Aixam - Crossline - Workshop Manual - 2010 - 2010

REPAIR MANUAL CONTENTS GROUP 0: GENERAL   General warranty terms ..................................................................................................................................... 2 Technical characteristics : - Light quadricycles category L6e ........................................................................................................................ 3,4 - Heavy quadricycles category L7e ..................................................................................................................... 5,6  Checks to perform before delivering the venicle ............................................................................................... 7  Work to perform during servicing....................................................................................................................... 8  Vehicle identification ......................................................................................................................................... 9 GROUP 1: ENGINE  KUBOTA Z402, Z602 engines - Cooling system................................................................................................................................................... 2 - Lubrication system ............................................................................................................................................. 3 - Injection system ................................................................................................................................................. 4 to 7 - Tightening torques Z402 .................................................................................................................................... 8 - Tightening torques Z602 .................................................................................................................................... 9 - Repairs ............................................................................................................................................................... 10 to 12  LOMBARDINI 523 MPI engine - Cooling system................................................................................................................................................... 13 - Lubrication system ............................................................................................................................................. 14 - Injection system ................................................................................................................................................. 15 - Tightening torques ............................................................................................................................................. 16, 17 - Repairs ............................................................................................................................................................... 18 GROUP 3: REVERSER AXLE    Reverser axle .................................................................................................................................................... 2 Transmission ..................................................................................................................................................... 3 Regulator assembly VSP 2000 LP2 version 2 ................................................................................................... 4 to 23 GROUP 4: FRONT AXLE  Front axle adjustment dimensions GROUP 5: REAR AXLE  Rear axle adjustment dimensions GROUP 6: WHEELS-BRAKES      Tire pressure ..................................................................................................................................................... 2 Renewing the brake fluid ................................................................................................................................... 3 Brakes ............................................................................................................................................................... 4, 5 Hand brake........................................................................................................................................................ 6 Summary on aluminum wheels 2010 ................................................................................................................ 7 GROUP 7: BODY       Front frame dimensions CITY ........................................................................................................................... 2 Aluminum cell dimensions CITY ........................................................................................................................ 3 to 5 Front frame dimensions CROSSLINE ............................................................................................................... 10 Aluminum cell dimensions CROSSLINE ........................................................................................................... 11 to 13 Body maintenance............................................................................................................................................. 18 Gluing ................................................................................................................................................................ 19 GROUP 8: ELECTRICITY-INSTRUMENTS         Instrument cluster .............................................................................................................................................. 2 to 20 Fuses ................................................................................................................................................................ 21 Centralised locking ............................................................................................................................................ 22 Guarantee on CLARION radio unit .................................................................................................................... 23 to 26 Changing a lamp ............................................................................................................................................... 27, 28 Electric diagram ................................................................................................................................................ 29 to 33 Air conditioning .................................................................................................................................................. 34 to 38 ABS ................................................................................................................................................................... GROUP 9: PAINT  Body colors ....................................................................................................................................................... 2, 3 REPAIR MANUAL General 0 INDEX      General terms of warranty ...................................................................................... 2 Technical characteristics  Light quadricycles category L6e ....................................................................... 3,4  Heavy quadricycles category L7e ..................................................................... 5,6 Checks to perform before delivering the vehicle ..................................................... 7 Work to perform during servicing ............................................................................ 8 Vehicle identification .............................................................................................. 9 REPAIR MANUAL General 0 GENERAL TERMS OF WARRANTY 1. All new vehicles in the AIXAM range are guaranteed for a period of two years from their delivery to the client, against all defects or manufacturing flaw. All spare parts or accessories sold by AIXAM are guaranteed against any defect or manufacturing flaw for a period of one year from the date of delivery to the customer. 2. The following is required to benefit from the AIXAM guarantee: - The user manual must be filled with the vehicle identification, name and address of the user customer, and the stamp of the approved dealer. - The AIXAM approved distributor registers the guarantee on the Internet on the day of sale. 3. The guarantee may be requested from any approved dealer in the AIXAM network. The customer will present his user manual bearing the stamp of the vehicle seller, the date of delivery to the customer and stamp of the AIXAM approved dealer having performed servicing and check between 500 and 1 000 km, planned by the manufacturer. 4. Under pain of losing the benefit of the guarantee, the customer will present his vehicle between 500 and 1 000 km to his approved AIXAM dealer. The latter will perform free of charge (except consumables and small supplies) the labour operations required for checking, adjusting, tightening planned by the manufacturer at that mileage. After performing these operations, the AIXAM approved dealer will apply his stamp in the appropriate box, while indicating the date and exact mileage. 5. The guarantee includes replacement or repair, according to manufacturer instructions, of the part recognised faulty, with labour required by this replacement or repair free of charge. Repair on site or towing fees are not included. 6. Interventions within the warranty will not extend its period. However, the use of the warranty does extend its period for a time equal to that necessary for the performance only of the works under warranty, provided the said works require inevitably an immobilisation of the vehicle during at least 7 consecutive days (Act of 18 January 1992 – Art. 4) 7. The manufacturer is the rightful owner of the parts removed within the warranty. 8. Elements not covered by the warranty: • Any part and equipment which is not an original AIXAM component. • Servicing operations, including balancing and adjustment of parallelism of the wheels ; engine and headlight tuning, changing glow plugs, ignition plugs, lamps, belts, transmission belts, parts required for maintenance of regulators, brake pads and linings, brake discs and drums, lubricants and fluids. • Damage, breakdowns and damage resulting from: -abuse, accidents, theft, fire, vandalism, -industrial fallout, acid, alkaline, chemical, resin, bird droppings, salt, hail, storms, lighting and others, -non-observance of servicing programs at the planned periods, -improper intervention, -interventions outside the AIXAM network, -use of non-original parts, -use of improper fuel or lubricant or containing foreign bodies or fuel other than recommended, -Overloading, even temporary. • The entire vehicle if the latter was subject to modifications or transformations not planned by the manufacturer, particularly when the vehicle no longer matches the original homologation criteria. • Normal wear of any element including the exhaust, belts and shock absorbers, as well as ageing of the trims, upholstery, paint and wheel covers. • Any vehicle with an odometer which was changed or modified in such a way preventing to establish the actual mileage, with an altered serial number or engine number. • Expenses resulting from the immobilisation of the vehicle including direct or indirect or commercial loss incurred by the owner or usual user of the vehicle. 9. Documentations relative to the warranty, servicing, and driving: All benefactors of the AIXAM warranty receive a user manual delivered with the new vehicle. The application of the terms of warranty is subject to the presentation of this user manual. 10. In any case, the AIXAM vehicle benefits from the legal warranty against hidden flaws, in compliance with the provisions of articles 1641 and following of the Civil Code. REPAIR MANUAL 0 General TECHNICAL CHARACTERISTICS Light quadricycle category L6e GENERAL CITY Genre Type and version Steering wheels Drive wheels CROSSLINE Light quadricycle category L6e SV43AF Front Front SV42AF DIMENSIONS (mm) CITY Front track width Rear track width 1345 1345 1345 1345 Wheelbase 1795 2000 524 401 2720 1500 1470 524 466 2990 1500 1540 Front overhang Rear overhang Overall length Overall width Height WEIGHT (kilograms) CROSSLINE CITY CROSSLINE Gross vehicle weight rating Gross driving weight rating Maximum load: 640 none On front axle On rear axle 350 400 Total On front axle On rear axle 380 230 150 Empty vehicle curb weight: ENGINE CITY CROSSLINE Brand KUBOTA Type Z402 Cycle DIESEL Number of strokes Number and position of the cylinders Bore (mm) Stroke (mm) Compression ratio Maximum power (kW CE) Maximum power engine speed (rpm) Maximum torque (N/M CEE) 4 2 INLINE 64 62,2 23 4 3200 14 Maximum torque engine speed (rpm) 2400 Maximum rotation engine speed (rpm) 3200 Fuel used Fuel tank (litres) Ignition Engine cooling GASOIL 16 By compression Liquid Sound level at the fixed point: Sound level value (dba) Maximum corresponding engine speed (rpm) 79 2400 REPAIR MANUAL 0 General TECHNICAL CHARACTERISTICS Heavy quadricycle category L7e GENERAL CROSSLINE Genre Heavy quadricycle category L7e Type and version ST62AF / ST92AF Steering wheels Drive wheels DIMENSIONS (mm) Front Front Front track width Rear track width 1345 1345 2000 Wheelbase 524 Front overhang Rear overhang 466 Overall length 2990 Overall width 1500 Height WEIGHT (kilograms) 1540 Gross vehicle weight rating 675 Gross driving weight rating none Maximum load: On front axle 350 On rear axle 500 Total 400 On front axle 240 Empty vehicle curb weight: On rear axle 160 ENGINE Brand Heavy quadricycle category L7e KUBOTA LOMBARDINI Type Z602 LGW 523MPI Cycle DIESEL GASOLINE Number of strokes Number and position of the cylinders Bore (mm) 4 4 2 INLINE 2 INLINE 72 72 73,6 62 24 8,7 Maximum power (kW CE) 11,2 15 Maximum power engine speed (rpm) 3600 5000 Stroke (mm) Compression ratio Maximum torque (N/M CEE) Maximum torque engine speed (rpm) Maximum rotation engine speed (rpm) Fuel used Fuel tank (litres) Ignition Engine cooling 34 37 2200 3000 3600 5000 GASOIL LEAD-FREE GASOLINE 95,98 16 16 BY COMPRESSION ELECTRONIC LIQUID LIQUID REPAIR MANUAL 0 General TECHNICAL CHARACTERISTICS MOVEMENT TRANSMISSION • • • • Gear type: continuous variable transmission Clutch type: centrifugal Control mode: automatic Transmission type: Engine → regulator → reverser reducer axle → wheels. • Maximum speed: 45km/h light quadricycle category L6e • Maximum speed: 75km/h heavy quadricycle category L7e. SUSPENSION • Front: independent wheels, pseudo Mac Pherson type, double effect hydraulic telescopic shock absorbers and helical springs. • Rear: independent wheels with pulled arms, double effect hydraulic telescopic shock absorbers and helical springs. STEERING • Steering type: rack BRAKING CHARACTERISTICS Type Diameter FRONT Discs 210 mm REAR Drums 160 mm • Service brake The front and rear linings are driven by hydraulic pistons controlled by a double circuit master cylinder. This master cylinder, which includes a brake fluid tank in its upper section, is