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Daily Turbodaily Turbodaily 4X4: Repair Manual Electrical/electronic Systelll
Daily Turbodaily Turbodaily 4X4: Repair Manual Electrical/electronic Systelll
TURBODAILY
TURBODAILY 4x4
30.8 30.10
35.8 35.10 35.12
35.10 EDC
35.10 W
40.8 40.1 0 40.12
40.10 W
A 40.1 0 A 40.12
45.10 A 45.12
A 45.10
49.10 49.12
A 49.10
59.12
Repair Manual
Electrical/electronic systelll
Update for manual
Print n°. 603.42.961
The data contained in this publication might fail to reflect the la-
test changes which the Manufacturer may introduce at any time.
for technical or sales purposes, or to meet the requirements 0
local legislation.
This manual is produced by our Technical Publications Department for use by Technicians to assist in carrying out repairs
or maintenance work and provide a better knowledge of IVECO products.
With the introduction of the new DailylTurbodailylTurbodaily 4x4 range our efforts have been devoted at improving
the electrical system litterature as a whole. It now includes this present manual entitled "ELECTRICAUELE(TRONIC
COMPONENTS" and a further manual entitled "ELECTRICAUELECTRONfC EQUIPMENT".
This manual provides comprehensive written and graphic information which is the result of thorough research work.
It is not nor does it set out to be an exhaustive survey of electrical equipment, sin(E~·the experts in this field are already
familiar with the complex and specific nature of such products, but it is limited to the essential, relevant documentation
that a motor vehicle electrical repair workshop must have available for information on electrical equipment, so that it
can carry out its work properly.
The "ELECTRICAUELECTRONIC COMPONENT" manual is therefore a valuable source of information for electrical
components, covering such areas as removal and refitting, inspection, bench testing, numerical codes, cable colour
codes, etc. It is specifically intended for use by qualified electrical engineers.
The other manual, "ELECTRICAUELECTRONIC EQUIPMENT", which complements this manual, covers each individ-
ual model ofthe vehicle range in question and contains full circuit diagrams and descriptions of the respective electrical
systems.
TABLE OF CONTENTS
CHAPTER
GENERAL
ELECTRICAL SYSTEM
STARTING II
INSTRUMENTS IV
LIGHTS V
SIGNALS VI
SERVICES VII
INDEX IX
GENERAL
Page
GENERAL 9
GRAPHIC SYMBOLS USED IN THIS MANUAL 10
GENERAL INSTRUCTIONS II
GENERAL INSTRUCTIONS CONCERNING ELECTRONIC
COMPONENTS 12
EARTH CONCEPT AND ELECTROMAGNETIC ,
COMPATIBILITY 13
READING KEYS 15
I
GENERAL
Composition of the manual
This manual consists of the section "GENERAL" plus nine chapters identified by Roman numerals, as follows:
Chapter II - STARTING
Chapter IV - INSTRUMENTS
Chapter V - LIGHTS
Chapter VI - SIGNALS
Chapter X - INDEX
All subjects covered in this manual are correct at the time of its preparation. This practically corresponds to the date
of printing.
Each chapter has its own progressive page numbering system to make future updatings easier. Pictures have a double
numbering system: the first figure refers to the chapter number while the second one is a progressive number; this way,
pictures can be easily traced in case a cross reference is needed.
In the following pages you will find the key that will help you read the information contained in this manual.
A On reading through this manual you will find a special information entitled "Simplified diagnosis" (above
the component diagram, see page 11.28 as an example). This information is meant to facilitate circuit diagnosis as
described on page 1.52. The electrical network to which the component under examination belongs is to be looked
for in the "Electric/electronic System" manual, print no. 603.42.961.
Unless otherwise specified, simplified diagnosis tests should be carried out on a vehicle in the following condition:
engine switched off, parking brake engaged and transmission in neutral.
Graphic symbols and abbreviations used in this manual
Component identifica-
Warning NA Normally open
tion numbers/letters
Warning relating to
1525021 Component code N.B. Note
electronic equipment
Ultrasound welding
Refer to ABS Wheel antilock system SU
point
Electronic injection
Analogue check EDC TGC General current relay
control device
Identification of a
component and elec- IT Iveco Tester -7777 - Cable colour code
tronic control units
Earth point:
Symbol identifying an M = Earth
MI
electric function I = Identification
number
N.B. Technical data and component specification given in this manual are supplied by way of example and must be
checked on the test bench.
General instructions
NEVER DISCONNECT THE BATIERIES FROM THE SYSTEM OR OPEN THE ISOLATING SWITCH
WITH THE ENGINE RUNNING.
ALWAYS CONNECT THE BATIERIES IN A PERMANENT WAY PRIOR TO STARTING THE ENGINE.
Before carrying out any servicing operation on the vehicle, chock the wheels securely to prevent the truck from
moving on its own.
Do not use quick charging devices to start the engine. Enginestarting should be performed only by means of
separate batteries or a suitable trolley
- Ensure correct polarity of battery terminals when starting the engine by means of an au><;iliary trolley.
- Incorrect polarity of electronic control unit input voltage (i.e. incorrect polarity of battery terminals) can lead
to electronic module breakage.
- When disconnecting the batteries from the system, always disconnect the chassis earth cable from battery nega-
tive terminal first of all.
- 'Before connecting the batteries, make sure the system is properly isolated.
When tracing the cause of a circuit failure, place a spare fuse between the battery negative terminal and the
chassis earth cable (main current breaker on).
- Before removing electrical/electronic components, disconnect the earth cable from the battery negative termi-
nal.
- When tracing the cause of circuit failure, place a spare fuse between the battery negative terminal and the chassis
earth cable (main current breaker on).
- Before removing electrical/electronic components, disconnect the earth cable from the battery negative termi-
nal.
- Disconnect the battery from the system when recharging it fron an external source.
- Disconnect external battery charger from mains supply before disconnecting it from the battery terminals.
- Never connect/disconnect the electronic module jack when the input line is alive.
- Dismantle electronic control units when working with temperatures over 80°C (drying oven).
- While performing electrical welding on the chassis, disconnect connectors from electronic control modules.
Always use the specified tightening torque data in connector nuts (temperature, pressure sensors, etc.).
Measurements on electronic modules controlling plugs, plug connections and electrical connections to
components must be taken using exclusively the specified testing lines and plugs. Under no circumstances should
metal wires, screwdrivers, clips or other similar devices be used. In addition to short circuit risks, this could cause
damage to plug connections with consequent contact problems.
General information on electronic compo-
nents
The standard system is traditionally a single-pole system. The body, chassis, metal container of electromechanical com-
ponents act as equipotential return conductorto the generator; since any point ofthe metal structure or any unisolated
negative terminal is at the same potential or EARTH. This is why the earth has been chosen as the reference for the
entire system, conventionally giving it a rating of O.
For obvious constructive reasons, different earth points scattered overthe vehicle according to the location ofthe com-
ponents,influence the system in the negative network.
Ideally, all the equipment should be connected to only one earth point to warrant a clearly defined earth reference,
especially for the electronic devices.
Due to the above-mentioned reasons, the supply earth or system earth characterised by strong direct current intensity
(> IAfor electromechanical components) must be distinguished from the analogue earth characterised by wave shapes
at determinate frequencies and with very small current intensities (mA,IlA) of the electronic/numerical systems.
The definition of signal earth or analogue earth depends on the sensitivity of the electronic systems to EMC (electro-
magnetic compatibility) since parasite signals induce malfunctioning and/or deterioration ofthe actual systems (as they
are emitted by systems on board and/or outside the vehicle).
In order to minimise continuous or transient disturbances or interferences caused by parasite radiations, it is of the
utmost importance to bear in mind all the time that the soundness of the reference plan or system earth depends
on the excellent conduction features (contact resistance tending to zero) in each of its connecting points.
To sum up we can say that earth intended as equipotential electric conductor, i.e. as potential reference of all the
electric/electronic components on board, is subdivided into system earth and analogue earth.
Earth points (M I , M2, M3 etc) are established by the manufacturer and must obviously be free from paint, oxidation,
grease, dust etc.
When refitting the earth wires to the chassis, thoroughly remove the old conductive paint and apply a new even coat
of BH44D or Kontaktolon paint proceeding as described below:
4. If mounting a new earthing contact, file the chassis anaphoresis paint around the terminal clamp fixing hole and
prepare a smooth supporting surface.
READING KEYS
Key to manual reading
76
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TABLE OF CONTENTS 0
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148030 I
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50000 I
COMPONENT PLAN ~ NUMERICAL COM-
VIEW PONENTCODE
CONNECTOR BLOCK
COMPONENT CON IDENTIFICATION LET-
NECTOR BLOCK I------.!!-II ~------j TER
COLOUR CODES ON
CABLES PERTAINING
, ...." -t..- - - l TO CONNECTOR TO
BE JOINED TO COM-
PONENT
Key to components described in chapter VIII (ABS/ASR, EDC etc. electronic control units)
COMPONENT PLAN
1 'R:ssRiouolOo-I...I----J COMPONENT NUM-
VIEW , ' BERCODE
CONNECTOR BLOCK
IDENTIFICATION LET-
CONTROL UNIT CON- TER -CONTROL UNIT
NECTOR CONNECTION
CONNECTOR BLOCK
PLAN VIEW - CON-L_-==--~::::::::=-----_=:
TECHNICAL VIEW OF
TROL UNIT CONNEC- ~t= CONNECTOR FROM
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76
STARTING liS
o
Spec ifi:atbns
I
'10DEL TYPE
Turbodaily
mLCO 12V-I02Ah-RC310A (either right-hand drive
or fitted with
"'" air-.:onditbnin2, system)
o "'"
tbnal extna:;)
"OSSIBLE FAILURES
Qui: k d iagncxsis I\ND REMEDIES
Defect
2. T"rmi.-..k bo<e or eo<dized or bumt Resto"" terminal effi=ierq, eo; ""'l uited
o
ELECTRICAL SYSTEM
Page
ENGINE TYPES 3
SYSTEM SPECIFICATIONS 4
LOCATION OF EARTH POINTS ON THE VEHICLE 6
CABLE ULTRASOUND WELDING 7
COMPONENTS 8
CONNECTOR BLOCKS 10
INSERTING/REMOVING WIRE TERMINALS - HOW TO PROCEED
WITH CONNECTOR BLOCKS OF DIFFERENT TYPES 13
COMPONENT REPLACEMENT INSTRUCTIONS 26
CIRCUIT DIAGNOSIS 52
COMMON COMPONENTS
CENTRAL INTERCONNECTING UNIT 57
STEERING WHEEL SWITCH 62
DASHBOARD 64
COMBINED MODULE 66
CENTRE CONTROL PANEL 68
I .
ELECTRICAL SYSTEM
Engine types
4983
4984
The wiring system installed on the various Daily and Turbodaily models is basically the same, with the exception
of the following data:
A B c D E
G F
4522
Regardless
on the of 0 ptlonal
b us version '
extras
includes
e ay ~oll
the ilandoWing
' c requested by the d'ffi
vanants I erent c ' w,nng s s t ·
_ eneral Current R I ,omponents: ountnes, the standard '
Emergency c . _ y em 'nstalled
G
Ircult
- Swing-slidin g d oor
- Internal lighting
A B c
F E D
4986
M4 MI M2 MS M3 4981
M2~.
Engine block Ih side Earth connection between engine and
chassis
~f ----
4988
+----
M3 Lh side member Power steering fiuid level indicator control
~IL device -Horns - Fuel level sender unit -
Side marker lights - Brake fiuid level indica-
tor control device - Tail external lighting-
4989
Telma-
Hood (close to rh headlight cluster) High/low beam light with rh parking light - Rh
front turn signal light - Air cleaner restriction
indicator switch - Windscreen washer pump
- Engine coolant level indicator
Hood (close to Ih headlight cluster) High/low beam light with Ih parking light-
Lh turn signal light - Fog lamps
4990
Cable ultrasound welding
This is the first time that ultrasound welding is used
A
on a commercial vehicle with the purpose of eliminating
the considerable number of power and earth jumpers in-
cluded with other components in its electrical system (fig.
1.4).
I , I
~ SU
4992
1.4 COMPONENT EARTH CONNECTION
Welding points are fitted inside the cable loom and A. CONNECTION VIA JUMPERS - B. CONNECTION VIA UL-
TRASOUND WELDING
are isolated from other cables by means of heat-shrink-
ing sheaths or insulating plastic material. All component
lines meet on one side of the point while on the other
side a single wire supplies earth or power connection for
all of them (fig. 1.5).
v
::::;r.'ii£ A
~
SU
B 4993
- hood/engine
- hood/chassis. 4998
- cab/hood 4999
B
- cab/doors
- cab/roof
- cab/headlight washer unit
- cab/power windows and adjustable mirrors
- cab/ASS
- ASS/ASS sensors
5000
5002
5(0)
5004
~
are insulated with heat and dust/waterproof polyvinyl
material.
Polyvinyl insulation also proves very efficient in the
prevention of corona and galvanic effects produced by
direct current. Such effects cause contact oxidation re-
31 B+ sulting in voltage drops atthe electrical component ter-
minals.
