3/6/2020

E474 Wiring Manual Framework (BS VI)

a
 INDEX
1. How to read circuit diagram
2. Wire Color Coding
3. General steps for troubleshooting process – Key Points
4. Connection of Breakout Box & Break out Harness
5. Vehicle Layout
6. Engine Layout
7. Fuse & Relay details
8. Vehicle Harness Layout
9. Engine Harness & Sensor Location.
10. Front Chassis Harness Connectors and Sensors.
11. EATS Harness Connectors and Sensors
12. Cabin Harness Connectors and Sensors.
13. Earth/Grounding Points.
14. Interface Connectors & their Pin Details.
15. EMS ‘s Pinouts.
16 CAN1 Communication Connector Pinout.
17.1 Instrument Cluster-C1 Connector Pin-out.
17.2 Instrument Cluster-C2 Connector Pin-out
18 DCU Pinouts.
19 Interface Connectors Pinouts Details.
20 Circuit Diagram.
21 Abbreviations.

2
1. How to read Circuit Diagram
Fuse No.: Rating
Wire Size, Color (Details
defined in Pg. no.:XXX) Splice (Details defined in Pg. no.:XXX)

Elect. Battery Cut-off

Sw. Relay
10.0 R 1 10.0 R 6.0 R
Maxi fuse
1 MF1: 80A 2
-ve +ve 2
Component Battery 6.0 W Maxi fuse
1 2
0.5 L MF2: 60A
0.5 W/L
RA:40
0.5 L
IGN. switch 1.5 W Interface Connector : Pin no.
2 BF:5 RA:40
(Details defined in Pg. no.:XXX)
0.5 L 7
Ign. Fuse
Rocker Battery Cut-
off Sw.
6 2
Pin No. 0.5 Br 0.5 Br

-ve Ground

3
2. Wire Color Coding
S. No. Code/ Short name Color Representation
1 R Red
2 L Blue
3 B Black
4 P Pink
5 W White
6 G Green
7 Gr Grey
8 Br Brown
9 V Violet
10 LG Light Green

4
3. General steps for troubleshooting process – Key Points
1. Identify the component.
2. Visually check the component connectors & harness are ok or not.
3. Find out the related circuit diagram from manual.
4. Tests:
a) Open circuit / Continuity Test:
- Ignition off.
- Open the component connector and use multimeter.
- See the circuit diagram for identifying Pin nos.
- Set the multimeter in Sound mode as shown below.
- Connect multimeter pins between the components connector pins as per circuit diagram.
- If Beep sound is coming then continuity is ok if not there is
open wire between pins. Change the harness.

Open Test

5
Contd..
b) Short circuit / Voltage Test: Voltage Test
 Open the component connector and use Multimeter.
 See the circuit diagram for identifying Pin nos.
 Ignition On.
 Set the multimeter in voltage mode.
 Check the voltage between Pin no. with ground.
 If voltage is as per given value in manual then it is ok
if voltage value is greater than or less than given manual
There must be wire short with battery supply or ground.
Change the harness.

C) Resistance Test:
 Ignition off.
 Open the component connectors and use multimeter. Resistance
 See the circuit diagram for identifying Pin nos. of component. Test

 Set the multimeter in Resistance mode.

 Connect multimeter pins between the components pins as
per circuit diagram.
 If resistance value is as per given value in manual then it is ok
if value is greater than or less than given manual there must be
faulty component. Change the component.

6
 4. Connection of Breakout Box & Break out Harness

9-pin Breakout
Engine EMS
Box (ST654435) 105-pin Break out harness
A-connector

Crank Sensor Female

connector Crank Sensor 105-pin EMS
A female connector Engine Harness
108-pin Break out harness
Sensor Breakout harness B-connector
(ST654439) A:77
0.5 R
Brake out
1 2-pin Crank Sensor 108-pin Breakout
2 Female Connector of
Harness
Box
Engine Harness (ST654436)
Crank Sensor Male (ST654434)
Connector of Breakout
Harness
0.5 W
A:78
Pin 1 to A:77 – Negative Signal
Pin 2 to A:78 – Positive Signal

After connecting breakout harnesses & their box as per above diagram. Perform Electrical test.

7
5. Vehicle Layout
Top View
VF VM VR
Driver Side (T1)
T1

Vehicle Vehicle Rear

T2
Front
Co-driver Side T3
(T3) Side View
S1

S2

S3

VF: Vehicle Front T1 : Vehicle Right or Driver side S1: Vehicle Top
VM: Vehicle Middle T2 : Vehicle Centre S2: Vehicle Middle
VR: Vehicle Rear T3 : Vehicle Left or Co-driver side S3: Vehicle Bottom

Example: Location of Fuse box : VFT3S3– In vehicle front, co-driver side

8
6.

9
Engine Layout
EF EM ER
Top View
T1

Engine Engine Rear

Front
T2

T3

S1

Side View S2

S3

EF: Engine Front T1: Right Top View S1 : Up Side View

EM: Engine Middle T2: Centre Top View S2 : Middle Side View
ER: Engine Rear T3. Left Top View S3 : Down Side View
Example : Location of Common Rail Pr. Sensor – EMT3S2 (Engine Middle Left Side in Middle)
10
7.

11
 Fuse & Relay details
A. Vehicle Fuse & Relay Box
Fuse Details Vehicle Location (VFT2S2)

12
Contd..
B. Vehicle Fuse & Relay Box
Fuse Details Vehicle Location (VFT2S2)

13
8. Vehicle Harness Layout

EATS HARNESS

REAR CHASSIS HARNESS

ENGINE HARNESS

CABIN HARNESS

PIGTAIL SWITCH HARNESS FRONT CHASSIS HARNESS

14
15
 9. Engine Harness & Sensor Location
7 8 9
6 10
5
4 11

3 12

2 13

14
1
1. Coolant Temp. Sensor (EMT3S2) 15 9. Cam Sensor (ERT2S1)
2. Boost Pressure Sensor (EMT3S2) 10. Crank Sensor (ERT2S2)
3. Viscus Fan Connector (EFT3S2) 11. Rail Pressure Sensor (EMT2S2)
4. HP Pump (EFT3S2) 12. Intake Throttle Valve (ERT3S2)
5. Injector (EMT2S1) 13. EGR Valve Actuator (EMT3S2)
6. HFM Sensor (EMT1S1) 14. Oil Pressure Sensor (EMT3S3)
7. VGT Actuator (EMT1S2) 15. Alternator (EMT3S2)
8. Starter Motor (ERT1S2)

16
Contd..
S.N. Description Sensor Connector View
Location View
01. Coolant Temp. Sensor
(EMT3S2)
1 2

02. Boost Pressure Sensor

(EMT3S2)

1 4

17
Contd..
S.N. Description Connector/Component Connector View
Location View
03. Viscus Fan Connector
(EFT3S2)

5 1

04. HP Pump Valve

(EFT3S2)

2 1
Contd..
S.N. Description Component / Sensor Connector View
Location View
05. Injectors (EMT2S1)

1 2

06. HFM Sensor (EMT1S1)

1 4
19
Contd..
S.N. Description Component Connector View
Location View
07. VGT Actuator
(EMT1S2)

5 1

08. Starter Motor

(ERT1S2)

20
Contd..
S.N. Description Sensor Location View Connector View

09. Cam Sensor (ERT2S1)

2
1 3

10. Crank Sensor (ERT2S2)

1 2

21
Contd..
S.N. Description Sensor / Component Location View Connector View

11. Rail Pressure Sensor

(EMT3S2)

1 2 3

12. Intake Throttle Valve

Actuator (EMT3S2)
2 6

1 5
22
Contd..
S.N. Description Component /Sensor Connector View
Location View
13. EGR Valve Actuator
2 6

1 5

14. Oil Pressure Sensor

(EMT3S2)

1 2
4
23
Contd..
S.N. Description Component / Coupler Connector View
Location View
15. Alternator (EMT3S2)

Alternator Alternator
+ve supply Charging
16.a) EMS A
1 21
(VFT2S2)

85 105

24
Contd..
S.N. Description Coupler Connector View
Location View
16.b) EMS B 1 7 23
(VFT2S2)

5 91

25
10.

26
11. Front Chassis Harness Connectors & Sensors

1.Water in Fuel Level Sensor (VMT3S3)

2.Starter motor (EMT2S3)
3.Starter Relay (VMT2S2)
4.Maxi fuse (VMT3S2)
5.Battery (VMT3S2)
6.Fuel level sensor (VMT1S1)
7.Vehicle Speed Sensor (VMT3S2)
8.Reverse Light Switch (VMT2S2)
9.Exhaust Brake Actuator (VLT1S3)
10.Air Restriction Sensor (VFT1S3)
27
10 Front Chassis Harness Connectors and Sensors
S.N. Description Sensor / Component Connector View
Location View
01. Water in Fuel Level Sensor
(VMT3S3)

1 2

02. Starter Motor Solenoid

(EMT2S3)

1
10 Front Chassis Harness Connectors and Sensors
S.N. Description Component Connector View
Location View
03. Starter Relay
(VMT2S2)

04. Maxi Fuse

(VMT3S2)

2 1

29
10 Front Chassis Harness Connectors and Sensors
S.N. Description Component Connector View
Location View
05. Battery
(VMT3S2)

06. Fuel Level Sensor

(VMT3S2)

4 1

30
Contd..
S.N. Description Sensor / Component Connector View
Location View
07. Vehicle Speed Sensor
(VMT2S2)

1 3

08. Reverse Light Switch

(VMT2S2)

2 1

31
Contd..
S.N. Description Component / Sensor Connector View
Location View
09. Exhaust Brake
Actuator
(VLT1S3)

1 2
10. Air Filter Restriction
Sensor
(VFT1S3)

1 2

32
11.

33
11. EATS Harness and Sensor location

8
2

1. Pre NOx sensor (VMT1S2)

2. Temp. sensor T4 (VMT1S2)
3 3. Temp. sensor T5 (VMT1S2)
4. DP sensor (VMT1S2)
5. Temp. sensor T6 (VMT1S2)
4 6. Urea dosing module (VMT1S2)
7. Post NOx sensor (VMT1S3)
8. DCU (VMT3S3)
5

6
7

34
 11 EATS Harness Connectors and Sensors
S.N. Description Sensor Connector View
Location View
1. Pre NOX Sensor
(VMT1S2)

1 4

2. Temp. Sensor Before

Catalyzer (T4)
(VMT1S2)

2 1
35
 Contd..
S.N. Description Sensor Connector View
Location View
3. Temp. Sensor After
Catalyzer (T5)
(VMT1S2)

2 1

4. DP Sensor
(VMT1S2)

3 1
36
 Contd..
S.N. Description Sensor / Component Connector View
Location View
5. Temp. Sensor SCR Upstream
(T6) (VMT1S2)

2 1

6. Urea Dosing Module

(VMT1S2)

2
1 1

37
 Contd..
S.N. Description Sensor / Component Connector View
Location View
7. Post NOX Sensor
(VMT1S3)

1 4

8. DCU (Dosing Control Unit)

(VMT3S3) 7 1

14 8

38
 Contd..
S.N. Description Component Connector View
Location View
9. Urea Dosing Injector
(VMT2S3)

10. Coolant In-Pipe line

(VMT2S3)

39
 Contd..
S.N. Description Component Connector View
Location View
11. Coolant Out Pipe
(VMT2S3)

12. Adblue Tank

(VMT3S3)

36
12.