controlled from inside the vehicle by a pedal within reach of the driver's right foot. A limiter allows automatic reduction of braking effectiveness on the rear axle. • Emergency brake A lever located near the driver's right hand, between both vehicle seats, actuates the rear brakes, by means of a cross-bar with two cables. This brake is adjusted mechanically by a screw on the level of each rear wheel or the crossbar. A pawl allows to hold this brake in the applied position. BODY: • Body: light engine-powered quadricycle (L6e), heavy engine-powered quadricycle intended for transporting persons (L7e) • Materials making up the body: thermoformed ABS • Number of seats: 2 light quadricycle category L6e, 4 heavy quadricycle category L7e • Seats: 2 and bench seat Heavy quadricycle category L7e • Number of doors: 2 • Nature of materials used for windows: - Windshield: laminated glass - Side windows: tempered glass - Rear window: tempered glass LIGHTING AND SIGNALING • Headlights: - indicators: 12V/21W - position lights: 12V/21W - low and high beam 12V/50W/60W • Rear lights: - rear and stop lights: 12V/21W/5W - fog lights: 12V/21W - backup lights: 12V/21W • Front fog lights: - fog lights: 12V/35W • Day lights: -LED lights: 12V/ 4W REPAIR MANUAL General 0 CHECKS PERFORMED BEFORE VEHICLE DELIVERY: •Check of closing and locking of all closing panels (doors, windows, hood, liftback, glove compartment,….) •Check of the board tooling. •Level check: - engine oil - reverser axle oil - washer fluid - brake fluid - coolant and antifreeze protection check •Sealing check: - brake circuit - cooling circuit •Tire pressure check, including the spare wheel. •Check tightening of wheels, ball joints, engine, regulator, reverser bridge and screws in general. •Check operation of electrical and lighting devices. •Adjustment of idle. •Check of parallelism. •Vehicle test. •Cleaning the vehicle interior and exterior •Check of the starting battery charge level and tightening of the lugs. REPAIR MANUAL 0 General WORK TO BE PERFORMED AT SERVICING INTERVENTIONS AND CHECKS TO PERFORMED UPON SERVICING engine oil draining and renewal with oil filter change First servicing at 1000 km or 1 year Servicing at 5000 km or 1 year and every 5000 km o o draining the reverser axle and oil change o oil level check on the reverser axle (top up if necessary) check of the level of coolant (top up if necessary) o o o o check sealing of the cooling circuit check of the level of brake fluid (top up if necessary) o o o o check sealing of the brake circuit o o o o check operation of the brakes including the handbrake cleaning and dust removal of the brakes, change the linings if required Additional works at 10000 km and every 10000 km o check of the level of battery electrolyte (top up with demineralised water if required) o Adjustment of the reverser lever 0 grease the battery terminals o check the condition of the belts and change if necessary o removing dust on entire regulator o check of regulator gap and replacement o of main bearings if required check screw tightening (wheels, engine,.......) o change or clean the air filter o o cleaning change fuel filter o o tire pressure check, including the spare wheel o Check sealing of shock absorbers Check the condition of suspension pins (engine, exhaust) Check the condition of the bellows (joints and steering rack) Reprogram the maintenance indicator o 0 0 0 0 check the charging circuit 0 0 o check proper operation of the lighting and electrical instrumentation o o Cleaning the fins of the cooling radiator 0 check and adjust parallelism o vehicle test o o CAUTION: Maintenance work to perform regularly (in addition to servicing recommended) Annually: renew the brake circuit fluid. Every two years: renew the coolant. Never use super fuel as antifreeze in diesel fuel. Use the products recommended in stores REPAIR MANUAL General 0 VEHICLE IDENTIFICATION 1-SERIAL NUMBER COLD PUNCH The serial number is punched on the right-hand cross-member, inner side of the car, under the right-hand seat slider. 2-MANUFACTURER PLATE The manufacturer plate is riveted to the right-hand stringer on the inner side of the car, next to the engraved serial number. REPAIR MANUAL 0 TIGHTENING TORQUES FUNCTION Torque in Nm SCREW COEF M8*20 2 18,4 27,6 Mini Maxi M8*35 2 18,4 27,6 M8*20+nylstop 2 Steering column nylstop M8 3 Steering joint (cardan) M8*35+nylstop 1 Steering rack M10*60 2 Tie rod Nylstop M10*1,25 2 Steering wheel M12 torx 1 Handbrake M8*20 2 Master Cylinder M8*25+nylstop 2 Banjo bolt limiter Thin thread banjo bolt 4 Brake pedal M 6 x 16 1 Safety belt (upper screw) 7/16' 20 UNF 2 Safety belt (lower screw) 7/16' 20 UNF 2 Seat belt retractor 7/16' 20 UNF 2 Belt buckle 7/16' 20 UNF 2 Seats front sliders M6*30 8 Front wheel hub nut Nylstop M16*1,5 2 Front suspension triangles M10*50+Nylstop 4 Front suspension ball joints Nylstop M12*1,25 2 Front shock absorbers (upper screw) Nylstop M10*1,00 2 Front shock absorbers (lower screw) Nylstop M12 2 18,4 18,4 18,4 36 32 40 18,4 18,4 20 8,8 25 25 25 25 8,8 140 38 40 16 36 64 38 38 40 40 90 BRAKES STEERING Column tensioner (upper screw) Column tensioner (lower screw) Flector column SEATS/BELT FRONT & REAR AXLE DESIGNATION Rear wheel hub axle M12*180+Nylstop Rear shock absorber (upper screw) M10*65+Nylstop TRANSMISSION Rear suspension arm 2 2 M10*65+nilstop 4 Front wheel M10*1,25 16 Rear wheel M10*1,25 16 Receiver inverter Spiralock nut M12 1 27,6 27,6 27,6 54 48 60 27,6 27,6 30 13,2 40 40 40 40 13,2 160 54 60 24 54 96 54 54 60 60 110 REPAIR MANUAL KUBOTA Z402 and Z602 engines 1 INDEX KUBOTA Z402 and Z602 engines:  Cooling system .................................................................................................... 2  Lubrication system ............................................................................................... 3  Injection system ................................................................................................... 4 to 7  Tightening torques Z402 ...................................................................................... 8  Tightening torques Z602 ...................................................................................... 9  Repair .................................................................................................................. 10 to 12 LOMBARDINI 523 MPI engine  Cooling system .................................................................................................... 13  Lubrication system ............................................................................................... 14  Injection system ................................................................................................... 15  Tightening torques ............................................................................................... 16, 17  Repair .................................................................................................................. 18 REPAIR MANUAL KUBOTA Z402 and Z602 engines 1 Cooling system Forced circulation cooling system with water pump. Temperature regulation is ensured by a thermostat fastened on the upper water manifold of the cylinder head. The thermostat is controlled as defined below: Start of thermostat valve opening Full opening of the thermostat valve 69.5 to 72.5 °C 85 °C The water pump is centrifugal and driven by the accessory belt. 1 : Radiator 2 : Water pump 3 : Fan 4 : Thermostat 5 : Cylinder head 6 : Engine block A: Thermostat closed, short circulation enhancing engine temperature build-up B: Thermostat open, long circulation to cool the engine. Quantity of coolant: 2 litres REPAIR MANUAL KUBOTA Z402 and Z602 engines Lubrication system 1 : Rocker 2 : Pressure switch 3 : Rocker ramp 4 : Valve 5 : NA on 400 6 : Distribution 7 : Crankshaft 8 : Oil pump 9 : Strainer 10 : Overpressure valve 11 : Oil filter 12 : Push rod 13 : Indexed push rod 14 : Camshaft 15 : Injection pump 16 : Piston A: Filter OK B: Clogged filter Quantity of Z402 oil: 1.80 litres Quantity of Z602 oil: 2.50 litres 1 REPAIR MANUAL KUBOTA Z402 and Z602 engines Injection system The injection pump delivers the quantity of fuel required to meet the driver's demand. The injection pump preserves the engine of any overspeeding and ensures idle running stability. The injection pump controls engine stopping when requested. It is divided into four separate parts: - Low pressure High pressure Regulation Control The low pressure circuit comprises the: 1. Fuel tank 2. Strainer 3. Fuel pre-filter 4. Supply pump 5. Main filter The high pressure circuit comprises the: 6. Injection pump 7. Injectors 1 REPAIR MANUAL KUBOTA Z402 and Z602 engines 1 Adjusting and tuning The basic adjustments are located on the injection pump or injection pump housing. 1. Engine Stop 2. Min acc. stop 3. Max acc. stop 4. Acceleration lever 5. Idle adjust screw 6. Engine stop lever 7. Max load adjust screw Idle adjust Idle adjustment is made from screw 5. However, idle speed must be reduced by 50 rpm by the min acceleration stop (2) and compensated with the idle adjust screw (5) to avoid untimely engine stalling. Load adjust Max load adjustment is done with screw 7. However, modifying this adjustment is not authorized. Adjustment of this screw is highly sensitive and may cause excessive smoke or lack of power. In case of problem linked with this adjustment, and once all other causes have been eliminated, call after-sales. REPAIR MANUAL KUBOTA Z402 and Z602 engines Regulation principle 1. Accelerator lever 2. Starting spring 3. Regulation lever 4. Regulation spring 5. Intermediate regulation lever 6. – 7. – Centrifugal regulator 8. – 9. – 10. Pump camshaft 11. Idle spring 12. Accelerator control 13. Flow control rod 1 REPAIR MANUAL KUBOTA Z402 and Z602 engines 1 Upon starting: Spring 2 drives lever 3 to the maximum flow position, the control rod is in the maximum flow position. When the engine starts, the centrifugal force applied to the regulator is stronger that the cold start spring, hence lever 3 is pushed to the minimum flow position, and the control rod pushes the idle spring 11. At idle: Centrifugal force applied to the regulator is sufficient to maintain lever 3 and the control rod on idle spring 11. The spring 11 ensures idle running stability. At full load: Upon acceleration request, lever 1 applies a tension on spring 2, which drives lever 5. Lever 5 drives lever 3, and moves the flow control rod in max load position. When speed reaches the maximum, the centrifugal force applied to the regulator becomes higher than that applied by spring 4, the control rod moves to a flow reduction. Upon engine stop: The engine stop lever pushes lever 3 in min flow position, the force applied to the lever is important enough to completely compact the idle spring, hence cutting engine injection. REPAIR MANUAL 1 KUBOTA Z402 and Z602 engines TIGHTENING TORQUES Z402 The screws, bolts and nuts must be tightened at the torque specified using a torque wrench. Several screws, bolts and nuts, such as those on the cylinder head, must be tightened in a specific sequence and torque. 1. Tightening torques for screws, bolts and nuts for particular use  For screws, bolts and nuts marked « * » in the table, smear the threading and seats with motor oil before tightening.  The letter « M » of dimension x pitch means that the dimension of the screw, bolt or nut relies on the metric system.  The dimension is the nominal outer diameter of the threadings in mm.  The pitch is the nominal distance in mm between two threads. Element * Cylinder head cover nuts * Cylinder head screws * Main bearing fastening screw 1 * Main bearing fastening screw 1 (flywheel side) * Main bearing fastening screw 2 * Flywheel screws * Piston rod screws * Rocker arm support nuts * Gear shaft screw * Crankshaft end bolt * Bearing box cover screws Glow plugs Injector holder assembly Oil pressure switch tapered screw Injection duct fastening nuts Overflow pipe assembly fastening nuts Starter nut B terminal fitting nut Dimension x pitch M6 x 1.0 M8 x 1.25 M6 x 1.0 M8 x 1.25 M7 x 1.0 M10 x 1.25 M7 x 0.75 M6 x 1.0 M6 x 1.0 M12 x 1.5 M6 x 1.0 M8 x 1.0 M20 x 1.5 PT 1/8 M12 x 1.5 M12 x 1.5 M8 N-m 3.9 to 5.9 37.2 to 42.1 12.7 to 15.7 23.5 to 27.4 26.5 to 30.4 53.9 to 58.8 26.5 to 30.4 9.8 to 11.3 9.8 to 11.3 117.6 to 127.4 9.8 to 11.3 7.8 to 14.7 49.0 to 68.6 14.7 to 19.6 24.5 to 34.3 19.6 to 24.5 8.8 to 11.8 Kgf-m 0.4 to 0.6 3.8 to 4.3 1.3 to 1.6 2.4 to 2.8 2.7 to 3.1 5.5 to 6 2.7 to 3.1 1.00 to 1.15 1.00 to 1.15 12.0 to 13.0 1.00 to 1.15 0.8 to 1.5 5.0 to 7.0 1.5 to 2.0 2.5 to 3.5 2.0 to 2.5 0.9 to 1.2 2. Tightening torques for screws, bolts and nuts for general use When tightening torque values are not specified, tighten the screws, bolts, and nuts at the values specified in the following table. Standard screws and Special screws and Grade bolts 4 bolts 7 Unit N-m M6 M8 M10 M12 Nominal diameter Kgf-m 7.9 to 9.3 0.80 to 0.95 17.7 to 20.6 1.8 to 2.1 39.2 to 45.1 4.0 to 4.6 62.8 to 72.6 6.4 to 7.4 N-m Kgf-m 9.8 to 11.3 1.00 to 1.15 23.5 to 27.5 2.4 to 2.8 48.1 to 55.9 4.9 to 5.7 77.5 to 90.2 7.9 to 9.2 The material grade is indicated by numbers engraved on the heads of screws and bolts. Always check the numbers indicated below before tightening. Number engraved None or 4 7 Material grade of the screw or bolt SS41, S20C screw and bolt S43C, S48C special screw and bolt (refined) REPAIR MANUAL KUBOTA Z402 and Z602 engines 1 TIGHTENING TORQUES Z602 Tightening torques for screws, bolts and nuts for particular use  For screws, bolts and nuts marked « * » in the table, smear the threading and seats with motor oil before tightening.  The letter « M » of dimension x pitch means that the dimension of the screw, bolt or nut relies on the metric system.  The dimension is the nominal outer diameter of the threadings in mm.  