34011 Fifth wheel light
35000 Number plate light
37002 Rear clearance light
39003 Overhead light for step lighting
39009 Courtesy light for reading lights
39022 Courtesy light for adjustable cab interior spot light
39027 Bunk ceiling light tool
39030 Cab side opening lighting lamp
40011 Electronic tachograph
40032 Sender unit for speedometer and tachograph
42030 Transmitter for engine oil pressure gauge
42031 Transmitter for front brake air pressure gauge
42032 Transmitter for rear brake air pressure
42351 Switch for signalling clogged air filter
42374 Switch on clutch for EDC
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
42393 Speed limiter adjustment switch

42608 Coolant pressure signalling 3-switch assembly
44031 Fuel level indicator transmitter with contact for reserve warning light
44035 Windscreen washer low fluid level indicator control
44036 Radiator low water level indicator control
44037 Insufficient power steering fluid level gauge control unit
47032 Transmitter for engine oil temperature signalling thermometer
47042 Fuel temperature sensor
48035 Engine speed sensor
48042 Engine speed sensor on timing system
50003 Electronic instrument panel with microprocessor for instrument and warning light display
52004 Switch for heated rear view mirrors
52007 Switch with pilot lamp for rear for light
52009 Switch with built in warning light for trailer light
52045 Switch for front drive engagement
52057 ABS shut-off switch
52070 Switch for engaging side power takeoff
52071 Switch for engaging rear power takeoff
52094 Switch for spot light
52200 Switch for electric or pneumatic horns
52302 Emergency light switch with incorporated indicator
52307 Switch for exterior lights
52321 Switch with incorporated indicator light for fog lights and rear fog lights inhibitor
52324 Engine brake prefitting switch
52502 Key-controlled switch for services with start-up
52600 Main power switch
53006 Switch for start-up from engine compartment
53007 Switch for stopping engine from engine compartment
53022 Front differential lock control switch
53039 Rear differential lock activation switch
53061 Cab hydraulic release consent switch
53062 Cab hydraulic release pump switch (lowering)
53063 Cab hydraulic release pump switch (raising)
53075 Momentary switch for opening the tool compartment
53300 Electric window switch - driver side
53302 Electric window switch - passenger side
53306 Sun roof motor control switch
53310 Total PTO on gearbox engagement signalling switch
53400 Cluster menu control switch (UP)
53401 Cluster menu control switch (DOWN)
53402 Cluster menu control switch (C)
53403 Cluster menu control switch (OK)
53501 Stop signalling switch
53503 Reverse light switch
53504 Front differential locking engaged indicator switch
53507 Switch for signalling low gears engaged
53508 Switch for preventing start-up with gears engaged and turning on reversing light
53509 Internal light switch
53510 Switch for switching on step lights
53511 Switch for signalling cab disconnected
53512 Switch for preventing start-up with handbrake off
53517 Switch for signalling transversal lock engaged
53521 Switch for signalling longitudinal lock engaged
53538 Switch for signalling body tipped
54033 6-function steering column switch unit
61001 Container for 3 1A diodes (2 with common anode)
61101 Diesel heating element
Base - 07/2012 Printed 603.95.397

NEW 682
61104 Air braking system drier resistor

61110 Heating element for diesel fuel decanter and pre-filter heating
64000 Electric windscreen washer pump
65000 Windscreen wiper unit
66005 Headlight washer pump
68000 Radio receiver
68001 Loudspeaker
68002 Antenna
70000 6 fuse holder (30 A)
72000 Standard 7-pole connector for electrical connection to trailer
72001 Supplementary 7-pole connector for electrical connection to trailer
72006 7-pole connector for tractor-trailer ABS/EBS electrical connection
72021 30-pole connector for electrical connection to ground diagnostics
72054 Power socket 6A
72069 16-pole connector for OBD (On Board Diagnostics)
75000 Connection panel
78013 Solenoid valve to adjust pressure
78050 Engine brake control solenoid valve
78052 ABS/EBS solenoid valve
78203 Solenoid valve for pneumatic horns
78206 Solenoid valve for longitudinal differential lock
78247 Electronic injection solenoid valve
78263 Solenoid valve for rear transverse differential lock
78264 Solenoid valve for front transverse differential lock
80000 Passenger door power window motor
80001 Driver door power window motor
82000 Electric windscreen defroster control unit
85000 Cigarette lighter
85006 Heated rearview mirror and electric adjustment (main)
85007 Heated rearview mirror and electric adjustment (approach)
85008 Heated rearview mirror and electric adjustment (wide-angle)
85010 Rear view mirror control
85011 Side mirror selection and side mirror heating on control
85031 Potential divider for power socket (max. 11A)
85040 Motor for sunroof with incorporated switch
85150 EDC control unit
85152 Accelerator load sensor for EDC
85153 Coolant temperature sensor (EDC)
85156 Turbo blower air pressure and temperature sensor for EDC
85157 Pressure adjustment sensor
86013 Sensor for signalling water in fuel filter
86021 Control unit for heated rear view mirror control
86029 Electronic control unit for centralised door locking
86116 Multiplex body controller control unit
88000 Control unit for ABS system
88001 Sensor for ABS system
89000 Refrigerator
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
CAN LINE
CAN means Controller Area Network. It is a dedicated wiring connecting the ECUs of a vehicle, creating a
structure similar to the nervous system.
This system allows the instantaneous exchange of large quantities of data between the various vehicle on-board
electronic systems.
It is a BIDIRECTIONAL communication mode that is increasingly being used in vehicles, due to the decrease in
conductors and interferences.
Information travel in compliance with a protocol that defines the communication modes:
❏ Information synchronization.
❏ Call and response mode between the various systems.
❏ Identification and correction of any transmission error.
CAN line setup

The cable used for the CAN line on the vehicle is a twisted cable.
It has this feature so as to eliminate any electric interference on the signals.
The sleeve is marked by the grey colour.
Figure 2
73652
A B
A. Sleeve (grey) - B. Twisted wires (white/green)
CAN line efficiency tests

To check the CAN line efficiency, some measurements need to be taken.
To take these measurements, connect to pin 22 and 21 of the 30-pin diagnostic connector and take the following
measurements:
Values to be measured (VDB)
0Ω ∼ 60 Ω ∼ 120 Ω 0.L.
CAN line short-circuited CAN line OK Interrupted resistor CAN line interrupted
Base - 07/2012 Printed 603.95.397

NEW 682
VDB (Vehicle Data Bus) communication Line
Figure 3
173796
Characteristics
❏ Data transmission speed 250,000 (BIT/SEC)
❏ Cable colour Black
List of control units
Ref. Component
Description
code
TSU / MTCO Tachograph simulator / tachograph control unit 40011
IC Instruments Cluster 50003
IBC2 Body Controller 86116
ABS ABS control unit 88000
MIRROR Mirror control unit 86021
Diagnostic Connector 30-pole diagnosis connector 72021
/30
OBD II Connector 16-pole connector for OBD (on-board diagnostics) 72069
Diagnostic Connector 7-pole diagnosis connector 72XXX
/7
EDC7 Engine Management control unit 85150
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Base - 07/2012 Printed 603.95.397

NEW 682
POWER NETWORK Figure 4
Never disconnect the batteries from the

! system with the engine running.
Before connecting the batteries to the
system, make sure that the system is
suitably insulated.
Disconnect the batteries from the system
when charging them.
The aim of the electrical system is to generate,

regulate, store and distribute the power needed for
173708
vehicle components to work.
To achieve this, power is supplied by a generator
POWER SUPPLY BATTERIES
(alternator 24V - 90A) and two batteries (12V, 165Ah
each) connected in series.
Figure 5
Power cable section:
= 2
❏ direct cable from battery (DGC) 70 mm
= 2
❏ starter motor cable 70 mm
= 2
❏ alternator cable 16 mm
= 2
❏ positive pin cable 16 mm
= 2
❏ cable to UCI 10 mm
= 2
❏ cables to fuses 4 mm
Operate according to what is detected on the vehicle

for the remaining sections.
173709
POSITIVE PIN
Negative network Figure 6

The batteries are connected to grounding point M9 on
the rear part of the gearbox assembly by means of a
brown 70 mm2 cable, another cable leaves the same
point to connect with the chassis grounding point on
the left longitudinal member.
The same electric, negative equipotentiality of the
chassis is provided to the vehicle cab, by means of a
braided wire connected onto the cab front (T1) and
onto the front right side member (T2).
173710
GROUND POINT OF BATTERIES ON GEARBOX

AND ON LEFT SIDE MEMBER
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
GROUNDING POINTS
Figure 7
1737111
M1 / M2. Left side cab interior ground - M3 / M3/1. Right side interior cab ground - M4. Cab interior right side
ground (signal ground) - M5. Ceiling ground - M7. Front right side external cab ground - M8. Ground on the lower
right side of the engine - M9. Battery ground on the gearbox and left side member ground - M10. Rear right side
member ground -
T1 / T2. Electrically negative equipotentiality braided cable
Base - 07/2012 Printed 603.95.397

NEW 682
ELECTRICAL EQUIPOTENTIAL BRAID

Though generally protected against the influence of on-board equipment voltage, electronic components
nevertheless remain particularly sensitive electromagnetic compatibility issues.
These can be of various nature:
❏ generated by the vehicle
❏ external.
A suitable size flexible electrolytic copper braid has been provided on the vehicles to minimize these phenomena
and return main cab and frame structures to the equipotential state.
Check that the braid is properly attached to the chassis and the cab, in the event of defective cab grounding.
Figure 8
1737121
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Figure 9
1737131
GROUND POINT BEHIND THE CLUSTER
Figure 10
173714
GROUND POINT BEHIND THE BODY CONTROLLER
Figure 11
1737151
ROOF PANEL GROUND POINT
Base - 07/2012 Printed 603.95.397

NEW 682
Figure 12
173716
GROUNDING POINTS FRONT RIGHT EXTERNAL CAB
Figure 13
173717
GROUNDING POINT ON LOWER RIGHT SIDE OF ENGINE
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Figure 14
173718
GROUND POINT OF BATTERIES ON GEARBOX AND GROUND OF LEFT SIDE MEMBER
Figure 15
173719
REAR RIGHT SIDE MEMBER GROUNDING POINT
Base - 07/2012 Printed 603.95.397

NEW 682
760310 MITSUBISHI 28V-90A ALTERNATOR

Figure 16
[03000]
Characteristics
Supplier MITSUBISHI 28 V 90A
Rated voltage 28.3 ± 0.5 V (20°C)
Nominal current supply 90A
Operating speed 5000 rpm
Belt tension 730 N
Direction of rotation clockwise, viewed from
pulley
Weight 6.9 kg
Tightening torque on terminal B+ 12.5 ± 2 Nm
ALTERNATOR WIRING DIAGRAM
L To the recharge warning light

IG Alternator switch
S Battery voltage sensor 03000
Figure 17 Figure 18
106282 106300
ALTERNATOR CURRENT DELIVERY CURVE PERSPECTIVE VIEW

Figure 19
106283
TECHNICAL VIEW
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Figure 20
137657
PERSPECTIVE VIEW WITH MATCHING ELECTRICAL CONNECTIONS
Cable colour
Ref. Function
code
L To terminal J2/B24 of the FFC control unit 7009
15 (IG) To terminal 87 from contactor 25213 (via fuse F6--70601) 8876
S Positive (+30) - Terminal B+ alternator 7777
B+ Positive +30 of power supply to alternator (terminal S) 7777

