The Repair Manual of T5G Electrical System

R.EL.T5G.
01
R.EL.T5G.01
The Repair Manual of T5G

Electric System
SINOTRUK No. 777 Hua'ao Road Jinan,

INTERNATIONAL Shandong Province, China, 250101
AFTER SALES SERVICE DEPARTMENT T5G Electrical Manual
1st Edition -English-
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The T5G Truck
2
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PREFACE
This manual provides assistance in performing repairs correctly on vehicles and units and
reflects the known technical situation appertaining at the copy deadline.
This publication assumes that persons who use it possess the requisite technical
knowledge in repairing vehicles and units.
Pictures and the corresponding descriptions are typical one-time representations; they do
not always correspond to the unit to be repaired or its peripherals.
The repair jobs are divided up into sections and subsections. Each subsection starts with
a page of jobs to do in advance. The jobs to do in advance contain a summary of the main
prerequisites for the repair section in question. The detailed description of work can follow
the jobs to do in advance. Only the tightening torques for screw/bolt connections which
deviate from the standard are indicated in the repair sections.
Important instructions concerning technical safety and the safety of personnel are
specifically highlighted, as indicated below.
CAUTION
Type and source of danger
• Refers to working and operating procedures which must be followed exactly
in order to avoid exposing people to risk.
WARNING
Type and source of danger
• Refers to working and operating procedures which must be followed exactly
in order to avoid serious or irreparable damage to property.
NOTE
An explanatory note which is useful for understanding the working or
operating procedure to be performed.
Comply with general safety regulations when performing any repair work.
We reserve the right to make modifications in the course of further development.
Best wishes from
SINOTRUK INTERNATIONAL.
PRINTER'S IMPRINT
Reprinting, copying or translation, even of extracts, is not allowed without the written
approval of SINOTRUK. All rights under the copyright law are strictly reserved by
SINOTRUK. If any changes or modifications are made without the written approval of
SINOTRUK then SINOTRUK shall not be liable for any material defects attributable to the
unauthorized changes or modifications. SINOTRUK is not liable for any damage
attributable to unauthorized changes or modifications.
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Content
1. INTRODUCTION ............................................................................................................. 6
1.1 SAFETY INSTRUCTIONS ..................................................................................... 6
1.1.1 Regulations for Preventing Accidents Leading to Injury to Personnel......... 6
1.1.2 Notes on Preventing Damage and Premature Wear on Units................... 10
1.1.3 Limited Liability for Parts and Accessories ................................................ 10
1.1.4 Regulations for Avoiding Injury and Environmental Contamination .......... 11
1.1.5 Special Information for Working on The Common-rail System.................. 12
1.1.6 Limp-home Program for Units with Electronic Control Units ..................... 14
1.1.7 Installation Instructions............................................................................... 14
2.The overview ................................................................................................................. 16
THE COMPOSITION OF THE REPAIR MANUAL ..................................................... 16
3. THE EXPLANTION OF PRINCIPLE CIRCUIT DIAGRAM ........................................... 18
3.1THE PRINCIPLE CIRCUIT DIAGRAM.................................................................. 18
3.2 READING THE CIRCUIT DIAGRAM ................................................................... 18
3.2.2 The Basic Concepts of Circuit Diagram ..................................................... 31
4. THE INSTRUMENT AND THE ALARMING INDICATORS .......................................... 34
4.1 THE COMBONATION INSTRUMENT ................................................................. 34
4.2 THE INSTRUMENT ALARMING LAMPS............................................................. 38
4.2.1 The instrument alarming lamps layout ....................................................... 38
4.2.2 The alarming lamp symbols and definition ................................................ 38
5. THE INTRODUCTION OF MINI CONTROLLER .......................................................... 50
5.1 THE MINI CONTROLLER .................................................................................... 50
5.1.1 Overview .................................................................................................... 50
5.1.2 The facade ................................................................................................. 50
5.1.3 The definition .............................................................................................. 51
5.1.4 The basic functions .................................................................................... 53
5.2 THE JUNCTION BOX ASSEMBLY ...................................................................... 55
6. THE CAB ROCKER SWITCHES .................................................................................. 56
6.1 THE LAYOUT OF OF ROCKER SWITCHES ...................................................... 56
6.2 The Rocker Switches ........................................................................................... 57
7.THE OTHER CAB ELECTRIC EQUIPMENTS .............................................................. 60
7.1 THE INTRODUCTION OF SOME SWITCHES.................................................... 60
7.1.1 The Key Switch .......................................................................................... 60
7.1.2 The Horn Switch......................................................................................... 60
7.1.3 The Left Combination switch ...................................................................... 61
7.1.4 The Right Combination Switch................................................................... 62
7.1.5 The lighting lamp switch ............................................................................. 64
7.2 THE OTHER ELECTRIC EQUIPMENTS ............................................................. 67
7.2.1 The Driving Recorder ................................................................................. 67
7.2.2 The 24V Electric Lighter ............................................................................. 67
7.2.3 MP3 ............................................................................................................ 67
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8. THE INTRODUCTION OF LIGHTING SYSTEM .......................................................... 68

8.1 THE FRONT LAMP .............................................................................................. 68
8.1.1 Install the Front Combination Lamp ........................................................... 68
8.2 THE REAR LAMP................................................................................................. 69
8.3THE INNER LIGHTING LAMPS AND READING LAMP....................................... 69
8.3.1 The Inner Lighting Lamps .......................................................................... 69
8.3.2 The Reading Lamp..................................................................................... 70
8.4 THE POSITION LAMP AND STEERING LAMP .................................................. 70
9.THE CHASSIS ELECTRIC EQUIPMENTS ................................................................... 72
9.1 THE INTRODUCTION OF CHASSIS HARNESS WIRE ..................................... 72
9.2 THE BATTERY BOX ELECTRIC EQUIPMENT AND WIRE ................................ 75
9.3 THE ENGINE AND STERTER MOTOR WIRE .................................................... 77
9.4 THE AIR DRYER AND THE INTER-AXLE DIFFERENTIAL LOCK ..................... 79
9.5 THE AIR FILTER WIRE AND FUEL SENSOR WIRE .......................................... 80
9.6 THE SIDE POSITION LAMP,SOLENOID VALVE AND TRAILER ....................... 82
WIRE .......................................................................................................................... 82
9.7 THE REAR LAMP AND WIRE,THE ABS HARNESS WIRE ................................ 85
9.8 THE ELETRIC OVERTURN DEVICE,AIR PRESSURE SENSOR ...................... 88
AND RATED WIRE..................................................................................................... 88
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1. INTRODUCTION
1.1 SAFETY INSTRUCTIONS
General
Only trained personnel are allowed to perform operating, maintenance and repair work on
trucks, buses and coaches.
The following sections include summaries of important regulations, listed according to

major topics, which must be complied with. The intention is to provide the knowledge
needed to avoid accidents which could lead to injury, damage and environmental pollution.
Please note that these are merely brief extracts taken from various accident prevention
regulations. Of course, all other safety regulations must be followed and the necessary
measures must be taken.
Additional references to danger are contained in the instructions at points where there is a
potential danger.
Accidents may happen in spite of all precautionary measures having been taken. In such
an eventuality, obtain immediate medical assistance from a doctor. This is particularly
important if the accident involves skin contact with corrosive acid, fuel penetration under
the skin, scalding by hot oil, antifreeze spraying into eyes, crushing of limbs etc.
1.1.1 Regulations for Preventing Accidents Leading to Injury to Personnel

Checking, setting and repair work
-Secure units during their removal.
-Support the frame when working on the pneumatic or spring suspension system.
-Keep units, ladders, stairs, steps and the surrounding area free from oil and grease.
-Only use tools that are in perfect condition.
-Only authorized technical personnel are entitled to perform checking, setting and repair
work.
Working on the brake system

-A dust extractor must be used if dust is released when working on the brake system.
-Perform visual, function and effectiveness checks on the brake system after carrying out
any work on it whatsoever. These checks must be made in accordance with the safety
inspection (SP).
-Check the function of ABS/ASR systems using a suitable test system (e.g. EOL).
-Collect any brake fluid that leaks out.
-Brake fluid is poisonous! Do not allow brake fluid to come into contact with food or open
wounds.
-Treat hydraulic fluid/brake fluid as hazardous waste!
Comply with the safety regulations for preventing environmental pollution.
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Working on vehicles with compressed natural gas (CNG) system

-Vehicles with a defective compressed natural gas system may not be brought into the
workshop. This also applies to vehicles whose engine cannot be switched off by
automatic emptying of the removal lines.
-When working on vehicles with a compressed natural gas system, set up a gas warning
device above the vehicle roof and in the engine compartment above the pressure
controller. Further gas warning devices must be carried by the persons working on the
vehicle.
-Smoking is not allowed in areas where work on vehicles with compressed natural gas
systems is carried out. All sources of ignition must be removed from these areas.
-Before carrying out welding work, the compressed gas tanks must be removed and the
gas-carrying lines must be flushed with inert gas.
-Compressed-gas tanks are only allowed to be exposed to temperatures up to 60℃ in
paint-drying booths. If the temperatures are any higher, the compressed gas tanks must
be removed or degassed using an inert gas such as nitrogen. The gas-carrying lines
must also be flushed with inert gas.
Working on the compressed natural gas (CNG) system