By way of example, we can say that maximum carry-
0+
4-+-,...---t>--77 78 - - ing capacity (this may vary from one country to another)
in continuous duty is 6A for 0.5 mm 2 conductors and
I IA for I mm2 conductors.
The heavy type number atthe side ofthe cable colour
code identifies, on circuit diagrams, cable sections above
.....- - - - - - - - - - - - - I mm 2
3679 For instance, figure 1.13 shows that section of cable 7777
1.13 CABLE SECTION IDENTIFICATION is 6 mm 2
Connector cell identification
5005
1.14 HIGHLIGHTING CELL IDENTIFICATION NUMBERS ON DIF-
FERENT CONNECTOR TYPES
'flff fi R Fl Fl fHH'\ t\
. 5006
1.15 CELL IDENTIFICATION (CABLE END MALE CONNECTORS)
Removing wire terminals from connectors and fasten-
ing cables to wire terminals - Special tools
§mB~
6, _BBB8888BlIIB M
1.16
\l ~,~
Tool with central sliding stem: use for removing wire
terminals from round connectors (fig. 1.17).
2409
1.17
2410
1.18
Installing and removing wire terminals
Tail headlight cluster connectors (bus and van version)
5007
2416
2411
1.22
- Working from the cable input end, insert the wire
terminal into the connector cell (fig. 1.23)
5008
1.23
5009
1.24
Electronic control unit connectors j
Proceed as follows to remove/replace wire terminals
from electronic control unit multiple connectors:
2420
129 INSERTING THE WIRE TERMINAL INTO THE CONNECTOR
2422
1.30 SECTION THROUGH THE CONNECTOR SHOWING WIRE TERMINAL AND RELEVANT REMOVAL bPERATION
MIC-MARK connectors
2424
2426
1.33 SECTION THROUGH THE CONNECTOR SHOWING WIRE TERMINAL AND RELEVANT REMOVAL OPERATION
Packard connectors
There are two types of Packard connectors: one of
them is fitted with side tabs while the other one has no
such tabs. A different wire terminal removal operation is
required depending on the connector type.
Within the side tab connector type there are special
power connectors that use cables of a larger section
compared to the other Packard connector types.
4817
1.36 SECTION THROUGH THE CONNECTOR SHOWING WIRE TERMINAL AND RELEVANT REMOVAL OPERATION
Packard connectors (without side tabs)
- push the wire terminal into the cell until a slight 1.37 WIRE TERMINAL REMOVAL WITH TOOL INSERTED IN RELE-
resistance is felt. A characteristic noise past this VANT CELL
2430 2431
1.39 SECTION THROUGH THE CONNECTOR SHOWING WIRE TERMINAL AND RELEVANT REMOVAL OPERATION
Connectors of the type shown in figures on this page
2432
2433
2434
142 SECTION THROUGH THE CONNECTOR SHOWING WIRE TERMINAL AND RELEVANT REMOVAL OPERATION
AMP connectors
4821
2436
2438
2439
2440
2441
2442
2443
2445
2446 2447
I.S4 CONDUCTOR SECURED TO CLIP BY MEANS OF SCREWS CONDUCTOR SECURED TO CLIP BY PRESSING
Fastening wire terminals to conductors
2448
(0 ~ 2449
( 0 ---------i! 2450
5013
5014
14V SQ-90A Alternator
161 REMOVING THE STARTER MOTOR
Carry out the following operations to remove the
14V SO-90A alternator:
- Disconnect power cables from battery.
- Disconnect alternator electrical cables.
- Remove bolts from belt tension adjustment
bracket and from alternator mounting (fig. 1.62).
- Remove the alternator.
5016
5018
5019
5020
I 5021
5022
Electronic tachometer
Combined module
(
DODD III
-
-
fuel level indicator
warning lights
The other module type contains the same instru-
ments - with the exception ofthe electronic rev counter
- arranged in a different way.
1.71 REMOVING THE ELECTRONIC SPEEDOMETER
The combined module is also fitted with a lamp test
switch and and instrument light dimming rheostat for
checking lamp efficiency and reduce instrument light in-
tensity.
Proceed as follows to remove the combined module:
- Undo both screws securing the module to the
dashboard (Fig. 1.72).
Carefully turn the module outwards.
- Disconnect instrument junction blocks.
Reassemble the unit by reversing the above steps.
5024
Warning lamps
Warning lamps are of the all-glass 12V 2W type.
5026 Proceed as follows to replace them:
Remove the combined module.
1.76 REMOVING INSTRUMENT LIGHT RHEOSTAT - Working from the module's rear end, turn the
bayonet-coupling warning lamp connector until
it is possible to remove it (fig. 1.77). •
The block is electrically connected to the system via
a tinned seat included in its printed circuit. i
Reassemble the unit by reversing the above steps. !
1
Ashtray assembly
Proceed as follows to replace the ashtray (fig. 1.78)1
- Use a screwdriver to work on both tabs (not vis-
ible from the ashtray outside).
- Gently prize the ashtray off its seat taking care not
to break its light pipe.
119
5027
121
IYECO Control
149
5032
137
1062
Chapter I: CI.u. page 1.57
1.88 LOCATION OF FUSES AND RELAYS ON THE C.IU
Auxiliary fuses and relays
Auxiliary fuses and relays can be found on the CI.U.'s
side.
Relays are fitted with a bracket to enable their fasten-
ing to the CI.U compartment wall by means of a screw.
Fuses are instead fitted to a special mounting also
fixed to the compartment wall.
Besides their application to possible optional extras,
auxiliary fuses and relays are used in the following circuit
functions:
- preheating
- power steering fluid level indicator
- engine coolant level indicator
- windscreen defrosting
5036
- Refit the rubber plug. 1.93 REMOVING HEADLIGHT AIMING CONTROL ACTUATOR
External lighting
The external lighting system consists of the the fol-
lowing components:
- high/low beam lights with built-in parking lights
- fog lamps (optional extra)
- front turn signal lights
turn signal side repeaters
- front and side marker lights (the van version has
prearrangement for side marker lights)
- number plate lights
- tail headlight cluster (parking, turn signal, stop, re-
verse, rear fog lights)
2612
5042
Turn signal side repeater 1.97 REMOvING FRONT TURN SIGNAL LIGHT
2519
Horns
Horns are assembled on the chassis frame under the
power steering fluid reservoir. Proceed as follows to re-
move horn(s):
- Disconnect junction block(s).
- Undo the nut securing the horn to its mounting
bracket (fig. 1.105).
Reassemble the unit by reversing the above steps.
- interior lighting 1.109 LOCATION OF SAFETY UNIT SWITCH AND GCR CLOSING
SWITCH
5058
- interior lighting 1.109 LOCATION OF SAFETY UNIT SWITCH AND GCR CLOSING
SWITCH
wheelhouse.
During an emergency this handle can be pulled to open
the vehicle door from the outside.
A B
To restore normal operation of the system, follow di-
rection given above concerning emergency door open-
ing from the inside.
The red handle is also meant to prevent the door be-
ing opened from the outside, via a suitable key, while the
vehicle is stationary. However; regardless of the fact the
door is locked, it can still be unlocked from the inside.
5060
Door locking device
1.1 16 SENDER UNIT A. LED - B, CONTROL PUSHBunON
City Dailyffurbodaily vehicles are fitted with a system
for locking doors through a remote control device con-
sisting essentially of a sender unit and an infrared receiver.
The sender unit includes (fig. 1.1 16):
- a control pushbutton
- a led forvisulizingthe signal delivered by the send-
er unit
The receiver includes (fig. I. I 17):
- a pushbutton for storing the code ofthe signal de-
livered by the sender unit
- a led for signalling reception of the signal
- a sensor for receiving the signal
To enable the door locking function operate the send-
er unit control button and aim the sender unit towards 5061
the infrared receiver located in the middle of the roof. 1.1 17 INFRARED RECEIVER A. LED - B. PUSHBunON - c. SENSOR
SWin~-sliding door - Emergency opening from the in-
side
An emergency door unlocking system can be put into
action in the event of a gearmotor or powerfailure. In this
case the door can be opened via a red handle (fig. 1.1 14)
located close to the door compartment on bus and City
DailylTurbodaily versions (close to the motor unit on
school bus version).
Proceed as follows: operate the black lever posi-
tioned beside the motor unit while rotatingthe doorsup-
porting shaft until motor gears are again in mesh.
wheelhouse.
During an emergency this handle can be pulled to open
the vehicle door from the outside.
A B
To restore normal operation of the system, follow di-
rection given above concerning emergency door open-
ing from the inside.
The red handle is also meant to prevent the door be-
ing opened from the outside, via a suitable key, while the
vehicle is stationary. However, regardless of the fact the
door is locked, it can still be unlocked from the inside.
5060
Door locking device
1.1 16 SENDER UNIT A. LED - B. CONTROL PUSHBunON
City DailylTurbodaily vehicles are fitted with a system
for locking doors through a remote control device con-
sisting essentially of a sender unit and an infrared receiver.
The sender unit includes (fig. I. I 16):
- a control pushbutton
- a led forvisulizingthe signal delivered by the send-
er unit
The receiver includes (fig. 1.1 17):
- a pushbutton for storing the code ofthe signal de-
livered by the sender unit
- a led for signalling reception of the signal
- a sensor for receiving the signal
To enable the door locking function operate the send-
er unit control button and aim the sender unit towards 5061
the infrared receiver located in the middle of the roof. 1.1 17 INFRARED RECEIVER A. LED - B. PUSHBunON - c. SENSOR
Top console
A console fitted on top ofthe centre instrument pan-
el houses the following components:
- safety unit switch (bus/school bus)
- Telma retarder control device and associated
warning lamp (optional extra)
- swing-sliding door pusbutton strip
- GCR closing switch (bus/school bus)
- electric/air horn switch
- hazard light warning lamp with built-in safety unit
control switch (bus/school bus)
Safety unit control switch
Operation of this switch produces the following ef-
fects:
5062
- engine stopping
1.1 18 CENTRAL INSTRUMENT PANEL - TOP CONSOLE (SCHOOL
BUS VERSION)
- turning on of hazard lights
- turning on interior lighting
- GCR opening
- turning on of warning lamp for hazard lights on
(fig.l.120 ref. A).
Perform the following operation to remove the safety
unit switch:
- Remove the swing-sliding door pushbutton strip
- Unscrew both knob threaded dowels and ring
nut securing the switch to the top console (fig.
I. I I9 ref AlB)
- Withdraw the switch through the button strip
seat
- Disconnect both switch junction blocks.
Reassemble the unit by reversing the above steps.
Hazard lights on warning lamp and switches assembled
1.119 REMOVING SAFETY UNIT CONTROL SWITCH on the top console
A. THREADED DOWEL - B. RING NUT· You may follow either one of the procedures de-
scribed below to remove these components:
- I) Use the tip ofa screwdriver to remove the plug
covering one of the empty compartments (de-
signed to house an optional extra not yet
installed) and push the desired component off its
seat through this opening.
- 2) Use a screwdriver to remove the protection
plate onto which switches are assembled. To do
so, prize the plate off the four tabs securing it to
the top console (fig. I. 120).
Reassemble the unit by reversing the above steps.
(~
Interior lighting for the bus/school bus version In-
cludes the following components:
Perform the following operation to remove the ceiling 1.121 EMOVING LENS FROM DRIVER'S PLACE CEILING LAMP
Step light
5057
323
316
322
1.127 AIR-CONDITIONING SYSTEM SWITCHES
A. AERATOR SWITCH - B. INTERIOR HEATING SWITCH
5069
Aerator
1.129 AERATOR
Air-conditioning system
322
1.127 AIR-CONDITIONING SYSTEM SWITCHES
A. AERATOR SWITCH - B. INTERIOR HEATING SWITCH
5069
Aerator
1.129 AERATOR
Tail headlight cluster and number plate light
To gain access to tail headlight cluster lamps loosen
the four screws fixing the lens to the headlight frame. The
headlight is also fitted with a side lens that operates tail
side marker lights whenever parking lights are switched
on.
Lamps are arranged as follows:
(Ih headlight: from left to right) - (rh headlight: from right
to left)
- tail side marker light
- turn signal light
- stop light
- parking light
/ - rear fog light
5071
- reversing light
1.130 TAIL HEADLIGHT CLUSTER AND NUMBER PLATE LIGHT Undo both screws fixing headlightto bumperto gain
accees to the reversing light bulb (fig. 1.130).
Above lights are also assembled on the van version.
Interior lighting (van)
In addition the centre ceiling lamp (page 1.37) the inte-
rior lighting system ofthe van version also includes a ceil-
ing lamp located on the side sliding door (fig. 1.131) and
another Iight fitted to the top of the rear double-door.
Both lights are either operated via a pushbutton (fig.
1.132) assembled on the rear door post or by pressure
applied to the ceiling lamp sides.
Access to the bulb is gained by removing the lens by
I\leans of a screwdriver.
5072
5073
Front axle
5074
Rear axle
Cab
Figure 1.1 33 shows the splitter gear engagement lever.
The detail highlights the position of splitter gears on sig-
nalling switch.
LI 35 TRANSFER CASE
A. ALL-WHEEL DRIVE SIGNALLING SWITCH
1860131 L . - _.....
5079
nected.
