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Automotive Training Courses
TRAINER manual
Reset and configurationes techniques
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INDEX
GLOSSARY�� 3
1. INTRODUCTION�� 5
2. BASIC TECHNIQUES OF SELF-DIAGNOSIS�� 7
2.1 Vehicle check-up�� 7
2.2 TGS3�� 8
2.3 WEB Special Code�� 9
3. ENGINE�� 11
3.1 Engine Test IVECO�� 11
3.1.1 EDC MS6.2�� 11
3.1.2 EDC 7�� 18
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3.1.3 EDC 7 UC31�� 23
3.2 Injectors and pumping units coding for Euro 4/5 systems�� 33
3.2.1 DMCI DAF injectors and pumps coding�� 33
3.2.2 Injectors Coding of Iveco Cursor�� 36
3.2.3 Volvo Injectors Coding �� 38
3.2.4: Coding of MAN and Volkswagen EDC17 injectors�� 39
3.2.5: MR/PLD Mercedes pump units coding�� 41
4. GEARBOX�� 45
4.1 Volvo I-Shift Transmission / Clutch Calibration�� 45
ie 4.1.1 Clutch Initialization (Old Clutch)�� 48

4.1.2 Clutch Initialization (New Clutch)�� 51
4.1.3 Gearbox calibration�� 51
4.1.4 Clutch engagement point calibration �� 53
4.2 Clutch initialization for Manual Transmission on Mercedes vehicles and MAN with comfort shift�� 55
4.2.1 Clutch initialization, Mercedes Transmission�� 55
4.2.2 Comfort-Shift MAN�� 56
4.3 Initialization of the Mercedes EPS transmission�� 59
4.3.1: Mercedes gearbox initialization�� 60
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4.4 Programming of the ZF As-Tronic gearbox�� 65
4.4.1 ZF control unit programming�� 67
5. VEHICLE ELECTRONIC SYSTEMS�� 73
5.1 Volvo ECAD dryer filter Reset�� 73
5.1.1 Air Dry filter reset�� 74
5.2 Volvo and Renault V.I. APM system�� 76
5.2.1 Cartridge Replacement �� 77
5.2.2 APM Module Replacement�� 78
5.2.3 Special Parametrizations�� 81
5.3 Scania APS system�� 83
5.3.1 Cartridge Replacement�� 84
6. VEHICLE MAINTENANCE�� 89
6.1 WS Mercedes Maintenance�� 89
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6.2 MAN Maintenance System�� 101

6.2.1 Types of scheduled maintenance�� 101
Legend:
Warning
Information/Notes
TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 2018 – V00 1>
2. BASIC TECHNIQUES OF SELF-DIAGNOSIS
One of the peculiarities of industrial vehicles world is the 2.1 Vehicle check-up
high number of electronic systems and often, on the same
vehicle, ECUs produced by different suppliers which still The new OEM Vehicle Check-up "Scan + DTCs Total Read"
need to interact one another with the chance to have the function allows the technician to diagnose on many models
need of a personalized diagnostics. of the main Truck brands the all the control units in just one
TACHOGRAPH
go. It is a real general check (Check-Up) of the all ECU fitted
MAINTENANCE SYSTEM ELECTRONIC KEY on the vehicle and, particularly allows:
• Check the all type of ECU which are fitted on the vehicle,
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AEBS ADVANCED EMERGENCY SEAT ADJUSTMENT
BRAKING SYSTEM
MULTIFUNCTION DISPLAY
SPEED ADJUSTMENT even if these are not yet supported by the TEXA Self-
IMMOBILIZER
AIRBAG
diagnosis.
BODY COMPUTER
PARKING SENSOR
• Very High-speed DTC reading process (from 3 to 20
POWER STEERING ELECTRONIC STEERING WHEEL
TRAILER CONTROL UNIT

times faster).
ENGINE CONTROL
LIGHTS ADJUSTMENT TRANSPORT INFORMATION SYSTEM • Check the status of the DTC: “Current” or ”Stored” of
ENGINE VEHICLE ADJUSTMENT every single one of them and of every single control
unit.
ie NETWORK SYSTEM
EBS
ABS
FMS
ESP
AUTOMATIC TRANSMISSION
FOUR-WHEEL DRIVE
SLOW MOTION
TPMS
CABIN MODULE
INFONTAINMENT
CLIMATE
HEATER
LDWS LANE DEPARTURE
WARNING SYSTEM
SUPPLIER CENTRAL UNIT
PARKING BRAKE
ADAPTIVE CRUISE CONTROL
THIRD STEERING AXIS