-Work on the compressed natural gas system may only be carried out by persons who
have been specifically trained to do so.
-The working area for the compressed natural gas system must be equipped with an
adequate ventilation system. The ventilation system must replace the air in the room with
new air at least three times per hour.
-After exchanging standard-fit components of the compressed natural gas system using
the prescribed procedures, check the assembly points for leaks. Perform these checks
using leak indicator spray or a gas warning device.
Operating the engine

-Only authorized personnel are permitted to start and operate an engine.
-Do not approach moving part of a running engine too closely and do not wear baggy
clothing. Use an extractor system if working in enclosed spaces.
-Danger of burns when working on engines at operating temperature.
-Danger of scalding when opening the hot cooling circuit.
Suspended loads
-People are not allowed to stand below suspended loads.
-Only use suitable lifting and gear that is in perfect working order. Use lifting devices with
sufficient load-carrying capacity.
Attachments and special bodies

-Comply with the safety instructions and regulations issued by the body builder in question
if attachments or special bodies have been fitted.
Working on high-pressure lines
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-Do not attempt to tighten or loosen pipe lines and hoses when they are under pressure
(e.g. lubrication circuit, coolant circuit and hydraulic oil circuit): Risk of injury due to
pressurized fluids emerging!
Checking injector nozzles

-Wear suitable protective equipment.
-Do not hold any part of your body under the jet of fuel when checking the injector nozzles.
-Do not inhale fuel vapours. Ensure that there is adequate ventilation.
Working on the vehicle electrical system

-Do not disconnect batteries when the engine is running!
-Always disconnect batteries when working on the vehicle electronic system, central
electrical system, alternator and starter! When disconnecting batteries, remove the
negative terminals first. When connecting batteries, fit the positive terminals first.
-Always use suitable test lines and test adapters when measuring at plug connections!
-If temperatures of over 80℃ are to be expected (e.g. in a drying oven after painting),
switch the battery master switch to “OFF” and then remove the control units.
-The chassis is not intended for use as an earth return! If attachments are to be fitted to
the vehicle (e.g. a wheelchair lift), additional earth (ground) lines with an adequate
cross-section must be fitted as well. Otherwise the earth connection may be created
along wire cables, wiring harnesses, gearbox shafts, gears etc. Severe damage could
result.
Be careful as battery gases are explosive!

-Oxyhydrogen gas may form in enclosed battery boxes. Take particular care after long
journeys or after charging the batteries with a battery charger.
-When the batteries are disconnected this gas may be ignited by sparks produced by
other continuously operating consumers, the tachograph etc. that cannot be shut down.
Blow compressed air through the battery box before disconnecting the batteries!
-Always leave the batteries connected when towing the vehicle! Only tow the vehicle if the
check lamps are still dimly lit but the battery starting power is not reached. Do not use a
rapid-charger to jump-start the vehicle!
-Always disconnect the positive and negative leads before charging and rapid-charging
batteries!
-Do not rapid-charge lead-gel and maintenance-free batteries! (not in the case of
“maintenance-free acc. to DIN”) The maximum charging capacity is 10% of the indicated
capacity per battery. In parallel circuits, the capacity is increased, in accordance with the
total number of batteries connected in parallel.
-Risk of short-circuits due to incorrect battery polarity!
-Do not put metal objects (spanners, mole grips, etc.) on the batteries, since they may
connect the terminals together. Risk of short-circuit!
-Disconnect the batteries and recharge them every 4 weeks if the vehicle is not in use for
prolonged periods.
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Caution! Battery acid is poisonous and corrosive!

-Wear appropriate protective clothing (gloves) when handling batteries. Do not tilt
batteries, acid may leak out. Similarly, do not tilt gel batteries.
-Measure voltage only using suitable testers! The input resistance of the measurement
device must be at least 10 MΩ.
-Only disconnect and connect plug connections for electronic control unit when the
ignition is switched off!
Electric welding
-Connect the “ANTIZAP SERVICE SENTRY” protection device as described in the
instructions accompanying the device.
-If this device is not available, disconnect the batteries and connect the positive cable to
the negative cable in order to make a firm conductive connection.
-If the battery master switch is manually operated, move it to the driving position. If an
electronic battery master switch is fitted, bridge “Negative” at the load-disconnecting
relay contacts (jumper cable > 1mm2) and “Positive” at the load-disconnecting relay load
contacts. In addition, switch on many loads such as: starter switch (ignition) in driving
position, hazard warning lights switch “on”, lighting switch in “driving lights on” position,
ventilation blower in “maximum” position. The greater number of consumers that are
switched on, the greater the protection. After completing welding work, first switch off all
the consumers and remove all jumpers (re-create original state), then connect the
batteries.
-Always earth the welding equipment as close as possible to the welding area. Do not lay
the cables to the welding equipment in parallel to electrical cables in the vehicle.
Working on plastic tubes–Danger of damage and fire!

-Mechanical or thermal loading of plastic tubes is not permitted.
Painting
-If paint spraying is to be carried out, do not expose the electronic components to high
temperatures (max. 95℃) for more than brief periods; a time of up to 2 hours is
permissible at a maximum of 85℃. Disconnect the batteries.
Painting of screw connections in the high-pressure section of the injection system is not
permitted. Risk of dirt ingress in the event of repairs.
Working with the cab tilted

-Keep the tilting area in front of the cab clear.
-Keep out of the area between the cab and the chassis during the tilting process. This is a
danger area!
-Always tilt the cab past the tilting point and secure the cab using a support rod.
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Working on the air-conditioning system

-Refrigerant fluids and vapours represent a health hazard; avoid contact with them and
protect your eyes and hands.
-Do not drain gaseous refrigerants in enclosed rooms.
-Do not mix CFC-free refrigerant R 134a with R 12 (CFC) refrigerant.
-Dispose of refrigerant in accordance with regulations.
Working on the independent heater

-Before commencing work, switch off the heater and allow all hot components to cool
down.
-Ensure that suitable collecting containers are available and no sources of ignition are
present when working on the fuel system.
-Keep suitable fire extinguishing equipment nearby and within easy reach!
-The heater may not be operated in enclosed areas such as garages or workshops unless
an extractor system is used.
1.1.2 Notes on Preventing Damage and Premature Wear on Units

General
-Units are only designed for their specified purpose - defined by the manufacturer
(designated use): Any other use is classified as not in accordance with the designated
use. The manufacturer is not liable for damage caused as a result of such other use. In
the event of such other use, the user alone bears the risk.
-Designated use also includes compliance with the operating, maintenance and repair
conditions specified by the manufacturer.
-The unit may only be used, maintained and repaired by persons who are familiar with it
and are fully aware of the risks.
-Arbitrary changes to the engine mean that the manufacturer is no longer responsible for
any damage incurred as a result of such changes.
-Similarly, tampering with the injection and control system can affect the unit’s
performance and exhaust-gas characteristics. This means that compliance with the
statutory environmental requirements is no longer assured.
-If malfunctions occur, determine the cause and remedy the problem immediately.
-Clean units thoroughly before repairs, ensuring that all openings where dirt is not allowed
to enter for safety or functioning reasons are closed.
-Never run a unit dry, in other words always make sure that it has been filled with oil
before running it.
-Never run engines without coolant.
-Apply a suitable information sign to units that are not ready to be operated.
-Comply with the specified maintenance intervals.
-Do not fill engine/gear oil above the maximum level mark. Do not exceed the maximum
permitted operational tilt.
1.1.3 Limited Liability for Parts and Accessories
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General
Only use accessories and genuine SINOTRUK parts that have been expressly approved
by SINOTRUK.
1.1.4 Regulations for Avoiding Injury and Environmental Contamination

Health protection precautions
Avoid prolonged, excessive or repeated skin contact with service products, excipients,
thinners or solvents. Protect your skin using a suitable skin protection agent or protective
gloves. Do not use service products, excipients, thinners or solvents to clean the skin.
Apply a greasy skin cream after cleaning your skin.
Service products and excipients

Do not use food or drink containers for draining and storing service products or excipients.
Comply with local-authority regulations when disposing of service products and
excipients.
Coolant
Treat undiluted antifreeze as hazardous waste. Follow the instructions issued by the
relevant local authority when disposing of used coolant (mixture of antifreeze and water).
Cleaning the cooling circuit

Do not pour cleaning fluids and rinsing water down the drain if this practice is restricted by
specific local regulations. However, the cleaning fluid and rinsing water must, in all cases,
be passed through an oil separator with a sludge trap.
Cleaning the filter insert