In general, this problem is caused either by sulphation 20
of the battery itself, or more probably by a partially B
short-circuiting component.
o 40
A defective circuit can be easily identified by connect-
ing an analogue voltmeter in SERIES to the chassis earth 2619
Renewal of components
Drops in voltage
Among the most frequent causes of circuit problems
177 are the different drops in voltage which adversely affect
1.142 USE OF A SHUNT TO CHECK THE EFFICIENCY OFA COM-
the reliability of the electrical system.
PONENT NEGATIVE NElWORK
These drops, which occur in the electrical contacts for
switches, remote control switches and relays are due ei-
ther to the poor connection of the wire terminals or to
178
5081
5083
FUSE ASSEMBLY
5 Lh front parking light, Ih number plate light, rh rear parking light, rh front marker
light, dashboard light
2 5 Rh front parking light, rh number plate light, Ih rear parking light, Ih marker light
3 7,5 Rh low beam light
4 7,5 Lh low beam light
5 7,5 Rh high beam light
6 7,5 Lh high beam light
7 3 Electronic speedometer
8 5 Lamp test, warning lamps, instruments
9 10 Fog lamps (optional extras)
10 3 Rear fog lamps
II 5 Not used
12 7,5 Not used
13 10 Hazard lights
14 5 Turn signal lights
IS 3 Engine stopping
16 7,5 Stop lights, reversing light
17 10 Horns
18 7,5 Interior lighting, cigar lighter, radio receiver set
19 IS Fuel filter heating (optional extra)
20 10 Windscreen wiper unit, windscreen washer pump
21 IS Electric heater
22 7,5 Key switch lighting, flasher light
23 25 Power windows (optional extra), engine cooling system
24 10 Not used
c.I.U. relays and diode holders
l ,..J
©[ ~O
o
-
.
][ =0
.'
][ -=0 ]! 1D
L .J
iB[ 1".0.'1 ]!O~D0 I 0 I
,-------,
i
E8 t:L;;o
Relay Description
@J E2 25009
IJj~1 E3 25209
l@" 85 86
~ E5 25810
~
5084
E8 25805
,
@] E 10 25004
@J EI 25008
@J E4 25003
I
30
!l5 ~"" 87
86
~ E6 25804
5085
~
------
E 12 25401
: m
[2J
E 13 25103
25202
E 14 A
------
,
30
85
fm" ~
87
86
5086
~ E 14B 25400
,
"e3
87a
87d
87b
87c
5087
EJ
,
E II
!
61000
~. ~ E9
'" 59100
31 452 5088
,
-
-iJJ L 5089
~
I
E 15 59000
r-
1 2 3
• 5 & 7 8 9 10 11 12 13 14 15 18 17 1819 2021 22 23,.1..4
,
,,
A
·7
••
f-I-
0
0
1
"+.-
,
,
2
II n
B 0•·7
11
I~
0 ':2"0'
'""'
E1
E2
0 .. _Y_85
0
1---s7o-: .,.-
n
,,,
~
"_v.:~~
87
a
•
E3
c·
'""' E4
·
88 ~ 15
onr ,
0
7
.,' ~
0 "ya. E5
0
~_I 30
," '""' os
.. '=' E6
a7~~
,:+.-I-J " O' E7
o• ·
0
7
0
~~
"V
~
-_'T'_~
E8
~W-'07
0
,-f--
=_. 'l
"
'~:
-,-f--
" I Ell
,,
d--
<' ~ I
:.
f<
\.T; I'
•• '-1' .
..
-1...
E of-- ~
7 ElO
0 l :.Lom-
0
f·_·I ....
"
12 OJ'
E11
,
,,1---- '""'
"':::!"' E12
F• ·
0
7
0
., .,
-.".
'""L~
.. E13
0 '---- ::~~
~
,1--
06:=85 E1.4
,2 07~
G •0 · '""' OS
"_'f_ EMS
;~
7
0
0
~' E15
+
i~p
L .
, h
,2 I
H
·•
0
7
')
0
0
'","
f--
L-
o K B
t==~=C=+= ~ [&-1 1-6-'-1I-I-I~~I
lM IIg," JJJF
'I I I I I I I II J
1170
CONNECTOR ASSEMBLY
Type
Connector Interlocking circuit
(cell no.)
A 12 Cab (bus)
B 10 Cab (steering column switch)
C 12 Hood (standard type)
D 12 Cab (bus)
E 12 Hood (standard type)
F 10 Cab (standard type)
G 10 Hood (standard type and variants)
H 12 Cab (standard type)
I 12 Cab (standard type)
J 8 Cab (variants)
K 6 Cab (steering column switch).,
L 4 Cab (standard type)
M 4 Cab (standard type)
N
+ Cab/hood/engine (standard type)
Steering column switch
[~f [\V~f~]
\
B K 5090
Q¢ --0
=0 -- ~ ~ a
n .---
~
n~ b
,J
( (
I \
b d
I
?
yll
(d
111\
\ U
dd
II
~ 1'\\
...-
~ J
()
a c
( b) d{ ) ()
g f{ ~ ) n t I;
s i
()
I) p
()
m
() {;
n
(;
q
'--
'----
j
r-
I I II I
109876543 2 1 6 5 4 3 2 1
~~~~~~~~~~ ~~~~~~
WIRING SYSTEM
25
Cable Function
Ref. no.
colour
2 3 4 5 6 7 8
I
17 16 15 14 13 12 II 10 9 5092
FRONT VIEW
Component
Ref. no. Description
code
12 II 10 9 8 7
CONNECTOR END VIEW 5093
Combined module (optical indicators, lamp test switch, instruments, instrument light
dimmer rheostat)
2 Electronic tachometer with digital clock
3 Heated rearview mirror switch with built-in warning lamp (optional extra)
4 Hazard light switch with built-in warning lamp
5 Exterior lighting switch
6 Tail fog lamp switch
7 Fog lamp/tail fog lamp interlock switch (optional extra)
8 Interior heating switch (bus)
9 Aerator switch with built-in warning lamp (bus)
10 Interior lighting switch (bus)
II Interior blue light switch (bus)
12 Headlight washer unit switch (optional extra)
Combined module (Daily vehicles)
3 5 7 9 II 13 15 17 23 24 23
2 4 6 8 10 12 14 16 18
-v-~-~-~-~-,~~-~-
I ell 11'Xj,1I II -...11()::l" II II r
'I vII II ~7'i" ¢'y'll II ~
IINIj'I
~
• :: "" ,I •
J'- __ .JL
,: II •
JL ... _!'-_ ._J'__ ._lL_ .. J'. __ .1'
--- ~;--_. ir-- -,r-· ~r-··-·..-- ",i-- "ji--"',---'
. '6'
~
~:i(8)::(CD)::(®)::E3::~oo~::~D::
-I I." I II I
r.1l::.
l..Y
22 29 23 28 27 26 25
3 5 7 II 13 15 17 24 25 24
2 4 6 8 12 14 16 18
23 22 21 20 19 30 29 24 28 27 26
I 2 3 4 5 6 3A
~= frf ~ -1--1
= f8lB9WLL a
/r----I·------
[=- I~ ~~ m'
~i o .MMD
. u~c"u ~-:=II
7 ~ ..
r 0 • ~"'UAUU bJ
I J
-
I
I
- J= 8 ......
_. __ .__ .-+
~ !Ii I ~! Ii I~ I Ii!~ ~a~i111,1,1
alill
o : :1 II I: I:HIII ii
: ! :1: 0: I :1 II :1 IIlI ; :~
I i P,i! ! !i
o IV_CO
o 101010101010
IJ
12 II
5096
FRONT VIEW
\ /
I
14 13 12
Page
II
Page
II
STARTING
Turbodaily vehicles - Simplified network
Page 11.27
II. I 08000 STARTER MOTOR- 190 I0 THERMOSTARTER- 20000 BATIERY - 52502 IGNITION SWITCH FOR STARTER-ASSISTED SERVICES - 860 II
PRE/AFTER-HEATING ELECTRONIC CONTROL
, UNIT
Turbodaily vehicles (School bus version) - Simplified network
1530231
Page 11.39
1080001
Page 11.31 Page 11.15
11.2 08000 STARTER MOTOR- 190 I0 THERMOSTARTER - 20000 BATIERY - 25900 GENERAL CURRENT RELAY (GCR) - 52502 IGNITION SWITCH
FOR STARTER-ASSISTED SERVICES - 52023 GCR CLOSING SWITCH - 860 I I PRE/AFTER-HEATING ELECTRONIC CONTROL UNIT
Batteries
Specifications
•.-..
e 5100
MARELLI 12V-88Ah-395A Daily
~ 5101
MARELLI 12V-95Ah-450A Turbodaily
~ 5102
DELCO 12V-I02Ah-RC 3 lOA
Turbodaily
(either right-hand drive
or fitted with
air-conditioning system)
Quick diagnosis
Electrolyte level often low I. Excessive voltage Check recharging circuit and/or check
if terminals are loose
Electrolyte level often low I. Excessive voltage Check recharging circuit and/or check
if terminal are loose
On-board testing
Capacity test
- Connect "Electric system test" equipment clips
to battery terminals observing polarity:
Position test selector knob on "INT" (interior).
Work on charge rheostat lev~r until reading on
amperometer is about three times the A/h nomi-
nal capacity.
Hold rheostat charge for 15 seconds.
5104
Read voltage value attained by the battery.
11.3 CAPACITY TEST WITH EQUIPMENT 9933002 Release the rheostat.
If voltage does not drop below 9.6 V the battery
is working properly:
I~ General information
The efficiency of the electric system is mainly
dependent on the charging state and regular
maintenance of accumulators, generally called batteries.
Perfect efficiency of the electric system is a
prerequisite for the active and passive safety of the
vehicle.
5105
5106
"'
Self-discharge. A discharge. resulting from internal 117 SECTIONAL VIEW OF A BATIERY CELL
reactions of the battery. Normally self-discharge value
may amount to I% of the daily rated capacity of the
battery for each stoppage day This percentage value
should always be remembered when batteries are
stored. If a battery is not recharged for more that 30 days
it is irreparably damaged Recharging of stored batteries
or of sulphated batteries - provided their condition is still
recoverable - is performed as permanent charge and at
minimum current intensity
Capacity. The quantity of electricity measured in a/h
which can be drawn from a battery
Rated capacity. The capacity that a battery can supply
during 10 or 20 hour discharging (according to
12V 88Ah
standards). This value is generally shown on battery
395A
holders (fig. 11.8). 3812
16 batteries.
12
------ 12.30 accelerate battery self-discharge via its fixing elements.
I\.
1\
0 60 time (days)
2693
Maintenance
- When electrically welding parts on the vehicle,
disconnect power cable from the battery positive
terminal and connect it to chassis earth.
- To prevent serious damage to the electrical
system caused by extreme current intensity
produced by battery, in case of a short circuit it 1112 TIGHTENING STAY BOLTS
is of the utmost importance to disconnect the
chassis earth cable from the battery negative
terminal before disconnecting any otherterminal
and before working on electrical or electronic
A
components.
- Disconnect cable from battery terminals when
recharging by means of an external battery
charger.
- Discharged batteries (electrolyte density I. 150 B
~I,
gil at 25 C) should be immediately recharged to
0
5107
0
Check efficiency of clips, fastening brackets etc. at 50 %- 0
;:::<
regular intervals ensuring batteries are perfectly clean.
0
I<'l
Measuring electrlyte density ;:::<
100% - 0
The electromotive force ofthe batteries depends on 0
~
electrolyte density and increases accordingly.
2704
&. Wait for electrolyte temperature to reach
ambient temperature and then check the charge
percentage using a digital voltmeter or an appropriate
hydrometer (fig. 11.20). Discharged battery electrlyte
11.23 TABLE OF ELECTROLYTE DENSITIES DEPENDING ON freezes at -55 C.
CLIMATES
Recharging batteries by means of an external charger
5110
._ .J
Ensure the external trolley knife switch is open. First
connect the trolley positive extension cable to battery
power cable positive terminal (RED). Then connect the
trolley negative extension cable to power cable negative
terminal (BROWN).
,,
Close the vehicle's knife switch, then close the
external trolley's knife switch, once the preheating stage
is over, start the engine. When the engine is running open
the external trolley's knife switch. Disconnect the clip for
the negative extension cable first, then disconnect the
positive one.
Above connections are shown in fig. 11.26, as follows:
A. Trolley with batteries for starting vehicle from the
outside
B. Battery on vehicle
A I. External trolley knife switch
2. Positive extension cable to be connected to positive
clip (+) of vehicle battery
3. Negative extension cable to be connected to
negative clip (-) of vehicle battery
4. Positive power cable for supply of vehicle
components
S. Negative power cable connected to engine earth
(M I)
6. Main current switch (if fitted)
7. Vehicle's metal frame (earth)
5111
A Observe vehicle system polarity.
Take great care when positioning external trolley
power clips: they should cover maximum possible
terminal surface area without however touching the
11.26 EXTERNAL TROLLEY TO VEHICLE BATIERY CONNECTION battery fixing brackets.
DIAGRAM
5112
11.27 CONNECTING VEHICLE BATIERIES TO EXTERNAL TROLLEY FOR REMOTE STARTING OPERATION
Starter motor
Specifications
...-...