Positive +30 to starter motor 7777
Positive +30 cab "pin positive" 7777
Base - 07/2012 Printed 603.95.397

NEW 682
760810 STARTER MOTOR "Nippondenso" 24V - 4.5kW[08000]

Figure 21
4956
TECHNICAL VIEW - 4.5kW

Figure 22
137659
CHARACTERISTIC CURVES 4.5KW
Figure 23 Figure 24
4958 6658
WIRING DIAGRAM PERSPECTIVE VIEW WITH MATCHING

ELECTRICAL
CONNECTIONS
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Connector Function Cable colour

code
+30 +30 positive for starter motor power supply from battery positive terminal (via the 7777
D.G.C.)
+30 +30 positive to the alternator 7777
+30 +30 positive to contactor for engine preheating activation consent 7777
+50 Positive +50 from key switch 8888
Technical specifications
Characteristics Version 4.5kW

Rated power 4.5kW
Rated voltage 24V
Coupling system Positive advance control
Adjusted time 30 sec.
Direction of rotation Clockwise seen from pinion end
Operating voltage 16V MAX
Weight approx. 8.4kg
Tightening torque for terminal +30 17.6 ÷ 24.5Nm (M10X1.5)
Tightening torque for terminal +50 2.6 ÷ 4.6Nm (M5X0.8)
SPECIFIC power
Version 4.5kW
Load
Test conditions Characteristics
No load 23V 90A MAX. (3500rpm)
Load 17V (39.2Nm) 530A MAX. (950rpm)
Stall 6V 900A MAX. (49.0Nm)
Base - 07/2012 Printed 603.95.397

NEW 682
JUNCTION CONNECTORS
Junction connector location
Figure 25
X56/3/A
X56/3/B
ST82000A
ST82000B
ST82000C 173720
The location of the connectors present (cab - chassis) could be subject to change due to wiring requirements.
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
List of connectors
Name Description
ST 01 Ignition switch
ST 02A Connection for steering column
ST 06A Connection for roof panel wings devices on the driver side
ST 06B Connection for tachograph
ST 08A Connection for driver side door
ST 08B Connection for driver side door
ST 09A Connection for passenger side door
ST 15 Connection for couplings in the high roof
ST 16 Connection for pneumatic horn
ST 31A Connection for cab rear
ST 79A Connection for external cab front
ST 79B Connection for windshield washer and warning horn unit
ST Y1 Connection for cable for right lights
ST Y2 Connection for cable for left lights
ST 82000A Connection for air conditioner with manual control
ST 82000B Connection for air conditioner with manual control
ST 82000C Connection for air conditioner with manual control
X56/3/A Connection for rear chassis wiring
X56/3/B Connection for trailer prefitting
Base - 07/2012 Printed 603.95.397

NEW 682
Junction connector ST01 (black) - ignition key

Figure 26
1 2 3 1 2 3
107169
CONNECTOR VIEW (CABLE SIDE)
Pin Function Cable colour

code
1 Positive +30 for key switch 7777
2 Terminal 15, ignition switch 8887
ST02A (grey) - connection for steering column

Figure 27
101564
Cable colour
Pin Function
code
1 Horn control 1116
2 Windscreen wiper (single swipe) 8886
3 Right turn signal light 1123
4 Left turn signal light 1129
5 Full beam headlights on 2200
6 Light flasher 2204
7 Windscreen wiper (intermittent) 8822
8 Windscreen wiper (slow speed) 8882
9 Windscreen wiper (maximum speed) 8881
10 Ground 0000
11 Cruise Control (Resume / CC OFF) 8154
12 Cruise Control (Set-) 8157
13 Cruise Control (Set+) 8156
14 Speed limiter signal 9968
15 - -
16 Engine brake control 8159
17 - -
20 Positive +30 for key switch 7777
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
ST06A junction connector (yellow) - roof panel wings devices on the driver side
Figure 28
101564
Cable colour
Pin Function
code
1 Positive for left speaker (roof panel) 1188
2 Negative for left speaker (roof panel) 1186

3 Positive for right speaker (roof panel) 1184
4 Negative for right speaker (roof panel) 1183
5 Electric roof opening control power 7010
6 Electric roof closing control power supply 7011
7 Battery direct positive (+Batt) for voltage reducer 7704
8 Positive power socket 12V 7770
9 Positive for bunk bed lights 12V 7770
10 - -
11 Positive for internal side lights (bunk lights) 4111
12 Positive for step light 4408
13 Positive for internal lights (spot lights) 4400
14 Positive for front right side marker 3314
15 Positive for front left side marker 3304
16 - -
17 - -
18 - -
19 - -
20 - -
Base - 07/2012 Printed 603.95.397

NEW 682
ST06B junction connector (black) - tachograph

Figure 29
101564
Cable colour
Pin Function
code
1 Right low beam headlight 2223
2 Left full beam headlight 2219
3 Positive for the right indicator lights 1123
4 Positive for the left indicator lights 1129
5 Positive for fog lamp contactor 3302
6 Speed sensor power supply (pin 1) 5514
7 Speed sensor ground (pin 2) 0058
8 Speed sensor signal (pin 3) 5517
9 - -
10 Lighting ideograms 4442
11 Horn control 1116
12 Battery direct positive (+Batt) 7768
13 Speed signal for fitters /diagnosis connector Pin 28 (B7 tachograph) 5542
14 K line (diagnostics connector pin 14) 2997
15 Positive +15 8879
16 Signal: internal light on when door is open 7768
17 Brake light signal (stop signal) 1117
18 Reverse gear signal 2226
19 CAN H line 6108
20 CAN L line 6108
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Junction connector ST08A (blue) - driver side door

Figure 30
101554
Cable colour
Pin Function
code
1 Positive for power window switches 8861
2 Connection 1 between side power window switches 8861
4 Ground for power window switches 0000
5 Positive for speaker (left door) 1188
6 Negative for speaker (left door) 1186
7 Central locking command (lock door) 0065
8 Central locking command (unlock door) 0064
9 Power supply to motor for central door locking (door closing) 9965
10 Power supply to motor for central door locking (door opening) 9964
11 Signal from left door button 0003
12 Ground for left door button 0066
Base - 07/2012 Printed 603.95.397

NEW 682
Junction connector ST08B (blue) - driver side door

Figure 31
101554
Cable colour
Pin Function
code
1 Left mirror heating power supply 8830
2 Ground 0000
3 Main left rearview mirror control (vertical) 8808
4 Left rearview mirror control (return) 8806
5 Main left rearview mirror control (horizontal) 8809
6 Wide-angle left rearview mirror control (vertical) 8842
7 Wide-angle left rearview mirror control (horizontal) 8843
9 Negative for rear view mirror selector button 0956
10 Negative from rear-view mirror button (movements to the right) 0953
11 Negative from rear-view mirror button (movements to the left) 0954
12 Negative from rearview mirror button (downward movements) 0951
13 Negative from rearview mirror button (upward movements) 0952
14 - -
15 Positive for rearview mirror control push button lighting 4442
16 - -
17 - -
18 - -
19 - -
20 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Junction connector ST09A (blue) - passenger side door

Figure 32
101554
Cable colour
Pin Function
code
1 Positive for power window switch 8861
4 Positive for speaker (right door) 1184
5 Negative for speaker (right door) 1183
6 Central locking command (lock door) 0065
8 Power supply to motor for central door locking (door closing) 9965
9 Power supply to motor for central door locking (door opening) 9964
10 Signal from right door button 0003
11 Ground for right door button 0066
12 - -
Base - 07/2012 Printed 603.95.397

NEW 682
Junction connector ST09B (blue) - passenger side door

Figure 33
101554
Cable colour
Pin Function
code
1 Right mirror heating power supply 8830
2 Ground 0000
3 Right main rearview mirror control (vertical) 8858
4 Right rearview mirror control (return) 8857
5 Right main rearview mirror control (horizontal) 8859
6 Wide-angle right rearview mirror control (horizontal) 8852
7 Wide-angle right rearview mirror control (vertical) 8853
8 - -
9 - -
10 - -
11 - -
12 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
ST15 junction connector (yellow) - Connection for couplings in the high roof
Figure 34
107538
Cable colour
Pin Function
code
1 Positive for left speaker (roof panel) 1188
2 Negative for left speaker (roof panel) 1186
3 Positive for right speaker (roof panel) 1184
4 Negative for right speaker (roof panel) 1183
5 Positive for internal side lights (bunk lights) 4111
6 Ground 0000
7 Electric roof opening control power supply 7010
8 Electric roof closing control power supply 7011
9 - -
10 - -
11 - -
12 - -
ST16 junction connector- connection for pneumatic horn

Figure 35
101531
Cable colour
Pin Function
code
1 Pneumatic horn positive 1133
2 Ground 0000
Base - 07/2012 Printed 603.95.397

NEW 682
ST31A junction connector (green) - Cab rear

Figure 36
101554
Cable colour
Pin Function
code
1 Positive for bunk bed lights 12V 7770
2 Ground 0000
3 Positive for switch for lighting tool compartment 7772
4 Positive for instrument lighting 4442
5 Tool compartment light ground / control switch lighting 0000
6 Ground for refrigerator 0000
7 Positive for refrigerator 7772
8 - -
9 - -
10 - -
11 - -
12 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
ST79A junction connector (yellow) - external cab front

Figure 37
107545
Cable colour
Pin Function
code
1 Horn positive 1116
2 Horn ground 0000
3 - -
4 - -
6 Positive from secondary brake pedal switch 8158
7 Positive for clutch sensor / Brake pedal switch on duplex 8362
8 Positive to coolant pressure indicator switch (air conditioning) 9993
10 Windscreen wiper motor (31B) 8873
11 Windscreen wiper motor (53 - Slow) 8882
12 Windscreen wiper motor (53B - Fast) 8861
13 Positive from coolant pressure indicator switch (air conditioning) 9993
14 Signal for clutch switch 0160
15 - -
Base - 07/2012 Printed 603.95.397

NEW 682
Junction connector ST79B (yellow) - windshield washer and warning horn unit
Figure 38
107531
Cable colour
Pin Function
code
1 Front brake air pressure sensor signal 5562
2 Front brake air pressure sensor positive 5560
3 Rear brake air pressure sensor positive 5560
4 Rear brake air pressure sensor signal 5561
5 Ground for front brake system air pressure sensor 0000
6 Ground for rear brake system air pressure sensor 0000
7 - -
8 - -
9 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
STY1 - STY2 junction connector

Figure 39
101551
STY1 junction connector - right light cluster cable

Cable colour
Pin Function
code
1 General power supply of the parking and marker lights 3390
2 Right low-beam headlamp power supply 2223
3 Right high-beam headlamp power supply 2221
4 Headlamp trim adjuster (position B) 9936
5 Front right indicator lamp 1123
6 Ground 0000
7 - -
STY2 junction connector - right light cluster cable

Cable colour
Pin Function
code
1 General power supply of the parking and marker lights 3390
2 Left low-beam headlamp power supply 2223
3 Left high-beam headlamp power supply 2221
4 Headlamp trim adjuster (position B) 9936
5 Front left indicator lamp 1123
6 Ground 0000
7 - -
Base - 07/2012 Printed 603.95.397

NEW 682
ST82000A - ST82000B junction connector

Figure 40
176001
ST82000A junction connector - manual control air conditioning system