When blowing compressed air through the filter insert, make sure the filter dust is
collected by a vacuum or is blown into a dust collection bag. Otherwise, use a respiratory
protection mask. Wear suitable rubber gloves or use a skin barrier cream when washing
out the insert, because cleaning agents have aggressive grease-dissolving
characteristics.
Engine/gear oil, filter cartridges, inserts and box-type filters, desiccant cartridges
Filter inserts, cartridges and box-type filters (oil and fuel filters, desiccant cartridges for the
air dryer) are classified as hazardous waste. Comply with local-authority regulations when
disposing of the above parts.
Used engine/gear oil

Lengthy or repeated skin contact with any type of engine/gear oil removes grease from
the skin. This can cause dry skin, irritation or skin inflammation. In addition to these
hazards, used engine oil contains dangerous materials which can trigger dangerous skin
diseases. Wear gloves, especially when changing the oil.
Handling AdBlue®
AdBlue® is a synthetically manufactured 32.5% urea/water solution that is used as an
NOx reduction additive for diesel engines with SCR catalytic converter. AdBlue® is not a
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hazardous substance but does decompose into ammonium hydroxide and carbon dioxide
when stored for prolonged periods. Ensure good ventilation in the workplace when
working on the AdBlue® system. Do not eat, drink or smoke in the workplace. Avoid skin
and eye contact with AdBlue®, thoroughly wash your hands and use a skin protection
cream before taking breaks and before finishing work. If your skin comes into contact with
AdBlue®, wash the skin using water and a skin cleaner, change out of dirty clothes
immediately. If the skin is irritated, consult a doctor. If AdBlue® gets into your eyes, rinse
your eyes with water or an eye-rinsing products for at least 10 minutes, keeping your
eyelids open. Remove any contact lenses beforehand. If symptoms persist, consult a
doctor. If AdBlue® is swallowed, consult a doctor immediately. Store AdBlue® containers
closed in liquid-tight storage areas. The storage temperature must not exceed 25℃. Soak
up leaked or split AdBlue® using binding agent and dispose of in the correct manner.
1.1.5 Special Information for Working on The Common-rail System

General
-A jet of fuel can cut through the skin. Risk of fire due to fuel atomization.
-Never undo the screwed connections on the fuel high-pressure side of the common-rail
system when the engine is running (high-pressure line from the high-pressure pump
to/on the rail and on the cylinder head to the injector). When the engine is running, the
lines are constantly carrying fuel under a pressure of 1800bar or more. Before the screw
connections are opened, wait at least one minute until depressurization has occurred,
using EOL to check the depressurization on the rail as necessary.
-Avoid standing near the running engine.
-Do not touch the live parts at the injector electrical connection when engine is running.
-Any changes to the original wiring can lead to the limit values specified in pacemaker
regulations being exceeded. Examples of such changes include non-twisted injector
wiring or the addition of the test box (contact box).
-There is no danger to operators and persons wearing a pacemaker if units with
SINOTRUK common-rail engines are used for their intended, i.e. approved, purpose.
-A jet of fuel can cut through the skin. Risk of fire due to fuel atomization.
-Never undo the screwed connections on the fuel high-pressure side of the common rail
system whilst the engine is running (injection line from the high-pressure pump to/on the
rail and on the cylinder head to the injector).
-Avoid standing near the running engine.
-When the engine is running, the lines are constantly carrying fuel under a pressure of
1800 bar or more.
-Before opening the screwed connections, wait for at least one minute so that the system
can be depressurized.
-If necessary, use SINOTRUK to check that the pressure in the rail has dissipated.
-Do not touch the live parts at the injector electrical connection when the engine is
running.
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Danger of damage due to dirt ingress

-Diesel-injection systems consist of precision engineered components that are subject to
extreme loads. Due to this high-precision technology, it is necessary to ensure the
greatest possible cleanliness during all work on the fuel system.
-Even dirt particles over 0.2 mm can cause component failure.
Before commencing work on the clean side

-Clean the engine and engine compartment with the fuel system closed. Do not use a
powerful jet when cleaning electrical components.
-Drive the vehicle into a clean area of the workshop where none of the work causes dust
to be swirled up (sanding, welding, brake repairs, brake checks, performance tests etc.).
-Avoid air movements (possible swirling up of dust due to starting of engines, the
workshop heating/ventilation system, due to draughts etc.).
-Clean and dry the area of the still closed fuel system using compressed air.
-Use a suitable extractor unit (industrial extractor unit) to remove loose dirt particles such
as paint chippings and insulating material.
-Areas of the engine compartment from which dirt particles could become detached, e.g.
tilted cab, engine compartment in bus motors, must be covered with a new, clean
covering foil.
-Wash your hands before starting to strip down the system and wear a clean set of
overalls.
After opening the clean side

-The use of compressed air for cleaning is not permitted.
-During assembly, remove loose dirt using a suitable extractor unit (industrial extractor
unit).
-Only lint-free cleaning cloths are allowed to be used on the fuel system.
-Clean tools and equipment before commencing work.
-Only use tools that show no signs of damage (cracked chrome coatings).
-Do not use any materials such as cloths, cardboard or wood when removing and
installing components, because these can give off particles and fibres.
-If any paint flakes off when connections are loosened (e.g. if they have been painted
over), these paint flakes must be removed carefully before completing the unfastening of
the screw connection.
-All parts removed from the clean side of the fuel system must immediately have their
apertures sealed with suitable plugs.
-This sealing material must be packed to protect it from dust before it is used, and must be
disposed of after one use.
-Following this, the components must be carefully stored in a clean, sealed container.
-Never apply used cleaning or test fluids to these components.
-New parts must not be removed from their original packaging until immediately before
use.
-Work on removed components may only be carried out in a suitably equipped workplace.
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-If removed parts are shipped, always use the new parts original packaging. It is
mandatory to comply with the following additional instructions during work on bus
engines:
Danger of damage due to dirt ingress

-Before opening the clean-side fuel system:
Clean the parts of the engine around the rail connections, injection lines, rail and valve
cover with compressed air.
-Remove the valve cover and then clean the part of the engine around the rail connections,
injection lines and rail again.
-Only loosen rail connections at first:
Release the union nuts of the rail connections and unscrew by 4 turns.
Raise the rail connections using a special tool.
Reason: only remove the pressure-pipe tubes completely once the injectors have been
removed so that no dirt can fall into the injectors from above.
-Remove the injectors.
-After removal, rinse out the injectors with a cleaning fluid, making sure that the
high-pressure connection hole is facing downwards.
-Remove the rail connections by unscrewing their union nuts.
-Clean the injector hole in the cylinder head.
1.1.6 Limp-home Program for Units with Electronic Control Units

General information
The units have an electronic control system that monitors the unit as well as itself
(self-diagnosis).
As soon as a malfunction occurs, the malfunction is evaluated and one of the following
measures is implemented automatically:
-Output of a fault message with fault code.

-Switchover to suitable default functions for further operation, albeit with restrictions. Have
malfunctions remedied by SINOTRUK after-sales immediately.
-If EOL is used, the fault code is output directly.
1.1.7 Installation Instructions

Installation of piping
-Mechanical deformation of piping is not permitted when performing installation work-risk
of fracture!
Installation of gaskets
-Only use genuine SINOTRUK seals
-Make sure the surfaces to be sealed are undamaged and clean.
-Do not use adhesives or sealing compounds. If necessary, to facilitate installation, use a
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little grease to stick the seal to the part to be mounted.

-Tighten the bolts evenly to the specified tightening torque.
Installation of O-rings
-Only use genuine SINOTRUK O-rings.
-Make sure the surfaces to be sealed are undamaged and clean.
Engine overhaul
-A range of very different factors affect the engine service life. It is therefore not possible
to indicate the exact number of operating hours or miles before a major overhaul is due.
-In our judgment, it is not advisable to open an engine or perform a major overhaul if the
engine has good compression values and the following operating values have not
changed significantly since they were measured and taken during the initial start-up:
-Charge pressure
-Exhaust temperature
-Coolant and lubricating oil temperature
-Oil pressure and oil consumption
-Smoke characteristics
The following criteria have a major influence on the engine service life:
-Correct power setting for the application type
-Correct installation
-Approval of the installation by authorized personnel
-Regular maintenance as per the maintenance schedule
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2.The overview
The T5G is the new truck product,that developed by the operation of SINOTRUK and
MAN.It adopts the TGS narrow body cab technology,inherits the T7 cab style, the cab
proportion is more harmonious, compact structure, more full of vigor and vitality.The cab in
accordance with international development trend of heavy card, and on behalf of the most
advanced level in the domestic heavy trucks.The electrical system adopts the products
from the domestic well-known military enterprises and the famous international
companies.The MINI controller comes from the company Sichuan Yaan,the Germany
VDO mainland electronics instrument system, Germany's bel air conditioning control
system, and the Germany WABCO ABS control unite, etc.
THE COMPOSITION OF THE REPAIR MANUAL