Daily
5113
BOSCH EV-12V-2,2kW
Turbodaily
Quick diagnosis
Lead-in torque adequate but engine I. Free wheel or solenoid faulty Replace
will not start
Pinion does not mesh I. Flywheel ring gear worn Change parts concerned
Supplier BOSCH KB 24V 5,4kW
Model EV 12V 2,2 kW
Type: 4 poles, series excitation, mesh by solenoid driven fork
Direction of rotation clockwise
Rated voltage 12 V
Rated output 2,2 kW
50 30
2711 5114
o 110
058.5
5115
PINION ADJUSTMENT
I. SUPPORT
3. PINION
S. ARMATURE
6. FRAME
7. INDUCTANCE WINDINGS
8. BRUSH HOLDER
9. COVER
10. SCREW
5260
EXf?LODED VIEW
On-board testing
test). Ifthis is so, conditions of circuit and connections are 11.29 VOLTAGE DROP TEST ON CIRCUIT AND CONNECTIONS
satisfactory.
liL:=;;==:::::J-
lk:=======:=iI
5118
+ li-C:=;:;:==::J-
\
1 5120
I
11.32 TESTING VOLTAGE DROP ON SOLENOID CONTACTS
5121
Lock the starter motor in a vice provided with lead Extreme care is required during the armature
insulation test.
caps. Dismantle the starter motor according to
instructions. Possible vibrations of the steel segment located on
the armature body mean that armature levers are
NOTE. To facilitate dismantling operations use only a
shorted or that mica removal is incorrect. Correct mica
plastic hammer. removal should be in the shape of a clear-cut U.
Remove the control relay and take out the
compensating plate. Reassembly
Remove the brush holder support, be careful not to During reassembly make sure that the armature
(without brushes) turns freely.
damage winding terminals.
Also check that brushes slide easily in their seat, check
After disassembly wash all components quickly, Use spring pressure on brushes (1.2 kg), and spring pressure
only detergents for electrical components: petrol, on coupling rod.
solvent or trichlorethylene. Lubricate bright sections with corrosion proof oils
and slightly smear the pinion with specific grease.
Given their volatility, strict compliance with NOTE. Do not put oil or grease on the commutator.
safety standards concerning inflammable liquids is rec- When reassembling the brush holder support make
ommended, as well as the use of protective glasses and sure not to damage winding terminals.
gloves.
Torque curve
Torque is nil when the starter motor is idling and
maximum when it is in stall.
Speed curve
22649
Rotation speed curve is maximum when the starter
11.34 BENCH TEST motor is idling and is nil when it is in stall.
Basic data
In the starter motor the magnetic field is generated 11.35 PERSPECTivE VIEW OF STARTER MOTOR
by the stator or fixed windings. The armature houses
inductive windings which are immersed in the inductive
magnetic field and crossed by current thereby developing
a motive torque on the armature shaft.
A
2735
11.40 TORQUE PERFORMANCE DEPENDING ON VOLTAGE
Electromagnet (solenoid). Purpose of this
electromagnet is to close the starter motor power circuit
via the excitation current of its own coil and with a
current absorption of several hundred amperes.
o A
2742
The protruding end ofthe electromagnet is provided -20 -10 o +10 +20 °C
with a slit housing the coupling lever pin.
groove with a driving nut which is in mesh with the pinion 11.47 MINIMUM STARTING SPEED
~~~--;-~+
/~ 50 30
Disengagement. The pinion remains in mesh until the
coupling lever is held in connection position.
After the engine is started flywheel rpm are higher
than pinion rpm; as this condition could impair starter
motor efficiency, the free wheel cuts in to release the
armature spindle from the pinion.
As soon as the ignition switch is disconnected driving
nut and pinion return to their rest position under action
2748
of the counter spring.
•.-...
Specifications
Daily-Turbodaily
SIPEA 1775
Turbodaily 4x4
Daily-Turbodaily
MARELLI Q 213C
Turbodaily 4x4
General directions
Supplier's name, manufacturing date, IVECO trademark must be stamped on the key switch.
The switch is supplied with two two-edged keys and manufacturer's code lock.
The steering lock cannot function unless the key has been set to position "0" (Stop) and removed from its seat.
The switch must be fitted with an antistarting repeater device.
Switching sequence
30
Position Function
0
[lQ][ill~~ STOP I Key can be removed
,,
,
\
\ I
0 I II [lQ][ill~~ IRUNNINGI Key cannot be
I I I removed
ISlA 50
1942
[lQ] [illll~ ~ I STARTING I Key cannot
removed and
be
will
return automatically
WIRING DIAGRAM I I I to osition I
Ignition switch for starter-assisted services
SIMPLIFIED DIAGNOSIS
Disconnect ignition switch connector blocks and B:
Set multimeter to VOLT:
- Ensure 12 Volts are available by setting one multi meter prod to terminal
+ 30 of connector block [[] and the otherone to earth.
Set multimeter to OHM.
- Turn the key to position 15 and ensure the presence of 0 Q by setting
multimeter prods to terminals + 30 and 15 of switch connector blocks.
- Turn the key to position 50 and ensure the presence of 0 Q by setting
multimeter prods to terminals + 30 and 50 of switch connector blocks.
,.,
T
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test. .L
~_15/A
30
5125
LAYOUT WITH CONNECTIONS
SIMPLIFIED DIAGNOSIS
Engage parking brake and set transmission in neutral.
Disconnect connectors IAJ and Ia from preheating control unit.
Set multimeter to VOLT
- Leave ignition switch in rest position. Ensure 12 Volts are available by set-
l
ting one multimeter prod to connector IAJ and the otherone to earth.
- Turn the key to position 15 and ensure the presence of 12 Volts by set-
~~ I "
In7,
to earth. ,"
.L
186011 1
5126
5 To thermostarter 8870
2 Earth 0000
3 Positive after ignition switch (+ 15) 8870
4 Positive after ignition switch (+50) 8888
6 To preheating warning lamp 5553
Pre/after-heating electronic control unit (Daily vehicles)
186011 I
I I
UlU
FRONT VIEW
5128
t{s)
90 E,..;
80
70
'" ~
o "
60
SO
"~ """ ~ ....
r---
40
c "~
~~ ~ ..........
39
30
27
21
20
/~( 80 ~
~ ~~
--- -
10 4,5
-..-
'r
-30 -20 -10 0
f"o.(,_
10 20 30 40 SO 60 70 80 DC
1,5
5129
Preheating Description
curve area
® Period during which both warning lamp and preheating system are in operation
® Tolerance field during which the warning lamp goes out while preheating remains on
© Period during which the warning lamp is off and preheating is on, This 15 to 20 sees. steadily
operative stage is calculated from the moment the warning lamp is switched off
@ After-heatingperiod with plugs on and warning lamp off This 15 to 20 sees. steadily operative
is calculated from the moment the starting stage is over (with engine running)
® Period during which both warning lamp and preheating are off
Pre/after-heating electronic control unit (Turbodaily vehicles)
SIMPLIFIED DIAGNOSIS
Engage parking Drake and set transmission in neutral.
Disconnect connectors [A] and [B] from preheating control unit and hood/
engine loom junction block.
Set multi meter to VOLT
- Leave ignition switch in rest position. Ensure 12 Volts are available by set-
ting one multimeter prod to terminal I of connector [A] (+30) and the
otherone to earth.
- Turn the key to position 15 and ensure the presence of 12 Volts by set-
ting one multimeter prod to terminal 2 of connector [B] (15) and the
otherone to earth.
- Turn the key to position 50 and ensure the presence of 12 Volts by set-
ting one multimeter prod to terminal 3 of connector [B] (50) and the
otherone to earth.
Set multi meter to OHM.
- Set ignition switch to rest position. Ensure the presence of 0 Q by setting
one multi meter prod to terminal 4 of connector [A] and the otherone
to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test. Print no. 603.42.961 Diagram no. 2
186011 1
5130
Supply (+ 30)
I (30) 8870
~ 2 (FGK) To thermostarter 8870
3 (T) To radiator motor water term perature sender unit 5577
4 (31) Earth 0000
I Not used
2 (15) Positive after the ignition switch (+ 15) 8870
rDl 3 (50) Positive after the ignition switch (50) 8888
L!!J 4 (L) To preheating on warning lamp 5553
5 - Not used
6 (MY) To fuel delivery solenoid valve 9972
Operation and specifications
The electronic control unit is protected against the
following external faults:
- inverted polarity
T(sec.)
- thermostarter shortcircuit
- temperature sensor shortcircuit
- warning lamp shortcircuit
60 -+---+---f--+--+--_+_- - supply voltage value higher than rated voltage (24
instead of 12V).
50 -+-----flI~--f--+--+--_+_- Both thermostarter and solenoid valve are always
supplied with direct voltage (intermittent supply is not
available).
40 -+--+-~~--t--t--t--
The control unit cuts in automatically when sensor
resistance is >21 50 --4%+ 2% Q (2064 - 2173 Q).
30 -+---+--+-.....L-.:~--+-
Automatic cut-in temperature resulting from the
sum of control unit and temperature sensor tolerances
20 -+---+-~r---+---+----",.....-
ranges from zero to +4 0c.
After-heating time depends on sensor resistance:
I0 -+---+-~r---+---+---+--
Resistance After-heating
2390 Q 72 ± 3,6 s
o 3790 Q 84 ± 4,2 s
Volt
9 10 II 12 13 6200 Q 104 ± 5,2 s
co - 250 s (WEHRLE)
T(sec.)
1 Automatic thermostarter cut-in stage with ignition
0
50 --+-----+----+----t--
o - F - - - - - - t - - - - - - t - - - - - - t - -......
5132
*••
Turn ignition key, starting switch in
Higher than
preset value for
running position (voltage at terminal
" 15") • •
preheating cut-in
After 2±O.2 seconds
Turn ignition key, starting switch in
• • •
running position (voltage at terminal
" 15") • • •
After 2 seconds
• • •
Preheating stage (duration according
to diagram) • • •
Lower than
preset value for
Starter motor is actuated before
preheating stage is completed
(warning lamp on). This incorrect
operation is inhibited:the control unit
is reset
I
I
•
I
• I
I ~
I
II I·
preheating cut-in End of preheating -st-a-g-e-----+-------+---.--r----.------tl-----r--I---~I • I
It--------------r--i ---+---
i • II
Engine starting stage (lasting
throughout starter motor tuming time)
-- • +I
-j-
.:
-+ --+,
I
•
L_ _ _
•
~
*
•
Warning lamp goes out when test is completed or if + 15 is not supplied (WEHRLE) .
Warning lamp remains on throughout test duration even if + 15 is not supplied (ITALAMEC).
4 Engine starting stage
A
0
Thermostarter, fuel delivery solenoid valve and If engine starting is performed before
warning lamp remain on throughout the engine starting preheating is completed (warning lamp on) the
stage. electronic control unit returns to zero and the warning
50 Air heating in the intake manifold iwth engine started lamp is turned off.
(after-heating stage) The control unit does not signal thermostarter and/or
When starter motor is turned off, thermostarter, fuel fuel delivery solenoid valve failure.
delivery solenoid valve and warning lamp remain on for The following table refers to the failure code (blink
the time shown on the table below. This depends on code) that is to say to warning lamp operation sequence.
engine coolant temperature.
Inverted polarity
Temperature
sensor
Break
• -_.-
• • -
Warning
Break
•
lamp Shortcircuit
•
Thermostart
er relay
Contacts not
closed • • J• - ---
Defect
inside
control unit
Contacts
stuck
-e- • -
• • - -
I
--r
circuit
Solenoid
Contacts not
closed
- f---
• • •
I
valve relay
-
Contacts
stuck
-- -
J_ _ 1 I • • I•J
I
Thermostarter
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from thermostarter.
Set multi meter to OHM.
- Set ignition switch to rest position. Check for 0 Q by setting one multi-
meter prod to connector IAJ (+ 30) and the otherone to terminal 2 of
connector IAJ of pre/after-heating electronic control unit (page 11.3 I).
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
119010 I
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from switch.
Set multimeter to OHM.
- Set ignition switch to rest position. Check for 0 Q by setting one multi-
meter prod to connector and the otherone to terminal 3 of con-
nector IAJ of pre/after-heating electronic control unit (page IIJI).
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
147105 I
SIMPLIFIED DIAGNOSIS
Disconnect connector from solenoid valve.
Set multimeter to OHM.
a
- Set ignition switch to rest position. Check for Q by setting one multi-
meter prod to connector and the otherone to terminal 6 of con-
nector of pre/after-heating electronic control unit (page 11.31).
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
178000 1
"lI,
---reo.=-,- - - 1 T I 9 - - - - - - '
1280021
~
(9903~
5134
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from switch,
Set multimeter to OHM,
- Check for 0 Q by setting one multimeter prod to terminal 6 of con-
nector IAJ and the otherone to earth,
- Check for 0 Q by setting one multimeter prod to terminalS of con-
nector IAJ and the otherone to earth,
- Press switch key and check for 0 Q by settingone multimeter prod to
terminals 1/5 and the otherone to terminals 2/6,
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component Then repeat the test
153023 1
5135
SIMPLIFIED DIAGNOSIS
Transmission in neutral, parking brake engaged.
Disconnect connector from GCR.