41
13. Body Harness Connectors & Sensors

10

11

12

1. Combination Switch (VFT2S2)

2. Instrument Cluster 1 (VFT2S2)
3. Infotainment system(VFT2S2)
4. Accelerate Pedal Sensor (VFT2S2)
5. CAN (VFT2S2)
6. Brake Lever Switch(VFT2S2)
7. Clutch Switch (VFT2S2)
8. ECO + Switch (VFT2S2)
9. ECO Power Switch (VFT2S2)
10. Ambient Temperature (VFT3S2)
11. Telematics ECU (VFT3S2)
12. DPF Switch (VFT2S2) 28
Contd..
S.N. Description Component Connector View
Location View
01.a) Combi. Switch: Wiper
6 1
(VFT2S2)

12 7

01.b) Combi. Switch:

8 1
Lighting
(VFT2S2)

16 9 43
Contd..
S.N. Description Component Connector View
Location View
02.a. Instrument Cluster(C1
17 32
connector)
(VFT2S2)

1 16

02.b. Instrument Cluster(C2

connector) 17 32
(VFT2S2)

1 16
44
Contd..
S.N. Description Component / Sensor Connector View
Location View
03. Infotainment
system(VFT2S2)

04. Accelerator Padel

Sensor
(VFT2S2)

1 6
Contd..
S.N. Description Component Connector View
Location View
05. CAN1 Communication
1 8
(VFT2S2)

9 16

06. Brake Level Sensor

(VFT2S2)

2 1
46
Contd..
S.N. Description Component Connector View
Location View
07. Clutch Switch
(VFT2S2)

2 1

08. ECO + Switch

(VFT2S2)

47
Contd..
S.N. Description Sensor/Component Connector View
Location View
09. ECO Power Switch
(VFT2S2)

10. Ambient Temperature

Sensor
(VFT3S2)

1 2
Contd…
S.N. Description Component/Connector Location View Connector View

11. Telematics Connector

(VFT3S2) 4 1

8 5
12. DPF Switch
(VFT2S2)

49
Contd..
S.N. Description Component Connector View
Location View
13. Brake Pedal Switch 1

1
4

50
13.

51
13 Earth/ Grounding Points
S.N. Description Location View Connector View

1. Battery Earth LH side back of Battery on Chassis

(VMT3S2) Frame

2. Chassis Earth LH side on Chassis

(VMT3S2) Frame

52
Contd..
S.N. Description Location View Connector View

3. Cab Earth RH RH side near to Accelerator Pedal on

(VFT1S2) Cabin Body

4. Cab Earth LH LH side below Dashboard & above EMS

(VFT3S2) on Cabin Body

53
Contd..

S.N. Description Location View Connector View

5. Engine Earth RH side near to starter motor on Engine

(EMT1S2) Body

54
14.

55
Interface Connector and their location
S.N. Description Interface Connector Connector View
Location View
01. Front Chassis to Cabin 29 36
(RA1) Harness
Interface Connector: 15 22
(36-Pole)
29
15111
9 14

8 1

02. Front Chassis to Cabin 3 1

(RA2) Interface 8 2
Connector 11
(15-Pole)
5

15 7
10
56
Contd..
S.N. Description Interface Connector Connector View
Location View
03. Cabin Harness to
6 1
Engine Harness (RBE2)
Interface Connector
(20Pole)
10 7
(VFT3S2)

20 15

04. Front Chassis to EATS

Harness (REATS1) 6 1
Interface Connector
10
(20Pole)
(VMT1S3) 7

20 15

57
Contd..
S.N. Description Interface Connector Connector View
Location View
08. Front Chassis to
Engine Harness (RAE2) 4
Interface Connector: 1
(16-Pole) 8
(VFT3S3) 5
12
9
16
13

09. Front Chassis Harness

to Rear Chassis 4 1
Harness (RR2)
Interface Connector
(8-Pole)

8 5
58
15.

Pin-Out Details

59
 15.a. Engine EMS ‘A’ Connector (105-Pin)

EXHAUST BRAKE
COOLANT TEMP. SENSOR INTAKE THROTTLE VALVE ACTUATOR EGR SWITCH GLOW PLUG
HP VALVE
1 2 2
1 3 4 5 6 1 2 4 5 6 1 1 2

35 04 25 60 15 87 62 66 68 73 45 89 56 36 94 101

Engine EMS ‘A’ Connector (105-Pin)

74 18 55 07 15 57 21 48 95 05 08 04 71 92

2 1 1 2 4 1 2 3 4 1 2 3 4 5
OIL PRESSURE SENSOR VISCOUS FAN VGT POSITION FEEDBACK
EXHAUST TEMP. BEFORE
CATALYZER : T4

60
 15.a. Engine EMS ‘A’ Connector (105-Pin)

AMBIENT TEMP. EGR COOLER OUT TEMP.

BOOST PRESSURE SENSOR WIF SENSOR FUEL TEMP. SENSOR IC OUTLET TEMP. I/P TEMPERATURE SENSOR: T4
I/P

3 4 1 2 1 2 1 2 1 2 2 1 2 1 2 1

54 06 18 34 11 16 63 16 39 17 27 20 41 20 18 74

Engine EMS ‘A’ Connector (105-Pin)

22 01 64 85 65 86 23 02 77 78 58 76 43 40 19 46 37 14 26 21

4 3 2 1 1 2 3 2 1 2 1 2 1
1 2 3
INJECTORS CRANK SHAFT SENSOR SCR EXHAUST TEMP. EXHAUST TEMP.
CAM SHAFT SNSOR RAIL PRESSURE SENSOR
UPSTREAM : T6 AFTER CATALYZER :
T5

61
15.b.Engine EMS ‘B’ Connector (91-Pin)

EMS RELAY 87
A
32

Engine EMS ‘B’ Connector (91-Pin)

03
SP1 36 B
05
BATTERY +VE 15 C ACC PADEL SENSOR
06
59 D
41
19 E

60 F
3 64
IGNITION SWITCH
4 43 2
17
01 65 3 HFM SENSOR
SP2
45 4
02
04
EMS GROUND 12 1 CLUTCH SWITCH
1 13
VSS SENSOR 46 1 BRAKE SWITCH 1
2 21
29 3 PARKING SWITCH 1
DCU RELAY 88
48 2&4 BRAKE SWITCH 1
EXHAUST BRAKE ACTUATOR 55
RELAY

62
15.b.Engine EMS ‘B’ Connector (91-Pin)

B +VE

86 30

Engine EMS ‘B’ Connector (91-Pin)

71 70
AC COMPRESSOR RELAY
86
85 87

82 30
1

DP SENSOR 2 18
STARTER SOLENOID
3
35

CAN 1L 80
CAN 1H 81 63 2
I/C SWITCH PIGTAIL
49 4
CAN 2H 75

CAN 2L 76

63
16. CAN1 Communication 16 Pins (Diagnostic)
4

CAB Earth

EMS RELAY
5
SP1

CAN1 Communication(Diagnostic)
Front Chassis CONN 1: 30 16
TELEMATICS : 05
ABS Exhaust Break Relay
CAN 2 :01
91-pin EMS CONN. B :64
DCU:10
Instrument Cluster C1 : 26 1 Instrument Cluster C1 : 30

ABS : 14 ABS : 03
I/C TO SUBHARNESS
14 Instrument Cluster C1 : 14
PARKING BRAKE: 06 Ignition Fuse 15A : BF1
ABS ECU : 01
DCU (DIAGNOSTIC) : 01
CAN 1L

Instrument Cluster C1 : 25

ABS : 06
CAN 1H
I/C TO SUBHARNESS
6
PARKING BRAKE: 06
ABS ECU : 03
DCU:11

64
 3
I/C FR. PIGTAIL HARNESS RH

17
RR AIR PR. +VE : B
:19

FR AIR PR. +VE :

18
B

I/C FR. CHASSIS HARNESS

6
FR AIR PR. SENSOR –VE : A

19
CONNE. 1 : 18

CAB EARTH

20
7
RR AIR PR. SENSOR :C

I/C FR. CAB HARNESS

21
CONNE. 2 : 11

AMBIENT SENSOR +VE : 1

22
I/C FR. CHASSIS HARNESS
9
CONNE. 1 :19
I/C ENGINE HARNESS C
1: 13
I/C FR. CHASSIS HARNESS

23
CONNE. 1 : 6
10

EX. BRAKE RELAY

SP4

I/C FR. CHASSIS HARNESS

CONNE. 1: 7
24

FR AIR PR. SENSOR : C

11

HIGH BEAM RELAY

CAN 1H : 6 I/C H/L PIGTAIL HARNESS

25

RH & LH : 2
12

CAN 1L : 14
26
Instr. Cluster (C1) Pin-Out Details: Green

FLASHER UNIT 1:7 & 8

13

27

CAN 2H : 6
17.1. Instr. Cluster (C1) Pin-Out Details 32 Pins: Green

CAN 2L : 14
28
14

BF1 IGNITION FUSE : 15A

BF1 -15A IGN.

30

SUPPLY FUSE

I/C FR. CHASSIS HARNESS

15

CONNE. 3 : 8
I/C FR. CHASSIS HARNESS
31

CONNE. 3 : 8

BF5-5A INS. CLUSTER

16

32

BF5 -5A INS. CLUSTER

65
17.2. Instr. Cluster (C2) Pin-Out Details 32 Pins: Blue

Instr. Cluster (C2) Pin-Out Details: Blue

FR. Fog Lamp Relay
1 Central Door Lock ECU : 02

I/C H/L Pigtail Harness LH : 04

19
5 I/C H/L Pigtail Harness RH/LH : 14

21 10 I/C Front Chassis CONN 1 : 10

CAB Earth

Brake Level Sensor : 02 22 11 Fog Lamp Relay

I/C Front Chassis CONN 1 : 11

Hydraulic Brake 2 : 01 23
12 I/C Engine Harness : 16

I/C H/L Pigtail Harness RH:06 32 13 I/C Sub Harness Parking Brake : 05

66
18. DCU Pin-Out Details 14 Pins

DCU Diagnostic CAN1 Diagnostic

14 6 DCU Relay 14 6

2 3 7 10 11

14-Pin DCU Connector

12 13 14
16

1 2
Urea Doser Ground

67
19.