The repair manual is mainly suitable for the T5G,and partial content is also suitable for
HOWO,A7 and used as the reference for other vehicle modes.The main content:
（1）The explanation of principle circuit
The principle circuit is very important for the repair operation.There are some explanations
about the rated electric equipments and codes,that could help the mechanic to
learn ,judge and solve the failure.
（2）The layout of cab harness wire
The detailed layout introduction of cab harness wire could help the mechanic to get the
position of failure equipment and solve the rated failure.
（3）The introduction of door electric equipment
With the rising of the life level,there are more requirements of vehicle,specially in the
safety and comfort performance.So the door equips the electric equipments to improve
the product level including the door controller,operation penal,electric rearview mirror,the
electric glass elevator,speaker and so on.
（4）The layout of junction boxes and connectors
The function of junction boxes is to amount and protect the connectors,those connect the
cab harness wire with the chassis harness wire and engine harness wire.Here is
convenient for mechanic to dismantle and test the circuits,it is the important device.
（5）The introduction of the cab interior electric equipments
There introduces the electric equipments,that amounted in the basic cab body.The main
equipments contains the instrument,rocker switch and other equipments.
（6）The introduction of the cab external electric equipments
There mainly contains the lamps,switch and some wires.
（7）The introduction of chassis electric equipments
There mainly introduces the cab external electric equipments and other equipments:the
chassis harness wire,the tail lamps,the starter motor wire,the battery,the differential
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locks,solenoid valve and air pressure sensors.
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3. THE EXPLANTION OF PRINCIPLE CIRCUIT DIAGRAM
3.1THE PRINCIPLE CIRCUIT DIAGRAM

In order to make the training better and confirm the partial circuit to solve the failure.
When analyzing the failure,there needs to check the partial and complete vehicle circuit,to
understand the relationship between every part and analyze the failure cause and solve
them.The main advantages of the circuit diagram as following:
（1）It is one complete vehicle circuit diagram,and there are the partial circuit diagrams,it
is convenient for mechanic to check.
（2）There are the symbols to express electrodes,the “-” means the negative electrode
and the “+” means the positive electrode.The circuit current is from upside to
downside,the positive electrode of power source“+”→ switch → electric equipment → the
ground line→ the negative electrode of power source “-”.
（3）The diagram is simple and clear,it is convenient for mechanic to read and analyze the
failure.
（4）Every partial diagrams connected well, clearly and it is same with the actual
situation.
The complete vehicle wiring harness adopts the single line mode,to control the positive
line and the rated voltage is 24V.Use the letters represent the colors as follows:
Letter A B C D E F G H I K L M N
Color Red Black White Yellow Grey Green Purple Orange Blue Light blue Brown Flat copper Pink
3.2 READING THE CIRCUIT DIAGRAM

The complete vehicle circuit diagram is composed of every partial circuit diagrams.In
order to understand the circuit diagram clearly ,the connection relationship between every
parts and the circuit working principle.One circuit diagram contains the scaleplate,parts
table and ground line explanation.There is a partial circuit diagram as following:
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Fig 3-1 The Complete Circuit Diagram
3.2.1 The Basic Electric Equipment Symbols

The symbol The component The symbol The component
The relay valve The key switch
The fuse The lighting diode
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The main switch The switch

(mechanical type)
The motor The roker switch
The battery The GND line
The alternator The sensor

(resistance type)
The diode The sensor

(electric type)
The horn The lamp
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The solenoid valve The air pressure

switch
The inductance The electromagnetic

clutch
CAN line The heater
The controller It is the 7th pin of 4th

connector.
This line connect

with the 4th line of 1.5--the line size
page 19. AGC--the colors
The 1st pin of

X101/3 connector.
Fig 3-2 The Symbol Table
T5G The electric marks and the names
No. Series Name

1 A series The controller
2 B series The controller
3 D series The diode
4 E series The lamps
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5 F series The fuse

6 G series The power source:battery,alternator
7 H series The electric horn
8 K series The relay valve
9 M series Motor
10 R series The heater
11 S series The switches
12 V series The deconcentrator
13 X series The connectors
14 Y series The solenoid valve
T5G The code and the rated electric equipment:
No. Code Name

1 A101 The electric connector
2 A102 The Mini controller
3 A103 The combination instrument
4 A111 The ADR controller
5 A152 The electric lifting device
6 A187 The left combination headlamp
7 A187/2 The left-front fog lamp
8 A188 The right combination headlamp
9 A188/2 The right-front fog lamp
10 A189 The left-rear combination lamp
11 A190 The right-rear combination lamp
12 A201 The AC controller module
13 A202 The speed regulating controller module
14 A401 The engine controller（ECU）
15 A402 The accelerator panel
16 A411 The remote accelerator
17 A412 The chassis electric connector
18 A601 The ABS controller
19 A701 The ECAS controller
20 A710 The ECAS controller
21 A801 MP3
22 A802 The vehicle driving recorder（VDR）
23 A805 MTCO
24 A806 The monitoring device
25 B101 The vehicle speed sensor
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26 B106 The fuel sensor

27 B107 The air pressure sensor of brake circuit 1
28 B108 The air pressure sensor of brake circuit 2
29 B201 The inner temperature sensor of cab
30 B202 The outside temperature sensor of cab
31 B203 The temperature sensor of evaporator
32 B269 The environment temperature sensor
The accelerator sensorⅠ

33 B401
The accelerator sensorⅡ

34 B402
The remote accelerator sensorⅠ

35 B440
The remote accelerator sensorⅡ

36 B441
37 B601 The left-front wheel sensor
38 B602 The right-front wheel sensor
39 B603 The left-rear wheel sensor
40 B604 The right-rear wheel sensor
41 B605 The EBL sensor
42 B701 The height sensor of front axle
43 B702 The pressure sensor of front axle air bag
44 B703 The pressure sensor of the lifting axle left air bag
45 B704 The pressure sensor of the lifting axle right air bag
46 B705 The left height sensor of driving axle
47 B706 The right height sensor of driving axle
48 B707 The left pressure sensor of driving axle
49 B708 The right pressure sensor of driving axle
50 B709 The pressure sensor of lifting axle main air bag
51 B801 The left door speaker
52 B802 The right door speaker
53 B9’ The smart vehicle speed sensor
54 D1 The zener diode of 30＃ power line
55 D2 The zener diode of 15＃ power line
56 D4 The diode of reverse signal
57 D6 The diode of wiper high gear
58 E101 The left inner lighting lamp
59 E102 The right inner lighting lamp
60 E105 The berth lamp
61 E108 The left glove box lamp
62 E109 The middle glove box lamp
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63 E110 The right glove box lamp

64 E113 The left tool box lamp
65 E114 The right tool box lamp
66 E115 The ash box lamp
67 E201 The left short beam lamp
68 E202 The right short beam lamp
69 E203 The left long beam lamp
70 E204 The right long beam lamp
71 E205 The left auxiliary long beam lamp
72 E206 The right auxiliary long beam lamp
73 E207 The left-front position lamp
74 E208 The right-front position lamp
75 E209 The left-front steering lamp
76 E210 The right-front steering lamp
77 E211 The left-front fog lamp
78 E212 The right-front fog lamp
79 E213 The left-front outline lamp
80 E214 The right-front outline lamp
81 E217 The left door lamp
82 E218 The right door lamp
83 E219 The left side steering lamp
84 E220 The right side steering lamp
85 E221 The left-rear outline lamp
86 E222 The right-rear outline lamp
87 E224 The working lamp
88 E225 The left-front side mark lamp
89 E226 The right-front side mark lamp
90 E227 The left-rear side mark lamp
91 E228 The right-rear side mark lamp
92 E231 The left-rear steering lamp
93 E232 The right-rear steering lamp
94 E233 The left brake lamp
95 E234 The right brake lamp
96 E235 The left-rear position lamp
97 E236 The right-rear position lamp
98 E237 The left-rear fog lamp
99 E238 The right-rear fog lamp
100 E239 The left reverse lamp
101 E240 The right reverse lamp
102 E307 The cab left-rear outline lamp
103 E308 The cab right-rear outline lamp
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104 F1 The lighter fuse