Set multimeter to OHM.
- Operate GCR closing switch. Check for 0 Q by setting one multimeter
prod to terminal of conector and the otherone to earth.
Disconnect connector lID from GCR and reconnect connector IAJ to
GCR
Set multi meter to Volts.
- Operate GCR closing switch. Check for 12V by setting one multimeter Co
prod to the GCR terminal (from which connector has just been re-
moved) and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component.
Then repeat the test.
125900 I
SIMPLIFIED DIAGNOSIS
Disconnect connector!AJ from switch.
Set multimeter to OHM.
- Check for a Q by setting one multimeter prod to terminal 6 of c.I.U.
connector!AJ and the otherone to terminal I of connector
If reading is other than specified, repeat the test by setting multimeter prod
to terminal 2 of connector
- Check for a Q by setting multi meter prods directly to terminals I and
2 of the switch.
If readings are other than specified, remedy as required by either repairing r.
the circuit or replacing the component. Then repeat the test.
153009 I
152029 I
5138
SIMPLIFIED DIAGNOSIS
Turn main current switch (MCS) handle in circuit opening position,
Set multimeter to OHM,
- Ensure infinite resistance is available by setting multimeter prods to MCS
terminals,
- Turn handle by 90°, Check for 0 Q (zero ohm) by setting multimeter f--------nn.--------,
prods to MCS terminals,
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test,
..=.:.--_wtU
152600 I
Description
Supplier's name and identification letters/numbers. device serial no, and production date according to IVECO STD. 10-0812
(N.PO,OOO 13) should be stamped on the switch,
SIMPLIFIED DIAGNOSIS
~.
tr
~ ~
- Check for 0 Q by setting one multi meter prod to terminal B of con-
nector lliJ and the otherone to c.I.U. connector E terminal 6.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
JJ...
-
I
~~U
L
I
I I
I I
I
w- I A
I
I Y
I
I
rfto ~ -
~ ~ I
1 471 06 I 161101 I
5139
SIMPLIFIED DIAGNOSIS
Disconnect connector from switch.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal 2 of con-
,nector and the otherone to c.I.U. connector terminal 6.
I
•
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1
471 091
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from resistor
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal I of ignition
timer switch connector and the otherone to connector
If readings are other than specified, remedy as required by either repairing •
;t'· ~t'
the circuit or replacing the component. Then repeat the test.
"""
• rom
J
I I
I I
I I
I l
I n
I U
I 1
I I
,
I I
If<!! :
I •
~
161103 I
Page
ALTERNATORS 3
SPECIFICATIONS 3
TESTS 8
TESTING MAX CURRENT OUTPUT 8
TESTING VOLTAGE DROP IN CHARGING CIRCUIT 8
TESTING VOLTAGE DROP IN EARTH CIRCUIT 9
VOLTAGE REGULATOR CALIBRATION TEST 9
ALTERNATOR DRIVE BELT TENSIONING 9
DISMANTLING AND BENCH TESTING 10
REASSEMBLY 10
CHARGING CIRCUIT II
GENERAL II
BASIC DATA II
TECHNICAUPRACTICAL HINTS 13
ELECTRONIC VOLTAGE REGULATOR 19
THEORETICAL OPERATION 21
VOLTMETER 22
III
CHARGING
Alternators
Specifications
••-11'.
MARELLI AA 125R-14V-55A
2817
1030001
D+a-....---~t--,
2812 2811
2. FAN
3. SPACER
4. SUPPORT
5. KEY
6. ROTOR
7. STATOR
8. STAY ROD
I 9. SUPPORT
1030001
25606 5144
1030001
r--_-....----<~-_o D+
5148 5146
I. NUT
2. SPRING WASHER
3. PULLEY
4. SPACER
5. SCREW
6. SUPPORT
7. BALL BEARING
8. PLATE
9. ROTOR
10. BALL BEARING
II. RING
12. STATOR
13. BUSH
14. SUPPORT
/ IS. SCREW
/
/~~""'" 16. VOLTAGE REGULATOR
17. BRUSH ASSDEMBLY
! 12 18. SCREW
1030001
r----_-_~~-.() D+
B+
5148
• 5252
I. NUT
2. SPRING WASHER
3. PULLEY
4. SPACER
5 SCREW
6 SUPPORT
7. BALL BEARING
8. PLATE
9. ROTOR
10. BALL BEARING
II. RING
12. STATOR
13. BUSH
14. SUPPORT
15. SCREW
16. VOLTAGE REGULATOR
17. BRUSH ASSDEMBLY
18. SCREW
19. RECTIFIER BRIDGE
17 20. SCREW
6) 21. SUPPORT
13 22. SCREW
EXPLODED VIEW
TESTS
Testing maximum output on vehicle
I~
Never let the engine run with the electrical
connections for the charging circuit disconnected or
slack at the battery terminals.
Proceed as follows:
Connect clamps for cables of the "Electrical Sys-
tem Test" equipment 99309003 to battery ter-
minals observing polarity (fig. 111.1).
Position the test selector in INT (internal).
Fit the inductive clamp to the main alternator
cable, observing polarity and direction of the
arrow (stamped on the clamp).
5150 - Start up the engine and rev it up.
111.1 MAXIMUM OUTPUT TEST
- Actuate the load rheostat lever until the reading
on the ammeter is equal to the maximum alterna-
tor output value.
~II~
- Connect the inductive clamp to the alternator
cable observing polarity and arrow direction.
Rev up the engine until current output is lOA.
Check the reading on the voltmeter: it should not
exceed 0.6 V if circuit and connections are in good
~==~,
working order:
5152
Remove the rotor by tapping lightly with the plastic If, during the test, the values differ considerably from
hammer on the edge of the rectifier end mounting. the typical curve. dismantle it once again and repeat the
checks.
Carefully unsolder the three phases with the aid of
NOTE. The bench test values depend greatly on the
pliers, in order to dissipate part of the heat and prevent I
battery charge conditions and capacity and
overheating.
the length of the test. which should be as
When dismantling is complete. quickly wash the parts I short as possible. The curve shows that. at
using liquid for electrical components: petrol. solvent. low speeds. the current output is nil whilst it
trichloroethylene. reaches the maximum value at around 4000
rpm. Starting from this point. this value IS
en
IS composed of the number of NS magnetic poles
arranged in alternating order and of an exciter winding:
the rotor:
/'
I
r--_-o_B-o--a6~,
proprotionally with the rotor rotation speed.
This very effectively limits the generator output
curve.
'I E
+
'-+_..... A F
//// ////
5155
[
..... B+
.... 1,-,.
,..... - transmission of the mechanical energy from the engine
to the alternator:
A
- ! ~+
The condition of the belt and its correct tension are
vital to the efficiency of the alternator:
~)
Its values may vary from a minimum of 200 mA
(current limited by the resistance ofthe charging warning
light) to a maximum onA (current limited by the voltage
regulator) according to the state of the battery charge.
2841
III. 19 STATOR FOR THREEPHASE ALTERNATOR
Typical curve. The typical curve graphically
reproduces the trend ofthe current output based on the
alternator speed.
f
2846 60
111.24 OWER DIODE where f is the frequency, P is the polar coupling and
A. SYMBOL - B. HALF-WAVE RECTIFIER
C. TECHNICAL DIAGRAM n the alternator rpm.
Terminal W is usually used for the indirect
measurement of the speed in diesel engines.
Residual magnetism. This is the magnetism which
remains in a magnetic iron casing after the magnetic force
has been removed.
2847
The pulley race should be free from cracks or grease. 111.26 RECTIFIER BRIDGE DIAGRAM
A. ROTOR WINDINGS - B. EXCITER DIODES
C. POWER DIODES
Bridge rectifier. This is a static device which converts
the field winding alternating voltage into continuous
voltage by means of a 6 or 12 diode bridge.
2849
B-+-
"///
The rotor is very compact and the slip rings and ball
bearings are fitted to the end of the shaft.
11130 BRUSHES A. MINIMUM LENGTH 7 mm It should be remembered that in systems where the
alternator is not equipped with exciter diodes, the
~---4"-'----I·C
battery recharging circuit warning light is controlled by a
special relay.
B
Stator. The stator is a hollow cylinder made up of
laminations 0.5 mm thick. Open slots in the stator inside
+ have the purpose of housing induced or stator windings.
A B
2855
2856
/
I is the current intensity.
5159 If the alternator is disconnected from the batterys
III.3S "BUFFER" CONNECTION FOR A BATIERY TO AN ALTERNA- (and therefore not forming a "buffer" connection) then
TOR AND RELEVANT VOLTAGE AND CURRENT CURVES
the latter behaves like a "no load" generator.
As a result, the voltage at the terminals exceeds the
U nominal voltage of the system, several times over.
90V
o RPM
2861
J
U -90V
I. /
+
-I
I
I
R
2864
/ /
5161
Page
COMBINED MODULE 3
ELECTRONIC REV COUNTER 4
ELECTRONIC REV COUNTER SENDER UNIT 5
ENGINE COOLANT TEMPERATURE GAUGE WITH BUILT-IN
WARNING LAMP 6
ENGINE COOLANT TEMPERATURE SWITCH AND SENDER
UNIT 7
FUEL LEVEL INDICATOR WITH BUILT-IN WARNING LAMP 8
FUEL LEVEL INDICATOR WITH RESERVE CONTACT WARNING
LAMP 9
ELECTRONIC TACHOMETER WITH CLOCK 10
ELECTRONIC TACHOGRAPHITACHOMETER SENDER UNIT II
ENGINE OIL PRESSURE W/LAMP SWITCH 13
PARKING BRAKE W/LAMP SWITCH 14
IVECO CONTROL DISPLAY PANEL 15
ENGINE COOLANT LEVEL INDICATOR CONTROL DEVICE 17
ENGINE OIL LEVEL INDICATOR CONTROL DEVICE 18
BRAKE FLUID LEVEL INDICATOR CONTROL DEVICE 19
FRONT WHEEL BRAKE LINING WEAR CIRCUIT SENSOR 20
REAR WHEEL BRAKE LINING WEAR CIRCUIT SENSOR 21
AIR CLEANER RESTRICTION SWITCH 22
POWER STEERING FLUID LEVEl,. INDICATOR
CONTROL DEVICE 23
., I
IV
Page
SIMPLIFIED DIAGNOSIS
Disconnect connector blocks and [Q from combined module.
Set multimeter to VOLT:
- Turn ignition switch key to position 15. Ensure 12 Volts are available by
setting one multimeter prod to terminal 2 of connector block IAJ and
the otherone to earth. -nn.~~~~~
Set multimeter to OHM.
- Turn the key to rest position and ensure the presence of 0 Q (zero ohm) ~
by setting one multimeter prod to terminal 7 of connector [Q and the
otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
5163
I Not used
[!]2 Supply (+ 15) 8879
3 Signal from electronic rev counter sender unit 5519
4-;-.9 Not used
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor IAJ and the otherone to terminal 3 of combined module connector
r--'~!
A (page IV3).
- Check for 0 Q by setting one multi meter prod to terminal 2 of connec-
tor IAJ and otherone to earth. r-;::==;==;::::=:::f-hl
If readings are other than specified, remedy as required by either repairing
,
T
the circuit or replacing the component. Then repeat the test. ,"
1-
"-
148030 I
5164
SIMPLIFIED DIAGNOSIS
Disconnect connector blocks and [Q from combined module.
Set multimeter to VOLT:
- Turn ignition switch key to position 15. Ensure 12 Volts are available by -------+.:--------\0-------::;*""...-----**----
setting one multimeter prod to terminal 2 of connector block IAl and
the otherone to earth. -nn,
Set multimeter to OHM. ~ &
a
- Turn the key to rest position and ensure the presence of Q by setting ~
one multimeter prod to terminal 7 of connector [Q and the otherone L!.~=t~~t=~==~
to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
5165
I Not used
2 S.~pply (+ 15) 8879
3-;-.7 Not used
8 To engine coolant temperature w/lamp 5528
9 Signal to engine coolant gauge 5552
SIMPLIFIED DIAGNOSIS
Disconnect connector [AJ from component under examination,
Set multimeter to OHM,
- Check for 0 Q by setting one multimeter prod to terminal I of connec- - - - - - - - - + - - - - - - - - + c - - t : - - - - -
tor [AJ and the otherone to terminal 8 of combined module connector '87'--
,~.
A (page IV3),
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
tor [AJ and otherone to terminal 9 of combined module connector A.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test,
~ ,
147030 I 147100 II
LJ
LAYOUT WITH CONNECTIONS
SIMPLIFIED DIAGNOSIS
Disconnect connector blocks and fa from combined module.
Set multimeter to VOLT:
- Turn ignition switch key to position 15. Ensure 12 Volts are available by - - - - - - - + : - - - - - - - t - ' ' \ - - - - + : - - - + : - - - - -
setting one multimeter prod to terminal 2 of connector block and
the otherone to earth.
Set multimeter to OHM. -nn.~ ~
- Turn the key to rest position and ensure the presence of 0 Q by setting ~
one multimeter prod to terminal 7 of connector [Q and the otherone I t~=i~~~~~~~
to earth. L
144001 I
NOTE. Refer to page IV3 for a complete view
of connectors !AJ and and relevant
wIring.