Interface Connector Pinouts

68
I/C Cabin Harness to Engine Harness (RBE2) 20 pole (Female Coupler)
0.5 Y 0.5 V/W
SWITCH PIGTAIL : 13 10
1.5 Y FEED PUMP RELAY
BF 28 11 Dummy
0.5 Y
AC COMPRESSOR RELAY 1.0 Y 0.5 G/L
0.5 Y
DCU RELAY 01 12 6 COMBI SWITCH WIPER CONN.
0.5 Y 0.5 L-P
EGR COOLER RELAY EX- BRK RELAY
0.5 Y SP3
FEED PUMP RELAY 1.0 L-P 1.0 L-P
0.5 Y 13 I/C FRONT CHASSIS CONN 1 : 7
EX- BRK RELAY 0.5 L-P

SP4 10 INSTRUMENT CLUSTER C1

0.5 B-L
17 02 1.0 P-L

0.5 O/W
14 AC COMPRESSOR RELAY
91- Pin EMS 45 03 2.5 BR
conn. B 01
2.5 BR
91- Pin EMS
0.5 G/B conn. B
65 02
04 4.0 BR

0.5 BR
I/C FRONT
04 91- Pin EMS CHASSIS
0.5 L-BR
EGR COOLER

SP2 0.5 BR conn. B CONN. 02 : 08

05 15
RELAY

0.5 BR 0.5 BR INSTRUMENT CLUSTER C1

0.75 R-B 15 31
06 0.5 BR
5 COMBI SWITCH WIPER CONN.
0.5 Y/R 0.5 BR
1 BRAKE LEVEL SENSOR
1 07
COMBI SWITCH 1.5 BR
0.5 L/B 04
LIGHTING CONN. 2 08 1.5 BR ABS ECU CONN. X1
09
0.5 G/L 0.5 L 1.0 BR
16 09 16 5
I/C FRONT CHASSIS CONN. 02 : 31
INSTRUMENT CLUSTER CONN. B

69
I/C Engine Harness to Cabin Harness (RBE1) 20 pole (Male Coupler)

0.75 Y 0.5 V/W

VISCUS FAN : 05 10 EMS CONN. A : 80
0.5 Y
HFM SENSOR : 01 SP5 0.5 G/R
1.0 Y 11 EMS CONN. A : 42
0.75 Y
METERING UNIT 2 : 01 01 0.5 G/L
0.75 Y 12 EMS CONN. A : 36
METERING UNIT 1 : 01
0.5 Y
1.0 P
GLOW PLUG PIGTAIL : 03 13 EX. BRAKE ACTUATOR : 01

0.5 B/L
2 02 1.0 BR
15 EX. BRAKE ACTUATOR : 02
0.5 O/W
HFM SENSOR 4 03
0.5 Y
0.5 G/B
0.5 Y 3 04

0.75 P/L

Dummy 05 AC COMPRESSOR CLUTCH 1 : 01

1.0 P/L
14
Dummy 06 0.75 P/L
AC COMPRESSOR CLUTCH 2 : 01
0.5 Y/R
EMS CONN. A : 51 07
0.5 L/B 0.5 L
EMS CONN. A : 52 08 16 ALATERNATOR CHG. : 02
0.5 G/L
EMS CONN. A : 12 09

70
 0.5 R/G 0.5 R/G

2
I/C TO CABIN HARNESS

3
CONN.2 : 4
0.5 B/W

2
3

DP SENSOR
0.5 B/W I/C TO CABIN HARNESS

1
CONN.2 : 5
0.5 L/W

4
0.5 L/W I/C TO CABIN HARNESS

4
CONN.2 : 6

1.0 O/G

6
0.5 W-L

7
I/C TO CABIN HARNESS
5

0.5 G CONN.2 : 7

DCU
7

10
11
0.5 Y 1.0 Y/Gr I/C TO CABIN HARNESS
8
6

CONN.2 : 11
PRE NOX
SENSOR : 2
POST NOX 0.5 B
9

SENSOR : 2
0.5 W/BR
I/C TO ENGINE HARNESS : 1
11

SP6

0.5 B/Gr
PRE NOX I/C TO ENGINE HARNESS : 2
12

SENSOR : 1
0.5 W
POST NOX
10

SENSOR : 1
MALE COUPLER (REATS1)

SP7
FEMALE COUPLER (REATS2)

0.5 W/O
0.5 W/BR I/C TO ENGINE HARNESS : 3
13

11

TEMP SENSOR
T4 0.5 B/Gr 0.5 B/G
1

I/C TO ENGINE HARNESS : 4

14

12

0.5 LG/L
0.5 W/O I/C TO ENGINE HARNESS : 11
15

TEMP SENSOR
T5 0.5 B/G
1

0.5 W/G
13 14

I/C TO ENGINE HARNESS : 5

I/C Front Chassis Harness to EATS Harness (REATS1 & REATS2) Conn. (20 POLE )

0.5 B/Br
0.5 W/G I/C TO ENGINE HARNESS : 6
16 17

TEMP SENSOR
T6 0.5 B/Br
1
16 17

0.5 B I/C TO CABIN HARNESS

0.5 B CONN.2 : 1
2

0.5 R
DCU

0.5 R
I/C TO CABIN HARNESS
3
18 19

18 19

CONN.2 : 2
71
I/C Front Chassis Harness to EATS Harness (REATS1 & REATS2) Conn. (20 POLE )

4.0 BR
FRAME EARTH
0.5 BR
FUEL LEVEL SENSOR :01
1.0 BR
1.5 BR AC CONDENSER FAN : 02
1.0 BR
I/C FRONT CHASSIS HARNESS:1 SP8 SP10 HORN : 02
0.5 BR

FEMALE COUPLER (REATS2)

0.75 BR 1.5 BR EXHAUST BRAKE PIGTAIL : 02
1.5 BR
POST NOX SENSOR : 3 1 1 0.5 BR

MALE COUPLER (REATS1)

AIR FILTER RESTRICTION SENSOR : 02
0.75 BR 1.5 BR
PRE NOX SENSOR : 3 REAR CHASSIS HARNESS : 06
1.5 BR 0.5 BR
DCU:14 EXHAUST BRAKE SOLONOID : 04
1.5 BR
I/C CABIN HARNESS CONN. 1 : 31

0.5 G
1.0 W/L 7 33
I/C FRONT CHASSIS HARNESS:5 SP9
0.75 W/L 1.0 W/L 0.5 Y
POST NOX SENSOR : 4 5 8 35
0.75 W/L
0.5 B
I/C CABIN HARNESS CONN. 1 : 31
PRE NOX SENSOR : 4
9 13
0.5 W
10 12

72
I/C Cabin Harness to Front Chassis Harness 36 Pole (RB1) Male Coupler
FLASHER UNIT 1 : 02 1.0 G/O
01 B75
I/C H/L PIGTAIL HARNESS RH : 13 1.0 Y/R
0.5 W TELEMETIC HARNESS : 06
STOP LAMP RELAY 02 12
CAN 2 : 06
1.0 L/R
HORN RELAY 03 INSTRUMENT CLUSTER C1 : 27
1.0 BR-B B76
AC ON RELAY 1.0 BR-B TELEMETIC HARNESS : 02
0.5 BR-B 0.5 B
ENGINE EMS CONN. B:42
0.5 BR-B
04 13
AC CONDENSOR RELAY CAN 2 : 14
INSTRUMENT CLUSTER C1 : 28
FLASHER UNIT 1 : 01 1.0 G/Y 1.0 Br/P
05 16 AC COMPRESSOR RELAY
I/C H/L PIGTAIL HARNESS : 08 I/C H/L PIGTAIL HARNESS :19
0.5 Gr/P
0.5 O/R 17
INSTRUMENT CLUSTER C1 : 23 06 UNI BOOSTER : 01
0.5 Gr/W
1.0 L/P 18 INSTRUMENT CLUSTER C1 : 06
EX. BRK RELAY 1.0 L/P
07 0.5 Gr/B
0.5 L/P 19
INSTRUMENT CLUSTER C1 : 10 INSTRUMENT CLUSTER C1 : 09
1.5 P
BF 30 08 0.5 O/W
20 ENGINE EMS CONN. B:13
INSTRUMENT CLUSTER C1: 19 0.5 Gr/R 1.0 W/L
09 21 BF 27
RR AIR PRESSURE SENSOR -VE 1.0 R/B
22 AC CONDENSOR RELAY
0.5 O
INSTRUMENT CLUSTER C2 : 10 10 0.5 Gr/W
1.0 R/B 23 ENGINE EMS CONN. B:86
FOG LAMP RELAY 1.0 R/B 0.5 P/W
11 24 ENGINE EMS CONN. B:70
0.5 R/B
INSTR. CLUSTER C2: 11 0.5 Gr/R
1.0 Y/B 25 ENGINE EMS CONN. B:21
BF 24 : 25A 32
0.5 W/R
0.75 L/Gr 28 ENGINE EMS CONN. B:51
FEED EMS RELAY 34
73
I/C Cabin Harness to Front Chassis Harness 36 Pole (RB1) Male Coupler
ABS ECU : 04 1.0 R/B
ABS EXHAUST BRAKE RELAY
BRAKE LEVEL SENSOR : 01 2.5 R/B
ENGINE EMS CONN. B:03
COMBI SWITCH WIPER CONN. : 05
2.5 R/B
INSTRUMENT CLUSTER C1: 31 ENGINE EMS CONN. B:05
INSTRUMENT CLUSTER C1: 15
SP2 2.5 R/B
ENGINE EMS CONN. B:06
1.0 BR SP1
1.0 R/B
31 ENGINE EMS CONN. B:41
0.5 R/B
30 0.75 R/B
ABS DIDAGNOSTIC 16PF : 16
ENGINE EMS CONN. B:01
0.5 R/B I/C H/L PIGTAIL HARNESS RH : 09
ENGINE EMS CONN. B:02
ENGINE EMS CONN. B:04 0.75 R/B
CAN 1 : 16
0.75 R/B
I/C ENGINE HARNESS : 15 CAN 2 : 16
0.5 R/B
DCU DIAG: 16
I/C FRONT CHASSIS HARNESS
CONN. 02 : 08
ABS DIAGNOSTIC 16 PF : 06
ABS ECU X1 15 PF : 03 ABS DIAGNOSTIC 16 PF : 14
0.5 G
33 ABS ECU X1 15 PF : 01
0.5 Y INSTRUMENT CLUSTER C1 : 26
INSTRUMENT CLUSTER C1 : 25
CAN 1 : 06
35
CAN 1 : 14
I/C SUB HARNESS PARKIG BRAKE : 06 I/C SUB HARNESS PARKIG BRAKE : 07