105 F10 The fuse of long beam lamp relay
106 F11 The fuse (10A)
107 F12 The fuse of reverse lamp relay
108 F13 The fuse of key switch
109 F14 The fuse of backup relay K4
110 F15 The fuse of backup power
111 F150 The fuse of vehicle power
112 F151 The one-off fuse
113 F152 The electric lifting fuse
114 F16 The fuse of air horn relay
115 F163 The fuse 30A
116 F17 The backup fuse
117 F18 The fuse of position lamp relay
118 F19 The fuse of right position lamp
119 F2 The fuse of backup relay K2 (25A)
120 F20 The fuse of electric horn relay
121 F21 The fuse of left position lamp
122 F22 The fuse of 15＃ relay (40A)
123 F23 The fuse of left door controller switch
124 F24 The fuse of right door controller switch
125 F25 The tractor ABS 30＃ fuse
126 F26 The trailer ABS 30＃ fuse
127 F27 The fuse of backup power 30＃
128 F28 The fuse of AC relay
129 F29 The fuse of brake lamp relay
130 F3 The fuse of inner lighting lamp,VDR,MP3
131 F30 The fuse of tractor ABS 15＃
132 F31 The fuse of trailer ABS 15＃
133 F32 The fuse of VDR 15＃
134 F33 The fuse of controller 15＃
135 F34 The fuse of working lamp,differential lock switch
136 F35 The fuse of combination switch
139 F36 The fuse of emergency warning switch
140 F37 The engine fuse ECU15
141 F38 The fuse of air dryer
142 F39 The fuse of ECAS,the backup power 15＃
143 F4 The fuse of front fog lamp relay
144 F40 The fuse of combination instrument 15＃
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145 F41 The fuse of Mini controller 15＃

146 F451 The fuse of preheater 200A
147 F5 The fuse of Mini controller
148 F6 The fuse of wiper relay
149 F7 The fuse of controller device
150 F8 The fuse of short beam lamp
151 F9 The fuse of instrument,diagnose switch
152 F901 The fuse of SCR main relay
153 F902 The fuse of urea pipe heater
154 F903 The fuse of urea injector
155 F904 The fuse of urea pump pipe heater
156 F905 The fuse of urea pump heater
157 F906 The backup fuse
158 F907 The fuse of ECU-30＃
159 F908 The one-off fuse
The battery Ⅰ
160 G101
The battery Ⅱ
161 G102
162 G103 The alternator
163 H111 The ADR indicator
164 H202 The electric horn
165 INJ11 The injector #1
171 K（15） The relay of 15＃
172 K（D+） The controller relay of engine
173 K1 The backup relay
174 K10 The air horn relay
175 K11 The electric horn relay
176 K111 The relay with double solenoid
177 K12 The relay of brake lamp
178 K13 The relay of 15＃ power
179 K152 The relay of electric lifting
180 K2 The relay of wiper high gears
181 K3 The relay of long beam lamp
183 K451 The preheater relay
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184 K5 The relay of position lamp

185 K6 The relay of wiper low gears
186 K7 The relay of front fog
187 K8 The relay of long beam lamp
188 K9 The relay of reverse lamp
189 K901 The SCR main relay
190 K902 The relay of urea pipe heater
191 K903 The relay of urea injector
192 K904 The relay of urea pump pipe
193 K905 The heater relay of urea pump
195 M101 The starter motor
196 M102 The wiper motor
197 M103 The washer motor
198 M104 The electric lifting motor
199 M201 The fan motor
200 M202 The motor
201 M203 The circular motor
202 M204 The mode motor
203 M205 The damper motor
204 M206 The water valve motor
205 R101 The air dryer
206 R102 The lighter (24V)
207 R106 The preheater
208 R109 The lighting regulating switch
209 R114 The fuse (120 Ω )
210 S101 The key switch
211 S102 The left combination switch
212 S103 The inter-wheel differential lock switch
213 S104 The light beam rotary knob switch
214 S106 The electric lifting rocker switch
215 S107 The horn changeover switch
216 S110 The emergency warning switch
217 S112 The working lamp switch
218 S113 The PTO switch
219 S114 The neutral switch of PTO
220 S115 The lifting axle switch
221 S116 The reverse lock
222 S119 The remote accelerator switch
223 S122 The engine diagnose switch
224 S124 The ABS diagnose switch
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225 S126 The driving-aidant switch

226 S127 The ASR switch
227 S131 The heater switch of main seat
228 S132 The heater switch of auxiliary seat
229 S133 The ABS switch for the off-road mode
230 S134 The ECAS switch
231 S138 The multi-mode switch
232 S150 The vehicle speed limited switch
233 S151 The brake switch
234 S152 The clutch switch
235 S155 The safety belt locking signal switch
236 S160 The ADR power switch
237 S161 The emergency power switch of cab (inner one)
238 S162 The emergency power switch of cab(outside one)
239 S163 The H/L pressure switch
240 S201 The main switch
241 S202 The park brake signal switch
242 S203 The signal switch of brake circuit 4
243 S204 The low gear signal switch of transmission
244 S205 The transmission neutral switch
245 S206 The reverse signal switch
246 S208 The PTO signal switch
The inter-axle differential lock signal switch of front
247 S209 axles
The inter-axle differential lock signal switch of
248 S210 middle axle
249 S211 The inter-axle differential lock signal switch
The 1st front axle inter-wheel differential lock signal
250 S212 switch
The 2nd front axle inter-wheel differential lock signal
251 S213 switch
The 1st rear axle inter-wheel differential lock signal
252 S214 switch
The 2nd front axle inter-wheel differential lock signal
253 S215 switch
254 S216 The neutral switch of transfer case
255 S217 The off-road gear signal switch of transfer case
256 S218 The coolant level switch
257 S219 The air filter blocked warning switch
258 S221 The cab left locking signal
259 S222 The cab right locking signal
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260 S225 The starting button

261 S226 The engine shut down button
262 S227 The electric lifting switch
263 S228 The oil-water separator switch
264 S231 The right combination switch
265 S307 The left door lamp switch
266 S308 The right door lamp switch
267 X101/1 The GND point of left wire box
268 X101/2 The GND point of right wire box
269 X101/5 The backup socket
270 X130/2 The deconcentrator of rocker switch
271 X131/1 The left-front GND deconcentrator
272 X131/2 The GND deconcentrator
273 X150/1 The deconcentrator of 15＃
The deconcentrator of symbols lighting power
274 X158/1 source
275 X231 The ABSGND point
276 X240 The backup power connector 24V
277 X430/2 The deconcentrator of ECU power
278 X5 The 7 holes socket for trailer
279 X6 The ABS7 holes socket
280 XOBD The diagnose port
281 Y101 The solenoid valve of air horn
282 Y102 The PTO solenoid valve
283 Y103 The solenoid of inter-wheel differential lock
284 Y105 The PTO neutral gear
285 Y106 The solenoid valve of inter-axle differential lock
286 Y107 The exhaust brake solenoid valve
287 Y108 The lifting axle solenoid valve
288 Y109 The solenoid valve of reverse lock
289 Y201 The electric clutch
290 Y601 The left-front wheel solenoid valve
291 Y602 The right-front wheel solenoid valve
292 Y603 The left-rear wheel solenoid valve
293 Y604 The right-rear wheel solenoid valve
294 Y605 The EBL solenoid valve
295 Y701 The front air bag solenoid valve
296 Y702 The lifting axle main solenoid valve
297 Y703 The lifting axle air bag solenoid valve (left one)
298 Y704 The lifting axle air bag solenoid valve (right one)
299 Y705 The driving axle air bag solenoid valve(left one)
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300 Y706 The driving axle air bag solenoid valve(right one)
301 Y707 The central solenoid valve
T5G The main connectors
No. Series Name

1 X101/1
The chassis wire harness connector
2 X101/2
3 X101/3 The frame wire harness connector
4 X101/5 The backup power socket
5 X101/7 The power socket of position lamp
6 X101/11
The right-front wire harness connector
7 X101/12
8 X101/15 The electric overturn wire harness connector
9 X101/16 The PTO wire harness connector
10 X101/19 The MTCO sensor connector
11 X101/20 The start/shut down connector of the engine
12 X102/1 The left-front wire harness connector
13 X130 The 30＃ power distributor
14 X131 The GND line deconcentrator
15 X401/1
16 X401/2 The engine wire harness connector
17 X401/3
18 X501/1
The AMT connector
19 X501/2
20 X601/2
The ABS connector
21 X601/4
22 X601/3 The EBL connector
23 X602 The trailer ABS connector
T5G The partial electric equipment and the short name
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No. Series Name