Cable colour
Pin Function
code
1 Ideogram lighting positive 4442
2 Positive +15 8879
3 Ground 0000
4 - -
5 - -
ST82000B junction connector - manual control air conditioning system

Cable colour
Pin Function
code
1 - -
2 - -
3 - -
4 A/C system on control 8871
5 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
ST82000C junction connector - manual control air conditioning system

Figure 41
107545
Cable colour
Pin Function
code
1 - -
2 - -
4 Positive +15 7550
3 - -
5 - -
6 - -
7 - -
8 A/C system on control 8871
9 Ground 0000
12 - -
13 - -
14 - -
15 - -
Base - 07/2012 Printed 603.95.397

NEW 682
X56/3/A junction connector - rear chassis wiring

Figure 42
176002
Cable colour
Pin Function
code
1 Rear fog light positive 2286
2 Fuel level gauge 0616
3 Positive for left stop light 1177
4 Positive for reverse light 2226
5 Rear right parking light positive 3315
8 Positive for right stop light 1172
9 Right rear side marker light positive 3308
10 Signal from transverse for differential lock signalling switch 6620
11 Rear transverse differential lock solenoid valve power supply 9325
12 Longitudinal lock engaged signal 6643
13 Rear longitudinal differential lock solenoid valve power supply 9324
14 - -
15 Left rear side marker light positive 3308
16 Fifth wheel light positive 2224
17 Right plate lights 3307
18 Fuel level indicator ground 5557
19 Rear left parking light positive 3305
20 Dumper tipping indicator 9144
21 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
X56/3/B junction connector - trailer prefitting

Figure 43
113250
Cable colour
Pin Function
code
1 Positive for left side marker light for trailer 3305
2 Left indicators positive for trailer 1180
3 Positive for trailer stop light 1179
4 Right indicators positive for trailer 1185
5 Right side marker light positive for trailer 3315
6 Trailer rear fog light positive 2270
7 Power supply for trailer interlocking with terminal +15 8876
8 Positive for trailer reverse light 2226
Base - 07/2012 Printed 603.95.397

NEW 682
7-poles current outlet for trailer electric connection

Figure 44
113252
72000 - standard 7-poles current outlet for trailer electric connection

code
1 Ground 0000
2 Right side marker light positive for trailer 3315
7 Spare -
72001 - auxiliary 7-poles current outlet for trailer electric connection

code
1 Ground 0000
2 Power supply for trailer interlocking with terminal +15 8876
3 Trailer reverse light 2226
4 Spare -
5 Spare -
6 Spare -
7 Trailer rear fog light 2282
72006 - 7-poles current outlet for trailer ABS electric connection

code
1 Positive +30 for trailer ABS 7777
3 Trailer ABS ground 0000
5 Trailer ABS fault warning light signal 6671
6 Spare -
7 Spare -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
BULKHEAD
Connector A - White
Connector B - Brown
Connector C - Yellow
Connector D - Blue
Connector F - Green
Figure 45
173721
Base - 07/2012 Printed 603.95.397

NEW 682
"A" connector pin-out (white)

Cable colour
Pin Function
code
1 Positive for ”EV” solenoid valve (unloading) front left wheel 9921
2 Positive for ”AV” solenoid valve (loading) front left wheel 9919
3 ABS speed sensor front left wheel 5570
5 ABS speed sensor front right wheel 5571
7 Positive for ”AV” solenoid valve (load) front right wheel 9918
8 Positive for ”EV” solenoid valve (unloaded) front right wheel 9920
9 Positive ”AV” (loaded) solenoid valve command rear left wheel 9929
10 Positive ”EV” (unloaded) solenoid valve command rear left wheel 9931
11 ABS speed sensor rear left wheel 5572
13 ABS speed sensor rear right wheel 5573
15 Positive ”EV” (unloaded) solenoid valve command rear right wheel 9930
16 Positive ”AV” (loaded) solenoid valve command rear right wheel 9928
17 Front left ABS solenoid valve ground 0000
18 Front right ABS solenoid valve ground 0000
19 Rear left ABS solenoid valve ground 0000
20 Rear right ABS solenoid valve ground 0000
22 Trailer ABS fault warning light signal 6671
23 Ground 0000
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
"B" connector pin-out (brown)

Cable colour
Pin Function
code
1 Left side marker and front clearance light 3304
2 Right side marker and front clearance light 3314
3 Left high beam headlamp 2219
4 Right high beam headlamp 2221
5 Left low beam headlamp 2231
6 Right low beam headlamp 2223
7 Left front direction 1129
8 Right front direction 1123
9 Right and left fog lights 2228
10 Pneumatic horn positive 1133
11 - -
12 Positive for windscreen washer motor pump (prefitting) 8886
13 Radiator water level signal 5527
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 - -
Base - 07/2012 Printed 603.95.397

NEW 682
"C" connector pin-out (yellow)

Cable colour
Pin Function
code
1 Front differential lock engaged signal 6659
2 Front transverse differential lock solenoid valve power supply 9063
3 Servo-assisted tilting hydraulic pump power supply 7730
4 Hydraulic cab uncoupling (+ lowering) pump motor power supply 9029
5 Power supply to heated diesel pre-filter 7753
6 Ground from cab lowering switch 0923
7 Ground from cab lifting switch 0922
8 Signal from switch for preventing start-up with handbrake off 6662
9 Battery direct positive (+Batt) for refrigerator 7777
10 PTO 1 activated signal 6131
11 PTO 2 activated signal 6132
12 PTO 1 solenoid valve power supply 9131
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
"D" connector pin-out (blue)

Cable colour
Pin Function
code
1 Speed sensor power supply 5514
2 Speed sensor ground 0058
3 Speed sensor signal 5517
4 License plate lights 3307
5 Positive from the reverse light 2226
6 Positive +15 for trailer 8869
8 Ground from reverse indicator switch 2268
9 Signal from neutral gear switch 7050
12 Rear side marker light positive 3308
16 Positive +15 (brake air drier) 8840
21 Positive for right marker lights for trailer / Positive for exterior light contactor for fitter 3315
connector
22 - -
23 - -
24 Fuel level gauge 0616
25 Fuel level indicator ground 5557
26 Dumper tipping indicator 9144
28 Clogged air filter sensor 6663
29 Slow gears engaged (signal) 9976
30 Positive for cab release indicator switch 8879
31 Signal from cab release indicator switch 6666
32 Ground for cab release indicator switch 0000
33 Positive from DGC for EDC deactivation contactor 7777
34 Rear transverse differential lock solenoid valve power supply 9325
37 Rear longitudinal differential lock solenoid valve power supply 9324
40 Fifth wheel light positive 2224
Base - 07/2012 Printed 603.95.397

NEW 682
"F" connector pin-out (green)

Cable colour
Pin Function
code
1 CAN H line 6108
2 CAN L line 6109
3 Ignition signal ”+50” 8888
4 Positive +30 for fuel heater element 7733
5 Positive +30 for EDC 8150
6 K line for 30-pin diagnostic connector (pin 2) 2298
7 Negative from engine stop button inside engine bay 9906
8 Negative from starter button inside engine bay 9905
9 Ground for accelerator pedal position sensor 0157
10 Signal from pressed accelerator switch 0159
11 Negative for pressed accelerator switch 0158
12 Positive for accelerator pedal position sensor 5158
13 Accelerator pedal position sensor signal 5157
14 Positive +15 from key switch for EDC 8051
15 - -
16 - -
17 - -
18 - -
19 - -
22 Hydraulic power steering fluid level signal 5525
23 - -
24 Windscreen washer fluid level signal 5521
25 - -
26 Water present in fuel filter signal 5530
28 - -
29 +15 Positive for sensor for detecting water in diesel filter 8879
30 - -
32 Signal for no battery charging warning light 7780
33 Alternator +15 8876
34 Air conditioning control 8004
35 Brake light signal (stop signal) (prefitting) 1117
36 - -
37 - -
38 - -
39 - -
40 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
INSTRUMENT PANEL
Figure 46
173722
Component
Ref. Description
code
1 Rev counter 48001 (50003)
2 Coolant thermometer 47001 (50003)
3 Fuel level gauge 44001 (50003)
4 Speedometer 40011 (50003)
5 Cap -
6 Cap -
7 External light switch 52307
8 Warning light cluster (50003)
10 Instruments Cluster 50005
11 Display (50003)
13 Display menu activation switch 53403
14 Display menu output switch 53402
15 Switch menu + 53400
16 Switch menu - 53401
17 ABS off switch 52057
18 Fog light switch 52321
19 Rear fog light switch 52007
20 Switch for side spot lights (bunk lights) 53509
21 Emergency light actuation switch 52302
Base - 07/2012 Printed 603.95.397

NEW 682
CENTRAL DASHBOARD
Figure 47
173723
Component
Ref. Description
code
1 Engine brake actuation switch 52324
2 Central spot light switch 52094
3 Loading platform light actuation switch 52009
4 Switch for electric or pneumatic horns 52200
5 Control for electric hatch 53306
5b Multipower power takeoff control 52220
6 Rear transverse differential locking switch 53039
7 Longitudinal differential locking switch 52045
8 Power takeoff switch 1 52071
9 Rearview mirrors heating 52005
9b Front transverse differential locking switch 53022
10 Cab tilting enable switch 53061
10b Power takeoff switch 2 52070
11 Parking brake (53512)
12 Air conditioner heating/ventilation or controls 82000
13 Radio 68000
14 Cigarette lighter 85000
15 Power socket 12V 72054
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Cab inside lights

Figure 48
173724
Component
Ref. Description
code
1 Overhead light for left step lighting 39003<
2 Tachograph simulator / Tachograph 40011
3 Central spot light ceiling fixture (left) 39022<
4 Central spot light ceiling fixture (right) 39022>
5 Overhead light for right step lighting 39003>
6 Ceiling fixture for side spot lights (bunk lights - right) 39027>
7 Ceiling fixture for side spot lights (bunk lights - left) 39027<
8 Courtesy light for reading lights 39009
Base - 07/2012 Printed 603.95.397

NEW 682
Rear view mirror adjustment / power window control / tool compartment opening control
Figure 49
173725
Component
Ref. Description
code
1 Rear-view mirror adjuster 85010
2 Mirror selector switch 85011
3 Driver’s side electric window switch 53300
4 Passenger’s side electric window switch 53302
5 Tool compartment opening switch 53075
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
LH DRIVE CONTROL [54033]

Figure 50
173797
Cable colour
Pin Function
code
1 Windscreen wiper (maximum speed) 8881
2 Windscreen wiper (slow speed) 8882
3 Windscreen wiper (intermittent) 8822
4 Windscreen wiper (single swipe) 8886
5 - -
6 Full beam headlights on 2200
7 Light flasher 2204
8 Ground 0000
9 Horn control 1116
10 - -
11 - -
12 - -
13 - -
14 - -
15 Right turn signal light 1123
16 Left turn signal light 1129
Base - 07/2012 Printed 603.95.397

NEW 682
RH DRIVE CONTROL [54030]

Figure 51
173798
Cable colour
Pin Function
code
1 - -
2 - -
3 Cruise Control (Set+) 8156
4 Cruise Control (Resume / CC OFF) 8154
5 - -
6 - -
7 Engine brake control 8159
8 - -
9 - -
10 - -
11 Cruise Control (Set-) 8157
12 - -
13 - -
14 - -
15 - -
16 Ground 0000
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
CRUISE CONTROL AND ENGINE BRAKE CONTROL