The pitch is the nominal distance in mm between two threads. Elements * Rocker cover bolts Injection duct fastening nut Overflow duct fastening nut Injector unit Glow plug * Rocker ramp nut * Cylinder head bolt * Fan drive pulley screw * Intermediate gear shaft fastening screws Injection pump fastening screws * Connecting rod head bolt * Flywheel bolt Main bearing cap cover fastening bolt * Main crankshaft bearing bolt 2 * Main crankshaft bearing bolt 1 Oil pressure switch Injector nose support Starter B terminal fastening nut (electromagnetic drive type) Starter B terminal fastening nut (planetary gear reduction type) Generator pulley nut Alternator pulley nut Drain plug with copper gasket Drain plug with copper gasket Drain plug with rubber coating gasket Dimension x pitch M6 x 1 M12 x 1.5 M12 x 1.5 M20 x 15 M8 x 1 M6 x 1 M8 x 1.25 N-m 6.86 to 11.3 24.5 to 34.3 19.6 to 24.5 49.0 to 68.6 7.8 to 14.7 9.8 to 11.3 37.3 to 42.2 117.7 to 127.5 9.8 to 11.3 17.7 to 21.6 26.5 to 30.4 53.9 to 58.8 9.8 to 11.3 26.5 to 30.4 12.7 to 15.7 14.7 to 19.6 34.3 to 39.2 Kgf-m 0.7 to 1.15 2.5 to 3.5 2.0 to 2.5 5.0 to 7.0 0.8 to 1.5 1.00 to 1.15 3.8 to 4.3 Pounds-feet 5.1 to 8.3 18.1 to 25.3 14.5 to 18.1 36.2 to 50.6 5.8 to 10.8 7.2 to 8.3 27.5 to 31.1 12.0 to 13.0 1.00 to 1.15 1.80 to 2.20 2.7 to 3.1 5.5 to 6.0 1.00 to 1.15 2.7 to 3.1 1.3 to 1.6 1.5 to 2.0 3.5 to 4.0 86.8 to 94.0 7.2 to 8.3 13.0 to 15.9 19.5 to 22.4 39.8 to 43.4 7.2 to 8.3 19.5 to 22.4 9.4 to 11.6 10.8 to 14.5 25.3 to 28.9 M8 7.8 to 9.8 0.8 to 1.0 5.8 to 7.2 M8 5.9 to 11.8 0.6 to 1.2 4.3 to 8.7 M10 x 1.25 39.2 to 44.1 58.3 to 78.9 32.4 to 37.3 63.7 to 73.5 44.1 to 53.9 4.0 to 4.5 5.95 to 8.05 3.3 to 3.8 6.5 to 7.5 4.5 to 5.5 28.9 to 32.5 43.0 to 58.2 23.9 to 27.5 47.0 to 54.2 32.5 to 39.8 M12 x 1.5 M6 x 1 M8 x 1.25 M7 x 0.75 M10 x 1.25 M6 x 1 M7 x 1 M6 x 1 PT 1/8 M12 x 1.25 M22 x 1.5 M22 x 1.5 REPAIR MANUAL KUBOTA Z402 and Z602 engines 1 REPAIR Anomaly Possible cause No fuel Fill up Air in the supply circuit Purge the air Water in the supply circuit Change the fuel and repair or change the supply system Clogged supply duct Clean Clogged fuel filter Clean or change Fuel or oil viscosity too high Use the fuel or motor oil specified Low hexadecane index fuel Use the fuel specified Fuel leak due to bad tightening of a fastening nut on the injection duct Tighten the nut Bad injection timing The engine does Camshaft wear not start Clogged injector The starter is inoperative Solution Adjust Change Clean Bad operation of the injection pump Repair or change Seized crankshaft, camshaft, piston, cylinder jacket or main bearing Repair or change No compression in the cylinder Change the cylinder head gasket, tighten the cylinder head screw, change the glow plug and injector holder Bad timing Readjust or change the timing gear Worn piston rings and jacket Change Excess play in timing Adjust Battery discharged Charge Faulty starter operation Repair or change Faulty key switch Repair or change Wiring disconnected Connect REPAIR MANUAL KUBOTA Z402 and Z602 engines 1 REPAIR (cont’d) Anomaly Possible cause Clogged or dirty fuel filter Clogged air filter Fuel leak due to bad tightening of a fastening nut on the injector duct The engine does not run regularly Bad operation of the injection pump Solution Clean or change Clean or change Retighten the nut Repair or change Bad injector opening pressure Stuck or clogged injector Faulty regulator operation Excess motor oil Adjust Repair or change Repair Reduce to level specified Wear or sticking of a piston ring and a jacket Repair or change Bad injection timing Exhaust gases Bad compression black, or dark grey Overload Bad quality fuel Clogged fuel filter Clogged air filter Faulty injector Bad injection timing Adjust Adjust neutral spaces Reduce the load Use the fuel specified Clean or change Clean or change Repair or change the injector Adjust The engine moving parts seem to be seized Repair or change Insufficient power Irregular fuel injection Repair or change the injection pump Faulty injector Repair or change the injector Lack of compression Change the cylinder head gasket, tighten the cylinder head screw, the glow plug and injector holder The cutting gap is set in the same direction Modify the location of the cutting gap for all piston rings Excessive oil consumption Worn or stuck oil control ring Worn piston ring groove Change Change the piston Worn valve stem and guide Change Worn crankshaft main bearings or trunnion Change bearings Oil leaked caused by a faulty lining or sealing Change REPAIR MANUAL KUBOTA Z402 and Z602 engines 1 REPAIR (cont’d) Anomaly Fuel mixed with lubrication oil Water mixed with lubrication oil Possible cause Solution Worn injection pump plunger Change the pump element or pump Faulty injector Injection pump Faulty cylinder head gasket Flaky casing or cylinder head Low motor oil Clogged strainer Discharge valve stuck by dirt Repair or change the injector Change Change Change Top up Clean Clean Fatigue or broken discharge valve spring Change Low oil pressure High oil pressure Overheating engine Too much running gap of a crankshaft bearing Too much running gap of a connecting rod head bearing Too much running gap of a push rod bushing Clogged oil passage Inappropriate type of oil Faulty oil pump Inappropriate type of oil Faulty discharge valve Low motor oil Change Change Change Clean Use the type of oil specified Repair or change Use the type of oil specified Change Top up Fan belt broken or loose Change or adjust Low coolant Top up Radiator honeycomb or fins clogged Clean Corroded radiator interior Clean or change Corroded coolant circuit Clean or change Faulty radiator plug Run with overload Faulty cylinder head gasket Bad injection timing Inappropriate fuel type Change Reduce the load Change Adjust Use the fuel specified Low electrolyte Fill distilled water and charge the battery Slipping fan belt Battery discharges Wiring disconnected too fast Rectifier disconnected Faulty fan generator Faulty battery Adjust belt tension or change it Reconnect Change Change Change REPAIR MANUAL LOMBARDINI 523 MPI engine COOLING SYSTEM 3. 4. 5. 6. 7. 8. Thermostatic valve Cylinder block Coolant temperature indicator thermostat Circulation pump Ventilation helix Radiator Quantity of coolant: 2 litres 1 REPAIR MANUAL LOMBARDINI 523 MPI engine LUBRICATION SYSTEM 1. Pressure switch 2. Rocker stud 3. Connecting rod head stud 4. Oil filter cartridge 5. Main bearing stud 6. Oil change plug 7. Oil gauge 8. Vent 9. Oil fill plug 10. Camshaft 11. Oil pressure adjust valve 12. Oil pump 13. Crankshaft 14. Oil suction filter 15. Hydraulic push rod Oil quantity (with filter) = 1.3 litres Oil quantity (without filter) = 1.2 litres 1 REPAIR MANUAL LOMBARDINI 523 MPI engine INJECTION SYSTEM 1. Filling pipe 2. Tank 3. Fuel pump / gauge plant 4. Filter 5. Supply duct 6. Injector supply pipe 7. Injector 8. Pressure regulator 9. Injector holding spring 10. Pressure regulator return pipe 11. Supply pipe fastening screw 1 REPAIR MANUAL 1 LOMBARDINI 523 MPI engine TIGHTENING TORQUES The following tables indicate the tightening torques for standard screws and main components. The tightening torques are also indicated with the tightening methods and sequences, in the indications of fitting of components and/or the plant. TABLE OF TIGHTENING TORQUES OF STANDARD SCREWS (wide pitch) Resistance class (R) Grade / Dimensions Diameter R>400N/mm² R>500N/mm² R>600N/mm² R>800N/mm² R>1000N/mm² R>1200N/mm² Nm Nm Nm Nm Nm Nm Nm Nm M3 0,5 0,7 0,6 0,9 1 1,4 1,9 2,3 M4 1,1 1,5 1,4 1,8 2,2 2,9 4,1 4,9 M5 2,3 3 2,8 3,8 4,5 6 8,5 10 M6 3,8 5 4,7 6,3 7,5 10 14 17 M8 9,4 13 12 16 19 25 35 41 M10 18 25 23 31 37 49 69 83 M12 32 43 40 54 65 86 120 145 M14 51 68 63 84 101 135 190 230 M16 79 105 98 131 158 210 295 355 M18 109 145 135 181 218 290 405 485 M20 154 205 193 256 308 410 580 690 M22 206 275 260 344 413 550 780 930 M24 266 355 333 444 533 710 1000 1200 M27 394 525 500 656 788 1050 1500 1800 M30 544 725 680 906 1088 1450 2000 2400 TABLE OF TIGHTENING TORQUES OF STANDARD SCREWS (thin pitch) Diameter R>400N/mm² R>500N/mm² R>600N/mm² R>800N/mm² R>1000N/mm² R>1200N/mm² Nm Nm Nm Nm Nm Nm Nm Nm M 8x1 10 14 23 17 20 27 38 45 M 10x1 21 28 26 35 42 56 79 95 M 10x1.25 20 26 24 33 39 52 73 88 M 12x1.25 36 48 45 59 71 95 135 160 M 12x1.5 38 45 42 56 68 90 125 150 M 14x1.5 56 75 70 94 113 150 210 250 M 16x1.5 84 113 105 141 169 225 315 380 M 18x1.5 122 163 153 203 244 325 460 550 M 18x2 117 157 147 196 235 313 440 530 M 20x1,5 173 230 213 288 345 460 640 770 M 20x2 164 218 204 273 327 436 615 740 M 22x1.5 229 305 287 381 458 610 860 1050 M 24x2 293 390 367 488 585 780 1100 1300 M 27x2 431 575 533 719 863 1150 1600 1950 M 30x2 600 800 750 1000 1200 1600 2250 2700 REPAIR MANUAL LOMBARDINI 523 MPI engine 1 TIGHTENING TORQUES Table of tightening torques for the main components DESCRIPTION Connecting rod Rocker cover Casing (crankshaft fastening screws) Casing (one-piece fastening screws) Timing belt roller nut Rocker stud holder nut Oil sealing ring flange screw (flywheel side) Crankshaft pulley screw (timing side) Camshaft pulley screw Timing shaft bearing panel Camshaft holder flange Small closing flange Suction manifold fastening screw Revolution sensor holder fastening screw Revolution sensor fastening screw Oil pressure switch Oil plug Engine cylinder head screw Flywheel screw Coolant thermostat DIAMETER x PITCH (mm) 8x1 6x1 M 10 M6 M 10 10x1.5 M6 16x1.5 sin 10x1.25 M 6x1 M 6x1 M 6x1 M 6x1 M 6x1 M 8x1.25 12x1.5 12x1.5 10x1.5 TIGHTENING TORQUE (Nm) 40 9 50 10 40 40 12 180(1)* 50 10 10 10 10 10 10 25 40 (2)* 80 30 (1)* Lubricate the lower part of the screw and pulley centre with some « Molysilp » (2)* For more precise information see « Fitting the cylinder head » REPAIR MANUAL 1 LOMBARDINI 523 MPI engine Damaged catalyst White smoke Blue smoke Crackling Noise (beating or rattling) High consumption Low performance Jolting acceleration Jolting once idle running stabilized Jolting upon reacceleration The engine stops sometimes The engine stops at idle Idle running too low Idle running too high Unstable idle running Overheating motor Difficult starting with warm engine Difficult starting with cold engine The engine does not start REPAIR Table of probable anomalies according to symptoms Air supply Air filter Leak on the manifold Butterfly body Fuel supply The pressure regulator stays open The pressure regulator stays closed Clogged pipes No pump flow Running injector Poor fuel quality Ignition Coil (coil short-circuit) Faulty spark plug cable Worn spark plugs Spark plugs too cold Spark plugs too warm Exhaust Leaks on the manifold Oxygen probe Engine and mechanical Leaky valve Valve stuck Bad valve sealing guide Jacket / piston wear Embedded combustion chamber Insufficient cooling Damaged cylinder head gasket Damaged revolution sensor phonic wheel Faulty hydraulic push rods Oil level too high Electrical equipment Low contact on fuel pump connector Burnt fuse Faulty relay Faulty engine wiring Faulty battery elements Battery terminals sulphated REPAIR MANUAL Reverser bridge 3 INDEX    Reverser axle ....................................................................................................... 2 Transmission ....................................................................................................... 3 Regulator set VSP 2000 LP2 version 2................................................................ 4 to 23 REPAIR MANUAL Reverser bridge REVERSER BRIDGE 3 REPAIR MANUAL TRANSMISSION TRANSMISSION 3 REPAIR MANUAL REGULATOR ASSEMBLY 3 REGULATOR ASSEMBLY VSP 2000 – LP2 – VERSION 2 INDEX          Important note...................................................................................................... 5 Maintenance frequency........................................................................................ 5 Tools required for handling .................................................................................. 6 Parts of the regulator ........................................................................................... 7 Installing the pulleys on the venhicle ............................................................................ 8 Tightening the screws .......................................................................................... 9 Removing the pulleys from the vehicle ................................................................ 10, 11 Inspecting the belt ................................................................................................ 12 Removing and refitting the pulleys ....................................................................... 13 to 23 REPAIR MANUAL REGULATOR ASSEMBLY 3 IMPORTANT NOTE All installation, servicing and repair operations must be performed only by skilled personnel.  This symbol identifies operations with a risk of severe injury if the instructions are not observed.  This symbol identifies a step with a risk of damaging parts or malfunction of the components. CVTech waives any liability for any damage or injury resulting from bad comprehension of the text, inappropriate use of the regulator or the tools recommended. The tightening torques indicated must be observed rigorously.   SERVICING FREQUENCY The regulator requires no lubrication. It is designed to run dry. Hence, certain cleanliness rules are applicable upon handling to prevent contact of any products with the regulator components. To increase the lifetime of the regulator, we recommend performing the following checks: Description Leading pulley Fixed flange Sliding flask Assembled centrifugal block Lower main bearing Spring Upper main bearing Check Periodicity Visual / General condition 10,000 km Visual 10,000 km Visual 10,000 km Visual 10,000 km Visual 10,000 km, change Visual 10,000 km Visual 10,000 km, change Led pulley Fixed flange Sliding flask Cam slider Spring Visual / General condition Visual Visual Visual / Dimensional Visual 10,000 km 10,000 km 10,000 km 10,000 km 10,000 km Belt Visual / Dimensional 10,000 km REPAIR MANUAL 3 REGULATOR ASSEMBLY TOOLS REQUIRED FOR HANDLING Flat blade screwdriver Socket 17mm and 30mm Hammer *Led pulley puller OE17 Torque wrench Retaining ring pliers Three legged puller Vise Press or press drill * Pulley removal tool 0MDP17 * Leading pulley puller OE13 Please note that the use of impact tools is not recommended. REPAIR MANUAL REGULATOR ASSEMBLY REGULATOR PARTS The regulator is composed of three main elements:  Leading pulley (3)  Led pulley (7)  Belt (10) 1. Flywheel 2. Gearbox 3. Leading pulley 4. Lock washer 5. Hex head screw (fastening) 6. Key 7. Led pulley 8. Lock washer 9. Hex head screw (fastening) 10. Belt 3 REPAIR MANUAL REGULATOR ASSEMBLY 3 INSTALLING PULLEYS ON THE VEHICLE First of all:  For a initial fitting on the vehicle, the installer must have the layout drawing. This drawing includes all specifications of the vehicle, the numbers of the pulleys and belt, as well as the dimensional geometry of the complete assembly.  Cleanliness is required on all components.  No lubrication product must be used. Installing the led pulley Fit the led pulley (7) onto the gearbox shaft (2) while adding the key (6). Installing the leading pulley and the belt To ensure easier fitting of the leading pulley and belt, an opening screw no. 0080-0055 (M6x1.0) may be used to open the flasks of the led pulley, and hence loosen the belt. Fit the leading pulley (3) by passing it in the belt (10) and then onto the flywheel shaft (1). REPAIR MANUAL REGULATOR ASSEMBLY 3 TIGHTENING THE SCREWS Once the leading and led pulleys, as well as the belt, installed, screw the two screws of the pulleys using a torque wrench to apply standardized torque. Nominal screw diameter Grade 8 mm 10 mm 8,8 8,8 Standardized torque (Newton metre) 21 to 28 42 to 54 To tighten the leading pulley, lock the engine rotation with a screwdriver or any other tool while ensuring you do not damage the parts. Do not forget to remove the opening screw from the led pulley flask. Otherwise, the pulley could be unbalanced. REPAIR MANUAL REGULATOR ASSEMBLY REMOVING THE PULLEYS FROM THE VEHICLE Before removal, identify the rotation direction of the belt so that it turns in the same direction again upon refitting. Remove the screw (5) from the leading pulley and the screw (9) from the led pulley. Unscrew the nut holding the leading pulley in the closed position. (Use a 30mm socket) Avoid dropping the cap and blocks. (Removing free parts is preferable.) 