74
I/C Front chassis Harness to Cabin Harness 36 Pole (RA1) Female Coupler
1.0 G/O
REAR CHASSIS HARNESS : 08 01 0.5 O/W

1.0 Y/R
20 VEHICLE SPEED SENSOR : 01
REAR CHASSIS HARNESS : 03 02 1.0 W-L
1.0 L-R 21 REVERSE TRANSMISSION SW. : 01
HORN : 02 03 1.0 R-B
22 AC CONDENSER FAN : 01
1.0 BR-B 0.5 Gr/W
AC PRESSURE SWITCH : 01 04 23 STARTER RELAY (LOW DRIVE ) : 02
1.0 G/Y 0.5 P/W
REAR CHASSIS HARNESS : 04 05 24 STARTER RELAY ( HIGH DRIVE ) : 01
0.5 O/R 0.5 Gr/R
FUEL LEVEL SENSOR : 02 06 25 VEHICLE SPEED SENSOR : 02
EXHAUST BRAKE SOLONOID : 01 1.0 L/P 0.5 W/R REAR CHASSIS HARNESS : 01
07 28
EXHAUST BRAKE PIGTAIL : 01 REVERSE TRANSMISSION SW. : 02
1.0 P 0.5 R-B
REAR CHASSIS HARNESS : 02 08 30 VEHICLE SPEED SENSOR : 03
0.5 BR
FUEL LEVEL SENSOR :01
0.5 Gr/R
FUEL LEVEL SENSOR : 03 09 1.0 BR
AC CONDENSER FAN : 02
0.5 O 1.0 BR
AIR FILTER RESTRICTION SENSOR : 01 10 SP10 0.5 BR
HORN : 02
1.0 BR EXHAUST BRAKE PIGTAIL : 02
0.5 W 31 0.5 BR
AIR FILTER RESTRICTION SENSOR : 02
I/C EATS HARNESS : 10 12 1.5 BR
REAR CHASSIS HARNESS : 06
0.5 BR
0.5 B EXHAUST BRAKE SOLONOID : 02
0.5 BR
I/C EATS HARNESS : 09 13 I/C EATS HARNESS : 01
0.5 G
33 I/C EATS HARNESS : 07
1.0 Br/P 0.5 L/GR
AC PRESSURE SWITCH : 02 16 34 FUEL LEVEL SENSOR : 04
0.5 Y
35 I/C EATS HARNESS : 08

75
I/C Front Chassis Harness to Engine Harness(RAE2 & RAE1) 20 POLE

0.5 W/BR
0.5 W/BR
02 2
74 02 0.5 B/GR TEMP. SENSOR T4
03 1
0.5 B/GR
18 03
0.5 W/O
0.5 W/O 04 2
105-PIN EMS CONN. 26 04 0.5 B/G TEMP. SENSOR T5
05 1

FEMALE COUPLER (RAE2)

A
0.5 B/G

MALE COUPLER (RAE1)

21 05
0.5 W/G

0.5 W/G
07 2
37 07 0.5 B/BR TEMP. SENSOR T6
08 1
0.5 B/BR
14 08 0.5 P/G
09 39
0.5 BR/W ECU - A
0.5 G/O
10 17

105-PIN EMS CONN. A 39 11

0.5 GR/W
17 12 11
0.5 G/O
1
0.5 GR/W WIF SENSOR
12 2

0.5 LG/L 0.5 LG/L

105-PIN EMS CONN. A 49 13 13 2 ULS SIGNAL

76
I/C Cabin Harness to Front Chassis Harness 15 Pole (RB2) Female Coupler
0.5 W-L INSTRUMENT CLUSTER C1 : 14

0.5 W-L
CAN 2 DIAGNOSTIC : 01
0.5 B
DCU DIAGNOSTIC : 14 01 0.5 W-L I/C HVAC SUB HARNESS : 01

0.5 R 0.5 W-L DCU DIAG : 01

DCU DIAGNOSTIC : 06 02
1.0 W-L WIPER RELAY 1
0.5 R-Y
ENGINE EMS CONN. B: 30 03 WASHER RELAY
1.0 W-L
0.5 P-W
ENGINE EMS CONN. B:35 04 1.0 W-L WIPER RELAY 2
0.5 O-W DRL RELAY
ENGINE EMS CONN. B:82 05 0.5 W-L

0.5 GR-B
SP11 CAN 1 DIAGNOSTIC : 01
0.5 W-L
ENGINE EMS CONN. B:18 06 0.5 W-L
07 0.5 W-L ABS DIAGNOSTIC 16PF : 01
4.0 R-B
MF 1 ( 40A) SP12 HYDRAULIC BRAKE 1 : 01
0.5 W-L
4.0 R-B 4.0 R-B
MF 3 ( 40A) 09 0.5 W-L FLASHER UNIT : 06
4.0 R-B
MF 5 ( 40A) 0.5 W-L TELEMATIC HARNESS : 05
4.0 R
MF 2 ( 60A) SP13 AC CONDENSER RELAY
0.5 W-L
4.0 R 4.0 R
MF 4 ( 40A) 10 1.0 W-L
ABS EXHAUST BRAKE RELAY
4.0 R
MF 6 ( 40A) 1.0 W-L AC ON RELAY
1.5 Y-GR
DCU RELAY 11 0.5 W-L ABS DIAGNOSTIC PIGITAL : 03

0.5 W-L ENGINE EMS CONN. B:64

1.5 Y
BF 32 13 0.5 W-L INSTRUMENT CLUSTER C1 : 30

1.0 W-L BF: 1

77
I/C Cabin Harness to Front Chassis Harness 15 Pole (RB2) Female Coupler

1.0 BR
WASHER RELAY
1.0 BR
WIPER CONTROLLER
0.5 BR
COMBI SWITCH LIGHTING CONNECCTOR : 08
2.5 BR
0.5 BR ENGINE EMS CONN. B:01
COMBI SWITCH WIPER CONNECTOR : 03
2.5 BR
1.0 BR ENGINE EMS CONN. B:02
ADD ON CONNECTOR : 02
1.0 BR SP14 2.5 BR
ENGINE EMS CONN. B:04
I/C TO INFOTAINMENT SYSTEM : 16
1.0 BR SP2 2.5 BR
I/C ENGINE HARNESS : 15
12 4.0 BR
1.0 BR 0.5 BR
AC ON RELAY 08 INSTRUMENT CLUSTER C1 : 31
1.0 BR 0.5 BR
INSTRUMENT CLUSTER C1 : 20 COMBI SWITCH WIPER CONNECTOR: 05
0.5 BR 0.5 BR
ABS DIAGNOSTIC ECU 16PF : 04 BRAKE LEVEL SENSOR : 01.
1.5 BR
0.5 BR ABS ECU X1 CONNECTOR 15PF : 04
I/C H/L PIGTAIL HARNESS RH : 17
0.5 BR
0.5 BR
INSTRUMENT CLUSTER C1 : 15
UNIBOOSTER : 02
1.0 BR
1.0 BR I/C FRONT CHASSIS CONN. 1 : 31
CAB EARH : 02

78
I/C Front Chassis Harness to Cabin Harness 15Pole (RA2) Male Coupler

0.5 B
I/C TO EATS HARNESS : 18 01
0.5 R 0.5 W-L
I/C TO EATS HARNESS : 19 02 07 I/C EATS HARNESS : 05
2.5 R-Y 0.5 R-Y
STARTER RELAY O/P 03
2.5 R-Y
STARTER SOLENOID
0.5 BR
EXHAUST BRAKE SOLONOID : 02
1.0 BR
0.5 R-G
HORN : 02
I/C EATS HARNESS : 02 04 1.5 BR
REAR CHASSIS HARNESS : 06
0.5 L-W 0.5 BR
I/C EATS HARNESS : 04 05 AIR FILTER RESTRICTION SENSOR : 02
0.5 B-W 0.5 BR
I/C EATS HARNESS : 03 06 EXHAUST BRAKE PIGTAIL : 02
SP10 1.0 BR
AC CONDENSER FAN : 02
4.0 BR 1.0 BR 0.5 BR
BATTERY EARTH 08 12 SIDE MARKER LAMP : 02
1.0 BR
I/C CABIN HARNESS CONN. 1 : 31
1.5 BR
4.0 R-B I/C EATS HARNESS : 01
MAXI FUSE : 01 09
0.5 BR
FUEL LEVEL SENSOR : 01
4.0 R
MAXI FUSE : 02 10 0.5 BR
FRAME EARTH

1.0 Y-GR
I/C EATS HARNESS : 06 11

79
I/C Front Chassis Harness to Rear Chassis Harness 8 Pole (RR2 ) Female Coupler
1.0 W/R
Reverse Transmission Sw:02 1
1.0 P
I/C to Cabin w/h conn1: 08 2
1.0 Y/R
I/C to Cabin w/h conn1: 02 3
1.0 G/Y
I/C to Cabin w/h conn1: 05 4
1.0 G/O
I/C to Cabin w/h conn1: 01 5
0.5 BR
Air filter restriction sensor:2
0.5 BR
Exhaust Brake Solenoid : 4
0.5 BR
Side Maker Lamp : 1 SP10
1.5 BR
4.0 BR
Frame Earth 6
1.0 BR
Horn : 2
1.0 BR
AC Condenser fan : 2
1.0 BR
I/C to Cabin w/h conn1: 12

0.5 BR
Fuel level Sensor: 01

1.5 BR
I/C to EATS Harness: 01

80
I/C Rear Chassis Harness to Front Chassis Harness to 8 Pole (RR1 ) Male Coupler

0.5 W/R
Rear comb. lamp LH
0.5 R/Y
Rear comb. lamp LH 0.5 W/R
1.0 R/Y 1.0 W/R
Rear comb. lamp RH
3 1 0.75 W/R
Reverse Buzzer 1(+ve)
Rear comb. lamp RH
0.5 R/Y 0.75 W/R
Reverse Buzzer 2(-ve)

1.0 G/Y
0.75 P
Rear comb. lamp LH 4 Rear comb. lamp LH
0.75 P
1.0 G/O Rear comb. lamp RH
0.5 P
Rear comb. lamp RH 5 1.0 P For Top light LH
2 0.5 P
For Top light RH
0.75 BR 0.5 P
Rear comb. lamp LH Side marker lamp:1
0.75 BR 0.5 P
Reverse Buzzer 1 Side marker lamp:2
0.75 BR
Rear comb. lamp RH
1.5 BR
6
0.5 BR
Side marker lamp:1
0.5 BR
Side marker lamp:2
0.75 BR
Reverse Buzzer 2

81
I/C Head lamp Harness to Cabin harness 22 Pole (RH1) Male Coupler
HEAD LAMP:3 1.5 L/R
1.5 L/R 1.0 W-L
01 10 CLUTCH SWITCH 2:2
H\L LEVELING MOTOR:3 0.5 L/P
1.5 L/R 1.5 Y/R 11 H\L LEVELING MOTOR:2
HEAD LAMP:6 02
0.5 R CLUTCH SWITCH 1:1
1.0 R/L 12
HEAD LAMP:5 03 CLUTCH SWITCH 2:3
1.0 R/Y 0.5 G/O
FOG LAMP RH:2 04 13 DOOR HARENESS RH:3
0.5 BR-G
0.5 BR
H\L LEVELING MOTOR:1 14 DOOR HARENESS RH:7
1.0 BR 0.5 BR-G
TOP LAMP:1 ROOM LAMP:2
0.5 BR 0.5 Y/GR
FOG LAMP RH:1 15 CLUTCH SWITCH 2:1
0.5 BR SP15
DOOR HARNESS RH:5 0.5 B/W
1.5 BR 16 DOOR HARENESS RH:4
1.5 BR
HEAD LAMP:4 05
0.5 BR 0.5 BR 0.5 BR
ROOM LAMP:1 CLUTCH SWITCH 1:2
0.75 BR 17
0.5 BR
BRAKE SWITCH 2:2 CLUTCH SWITCH 2:4
1.5 BR 0.75 GR-R
CAB EARTH 18 BRAKE SWITCH 2:1
0.5 P 0.5 P 0.5 GR/P
HEAD LAMP:1 06 19 VACCUM SWITCH 2:1
0.5 P
TOP LAMP:2 0.5 B/L
0.5 G/L 20 BRAKE SWITCH 1:1
DOOR HARNESS RH:1 07
ROOM LAMP:3 1.0 R/Y 0.5 O/B
21 BRAKE SWITCH 1:3
08
DOOR HARNESS:6
0.5 R/B 1.0 Y
BRAKE SWITCH 1:2/4 09 22 HEAD LAMP:2