Figure 52
173799
RIGHT MULTIFUNCTION LEVER
The multifunction lever located on the right side of the steering column allows activation of the engine brake
function and Cruise Control.
The engine brake function is selected by moving the lever into position 1.
When the engine brake function is selected, a signal from the lever is sent to the BC (Body Controller) control unit.
The BC activates the engine brake on warning light on the Instrument Cluster IC, and sends the engine brake
request to the EDC and ABS control unit (when present).
Both functions of engine brake and engine brake on the exhaust are activated at the same time.
When the driver manually selects the engine brake, this choice is displayed on the instrument panel by a flashing
light which goes to steady when the engine brake is working. In manual mode, the engine brake function is also
affected by the position of the accelerator pedal (pedal released).
In automatic mode, the engine brake is applied by the EDC control unit when it receives a request from the ABS
control unit.
In this condition, the EDC control unit center pilots the engine brake solenoid valve and the VGT actuator to the
fully closed position.
Base - 07/2012 Printed 603.95.397

NEW 682
INSTRUMENT CLUSTER [50005]

Description
Figure 53
173726
This system has the following features and is made up of:

❏ a speedometer (in both km/h and mph)
❏ a rev counter
❏ a fuel level gauge
❏ an engine coolant temperature gauge
❏ a display for: error messages
❏ three sets of warning lights
❏ four scrolling keys for the various menus (Highline model only)
❏ a button for adjusting background lighting
❏ a trip meter reset button (change page on Baseline)
In addition to being connected to the vehicle's CAN line, the Instrument Cluster receives a set of signals directly
from several sensors or relays on the vehicle electric system.
The Instrument Cluster also receives the signals from the four buttons for the various menus. The operating logic
for the buttons is completely standard: the arrows are for changing page; If you select a page with numerous lines,
the display allows you to view only 3 lines at a time or a page with a sub-menu. Pressing OK allows you to access
the page and you can then use the arrows.
Button C allows you to return to the previous page.
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
The display is in black-and-white. The lack of a colour display has been offset by the logic of associating yellow or
red warning lights with symbols to communicate important information to the driver.
Signals are sent directly to the Instrument Cluster (no CAN line is provided) from the:
❏ Engine oil level
❏ Fuel level sensor
❏ Presence of water in the diesel fuel filter sensor
❏ Air filter clogged signal
❏ Rear brake converter travel sensor
❏ Rear brake fluid level sensor
❏ Immobiliser warning light
❏ Battery charge indicator
❏ Trailer ABS failure indicator
All the other signals are received through the CAN line so as to allow the relevant message to be displayed.
The Instrument Cluster does not store error messages; it only displays them.
The systems that can currently be diagnosed are as follows: EDC, POWER MIRRORS, BODY CONTROLLER.
If the "HIGHLINE" model Cluster is available, a diagnosis of these systems can be shown on the display and this
allows you to identify failure codes.
These codes can be referred to by means of the "MENU" buttons provided on the dashboard.
Base - 07/2012 Printed 603.95.397

NEW 682
Versions available
There are two models of the IC system available: BASELINE and HIGHLINE versions.
These versions differ in that they have or don't have control buttons and screen shots on the IC display.
Baseline
No menu control button
Trip meter reset button. Also used in part for changing IC screen shots
Highline
Four menu/IC screen shot control buttons
Trip meter reset button (also used for trip 1 function)
Screen shots available with vehicle running
Baseline
time/km/partial km
time/km/partial time
time/miles/partial miles (UK market)
brake air pressure/engine oil pressure
Highline
time/km/partial km/°C/gear engaged (automatic transmission)
time/km/partial time/°C/gear engaged (automatic transmission)
engine oil pressure/brake air pressure
trip 1
trip 2
Screen shots available with vehicle stopped
Baseline
time/km/partial km
time/km/partial time
time/miles/partial miles (UK market)
engine oil level
brake air pressure/engine oil pressure
Highline
time/km/partial km/°C/gear engaged (automatic transmission)
time/km/partial time/°C/gear engaged (automatic transmission)
engine oil level/percentage brake pad wear
engine oil pressure/brake air pressure
trip 1
trip 2
fuel gauge/consumption indicator in litres
Engine oil level/percentage brake pad wear
lights test
diagnostics
vehicle maintenance
language/units of measurement setting
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Optical indicators on cluster

Figure 54
173727
Ref. Description Colour Symbol

1 External lights Green
2 Supplementary full beam headlights Blue
3 High-beam headlamps Blue
4 Hazard lights Red
5 Instrument panel failure Red
6 Fog lights Green
7 Rear fog lights Yellow
8 SLOW gears engaged Yellow
9 Engine preheating Yellow
10 Programmable speed limiter Yellow
11 Heated mirrors Yellow
12 Rear transverse differential locked Yellow
13 Longitudinal differential locked. - Transfer case in neutral Yellow
14 Rear transverse differential lock Yellow
Base - 07/2012 Printed 603.95.397

NEW 682
Figure 55
173728
Ref. Description Colour Symbol

15 Side PTO I ON Yellow
16 Rear PTO II / transfer case ON Yellow
17 Left tractor direction Green
18 Retarder engaged Yellow
19 Engine brake ON Yellow
20 Braking system failure Red
21 Emergency brake ON Red
22 Tractor unit ABS failure Yellow
23 Trailer ABS failure Yellow
24 Special emergency brake (FF vehicles) ON Red
25 OBDII anomaly Yellow
26 Low pneumatic suspension pressure Red
27 Right trailer direction Green
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Figure 56
173729
Ref. Description
28 Analog rev counter
29 Instrument lighting intensity adjustment
30 Major fault indicator
31 Coolant temperature (high temperature warning light)
32 Display
33 Fuel level sensor
34 Minor fault indicator
35 Odometer trip counter reset button
36 Analog speedometer
Base - 07/2012 Printed 603.95.397

NEW 682
Indicators on display (failure)

When one of the following functions is activated or one of the following malfunctions occurs, the corresponding
symbol will appear on the display.
Yellow symbols appear on the left side of the display, (minor faults and problems) while red symbols appear on the
right side (serious faults).
Figure 57
173800
Description Colour Symbol

Warning light for minor faults
Yellow
and non-serious problems
Serious fault warning (Stop) Red
Description Colour Symbol Description Colour Symbol

Low rear axle brake air
Red Low radiator water level Red
pressure
Front axle brake linings worn Red EDC Red
Rear axle brake linings worn Red Gearbox failure Red
Low brake fluid level Red High gear fluid temperature Yellow
Rear AoH converter at end
Red High retarder temperature Yellow
of travel
Tractor unit EBS fault Red Retarder failure Yellow
Tractor unit EBS fault Red Air suspension failure Red
Low engine oil pressure Red IBC failure Red

High engine coolant
Red Alternator not charging Red
temperature
Second alternator not
Low engine oil level Red Red
charging
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Description Colour Symbol Description Colour Symbol

Power steering fluid low Red External lighting Yellow
Cab unhooked Red Dumper tilted Yellow
Tail lift Red Air filter clogged Yellow
Airbag malfunction Red Water in fuel pre-filter Yellow

Windscreen washer fluid
Doors open Red Yellow
low
Vehicle braked by EBS Yellow Driving time malfunction Yellow
Active ASR (brake control) Yellow Perform maintenance -
Tractor unit EBS fault Yellow - -
Tractor unit EBS fault Yellow Trailer connected -
EDC failure Yellow EDC in PTO mode -
Immobiliser fault/ON Yellow Seat belts unfastened Red
Immobiliser fault/ON Yellow Instrument panel fault Yellow
Starter disabled Yellow Instrument panel Red
Gearbox failure Yellow Low external temperature -

Gear changes limited on
Yellow - -
automatic transmission
Air suspension failure Yellow CAN network failure Yellow
Pneumatic suspension not in
Yellow CAN network failure Red
operating condition
IBC malfunction Yellow
Base - 07/2012 Printed 603.95.397

NEW 682
Cluster (pin-out)
Figure 58
173730
Cable Cable
Pin A - Black colour B - Blue colour
1 - - K line (diagnostics connector pin 14) 2994
2 CAN H line 6108 - -
3 CAN L line 6109 Trailer ABS fault warning light signal 6671
4 - - - -
5 - - - -
6 - - - -
7 - - - -
8 - - - -
9 - - - -
10 - - Dumper tipping indicator 9144
11 Fuel level indicator ground 5557 Clogged air filter sensor 6663
12 Fuel level gauge 0616 Water in diesel filter sensor 5530
13 - - ”UP” menu button 5900
14 - - - -
15 - - ”DOWN” menu button” 5901
16 - - ”OK” menu button 5902
17 - - Signal for no battery charging warning 7780
light
18 Positive +15 8879 - -
19 Ground 0000 - -
20 Positive +30 7772 ”C” menu button 5903
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
TACHOGRAPH [40011]
Figure 59
173731
Cable
Pin Function
colour code
2 Lighting ideograms 4442
3 Positive +15 8879
4 CAN H lineLigne” 6108
A
5 Ground 0066
6 Ground 0066
7 - -
8 CAN L line” 6108
1 Speed sensor power supply (pin 1) 5514
2 Speed sensor ground (pin 2) 0058
3 Speed sensor signal (pin 3) 5517
4 - -
B
5 - -
6 - -
7 Speed signal for fitters (to diagnostic connector pin 28) 5542
8 - -
4 Reverse gear signal 2226
C
5 - -
6 - -
7 - -
8 - -
3 Right low beam headlamp / Headlamp trim consent 2223
4 - -
D
5 Horn control 1116
6 - -
7 Signal: Cluster B1/Diagnosis Pin 8 7768
Base - 07/2012 Printed 603.95.397

NEW 682
VOLTAGE REDUCER [85031]

Figure 60
173732
Characteristics:
Input voltage 18 ÷ 32V
Output voltage 14V ± 3%
Current absorption ≤ 19mA
Output current 0 ÷ 20.5 A
Operating temperature range -30 ÷ +60
Cable
Pin Description
colour code
1 NC Not used -
2 +14 Not used -
3 31a Not used (ground) -
4 +14 User power supply positive 7770
5 Not used (ground) -
6 31b Reducer power ground 0000

7 30 Voltage reducer positive 7704
8 +14 User power supply positive 7770
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
CENTRAL INTERCONNECTING UNIT [75000]

Figure 61
173733
Ref. Description
1 Fuse holder (70000/3 - /1 - /2)
2 Remote-control switches
3 30-pole diagnosis connector
4 Body Controller
5 Control unit / Contactors
Base - 07/2012 Printed 603.95.397

NEW 682
Contactor assembly
Figure 62
173734
Ref. Description Component code

A Contactor for power supply +15 from diagnostic connector 25705
B Fog light contactor 25003
C Contactors for external lights (fitters) 25035
D Diesel heating contactor 25810
D Contactor for heated rearview mirrors 25813
F(E1) Contactor for key controlled power supply 25213
H - -
G(E3) Contactor for horn control 25805
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Supplementary relay switches