3 REPAIR MANUAL REGULATOR ASSEMBLY 3 Use the OE13 leading pulley puller, and if necessary use the EO17 led pulley puller (the led pulley may sometimes be removed manually). For the leading pulley: Insert the rod of the X-1720A puller inside the shaft and screw the X-1720C adapter at the end of the shaft. (pressurize it by a half-turn) Although not recommended by CVTech, a few slight hammer strokes on the puller may help to separate the leading pulley shaft from the flywheel. For the led pulley: Screw the OE17 adapter inside the shaft. Screw the puller screws until the pulleys leave their location. REPAIR MANUAL REGULATOR ASSEMBLY 3 INSPECTING THE BELT The belt must be inspected to avoid breakage, likely to cause personal and/or material damage.  Change the belt when cracks appear when turning the belt inside out.  Change the belt when it reaches a width of 28.5 mm, i.e. about 2 mm narrower than the new belt. REPAIR MANUAL REGULATOR ASSEMBLY REMOVING AND REFITTING THE PULLEYS Leading pulley 1. Fixed flange 2. Spacing washer 3. Sliding flask 4. Lower main bearing 5. Spacing washer (2mm) 6. Spacing washer (1mm) 7. Spacing washer (0.5mm) 8. Spring 9. Spacing washer (1.21mm) 10. Spacing washer (0.68mm) 11. Upper main bearing 12. Retaining washer 13. Counterweight 14. Centrifugal block 15. Assembled centrifugal block 16. Cap 17. Flat washer 18. Nut 19. Lock washer 20. Fastening screw 3 REPAIR MANUAL REGULATOR ASSEMBLY 3 Removing the leading pulley Removing the cover and centrifugal blocks Remove the nut (18) and washer (17). The cover and centrifugal blocks are now released. Inspection recommended  Damage to centrifugal blocks  Wear of flanges (by belt friction) Removing the sliding flask Using the 0MDP17 removing tool is indispensable to avoid sudden removal of the sliding flange (spring effect). Although less securing, a table press (see illustration) or a drill press may be used. REPAIR MANUAL REGULATOR ASSEMBLY 3 After removing the sliding flange from the fixed flange shaft, position the latter on the removal tool in order to lower the upper main bearing (11). Lower the upper main bearing (11) to be able to remove the retaining ring (12) with a flat blade screwdriver. Rise the sliding flange slowly to remove it. Avoid dropping parts if removing is performed with a table press. According to the pulley’s adjustment, please note that you must carefully observe the quantity and position of the spacer washers (5-6-7) and (9-10) to avoid modifying the initial yield of the pulley. Cleaning the sliding parts with a degreaser is indispensable to maintain optimum performance. Inspection    Damage to the main bearings 4 and 11 Wear of the flange (by belt friction) Damage to the spring (8) REPAIR MANUAL REGULATOR ASSEMBLY 3 Removing the fixed flange (if required) 1 Fixed flange 1a Bearing 1b Tightening ring Before each part removing step, clean the shaft carefully. Using a puller is required to prevent damaging the parts which do not require changing. Removing the tightening ring (1b) Removing the bearing (1a) Inspection    Shaft damage. (inside and outside) Wear of the flange (by belt friction) Change the bearing (1a), if required REPAIR MANUAL REGULATOR ASSEMBLY 3 Refitting the leading pulley Refitting the sliding flange Refitting the sliding flange is performed by reversing the removal sequence (see removing the sliding flange). Please note to return the spacing washers to their original position. Refitting the fixed flange To refit the flange, we recommend using a press and a tube 32 mm inner diameter and length 125 mm. - As per the illustration: -Insert the bearing (1a). Insert the tightening ring (1b) Ensure you have perfect contact between the shaft shoulder, bearing and tightening ring without applying pressure with the press to prevent damaging the components. Before fitting the sliding flange (3) onto the fixed flange (1), it is important to fit the spacing washer (2). REPAIR MANUAL REGULATOR ASSEMBLY Fitting the sliding flange onto the fixed flange shaft Ensure you properly centre the spacing washers (5-6 and 7) on the shaft upon assembly. Fitting the cover and centrifugal blocks Fit the three blocks as shown in the illustration. Tightening the pulley To tighten the pulley, use a torque wrench with a 30 mm socket. Apply a tightening torque of 95 to 108 Newton metre. 3 REPAIR MANUAL REGULATOR ASSEMBLY 3 Led pulley 1. Fixed flange 2. Sliding flask 3. Cam pad 4. Spring 5. Key 6. Cam 7. Retaining washer Removing the led pulley Please note that the spring position must be observed carefully in the sliding flange and cam. When refitting the pulley, the positions must be the same as upon removal to avoid impacting the performance of the pulley. REPAIR MANUAL REGULATOR ASSEMBLY 3 Removing the cam Using the 0MDP17 removing tool is indispensable to avoid sudden removal of the sliding flange (spring effect). Adjust the locking screw to prevent the pulley from turning. Lower the cam (3 to 4 mm maximum) to release the retaining washer. Remove the retaining ring using appropriate pliers. REPAIR MANUAL REGULATOR ASSEMBLY 3 Carefully refit the cam to release the shaft. Inspection  Cam deterioration.  Spring deterioration.  Visual inspection of the components. Removing the sliding flask The cam sliders can be removed using a flat blade screwdriver. Inspection  Changing the cam sliders (3) is required following the wearing of half the initial thickness X.  Wear of the flange (by belt friction)  Wear of inner bushings of the flange (Parts non replaceable without damaging the flange) Cleaning the inner bushings with a degreaser is indispensable to maintain optimum performance. REPAIR MANUAL REGULATOR ASSEMBLY 3 Fixed flange The fixed flange (1) is not removable without damaging the parts. Just perform an inspection. Inspection  Shaft deterioration (internal and external)  Wear of the flange (by belt friction)  Visual inspection. Refitting the led pulley Fitting the cam sliders on the sliding flask Fitting cam sliders (3) can be performed using a hammer. Ensure you do not damage the sliders by excessive use of the hammer. Fitting the spring onto the sliding flange Position the spring (4) in the sliding flange (2) at the position noted during removal. Position the key (5) on the shaft of the fixed flange (1). REPAIR MANUAL REGULATOR ASSEMBLY 3 Fitting the cam Fitting the cam (6) is performed in the reverse sequence of removal.      Position the spring in the cam at the position noted upon removal. Engage the cam (6) onto the shaft of the fixed flange (1) and onto the key at the same time With the fixed flange (1) locked in rotation, turn the sliding flange (2) by one third (1/3) turn counter clockwise. Lower the cam (6) to engage it onto the cam sliders (3). Fit the retaining washer (7). REPAIR MANUAL FRONT AXLE INDEX Front axle adjustment dimensions .................................................................................. 2 4 REPAIR MANUAL FRONT AXLE 4 Front axle adjustment dimensions City a=0° , -0,5° Crossline a=0° , -0,5° City b=-0,5° +/-1° Crossline b=-0,5° +/-1° City c=5,8° +/-1° Crossline c=5,8° +/-1° REPAIR MANUAL REAR AXLE INDEX Rear axle adjustment dimensions................................................................................... 2 5 REPAIR MANUAL REAR AXLE Rear axle adjustment dimensions City a=0° , +0,5° Crossline a=0° , +0,5° City b=0° , +0,5° , -1° Crossline b=0° , +0,5° , -1° 5 REPAIR MANUAL WHEELS-BRAKE 6 INDEX      Tire pressure........................................................................................................ 2 Renewing brake fluid ........................................................................................... 3 Brakes.................................................................................................................. 4, 5 Hand brake .......................................................................................................... 6 Summary of aluminum wheels 2008 .................................................................... 7 REPAIR MANUAL 6 WHEELS-BRAKE Tires 145 /70 R13 155 /65 R14 AIXAM CITY CROSSLINE L6e CROSSLINE L7e 1,6 1,6 1,6 1,6 1,6 1,6 REPAIR MANUAL WHEELS-BRAKE Brake fluid 6 REPAIR MANUAL WHEELS-BRAKE Brakes Brakes The braking system is of the hydraulic non powered type. The circuit is in X. This means the front right wheel circuit is the same as the rear left wheel. This type of circuit ensures optimum safety in case of failure. Service brake The system is composed of:  Master cylinder  Piping  Rear braking pressure corrector  Calliper  Drum brake Tandem master cylinder: 1. Body 2. Pressure chamber 3. Outlet to circuits 4. Fluid tank 5. Thrust rod 6. Intermediate piston 7. Central valve 8. Central valve stop 9. Intermediate cup 10. Main cup 11. Compensation hole 6 REPAIR MANUAL 6 WHEELS-BRAKE Rear braking pressure corrector: The corrector is divided into two separate parts to ensure the braking circuit is safe. The latter is designed to restrict braking pressure to 18 bars maximum. RR pressure (b) 1 : Body of the limiter 2 : Cap of the limiter 3 : Copper gasket 4 : Main gasket 5 : Piston 6 : Secondary gasket 7 : Rating spring RR pressure FR pressure (b) REPAIR MANUAL WHEELS-BRAKE Hand brake 6 REPAIR MANUAL WHEELS-BRAKE 6 Summary for aluminium wheels 2010 Reference Static load DIAL 14'' MONTUPET 14'' 4.5Jx14''ET17 6AG080 200 kg 4.5Jx14ET17 6AA080 300 kg Vehicle CITY SL CROSSLINE VSP SL CROSSLINE TQM SL X X X WE DRAW YOUR ATTENTION TO THE FACT THAT THE «6AG080» WHEEL CANNOT BE FITTED ON THE CROSSLINE VSP AND TQM BECAUSE OF THE STATIC LOAD INDEX. REPAIR MANUAL BODY 7 INDEX        Front frame dimensions CITY ........................................................................... 2 Aluminum cell dimensions CITY ....................................................................... 3 to 5 Front frame dimensions CROSSLINE ............................................................... 10 Aluminum cell dimensions CROSSLINE ........................................................... 11 to 13 Aluminium cell dimensions COUPE .................................................................. 11 to 13 Body maintenance ............................................................................................ 18 Gluing................................................................................................................ 19 REPAIR MANUAL BODY Front frame dimensions CITY 7 REPAIR MANUAL BODY Aluminium cell dimensions CITY A B C D CITY +/- mm 1492 2 1561,2 2 1225 2 1510,6 2 7 REPAIR MANUAL BODY Aluminium cell dimensions CITY E F G H I J K CITY +/- mm 1178,8 2 1383,3 2 946 2 1147 2 631,3 2 425 2 1185 2 7 REPAIR MANUAL BODY Aluminium cell dimensions CITY L M N O CITY +/- mm 1257 2 1371,3 2 615 2 1179 2 7 REPAIR MANUAL BODY Front frame dimensions CROSSLINE 7 REPAIR MANUAL BODY Aluminium cell dimensions CROSSLINE A B C D CROSSLINE +/- mm 1492 2 1561,2 2 1225 2 1510,6 2 7 REPAIR MANUAL BODY Aluminium cell dimensions CROSSLINE E F G H I J K CROSSLINE +/- mm 1178,8 2 1383,3 2 946 2 1352 2 696,3 2 425 2 1281 2 7 REPAIR MANUAL BODY Aluminium cell dimensions CROSSLINE L M N O CROSSLINE +/- mm 1331,3 2 1371,3 2 615 2 1179 2 7 REPAIR MANUAL BODY Aluminium cell dimensions COUPE 7 REPAIR MANUAL BODY Aluminium cell dimensions COUPE 7 REPAIR MANUAL BODY Aluminium cell dimensions COUPE 7 REPAIR MANUAL BODY Bodywork servicing 7 REPAIR MANUAL BODY Gluing 7 REPAIR MANUAL 7 BODY Frame tailgate 7AR080 mounting process Materials needed: Tools Components 1 glue gun 7AR460 1 City TAILGATE DOOR INNER PANEL Primer machine 7K102A 2 UPPER JOINT HEAD 1 riveting machine 4 Rivets 4,8X16 2 nitrile washers 7AG358: BODY GLUING KIT 7AG359: WINDSHIELD GLUING KIT Step 1: preparation of the parts to be glued Sand the part and clean it with degreasing agent on the area that will receive the primer. Then immediately apply the primer on the frame. Alu primer Apply the primer on the side of the joint attachment screw and on the faces in contact with the liner and the window. Apply the primer on the liner. Left side Plastic primer Right side REPAIR MANUAL BODY Step 2: Gluing elements Apply glue to the liner and to the aluminum frame being careful not to spill over the primer 7K358 Glue Step 3: Setting up the frame Set the armature in the liner making sure that the elements are in contact at the gluing points. 7 REPAIR MANUAL BODY Rivet the tailgate hook with the frame Step 4: Assemble joints head 7K102A Apply glue on the frame for gluing the tailgate glass Windshield glue Rivet the frame adding a washer nitrile with lining at the joints 7 REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 INDEX        Instrument cluster ............................................................................................. 2 to 20 Fuses ................................................................................................................ 21 Centralised locking ............................................................................................ 22 Guarantee of the CLARION radio unit............................................................... 23 to 26 Changing a lamp ............................................................................................... 27, 28 Electric diagrams .............................................................................................. 29 to 33 Electric schematic per function ......................................................................... 