'\
5167
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to OHM.
a
- Check for Q by setting one multimeter prod to terminal I of connec-
tor and the otherone to terminal 7 of combined module connector
(page 1V.3).
a
- Check for Q by setting one multimeter prod to terminal 3 of connec-
tor and otherone to terminal I of combined module connector A.
a
- Check for Q by setting one multimeter prod to terminal 2 of connec-
tor and the otherone to earth.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1 44 031 I
SIMPLIFIED DIAGNOSIS
Disconnect connector block!AJ from component under examination.
Set multimeter to VOLT:
- Turn ignition switch key to position 15, Ensure 12 Volts are available by
setting one multimeter prod to terminal 3 of connector block!AJ and
the otherone to earth.
Set multimeter to OHM,
- Turn the key to rest position and ensure the presence of 0 Q by setting
one multimeter prod to terminalS of connector!AJ and the otherone
to earth.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
140002 I
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor IAJ and the otherone to terminal I oftachometer connector B (page
..
•
R
IV. I0)
- Check for 0 Q by setting one multimeter prod to terminal 3 of connec-
tor and otherone to terminal 3 of tachometer connector B.
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
tor IAJ and the otherone to terminal 2 of tachometerconnector B.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
I To tachometer/tachograph 5514
2 To tachometer/tachograph 0058
3 To tachometer/tachograph 5517
4 Tachometer/tachograph sender unit
Tachograph/tachometer sender unit
2A 8V supply +
2B Earth
1 4 003 2 1
--=-:r--------"
1
r
\1... 1 "'~
J----~I 1Rl
,_..J.. _ _ Jr-L1
I . I
I 1
....
~~
Temperature range "A"
II
nJ~ 7 min
I~
Temperature range "B"
2897 2898
ELECTRICAL CONNECTIONS
Technical data
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination,
Set multi meter to OHM,
- Check for 0 Q by setting one multimeter prod to connector IAJ and the
otherone to terminal 5 of combined module connector B (page 1V.3).
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1425501
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to OHM.
a
- Check for Q by setting one multimeter prod to connector IAJ and the
otherone to terminal I of combined module connector C (page IV3).
If readings are other than specified, remedy as required by either repairing •
the circuit or replacing the component. Then repeat the test. j
1 42 1021
5172
SIMPLIFIED DIAGNOSIS
Disconnect connector block [AJ from component under examination.
Set multimeter to VOLT:
- Turn ignition switch key to position 15, Ensure 12 Volts are available by
setting one multi meter prod to terminal 6 of connector block [AJ and
the otherone to earth.
Set multimeter to OHM.
- Turn the key to rest position and ensure the presence of 0 Q by setting
i
one multimeter prod to terminal I I of connector [AJ and the otherone
to earth,
If readings are other than specified, remedy as required by either repairing
:t
[~.-
the circuit or replacing the component. Then repeat the test.
1500001
IVECO 1
Wi
I [~ 9::;r.
~
w\(@) ,
o
(~", ,,.....,'
'8'
o 0 0 0 (J 0
5173
Description
The functions being checked are the following:
engine coolant level
- engine oil level
- windshield washer fluid level
- brake fluid level
- front axle brake wear
- rear axle brake wear
Operation
When the ignition switch is turned to services (+ 15)
it is possible to visually inspect the efficiency of all the
warning lights (LEOs). They come on for a period of
about 5 seconds.
Then, if the system is working properly, the LEOs go
m IVECO I out and only the general green LED remains on.
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal 2 of con-
nector IAJ and the otherone to terminal 85 of engine coolant
level indicator relay
- Check for 0 Q by setting one multimeter prod to terminal 3 of con-
nector IAJ and otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1
44 036 1
I Not used
2 Relay for engine coolant level w/tamp 5527
3 Earth 0000
Engine oil level indicator control device
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to OHM.
a
- Check for Q by setting one multimeter prod to terminal I of con-
nector and the otherone to terminal 10 of IVECO Control display
panel connector (page IV.IS).
- Check for a Q by setting one multi meter prod to terminal 2 of con-
nector IAJ and otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1440321
5175
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal 2 of con-'
nector lAJ and the otherone to terminal 8 of IVECO Control display
panel connector (page IV 15).
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor and otherone to earth.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1440331
5176
I Earth 0000
2 To IVECO Control display panel (brake fluid level indicator) 6613
Front rh wheel brake lining wear sensor
SIMPLIFIED DIAGNOSIS
Disconnect connector fA] from component under examination.
Set multimeter to OHM.
- Check for a Q by setting one multimeter prod to terminal 2 of connec-
tor fA] and the otherone to terminal 2 of IVECO Control display panel
connector A (page IVIS).
- Check fora Q by setting multimeter prods to terminals I and 2 of sensor
connector.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
- Repeat the same test with the front Ih wheel sensor. Use the wiring dia-
gram on the side as a reference guide.
1860021
5177
I Earth 8814
2 To front Ih wheel brake lining wear sensor 8814
Rear rh wheel brake lining wear sensor
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to OHM.
- Check for a Q by setting one multimeter prod to terminal 2 of connec-
tor and the otherone to terminal I of IVECO Control display panel
connector A (page IV.IS).
- Check fora Q by setting multimeter prods to terminals I and 2 of sensor
connector. .
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
- Repeat the same test with the rear Ih wheel sensor. Use the wiring dia-
gram on the side as a reference guide.
186003 I
5178
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to OHM.
- Disconnect connector IAJ from component under examination.
Set multimeter to OHM. .
f
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
tor A and the otherone to terminal 2 of combined module connector ~"nn~
, .. ~
-'-
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1 42 351 I
5179
I Earth 0000
2 To air cleaner restriction w/lamp 6663
Power steering fluid level indicator control device
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
torlAl and the otherone to terminal 85 of power steering fluid level indi-
cator relay.
- Check for 0 Q by setting one multimeter prod to terminal I of connec- ~.1~
tor and the otherone to earth. tJ
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1440371
I Earth 0000
2 To power steering fluid level indicator relay 5525
Front differential lock warning lamp switch
SIMPLIFIED DIAGNOSIS
Disconnect connector [6J from component under examination,
Set multimeter to OHM,
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor [6J and the otherone to terminal 6 of combined module connector
A (page IV3),
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
tor [6J and the otherone to earth,
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1535041
5181
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal I of connec- «, ".
~(~g:~~~~e otherone to terminal 6 of combined module connector ~ ~mrr~~~~~t~1
- Check for 0 Q by setting one multlmeter prod to terminal 2 of connec- ". , , •• _. •I
tor and the otherone to earth. ~~I ~~~.
If readings are other than specified, remedy as required by either repairing ". _~~=t'
the circuit or replacing the component. Then repeat the test. -
1535051
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec- - - - - ' = : b - - - - - - t : - - - - t . - i r,
tor and the otherone to terminal I of combined module connector
B (page IV3).
•
I
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test. +~i:::=t'
1535061
5183
I Earth 0000
~2 To all-wheel drive warning lamp 6602
Front differential lock control switch
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor and the otherone to terminal I of front differential lock device
connector (page IV29).
- Check for 0 Q by setting one multimeter prod to terminal 3 of connec-
tor [6J and otherone to terminal 2 of front differential lock connector.
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
tor and the otherone to terminal 87 of front differential lock interlock
relay
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1530 22 1
SIMPLIFIED DIAGNOSIS
Disconnect connector block from component under examination.
Set multimeter to VOLT:
- Move ignition switch key to position 15. Ensure 12 Volts are available by - + ! - - - - - - - - - - * + - - - I O
setting one multimeter prod to terminal 4 of connector block IAJ and
the otherone to earth.
Set multimeter to OHM. ~~
=:JJ
- Turn the key to rest position and ensure the presence of 0 Q by setting
one multimeter prod to terminal I of connector a and the otherone to
earth.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1550021
I Earth 0000
2 To max speed warning lamp with all-wheel drive on 5551
3 Not used
4 Supply (+ 15) 8879
5 Not used
6 Vehicle speed signal 5513
Front differential lock device
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multi meter prod to terminal I of connec-
tor and the otherone to terminal I of front differential lock control
switch.
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
tor and the otherone to terminal 3 of front differential lock switch
connector.
- Ensure efficiency of 16A fuse.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1850251
Earth 0000
Page
v
EXTERIOR LIGHTING
Exterior lighting switch
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination:
Set multimeter to VOLT:
- Ensure 12 Volts are available by setting one multimeter prod to terminal
5 of connector and the otherone to earth.
- Put ignition switch key in position 15. Check for 12 V by setting one
multimeter prod to terminal I of connector and the otherone to
earth.
Set multimeter to OHM.
- Set the key to rest position.
- Press switch to Ist release and check forO Q by setting multimeter prods
to terminals 3 and 5 of switch connector block.
- Repeat the same test with terminals 3-1 and 2--4 but pressing the switch
to the 2nd release.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
Print no. 603.42.961 Diagram no. 5
15230 7 1
S186
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT
- Press the exterior lighting switch (page V3) to Ist release. Check for 12
V by setting one multimeter prod to terminal 2 of connector IAJ and the
otherone to earth (parking lights)
- Put the ignition switch key in position 15 and press the exterior lighting
switchto 2nd release. Check for 12 V by setting one multimeter prod
to terminal 3 of connector IAJ and the otherone to earth (low beam
lights).
- Set the steering column switch in high beam light position. Check for I2
V by setting one multimeter prod to terrmnal 4 of connector IAJ and the
otherone to earth.
Set multimeter to OHM.
- Put the ignition switch key in rest position.
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor IAJ and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test. Print no. 603.42.961 Diagram no. 6
1
30 00 1 1
5187
I Earth 0000
2 Supply of parking light lamp 3334
3 Supply of low beam light lamp 2223
4 Supply of high beam light lamp 2221
Fog light switch with rear fog light interlock device
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT
- Put the ignition switch key in position 15. ---=--=--#Ff.==ff.=f;~~Q~:;:::;:;:::;:;:::;~~!k
- Press the exterior lighting switch (page V.3) once. -In', m , •
152304 I
5188
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multi meter to VOLT
- Put the ignition switch key in position 15.
- Press the exterior lighting switch (page V3) (either Ist or 2nd release).
- Press the fog light switch (page V6).
- Check for 12 V by setting one multi meter prod to terminal [6] of con-
nector and the otherone to earth.
Set multimeter to OHM.
- Put the ignition switch key in rest position.
- Check for 0 Q by setting one multi meter prod to terminal A of connec-
tor I.6J and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
130011 I
5189
A Earth 0000
B Supply of fog headlight lamp 2228
Front marker light
SIMPLIFIED DIAGNOSIS
Disconnect connectors and [ill from component under examination.
Set multimeter to VOLT
- Press exterior lighting switch (page V3) to Ist release.
- Check for 12 V by setting one multimeter prod to terminal of connector
IAJ and the otherone to earth.
Set multimeter to OHM. ",
- Return exterior lighting switch in rest position.
- Check for 0 Q by setting one multimeter prod to terminal of connector
and the otherone to earth. n.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test. ..., r-r--
I I I I I I
,~ttttt,
L._!._J-t""_4-_ J
<IIi>
137001 I
5190
SIMPLIFIED DIAGNOSIS
~I -h I'~
Disconnect connector from component under examination.
Set multimeter to VOLT
- Press exterior lighting switch (page V3) to 1st release.
- Check for 12 V by setting one multimeter prod to terminal 2 of connec- I ------r-j"
tor IAl and the otherone to earth. ~ ~ ~ a ~ ~~
Set multimeter to OHM.
- Return exterior lighting switch in rest position.
- Check forO Q by setting one multimeter prod to terminal I ofconnector •
and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
137005 I
5191
I Earth 0000
2 Supply of marker light bulb 3335
Number plate headlight
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to VOLT
- Press exterior lighting switch (page V.3) to I st release.
- Check for 12 V by setting one multimeter prod to terminal I of connec-
tor IAJ and the otherone to earth. ~
Set multimeter to OHM. J
- Return exterior lighting switch in rest position. L..+.---+.--+..-J
- Check forO Q by setting one multimeter prod to terminal 2 ofconnector
IAJ and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
[35000 I
5192
SIMPLIFIED DIAGNOSIS
Disconnect connector and [[] from component under examination.
Set multimeter to VOLT
- Press exterior lighting switch (page V.3) to I st release.
- Check for 12 V by setting one multimeter prod to terminal of connector
and the otherone to earth.
Set multimeter to OHM.
- Return exterior lighting switch in rest position.
- Check for 0 Q by setting one multimeter prod to terminal ofconnector
and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
135000 I
5193
Earth 0000
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to VOLT
- Put the ignition switch key in position 15.
- Press exterior lighting switch (page V.3) to Ist release and check for 12
V by setting one multimeter prod to terminalS of connector and the
otherone to earth.
- Press exterior lighting switch to 2nd release and repeat the test.
Set multimeter to OHM.
- Return exterior lighting switch in rest position.
- Press the rear fog lamp key switch.
- Checkfor 0 Q by setting multimeter prods to terminals I and 5 of rear
fog lamp switch.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1520061
5194
134000 I
h· I'~
Disconnect connector IAJ from component under examination.
Set multimeter to VOLT
- Put the ignition switch key in position 15 and press the exterior lighting
switch (page V3) to Ist release.