• When available, access to the "DTC help" functions with
the relative repair procedures.
• Possibility of selecting and displaying of only a certain
group of ECUs (even only 1 at a time)
• DTC erasing process without needs to be physically
connected to the specific ECU.
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COMPRESSED AIR MANAGEMENT ELECTRONIC CLUTCH
PNEUMATIC SUSPENSIONS
This feature is not available on all vehicles.
Figure 1
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D3T “Reset and configurationes techniques” - Automotive Training Courses
2.2 TGS3
The TGS3 (Total Global Scan 3) function is the third evolution of TEXA's now well-established scanning system and allows to
obtain a list of the vehicle ECUs which are on the vehicle, select the desired systems and perform a scan to obtain the status
(DTC stored etc.) of the control unit.
Unlike the "OEM Vehicle Check-up" feature, the TGS3 is a sort of diagnostic automatism, which allows the user to access from
a single screen only those electronic control units actually supported by the TEXA Self-Diagnosis and the information shown
is only related to the presence or absence of the control unit and if there are DTCs stored, without showing any more detailed
information
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Figure 2: Scanning with TGS3
8> TEXA S.p.A. - Copyright © All rights reserved. Images and texts are property of TEXA S.p.A. Unauthorized disclosure and reproduction, even partial, are prohibited – 2018 – V00
2.3 WEB Special Code
With version 30 of the SW IDC5 Truck, the management of the SPECIAL CODE has been simplified. The operations that in fact
up to version 29.0.2 required that the Special Code be inserted, are now enabled for all.
For these ECU Settings it is therefore no longer necessary to request the SPECIAL CODE.
The settings that require the SPECIAL CODE and the Internet connection will be remain the same.
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Parameter settings: save to PC
Figure 3: Example of regulation with internet connection (up to vers 29.0.2)
For the execution it is therefore necessary, for those who have not already done so, to request the SPECIAL CODE.
ie Figure 4: Example of regulation with internet connection (from vers 30.0.0)
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For the user who has not yet made the request, simply subscribe to the specific form to be requested from your TEXA Dealer,
which will then be sent to TEXA.
The activation will be communicated to the TEXA Dealer, from that moment, it will be possible to perform all the available
ECU Settings. For the user who has already made the request, the new mode will be activated through one of the following
procedures:
- Performing an ECU settings which requires the internet connection.
- By accessing to the TEXA software SETTINGS menu - SERVICE PROGRAMS – CHECK SPECIAL CODE WEB STATUS, then
CHECK.
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3. ENGINE
3.1 Engine Test IVECO Cylinder performance test
IN GENERAL:
The procedure known as the Engine Test allows a specific The cylinders performance test allows to evaluate the
diagnosis of the main mechanical components of the engine contribution of each individual injector to the total efficiency
such as: of the engine.
• Injection system; WHEN TO EXECUTE:
• Compression; The procedure is performed when the engine has idle
• Turbocharger; balancing problem and of efficiency during the engine
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acceleration.
• Engine brake.
PROCEDURE EXECUTION:
These procedures are different according to whether the To perform the test it is necessary that:
• The engine is at operating temperature
vehicle is equipped with an EDC MS6.2, EDC7 or EDC7UC31 • There are no DTCs stored
control unit. • The PTO and the air conditioning are switched off
• The battery charge is good, and the electrical system is
3.1.1 EDC MS6.2 efficient
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This control unit is present on Euro 2/3 version vehicles
with Cursor 8-10-13 engines.
The procedures available are:
- Cylinder performance test;
- Compression test;
- Turbine test;
The test involves a first phase where the engine performs a
series of accelerations. After this first stage the engine ECU
will perform other 7 accelerations, of which the first will be
used as a reference (with the all injectors active) and the
other 6 with 1 injector disengaged at a time.
During the test the contribution to the general performance
of the engine for each injector is evaluated.
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- Engine brake test.
A positive% value identifies a greater contribution while a negative value implies a lower return.
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Figure 6: Cylinder performance test results
4. GEARBOX
4.1 Volvo I-Shift Transmission / Clutch The 3 elements are made of aluminum to contain the
Calibration weights and the central box is equipped with crossed ribs to
reduce noise and increase stiffness.
The Volvo I-Shift gearbox is a gearbox used in the FM and The clutch used in this gearbox is a dry single-disc clutch
FH ranges and has been available since 2002 in 2 versions with traction-type involute grooves.
VT and AT.
The difference between these two versions is linked to the
type of the clutch management and to the planetary group.
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The gearbox is a 12-speed forward and 4-speed reverse
gear and can be in both Direct Drive and Over Drive versions.
The VT transmission type code is VT2412B.
V Volvo
T Transmission
O OverDrive
ie 24
12
B
2400 Nm Torque
Gears Number
Generation
Table 13: : I-Shift VT Gearbox identification
The VT2412B transmission is a variant of the VT series