1 ABS Anti-skid Brake System
2 ADR Dangerous goods transport vehicle
3 AMT Automated mechanical transmission
4 ASR Avoid the sideslip
5 CBCU The body of the central control unit
6 EBL Electronic brake-force distribution
7 ECAS The electric control air system
8 ECU The engine control unit
9 EGR The exhaust gas recycling
10 MTCO Disc paper recorder
11 SCR Selective catalytic reduction
12 TPM The tire pressure monitor
13 VDR The vehicle driving recorder
3.2.2 The Basic Concepts of Circuit Diagram

a、The always on line
This line connects the battery and electric equipment directly,there is on any control
units.
b、KL30# power
KL30# power is only controlled by the main power switch,and the rated voltage is 24V.
c、KL15# power
KL15# power is controlled by the key switch,when the key switch on,there is the power
and the rated voltage is 24V.
d、KL50# power
KL50# power is controlled by the key switch,when the key switch at the Start position,
there is the power and the rated voltage is 24V.
e、KL75# power
When the key at the Acc position,the KL75# power is on and the rated voltage is 24V.The
75# power is specially supplied for the auxiliary equipments,for example the radio and the
cigarette lighter.
f、KL31# line
The KL31# line is the ground line,it connects with negative electrode of battery.
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g、The single line,ground line(GND)
In the vehicle electric system,the single line mode means the system using the vehicle
frame as the common line(the negative line),and there are many points on the frame
as the negative electrode.If those points not connected well,there would be some
failure.So there requires that connected and tightened every points well and protect
them.
h、CAN（CAN-BUS）
CAN（Controller Area Network ),it is the control and communication net.There are
。
separated into the power CAN（P-CAN）and the instrument CAN（I-CAN）
I、The H control and the L control
There are two type signals in CBCU,the H control signal (high signal) and the L control
signal (low signal).For example,the emergency alarming signal is H control signal and
the horn signal is the L control signal.
The difference as following diagrams:
The Fig 3-3 shows the H control circuit,and the Fig 3-4 shows the L control circuit.
Fig 3 -3The H Control
The CAN-H is control the positive line.
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Fig 3-4 The L Control

The CAN-L is control the negative line.
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4. THE INSTRUMENT AND THE ALARMING INDICATORS
4.1 THE COMBONATION INSTRUMENT

The combination contains:The vehicle speed meter,The engine speed meter,The coolant
temperature meter,The fuel level meter,The voltage meter,The air pressure meter,The
button 1,The button 2 and 4 connectors.
Fig 4-1 The Combination Instrument
Fig 4-2 The Combination Instrument
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A. The vehicle speed meter
It is to show the vehicle speed,the range is 0～125km/h，the min scale is 5km/h and the
max scale is 20km/h.
B. The engine speed meter
It is to show the engine speed,the speed range is 0～3000r/min，the min scale is 100 r/min
and the max scale is 500 r/min.
The green area is engine economic speed area,when the engine speed more than 2300
r/min，the res warning lamp is shining and the screen shows the rated failure massage.
C. The coolant temperature meter
It is to show the coolant temperature,the range is 40～120℃，the point C is 40℃，point H

is 120℃ and every min scale is 20℃.
When the coolant temperature over than 96℃，the red warning lamp is on,and the screen
show the rated failure massage.
D. The fuel meter
It is to show the fuel level,the position E means the fuel tank is empty,the position F means
the fuel tank is full.
When the fuel less than 1/8，the fuel warning lamp is on and the screen show the rated
failure massage.
E. The voltage meter
It is to show the power voltage,the range is 16～32V and every scale is 2V.
When the battery voltage lower than 20V or higher than 32V，the red warning lamp is on.
F. The air pressure meter
It is to show the air pressure of circuit 1 or 2，the showing range is 0～12×0.1MPa，and

every scale is 0.1MPa.When the meter pointer in the red area,the air pressure less than
5.5×0.1MPa，the screen shows the rated failure massage.
Normally the air pressure meter shows the lower air pressure from 2 air circuits,and the
rated indicator is on.The driver can also change-over from circuit 1 to 2 by pressing the
changeover button.
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The air pressure 1 The air pressure 2
Fig 4-3 The Air Pressure Meter
G.The button 1
Short press it to changeover the circuit 1 or circuit 2.Long press this button to reset the
small mileage.
H.The button 2
Short press it to show the air pressure date,even vehicle speed,total fuel consumption ,small
fuel consumption and the engine working hours in circular.Long press it to changeover the
background lighting.
Fig 4-4 The Back Surface of Instrument
Connector X1 White 白色插接件
No. Description No. Description

1 Low beam 11 Rear shaft lock
2 Daytime running light 12 Off road gear
3 Lifting bridge 13 Neutral gear
4 Low coolant 14 Air filter
5 First front wheel lock 15 Exhausted brake
6 Second front wheel lock 16 Air intake preheater
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7 First rear wheel lock 17 Water in fuel

8 Second rear wheel lock 18 Empty
9 Front shaft lock 19 Main ABS
10 Middle shaft lock 20 ASR
Connector X2 Black 黑色插接件

1 5V sensor power output 5V 11 12V sensor power output
2 5V sensor power output 5V 12 Empty
3 5V sensor power output 5V 13 CAN-LOW
4 5V sensor power output 5V 14 CAN-HIGH
5 Rear fog output 15 CAN-ADAPT
6 Front fog output 16 Sensor GDN
7 Lamp (PWM) output 17 Sensor GDN
8 Hazard output 18 Sensor GDN
9 Empty 19 Sensor GDN
10 Vehicle speed output 20 Sensor GDN
Connector X3 Blue 蓝色插接件

1 IIIumination PWM input 11 Air pressure 2 input
2 Empty 12 Oil pressure input
3 KL15 13 LNG level input
4 Battery changing 14 Air filter input
5 Empty 15 Empty
6 GND 16 Empty
7 Coolant temperature input 17 Empty
8 Fuel level input 18 Vehicle speed input
9 GND level input 19 Engine speed input
10 Air pressure input 20 KL 30
Connector X4 Gray 灰色插接件

1 Little lamp 11 Air pressure 3
2 Main turn left 12 Air pressure 4
3 Trailer left 13 Low gear
4 Trailer right 14 Safe belt
5 Engine amber warning 15 Cabin lock
6 Front fog 16 PTO 1
7 Rear fog 17 PTO 2
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8 High beam 18 OBD

9 Main turn right 19 Trailer ABS
10 Parking brake 20 ECAS
4.2 THE INSTRUMENT ALARMING LAMPS

4.2.1 The instrument alarming lamps layout
Fig 4-5 The Instrument Alarming Lamp Layout
4.2.2 The alarming lamp symbols and definition
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The display screen
The screen view
Fig 4-6 The EurⅢ Screen View
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Fig 4-7 The EurⅣ Screen View
The oil/Adblue level
The EurⅢ vehicles display view is as the fig10,it is the Adblue level information.
When the ECU not connected with the CAN line,or the KL15 is on(for 3 seconds) but no
signal,or the system is normal but the instrument not receive any signal for 20
seconds,the meter would show 0.
When the ECU connected with the CAN line,if there is no signal about 5 cycles,the
information is timeout and show 0.
Fig 4-8 The EurⅢ Oil Pressure Display View
The EurⅣ vehicle Adblue level display view shown as fig11,now is not the oil pressure
value.This information is from the CAN line,if there is no signal for 5 cycles,it will show.
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Fig 4-9 The EurⅣ Vehicle Adblue Level Display
The Total Odometer and Tripmeter
The Total Odometer unit is 1km,the display range is 0 ～999999km.When the total
odometer is less than 1000km,it could be reset to 0 by the EOL.When it is more than
1000km,it only could reset the value more than the stored value.If resetting failure,the
meter will show “------”.The MTCO get the mileage information from the CAN line.
Fig 4-10 The Total Odometer
The tripmeter display range is 0～999.9km.When the KL30 no power,the tripmeter only
show the integer part.And the MTCO get the mileage signal from the CAN line.
Fig 4-11 The Tripmeter Display
The operation of button1 and button 2
Shown as the following fig14.Short press(less than 3s)，long press(more than 3s).The
KL15 is on and the engine is not started,press the button 1and button 2 for 10s to enter
the diagnosis mode.
Fig 4-12 The View Controlled by The Button1 and Button 2
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The button 1(the right one）
In the driving mode：
Short press to change over the air1 or air2,long press it to zero cleaning the tripmeter.
Fig 4-13 The Air Pressure Display
In diagnosis mode:
① Changing-over the diagnosis point:short press it to change over the diagnosis

point,long press it to exit the diagnosis mode.
②Changing-over the DM1 information:short press it to change over the information

forward,long press it back to the last diagnosis point.
Fig 4-14 The Diagnosis Point Display
Fig 4-15 The Selecting View
The button 2(the left one)
In the driving mode:
Short press it:the air pressure(fig 15),the even vehicle speed,the total fuel consumption,the
tripmeter fuel consumption.Long press it to enter the lighting adjusting to adjust the
background lighting.
Fig 4-16 The Total Fuel Consumption Display
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Fig 4-17 The Tripmeter Fuel Consumption
Fig 4-18 The Engine Working Time
The diagnosis mode:
①Select the DM1:short press it to enter the diagnosis point DM1.
②Changing-over the DM1 information,short press to back to the last information.
Fig 4-19 The DM1 Display View
If there is only one DM1 information,shown as following:
If there are many DM1 information,shown as the following:
Fig 4-21 The DM1 Display View(the first information)
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Fig 4-23 The DM1 Display View(the last information)
The differential lock display
The differential lock display is shown as the following diagram.According to the 9 input
parameters,the instrument display the differential lock working situation,the power take-off
box working situation and the neutral gear signal.Shown as the following diagram:
Fig 4-24 The Differential Lock Display
Fig 4-25 The Differential Switch Position
The economic fuel consumption mode
When received the CAN torque information,the instrument would display the related
working mode. (X for H、M、L or blank X X means no display).Mode0 (torque is