- Check for 12 v by setting one multimeter prod to terminal lOaf con nee- )0
tor IAJ and the otherone to earth.
- While keeping exterior lighting switch pressed (I st release and then 2nd
III ~
;
~
; ~ j!j ~ ~ s
release) press the rear fog lamp key switch. Check for 12 V by setting one
multimeter prod to terminal 90f connector and the otherone to earth.
- Set transmission in reverse gear. Check for 12 V by setting one multi me-
ter prod to terminal 4 of connector IAJ and the otherone to earth.
- Set the steering column switch lever in turn signal light position. Check
for 12 V by setting one multimeter prod to terminal 2 of connector
and otherone to earth.
- Depress the brake pedal. Check for 12 V by setting one multi meter prod
to terminal 3 of connector and the otherone to earth.
Set multimeter to OHM,
- Put the ignition switch key in rest position. Check for 0 Q by setting one
multimeter prod to terminal 8 of connector and the otherone to
earth.
If readings are other than specified, remedy as required by either repairing Print no. 603.42.961, School bus Basic Wiring Diagram
the circuit or replacing the component. Then repeat the test.
134000 I
5196
I Not used
2 Supply of hazard/turn signal light bulb 1120
3 Supply of stop light bulb 1177
4 Supply of reversing light bulb 2227
5 Not used
6 Not used
7 Not used
8 Earth 0000
9 Supply of rear fog light bulb 2283
10 Supply of parking light bulb 3334
LAMPS
General
D E E D 27942
~
bulb.
When close to the filament, where the temperature
~T
rises to over 1400o C, tungsten separates from halogen
and once more combines itself with the original material.
~
<1400' >1400' <1400' The high operating temperature and the use of
'-------------- quartz as an external wrapper of this type of lamps
3019 means that their replacement calls for absolute care in
handling them (they should only be held by their metal
V.3 HALOGEN LAMP (REGENERJlTION PRINCIPLE) base).
The presence of grease marks on the bulb (left by
fingers) at high temperatures can in fact develp a
"devetrification" process which impairs the operation of
the lamp and reduces its illumination power.
3021
problems.
V6 FLUORESCENT lAMP
Owing to such advantages, the use of fluorescent
lamps is suggested forthe internal lighting of buses where A
driver and passengers need an ideal level of comfort
without endangering the passive safety of the vehicle.
r:--'--'-'-'-'-'+\
L.- BC~
__ . __ .
. ~I*
. ----.J
4697
Parabola
---
----
---
---+-. - - - - - - -
--
---
-- 3032
t----------{'- ~r---=.... ~
.-:.=------~
Fog lights
5198
cu @ 12 40/45
Low beam lights
High beam lights
rn R2
5199
~
Low beam lights
•
12 55/60
High beam lights
H4
3022
W H3
3023
@ 12 55 Fog lights
~
Turn signal lights
Stop lights
P21W
® 12 21
Rear fog lights
Reversing lights
3024
~ @ 12 5 Blue lights
CSW
3942
CIOW
3942
B
Number plate lights
RSW
3025
© 12 5 Tail parking lights
Marker lights
~ 2W
3028
§ 12 2 Instrument and warning lamp lights
~ LED
3029
0,
'-'
, I,2 -;- 1,5 10-;-.50 mW IVECO Control warning lamps
SIGNALS
Page
VI
SIGNALS
Steering column switch (Turn signal lights)
SIMPLIFIED DIAGNOSIS
Disconnect connector [ill from c.I.U.
Set multimeter to VOLT:
- Move ignition switch key to position 15.
- Ensure 12 Volts are available by setting one multimeter prod to terminal
9 of c.I.U. connector [ill and the otherone to earth.
Set multimeter to OHM.
- Putthe key in rest position. '"
- Set the steering column switch to Ih turn signal light. Check for 0 Q by
setting multimeter prods to terminals 9 and 6 of steering wheel switch
connector [ill. Set the steering wheel switch to rh turn signal light posi-
tion.
- Check for 0 Q by setting multi meter prods to terminals 9 and 7 of steer-
ing wheel switch connector [ill
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
Print no. 603.42.961 Diagram no. 7
NOTE. Refer to page 1.64 for a complete view of steering wheel switch and relevant wiring. I 154033 B 1
SIMPLIFIED DIAGNOSIS
Disconnect connector!AJ from component under examination.
Set multimeter to VOLT:
- Put the ignition switch key in position 15.
- Set steering wheel switch (page VIJ) to turn signal light position.
- Ensure 12 Volts are available by setting one multimeter prod to terminal
I of connector and the otherone to earth.
Set multimeter to OHM.
a
- Put the key in rest position. Check for Q by setting one multimeter
prod to terminal 2 of connector!AJ and the otherone to earth:
If readings are other than specified, remedy as required by either repairin~'
the circuit or replacing the component. Then repeat the :test.,
1320021
SIMPLIFIED DIAGNOSIS
Disconnect connector lAJ from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
tor lAJ and the otherone to terminal 9 of c.I.U. connector I.
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
133001 I
1 Earth 0000
2 Supply of hazard/turn signal side repeater bulb .1126
Hazard light switch with built-in warning lamp
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT:
- Check for 12 V by setting one multimeter prod to terminal 2 of connec-
tor IAJ and the otherone to earth.
- Put ignition switch key to position 15.
- Ensure 12 Volts are available by setting one multimeter prod to terminal
8 of connector and the otherone to earth.
Set multimeter to OHM.
- Put the key in rest position.
- Press the hazard light switch. Check for 0 Q by setting multimeter prods
to switch terminals 4 and 2.
- Check for 0 Q by setting multi meter prods to switch terminals 7 and I
first and then to terminals 7 and 3.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
152302 I
5203
Supply of steering wheel switch (side rh turn signal light bulb) IIII
To side rh turn signal light bulb 1124
2 Supply (+ 30) 7728
3 Supply of steering wheel switch (side Ih turn signal light bulb) 1111
To side Ih turn signal light bulb 1126
4 Supply of electronic flasher light (hazard/turn signal light with hazard light switch) 8872
[!]s Supply of turn signal light bulbs with hazard light switch on 1103
6 Supply (+ 15) of electronic flasher light 8872
(hazard/turn signal light and jumper to switch cell no. 4)
7 Supply of switch lighting bulb 8879
8 Supply (+ 15) 8872
9 Not used
10 Earth 0000
Stop signal switch
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to VOLT:
- Put switch key in position 15. Ensure 12 Volts are available by setting one
multi meter prod to terminal I of connector IAJ and the otherone to
earth.
Set multimeter to OHM.
- Put the key in rest position and operate the switch.
- Check for 0 Q by setting multimeter prods to terminals I and 2 of con-
nector A.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
15350 I 1
5204
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT:
- Put switch key in position 15.
- Ensure 12 Volts are available by setting one multi meter prod to terminal
I of connector IAl and the otherone to earth.
Set multimeter to OHM.
- Put the key in rest position and operate the switch.
- Check for 0 Q by setting one multimeter prod to terminal ofconnector
IAl and otherone to either connector C or terminal 4 of tail headlight
connector (pages V 13N 14).
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
153503 I
5205
SIMPLIFIED DIAGNOSIS
Disconnect connectors and [ID from component under examination. [0
~
Set multimeter to VOLT
- While keeping the steering wheel pushbutton pressed check for 12 V
by setting one multi meter prod to terminal of connector IAJ and the
otherone to earth.
Set multimeter to OHM.
- Return the steering wheel pushbutton to rest position. Check for 0 Q
by setting one multimeter prod to terminal of connector [ID and the
otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1 22 00 I 1
Earth 0000
Electric/air horn switch (bus)
SIMPLIFIED DIAGNOSIS
Disconnect connector IAI from component under examination.
Set multimeter to VOLT
- While keeping the relevant steering wheel pushbutton pressed check
for 12 V by setting one multimeter' prod toterminal 5 of connector
and the otherone to earth. .
'Set multimeter to OHM.
a
'- Check for Q by setting multimeter prods to terminals 5 and I of horn
, switch. .
- Press the switch key and repeat the test.
If readings are other than specified, remedy as required by either repairing
. the circuit or replacing the component. Then repeat the test.
152200 I
5207
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from warning lamp and operate safety unit
switch.
Set multimeter to VOLT
- Check for 12 V by setting one multimeter prod toterrninal I of connec-
tor and the otherone to earth. If reading is other than specified set
one multimeter prod to terminal 2 of connector IAJ and repeat the test.
Set multi meter to OHM.
- Check for 0 Q by setting one multi meter prod to terminal I of connec-
tor and the otherone to earth. Press the switch key and repeat the
test. If reading is other than specified set one multi meter prod to termi-
nal 2 of connector and repeat the test.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1 582 021
5208
Page
VII
Page
154033 E-F I
5209
SIMPLIFIED DIAGNOSIS
Disconnect connector!AJ from component under examination.
Set multimeter to VOLT:
- Turn ignition switch key to position 15.
- Ensure 12 Volts are available by setting one multimeter prod to terminal
3 of connector and the otherone to earth.
Set multimeter to OHM.
- Set the key to rest position.
- Ensure the presence of 0 Q by setting one multimeter prod to terminal
6 of connector C and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1650001
5210
SIMPLIFIED DIAGNOSIS
Remove component under examination from the c.I.U.
Set multimeter to VOLT:
- Turn ignition switch key to position 15.
- Ensure 12 Volts are available by setting one multimeter prod to terminal
3 of connector E9 (page 1.54) and the otherone to earth.
Set multimeter to OHM.
- Set the key to rest position.
- Ensure the presence of 0 Q by setting one multimeter prod to terminal
6 of c.1.u. connector E9 and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
159100 I
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to VOLT
- Turn ignition switch key to position 15. .
~
- Put steering column switch in windscreen washing position. Ensure 12
Volts are available by setting one multimeter prod to terminal 2 of con-
nector and the otherone to earth.
Set multimeter to OHM.
- Set the key to rest position. T
- Ensure the presence of 0 Q by setting one multimeter prod to terminal 1"
I of connector IAJ and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
164000 I
5212
I Earth 0000
2 Electric pump enablement 8886
Windscreen washer electric pump
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
tor and the otherone to terminal 7 of IVECO Control display panel
connector (page IV.IS).
- Check for 0 Q by setting one multimeter prod to terminal 3 of connec-
tor and the otherone to earth.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. 1 'len repeat the test.
1
44 0351
5213
I Not used
2 To IVECO Control display panel (windscreen washer fluid level) 5521
3 Earth 0000
Headlamp washer unit switch
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to VOLT
- Press the exterior lighting switch (page V3) to I st release.
- Check for 12 V by setting one multimeter prod to terminalS of connec-
tor IAJ and the otherone to earth.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor and the otherone to terminal S of head lamp washer unit timer
connector (page VI1.9).
- Press the switch and check for 0 Q by setting multimeter prods to termi-
nals I and 5 of same switch.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
153004 I
5214
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to VOLT
- Check for 12 V by setting one multi meter prod to terminal 30 ofconnec-
tor and the otherone to earth.
- Set the ignition key to position 15 and check for 12 V by setting one
multimeter prod to terminal 56 of connector IAJ and the otherone to
earth.
Set multimeter to OHM.
- Return the key to rest position. Check for 0 Q by setting one multimeter
prod to terminal 31 of connector and the otherone to earth. I Ii I
~, ~
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
. I
, I
1660 I 0 I
5215
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT
- Press the exterior lighting switch (page V.3) to Ist release and operate
the head lamp washer unit switch (page VI1.8).
- Check for 12 V by setting one multimeter prod to terminal I of connec-
tor!AJ and the otherone to earth.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
tor!AJ and the otherone to earth.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
166005 I
5216
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT
- Put the ignition key in position 15.
- Check for 12 V by setting one multimeter prod to terminal I of connec-
tor and the otherone to earth.
Set multimeter to OHM.
- Return the ignition key to rest position.
- Ensure resistance value is = 00 by setting multimeter prods to connector
terminals I and 2.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1
471 0 4 1
5217
SIMPLIFIED DIAGNOSIS ~
Disconnect connectors and B from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal of connector .,--.- - - - - - + - - - - - - - - - - - - - - -
B and the otherone to connector D of cab interior ceiling lamp (page •
the circuit or replacing the component. Then repeat the test. 1"
1520211
5218
Earth 0000
SIMPLIFIED DIAGNOSIS
Disconnect connectors ,[B] ,ra and [Q] from component under examina-
tion,
Set multimeter to VOLT
- Check for 12 V by setting one multimeter prod to terminal I of connec-
tor and the otherone to earth.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to connector fa and the
otherone to earth.
,.,
T
- Open the door and check for 0 Q by setting one multi meter prod to -'-
connector [Q] and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
139022 I
5219
Earth 0000
Earth 0000
SIMPLIFIED DIAGNOSIS
Disconnect connectors and B from component under examination.
Set multimeter to VOLT
- Check for 12 V by setting one multimeter prod to terminal of connector
[AJ and the otherone to earth. "
",
HI8-----r----,
Set multimeter to OHM.
- Open the rear door and check for a Q by setting one multi meter prod
to connector lliJ and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
139014 I 139016 I
5220
SIMPLIFIED DIAGNOSIS
Disconnect connectors IAJ from component under examination.