34 REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Instrument cluster INDEX                      Tachometer................................................................................................................3 Odometer and trip master ..........................................................................................3 Changing kilometres to MILES ..................................................................................4 Fuel level indicator .....................................................................................................4 Clock ..........................................................................................................................4 Maintenance indicator ................................................................................................5 to 7 Outside temperature indication ..................................................................................7 AGB indication ..........................................................................................................8 Brightness adjustment function ..................................................................................8 Indicators and warning lights function ........................................................................9 Automatic warning lights function ..............................................................................10 DIESEL engine preheating function ...........................................................................11 Controlling interior lighting .........................................................................................12 Defrosting function .....................................................................................................13 Engine stop function ..................................................................................................13 Lights forgotten function.............................................................................................13 Buzzer function ..........................................................................................................13 Lamps ........................................................................................................................14 Serigraphy on each model .........................................................................................15, 16 Description of input and output connectors and signals .............................................17 to 18 Summary of the different models ...............................................................................19 REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Tachometer: - Analog display with needle and stepper motor. Pulse sensor of the Hall type (by COMEX), assembled on the intermediate shaft of the reducing gearbox, with 8 pulses per shaft revolution. The pulse sensor is supplied by the dashboard. If the dashboard receives no pulse for 1 second, the needle returns to the indication 0. If the pulse frequency is excessive, the needle maintains a maximum indication. It the car is reversing, the speed indicated is 0 km/h. Odometer and tripmaster: - Pulse sensor of the Hall type. Same sensor as that used by the tachometer. Odometer with 6 digits and maximum display of 999,999 km or miles. When it reaches 999,999, it is blocked. The odometer value displayed is preceded with the non-used zeroes, e.g. 000234. Tripmaster with 4 digits, 3 plus 1 decimal place. Maximum value 999.9 km or miles. The tripmaster value is not preceded with zeroes, e.g. 31.2 km. When the tripmaster reaches 999.9 km or miles, it returns to 0. The work unit km or miles is displayed next to the odometer value. The odometer and tripmaster are saved when the ignition is cut to preserve the EEPROM. Memorization is guaranteed in case of sudden battery cut. Display on LCD cluster 1: - The odometer and tripmaster are displayed on the left-hand LCD. - Selection between the odometer and tripmaster is performed by a short press (<3 sec.) on the left-hand button. - Resetting the tripmaster is performed only when it is displayed, by a long press (>3 sec.) on the left-hand button. Display on LCD cluster 2: - The general odometer is displayed on the right-hand LCD. - The tripmaster is displayed on the left-hand LCD. Resetting the tripmaster is performed by a long press (>3 sec.) on the left-hand button. REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Changing from km to miles or vice-versa: With the left button pressed, and then turn the ignition on. The dashboard changes from km to miles or vice-versa. Fuel level indicator and reserve indicator: - LCD bar-graph display. 6 bars + fuel pump symbol. - When 1 bar remains lit, the bar flashes (2 Hz) and the reserve indicator lights up. - When a circuit is open, all bars are lit, one after the other in a cycle, at a frequency of 2 Hz. Clock: - The clock function is still present. The dashboard maintains maintenance counting by time. - The clock is displayed on the right-hand LCD. - The clock can be of two types, 12 hours (am-pm) or 24 hours. If the work unit is km, then the clock works with the 24 hour style. If the work unit is miles, then the clock works with the 12 hour style (am-pm). - The two points between the hours and minutes are fixed. - Clock precision: ±1 second per day. - The clock maintains time counting for maintenance (1 year). - After connecting the battery, the clock displays 12 :00, am – pm if the dashboard is in miles. Setting the clock: - Setting the clock is possible only when the vehicle is stopped. - If the clock is being set with the vehicle running, the setting is cancelled. - To enter the hour setting, hold the right-hand button pressed (>3 seconds): the hours flash. - Set the hours by short pressing on the right-hand button. - Hold the right-hand button pressed (>3 seconds) to enter the tens of minutes setting: the tens of minutes flash. - Set the tens of minutes by short pressing on the right-hand button. - Hold the right-hand button pressed (>3 seconds) to enter the minutes setting: the minutes flash. - Set the minutes by short pressing on the right-hand button. - Exit the setting mode by long pressing on the right-hand button (>3 seconds). REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Maintenance indicator function: Maintenance indication can be performed in two ways, per mileage or per time. Maintenance calibration for all models: - 1st maintenance: 1000 km (621 mi) or 1 year. - 2nd and subsequent maintenance: Every 5000 km (3107 mi) or 1 year. Days counter for maintenance per time: The time counter is activated after the first 10 km. Viewing the maintenance state: After ignition, the maintenance symbol (key) appears for 5 seconds on the left-hand display. Viewing the mileage has priority over viewing the time remaining. If the mileage exceeds 200 km before maintenance, the LCD displays the mileage remaining + the « key » symbol for 5 seconds. If the mileage is less than 200 km before maintenance, the LCD displays the mileage remaining flashing + the « key » symbol for 5 seconds. If the total mileage before maintenance has been exceeded, the LCD displays the mileage in negative flashing + the « key » symbol for 5 seconds. If the mileage remaining before maintenance exceeds 200 km and the time remaining is less than 20 days, the LCD displays the number of days flashing + the « key » symbol + the « 1 year » symbol for 5 seconds. REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 If the total time (days) before maintenance has been exceeded, the LCD displays the mileage in negative flashing + the « key » symbol and « 1 year » for 5 seconds. If the mileage for maintenance is exceeded, the LCD displays the « key » symbol on the left-hand display, permanently. If the time before maintenance is exceeded, the LCD displays the « key » + the "1 year" symbol on the left-hand display, permanently. Additional function: After ignition, to see the time remaining before the next maintenance, press the two buttons on the display simultaneously. REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Maintenance «Reset»: Maintenance can be reset at any time, except when the maintenance mileage or time has been exceeded. To perform a reset: Turn the ignition and wait for the dashboard to be in normal operation (do not exceed 15 sec.) Right after, hold the two buttons pressed (right and left) for 6 seconds. The « rESEt » message appears on the left-hand display. Outside temperature indication function: The outside temperature operates from a resistive sensor (CTN) with a nominal resistor R25 = 5K ±1% and a constant B25/50 = 3470K ±1%. Displaying the outside temperature is possible only on models with two LCD. It appears in the right-hand LCD. The display unit is always degrees Celsius (ºC). The display on the right-hand LCD has the negative sign + 2 digits + the ºC symbol. Display accuracy is ±1ºC. Warning when outer lower temperature below +3ºC. In this condition, the display flashes. If the sensor is not connected (circuit open) or if the sensor is in short-circuit, there is no display. REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 AGB indication function: This function determines whether the car is in reverse « R », forward « D », neutral « N ». The display is made on the left-hand LCD. Brightness setting function: There are two backlighting modes: day mode and night mode. Day mode: - The car has its lights off. Only the LCD is lit. In this mode, no setting is possible and light intensity is set to maximum. Night mode: - The car has its lights on. The LCD and tachometer are lit. This mode allows to select 8 levels of light brightness. Light intensity setting: By a short press on the right-hand button. Intensity increases by one step whenever the button is pressed and, after the eighth time, it loops back to the lowest intensity. This setting is possible only if the clock setting is not activated. Protection function: If battery voltage exceeds 16 Volts, the lighting switches off and is restored when the voltage drops below 15.7 Volts. REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Indicators and warning lights function: Right indicator: two 21W lamps + 1 5W lamp, with detection of one or two burnt 21W lamps. The indicator is accompanied with a beep. Left indicator: two 21W lamps + 1 5W lamp, with detection of one or two burnt 21W lamps. The indicator is accompanied with a beep. Warning lights: four 21W lamps + two 5W lamps without burnt lamp detection, plus a beep The dashboard lamp flashes with the warning lights. Indicator in normal operation: - 100 strokes per minute with a 50% cyclic ratio. 300 ms on and 300 ms off. The dashboard lamp flashes with the indicator. - When the indicator is lit, a beep is emitted with a frequency of 2857 Hz and lasting 7 ms. TICK sound simulation. - When the indicator switches off, a beep is emitted with a frequency of 2,581 Hz and lasting 4 ms. TACK sound simulation. Indicator in burnt lamp operating mode: - 200 strokes per minute with a 50% cyclic ratio. 150 ms on and 150 ms off. The dashboard lamp flashes with the indicator. - When the indicator is lit, a beep is emitted with a frequency of 2857 Hz and lasting 7 ms. TICK sound simulation. - When the indicator switches off, a beep is emitted with a frequency of 2,581 Hz and lasting 4 ms. TACK sound simulation. Warning lights: - 100 strokes per minute with a 50% cyclic ratio. 300 ms on and 300 ms off. The dashboard lamp flashes with the three dashboard lamps: right indicator, left indicator and warning. - When the warning is lit, a beep is emitted with a frequency of 2857 Hz and lasting 7 ms. TICK sound simulation. When the warning switches off, a beep is emitted with a frequency of 2,581 Hz and lasting 4 ms. TACK sound simulation. REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Automatic warning lights activation function: This function controls the warning lights automatically according to sudden speed variations. This function can be activated or inhibited using the buttons on the dashboard: To change the state of this function, ON-OFF or OFF-ON:   Turn the ignition on and wait for the dashboard to switch to normal operation. Then, hold the right-hand button pressed for 10 seconds. The message « A On » or « A OFF » is displayed in the left-hand LCD. This message means the automatic warning lights function is activated. This message means the automatic warning lights function is inhibited. REPAIR MANUAL 8 ELECTRICITY-INSTRUMENTS Diesel engine preheating function: The temperature sensor sends the signal to the thermostat unit. Whenever the ignition is activated, the preheating relay and preheating lamp are controlled as per the following calibration tables: Open-circuit Short-circuit Témpérature moteur Temporisation témoin Temporisation bougies Engine temperature Ohms Lamp timeout (Seconds) Plug timeout (Seconds) Ohms ºC (Secondes) (Secondes) °C "----" 9900 10 16 -30 9052 39 46 -20 4651 22 29 -10 2865 15 22 0 1600 10 16 10 1044 7 12 20 646,9 5 8 30 419,8 3 6 40 300 2 4 "----" 100 10 16 IfSiRR>>990 9900 Si 9800 > R > 9052 Si 9052 > R > 4651 Si 4651 > R > 2865 Si 2865 > R > 1600 Si 1600 > R > 1044 Si 1044 > R > 646 Si 646 > R > 419 Si 419 > R > 300 Si R < 100 If the dashboard detects an open circuit or short-circuit, it takes the default value of 10 seconds for the lamp and 16 seconds for the glow plugs. This function can be activated or inhibited using the buttons on the dashboard: (only on 8AJ033A models) To change the state of this function, ON-OFF or OFF-ON: Turn the ignition on and wait for the dashboard to switch to normal operation. Then, hold the left-hand button pressed for 10 seconds. The message « d On » or « d OFF » is displayed in the left-hand LCD. This message means the diesel preheating function is activated. This message means the diesel preheating function is inhibited. REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Interior lighting control function (dome light): This function is available only on models with 2 LCD: 8AJ033, 8AJ033A, 8AG033A, 8AG033B and 8ME033B. This function controls interior lighting (on 5W lamp) Switching on and off is progressive. This function can be controlled differently: State no.1: If the dome light is off with the door closed. When the door is opened: - The dome light lights up progressively over 5 seconds. - It switches off after 30 seconds. State no.2: State no.1 + ignition: - Progressive extinction of the dome light over 5 seconds, with the door open. State no.3: State no.1 + door closed: - The dome light switches off after 10 seconds. State no.4: State no.2 + door open: - The dome light lights up progressively over 5 seconds. - It switches off after 30 seconds. State no.5: State no.3 + ignition: - Progressive extinction of the dome light over 5 seconds, with the door closed. This function can be activated or inhibited using the buttons on the dashboard: To change the state of this function, ON-OFF or OFF-ON: hold the right-hand button pressed and then, turn ignition on. The message « P On » or « P OFF » is displayed in the left-hand LCD. This message means the dome light control function is activated. This message means the dome light control function is inhibited. Protection function: The dome light lamp is protected. If battery voltage exceeds 16 Volts, the function is inhibited, and is restored when the voltage drops below 15.7 Volts. REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Defrosting control function: This function is available only on models with 2 LCD: 8AJ033, 8AJ033A, 8AG033A, 8AG033B and 8ME033B. Operates by short presses (pulses) on the defrosting control. Ignition on and pulse on the defrosting command: control of the defrosting relay starts for 12 minutes (720 seconds) with the associated lamp lit, except for the electric model which has a timeout of 4 minutes (240 seconds). If an additional pulse is produced or if ignition is switched off, control is cancelled and the lamp switches off. Protection function: The defrosting output is protected. If battery voltage exceeds 16 Volts, the function is inhibited, and is restored when the voltage drops below 15.7 Volts. Engine off control: When the ignition is off, the dashboard activates the engine off relay for 8 seconds. Then the dashboard "falls asleep". The engine off relay is controlled by ignition off. Lights on alarm: If ignition is off, the car lights are lit: when