82
H/L LEVELING MOTOR :2
I/C Cabin Harness to Head Lamp Harness RH 22 Pole (RH2) Female Coupler
1.5 L/R 1.0 R-B
ABS EXHAUST BRAKE RELAY : 30
LOW BEAM RELAY : 87 1.5 L/R
01 2.5 R-B
ENGINE EMS CONN. B:03
PIGTAIL HARNESS LH: 01 2.5 R-B
1.5 L/R ENGINE EMS CONN. B:05
1.5 Y/R 2.5 R-B
HI BEAM RELAY : 87 ENGINE EMS CONN. B:06
1.5 Y/R SP1
PIGTAIL HARNESS LH: 02 1.5 Y/R 02 1.0 R-B
ENGINE EMS CONN. B:41
0.5 R/B
INSTRUMENT CLUSTER C1 : 11
1.5 Y/R 09 0.75 R-B
ABS DIDAGNOSTIC 16PF : 16
1.0 R/L
0.5 R-B
FLASHER UNIT 1 : 04 03 I/C FRONT CHASIS CONNECTOR 1 : 30
1.0 R/Y 1.0 R/Y 0.75 R-B
FR FOG LAMP RELAY : 87 CAN 1 DIAGONSTIC : 16
04 0.75 R-B
0.5 R/Y CAN 2 DIAGONSTIC : 16
INSTRUMENT CLUSTER C2 : 19
2.5 R-B
EMS RELAY
1.0 P
BF 9 :15A 1.0 BR-G 1.0 BR-G
0.5 P
I/C PIGTAIL HARENESS LH : 14
I/C TO H/L PIGTAIL HARNESS LH: 06 14
1.0 P
0.5 B/W
FOG LAMP RELAY : 85 1.0 P
06 16 I/C INFOTAINMENT SYSTEM : 04
0.5 P
INSTRUMENT CLUSTER C2 : 32
0.5 GR-R
I/C TO HVAC SUB HARNESSS: 04
0.5 P 18 STOP LAMP RELAY : 30
0.5 GR-P
UNIBOOSTER : 01
I/C INFOTAINMENT SYSTEM :20
0.5 GR-P 0.5 GR-P
0.5 G/L INSTRUMENT CLUSTER C1 : 03
19
I/C INFOTAINMENT SYSTEM : 03
07 0.5 GR-P
I/C TO FRONT CHASSIS HARNESS CONN. 1 : 17
0.5 L-P 0.5 L-P
I/C SWITCH PIGTAIL CONNECTOR : 05 11 0.5 B-L
20 ENGINE EMS CONN. B:46

0.5 R 0.5 O-B

ENGINE EMS CONN. B:12 12 21 ENGINE EMS CONN. B:48

1.0 G/O 1.0 G/O 1.0 Y 1.0 Y

FLASHER UNIT 1 : 02 13 22 DRL RELAY : 87

83
I/C Cabin Harness to Head Lamp Harness RH 22 Pole (RH2) Female Coupler

1.0 BR
FLASHER UNIT :12

1.0 BR 1.0 BR
I/C FRONT CHASIS CONNECTOR 3 :12 I/C H/L PIGTAIL HARNESS LH : 05

1.0 BR 0.5 BR
WASHER RELAY :30 CAN2 DIAGONSTIC : 05
1.0 BR 0.5 BR
WIPER CONTROLLER ABS DIAGONSTIC PIGTAIL : 02
1.0 BR 0.5 BR
COMBI SWITCH LIGHTING CONNECCTOR : 08 COMBI SWITCH WIPER CONNECTOR : 01
0.5 BR
0.5 BR 4.0 BR
COMBI SWITCH WIPER CONNECTOR : 03
05 CAB EARTH
1.0 BR 0.5 BR
ADD ON CONNECTOR : 02 COMBI SWITCH LIGHTING CONNECTO R: 03
SP14 0.5 BR
1.0 BR COMBI SWITCH LIGHTING CONNECTOR : 13
I/C TO INFOTAINMENT SYSTEM : 16
1.0 BR 0.5 BR
COMBI SWITCH LIGHTING CONNECTOR : 11
17
0.5 BR
INSTRUMENT CLUSTER C2 : 21
1.0 BR
AC ON RELAY : 30 0.5 BR
CLOCK SPRING CONNECTOR : 04
0.5 BR
ABS DIAGNOSTIC ECU 16PF : 04
0.5 BR 1.0 R-Y
UNIBOOSTER : 02 DRL RELAY

INSTRUMENT CLUSTER C1 : 20 0.5 BR 0.5 R-Y 0.5 R-Y

1.0 BR
08 BF 23 (5A)

CAB EARTH 1.0 R-Y

I/C TO SUB HARNESS PARKING BRAKE : 08

84
20.

85
Power Supply Circuit Diagram
0.5 R/Br
16 Instr.
1.5 Y/W 0.5 R/Br
BF5 5A 0.5 R/Br
Cluster C1
4.0 R/B 4.0 Y/W
MF1 40A 32
SP26 1.5 Y/W
SP25 SP12 4.0 R/B
BF29 20A
RM: 1 RA2 : 9 MF3 40A
10.0 B 10.0 R 6.0 R/B 4.0 R/B 4.0 R/B 4.0 R/B
DCU RELAY
MF1 80A MF5 40A 1.5 L/B RB2 : 11
-ve 30 1.5 Y/Gr
87

Battery
4.0 R
MF2 60A
SP3
1.0 Y 0.5 BR/Gr

1.0 Y/Gr
RA2 : 10
SP13 4.0 R
85 86
RM: 2 MF4 40A
4.0 R 4.0 R 4.0 R 4.0 R
MF2 60A MF6 40A

1.5 Y

REATS : 6
EMS B:88
2.5 Y/B

1.5 R/B

1.0 O/G
1.5 Y/B
BF28
BF6 10A
Ignition 15A
Switch EMS B
2.5 Y/B 2.5 L/B 2.5 R-B 2.5 BR
DCU : 7
BF30 30A 1 B03 B01 SP2
EMS RELAY 2.5 R-B 2.5 BR 2.5 BR
B05 B02
2.5 Y/B 2.5 R-L 30 87 2.5 R-B ECU Ground
BF4 30A B06 2.5 BR
B04
1.5 R/L

1.0 R-B
SP1 B41 1.5 Y/W
SP24 2.5 Y/B BF3 10A
BF24 25A 85 86 SP11
0.5 W-L 1.0 W-L 1.5 Y/W
0.5 Gr/B
B64 BF1 15A 2
B87 SP27 Ignition
Instr.

0.5 W-L
Switch
0.5 W-L Cluster C1
14 30
Instr. Cluster C1
86
Cranking Circuit Diagram

91-PIN EMS CONN. B

RB1: 24
Starter Relay
0.5 P/W 0.5 P/W 2.5 R-Y
Ignition 86 87
B70 Starter Motor Solenoid
Switch
0.5 L/Y
4 B43
RB1: 23
2.5 R/B
SP26
B86
0.5 Gr/W 0.5 Gr/W 85 30

4.0 R/B
RM:1

6.0 R/B
MF1:80A

87
Crankshaft Sensor Circuit Diagram

105-Pin EMS
Connector A
0.5 W
77

1
2 Pin Sensor
2
0.5 LG
78

Voltage Test- Characteristics- Continuity Test-

Pin1 to Ground : 2.5 V 1. Working Principal – Variable Reluctance Pin1 to EMS Pin-77: +ve Signal
Pin2 to Ground : 2.5 V 2. Resistance - 860 ohms Pin2 to EMS Pin-78: -ve Signal
3. Operating voltage – 5V

88
Camshaft Sensor Circuit Diagram

105-Pin EMS
Connector A
0.5 Br/Y
43

1 0.5 G
3 Pin Sensor 76
3
2
0.5 Y
58

Voltage Test- Characteristics Continuity Test-

Pin3 to Ground : 5 - 5.5 V 1. Working Principal – Hall effect Pin1 to EMS Pin-43 : Ground
2. Resistance - 860 ohms Pin2 to EMS Pin-76 : Signal
3. Operating voltage – 5V Pin3 to EMS Pin-58 : Supply

89
Injector 1 Circuit Diagram

105-Pin EMS
Connector A

1.5 L
23

1
2-Pin Injector 1
connector 2
1.5W
02

Voltage Test- Characteristics:- Continuity Test-

Pin 1 to Ground – 2.5V-4.0V 1. Operating Temperature – 115°C to 120°C Pin 1 to EMS Pin 23 -Signal
Pin 2 to Ground – 2.5V-4.0V 2. Max Temperature - 140°C Pin 2 to EMS Pin 02 -Signal
3. Operating Voltage - 12 V
4. Over Pressure Inside the cylinder head core max - 6 kpa

90
 Injector 2 Circuit Diagram

105-Pin EMS
Connector A

1.5 G
65

2-Pin Injector 2
1
connector
2
1.5 L/G
86

Voltage Test- Characteristics:- Continuity Test-

Pin 1 to Ground – 2.5V-4.0V 1. Operating Temperature – 115°C to 120°C Pin 1 to EMS Pin 65 -Signal
Pin 2 to Ground – 2.5V-4.0V 2. Max Temperature - 140°C Pin 2 to EMS Pin 86 -Signal
3. Operating Voltage - 12 V
4. Over Pressure Inside the cylinder head core max - 6 kpa

91
 Injector 3 Circuit Diagram

105-Pin EMS
Connector A
1.5 L/Y
64

2-Pin Injector 3 1
connector
2
1.5 W/B
85

Voltage Test- Characteristics:- Continuity Test-

Pin 1 to Ground – 2.5V-4.0V 1. Operating Temperature – 115°C to 120°C Pin 1 to EMS Pin 64 -Signal
Pin 2 to Ground – 2.5V-4.0V 2. Max Temperature - 140°C Pin 2 to EMS Pin 85 -Signal
3. Operating Voltage - 12 V
4. Over Pressure Inside the cylinder head core max - 6 kpa

92
 Injector 4 Circuit Diagram

105-Pin EMS
Connector A

1.5 O
22

2-Pin Injector 4 1
connector
2
1.5GR
01

Voltage Test- Characteristics:- Continuity Test-

Pin 1 to Ground – 2.5V-4.0V 1. Operating Temperature – 115°C to 120°C Pin 1 to EMS Pin 22 -Signal
Pin 2 to Ground – 2.5V-4.0V 2. Max Temperature - 140°C Pin 2 to EMS Pin 01 -Signal
3. Operating Voltage - 12 V
4. Over Pressure Inside the cylinder head core max - 6 kpa