transmissions which includes a clutch electro-pneumatic
management system and the synchronizers on the base
Figure 60: I-Shift clutch: closed clutch (left), open clutch (right)
The drive mechanism has a fork which is actuated by the

pneumatically driven piston.
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gearbox are not installed. The clutch operates in a pulling way so that the air pressure
The gearbox is mainly composed by 3 elements: is used for the itself opening while the springs of the
- The front bell housing with a dry single-disc clutch pressure plate bring the clutch to close position when the
- The central box which includes the primary shaft, the air is discharged.
transmission shaft and the reverse motion gear
- The back box which includes the planetary unit and the
output shaft.
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Figure 61: Clutch fork
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Figure 63: I-Shift clutch: open clutch (left), closed clutch (right)
The drive mechanism (with ACT ZF) has a piston disposed

concentrically to the gear input shaft.
The clutch is always a CS43B-O and pressure-controlled.
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Figure 62: Clutch Actuator
Legend:
1) Inductive position sensor
In fact, the pneumatic control actuator pushes on the
springs of the pressure plate and disengages the clutch. The
command is therefore always under air pressure.
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2) air inlet
3) air exhaust
a) slow regulation channel
b) fast regulation channel
VAFE) Quick coupling solenoid valve
VASE) Slow coupling solenoid valve
VAFD) Quick release solenoid valve
VASD) Solenoid valve slow disengagement
Subsequently, a specific series of automated transmissions

Figure 64: Clutch Fork
is developed, marked with the AT indication.
The type code of the AT transmission is AT2412C.
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A Automatic
T Transmission
O OverDrive
24 2400 Nm of Torque
12 Number of forward gears
C Generation
Table 14: I-Shift AT change identification
Figure 65: Clutch travel sensor

The clutch used in this gearbox is a dry single-disc clutch
with push-type involute grooves.
5. VEHICLE ELECTRONIC SYSTEMS
5.1 Volvo ECAD dryer filter Reset - In pneumatic-mechanical mode (reserve)
The AIRDRY-E device used in Volvo's FM / FH vehicles is In this second mode, the VECU, via the CAN bus,
an evolution of the AIRDRY systems used to manage the communicates Trouble codes to the driver’s display.
compressed air and is produced by Wabco which calls For the correct functioning of the ECAD some vehicle
ECAD (Electronically Controlled Air Dryer). information is required:
- Engine status
- Accelerator pedal position
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- Vehicle speed
- External temperature
- EBS operating status
ie Figure 92: ECAD Wabco
The system is developed to be managed through a control

unit which is already installed on the vehicle. In the Volvo
Figure 93: Internal structure of the ECAD system
Internally there are:

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case, the system is controlled by the VECU vehicle control - a regeneration solenoid valve
unit. It includes: - a pressure regulation solenoid valve
- Dryer filter - a mechanical pressure regulator
- Exhaust valve
- The regeneration solenoid valve The circuits recharging process is managed in the
- The compressor control solenoid valve traditional way, through the tank protection valve, which
- The heater (optional) defines the charging order. The charging pressures of the
vehicle are related to the vehicle speed (> o <30 km / h),
The device can operate: the suspension type, the country where the vehicle will be
- In electro-pneumatic mode registered and the amount of dried air (p).
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v < 30 km/h v > 30 km/h