Set multimeter to VOLT <1'
- Check for 12 V by setting one multimeter prod to terminalS of connec-
tor IAJ and the otherone to earth.
Set multimeter to OHM.
','~~~J§W
- Press the switch key and check for 0 Q by setting multi meter prods to
terminals I and S of same switch. ~
~"
" N
T
,
-'-
,"
152021 I
5221
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT
- Check for 12 V by setting one multimeter prod to terminalS of connec-
tor IAJ and the otherone to earth.
Set multi meter to OHM.
- Press the switch key and check for 0 Q by setting multimeterprods to
terminals I and 5 of same switch.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
152017 I
5222
SIMPLIFIED DIAGNOSIS
Disconnect connectors [d [Q] from component under examination.
Set multimeter to VOLT
- Press the interior lighting switch (page VII.IS) and check for 12 V by set-
ting one multi meter prod to terminal of connector IAJ and the otherone --r::f==+=~44r:=
to earth,
- Press the interior blue lighting switch (page VII. 16) and check for 12 V
by setting one multimeter prod to connector [ID and the otherone to
earth.
Set multimeter to OHM.
- Check for 0 Q by setting one multi meter prod to connector and the
otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
139019 I
5223
Earth 0000
Step lighting ceiling lamp (bus)
SIMPLIFIED DIAGNOSIS
Disconnect connectors IAJ and from component under examination.
Set multimeter to VOLT
- Check for 12 V by setting one multimeter prod to end of cable Aand
the otherone to earth.
Set multimeter to OHM.
- Check for 0 Q by setting one multi meter prod to end of cable iliJ and the
otherone to tenminal I of connector C2 (Worksho p Manual chart 16).
...,
~
_."
If readings are other than specified, remedy as required by either repairing xnv,
the circuit or replacing the component. Then repeat the test.
~ ~
139003 I
5224
SIMPLIFIED DIAGNOSIS
Disconnect connectors and from component under examination.
Set multimeter to VOLT
- Check for 12 V by setting one multimeter prod to terminal of connector
and the otherone to earth.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal ofconnector
and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1390051
S22S
LAYOUT WITH CONNECTIONS
Ceiling lamp supply via luggage compartment door opening system 0000
Cigar lighter
SIMPLIFIED DIAGNOSIS
Disconnect connector [6J from component under examination.
Set multimeter to VOLT
- Check for 12 V by setting one multimeter prod to terminal 2 of connec-
tor [6J and the otherone to earth.
Set multimeter to OHM.
a
- Check for Q by setting one multimeter prod to terminal I ofconnector -1m.
lliJ and the otherone to earth.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1850001
5226
I Earth 0000
2 Cigar lighter supply (+ 30) 7721
Ashtray light
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT
- Press the exterior lighting switch (page V3) once.
- Check for 12 V by setting one multimeter prod to terminal 2 of connec-
tor and the otherone to earth.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor IAl and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
r-+-.---+a..:;-,-,
I I I
~
I
****
L_ .. _ ....
T
... -
m,
139020 I
5227
I Earth 0000
2 Parking light positive for ashtray light 4420
Interior lighting switch (bus)
SIMPLIFIED DIAGNOSIS
Disconnect connector [6] from component under examination.
Set multimeter to VOLT
- Put the ignition switch key in position 15.
- Check for 12 V by setting one multimeter prod to terminalS of connec-
tor [6] and the otherone to earth.
Set multimeter to OHM.
- Return the key to rest position.
- Press the switch key and check for 0 Q by setting multimeter prods to
terminals I and 5 of same switch.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
152030 I
5228
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT
- Put the ignition switch key in position 15.
- While keeping the interior heating switch key pressed (page VII.22)
check for 12 V by setting one multimeter prod to terminal 2 of connec-
tor and the otherone to earth.
Set multimeter to OHM.
- Return the key to rest position,
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor IAJ and the otherone to earth.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
1 120091
I Earth 0000
2 Interior heating motor 7003
Internal aerator switch with built-in warning lamp
SIMPLIFIED DIAGNOSIS
Disconnect connector lAJ from component under examination.
Set multimeter to VOLT
- Put the ignition switch key in position 15.
- Check for 12 V by setting one multimeter prod to terminal 40f connec-
tor and the otherone to earth.
Set multimeter to OHM.
- Return the key to rest position.
- Set the switch to either one of the two available positions and check for
o Q by setting multimeter prods to terminals 4-7 and 3-8 of same
switch.
- Put the switch in the other position and check for 0 Q by setting multi-
meter prods to terminals 4-1 and 3-2 of same switch.
If readings are other than specified. remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
152311 I
SIMPLIFIED DIAGNOSIS
Disconnect connector I.AJ from component under examination.
Set multimeter to VOLT
- Press the exterior lighting switch (page V3) once.
- Check for 12 V by setting one multimeter prod to terminal 50f connec-
tor I.AJ and the otherone to earth.
Set multi meter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal 4 of connec-
tor I.AJ and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
152312 I
5232
SIMPLIFIED DIAGNOSIS
Disconnect connector!Al from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor IAJ and the otherone to terminal 3 of head lamp alignment unit actua-
tor switch (page VI1.25).
- Repeat the test with multimter prods set to terminal 2 of connector IAJ
and terminal 2 ofthe switch and terminal 3 of connector and terminal
I of the switch.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
130100 I
5233
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from component under examination.
Set multimeter to VOLT
- Put the ignition switch key in position 15.
- Check for 12 V by setting one multimeler prod to terminal 4 of connec-
tor IAJ and the otherone to earth. •
Set multimeter to OHM. .~ [
- Return the key to rest position. 1
- Check for 0 Q by setting one multimeter prod to terminal 3 of connec- T
153300 1 153302 1
5234
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor IAJ and the otherone to terminal 2 of power window switch(page
VI1.27).
- Check for 0 Q by setting one multimeter prod to terminal 2 of connector
and the otherone to terminal 8 of power window switch connector.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
180000 I 180001 I
5235
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT
- Put the key in position 15.
- Check for 12 V by setting one multimeter prod to terminal 4 of connec-
tor and the otherone to earth.
- Repeat the same test on terminalS.
Set multimeter to OHM.
- Return the key to rest position.
- Check for a Q by setting one multimeter prod to terminal 7 of connec-
tor and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
152310 I
5236
SIMPLIFIED DIAGNOSIS
Disconnect connector!AJ from component under examination.
Set multimeter to VOLT
- Put the key in position 15.
- Check for 12 V by setting multimeter prod to terminalS of connector "'1
!AJ and the otherone to earth.
Set multimeter to OHM. I I' 1'1' -;-1- l' I' 1,11
- Return the key to rest position.
- While keeping the switch key pressed check for 0 Q by setting multime-
ter prods to terminals I and 5 of same switch.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
152005 I
5237
SIMPLIFIED DIAGNOSIS
Disconnect connectors and from component under examina-
tion.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal I of connec-
tor and the otherone to terminal I of adjustable rearview mirror
switch (page VI1.29).
- Check for 0 Q by setting one multimeter prod to terminal 2 of connec-
tor and the otherone to terminal 6 ofthe switch. Repeat the test with
multimeter prods set to terminal 3 of connector IAJ and terminal 2 of
the switch.
- Check for 0 Q by setting one multimeter prod to terminal of connector,
Ia and the otherone to terminal I of heated rearview mirror connector
(page VIIJO).
- Check for 0 Q by setting one multimeter prod to terminal of connector
[BJ and the otherone to earth.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test. Print no. 603.42.961 Diagram no. 13
1850061
5238
Earth 0000
Page
VIII
ABS system electronic control unit
SIMPLIFIED DIAGNOSIS
Disconnect connector from component under examination.
Set multimeter to VOLT
- Put the ignition switch key in position 15.
- Check for 12 V by setting one multimeter prod to terminal I of connec- =-+-----~==;;t::::.~1'
tor and the otherone to earth. ~ ~
Set multimeter to OHM. ~ .-n'Ml~.,--_ _L-L------,:~::=~~~;l
- Return the key to OFF position. • MrO_ _u_" ~"________""_ __'rr__,
188000 I
= = 35
19 0000000000000000000
000000000000000000
= = 18
18 To ABS solenoid valve and relay unit (solenoid valve) light blue/red
19 To ABS solenoid valve and relay unit (solenoid valve) light blue/white
20 Earth brown
21 To ABS front rh sensor brown
22-23 Not used
24 To ABS rear rh senosr light blue
25 Supply (+ 15) with stop signal switch on light blue
[K] 26 To ABS rear rh senosr brown
27 To ABS solenoid valve and relay unit (relay) light blue/black
28 To ABS solenoid valve and relay unit (relay) grey
29 ABS system failure indicator violet
30-31 Not used
32 To ABS solenoid valve and relay unit light blue/yellow
33 Not used
34 Earth brown
35 To ABS solenoid valve and relay unit (solenoid valve) grey/black
ABS system front wheel sensors
SIMPLIFIED DIAGNOSIS
Disconnect connector IAJ from ABS sensors.
Set multimeter to OHM.
a
- Check for Q by setting one multimeter prod to terminal 2 of connec-
tor and the otherone to terminal 4 of ABS control unit connector.
a
- Check for Q by setting one multimeter prod to terminal I of connec-
tor and the otherone to terminal 6 of ABS control unit connector.
Repeat the test with multimeter prods set to terminal 5 of connector
and terminal I I of control unit, terminal 4 ofconnector and termi-
nal 21 of control unit.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
188001 I
AS Front left
AD Front right
SIMPLIFIED DIAGNOSIS
Disconnect connector blocks and [ID from component under examina-
tion.
Set multimeter to VOLT:
- Check for 12 V by setting one multimeter prod to terminal 6 of connec-
tor and the otherone to earth.
- Check for I 2 V by setting one multimeter prod to terminal 10 ofconnec-
tor and the otherone to earth.
Set multimeter to OHM.
a
- Check for Q by setting one multimeter prod to terminal of connector
and the otherone to earth.
If readings are other than specified, remedy as required by either repairing -,:r-u-7778
the circuit or replacing the component. Then repeat the test. UJ VUIl
188003 I
SIMPLIFIED DIAGNOSIS
Disconnect connector IAl from component under examination.
Set multimeter to VOLT
- Put the ignition switch key in position 15.
- Check for 12 V by setting one multimeter prod to terminal I of connec- ~
tor IAl and the otherone to earth. • ~
Set multimeterto OHM. '~ ",," 1I,,--.IiXV1~I',-----_ _L---i-_~=~~~;=]
- Return the key to OFF position.
- Check for 0 Q by setting one multimeter prod to terminal 10 of connec-
tor and the otherone to earth. Repeat the test with multimeter
--+-++-++-++-++-++-r-t-+-,
prods set to terminals 20 and 34.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
188000 I
35
18
SIMPLIFIED DIAGNOSIS
Disconnect connector from ABS sensors.
Set multimeter to OHM.
- Check for 0 Q by setting one multimeter prod to terminal 6 of connec-
tor and the otherone to terminal 9 of ABS control unit connector.
- Check for 0 Q by setting one multimter prod to terminal 7 of connector
and the otherone to terminal 7 of ABS control unit connector. Re-
peat the test with multimeter prods set to terminal 8 of connector
and terminal 26 of control unit, terminal 9 of connector and terminal
24 of control unit.
If readings are other than specified, remedy as required by either repairing
the circuit or replacing the component. Then repeat the test.
188001 1
PS Rear left
PD Rear right
I Not used
2 Not used
3 Not used
4 Not used
5 Not used
6 To terminal 9 of ABS control unit brown
7 To terminal 7 of ABS control unit light blue
8 To terminal 26 of ABS control unit brown
9 To terminal 24 of ABS control unit light blue
GENERAL LIST OF CONTENTS
Page
INTRODUCTION VII
GENERAL I
WIRING ON THE VEHICLE 7
CIRCUITRY DATA SHEETS 57
OPERATIONAL WIRING DIAGRAMS 115
MODEL YEAR '98 CIRCUITRY DATA SHEETS 131
CROSS - REFERENCES 149
INTRODUCTION
Warnings
The symbols listed below are often used in the following pages. For your personal safety and the safety ofthe vehicle.
it is imperative to follow carefully all the instructions and warnings given below.
&. Shows that failure to comply with the instructions may result in physical injuries.
~~ Shows that failure to comply with the instructions may result in damages to the electrical equipment and/or-
the systems and/or instruments.
&. For more detailed information on the components adopted for the DailyfTurboDailyfTurboDaily 4X4 ran-
ge, see the manual "Electrical/electronic components", publication n°. 603.42.971.
The technical codes (component codes and cable colour codes) can be found in manual "Warnings and Technical
codes" publication nO . 603.42.936.
~
Connector on UCI Laminar fuse on UCI
B
B =identification letter I = identification number
EDC
EI
Electronic injection control
<:>
g
M Identification of a grounding point <:> Connection to the ground via cable
SU Ultrasonic welding
1-
I
I
TGC Main switch 4t--- Optional electrical connection
I
UCI
-7777-
Central Interconnection Unit
~
Grounding connection to the
frame and/or bodywork
*6 in 4x4 version
Connection or component present
. .
In van version
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