93
Coolant Temp. Sensor Circuit Diagram

105-pin EMS
Connector A

0.5 W/Y
35

1
2 Pin Sensor
2
0.5 B/Y 0.5 B/Y
04

Voltage Test- Continuity Test-

Pin1 to Ground : 4.5-5.5V Pin1 to EMS Pin-35: Supply
Pin2 to EMS Pin-04: Ground

94
Rail Pressure Sensor Circuit Diagram

105-pin EMS
Connector A
0.5 O/G
40

1 0.5 BR/G
3 Pin Sensor 19
3 2
0.5 P/Y
46

Voltage Test- Continuity Test-

Pin3 to Ground : 5-5.5V Pin1 to EMS Pin-40: Pr. Signal
Pin2 to EMS Pin-19: Ground
Pin3 to EMS Pin-46: Supply

95
 Oil Pressure Sensor Circuit Diagram

105-pin EMS
Connector A
0.5 P/L
55

1 2
0.5 O/B

4-Pin Sensor 07
4 3
SP19
0.5 B/W 0.5 B/W
15

Specifications:-

Voltage Test- Pressure(kpa) volts

Continuity Test-
Pin1 to Ground : 4.5-5.5V -50 0 Pin1 to EMS Pin-55: Supply
100 1V Pin2 to EMS Pin-07: Pr. Signal
300 2.25V Pin4 to EMS Pin-15: Ground
500 3.35V
612.5 4V
1000 4.5V
2100 4.75V

96
Metering Unit Circuit Diagram

Fuse and
Relay Box 91-Pin EMS
SP3 CONN.B
SP5 RBE1 : 1 BF 28
0.5 R-B 2.5 R-B
0.75 Y 1.0 Y 1.0 Y 1.5 Y
1 15 A 03
SP1
2 Pin Actuator 105-Pin EMS CONN. A
0.75 G/R 0.75 G/R
2 25

Voltage Test- Continuity Test-

Pin1 to Ground : 11-12V Pin1 to BF28 : Supply
Pin2 to EMS Pin-25 : Signal

97
TMAP Sensor Circuit Diagram

105-pin EMS
Connector A
0.5 B/Gr 0.5 B/Gr
18
0.5 G/P
1 2 34
4 Pin Sensor
4 3 0.5 P/B
54

0.5 O/BR
06

Voltage Test- Continuity Test-

Pin3 to Ground : 5-5.5V Pin1 to EMS Pin-18: Ground
Pin2 to EMS Pin-34: Temp. Signal
Pin3 to EMS Pin-54: Supply
Pin4 to EMS Pin-06: Pr. Signal

98
 HFM Sensor Circuit Diagram

91-pin EMS
SP3 BF28 CONN. B
SP5 RBE1-1
0.5 Y 1.0 Y 1.0 Y 1.5 R-B 2.5 R-B
1.5 Y
15 A 03
REB : 2 0.5 B/L SP1
0.5 B/L
17
1 2
4 Pin Sensor 0.5 G/B REB : 4 0.5 G/B
4 3 65 91-pin EMS
0.5 O/W REB : 3 0.5 O/W
CONN. B
45

Voltage Test- Characteristics- Continuity Test-

Pin1 to Ground : 11-12V 1. Working Principal – HFM (Absolute frequency)+ NTC Pin1 to BF28 : SUPPLY
2. Operating Voltage – 12V Pin2 to EMS Pin 17 : Ground
NTC nominal value: R = 2 kΩ ± 5 % at T = 25°C Pin3 to EMS Pin 65 : TEMP. Signal
Pull up-resistance:R ≥ 2 kΩ Pin4 to EMS Pin 45 : SIGNAL

99
Air Filter Restriction Sensor Circuit Diagram

RA1:10 INSTR. CLUSTER C2

0.5 O 0.5 O
1 10

2 Pin Sensor
0.5 BR 4.0 BR
2
FRAME EARTH
SP10

Voltage Test- Continuity Test-

Pin1 to Ground :5-5.5 V Pin2 to Cab. Earth: Ground
Pin1 to C1:10: Supply

100
Ambient Sensor Circuit Diagram

ECU A
0.5 GR/W 0.5 GR/W
16

2-pin ambient 2
Sensor Connector
1
ECU A
0.5 R/Y
11

Voltage Test- Continuity Test-

Pin1 to Ground : 2.5-4.0V Pin1 to ECU A 11 - Signal
Pin2 to ECU A 16- Ground

101
Vehicle Speed Sensor Circuit Diagram

91-pin EMS
Connector B
RA1:20
0.5 O/W 0.5 L/P
13
RA1:25
1 0.5 Gr/R 0.5 Gr/R
3 Pin Sensor 21
3 2
RA1:30
0.5 R/B 0.5 R/B 2.5 R/B
03
SP1

Voltage Test- Continuity Test-

Pin3 to Ground : 11-12V Pin1 to EMS Pin 13 : SIGNAL
Pin2 to EMS Pin 21 : Ground
Pin3 to EMS Pin 03 : SUPPLY

102
Viscous Fan Connector Circuit Diagram
105-pin EMS
CONN. A
0.5 R/Br
1 57
0.5 B/G 0.5 B/G
2 21
0.5 L
5 Pin Connector 3 48
0.75 B/W
4 95
91-pin EMS
REB :1 Fuse BF28 CONN. B
0.75 Y 1.0 Y 1.0 Y 1.5 Y 1.5 R-B 2.5 R-B
5 15 A 03
SP5 SP3 SP1

Voltage Test- Continuity Test-

Pin5 to Ground : 11-12V Pin1 to EMS Pin 57 : Supply
Pin2 to EMS Pin 21 : Ground
Pin3 to EMS Pin 48 : Signal
Pin4 to EMS Pin 95 : Signal
Pin5 to BF28 : Supply

103
Water in Fuel Sensor Circuit Diagram
105-pin EMS
CONN. A
RAE1:11
0.5 G/O 0.5 G/O
63

1
2 Pin Sensor
RAE1:12
0.5 GR/W 0.5 GR/W
2 16

Voltage Test- Continuity Test-

Pin1 to Ground : 0-4.5 V Pin1 to EMS Pin 63 : Signal
Pin2 to EMS Pin 16 : Ground

104
Feed pump relay & Fuel Level Sensor Circuit Diagram

SP10
0.5 BR 4.0 BR

Frame Earth
RA1:6
0.5 O/R 0.5 O/R
A B 23 INSTR. CLUSTER C1
4 Pin Sensor
D C 0.5 Gr/R
RA1:9 0.5 Gr/R 0.5 Gr/R
INSTR. CLUSTER C1
19

RA1:34 0.75 L/Gr

0.5 L/Gr 30 87 0.75 Y/P
10A BF22
RBE:10 0.5 Y 1.5 Y
0.5 V-W 0.5 V-W
105-PIN EMS CONN. A 80 15A BF28
86 85

FEED PUMP RELAY SP3

Voltage Test- Continuity Test-

PinD to Ground : 11-12V PinA to Ground : Ground
PinB to C1:23 : Signal
PinC to C1:19 :Signal
PinD to Relay :Supply

105
DP Sensor Circuit Diagram

91-pin EMS
CONN. B
REATS2:4 0.5 L/W RA2:5
0.5 L/W 0.5 O/W
82

1 SP17
REATS2:3 0.5 B/W RA2:6 0.5 Gr/B
0.5 B/W 0.5 B/W
3 Pin Sensor 18
2
3
REATS2:2 RA2:4
0.5 R/G 0.5 R/G 0.5 R/G 0.5 P/W
35
SP16

Voltage Test- Continuity Test-

Pin3 to Ground : 5-5.5V Pin1 to EMS Pin-82 : SIGNAL
Pin2 to EMS Pin-18 : GROUND
Pin3 to EMS Pin-35 : SUPPLY

106
Pre NOx Sensor Circuit Diagram

91-pin EMS
SP7 REATS2:10 RA1:12 CONN. B
0.5 W 0.5 W 0.5 W 0.5 W
75
SP6 REATS2:9 RA1:13
0.5 B 0.5 B
1 2 0.5 B 0.5 B
76
4 Pin Sensor 0.75 BR
SP8
1.5 BR
REATS2:1
1.5 BR
SP10 4.0 BR
3
4 FRAME EARTH
REATS2:5 RA2:7
SP9 BF1
0.75 W/L 1 W/L 0.5 W/L 0.5 W/L 1.0 W/L
FUSE AND
15 A
RELAY BOX
SP11
1.5 Y-W SP27

02 IGNITION SWITCH

Voltage Test- Characteristics- Continuity Test-

Pin4 to Ground –11.0-12.0 V 1. Nominal Voltage – 12V Pin1 to EMS Pin 75 - Signal
2. Operating voltage CAN H - 2-4V Pin2 to EMS Pin 76 - Signal
3. Operating Voltage CAN L – 1-3V Pin3 to Frame Earth – Ground
Pin4 to Fuse & Relay Box BF1 (15A) - Supply

107
 Post NOx Sensor Circuit Diagram

91-pin EMS
SP7 REATS2:10 RA1:12 CONN. B
0.5 W 0.5 W 0.5 W 0.5 W
75
SP6 REATS2:9 RA1:13
0.5 B 0.5 B
1 2 0.5 B 0.5 B
76
4 Pin Sensor SP8 REATS2:1 SP10
0.75 BR 1.5 BR 1.5 BR 4.0 BR
3
4 FRAME EARTH
REATS2:5 RA2:7
SP9 BF1
0.75 W/L 1 W/L 0.5 W/L 0.5 W/L 1.0 W/L
FUSE AND
15 A
RELAY BOX
SP11
1.5 Y-W SP27
IGNITION SWITCH
02

Voltage Test- Characteristics- Continuity Test-

Pin4 to Ground –11.0-12.0 V 1. Nominal Voltage – 12V Pin1 to EMS Pin 75 - Signal
2. Operating voltage CAN H - 2-4V Pin2 to EMS Pin 76 - Signal
3. Operating Voltage CAN L – 1-3V Pin3 to Frame Earth – Ground
Pin4 to Fuse & Relay Box BF1 (15A) - Supply

108
Urea Level Sensor Circuit Diagram

SP16 REATS2:2 RA:4

0.5 R/G 0.5 R/G 0.5 R/G 0.5 P/W
35 91-pin EMS CONN. B

REATS2:15 RAE:13
1 2 0.5 LG/L 0.5 LG/L 0.5 LG/L
49 105-pin EMS CONN. A
3 Pin Sensor
4.0 BR
3
SP17 REATS2:3 RA:6
0.5 B/W 0.5 B/W 0.5 B/W 0.5 GR/B
18 91-pin EMS CONN. B

Voltage Test- Continuity Test :

Pin1 to Ground – Not Updated Pin1 to EMS Pin B 35 - Supply
Pin2 to EMS Pin A 49 - Signal
Pin3 - Ground

109
 Temperature sensor (T4) Circuit diagram (at DOC In)

105-pin EMS
CONN. A
REATS2:12 RAE:3
0.5 B/Gr 0.5 B/Gr 0.5 B/Gr 0.5 B/Gr
1 18

2 Pin Sensor Specification:-

REATS2:11 RAE:2
0.5W/BR 0.5W/BR 0.5W/BR T °C RΩ
2 74
-40°C 169.7Ω
-20°C 185.1Ω
0 °C 200.5Ω
25°C 219.6Ω
50°C 238.5Ω
100°C 275.9Ω
Voltage Test- Continuity Test- 150°C 312.7Ω
Pin2 to Ground :0-4.5 V Pin1 to EMS Pin 18 : Ground 200°C 349.0Ω
Pin2 to EMS Pin 74 : Signal 250°C 384.6Ω
300°C 419.7Ω
350°C 454.2Ω
400°C 488.2Ω
500°C 554.2Ω
600°C 617.8Ω
800°C 738.2Ω