Figure 63
173735
Ref. Description Component code

1 Start-up contactor 25200
2 Contactor for connection of air-conditioning system 25327
3 Cab hydraulic release pump contactor (lowering) 25722
4 Cab hydraulic release pump contactor (raising) 25723
5 Contactor to turn off engine with power-pack failure 25906
6 Container for 3 1 A diodes (2 with common anode) 61001
7 Contactor for short activation of air-conditioning system 25326
8 Contactor to turn on internal lights when front door opens 25530
9 Contactor for EDC deactivation 25903
10 Overhead reading light contactor 25819
11 Remote reversing light switch 25007
12 Contactor for cab tilting motor 25847
Base - 07/2012 Printed 603.95.397

NEW 682
Diagram of fuses
Figure 64
173736
Red fuse box (70000/1)

Ref. Function Capacity (A) Terminal
1 Diagnostics connector 10 +30
2 Cigarette lighter / Spot lights 10 +30
3 Fog light / Power roof 10 +30
4 Rearview mirrors heating 10 +30
5 Reversing lights 10 +15/1
6 Air conditioning / Fifth wheel / Differential lock 10 +15/1
White fuse box (70000/2)
1 Diesel filter heating 20 +30
2 Tool compartment lights 10 +30
3 Trailer ABS 20 +30
4 ABS 20 +30
5 ABS 5 +15/1
6 Starter motor 20 +30
Green fuse box (70000/3)
1 Refrigerator 10 +Batt
2 Cab tilting 30 +30
3 Heated diesel pre-filter 20 +30
4 - - -
5 - - -
6 - - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Figure 65
173737
Capacity
Ref. Function Terminal
(A)
1 Body Controller / Tachograph / Instrument Cluster 5 +15/1
2 Cab decoupled / Diesel filter water sensor / Engine brake prefitting 5 +15/1
3 Tachograph / Body Controller (Left low beam - right high beam) 10 +Batt
4 Fitters 10 +30
5 EDC7 5 +15/2
6 Trailer socket / Chassis fitter socket 5 15/2
Central locking / Radio 24V / 24V/12V voltage reducer (Bunk bed lights -
7 10 +Batt
Power socket)
8 Body Controller (Right low beam - left high beam) 10 +30
9 Cab fitters / ABS trailer socket 5 +15/2
10 Body Controller (left marker lights and brake lights) 10 +30
11 Body Controller (direction - emergency lights) 10 +30
12 Horn 10 10A
13 Electric windows 20 +15/2
14 Windscreen defroster electric heater / Air conditioning 20 +15/2
15 Body Controller (windscreen wiper - windscreen washer) 10 +30
16 Brake air drier / Rearview mirror control control unit 5 +15/1
17 External light fitters (+58) 10 +30
18 Instrument Cluster 5 +30
19 EDC7 20 +30
20 Body Controller (right marker lights and rear fog lights) 10 +30
21 ÷ 26 - - -
Base - 07/2012 Printed 603.95.397

NEW 682
Connector assembly
Figure 66
173738
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Connector "A" - "B" - "C"

Figure 67
174565
Pin Function Cable colour code

1 - -
2 - -
3 Positive +15 for power window switches 8861
A 4 Positive +30 (Body Controller) 7772
5 Positive +15 electric heater 8879
6 Positive +30 (Body Controller) 7772
1 Positive +15 for fitters 7772
B
2 Positive +15 (from key switch) 8887
1 Battery direct positive (+Batt) after fuse (Body Controller / Tachograph) 7768
2 - -
3 - -
C
4 - -
5 Battery direct positive (after fuse) for roof panel cable connection 7704
6 - -
Base - 07/2012 Printed 603.95.397

NEW 682
Connector "E"
Figure 68
174566
Pin Description Cable colour code

1 - -
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
E
11 - -
12 - -
13 - -
14 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Connector "F"
Figure 69
174567

1 - -
2 +15 positive fitter connector 7772
5 - -
6 - -
7 - -
8 Positive +15 (brake air drier) 8840
9 - -
10 - -
F
12 - -
13 - -
14 - -
15 Negative signal from the horn activation button 1116
16 Direct positive battery (+batt) for central locking control unit 7728
17 - -
18 Positive +30 (Instrument Cluster) 7772
19 - -
20 Positive +30 for buzzer control contactor 7777
Base - 07/2012 Printed 603.95.397

NEW 682
Connector "G" - "H"

Figure 70
174568

A Battery positive after DGC 7777
B Battery positive after DGC 7777
1 - -
2 - -
3 Positive +30 fitters light contactor 7772
4 - -
GH
5 - -
6 Positive +15 (Body Controller / Tachograph / Instrument Cluster) 8879
7 - -
8 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Connector "I"
Figure 71
174569

1 Ground 0000
2 - -
3 - -
4 - -
5 Positive +15 for rearview mirror control control unit 8879
6 - -
I
7 - -
8 Positive +30 for buzzer control 1116
9 Battery direct positive (+Batt) (Body Controller / Tachograph) 7777
10 - -
11 - -
12 - -
Base - 07/2012 Printed 603.95.397

NEW 682
Internal wiring diagram

Figure 72
173739
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
LOCATION OF CONTROL UNITS

Figure 73
173740
Ref. Description
1 ABS
2 Rearview mirror control unit
3 Central locking control unit
4 Supplementary relay switches
Base - 07/2012 Printed 603.95.397

NEW 682
BODY CONTROLLER (IBC2) [86116]

Connection connectors
Figure 74
173791
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Connector "A" (Black)
Cable
Ref. Function
colour code
2 Brake air sensor positive 5560
3 Ground for brake air sensors 0000
4 Signal from switch for preventing start-up with handbrake off 6662
5 Signal from engine brake selector 9024
6 Slow gears engaged (signal) 9976
8 Rear fog light switch 2283
9 Windscreen wiper electric pump control (drive control) 8886
10 Hand brake on switch signal 9907
11 - -
12 - -
13 Rear brake air pressure sensor signal 5561
14 - -
15 Engine brake signal (drive control) 8159
16 - -
17 Signal from Speed Limiter switch 9968
18 Signal from fog lamp switch 2228
19 - -
21 Front brake air pressure sensor signal 5562
22 Emergency light switch signal 2507
23 Signal from left door button 0003
24 Windscreen wiper control (Slow) (drive control) 8882
25 Drive control (right direction light control) (Drive control) 1123
26 Drive control (light flash button) (Drive control) 2204
27 Cruise Control (SET-) (Drive control) 8157
28 Cruise Control (Resume / CC OFF) (Drive control) 8154
29 Windscreen wiper control (Intermittent) (drive control) 8822
30 Windscreen wiper control (Fast) (drive control) 8881
31 Signal from central ceiling fixture activation button 0010
33 Signal from right door button 0003
35 Left direction lights (drive control) 1129
36 High beam headlamps (drive control) 2200
37 Signal from cab release indicator switch 6666
38 Cruise Control (SET+) (Drive control) 8156
39 Front wheel pads wear signalling 6012
40 Rear wheel pads wear signal 6013
Base - 07/2012 Printed 603.95.397

NEW 682
Connector "B" (White)
Cable
Pin Function
colour code
1 Rear power take-off engaged signal 6131
2 Side power-take off engaged signal 6132
3 Negative from starter button inside engine bay 9905
5 Spare -
6 Front differential lock engaged signal 6659
7 Radiator water level signal 5520
8 Hydraulic power steering fluid level signal 5525
10 Spare -
11 Signal from neutral gear switch 7050
12 Spare -
13 Spare -
14 Spare -
15 Spare -
16 Control for internal white light 0941
17 Spare 8876
18 Spare -
19 Spare -
20 Spare -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Connector "C" (Black)
Cable
Pin Function
colour code
1 Spare -
3 Positive for internal roof lamp 4441
4 Right high beam headlamp 2221
5 Left low beam headlamp 2231
6 Windscreen wiper motor (53B - Fast)) 8861
7 Windscreen wiper motor (53 - Slow) 8882
8 Positive for windscreen washer motor pump (prefitting) 8886
9 Windscreen wiper motor (31B) 8873
10 Ground 0000
11 CAN H line 6108
12 CAN L line 6109
13 Spare -
15 Positive for step light 4408
Base - 07/2012 Printed 603.95.397

NEW 682
Connector "D" (blue)
Cable
Pin Function
colour code
2 Spare -
6 Positive for front left side / clearance marker light 3304
7 Rear side marker light positive 3308
9 Positive +30 7772
10 Right low beam headlamp / Headlamp trim consent 2223
14 License plate lights 3307
16 Positive for front side / clearance marker light 3314
Positive for right marker lights for trailer / Positive for exterior light contactor for fitter
17 3315
connector
Connector "E" (White)
Cable
Ref. Function
colour code
1 Spare -
2 Spare -
3 Reading light contactor control 4423
4 Positive +15 8879
5 Positive from key switch during ignition (+50) 8037
6 Command for engine starting contactor 9032
7 Spare -
8 Spare -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
REAR VIEW MIRROR CONTROL CONTROL UNIT [86021]

Figure 75
173792
Cable
Pin Function
colour code
1 Wide-angle left rearview mirror control (horizontal) 8843
2 Wide-angle right rearview mirror control (vertical) 8853
3 Right main rearview mirror control (vertical) 8858
4 Main left rearview mirror control (vertical) 8808
5 Right rearview mirror control (return) 8857
6 Spare -
7 Negative for rear view mirror selector button 0956
8 Spare -
9 Negative from rear-view mirror button (movements to the right) 0953
10 Control unit ground 0000
11 Spare -
12 Spare -
13 Positive for control unit power supply 8879
14 Wide-angle right rearview mirror control (horizontal) 8852
15 Right main rearview mirror control (horizontal) 8859
16 Wide-angle left rearview mirror control (vertical) 8842
17 Left rearview mirror control (return) 8806
18 Main left rearview mirror control (horizontal) 8809
19 CAN H Line (BCB) Ws/Bi
20 CAN L Line (BCB) Gv/Ve
21 Negative from heated rearview mirror control switch 0957
22 Negative from rear-view mirror button (movements to the left) 0954
23 Spare -
24 Negative from rearview mirror button (downward movements) 0951
25 Negative from rearview mirror button (upward movements) 0952
26 Positive for heated rearview mirror control contactor 8819
Base - 07/2012 Printed 603.95.397

NEW 682
CENTRAL LOCKING CONTROL UNIT [86029]

Figure 76
173793
Cable
Pin Function
colour code
1 (+) Battery direct positive (+Batt) 7728
1 3 Central locking command (lock door) 0065
4 (M1) Power supply to motor for central door locking (door opening) 9964
5 (M2) Power supply to motor for central door locking (door closing) 9965
1 - -
2 Ground 0066
2 3 - -
4 - -
5 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
DIAGNOSIS SOCKETS
Diagnosis connector - [72021]
Figure 77
16 1 2 (+)
1526 1718 3 26 1718
1425 19 4 25 19 3027
13 5
24 24 2928
12 23 2120 6 20
1110 22 7 (-) 23 2221 (v)
9 8
DIAGNOSIS CONNECTOR (FRONT VIEW) 113302
Pins 27, 28, 29, 30 might be printed with different positions from those reported in this picture.
Cable colour
Pin System Function
code
1 Spare - -
2 EDC (ECM) K 2298
3 Spare - -
4 ABS K 2299
5 Spare - -
6 Spare - -
7 Spare - -
8 Spare - -
9 Spare - -
10 Spare - -
11 Power supply for ignition switch ancillaries + 15 8802
12 Spare - -
13 Spare - -
14 Tachograph/ IC K 2994/2997
15 Spare - -
16 Spare - -
17 Spare - -
18 Spare - -
19 Spare - -
20 Spare - -
21 CAN H (VDB) H Ws/Bi
22 CAN L (VDB) L Gn/Ve
23 Spare - -
24 Spare - -
25 Engine start signal - 9905
26 Signal ground - 0000
27 Spare - -
28 Speed signal (B7-tachograph) v 5542
29 Signal ground 31 0000
30 Positive + 30 7772
Base - 07/2012 Printed 603.95.397