0)= H，Mod1 = M，Mode2 = L，Mode3 (no location)= Blank.
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Fig 4-26 The Economic Mode
The time display
If the MTCO is on,the screen will show the time and it is controlled by the CAN.
If the MTCO is off,there is no time display.
Fig 4-27 The Time Display
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The alarming symbol
There are 6 alarming symbols
The maintenance
The maintenance prompt function:
The intake CAN information:the engine labor hour,the mileage information.
If the labor hour less than 1 week or the mileage not more than 5600km,the yellow lamp
would be lighted.
If the labor hour less than 1 day or the mileage not more than 800km,the red lamp would
be lighted and the buzzer is on.
The time value and mileage value are setted by the EOL.
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This function need be activated by the EOL
5. THE INTRODUCTION OF MINI CONTROLLER
5.1 THE MINI CONTROLLER
5.1.1 Overview
The Mini controls the flashing lamp,wiper,fog lamps,preheater,exhaust brake and stoping
the engine.
5.1.2 The facade
Fig 5-1 The Common Rail/Natural Gas Vehicle Mini Controller
Fig 5-2 The EGR/EurⅡ Natural Gas Vehicle Mini Controller
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5.1.3 The definition
The The working Basic Basic Optional Optional

The name I/O
pin No. type sizeⅠ sizeⅡ sizeⅠ sizeⅡ
A1 30 ＃ H IN √ √ √ √
A2 GND L IN √ √ √ √
The emergency alarming

A3 H IN √ √ √ √
switch
A4 The steering switch(F) H IN √ √ √ √
A5 The steering lamp H IN √ √ √ √
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The name I/O
switch(R)
A6 The rear fog lamp switch H IN √ √ √ √
The short beam lamp is

A7 H IN √ √ √ √
on
A8 The return signal of wiper L IN √ √ √ √
A9 Self-diagnosis 5 pulses IN The backup one(产品调试通信)
The pulse
A10 The alternator W port signal(0~1. IN √ √ √ √
5KHz)
A11 The position lamp switch H IN √ √ √ √
A12 The wiper interval switch H IN √ √ √ √
A13 The wiper washing switch H IN √ √ √ √
A14 15 ＃ H IN √ √ √ √
The trailer steering lamp

A15 H OUT NC √ NC √
switch(F)
The trailer steering lamp

A16 H OUT NC √ NC √
switch(R)
The tractor steering lamp

A17 H OUT √ √ √ √
switch(F)
The tractor steering lamp

A18 H OUT √ √ √ √
switch(R)
A19 The rear fog lamp H OUT √ √ √ √
The high beam lamp

A20 H IN √ √ √ √
working situation
A21 The front fog relay valve H OUT √ √ √ √
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The name I/O
A22 The engine working H OUT √ √ √ √
A23 The front fog lamp switch H IN √ √ √ √
The wiper relay valve(low

A24 H OUT √ √ √ √
speed)
The wiper switch(low

A25 H IN √ √ √ √
speed)
B1 The preheater relay valve H OUT NC NC √ √
The exhaust brake relay

B2 H OUT NC NC √ √
valve
B3 The neutral gear signal L IN NC NC √ √
Common is
B4 The clutch signal H IN NC NC √ √
open
B5 The exhaust brake switch L IN NC NC √ √
B6 The preheater switch H IN NC NC √ √
Note：NC means no wiring,√means there is this wiring.
5.1.4 The basic functions

The front fog lamp control principle
When the 15＃ line is on,turn on the position lamps,press the fog lamp switch to light up
the fog lamp.When there is no 15＃ power or turn off the fog lamp switch,the fog lamp is
off.
The rear fog lamp control principle
The rated power of rear fog lamp is 84W(no trailer,the rated power is 42W).When the 15
＃ line is on and the high/short beam lamp/front fog lamp is on,press the rear fog lamp
switch to turn on the rear fog lamp. Press it again or turn off the headlamp to turn the rear
fog lamp off.
The steering lamps and the rated power
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① the tractor left/right steering lamp
The rated power：21W×3
The open-circuit：＜48W
The short-circuit：＞90W
② the trailer left/right steering lamp
The rated power：21W
The open-circuit：＜3W
The short-circuit：＞80W
The emergency alarming
Turned on the emergency alarming switch,all the steering lamps would be flashing
alarming by 90±5 times/minute.If there is open-circuit failure(except the trailer left/right
steering circuit),the steering lamps would be flashing by 180±20 times/minute,if there is
short-circuit failure,the steering lamps is off.
Turning left
When the 15＃ in on,turn on the left steering lamp switch,the left steering lamp would be
shining by 90±5 times /minute.If there is open-circuit failure,the related lamp would be
shining by 180±20 times /minute.When all the steering lamps with open-circuit failure,all
the steering lamps would be off.
The right steering lamp is the same with the left one.
The wiper relay valve(low speed) control principle
The resistance of low speed relay valve is 300Ω～500Ω.
The washing function
When the 15＃ is on,turn on the washing switch to drive the wiper motor.If the switch is
on less than 1s,turn off the washing switch,there will be only one working cycle.If keep the
washing switch on more than 1s，turn off the washing switch,there will wash for 3±1
cycles.
The wiper interval
When the 15＃ is on,turn the wiper interval switch on,the wiper wash the window
intermittently,one cycle is about10±1s.Turn off the switch,the washing stop.
The wiper low speed
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When the 15＃ is on,turn on the low speed switch to drive the wiper working at low speed.
The engine working situation control
When the 15＃ is on,the pulse of alternator W port is more than 100±10Hz,the engine
working pin output the driving signal,if the pulse is less than 80Hz±10 Hz or no
power,there is no driving signal.
The exhaust brake
The exhaust brake device rated power is 30W,when the 15＃ is on,turn on the exhaust
brake switch.If there is no neutral signal and the clutch signal is high,the exhaust brake
device will be driven,if not the exhaust brake no reaction.
Shut down the engine
When the pulse of alternator W port is more than100±10Hz,turn off the 15＃,if the neutral
signal is normal,the exhaust brake device will keep braking for 10±1s.
The preheater relay valve
When the neutral signal is normal,turn on the preheater switch,if the power voltage is
more than 22.5±0.5V,the controller will drive the preheater working for 30±1s.If press the
switch again (during the 30s),it would be off.If the pulse of alternator W port is more
than100±10 Hz,it also would be off.
5.2 THE JUNCTION BOX ASSEMBLY
The Preview of Junction Box
There are 41fuses,5 backup fuse,13 relay valves and 30A relay valves(K1～K6).The
K1,K2 and K4 are open type relays,the K3 and K5 are tandem type,the K6 is one
changing-over type, the K7～K12 are open type(15A),and the K13 is open type (70A).
This junction box is suit for all the vehicle modes,according to the different vehicle
modes,the K9～K12 relay valves are different.
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6. THE CAB ROCKER SWITCHES
6.1 THE LAYOUT OF OF ROCKER SWITCHES
1 The combination instrument 16 The backup switch

2 The lighting rotary knob 17 The backup switch
3 The differential lock cover 18 The backup switch
4 The horn change-over switch 19 The idle speed warning switch
5 ECU diagnose switch 20 ABS diagnose switch
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6 The headlamp adjusting switch 21 ASR switch

7 The multi-torque switch 22 Off-road switch
8 The power switch 23 The backup switch
9 The cab overturning switch 24 The backup switch
10 The working lamp or power main switch 25 The backup switch
11 The PTO switch or driving switch 26 The backup switch
12 The PTO neutral gear switch 27 The lighter
13 PTO switch 28 The AC control panel
14 The vehicle speed regulating switch 29 The backup switch
15 The smart brake switch 30 MP5
Fig 6-1 The Rocker Switches
6.2 The Rocker Switches