110
Temperature sensor (T5) Circuit diagram (at DPF In)

105-pin EMS
CONN. A
REATS2:14 RAE2:5
0.5 B/G 0.5 B/G 0.5 B/G 0.5 B/G
1 21

2 Pin Sensor REATS2:13 RAE2:4 Specification:-

0.5W/O 0.5W/O 0.5W/O
2 26 T °C RΩ
-40°C 169.7Ω
-20°C 185.1Ω
0 °C 200.5Ω
25°C 219.6Ω
50°C 238.5Ω
100°C 275.9Ω
150°C 312.7Ω
Voltage Test- Continuity Test- 200°C 349.0Ω
Pin2 to Ground : 0-5 V Pin1 to EMS Pin 21 : Ground 250°C 384.6Ω
Pin2 to EMS Pin 26 : signal 300°C 419.7Ω
350°C 454.2Ω
400°C 488.2Ω
500°C 554.2Ω
600°C 617.8Ω
800°C 738.2Ω

111
Temperature sensor (T6) Circuit diagram (at DPF Exhaust)

105-pin EMS
CONN. A
REATS2:17 RAE2:8
0.5 B/Br 0.5 B/Br 0.5 B/Br
1 14
2 Pin Sensor REATS2:16 Specification:-
RAE2:7
0.5W/G 0.5W/G 0.5W/G
2 37 T °C RΩ
-40°C 169.7Ω
-20°C 185.1Ω
0 °C 200.5Ω
25°C 219.6Ω
50°C 238.5Ω
100°C 275.9Ω

Continuity Test- 150°C 312.7Ω

Voltage Test-
Pin2 to Ground : 0-5 V Pin1 to EMS Pin 14 : Ground 200°C 349.0Ω
Pin2 to EMS Pin 37 : Signal 250°C 384.6Ω
300°C 419.7Ω
350°C 454.2Ω
400°C 488.2Ω
500°C 554.2Ω
600°C 617.8Ω
800°C 738.2Ω

112
112
Inter Cooler Outlet temperature sensor circuit diagram

105-pin EMS
Connector A
SP18
0.5 B/P 0.5 B/P
20

1
2 Pin Sensor
2
0.5 W/B
27

Voltage Test- Continuity Test-

Pin2 to Ground : 0-4.5 V Pin1 to EMS Pin 20 : GROUND
Pin2 to EMS Pin 27 : SIGNAL

113
 EGR Cooler Temperature Sensor Circuit Diagram

105-pin EMS
Connector A
SP18
0.5 B/P 0.5 B/P
20

1
2 Pin Sensor
2
0.5 W/R 41

Continuity Test-
Voltage Test-
Pin1 to EMS Pin 20 : GROUND
Pin2 to Ground : 0-4.5 V
Pin2 to EMS Pin 41 : SIGNAL

114
EGR Valve Actuator Circuit Diagram

105-pin EMS
Connector A
0.75 R/GR
68

11 0.5 O/L
73
3 2
6 Pin Actuator
4 0.5 B/Y
6 5 45

0.75 Br/P
89
0.5 P/W
56

Voltage Test- Continuity Test-

Pin1 to Ground – 11V - 12V Pin1 to EMS Pin 68 -Motor +ve
Pin6 to Ground – 5-5.5V Pin2 to EMS Pin 73 -Signal
Pin4 to EMS Pin 45 -Ground
Pin5 to EMS Pin 89 -Motor –ve
Pin6 to EMS Pin 56 -Supply

115
 Intake Throttle Valve Actuator Circuit Diagram
105-pin EMS
connector A
0.5 Y/Gr
60

11 2 0.5 B/W 0.5 B/W

15
3
SP19
4 0.75 Br/R
6 Pin Actuator 6 5 87

0.75 O/Gr
62
0.75 R/L
66

Characteristics-
Voltage Test- Continuity Test- ITV Position Percentage % Voltage
Pin1 to Ground – 4-5.0V Pin1 to EMS Pin:60 - Supply Diagnostic Range 95 % 4.75V
Pin6 to Ground – 5-5.5V Pin3 to EMS Pin:15 - Ground Fully Closed 90 % 4.5V
Pin4 to EMS Pin:87 - Motor –ve Min Closed 88.46% 4.424V
Pin5 to EMS Pin:62 - Signal
Min Open 20.10% 1.005V
Pin6 to EMS Pin:66 - Motor +ve
Open 15% 0.79V
Fully Open 10% 0.5V
Diagnostic range 5% 0.25V

116
VGT Actuator Circuit Diagram

105-pin EMS
Connector A
0.5 P
05
0.5 O
11 2 08
5 Pin Actuator

3 0.5 B/Y 0.5 B/Y

5 4 04

0.75 R/B
71
0.75 B/Br
92

Voltage Test- Continuity Test-

Pin1 to Ground : 5-5.5V Pin1 to EMS Pin 05 : SUPPLY
Pin4 to Ground : 5-5.5V Pin2 to EMS Pin 08 : SIGNAL
Pin3 to EMS Pin 04 : GROUND
Pin4 to EMS Pin 71 : MOTER +VE
Pin5 to EMS Pin 92 :Motor -ve

117
 Exhaust Brake Actuator Circuit Diagram

SP4 EX. BRAKE RELAY

RA:13 0.5 Y/R
1.0 L/ P 1.0 L/P 1.0 L/P 87 30
2 Pin Exhaust Brake 1
Solenoid SP3 EMS
1.5 Y 0.5 Y 86 85 0.5 GR
BF28:15 B55

1.5 R-B
2
30 87 a
1.0 R-B
0.5 BR 87
SP1
0.5 B 86 85 1.0 W-L 1.0 W-L
ABS ECU X1 CONN. BF1 -15A
SP10
ABS Exhaust BRAKE SP11 Ign.Fuse
4.0 BR SP2 4.0 BR
RB2: 8
4.0 BR
Frame Earth
0.5 BR

5
RBE2:12 Battery Earth
0.5 L/G 0.5 L/G
6
Combi Sw./ Exhaust
brake Sw. EMS
A36
Brake Switch2 Circuit Diagram
Rear comb. Lamp
RB1: 2 RR2: 3 LH and RH
1.0 Y/R 1.0 Y/R 1.0 R/Y
03
30 87 1.0 Y/L
RH2: 18
85 86 0.5 Y/L 1.0 Y/L
BF14:5A
0.75 Gr/R 0.5 Gr/R
Stop Lamp Relay Rev/Stop
lamp fuse
2-pin Switch 1
1
2 2

0.75 BR 1.5 BR

SP15
Cabin Earth

Voltage Test (In Volt): Continuity Test-

Pin1 to Ground : 10V – 12V Pin1 to Relay - Supply
Pin2 to Earth - Ground

119
 DPF Inhibition Switch Circuit Diagram

Parking Lamp Relay BF12

FUSE BOX
1.0 P 1.0 P/L 87 30 1.5 R/W
BF9 MF2
Combi switch Light

0.5 P
0.5 GR/W 85 86 0.5 R/W BF13
12
1
1 2
0.5 BR 1.0 BR
Cabin Earth LH

7
3 0.5 GR/W 0.5 GR/W
ENGINE ECU (B:50)
6
8
FUSE BOX IGN SWI.
0.5 W/L 0.5 W/L 1.0 Y/L
BF1 2

Voltage Test (In Volt): Continuity Test:

120
 DPF Switch Circuit Diagram

RPH 1:12 EMS ECU

0.5 P/R 0.5 P/R
B44

RPH 1:16 PARKING LAMP

1 0.5 P 0.5 P 0.5 P 1.0 P
BF9:15A
1 3
RPH 1:13 VPWR
4 0.5 Y 0.5 Y 0.5 Y 1.0 Y
BF28:15A
RPH 1:07
5 0.5 BR 1.0 BR 1.0 BR 1.0 BR
CABIN EARTH
6

0.5 BR

Voltage Test (In Volt): Continuity Test:

121
Brake Switch 1 Circuit Diagram

91-Pin EMS
CONN. B
0.5 B/L RH2:20 0.5 B-L
1 46

0.5 R/B 0.5 R/B RH2:9

0.5 R-B 2.5 R-B
4 03
4 Pin Switch 0.5 R/B SP1
2
RH2:21
0.5 O/B 0.5 O-B
3 48

Voltage Test- Continuity Test-

Pin3 to Ground : 11-12V Pin1 to EMS Pin 46 : SIGNAL
Pin2 to EMS Pin 48 : SIGNAL
Pin3 to EMS Pin 03 : SUPPLY
Pin4 to EMS Pin 48 : SIGNAL

122 122
Rear Air Pressure Sensor Circuit Diagram

INSTR. CLUSTER A
0.5 GR/R 0.5 GR/R
19

A 0.5 P/B
3 Pin Sensor B 17
C
0.5 O/B
07

Voltage Test- Continuity Test-

PinB to Ground : 4.5-5.5V PinA to A-19: Ground
PinB to A-17: Supply
PinC to A-07: Signal
Front Air Pressure Sensor Circuit Diagram

INSTR. CLUSTER A
0.5 Gr/R
19

A 0.5 P/R
3 Pin Sensor B 18
C
0.5 O/W
24

Voltage Test- Continuity Test-

PinB to Ground : 4.5-5.5V PinA to A-19: Ground
PinB to A-18: Supply
PinC to A-24: Signal

124
Ignition Switch Circuit Diagram

4 Pin Switch
Ignition SW. Fuse SP24 SP12 RB2 : 9
4.0 R/B
RM: 1
2.5 L/B 2.5 Y/B 2.5 Y/B 4.0 R/B 4.0 R/B 4.0 R/B
1 BF30:30A MF3:40A MF1:80A
0.5 W/L SP26
Ignition supply Fuse SP11 14 INSTR.
1.0 w/L
1.5 Y/W 1.5 Y/W Cluster
2 BF1:15A 0.5W/L

0.5W/L
30 C1
SP27
B64
EMS

Accessories Fuse
1.5 L/Gr
3 BF7:10A

0.5 L/Y 91-pin EMS

4 43 Connector B

125
Unibooster Circuit Diagram

Inst. Cluster A
0.5 Gr/P 0.5 Gr/P

1 03
0.5 Br 1.0Br
2
SP14
Cabin Earth

126
Combi Switch Lighting conn./ Cruse Control Switch

RBE2: 08
0.5 L/B 0.5 L/B
02 A52 EMS- A
Combi Sw.
Lighting Conn./
Cruse Control Sw. 0.5 BR 4.0 BR
15
Cabin Earth