NEW 682
OBD diagnosis connector (blue) [72069]

Figure 78
173794
Cable colour
Pin Function
code
1 - -
2 - -
3 - -
4 Ground 0000
5 - -
6 CAN H line (VDB) White
7 K line 2298
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
14 CAN L line (VDB) Green
15 - -
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
7 pole diagnostics connector [72XXX]

Figure 79
173795
Cable colour
Pin Function
code
1 Positive +30 7772
4 Ground 0000
5 K line 2298
7 Ground 0000
Base - 07/2012 Printed 603.95.397

NEW 682
EDC SYSTEM FUNCTIONS

The electronic control unit EDC 7 UC31 manages the following main functions:
Fuel injection
Auxiliary functions (cruise control, speed limiter, power take-off, etc.)
Self-diagnosis
Recovery
Also permits:
Interface with other on-board electronic systems (if present)
Diagnosis
Fuel dosing
The fuel metering is calculated in relation to:
- accelerator position
- engine rpm
- quantity of air introduced.
The outcome may be corrected in relation to:
- water temperature
or to avoid:
- noise
- smoke emissions
- overloading
- overheating
The delivery can be modified in the case of:
- engine brake actuation
- activation of external devices (such as speed limiter, cruise control, etc.)
- serious trouble decreasing the load or stopping the engine.
After determining the mass of air introduced by measuring its volume and temperature, the control unit calculates
the corresponding mass of fuel to inject into the relevant cylinder also taking into account the temperature of the
diesel.
Correcting flow rate according to water temperature
When it is cold, the engine encounters greater resistance to its action: the mechanical friction is high, the oil is still
very viscous, the various operating clearances are not yet optimal.
In addition to this, injected fuel tends to condense on the still cold metallic surfaces.
The fuel supply for a cold engine is therefore greater than for a warm one.
Correction of fuel introduction to prevent noise, smoke emissions or overloading.
The behaviour that could lead to this kind of trouble is well known.
The designer has therefore included special instructions in the control unit to avoid it.
De-rating
In the event of the engine overheating, injection is modified, decreasing the delivery to a varying degree, in
proportion to the temperature reached by the coolant.
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Injection advance electronic control

The advance (start of delivery, expressed in degrees) may differ from one injection to the next and from one
cylinder to another. It is calculated, in the same way as the flow, in relation to the engine load (accelerator position,
engine speed and air introduced).
The advance is appropriately corrected:
- in phases of acceleration
- according to the coolant temperature
and also to obtain:
- lower emissions, noise and overloading
- better vehicle acceleration
When starting the engine, a high degree of advance is used based on water temperature.
Feedback from the start of delivery is supplied by the change in impedance of the injector solenoid valve.
Starting the engine
During the first few turns of the engine, the timing and cylinder no. 1 recognition signals (flywheel sensor and
camshaft sensor) are synchronized.
The accelerator pedal signal is ignored upon engine start. Engine start-up fuel flow is set exclusively on the basis
of the water temperature, following a dedicated map.
When the control unit detects enough speed and acceleration in the flywheel to indicate that the engine is started
up and no longer driven by the starter motor, it re-activates the accelerator pedal.
Run Up
When the key contact is excited, the control unit transfers the information stored at the time of the previous engine
stop (see: After run), and runs system diagnostics.
After Run
Each time the engine is switched off using the key, the control unit remains supplied by the main relay for several
seconds,
allowing the microprocessor to transfer some of the data from the (volatile type) main memory to a non-volatile
memory that can be deleted and rewritten (Eeprom) so that it is available for subsequent starting (see: Run Up).
The data mainly consists of:
- various settings (engine low idle setting, etc.)
- settings of some components
- fault memory
The process lasts a few seconds, typically from 2 to 7 (depending on the amount of data to save), after which the
ECU sends a command to the main relay to disconnect from the battery.
This procedure should never be interrupted, for instance by switching off the engine with the battery isolator or
disconnecting the battery isolator before at least 10 seconds have passed after the engine is switched off.
If this happens, the system functions are guaranteed until the fifth incorrect shutdown operation (not necessarily
consecutive) after which an error is stored in the faults log and the engine will run with reduced performance the
next time it is switched on, while the EDC indicator stays on.
Repeated interruptions of the procedure could in fact lead to damage to the control unit.
Cut - off
This function cuts off the supply during deceleration.
Cylinder balancing
The individual balance of the cylinders contributes to improving comfort and driveability.
This function permits individual, customized control over the delivery of fuel and the start of delivery for each
cylinder, which can even differ from one cylinder to another, to compensate for the hydraulic tolerances of the
injector.
The differences in flow (delivery specification) between the various injectors cannot be evaluated directly by the
control unit. This information is supplied by entering the code of each injector by means of the diagnostic tool.
Synchronisation search
If the camshaft sensor signal fails, the control unit can still recognise the cylinders into which fuel is to be injected.
If this occurs when the engine is already running, the combustion succession has already been obtained, and
therefore the control unit continues with the sequence on which it is already synchronised.
If this occurs when the engine is off, the control unit energizes a single solenoid valve. Within a maximum of 2
revolutions of the crankshaft, injection will take place in that cylinder, so the control unit simply needs to
synchronize with the firing sequence and to start up the engine.
Base - 07/2012 Printed 603.95.397

NEW 682
Components on engine
Figure 80
125717
A. Fuel temperature sensor - B. Camshaft timing sensor - C. EDC 7 control unit - D. Fuel regulator valve on high
pressure pump - E. Starter motor - F. Oil temperature/pressure transmitter - G. Alternator - H. Air
pressure/temperature sensor -
I. Air conditioning compressor - L. Water temperature sensor - M. Connector on engine head to connect with
electro-injectors - N. Engine speed sensor on flywheel
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
EDC 7 UC31 electronic control unit [85150]

Figure 81
115802
1. Injector connector - 2. Chassis connector - 3. Sensor connector - 4. Atmospheric pressure sensor
Base - 07/2012 Printed 603.95.397

NEW 682
Electric injector connector 3 (A)

Figure 82
102374
Pin Function
1 Solenoid valve for electronic injection in cylinder 5
7 -
8 -
9 High-pressure pump
10 High-pressure pump
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Sensor connector 2 (C)

Figure 83
102375
Pin Function
1 Variable geometry turbine control solenoid valve
2 -
3 Variable geometry turbine control solenoid valve
4 Engine brake control solenoid
5 Engine brake control solenoid
6÷8 -
9 Ground for engine speed sensor on timing (phase sensor)
10 Engine rpm signal on timing system (timing sensor)
11 -
12 Rail fuel pressure sensor (ground)
13 Rail fuel pressure sensor (power supply)
14 Rail fuel pressure sensor (signal)
15 Coolant temperature sensor signal
16 -
17 Fuel temperature sensor ground
18 -
19 Engine rpm sensor ground (flywheel sensor)
20 Turbocharger speed sensor ground
21 ÷ 22 -
23 Engine rpm sensor signal (flywheel sensor)
24 Ground for oil pressure/temperature sensor
25 Ground for air pressure/temperature sensor
26 Ground for coolant temperature sensor
27 Oil temperature sensor signal
28 Oil pressure sensor signal
29 -
30 Turbocharger speed sensor signal
31 -
32 Power supply for oil pressure/temperature sensor
33 Power supply for air pressure/temperature sensor
34 Air pressure sensor signal
35 Fuel temperature sensor signal
36 Air temperature sensor signal
Base - 07/2012 Printed 603.95.397

NEW 682
Chassis connector B
Figure 84
50350
Pin Cable colour

Function
code
1 - -
2 Positive +30 8150
3 Positive +30 8150
4 - -
5 Ground 0000
6 Ground 0000
7 - -
8 Positive +30 8150
9 Positive +30 8150
10 Ground 0000
11 Ground 0000
12 Positive for thermo-starter relay 8885
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 - -
20 - -
22 - -
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 Signal from pressed accelerator switch 0159
30 - -
31 K line for 30-pin diagnostic connector (pin 2) 2298
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 Positive from key switch +15 8051
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Chassis connector B
Cable colour
Pin Function
code
41 - -
42 - -
43 - -
44 - -
45 - -
46 - -
47 Negative from engine stop button inside engine bay 9906
48 Negative for pressed accelerator switch 0158
50 - -
51 - -
52 CAN L line (white wire) 6109
53 CAN H line (green wire) 6108
54 - -
55 Negative for engine brake solenoid valve 0043
56 - -
57 - -
58 Positive for engine brake solenoid valve 9966
59 - -
60 - -
61 - -
62 PTO control (from fitters) 8854
63 - -
64 - -
65 PTO control (from fitters) 0166
67 - -
68 - -
69 - -
70 - -
71 - -
72 - -
73 - -
74 - -
75 Negative for pre-post heating element control relay 0094
76 - -
77 Ground for accelerator pedal position sensor 0157
78 Accelerator pedal position sensor signal 5157
79 Positive for accelerator pedal position sensor 5158
80 - -
81 - -
82 - -
83 - -
84 - -
85 - -
86 - -
87 - -
88 - -
89 - -
Base - 07/2012 Printed 603.95.397

NEW 682
Electro-injectors [78247]
Figure 85
114255
This is an N.O. solenoid valve.

They are connected to the EDC control unit on connector A.
The resistance of the coil of each individual injector is 0.56 - 0.57 Ohm.
The electro-injector essentially consists of two parts:
❏ actuator - spray nozzle composed of pressure rod, plunger and nozzle;
❏ driving solenoid valve constituted by coil and pilot valve.
The solenoid valve checks the lift of the nozzle needle.
START OF INJECTION
When coil is energised, it makes shutter move upwards.
The control volume fuel flows towards flow duct making a pressure drop occur in control volume.
Simultaneously the fuel pressure into pressure chamber makes plunger lift, with following fuel injection into the
cylinder.
END OF INJECTION
When coil is de-energised, shutter goes back to its closing position, in order to re-create such a force balance as
to make plunger go back to its closing position and end the injection.
Printed 603.95.397 Base - 07/2012

PT. CHAKRA JAWARA
NEW 682
Engine coolant temperature sensor [85153]

It is a N.T.C. sensor located on the head water output manifold on the engine left side.
It determines the coolant temperature for the various control logics of operation of the engine when hot or cold and
identifies the need to enrich the mixture when the engine is cold or reduce fuel injection when it is hot.
It is connected to electronic control unit pins 15 / 26.
Figure 86
104266
Description Cable colour

Pin 15 of the EDC control unit (”C” sensor connector) K
Pin 26 of the EDC control unit (”C” sensor connector) Y
Base - 07/2012 Printed 603.95.397

NEW 682
Fuel temperature sensor [47042]
Characteristics
Supplier BOSCH
Max. tightening torque 35 ± 3.5 Nm
Figure 87
104267

Pin 18 of the EDC control unit ("C" sensor connector) O/B
Pin 35 of the EDC control unit ("C" sensor connector) W/R
Printed 603.95.397 Base - 07/2012

100 ELECTRIC/ELECTRONIC SYSTEM PT. CHAKRA JAWARA
NEW 682
High pressure pump (Pressure regulator) Figure 88

[78013]
Pump with 3 radial pistons controlled by the timing
gears, requiring no timing adjustment, with rotor type
feed pump fitted to the back.
A. Connection between fuel return outlet and filter
bracket
B. Connection for fuel inlet from heat exchanger
control unit
C. Connection for fuel inlet from fuel filter
D. Connection between fuel outlet from feed pump
and filter
E. Connection between fuel outlet and rail
1. High-pressure pump
2. Fuel pump
3. Pressure regulator (NA solenoid valve regulated
by the control unit by means of PWM signal).
Pressure regulator
Situated at the inlet of the high pressure pump, on the
low pressure system, this device adjusts the quantity
of fuel reaching the high pressure pump in accordance
with the commands received from the control unit.
It mainly consists of the following parts:
❏ tapered shutter;
❏ valve control pin;
❏ pre-load spring;
❏ coils.
In the absence of a control signal, the pressure
regulator is normally open, and thus the high pressure
pump is in maximum delivery mode.
The control unit regulates a PWM control signal which
reduces, to a greater or lesser extent, the section
carrying fuel to the high pressure pump.
This component cannot be replaced individually and
thus should not be dismantled.
The amount of fuel feeding the high pressure pump is
metered by a proportional valve on the low pressure 000912t
system - managed by the EDC 7 control unit.