opening the door the dashboard emits a signal at a frequency of 2581 Hz. This sound signal overrides the warning lights beep. Buzzer function: See indicator function page 9 See warning light function page 10 Protection function: The buzzer is inhibited if the battery voltage exceeds 16 Volts. It is restored when the voltage drops below 15.7 Volts. REPAIR MANUAL 8 ELECTRICITY-INSTRUMENTS Lamp: LEFT INDICATOR (Green) RIGHT INDICATOR (Green) BRAKING (Red) HIGH BEAM (Blue) BATTERY CHARGE (Red) RESERVE (Yellow) NEUTRAL (Green) BRAKE PADS (Yellow) LOW BEAM (Green) DEFROSTING (Yellow) WARNING LIGHTS (Red) INJECTION FAILURE (Yellow) OIL TEMPERATURE (Red) DIESEL PREHEATING (Yellow) FRONT FOG LIGHT (Green) FREE WATER TEMPERATURE (Red) REAR FOG LIGHT (Yellow) Indicators not activated: - Injection failure (Yellow) - Front fog (Green) - Free Indicators for models 8AJ033, 8AJ033A, 8AG033A, 8AG033B and 8ME033B: - Left indicator (Green) Brake pads (Yellow) - Battery charge (Red) Oil temperature (Red) - Fuel reserve (Yellow) Defrosting (Yellow) - Neutral (Green) Diesel preheating (Yellow) - Warning lights (Red) High beam (Blue) - Water temperature (Red) Braking (Red) - Rear fog (Yellow) Right indicator (Green) - Low beam (Green) Indicators for models 8AG033, 8MD033CA and 8MD033BA: - Left indicator (Green) Brake pads - Battery charge (Red) Oil temperature - Fuel reserve (Yellow) - Neutral (Green) Diesel preheating - Warning lights (Red) High beam (Blue) - Water temperature (Red) Braking - Rear fog (Yellow) Right indicator - Low beam (Green) (Yellow) (Red) (Yellow) (Red) (Green) REPAIR MANUAL ELECTRICITY-INSTRUMENTS Serigraphy on each model: Models 8AG033 (single LCD) Model 8AG033A 8 REPAIR MANUAL ELECTRICITY-INSTRUMENTS Model 8AG033B Model 8AJ033 and 8AJ033A 8 REPAIR MANUAL ELECTRICITY-INSTRUMENTS Description of input and output connectors and signals: There are three connectors, J1, J2 and J3. J1 30-pin connector: MOLEX connector Or FRAMATOME connector PIN-1: Free PIN-2: NEUTRAL input (see AGB function) PIN-3: ENGINE TEMPERATURE CTN gauge input (Diesel preheating) PIN-4: FUEL gauge input PIN-5: WARNING switch input (Activated by ground connection) PIN-6: POSITION LIGHTS input (Activated by connection to positive) PIN-7: Positive input of the KEY PIN-8: DEFROSTING switch input (Activated by ground connection) PIN-9: LEFT INDICATOR input (Activated by ground connection) PIN-10: Ground (-) for SPEED SENSOR PIN-11: Free – Not used on this model PIN-12: REAR FOG input (Activated by connection to positive) PIN-13: LOW BEAM input (Activated by connection to positive) PIN-14: HIGH BEAM input (Activated by connection to positive) PIN-15: BRAKING input (Activated by ground connection) PIN-16: Free PIN-17: OIL TEMPERATURE input (Activated by ground connection) PIN-18: AGB_REVERSE input (see AGB function) PIN-19: Do not use – Do not connect cable – Private use of FACOMSA PIN-20: RIGHT INDICATOR input (Activated by ground connection) PIN-21: SPEED SENSOR pulse input (Input of open manifold type) PIN-22: Ground (-) for OUTSIDE TEMPERATURE CTN gauge PIN-23: Supply (+) for SPEED SENSOR. PIN-24: Free PIN-25: BATTERY CHARGE input (Activated by ground connection) PIN-26: Input (+) OUTSIDE TEMPERATURE CTN gauge PIN-27: Ground (-) for FUEL gauge PIN-28: DOOR input (Activated by ground connection) PIN-29: BRAKE PADS input (Activated by ground connection) PIN-30: Free – Not used on this model 8 REPAIR MANUAL ELECTRICITY-INSTRUMENTS J2 15-pin connector: MOLEX connector Or FRAMATOME connector PIN-1: GROUND (GND) PIN-2: GROUND (GND) PIN-3: BATTERY POSITIVE (+12V) PIN-4: BATTERY POSITIVE (+12V) PIN-5: LEFT INDICATOR output PIN-6: LEFT INDICATOR output PIN-7: RIGHT INDICATOR output PIN-8: RIGHT INDICATOR output PIN-9: DOME LIGHT control output PIN-10: DOME LIGHT control output PIN-11: DEFROSTING RELAY output PIN-12: DIESEL PREHEATING RELAY output PIN-13: ENGINE STOP RELAY output PIN-14: WATER TEMPERATURE Input (Activated by ground connection) PIN-15: Free J3 8-pin connector: Do not use this connector. 8 REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Summary of the different models: Reference Box Designation Marking on cluster Marking on Scale tachometer Electronics non mounted Right LCD Dome light control 80 km/h & AM8KM07A Defrosting control 50 mph Front fog light lamp Injection failure lamp 8AG033 model 1 VSP AIXAM MEGA 80km/h+mi BG Make: FACOMSA 1/12 400D AIXAM Pack Type: LCD 1 Diesel engine 8AG033A model 2 VSP AIXAM 80km/h HG Make: FACOMSA 1/12 400D AIXAM Luxe- Type: LCD 2 SL Diesel engine AM8K07A 80 km/h Front fog light lamp Injection failure lamp 8AG033B model 3 VSP AIXAM 80km/h HG 1/12 400D AIXAM Sport+R Diesel engine AM8K07A 80 km/h Front fog light lamp Injection failure lamp 8AJ033A model 4 1/8 TQM AIXAM 120km/h +mini HG Make: FACOMSA AIXAM 600D + 523 Type: LCD 2 MPI gasoline Lamps present on all models:                Make: FACOMSA Type: LCD 2 Right indicator Left indicator High beam Low beam Water temperature Braking Battery charge Reserve Neutral Brake pad Oil temperature Defrosting (top range) Warning Rear fog Diesel preheating AM12KM07A 120 km/h Front fog light lamp & 70 mph Injection failure lamp REPAIR MANUAL 8 ELECTRICITY-INSTRUMENTS FUSES FUSES BOXE Spare Spare Spare Spare Spare Spare ALLOCATION OF THE FUSES: position Calibre Color Allocation F1 NA NA Non allocated F2 25A WHITE Centralised locking – power windows system F3 F4 20A 20A YELLOW Rear window defrosting YELLOW Engine stop F5 15A BLUE Horn – car radio – cigarette lighter F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 15A 15A 15A 10A 2A 25A NA 20A 15A 3A 15A 20A 7.5A 3A 3A BLUE High beam BLUE Low beam BLUE Position lights – rear fog lights RED Warning lights – control panel GREY Dome light WHITE Power windows NA Non allocated YELLOW Front wiper/washer BLUE Cab fan BLUE Daylight road lights (DRL) PINK Reversing radar – reversing light YELLOW Glow plug supply BROWN Stop lights PINK Alternator – preheating relay PINK Control panel – centralised locking – defrosting relay RELAY ALLOCATION: Position C14 C15 C16 C17 Allocation Starting safety relay Preheating relay Engine stop relay Rear window defrosting relay CAUTION: When you change a fuse, always use the same amperage (risk of fire) REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 CENTRALIZED LOCKING CONNECTION 1. 2. 3. 4. 5. 6. 7. +12V locking output +12V power supply input Ground input +12V unlocking output +12V after-contact input +12V indicator output +12V indicator 2 output USING A REMOTE CONTROL BUTTON 1 LOCKING: Press this button once: the doors are locked, the indicators flash once. BUTTON 1 BUTTON 2 DOOR UNLOCKING: 1 short pulse (< 1.5 s), the doors are unlocked, the indicators flash twice. BUTTON 2 Ref: 8AG101 REMOTE CONTROL PROGRAMMING TABLE Please apply the procedure below to enter the programming mode: • A • Insert the key into the Neiman • B • Turn the key 5 times from the OFF position to the Contact (Ignition) position. Switching from OFF to contact must be performed in less than 3 s. At the last key turn, stay in the Contact position for 3 s. • C • The indicators will then be lit for 2 s.: programming a remote control Please refer to the table below to program a remote control: N Number Programmabl of key e function turns 5 Coding a remote control After the N key turns, the indicators flash: 3 TIMES 1• 2• 3• 4• 5• After the 5th key turn (key on ACC) the indicators are lit steady for 2 s. Before 10 s., press the remote control you wish to code on the vehicle. The indicators flash twice to validate this new remote control. Restart the operation for the other remote controls before 10 s. After 10 s. (or key set to OFF), you quit the programming mode, the indicators flash 3 times. REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 GUARANTEE OF «CLARION» RADIO UNITS We inform you that due to a new Clarion Policy, the warranty procedure for the car radio (8AA060A) has been modified. Warning, this new warranty procedure concerns the car radio only (the multimedia station is still covered with the procedure you will find in Appendix below down this page) As from now on, in the case a car radio is defective, we kindly ask you to proceed like for any other standard warranty claim. - You perform the diagnosis and confirm the defect - If the defect requires replacement, then you order the part to AIXAM MEGA aftersales (part # 8AA060A) - You replace the part and then submit the warranty claim on the website and indicate in the comment zone your diagnosis. Warning: do not throw the car radio away as it is subject to part return REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Form PRIOR EXCHANGE OR RETURN REQUEST FORM FOR PREPARATION OF A PRODUCT (UNDER & OUT OF GUARANTEE) Please return to Clarion France by fax at: (0033) (0)3 83 49 57 24 PRIOR EXCHANGE RETURN FOR REPAIR 1. Information on requester Point of sales Contact Fax No. Phone no. Email address (if exists) Exact address Town Postal code 2. Information on client (end consumer) Name Address Town Postal code 3. Information on product Exact reference Serial no. (14 characters) Date of 1st registration Antitheft code (if exists) Fitted by private individual reseller REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Form 4. Conditions of occurrence of the problem Description Status Frequency Engine condition Other Failure upon unpacking Under guarantee Out of guarantee Intermittent Permanent Running Stopped On certain radio stations Upon connecting When starting the vehicle Vehicle electronic consumption 5. Information on the vehicle Make Model IMPORTANT: All the fields appearing in bold characters must be filled for the prior exchange request to be validated by our services. Nevertheless, we also prompt you to fill in the optional fields (non bold characters) in order to provide us with maximum information, allowing us to improve our service constantly. In addition, we draw your attention to the fact that entering your email address allows virtually instant issuance of the exchange approval. I the undersigned certify having read the terms of prior exchange of Clarion products and commit hereby to pay the invoice issued by Clarion France (invoicing in usual condition plus a penalty of 48€) in case of non return of the faulty product within 10 days after receiving the product overhauled or excluded from the guarantee (invoicing within 45 days) due to improper installation, abnormal use or non compliant maintenance by the end consumer. Date: Signature and company stamp Fax Clarion France After-sales: (0033) (0)3 83 49 57 24 REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 SUMMARY OF THE PROCEDURE APPLICABLE BEFORE EXCHANGING A PRODUCT (UNDER & OUT OF GUARANTEE). To offer a high quality service, please follow systematically the procedure below in the presence of a faulty Clarion product. 1 After having observed the symptom described by the consumer, fill in the appropriate form while ensuring all fields in bold characters are filled. 2 Send this duly filled form to the Clarion national operator (fax no. 00 33 3 83 49 57 24) or by Email: [email protected] 3 If your request is accepted, you then receive in the shortest times a form with the authorization no., as well as the details related to the product exchange (reference, serial no.…) 4 You receive within 48 H an overhauled product, with the same reference, packaged in a specific packing. 5. You repackage the faulty product in this specific package while sticking the pre-printed label supplied onto the said package (shipping costs paid by Clarion). CAUTION: when sending several products, the authorization no. must match the product concerned. Also, the product must always be returned bare, without accessory. 6. From then, you are given 10 days to return the faulty product under guarantee. This shipping is performed thanks to the shipping bill you received with the exchanged product. A phone number will allow you to call the carrier to organize collection of the said product. Reshipping the faulty product must be performed within a maximum time of 10 days, otherwise, the product will be billed to you in the following conditions:  Product returned out of time: billing with 60% discount in respect of usual conditions (by credit note) plus 48 € penalties.  Product not returned: billing in usual conditions plus 48 € penalty. Period and coverage of the guarantee Products distributed by Clarion Europe S.A.S are covered by a legal two-year guarantee on parts and labour applicable from the date of purchase by the end user for all products sold after 1 January 2002. Products marketed and installed in pre-equipment by AIXAM in the vehicles of its make are covered by this same guarantee for a time of three years. The application of this legal st guarantee will be effective only in the presence of the date of 1 registration. Therefore, this date must always be filled upon the exchange request. This legal guarantee excludes products damaged following improper installation, abnormal use or maintenance not conforming with the instructions of use supplied by Clarion Europe S.A.S (e.g. products faulty following improper connection, intervention by a non-approved technician) Return for repair To provide a high quality consumer service, Clarion Europe S.A.S reserves the right to resort to a product return for repair when various conditions do not allow prior exchange within the lead time allocated. The point of sales is then informed of this situation in the shortest possible times and may in no event dispute this decision. All included costs for exchanging products out of guarantee. Preliminary exchange also applies to products out of guarantee within the limit of the stocks available and in all inclusive conditions available upon your request. The lump sum – variable according to the type of device – includes the return shipping costs. Established in: For AIXAM, on: REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 CHANGING A LAMP Changing a lamp on a light Old model New model 1. Position light lamp - Swivel the lamp holder by a quarter turn to the left and pull it out. - Remove the lamp by pulling to change it. - Refit the lamp holder while ensuring the locating pins (one large, one small) is opposite the corresponding notches on the back of the projector. - Turn it by a quarter turn to the right while pressing it to push the seal. 2. Low beam, high beam lamp - Remove the headlight cover. To unlock, press the upper clip and remove it. - Remove the sealing lens on the rear face of the headlight and pull on it to remove it from the lamp socket. - Press the lamp locking wire by sliding it to the right and lowering it. - Pull out the lamp. - Refit the new lamp while ensuring its spigots enter their housings (do not touch the glass part of the lamp with your fingers). - Fold its locking wire and press it by sliding it to the left. - Reposition the sealing lens onto the lamp socket. - Engage the lens on the rear face of the headlight. - CAUTION: do not omit the two previous operations, otherwise water may enter the headlight and damage it. - Engage the protection cover on the seal while ensuring the cut for passing the electric harness is vertical, otherwise the clip cannot be engaged and you may lose the cover. 