Voltage Test- Continuity Test-

Pin2 to Ground: 10-12V Pin2 to EMS A Pin 52:Supply
Pin15 to Cab Earth: Ground

127
Brake Level Sensor Circuit Diagram

SP2 RB2:8
0.5Br 4.0 Br 4.0 Br
1
0.5B/L
22 Battery Earth
2
Inst. Cluster B

128
 Accelerator Pedal Sensor Circuit Diagram

91-pin EMS
CONN. B
0.5 Y/G
32
0.5 Y/O
B 36
A 0.5 Gr/G
C 15
6 Pin Sensor
D 0.5 G/R
59
F E
0.5 Gr/Y
19
0.5 G/W
60

Voltage Test- Characteristics- Continuity Test-

PinA to Ground – 5-5.5V 1. Working - Potentiometer PinA to EMS Pin:32 -Supply
PinB to Ground – 5-5.5V 2. Operating Voltage – 5V PinB to EMS Pin:36 -Supply
3. Max Current consumption – 10mA PinC to EMS Pin:15 -Ground
4. Potentiometer Resistance P1 – 1.2 KΩ PinD to EMS Pin:59 -Signal
5. Potentiometer Resistance P2 – 1.7 KΩ PinE to EMS Pin:19 -Ground
PinF to EMS Pin:60 -Signal

129
Clutch Switch 1 Circuit Diagram

91-pin EMS
CONN. B
RH2:12
0.5 R 0.5 R 0.5 R
1 12
2 Pin Switch RH2:17
0.5 Br 0.5 Br 0.5 BR 1.0 BR
2

Cabin Earth

Voltage Test- Continuity Test-

Pin1 to Ground : 10-12V Pin2 to Cab. Earth : Ground
Pin1 to EMS Pin 12 : Supply

130 130
 Power + Eco Switch Circuit Diagram

RAH:02 0.5 BR/P

0.5 BR/P Parking Lamp Relay
ECU B-49 Combi. Sw.
0.5GR/W 0.5R/W
85 86
12
RAH:16 2.5R/W
0.5P 0.5P 1.5R/W
11 0.5P 1.0P
BF9:15A 1.5P/L
MF2:60A
2 3 87 30
6 Pin

4.0 R
SP20 SP21 SP13
Switch 1.5Y/W Ign. Sw. RB2:10

4.0 R 4.0 R
6 RAH:3
5 4
0.5W/L 0.5W/L 0.5W/L 1.0W/L BF1:15A 2 RM:2

SP23 SP11 SP27

0.5BR MF2:60A
RAH:7

10.0 R
0.5BR 1.0BR 1.0BR 1.0BR
10.0 B
SP25

10.0 R
SP22 SP14 -ve

Cab Earth Battery

131
Eco+ Switch Circuit Diagram

RAH:4 0.5 BR/P

0.5 BR/P Parking Lamp Relay
ECU B-63 Combi. Sw.
0.5GR/W 0.5R/W
85 86
12
RAH:16 2.5R/W
0.5P 0.5P 1.5R/W
11 0.5P 1.0P
BF9:15A 1.5P/L
MF2:60A
2 3 87 30
6 Pin

4.0 R
SP20 SP21 SP13
Switch Ign. Sw. RB2:10

4.0 R 4.0 R
6 RAH:3 1.5Y/W
5 4
0.5W/L 0.5W/L 0.5W/L 1.0W/L BF1:15A 2 RM:2
SP23 SP11 SP27
0.5BR MF2:60A
RAH:7

10.0 R
0.5BR 1.0BR 1.0BR 1.0BR
10.0 B
SP25

10.0 R
SP22 SP14 -ve

Cab Earth Battery

132
 Reverse Transmission Switch

Ign. Sw.
RA1:21
1.0W/L 1.0W/L 1.5 Y/W
1 BF2:5A 2
2 Pin Switch
1 Rear Combi. Lamp LH

RR2:1
1.0 W/R 1.0W/R 0.5W/R
2 1 Rear Combi. Lamp RH

2 Reverse Buzzer 1&2

133
 DCU (DOSING CONTROL UNIT) Circuit Diagram

REATS2:18 RA2:1
0.5 B 0.5 B 0.5 B
2 14 Diagnostics
0.5 R REATS2:19 0.5 R RA2:2 0.5 R DCU
6
3
1.5 L/B
REATS2:6 RA2:11 1.5 Y/ GR
1.0 O/G 1.0 Y/GR 87 30
20A BF29
7 DCU RELAY
0.5 BR/GR 0.5 Y
91-pin ECU B : 88 86 85 15A BF28
SP3 1.5 Y
REATS2:7 RA1:33
0.5G 0.5G 0.5 G
DCU 10 80 91-pin EMS CONN. B
(DOSING CAN L
CONTROL CAN H
RA1:35
UNIT) 11
0.5 Y REATS2:8
0.5 Y 0 .5 Y
81 91-pin EMS CONN. B

0.75 G
12 1
UREA DOSER
13
0.75 O
2
REATS2:1
1.5 BR 1.5 BR 1.5 BR 4.0 BR
14
EARTH
SP8 SP10

134
 HSA Switch Circuit Diagram

RAH:04 Parking Lamp Relay

0.5 G/Y 0.5 G/Y
ABS X1 Combi. Sw.
0.5GR/W 85 0.5R/W
86
RAH:16
12
2.5R/W
0.5P 0.5P 0.5P 1.5R/W
11 1.0P
BF9:15A 1.5P/L
MF2:60A
2 3 87 30
6 Pin

4.0 R
SP20 SP21 SP13
Switch Ign. Sw. RB2:10

4.0 R 4.0 R
6 0.5W/L 0.5W/L
RAH:3
0.5W/L 1.0W/L
1.5Y/W
5 4
BF1:15A 2 RM:2

SP23 SP11 SP27

0.5BR MF2:60A
RAH:7

10.0 R
0.5BR 1.0BR 1.0BR 1.0BR
10.0 B
SP25

10.0 R
SP22 SP14 -ve
Cab Earth
Battery

135
ESS Switch Circuit Diagram

RAH:11
0.5P/B 0.5 P/B
ECU B-84
Parking Lamp Relay
Combi. Sw.
0.5GR/W 0.5R/W
85 86
SP20 RAH:16 SP21 12 85
2.5R/W
0.5P 0.5P 0.5P 1.0P 1.5R/W
11 BF9:15A 1.5P/L
MF2:60A
2 3 87 30
6 Pin

4.0 R
DPF Sw. SP13
Switch SP1 RB2:10

4.0 R 4.0 R
4 0.5Y RAH:13 SP3
0.5Y 1.5Y 1.5R/B 2.5R/B
5 6 BF28:15A ECU B-03 RM:2

SP23 SP11 Ign. Sw.

0.5W/L RAH:3
0.5W/L 1.5Y/W
MF2:60A
0.5W/L 1.0W/L
BF1:15A 2

10.0 R
10.0 B
RAH:7 1.0BR SP27 SP25
0.5BR 1.0BR 1.0BR

10.0 R
-ve

SP22 SP14 Battery

Cab Earth

136
CAN 1 Diagnostic Circuit Diagram

0.5 Y
25
INSTRUMENT
CLUSTER C1 0.5 G
26
0.5 Y
81
91-pin EMS
CONN. B 0.5 G
80
0.5 Y

CAN1 H
REATS1:8 RB1:35
0.5 Y
11
DCU
REATS1:7 RB1:33
0.5 G 0.5 G
10
CAN1 L

137
CAN 2 Diagnostic Circuit Diagram

0.5 W
27
INSTRUMENT
CLUSTER C1 0.5 B
28
0.5 W
75

91-pin EMS
CONN. B 0.5 B
76
REATS1-10 RB1-12
0.5 W
01
Pre/Post REATS1-9 RB1-13 0.5 W
NOx Sensor 0.5 B
CAN2 H
02
0.5 W
06
TELEMETIC HARNESS

0.5 B 0.5 B
02
CAN2 L

138
DCU Diagnostic CAN3 Circuit diagram

REATS1:19 RB:2
0.5 R 0.5 R 0.5 R
03
CAN3 H

DCU
REATS1:18 RB:1
0.5 B 0.5 B 0.5 B CAN3 L
02

139
 21. ABBREVIATIONS
Short Name Desc. Short Name Desc.

RAE2 16 Pin Front Chassis Harness To Engine Harness Interface A 105 Pin EMS Connector
Connector
REATS2 20 Pin EATS Harness to Front Chassis Harness Interface B 91 Pin EMS Connector
Connector
RAE1 16 Pin Engine Harness to Front Chassis Harness Interface RA1 36-Pin Front Chassis Harness To Cabin Harness Interface
Connector Connector

RB2 15-Pin Cabin Harness to Front Chassis Interface Connector RA2 15-Pin Front Chassis Harness To Cabin Harness Interface
Connector

RB1 36-Pin Cabin Harness to Front Chassis Interface Connector RBE1 20-Pin Engine Harness to Cabin Harness Interface Connector

RH2 22-Pin Head Lamp Harness to Cabin Harness Interface RR2 08-PinFront Chassis Harness to Rear Chassis Harness
Connector Interface Connector

REATS1 20 Pin Front Chassis Harness to EATS Harness Interface RH1 22-Pin Cabin Harness to Head Lamp Harness Interface
Connector Connector

RBE2 20-Pin Cabin Harness to Engine Harness Interface Connector RAH 20-Pin Switch pigtail harness to cabin harness interface
connector
140
21. ABBREVIATIONS
Splice Description & Page No. Splice Description & Page No.
SP1 RB1:30 (Page-73) SP16 DP Sensor:3 & Urea Level:1 (Page-105 & 108)
SP2 RBE2:15 (Page-68) SP17 DP Sensor:2 & Urea Level:3 (Page-105 & 108)
SP3 RBE2:01 (Page-68) SP18 I-C Outlet:1 & EGR Cooler:1 (Page-112 &113)
SP4 RBE2:13 (Page-68) SP19 ITV:3 & Oil Pressure:4 (Page-95 & 115)
SP5 RBE1:01 (Page-69) SP20,21,22,23 (Page-128,129,132,133)
SP6 REATS2:9 (Page-70) SP24 MF-3(40A) (Page-85)
SP7 REATS2:10 (Page-70) SP25 Battery +ve (Page-85)
SP8 REATS2:01 (Page-71) SP26 RM:1 (Page-85)
SP9 REATS2:5 (Page-71) SP27 Ignition Sw:2 (Page-85)
SP10 REATS1:01 (Page-71)
SP11 RB2:07 (Page-76)
SP12 RB2:9 (Page-76)
SP13 RB2:10 (Page-76)
SP14 RB2:15 (Page-77)
SP15 RH1:05 (Page-81)
141
 ABBREVIATIONS
Short Name Desc. Short Name Desc.
CAN H Controlled Area Network High Temp. Temperature

CAN L Controlled Area Network Low

VSS Vehicle Speed Sensor Pr. Pressure

C1 Instrument Cluster Connector (Green) +ve Positive

C2 Instrument Cluster Connector (Blue) -ve Negative

DCU Dosing Control Unit Ign. Ignition

BF Blade Fuse Sw. Switch

MF Maxi fuse

SCR Selective catalytic reduction H/L Head Lamp

I/C Interface connector Instr. Instrument

ECU Electronic Control Unit HP High Pressure Pump

WIF Water in Fuel Sensor MAP Manifold Absolute Pressure Sensor 142