System System
Vehicle Type System ON System ON
OFF OFF
p < 360 l p > 360 l p < 360 l p > 360 l
Vehicles with ordinary suspension, ABS and regulation 7,5 bar 7,5 bar 8,5 bar 7,5 bar 7,5 bar 8,5 bar
pressure 8.5 bar
Vehicles with ordinary suspension, EBS and regulation 10,6 bar 10,1 bar 12,0 bar 10,6 bar 10,6 bar 12,0 bar
pressure 12 bar
Vehicles for the Japanese market with 10 bar regulation 9,0 bar 9,0 bar 9,8 bar 9,0 bar 9,0 bar 9,8 bar
pressure
Standard vehicles with 12 bar regulation pressure 10,6 bar 10,1 bar 12,0 bar 9,6 bar 9,6 bar 12,0 bar
Vehicles with high pressure regulation 10,6 bar 10,6 bar 12,0 bar 10,6 bar 10,6 bar 12,0 bar
Table 21: Recharge pressures for Volvo pneumatic systems
5.2 Volvo and Renault V.I. APM system The device can operate:
• in electro-pneumatic mode;
For Volvo, Midlum, Premium and Magnum Renault VEI • in pneumatic-mechanical mode (reserve).
vehicles, the FL / FE range an electronic dryer produced by
Knorr-Bremse is used and named EAC1 (APM for Renault In this second mode the system, via the CAN bus,
and Volvo manufacturers). communicates trouble codes to the driver’s display.
For a correct functioning the APM some vehicle information
is required:
- engine status;
- accelerator pedal position;
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- vehicle speed;
-external temperature;
- brake status
ie Figure 95: APM Renualt V.I.
The system is an innovation in the pneumatic truck system,