The delivery pressure to the rail is regulate between
250 and 1400 bar by the control unit acting on the
pressure regulator solenoid valve.
It is a N.O. solenoid valve.
Its resistance is about 3.2 Ω.
It is connected to control unit pins C5 - C7.
Base - 07/2012 Printed 603.95.397

NEW 682
Flywheel pulse transmitter [48035]
Characteristics
Supplier BOSCH
Max. tightening torque 8 ± 4 Nm
Figure 89
104269

Pin 19 of the EDC control unit ("C" sensor connector) B
Pin 23 of the EDC control unit ("C" sensor connector) W
Printed 603.95.397 Base - 07/2012

NEW 682
Camshaft pulse transmitter [48042]
Characteristics
Supplier BOSCH
Max. tightening torque 8 ± 4 Nm
Resistance 880 ÷ 920 Ω
This inductive sensor is located on the camshaft.

It generates signals obtained from changes in magnetic flux created by spaces between the teeth on the pulser ring
fitted to the
crankshaft. Number of teeth 6 plus 1 for timing.
The signal generated by this sensor is used by the control unit as the injection timing signal.
The sensor gap is NOT ADJUSTABLE.
Figure 90
104269

Pin 9 of the EDC control unit ("C" sensor connector) W
Pin 10 of the EDC control unit ("C" sensor connector) R
Base - 07/2012 Printed 603.95.397

NEW 682
Figure 91 Oil pressure/temperature sensor

[42030]/[47032]
This component is identical to the air
pressure/temperature sensor and replaces single
sensors 47032 / 42030.
It's fitted on the engine crankcase.
It measures the engine oil temperature and pressure.
The values sent are transmitted to the EDC control unit
which, in turn, governs the indicator on the dashboard
(indicator/low pressure warning light).
Pin (EDC) 24/C - 32/C Power supply
Pin (EDC) 27/C Temperature
Pin (EDC) 28/C Pressure
The engine oil temperature is used by the control unit
unit only.
50324
External view of sensor Ref. Description Control unit pin
1 Ground 24C
2 Temp. Sign. 27C
Figure 92
3 +5 32C
4 Press. Sign. 28C
50323
Connector
Figure 93
50344
Wiring diagram
Printed 603.95.397 Base - 07/2012

NEW 682
Figure 94 Air temperature and pressure sensor [85156]

This component incorporates a temperature sensor
and a pressure sensor.
It replaces the temperature sensors (85155) and
pressure sensors (85154) available in the previous
system.
It is fitted to the intake manifold so that, by measuring
the maximum quantity of air taken in, it makes it
possible to determine the exact amount of fuel to be
injected at each cycle.
It runs on 5 Volts.
The output voltage is proportional to the pressure (or
temperature) measured by the sensor.
Pin (EDC) 25/C - 33/C Power supply
Pin (EDC) 36/C Temperature
126310 Pin (EDC) 34/C Pressure
External view of sensor
Ref. Description Control unit pin
Figure 95 1 Ground 25C
2 Temp. Sign. 36C
3 +5 33C
4 Press. Sign. 34C
114273
Connector
Figure 96
50344
Wiring diagram
Base - 07/2012 Printed 603.95.397

NEW 682
Fuel pressure sensor on rail [85157]

Fitted to one end of the rail, this sensor measures the pressure of the fuel so as to determine injection pressure.
The value of injection pressure is used to keep the pressure level under control and to determine the time duration
of the injection electronic command.
It runs on 5 Volts.
It is connected to the control unit by pins 12C - 13C - 14C.
Figure 97
114620
Pin
Ref. Description
Control unit
1 Ground 12C
2 Pressure 13C
3 Supply 14C
Engine brake solenoid valve [78050] This is a N.C. on-off solenoid valve.
The control unit which controls this solenoid valve
Figure 98 opens the passage to the engine oil to activate the
hydraulic cylinders of the engine brake.
It is connected to the control unit between pins C4/C5.
The coil resistance is ~ 37 ÷ 47 Ohm.
115704
Printed 603.95.397 Base - 07/2012

NEW 682
ABS (ANTI-LOCK BRAKE SYSTEM)

The ABS - EBL braking system is available as an alternative to the EBS system on 4x2 e 6x2 trucks.
ABS (Anti-Lock Brake System)

The braking of a moving vehicle and resulting deceleration and stopping distances mainly depend on the grip
between the tyres and the road surface.
With a fully efficient braking system, a further improvement in braking can only be achieved by acting on the friction
of the tyres or on the grade of the road surface.
Even in these optimum conditions, absolute braking safety is in any case not guaranteed when faced with
especially difficult situations, such as poor grip due to a wet or icy road surface: the driver is forced to moderate
use of the brakes in order to avoid partially locking one or more wheels, with the risk of skidding dangerously.
The function of the "ABS" is therefore to ensure vehicle stability (under all braking conditions), preventing the
wheels from locking irrespective of the state of the road surface, so as to ensure the available grip is made full use
of.
Even in the case of emergency braking, the system makes it possible to keep direction, that is to turn the steering
wheel to avoid obstacles with no risk of skidding.
In short, the anti-lock brake system (ABS):
- Prevents the wheels to lock while braking, irrespectively of the grip condition of the road surface.
- Shortens stopping distances.
- Provides safety for the driver who can keep the vehicle's stability and direction.
Base - 07/2012 Printed 603.95.397

NEW 682
Operating logic
The purpose of the control unit is to decelerate the vehicle as quickly as possible while preserving stability and
preventing the wheels from locking.
To achieve this, the control unit is given the following data during braking:
- The intensity of braking requested by the driver via the rear axle pressure sensor.
- The deceleration due to the pressures made available via the speed sensor signals.
Continuous monitoring and processing of this data, in relation to the desired objective, determines the operation of
the rear axle modulator valves and hence optimises braking.
Braking pressure
Braking FRONT AXLE
Braking request intensity
event Wheel speed
Braking pressure
REAR AXLE
CONTROL UNIT
OBJECTIVE
Skidding = 0
ABS electronic control unit [88000]

Figure 99
107016
It has the task of managing the braking system by setting the deceleration values in terms of the parameters
measured by the various components of the system itself.
It communicates with the on-board electronics via the CAN line and is connected to the vehicle's wiring via two
polarised connectors.
Though offering the possibility of a blink code displayed via the ASR warning light for preliminary diagnosis, the
electronic control unit is provided with an advanced self-diagnosis system capable of identifying and storing any
intermittent anomaly to an operating system subject to environmental conditions, and ensuring proper and reliable
repair.
Printed 603.95.397 Base - 07/2012

NEW 682
ABS control unit pin - out

Figure 100
107017
X1 connector
Cable colour
Pin Description
code
Safety signal sensor for maximum rear axle braking with front axle failure with
2 6245
ABS
4 Ground 0000
5 Ground from switch for ABS exclusion 0049
6 - -
7 Positive +15 8879
8 Positive +30 7772
9 Signal ground 0050
11 - -
12 - -
13 - -
14 - -
15 - -
X2 connector
Cable colour
Pin Description
code
1 Positive for ”EV” solenoid valve (unloaded) front right wheel 9920
2 Positive ”EV” (unloaded) solenoid valve command rear left wheel 9931
3 Positive for ”EV” solenoid valve (unloading) front left wheel 9921
4 Positive for ”AV” solenoid valve (load) front right wheel 9918
5 Positive ”AV” (loaded) solenoid valve command rear left wheel 9929
6 Positive for ”AV” solenoid valve (loading) front left wheel 9919
7 - -
8 Positive ”EV” (unloaded) solenoid valve command rear right wheel 9930
9 Positive ”AV” (loaded) solenoid valve command rear right wheel 9928
16 - -
Base - 07/2012 Printed 603.95.397

NEW 682
Circuit diagrams
Page
❏ Keys to interpretation ................................... 111

❏ Board 1. Battery direct positive .................... 112
❏ Board 2. Positive after general current switch
(+30)_01 ....................................................... 114
(+30)_02 ....................................................... 116
(+30)_03 ....................................................... 118
❏ Board 5. Ancillary equipment power supply
(+15/1)_01 .................................................... 120
❏ Board 6. Ancillary equipment power supply
(+15/1)_02 .................................................... 122
❏ Board 7. Service power supply (+15/2) ........ 124
❏ Board 8. Body Controller_01 ........................ 126
❏ Board 9. Body Controller_02 ........................ 128
❏ Board 10. Body Controller_03 ...................... 130
❏ Board 11. Body Controller_04 ...................... 132
❏ Board 12. Instrument Cluster ....................... 134
❏ Board 13. Tachograph simulator (TSU) /
Tachograph .................................................. 136
❏ Board 14. EDC (Connector B)...................... 138
❏ Board 15. EDC (Connector A/C) .................. 140
❏ Board 16. ABS ............................................. 142
❏ Board 17. Cigarette lighter/Horns/Electric
heater ........................................................... 144
❏ Board 18. CAN line ...................................... 146
❏ Board 19. Diagnosis sockets ....................... 148
❏ Board 20. Trailer sockets ............................. 150
❏ Board 21. Refrigerator/Voltage reducer/Reading
lights ............................................................. 152
❏ Board 22. Radio (high roof) / (low roof) ........ 154
❏ Board 23. Heated pre-filter/Heated filter/Brake
air drier ......................................................... 156
❏ Board 24. Power windows/Power roof/Tool
compartment lights/Fifth wheel lights ........... 158
❏ Board 25. Central locking ............................. 160
Printed 603.95.397 Base - 07/2012

NEW 682
Page
❏ Board 26. Adjustable heated rearview mirrors

❏ Board 27. Manual control air-conditioning .... 164
❏ Board 28. Cab tilting ..................................... 166
❏ Board 29. Longitudinal/transverse differential
locking .......................................................... 168
Base - 07/2012 Printed 603.95.397