3. Indicator light lamp - Swivel the lamp holder by a quarter turn to the left and pull it out. - Press the lamp by pivoting it to the left and pull it out. - Fit the new lamp onto the holder by aligning the spigots facing the cuts in the holder, press the latter while turning it to the right. - Refit the lamp holder onto the headlight while positioning its spigots (one large, one medium, one small) opposite the appropriate cuts in the headlight. - Press the lamp holder and turn it by a quarter turn to the right REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 Changing a lamp on a fog light - Remove the lamp holder by turning it to the left. The lamp is fully part of the holder. - Refit the lamp holder while ensuring the fastening spigots match those on the rear face of the headlight and turn it to the right. Changing a lamp on a rear light - Open the rear window - Push the custode lining away - Release the connector - Pull it out and change the lamp 1 2 3 1 1. Rear light and stop light lamp 2. Indicator light lamp 3. Backup light lamp 4. Rear fog light lamp 4 Changing the interior lighting lamp Unclip the interior lighting from the dome light to change the lamp. REPAIR MANUAL ELECTRICITY-INSTRUMENTS ELECTRIC DIAGRAMS Dashboard harness 8 REPAIR MANUAL ELECTRICITY-INSTRUMENTS Engine harness 8 REPAIR MANUAL ELECTRICITY-INSTRUMENTS 8 REPAIR MANUAL AIR CONDITIONING 8 Warning ! When working on air conditioning systems containing refrigerant and requires emptying or opening the circuit, the emptying or opening of the system, it is mandatory that the engineer is qualified and holds the relevant license and that the business premises has also achieved a "Certificate of compliance". It is prohibited to discharge refrigerant into the atmosphere. HOW TO OPERATE THE AIR CONDITIONING: a/ Fan speed controler b/ A/C commutator c/ Air recirculation speed CHARACTERISTICS: Type of Gas: R134A Gas Qty.: 400g Oil type: ZXL 200 PG Oil Qty.: Compressor coil resistance: 3.5 Ω Compressor belt tension: MAINTENANCE: Every 2 years check the charge of the gas. Every 4 years replace the Filter/Drier Main factors of risks: The loss of gas: The system is supposed to be tight, but to limit the risk of loss of air conditioning gas must rotate at least every 15 days (especially in winter, at least for 1/4 hours) to improve the flow of oil ( pending with the fluid) to lubricate the joints. The water problem: PAG oils are very hygroscopic, i.e. they have a strong tendency to absorb moisture from the air. The drier the moisture but retains its capacity is limited: 3 grams of water max. The circuit is supposed to be sealed and pressurized water can come from an insufficient degree of vacuum before the refrigerant charge REPAIR MANUAL AIR CONDITIONING SCHEMATIC AND COMPONENTS 1 2 3 4 5 Compressor 6 Thermal Expansion Valve (TXV) Condenser 7 Evaporator Filter/Drier 8 LP Service Port Pressure Switch 9 Passenger Compartment fan HP Service Port 10 Motor fan unit 11 Fan Shroud 16 Engine compartment 12 HP Liquid 13 LP Gas 14 HP Gas 17 Outside Air 18 Cooled Air 19 Dash Panel 15 Passenger 20 Outside or Compartment recycled air 8 COMPONENTS LOCALISATION : Passenger Compartment 1 Compressor - 2 Condenser - 3 Filter/ Drier Belt Adjustment Bolts and 15A Motor Fan Fuse 3 Filter/Drier – 4 Pressure Switch: Passenger compartment 7 Evaporator/Radiator - 6 TXV - 21 Evaporator probe: Evaporator/Radiator is one assembly. 6 TXV - 5 HP Service Port - 8 LP Service Port: The ports are behind the dashboard, passenger side. 20 Three Ways Flap Valve : OPERATION: The compressor increase the gas pressure from low (about 2 bars), to high pressure (about 7-15 bars), thereby the temperature of the gas increases. When the gas passes into the condenser, as it is warmer than outdoor air, it lost heat (J) and becomes liquid. The liquid passes into the bottle desiccant that the filter, removes moisture serves as a buffer reservoir. The high pressure liquid passes through the thermal expansion valve, its pressure and temperature fall quickly to reach about 2 bars and 0 ° C. In passing through the evaporator, the fluid picks up heat to the air entering the passenger compartment and vaporizes. The air entering the cabin is well cooled and dried by condensation of moisture it contained. The gas then goes back to the compressor inlet. For the compressor to engage requires that the driver presses the air-conditioning, the interior fan motor is at least on the first speed, the pressure switch gives a high pressure value between 2 and 29 bars and that the probe evaporator gives a temperature greater than 3 ° C. When the pressure switch detects a high pressure of at least 15 bar, it switch on the condenser cooling fan motor and stop it when the pressure drops to 12 bars. OPERATION CHECK-UP: Control that the compressor clutch sticks when air conditioning is turned on otherwise check the resistance of the coil and the power supply. If the pressure in the circuit is less than 2 bars, this means that lack of the gas in the installation thus the pressure switch cuts off power. DIRECTIONS: Try parking in the shade to reduce the need for air conditioning to help cool the interior. Open the windows, before engaging the air conditioning system, to remove the maximum amount of heat and then close them as soon as you switch the air conditioning on. In order to prevent sore throats do not aim the vents directly at the face. To ensure correct performance of the system is maintained, reduce refrigerant leaks and ensure the air conditioning system is well maintained, run the air conditioning system for at least 15 minutes each week regardless of external temperatures. REPAIR MANUAL ABS 8 Operating mode:  Role of ABS (Anti-lock Braking System):  Prevent blockages of any wheel to keep control of the vehicle whatever the external conditions are, either by limiting the braking pressure or reducing it if necessary.  Optimize braking distances by avoiding wheel lockup.  Role of the EBD (Electronic Brake-force Distribution):  Ensure the distribution between front/rear braking  Optimize the rear braking power in real time  If ABS light only is on: The ABS is deactivated as a major failure as occurred on the system:  EBD is still working so the vehicle will remain stable under braking  If ABS light and braking light are on at a time:  The ABS and EBD functions are deactivated as a major failure has occurred on the system.  The vehicle must be stopped as the stability of the vehicle is no longer guaranteed and the rear brakes will be in full capacity = risk of blockage. REPAIR MANUAL ABS 8 DTAM Diagnostic tool: Connection: Connect the diagnostic tool to the OBD socket of the vehicle, switch on the ignition key in the vehicle. Once contact is established, select the vehicle and the function you want to use. Identification: With the identification, you can control the version and the serial number of the ABS calculator mounted on the vehicle. REPAIR MANUAL ABS Display of the default codes: With this function, you can read the potential default codes listed on the calculator. Settings: The setting menu, gives you the speed measured on each of the wheels of the vehicle. 8 REPAIR MANUAL ABS 8 Bleeding the circuit with the DTAM tool: The bleeding of the ABS must be done with the DTAM tool, whenever the hydraulic unit is replaced. For other interventions, a standard bleeding will be sufficient. Deleting the defaults codes: Managing and deleting the default codes will help you resetting the calculator if needed. REPAIR MANUAL ABS 8 Save the data: Saving the data will help you retrieving the information from the calculator to the DTAM tool so that you can download them later on, on your computer. REPAIR MANUAL ABS 8 Diagnosis: Several problems may occur: Caution: the ABS sensors cannot be diagnosed with a standard ohmmeter, you must use the DTAM tool. -Faulty ABS sensor  replace the ABS sensor -Ring (annular gear) dirty or unsealed front wheel : place the vehicle on a lift and check the status (cleanliness/sealing) of the ring on the transmission. on a rear wheel : remove the drum and check any discrepancy -Electric problem within the beam, between the sensor and the master cylinder  check with the ohmmeter the continuity of the circuit between: - the sensor socket (to unplug) - The blue socket next to the master cylinder (make sure to connect to the correct wire) Need two persons to detect the origin of the failure, one to shake the harness at various points and the other one to detect potential failures of the harness with the ohmmeter. Check electric power supply: permanent +; after ignition+ and masses. Check the information displayed by the brake light switch, positive supply. REPAIR MANUAL ABS Wiring diagram: 8 REPAIR MANUAL ABS DESIGNATION MARK EP8 C18 C37 C38 C102 C103 C104 C105 C106 C107 C108 DESIGNATION Splice Number 8 Brake light switch Gray connector 30 channels instrument panel Red connector 16 channels instrument panel Rear left ABS sensor Rear right ABS sensor Front left ABS sensor Rear right ABS sensor Demultiplexer for ABS light activation on instrument panel EOBD diagnostic socket ABS unit connector Locating connector terminals of the ABS unit (C108) Fuse location (C40) 8 REPAIR MANUAL PAINT 9 INDEX  Body colors .......................................................................................................... 2, 3 REPAIR MANUAL PAINT Preparation of parts to be painted Recommendations of use of parts to be painted: Do not use solvent or diluent it would permanently damage the body part Step 1: Sanding: Lightly sand the item to paint with an abrasive nylon hand pad (1200) to improve the adherence and "break the surface of PMMA" Step 2: Smooth cleaning of the surface to paint: Use only isopropyl alcohol to clean the whole surface to be painted Step 3: Priming: Apply a primer coating adhesion layer preferably a special plastic hydro (sand if necessary) Step 4: Paint the element: Apply a layer of paint preferably hydro (base + varnish, or 2 layers lacquer) Paint line up to 80°C max. 9 REPAIR MANUAL 9 PAINT BODY COLORS AIXAM reference AKZO NOBEL SIKKENS reference DUPONT reference Page 132 SPIES HECKER STANDOX reference reference Navy blue A 507 Page 133 Page 134 Metal orange A 202 Page 135 Page 136 Page 137 Page 138 Metal black A 409 Page 139 Page 140 Page 141 Page 142 Pearl white A 408 Page 143 Page 144 Page 145 Page 146 Silver grey A 707 Page 147 Page 148 Page 149 Page 150 Steel grey A 708 Page 151 Page 152 Satin black (roof) A 411 Red M 306 Page 153 Pure white A 407 Page 154 Page 155 Page 156 Page 157 Aluminum structure black A 410 Page 158 Page 159 Page 160 Page 161 REPAIR MANUAL 9 PAINT NAVY BLUE A 507 DUPONT Color Owner AIXAM From/To Years Paint Code A507 Brand Panel # Color Name NAVY BLUE Lead Free Quality CROMAX CROMAX Color Variance Coat 2 COAT: BASECOAT Formulation Date S-M-P Ind P Quantity To Mix Ingredient 1.0LTR (100% Fill) Description 2010 - 2010 Y Oct 14, 2010 Display Units GRAMS Amount Accum. Amount 1640WB 1650WB LOW VISCOSITY BINDER HIGH VISCOSITY BINDER 493.9 164.6 493.9 658.5 1430W 1427W BLUE SHADE GREEN H.S. GREEN SHADE BLUE H.S. 97.7 76.4 756.2 832.6 1507W 1418W LILAC PEARL BRIGHTNESS ADJUSTER 68.8 57.9 901.4 959.3 1405W JET BLACK - BLUE SHADE 40.1 999.4 1541W VERY COARSE ALUMINUM 20.3 1019.7 REPAIR MANUAL 9 PAINT NAVY BLUE A 507 SPIES HECKER Color Owner AIXAM From/To Years 2010 - 2010 Paint Code A507 Brand Panel # 850338 Color Name BLEU MARINE Lead Free Y Quality 280 280 - PERMAHYD BASISLACK Color Variance Coat 2 COAT: BASECOAT Formulation Date S-M-P Ind P Code 858-SH 858-SH 858-SH 858-SH 858-SH 858-SH Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Oct 14, 2010 Display Units GRAMS Amount Accum. Amount WB854 LASURTIEFBLAU 334.2 334.2 WB803 SPEZIALSCHWARZ 253.5 587.7 WB815 LEUCHTSILBER 220.9 808.6 WB871 PERLROSA 154.1 962.7 WB800 EFFEKT 57.3 1020.0 WB856 DUNKELVIOLETT 7.3 1027.3 Language ALL Region Language EUROPE CZECH EUROPE DANISH EUROPE DUTCH EUROPE ENGLISH EUROPE ESTONIAN EUROPE FRENCH Region Text ODSTIN NENI PRESNE DOSAZITELNY KUN TIL HELLAKERING KLEUR NIET EXACT TE BEREIKEN APROXIMATE MATCH ONLY UELEVAERVIMISEKS AINULT FORMULE APPROCHANTE REPAIR MANUAL 9 PAINT NAVY BLUE A 507 STANDOX Color Owner AIXAM From/To Years 2010 - 2010 Paint Code A507 Brand Panel # 833850 Color Name BLEU MARINE Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance Coat 2 COAT: BASECOAT Formulation Date S-M-P Ind P Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Display Units GRAMS Amount Accum. Amount WB372 SPEZIALSCHWARZ 254.5 254.5 WB359 BLAU 335.6 590.1 WB331 ROT 154.7 744.8 WB398 BRILLANTSILBER 221.8 966.6 WB009 METALLIC-ADDITIV 57.5 1024.1 WB355 VIOLETT 7.3 1031.4 Language ALL Code 858-SX 858-SX 858-SX 858-SX 858-SX 858-SX Oct 14, 2010 Region EUROPE EUROPE EUROPE EUROPE EUROPE EUROPE Language CROATIAN CZECH DUTCH ENGLISH FINNISH FRENCH Region Text PRIBLIZNA RECEPTURA JEN VE VERZI S OBSAHEM PB - OZNACTE SYMB FORM. SLECHTS BIJ BENADERING BEREIKBAAR APPROXIMATE MATCH ONLY LYIYLLINEN: T-VAADITTU FORMULE APPROCHANTE REPAIR MANUAL 9 PAINT METAL ORANGE A 202 AKZO NOBEL SIKKENS SIKKENS reference AIX 202 Compositions Autowave MM Layer 1 361 744 527 568 Layer 2 959,3 962,6 980,6 1009,3 267 568 333PG 666 4 6 55,9 998,6 Autobase plus Layer 1 Q065 Q326 Q160 Q271 Q348 Layer 2 227,2 683,4 687,7 715,9 987,8 Q235 Q431 Q941M Q943M Q065 Q070 2,9 9,3 36,7 100,7 311 914,5 REPAIR MANUAL 9 PAINT METAL ORANGE A 202 DUPONT UNDERCOAT Color Owner AIXAM From/To Years Paint Code A202 Brand Panel # Color Name ORANGE Lead Free Quality CROMAX CROMAX Color Variance Coat 3 COAT - EUROPE: 3-COAT UNDERCOAT Formulation Date S-M-P Ind S Quantity To Mix 1.0LTR (100% Fill) Ingredient Description 2010 - 2010 Y Dec 04, 2009 Display Units GRAMS Amount Accum. Amount 1640WB LOW VISCOSITY BINDER 692.3 692.3 1650WB HIGH VISCOSITY BINDER 122.1 814.4 1445W TRANSPARENT YELLOW 147.2 961.6 1453W ORANGE 41.8 1003.4 1443W BRIGHT YELLOW 4.1 1007.5 1407W BLACK L.S. 3.8 1011.3 SHADE Color Owner AIXAM From/To Years Paint Code A202 Brand Panel # Color Name ORANGE Lead Free Quality CROMAX CROMAX Color Variance Coat 3 COAT - EUROPE: 3-COAT BASECOAT Formulation Date S-M-P Ind P Quantity To Mix 1.0LTR (100% Fill) Ingredient Description 2010 - 2010 Y Dec 04, 2009 Display Units GRAMS Amount Accum. Amount 1640WB LOW VISCOSITY BINDER 932.2 932.2 1650WB HIGH VISCOSITY BINDER 49.1 981.3 GOLD PEARL 20.5 1001.8 1505W REPAIR MANUAL 9 PAINT METAL ORANGE A 202 SPIES HECKER UNDERCOAT Color Owner AIXAM From/To Years 2010 - 2010 Paint Code A202 Brand Panel # 881136 Color Name ORANGE Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance Coat 3 COAT - EUROPE: 3-COAT UNDERCOAT Formulation Date S-M-P Ind S Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Nov 30, 2009 Display Units GRAMS Amount Accum. Amount WB379 ORANGE 521.4 521.4 WB380 GELB 284.7 806.1 WB370 WEISS 