Figure 96: EAC1 Circuit
Legend:
11. Compressor Power supply
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12. External power supply
it includes the all traditional functions of the Air Dryer
21. Front circuit
assembly, the 4-way valve and the regulator pressure and 22. Rear circuit
new functions for the optimizing and the production of 23. Trailer braking circuit
23.1 Parking brake circuit
compressed air. 24. Gearbox and Clutch
In fact, having the chance of an electrical management 25. Suspension circuit
of the pressure regulation and the system regeneration 26. Services
3. Drain
phases allows the system to manage them regardless of 4/27. Compressor control
the system's recharge conditions. This allows to reduce fuel 6. Parking brake signal
consumption, to extend the life of the drying cartridge, to
make the air treatment more effective. The circuits are recharged in the traditional way, through
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It includes: the tank protection valve, which defines the charging order.
• on the filter body: The charging pressures of a vehicle depend on the vehicle
- dryer filter; speed (> or <35 km / h) and the position of the parking
- pneumatic pressure regulator; brake
• on the valve body:
- 6-circuit tank protection valve;
- regeneration solenoid valve;
- pressure regulating solenoid valve;
- parking brake solenoid valve;
- heating resistance;
• the control unit with 4 (3 in the standard version)
pressure sensors and 1 temperature sensor.
6. VEHICLE MAINTENANCE
6.1 WS Mercedes Maintenance
Mercedes vehicles are equipped with a complex and very effective maintenance system that allows to optimize maintenance
interventions by calculating for some vehicles systems (groups) a deadline depending on the state of usury and the aging of
the group itself.
The system is controlled by a specific control unit (WS) or a virtual control unit (integrated WS in the GM or MS integrated in
the CGW).
The WS ECU uses different signals detected by the various groups to define the maintenance deadline.
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This value is calculated according the workload of specific system as well as the aging of the group itself.
Since the systems maintenance can be very large, the system will create time window in order to put together more service
expiration and optimize the vehicle service stop.
In the first Mercedes WS versions, connecting to the General Maintenance system, it is possible to set the value
“Grouping Deadlines” that allows the grouping of nearby services deadlines. In the recent variants, the WS ECU is
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automatically set in this mode and the “Grouping Deadlines” is done all the time automatically.
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Figure 109: Grouping Deadlines procedure
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The maintenance expiration notice is available from a maximum of 60 days before for “Periodic Maintenance” at a minimum
of 14 days before for “Flexible” ones (this value can be changed through the Pre-warning limit (days) set in the Periodic
Maintenance menu).
Reaching the “Limit Interval” the ECU is programmed in order to manage the Maintenance and the related Reset. If the Reset
will not be performed, the system will warn the driver with a message of Expired Maintenance, which can be anyway removed
from the Display simply by using the buttons on the vehicle cluster.
However, there is a second overriding threshold which does not provide for the cancellation of the message Urgent Maintenance
and which appears when the maintenance is not performed for a long time.
Maintenance services are divided into:
- Telligent® maintenance
- General maintenance
- Periodic maintenance
The first are “Flexible” maintenance, i.e. those whose duration is calculated by the control unit according to the load and aging
of the group.
General maintenance are general operations that do not have a specific time or mileage.
They are performed together with Telligent ® or periodic maintenance.
They are therefore additional services that must be performed in the various vehicle system (groups).
Finally, periodic maintenances are those maintenance that must be carried out according to a specific time maintenance plan.
In the maintenance tables, the manufacturer assigns an abbreviation to define each type.
Code Description
W Telligent Maintenance
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V2 Valve Adjustment clearance to the 1st, 3rd, 5th, 7th, etc. general maintenance
V3 Valve Adjustment clearance to the 1st, 4th, 7th, 10th, etc. general maintenance
Z1 Operations to be carried out at the first Telligent maintenance
Z2 Operations to be carried out every 2 Telligent maintenance
ZA Operations to be carried out every 200000 km or 2 Years
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Code
J1
J2
J3
J6
F1
F2
Annual and safety maintenance Operations
Maintenance operations to be performed every 2 years
30000 km/600h for natural gas engines
60000 km/1200 h for natural gas engines
Table 23: Maintenance list ACTROS-ATEGO-AXOR 950-952-953-954-374-375-940-942-943-944-972-974-975-976, ECONIC 957
Description
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M Engine Telligent Maintenance
Z Additional Telligent Maintenance
V3 Valve Adjustment clearance to the 1st, 4th, 7th, 10th, etc. general maintenance
Z1 Operations to be carried out at the first Telligent maintenance
Z2 Operations to be carried out every 2 Oil Change or Retarder
ZA Operations to be carried out every 200000 km or 2 Years
J1 Annual maintenance Operations
J2 Maintenance operations to be performed every 2 years
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JS Maintenance operations related to the safety and need to be performed annually
Table 24: ACTROS maintenance list 930-932-933-934
Code Description
M Engine Telligent Maintenance
J Telligent periodic maintenance (gearbox or axle)
Z Addition Telligent maintenance
V2 Valve Adjustment clearance to the 2nd, 4th, 6th, 8th, engine maintenance etc. (OM936)
V3 Valve Adjustment clearance to the 1st, 4th, 7th, 10th, etc. general maintenance (OM47x)
Z1 Operations to be carried out at the first Telligent engine maintenance
Z2 Operations to be carried out every 2 Telligent engine maintenance

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Automotive Training Courses

Reset and configurationes techniques

ie 4.1.1 Clutch Initialization (Old Clutch)�� 48

6.2 MAN Maintenance System�� 101

TRAILER CONTROL UNIT

ADAPTIVE CRUISE CONTROL

THIRD STEERING AXIS

Figure 2: Scanning with TGS3

Figure 6: Cylinder performance test results

The VT2412B transmission is a variant of the VT series

The drive mechanism has a fork which is actuated by the

Figure 61: Clutch fork

The drive mechanism (with ACT ZF) has a piston disposed

Subsequently, a specific series of automated transmissions

Figure 65: Clutch travel sensor

ie Figure 92: ECAD Wabco

The system is developed to be managed through a control

Internally there are:

v < 30 km/h v > 30 km/h

ie Figure 95: APM Renualt V.I.

The system is an innovation in the pneumatic truck system,

J6 Maintenance operations to be performed every 6 years

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