NEW 682
Keys to interpretation
Consider the following as a key to interpretation of the circuit diagrams.
Figure 1
Relay Component Connector

code code Welding code
Fuse Cable Cable Clamp Ground

code section code component code
130022
Printed 603.95.397 Base - 07/2012

NEW 682
Board 1. Battery direct positive

Figure 2
173679
Base - 07/2012 Printed 603.95.397

NEW 682
Board 1. List of components

89000 Refrigerator
Printed 603.95.397 Base - 07/2012

NEW 682
Board 2. Positive after general current switch (+30)_01

Figure 3
173680
Base - 07/2012 Printed 603.95.397

NEW 682

08000 Starter motor
19005 Thermostarter
22000 Horn
Printed 603.95.397 Base - 07/2012

NEW 682

Figure 4
173681
Base - 07/2012 Printed 603.95.397

NEW 682

30011 Fog light
Printed 603.95.397 Base - 07/2012

NEW 682

Figure 5
173682
Base - 07/2012 Printed 603.95.397

NEW 682

08000 Starter motor
70000 Fuse holder 6
Printed 603.95.397 Base - 07/2012

NEW 682
Board 5. Ancillary equipment power supply (+15/1)_01

Figure 6
173683
Base - 07/2012 Printed 603.95.397

NEW 682

Printed 603.95.397 Base - 07/2012

NEW 682
Board 6. Ancillary equipment power supply (+15/1)_02

Figure 7
173684
Base - 07/2012 Printed 603.95.397

NEW 682

42608 3-switch assembly signalling coolant pressure
52045 Switch for front drive engagement
Printed 603.95.397 Base - 07/2012

NEW 682
Board 7. Service power supply (+15/2)

Figure 8
173685
Base - 07/2012 Printed 603.95.397

NEW 682

Printed 603.95.397 Base - 07/2012

NEW 682
Board 8. Body Controller_01

Figure 9
173686
Base - 07/2012 Printed 603.95.397

NEW 682

53508 Switch for preventing start-up with gears engaged and turning on reversing light
Printed 603.95.397 Base - 07/2012

NEW 682

Figure 10
173687
Base - 07/2012 Printed 603.95.397

NEW 682

35000 Number plate light
37002 Rear clearance light
52307 Switch for exterior lights
Printed 603.95.397 Base - 07/2012

NEW 682

Figure 11
173688
Base - 07/2012 Printed 603.95.397

NEW 682

39003 Overhead light for step lighting
39027 Bunk ceiling light tool
42393 Speed limiter adjustment switch
52007 Switch with pilot lamp for rear for light
52094 Switch for spot light
52302 Emergency light switch with incorporated indicator
53507 Switch for signalling low gears engaged
53509 Internal light switch
64000 Electric windscreen washer pump
65000 Windscreen wiper unit
Printed 603.95.397 Base - 07/2012

NEW 682

Figure 12
173689
Base - 07/2012 Printed 603.95.397

NEW 682

30011 Fog light
42031 Transmitter for front brake air pressure gauge
42032 Transmitter for rear brake air pressure
44035 Windscreen washer low fluid level indicator control
44036 Radiator low water level indicator control
44037 Insufficient power steering fluid level gauge control unit
52321 Switch with incorporated indicator light for fog lights and rear fog lights inhibitor
Printed 603.95.397 Base - 07/2012

NEW 682
Board 12. Instrument Cluster

Figure 13
173690
Base - 07/2012 Printed 603.95.397

NEW 682

42351 Switch for signalling clogged air filter
44031 Fuel level indicator transmitter with contact for reserve warning light
53400 Cluster menu control switch (UP)
53401 Cluster menu control switch (DOWN)
53402 Cluster menu control switch (C)
53403 Cluster menu control switch (OK)
53538 Switch for signalling body tipped
Printed 603.95.397 Base - 07/2012

NEW 682
Board 13. Tachograph simulator (TSU) / Tachograph

Figure 14
173691
Base - 07/2012 Printed 603.95.397

NEW 682

30011 Fog light
40032 Sender unit for speedometer and tachograph
Printed 603.95.397 Base - 07/2012

NEW 682
Board 14. EDC (Connector B)

Figure 15
173692
Base - 07/2012 Printed 603.95.397

NEW 682

19005 Thermostarter
42374 Switch on clutch for EDC
53007 Switch for stopping engine from engine compartment
85152 Accelerator load sensor for EDC
Printed 603.95.397 Base - 07/2012

NEW 682
Board 15. EDC (Connector A/C)

Figure 16
173693
Base - 07/2012 Printed 603.95.397

NEW 682

42030 Transmitter for engine oil pressure gauge
47032 Transmitter for engine oil temperature signalling thermometer
47042 Fuel temperature sensor
48035 Engine speed sensor
48042 Engine speed sensor on timing system
78013 Solenoid valve to adjust pressure
78247 Electronic injection solenoid valve
85153 Coolant temperature sensor (EDC)
85156 Turbo blower air pressure and temperature sensor for EDC
85157 Pressure adjustment sensor
Printed 603.95.397 Base - 07/2012

NEW 682
Board 16. ABS

Figure 17
173694
Base - 07/2012 Printed 603.95.397

NEW 682

52057 ABS shut-off switch
78052 ABS/EBS solenoid valve
88001 Sensor for ABS system
Printed 603.95.397 Base - 07/2012

NEW 682
Board 17. Cigarette lighter/Horns/Electric heater

Figure 18
173695
Base - 07/2012 Printed 603.95.397

NEW 682

22000 Horn
Printed 603.95.397 Base - 07/2012

NEW 682
Board 18. CAN line

Figure 19
173696
Base - 07/2012 Printed 603.95.397

NEW 682

72XXX 7-pole diagnosis connector
Printed 603.95.397 Base - 07/2012

NEW 682
Board 19. Diagnosis sockets

Figure 20
173697
Base - 07/2012 Printed 603.95.397

NEW 682

72XXX 7-pole diagnosis connector
Printed 603.95.397 Base - 07/2012

NEW 682
Board 20. Trailer sockets

Figure 21
173698
Base - 07/2012 Printed 603.95.397

NEW 682

Printed 603.95.397 Base - 07/2012

NEW 682
Board 21. Refrigerator/Voltage reducer/Reading lights

Figure 22
173699
Base - 07/2012 Printed 603.95.397

NEW 682

39009 Courtesy light for reading lights
72054 Power socket 6A
89000 Refrigerator
Printed 603.95.397 Base - 07/2012

NEW 682
Board 22. Radio (high roof) / (low roof)

Figure 23
173700
Base - 07/2012 Printed 603.95.397

NEW 682

68001 Loudspeaker
68002 Antenna
Printed 603.95.397 Base - 07/2012

NEW 682
Board 23. Heated pre-filter/Heated filter/Brake air drier

Figure 24
173701
Base - 07/2012 Printed 603.95.397

NEW 682

Printed 603.95.397 Base - 07/2012

NEW 682
Board 24. Power windows/Power roof/Tool compartment lights/Fifth wheel lights

Figure 25
173702
Base - 07/2012 Printed 603.95.397

NEW 682

Printed 603.95.397 Base - 07/2012

NEW 682
Board 25. Central locking

Figure 26
173703
Base - 07/2012 Printed 603.95.397

NEW 682

12010 Motor for locking or unlocking door on passenger side
12011 Motor for outside air intake door
Printed 603.95.397 Base - 07/2012

NEW 682
Board 26. Adjustable heated rearview mirrors

Figure 27
173704
Base - 07/2012 Printed 603.95.397

NEW 682

52004 Switch for heated rear view mirrors
85006 Heated rearview mirror and electric adjustment (main)
85010 Rear view mirror control
85011 Side mirror selection and side mirror heating on control
Printed 603.95.397 Base - 07/2012

NEW 682
Board 27. Manual control air-conditioning

Figure 28
173705
Base - 07/2012 Printed 603.95.397

NEW 682

42608 Coolant pressure signalling 3-switch assembly
Printed 603.95.397 Base - 07/2012

NEW 682
Board 28. Cab tilting

Figure 29
173706
Base - 07/2012 Printed 603.95.397

NEW 682

Printed 603.95.397 Base - 07/2012

NEW 682
Board 29. Longitudinal/transverse differential locking

Figure 30
173707
Base - 07/2012 Printed 603.95.397

NEW 682

Printed 603.95.397 Base - 07/2012

NEW 682
Base - 07/2012 Printed 603.95.397

PT. CHAKRA JAWARA
NEW 682

IVECO 682 - Instruction Manual

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IVECO 682 - Instruction Manual

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PT.

VEHICLE IDENTIFICATION DATA .................... 3

❏ Vehicle Identification Plate ........................... 4

❏ Vehicle identification number (V.I.N.) punched

P.I.C. NUMBER CODING ................................... 5

COMPOSITION OF MODELS ............................ 9

Printed 603.95.397 Base - 10/2013

Base - 10/2013 Printed 603.95.397

VEHICLE IDENTIFICATION DATA

Manufacturer plate Engine

Printed 603.95.397 Base - 10/2013

Vehicle Identification Plate (located on rear cross member)

Vehicle identification number (V.I.N.) punched on the chassis

Positions 1-2-3: Manufacturer identification

Base - 10/2013 Printed 603.95.397

P.I.C. NUMBER CODING

AXLE CONFIGURATION - GROSS VEHICLE MASS

4 Tractors 4x2 (18 ton)

6 Chassis cab 6x4 (25 ton)

Printed 603.95.397 Base - 10/2013

TYPE OF REAR AXLE - TYPE OF SUSPENSION

H.R. = Double reduction rear axle

Base - 10/2013 Printed 603.95.397

WHEEL WHEEL WHEEL

 4x2 3650  6x4 3400 O 6x4 3225 1

 8x4 5100 O 6x4 3600 2

 4x2 4325 O 6x4 4125 4

 6x4 6000 O 6x4 4600 6

Printed 603.95.397 Base - 07/2012

CAB TYPE - DRIVE - BRAKES COMBINATION

AS - C Right Drum Drum A

AS - C Left Drum Drum I

AS - L Right Drum Drum D

AS - L Left Drum Drum 4

Base - 07/2012 Printed 603.95.397

MODELS TRACTOR CAB TIPPER

Single reduction rear axle • • • • •

Printed 603.95.397 Base - 07/2012

IVECO RECOMMENDED LUBRICANTS PARTS TO BE REFILLED Quantity

Urania FE 5W30 (1) F2C Engine

Tutela TRUCK DOT Clutch circuit - -

Base - 07/2012 Printed 603.95.397

Lubricants and fuels international name Original products

Printed 603.95.397 Base - 07/2012

Lubricants and fuels international name Original products

Base - 07/2012 Printed 603.95.397

REPAIR OPERATIONS ON VEHICLE ............... 3

Printed 603.95.397 Base - 10/2013

Base - 10/2013 Printed 603.95.397

Repair operations on vehicle

MAIN REPAIR OPERATIONS ON VEHICLE ..... 5

❏ Replacement of injectors on vehicle ............. 5

❏ Fuel filter replacement on vehicle ................. 8

❏ Replace muffler on vehicle ........................... 10

❏ Replace oil sump on vehicle ......................... 14

❏ Replace fan on vehicle ................................. 16

Printed 603.95.397 Base - 07/2012

❏ Replace intercooler on vehicle ..................... 17

❏ Replace condenser on vehicle ..................... 17

❏ Replace thermostat on vehicle ..................... 20

❏ Air conditioner compressor drive belts

❏ Replacement of rocker cover on vehicle ...... 23

❏ Replace rod-piston on vehicle ...................... 29

❏ Starter motor replacement on vehicle .......... 33