141.0 947.1 WB367 OXIDROT 99.6 1046.7 WB364 SCHWARZTONER 6.9 1053.6 SHADE Color Owner AIXAM From/To Years 2010 - 2010 Paint Code A202 Brand Panel # 881136 Color Name ORANGE Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance Coat 3 COAT - EUROPE: 3-COAT BASECOAT Formulation Date S-M-P Ind P Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Nov 30, 2009 Display Units GRAMS Amount Accum. Amount WB302 GELB 443.1 443.1 WB380 GELB 443.0 886.1 WB379 ORANGE 86.1 972.2 WB367 OXIDROT 37.5 1009.7 WB376 BRILLANTROT 29.8 1039.5 WB383 MARON 11.7 1051.2 REPAIR MANUAL 9 PAINT METAL ORANGE A 202 STANDOX UNDERCOAT Color Owner AIXAM From/To Years 2010 - 2010 Paint Code A202 Brand Panel # 881136 Color Name ORANGE Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance Coat 3 COAT - EUROPE: 3-COAT UNDERCOAT Formulation Date S-M-P Ind S Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Nov 30, 2009 Display Units GRAMS Amount Accum. Amount WB379 ORANGE 521.4 521.4 WB380 GELB 284.7 806.1 WB370 WEISS 141.0 947.1 WB367 OXIDROT 99.6 1046.7 WB364 SCHWARZTONER 6.9 1053.6 SHADE Color Owner AIXAM From/To Years 2010 - 2010 Paint Code A202 Brand Panel # 881136 Color Name ORANGE Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance Coat 3 COAT - EUROPE: 3-COAT BASECOAT Formulation Date S-M-P Ind P Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Nov 30, 2009 Display Units GRAMS Amount Accum. Amount WB302 GELB 443.1 443.1 WB380 GELB 443.0 886.1 WB379 ORANGE 86.1 972.2 WB367 OXIDROT 37.5 1009.7 WB376 BRILLANTROT 29.8 1039.5 WB383 MARON 11.7 1051.2 REPAIR MANUAL 9 PAINT METAL BLACK A 409 AKZO NOBEL SIKKENS SIKKENS reference AIX 409 Compositions Autowave MM 245 888EC 666 971 342 974 486 494,3 527,5 588,9 773,3 1012,6 Autobase plus Q766 Q160 Q811U Q140 Q550 Q065 327,3 351,5 380,6 540,3 745,8 968,6 REPAIR MANUAL 9 PAINT METAL BLACK A 409 DUPONT Color Owner AIXAM From/To Years Paint Code A409 Brand Panel # Color Name NOIR Lead Free Quality CROMAX CROMAX Color Variance Coat 2 COAT: BASECOAT Formulation Date S-M-P Ind M Quantity To Mix 1.0LTR (100% Fill) Ingredient Description 2009 - 2009 Y Feb 01, 2010 Display Units GRAMS Amount Accum. Amount 1640WB LOW VISCOSITY BINDER 795.8 795.8 1405W JET BLACK - BLUE SHADE 88.7 884.5 1427W GREEN SHADE BLUE H.S. 45.6 930.1 1432W YELLOW SHADE GREEN 23.5 953.6 1420W VIOLET 19.0 972.6 1418W BRIGHTNESS ADJUSTER 18.3 990.9 1402W WHITE L.S. 11.5 1002.4 1535W COARSE BRIGHT ALUMINUM 4.1 1006.5 REPAIR MANUAL 9 PAINT METAL BLACK A 409 SPIES HECKER Color Owner AIXAM From/To Years 2009 - 2009 Paint Code A409 Brand Panel # 837273 Color Name NOIR Lead Free Y Quality 280 280 - PERMAHYD BASISLACK Color Variance Coat 2 COAT: BASECOAT Formulation Date S-M-P Ind P Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Dec 16, 2009 Display Units GRAMS Amount Accum. Amount WB803 SPEZIALSCHWARZ 729.3 729.3 WB815 LEUCHTSILBER 60.0 789.3 WB854 LASURTIEFBLAU 100.0 889.3 WB868 PERLLILA 42.2 931.5 WB823 LASURROETLICHGELB 53.2 984.7 WB893 PERLBLAU 28.1 1012.8 WB871 PERLROSA 10.2 1023.0 REPAIR MANUAL 9 PAINT METAL BLACK A 409 STANDOX Color Owner AIXAM From/To Years 2009 - 2009 Paint Code A409 Brand Panel # 827337 Color Name NOIR Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance Coat 2 COAT: BASECOAT Formulation Date S-M-P Ind P Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Dec 16, 2009 Display Units GRAMS Amount Accum. Amount WB372 SPEZIALSCHWARZ 726.4 726.4 WB359 BLAU 99.6 826.0 WB398 BRILLANTSILBER 59.8 885.8 WB380 GELB 53.0 938.8 WB321 AMETHYST 42.0 980.8 WB303 BLAU 28.0 1008.8 WB331 ROT 10.1 1018.9 REPAIR MANUAL PAINT 9 PEARL WHITE A 408 AKZO NOBEL SIKKENS SIKKENS reference AIX 408 Compositions Layer 1 Layer 2 98 93 0 0,5 971 0,2 332YA 2,5 744 0,5 334WB 10,5 558 8,6 666 86,5 REPAIR MANUAL 9 PAINT PEARL WHITE A 408 DUPONT UNDERCOAT Color Owner AIXAM Quality CROMAX CROMAX Paint Code A408 Lead (Pb) Free Y Color Name BLANC Owner Region EUROPE Coat 3-COAT UNDERCOAT EU Stock # / Alt # X7216 / 0 Formula Standard # Hiding (µ) 16 Formulation Date Value Shade 2 Quantity To Mix Ingredient Mar 24, 2009 NEW FORMULA 1.0LTR (100% Fill) Display Units GRAMS Ingr Quality Description Amount Accum. Amount 1640WB LOW VISCOSITY BINDER 275.4 275.4 1650WB HIGH VISCOSITY BINDER 275.4 550.8 1401W WHITE H.S. 522.7 1073.5 1482W YELLOW OXIDE 14.9 1088.4 1407W BLACK L.S. 10.0 1098.4 1453W ORANGE 0.5 1098.9 SHADE Color Owner AIXAM Quality CROMAX CROMAX Paint Code A408 Lead (Pb) Free Y Color Name BLANC Owner Region EUROPE Coat 3-COAT BASECOAT EU Stock # / Alt # X7216 / 0 Formula Standard # Hiding (µ) 0 Formulation Date Value Shade 0 Quantity To Mix Ingredient NEW FORMULA 1.0LTR (100% Fill) Ingr Quality Mar 24, 2009 Display Units GRAMS Description Amount Accum. Amount 1640WB LOW VISCOSITY BINDER 765.1 765.1 1650WB HIGH VISCOSITY BINDER 135.1 900.2 1511W SATIN WHITE PEARL 69.9 970.1 1514W RUTILE RED PEARL 19.6 989.7 1501W WHITE PEARL 15.9 1005.6 1505W GOLD PEARL 6.2 1011.8 1403W CRYSTALLINE FROST 1.8 1013.6 REPAIR MANUAL 9 PAINT PEARL WHITE A 408 SPIES HECKER UNDERCOAT Color Owner AIXAM From/To Years 2008 - 2009 Paint Code A408 Brand Panel # 823901 Color Name BLANC Lead Free Y Quality 280 280 - PERMAHYD BASISLACK Color Variance Coat 3 COAT - EUROPE: 3-COAT UNDERCOAT Formulation Date S-M-P Ind S Quantity To Mix Ingredient 1.0LTR (100% Fill) Feb 17, 2009 Display Units GRAMS Ingr Quality Description Amount Accum. Amount 1102.8 1102.8 WB801 H017 WEISS WB825 H017 SCHWARZLASUR 46.8 1149.6 WB835 H017 BLUTORANGE 6.1 1155.7 WB851 H017 GELB 5.4 1161.1 SHADE Color Owner AIXAM From/To Years 2008 - 2009 Paint Code A408 Brand Panel # 823901 Color Name BLANC Lead Free Y Quality 280 280 - PERMAHYD BASISLACK Color Variance Coat 3 COAT - EUROPE: 3-COAT BASECOAT Formulation Date S-M-P Ind P Quantity To Mix Ingredient 1.0LTR (100% Fill) Ingr Quality Feb 17, 2009 Display Units GRAMS Description Amount Accum. Amount WB888 H017 TRANSPARENT 827.3 827.3 WB870 H017 PERLFEINWEISS 168.7 996.0 WB801 H017 WEISS 8.6 1004.6 WB821 H017 OCKERGELB 8.7 1013.3 WB825 H017 SCHWARZLASUR 8.6 1021.9 WB811 H017 ROT 7.1 1029.0 REPAIR MANUAL 9 PAINT PEARL WHITE A 408 STANDOX UNDERCOAT Color Owner AIXAM From/To Years 2008 - 2009 Paint Code A408 Brand Panel # 890123 Color Name BLANC Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance Coat 3 COAT - EUROPE: 3-COAT UNDERCOAT Formulation Date S-M-P Ind S Quantity To Mix Ingredient 1.0LTR (100% Fill) Feb 17, 2009 Display Units GRAMS Ingr Quality Description Amount Accum. Amount 1098.4 1098.4 WB370 S017 WEISS WB364 S017 SCHWARZTONER 46.6 1145.0 WB379 S017 ORANGE 6.1 1151.1 WB378 S017 SONNENGELB 5.4 1156.5 SHADE Color Owner AIXAM From/To Years 2008 - 2009 Paint Code A408 Brand Panel # 890123 Color Name BLANC Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance Coat 3 COAT - EUROPE: 3-COAT BASECOAT Formulation Date S-M-P Ind P Quantity To Mix 1.0LTR (100% Fill) Ingredient Ingr Quality Feb 17, 2009 Display Units GRAMS Description Amount Accum. Amount WB399 S017 TRANSPARENT 824.0 824.0 WB329 S017 WEISS 168.0 992.0 WB368 S017 OCKERTONER 8.7 1000.7 WB370 S017 WEISS 8.6 1009.3 WB364 S017 SCHWARZTONER 8.5 1017.8 WB384 S017 OXIDROTTONER 7.0 1024.8 REPAIR MANUAL 9 PAINT METAL GREY A 707 AKZO NOBEL SIKKENS SIKKENS reference AIX 707 Compositions Autobase 334WA 633,6 533 639,3 550 644,9 400 654,4 0 673,9 333DF 986 REPAIR MANUAL 9 PAINT Formula Standard # METAL GREY A 707 DUPONT 253428 Years Used 1999 - 2000 EU Stock # / Alt # M6081 / 0 Lead (Pb) Free Y Color Name GRIS PCP N Formula Owner Region EUROPE Quality CROMAX CROMAX Formulation Date Nov 06, 2001 Value Shade 4 Coat BASECOAT Paint Code A707 EU Alt Color Change Color Owner Overall Repair AIXAM Asia Color Variance Quantity To Mix Ingredient 1.0LTR (100% Fill) Ingr Quality Display Units GRAMS Description Amount Accum. Amount 1640WB LOW VISCOSITY BINDER 616.8 616.8 1650WB HIGH VISCOSITY BINDER 108.8 725.6 1531W MEDIUM FINE ALUMINUM 216.6 942.2 1401W WHITE H.S. 43.8 986.0 1501W WHITE PEARL 13.6 999.6 1405W JET BLACK - BLUE SHADE 8.5 1008.1 1464W MAGENTA 2.7 1010.8 1427W GREEN SHADE BLUE H.S. 2.6 1013.4 REPAIR MANUAL 9 PAINT METAL GREY A 707 SPIES HECKER Color Owner AIXAM From/To Years 1999 - 2000 Paint Code A707 Brand Panel # 78704 Color Name GRIS Lead Free Y Quality 285 285 - PERMAHYD PERLMUTT BASISLACK Color Variance Coat 2 COAT: BASECOAT Formulation Date S-M-P Ind P Quantity To Mix Ingredient 1.0LTR (100% Fill) Ingr Quality Oct 03, 2001 Display Units GRAMS Description Amount Accum. Amount WB891 H018 PERLWEISS 746.0 746.0 WB817 H018 MICROSILBER EXTRA 248.7 994.7 WB801 H018 WEISS 49.7 1044.4 WB827 H018 LASURSCHWARZ 24.9 1069.3 REPAIR MANUAL 9 PAINT METAL GREY A 707 STANDOX Color Owner AIXAM From/To Years 1999 - 2000 Paint Code A707 Brand Panel # 839110 Color Name GRIS Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance S!H+ Coat 2 COAT: BASECOAT Formulation Date Jun 03, 2008 S-M-P Ind P Quantity To Mix Ingredient 1.0LTR (100% Fill) Ingr Quality Display Units GRAMS Description Amount Accum. Amount WB339 S017 SAPHIRBLAU 371.7 371.7 WB302 S017 GELB 265.0 636.7 WB313 S017 MONDSILBER 182.8 819.5 WB329 S017 WEISS 100.0 919.5 WB370 S017 WEISS 54.6 974.1 WB384 S017 OXIDROTTONER 52.6 1026.7 WB324 S017 HELLGRUEN 43.6 1070.3 WB388 S017 AZURBLAU 1.2 1071.5 REPAIR MANUAL 9 PAINT STEEL GREY A 708 AKZO NOBEL SIKKENS SIKKENS reference AIX 708 Compositions Autowave MM 666 645 971 663,5 0 685,1 335 712,5 379 759,7 744 864,3 888CC 913,6 888EC 1025,6 REPAIR MANUAL 9 PAINT STEEL GREY A 708 DUPONT Formula Standard # 757844 Years Used 2005 - 2005 EU Stock # / Alt # X2066 / 0 Lead (Pb) Free Y Color Name GRIS PCP N Formula Owner Region EUROPE Quality CROMAX CROMAX Formulation Date Nov 25, 2004 Value Shade 5 Coat BASECOAT Paint Code A708 EU Alt Color Change Color Owner AIXAM Asia Color Variance Quantity To Mix Ingredient 1.0LTR (100% Fill) Ingr Quality Display Units GRAMS Description Amount Accum. Amount 1640WB LOW VISCOSITY BINDER 385.8 385.8 1650WB HIGH VISCOSITY BINDER 256.8 642.6 1535W COARSE BRIGHT ALUMINUM 252.2 894.8 1405W JET BLACK - BLUE SHADE 47.1 941.9 1401W WHITE H.S. 23.7 965.6 1418W BRIGHTNESS ADJUSTER 19.6 985.2 1420W VIOLET 14.7 999.9 1424W ORGANIC BLUE 11.3 1011.2 REPAIR MANUAL PAINT RED M 306 AKZO NOBEL SIKKENS SIKKENS reference AIX 306 Compositions First layer 358 744 955 534,4 535 1014,2 Autobase 359 956 00 744 636,5 964,4 987,2 988 9 REPAIR MANUAL PAINT PURE WHITE A 407 AKZO NOBEL SIKKENS SIKKENS reference AIX 306 Compositions Autowave MM 98 1161,4 342 1161,6 360 1162,1 744 1162,6 558 1165,5 9 REPAIR MANUAL 9 PAINT PURE WHITE A 407 DUPONT Color Owner AIXAM From/To Years Paint Code A407 Brand Panel # Color Name BLANC PUR Lead Free Quality CROMAX CROMAX Color Variance Coat 2 COAT: BASECOAT Formulation Date S-M-P Ind S Quantity To Mix Ingredient 2009 - 2009 Y Mar 30, 2009 1.0LTR (100% Fill) Ingr Quality Display Units GRAMS Description Amount Accum. Amount 1640WB LOW VISCOSITY BINDER 386.4 386.4 1650WB HIGH VISCOSITY BINDER 165.6 552.0 1401W WHITE H.S. 548.4 1100.4 1407W BLACK L.S. 1.3 1101.7 1482W YELLOW OXIDE 0.7 1102.4 1431W BLUE SHADE GREEN L.S. 0.1 1102.5 REPAIR MANUAL 9 PAINT PURE WHITE A 407 SPIES HECKER Color Owner AIXAM From/To Years 2009 - 2009 Paint Code A407 Brand Panel # 827838 Color Name BLANC PUR Lead Free Y Quality 280 280 - PERMAHYD BASISLACK Color Variance Coat 2 COAT: BASECOAT Formulation Date S-M-P Ind S Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Jun 17, 2009 Display Units GRAMS Amount Accum. Amount 1148.5 1148.5 WB801 WEISS WB825 SCHWARZLASUR 7.5 1156.0 WB811 ROT 6.0 1162.0 WB851 GELB 0.4 1162.4 REPAIR MANUAL 9 PAINT PURE WHITE A 407 STANDOX Color Owner AIXAM From/To Years 2009 - 2009 Paint Code A407 Brand Panel # 883827 Color Name BLANC PUR Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance Coat 2 COAT: BASECOAT Formulation Date S-M-P Ind S Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Jun 17, 2009 Display Units GRAMS Amount Accum. Amount 1153.1 1153.1 WB370 WEISS WB384 OXIDROTTONER 6.0 1159.1 WB364 SCHWARZTONER 7.5 1166.6 WB378 SONNENGELB 0.4 1167.0 REPAIR MANUAL 9 PAINT ALUMINUM STRUCTURE BLACK A 410 AKZO NOBEL SIKKENS SIKKENS reference AIX 410 Compositions Autowave MM 245 1014 Autobase plus Q140 726,6 Q326 738,7 Q065 959,4 REPAIR MANUAL 9 PAINT ALUMINUM STRUCTURE BLACK A 410 DUPONT Color Owner AIXAM From/To Years Paint Code A410 Brand Panel # Color Name NOIR Lead Free Quality CROMAX CROMAX Color Variance Coat 2 COAT TINTED CLEAR: BASECOAT TC Formulation Date S-M-P Ind P Quantity To Mix 1.0LTR (100% Fill) Ingredient 2010 - 2010 Y Mar 31, 2010 Display Units GRAMS Description Amount Accum. Amount 1640WB LOW VISCOSITY BINDER 831.5 831.5 1405W JET BLACK - BLUE SHADE 142.6 974.1 1484W RED OXIDE 12.2 986.3 1401W WHITE H.S. 10.9 997.2 1512W SATIN BLUE PEARL 5.4 1002.6 1533W FINE ALUMINUM 4.0 1006.6 Language ALL Region Code Region Language Text 858-DRE EUROPE ENGLISH OVERALL REPAIR 955-DRE EUROPE ENGLISH COLOR NEEDS FLAT CLEARCOAT REPAIR MANUAL 9 PAINT ALUMINUM STRUCTURE BLACK A 410 SPIES HECKER Color Owner AIXAM From/To Years 2010 - 2010 Paint Code A410 Brand Panel # 839666 Color Name NOIR Lead Free Y Quality 280 280 - PERMAHYD BASISLACK Color Variance Coat 2 COAT TINTED CLEAR: BASECOAT TC Formulation Date S-M-P Ind S Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Display Units GRAMS Amount Accum. Amount WB803 SPEZIALSCHWARZ 710.5 710.5 WB859 BRILLANTBLAU 157.7 868.2 WB823 LASURROETLICHGELB 93.1 961.3 WB843 GRANADAROT 51.5 1012.8 WB801 WEISS 4.9 1017.7 Language ALL Region Code Apr 08, 2010 Region Language Text 955-SH EUROPE ENGLISH APPLY FLAT CLEARCOAT 955-SH EUROPE GERMAN MATTKLARLACK EINSETZEN 955-SH EUROPE POLISH NANIESC MATOWY LAKIER BEZBARWNY REPAIR MANUAL 9 PAINT ALUMINUM STRUCTURE BLACK A 410 STANDOX Color Owner AIXAM From/To Years 2010 - 2010 Paint Code A410 Brand Panel # 866639 Color Name NOIR Lead Free Y Quality STHYD STANDOHYD BASECOAT Color Variance Coat 2 COAT TINTED CLEAR: BASECOAT TC Formulation Date S-M-P Ind S Quantity To Mix 1.0LTR (100% Fill) Ingredient Description Apr 08, 2010 Display Units GRAMS Amount Accum. Amount WB372 SPEZIALSCHWARZ 713.4 713.4 WB380 GELB 93.4 806.8 WB358 VELOURSBLAU 158.4 965.2 WB361 RUBINROT 51.7 1016.9 WB370 WEISS 4.9 1021.8 Language ALL Region Code 955-SX 955-SX 955-SX 955-SX Region EUROPE EUROPE EUROPE EUROPE Language CROATIAN ENGLISH GERMAN SERBIAN Text UPOTRJEBITE 2K SUPERMATT BEZBOJNI LAK APPLY STANDOCRYL 2K CLEAR SUPER MAT MATTKLARLACK EINSETZEN UPOTREBITE 2K KLARLACK SUPERMATT 955-SX EUROPE SLOVENIAN UPORABITE 2K KLARLACK SUPERMATT REPAIR MANUAL PAINT Rouge nacré A308 AKZO NOBEL SIKKENS Référence SIKKENS AIX 308 Compositions Autowave MM sur 100grs Couche de fond 527 9.00 400 4.00 666 64.00 355 6.00 888DF 16.00 335 6.00 Couche de finition 666 82.50 350 4.50 527 13.00 +CBP040 9 REPAIR MANUAL PAINT Rouge nacre A308 LECHLER Référence LECHLER AIX308 AIX 308 Compositions sur 100 Gr Couche de fond 485 256 48 186 390 221 689 487 Base HF582 143 221 26,45 8,4 3,6 1,32 4,2 7,93 2,43 45,67 43,86 3,51 2,63 9 REPAIR MANUAL PAINT Noir Brillant A412 NOBEL SIKKENS 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9 REPAIR MANUAL PAINT 9