1 The horn change-over switch 10 The ASR switch
2 The engine diagnose switch 11 The headlamp regulating switch
3 The working lamp switch 12 The engine multi-torque switch
4 The emergency warning switch 13 The smart brake switch
5 The PTO switch 14 The lifting shaft switch
6 The PTO neutral gear switch 15 The reverse switch
7 The second PTO switch 16 The auxiliary equipment power
switch(the pump vehicle）
8 The cab overturning switch 17 The driving switch（the pump vehicle）
9 The ABS diagnose switch 18 The pump switch of pump vehicle
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Fig 6-2 The Marks of Rocker Switches
The horn change-over switch：press it to enter the air horn mode and press it again to
back the electric horn mode.
The engine diagnose switch：press down this switch to read the failure code from the
instrument.
The working lamp switch：press down this switch to turn on the working lamp that
behind the cab.
The emergency warning switch：press down this switch ,all the steering lamps and the
rated indicators are shining.
The PTO switch:press down this switch to connect the PTO device.
The PTO neutral gear switch:For the HW13710,HW12710 transmission,there needs

press down the PTO switch and PTO neutral gear switch at the same time.
The second PTO switch:if the transmission with double PTO devices,press down the
second PTO switch to connect the second PTO device.
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The cab overturn switch：press this switch,set the up/down mode,then turn on the
outside switch to lift up/down the cab.
The ABS diagnose switch：Start the engine,if the ABS indicator is on all time,that
means there is failure in system.Press on the ABS diagnose switch to read the failure
code.
The ASR switch：the function of ASR switch to activate the TPM function.
The headlamp lighting regulating switch:roll the switch to adjust the light beam.
The engine multi-torque switch:roll the switch to regulate the engine multi-torque
mode.
The smart brake switch:press on the switch to enter the vehicle speed limited mode.
The lifting shaft switch:press on the switch,the lifting shaft airbag is injected by the
air.Turn off the switch,deflate the air.
The reverse switch:press the switch,the reverse lock locked.
The auxiliary equipment power switch：turn on/off the power source.
The driving switch:turn on this switch,the pump truck enter the driving mode.
The pump switch:press on the switch to turn on the pump device.
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7.THE OTHER CAB ELECTRIC EQUIPMENTS
7.1 THE INTRODUCTION OF SOME SWITCHES
7.1.1 The Key Switch

The key switch is mounted at the right side of steering column.
When the key at the position “0”，the power of all the vehicle is cut off,and the
key could be pulled out.
When the key at position “Ⅰ”，some electrical equipments are connected.
The position “Ⅱ”，it is the driving position.
Turn the key to the position “Ⅲ” to start the engine.
NOTE:
-Turn the key to the position “Ⅲ”to start the engine,after finished the starting,the key would
back to the position “Ⅱ”automatically.
-If you want to start again,turn the key back to the position “0”,then turn it to the position
“Ⅲ”to start the engine again.
-During the driving,it is not allowed to turn the key to position “0”,that would lock the
steering wheel and lose the steering function.
The Key Switch
Fig 7-1 The Key Switch
7.1.2 The Horn Switch

The vehicle equipped with the electric horn,the electric controlled air horn,and there is a
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change-over switch to realize two modes.
The horn switch is positioned at the end of the left combination switch.
Press the change-over switch to chose the horn mode,then press the steering wheel horn switch.
Fig 7-2 The Change-over Switch
7.1.3 The Left Combination switch
Fig 7-3 The Left Combination Switch
The left combination switch is positioned at the left side of the steering column.It controls
the long/short beam,the left/right steering ,the wiper and the horn.
The right steering indicator
Push the left combination switch forward,the right steering indicator would be lighted.
If the truck with trailer,the trailer right steering indicator would also be lighted.
When the steering wheel back to straight position,the switch back to position 0
automatically.
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The left steering indicator
Push the left combination switch rearward,the left steering indicator would be
lighted.
If the truck with trailer,the trailer right steering indicator would also be lighted.
When the steering wheel back to straight position,the switch back to position 0
automatically.
The Wiper
Turn the switch to the showing position to turn off the wiper,the other marks are “The
intermittent wiper gear”,“The normal speed gear”and“The fast speed gear”.
The washing system
Press the button(not more than 1s) as the diagram arrow showing,the washing system
would inject the water and wash the screen once.
Press the button(more than 1s) as the diagram arrow showing,the washing system would
inject the water and wash the screen three times.
Press the button as the arrow showing all the time,the washing system would work all the
time.
7.1.4 The Right Combination Switch

The right combination switch is positioned at the right side of the steering column.It
contains 5 functions:
：
Lift up the handle to set the button（SET+）
：
Press down the handle to set the button（SET-）
The recovery button（MEM）：press the button MEN as the arrow.
The cancel button(OFF)：press the button OFF as the arrow.
The exhaust brake switch：push the handle rearward.
Fig 7-4 The Right Combination Switch
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The Cruise Function
In the cruise mode, the vehicle could drive at the cruise speed without stepping
accelerator.That needs meet the following conditions:
-The vehicle speed signal normal,and the speed is more than 30km/h；
-The RSL/RSG is in the default state； -The engine CAN line is normal；
-The engine is in the torque mode； -The transmission not in neutral gear；
-Not step on the clutch pedal； -Not step on the brake penal.
Enter the cruise mode by lifting up the right combination switch or pressing down the right
combination switch.
In the cruise mode,the driver can set the cruise speed by lifting up or pressing down the
right combination switch.
If one of above conditions is not met or operate the OFF button as the diagram
showing,the vehicle exit the cruise mode.
When all the conditions are met again,the driver can press the button (MEM）to enter the
cruise mode again,the cruise speed is the last setting speed value.
The Vehicle Speed Regulating Function
Press down the Cruise switch,the driver could regulate the limited speed by pressing
down or lifting up the right combination switch.
The button（SET+）and （SET-）are allowed be point pressed or long pressed.
Finish the setting,the vehicle max speed would not faster than the setting speed value
except that the driver step on the accelerator to the end.
When the driver move the handle rearward to turn on the switch OFF,the system exit the
engine speed-adjusting mode.
The following reasons would cause that the engine speed could not be set/adjusted:
-The vehicle speed signal failure； -The vehicle in driving mode；
-The engine CAN line failure； -The engine shut down；
-The engine speed more than 2200rpm； -Not operate the park brake；
-The accelerator signal failure； -step on the accelerator；
-The vehicle not on neutral gear； -The speed knob failure.
The exhaust brake function
When the vehicle meet the following conditions,the vehicle would realize the exhaust
brake function.
-Not step on the clutch；
-The vehicle is not on the neutral gear；
-The engine speed is more than 800rpm；
-Push the right combination switch inward to turn on the exhaust brake switch.
If the exhaust brake with failure,the reasons as following:
-step on the clutch；
-The vehicle at neutral gear；
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-The engine speed less than 800rpm；

-The exhaust brake switch failure；
-The exhaust brake valve failure.
7.1.5 The lighting lamp switch
（1）The Rotary Switch（the lighting lamp）
Turn off the lighting lamp
The outline lamp gear
The short beam gear
The front fog indicator

The rear fog indicator
Fig 7-5 The Rotary Switch
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Turn on the outline lamps
Turn the rotary switch from position ① to position ②(the outline lamp gear)，the outline
lamps and the side mark lamps are on.
Turn on the front fog lamp
Turn the rotary switch from position ① to position ②(the outline lamp gear) or position
③(the short beam lamp gear)，press down the switch to turn on the front fog lamp,and the
rated indicator is on.Press down it again to turn off the fog lamp,and the indicator
is off.
Turn on the rear fog lamp
Turn the rotary switch from the position ① to the position ② or position③，pull out the
switch to turn on the rear fog lamp,the rear fog lamp indicator is on.Pull out it again
to turn off the rear fog lamp and the indicator is off.
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（2）The Front Headlamp controlling
The original position of left combination switch is the short beam lamp gear position.
Press down the left combination switch to the long beam gear.
Lift up the combination switch,that is the lighting changing gear.
Fig 7-6 The Combination Switch
Turn on the front short beam lamp
Turn the key to the position “Ⅱ”.
Turn the rotary switch from position ① to position ③(the short beam lamp gear)，and the
combination switch at the original gear,the front short beam lamp is on.The rated indicator
is on.
Turn on the long beam lamp
Turn the key to the position “Ⅱ”.
Turn the rotary switch from position ① to short beam gear position ③，press down the
handle to turn on the long beam lamp and the indicator would be lighted.
The front headlamp shining
Push the combination switch upward to the beam-changing gear,the front headlamp
shining.
Relax the combination switch,and it would back to the short beam gear automatically.
The indicator and the indicator be lighted.
（3）The instrument background lamp and the switch indicators
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Turn the rotary switch from the position ① to the position ②(the outline lamp gear) or the
position ③(the short beam lamp gear)，the instrument background lamp and the switch
indicators are on.
7.2 THE OTHER ELECTRIC EQUIPMENTS
7.2.1 The Driving Recorder
Fig 7-6 The Vehicle Traveling Date Recorder
7.2.2 The 24V Electric Lighter
Turn the key on the position “Ⅰ”or“Ⅱ”.
Push the lighter inward until hear the locking sound,when the lighter be heated,it would
pop-up automatically.
Fig 7-7 The Lighter
NOTE:
-The max power of lighter socket is 240W（24V/10A）,and the rated voltage of lighter is 24V.
-To avoid being burned by the heated lighter,please hold the top end of the lighter and move
it.
7.2.3 MP3
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Fig 7-8 The MP3
8. THE INTRODUCTION OF LIGHTING SYSTEM
8.1 THE FRONT LAMP
8.1.1 Install the Front Combination Lamp

a. Install the front combination lamp on the vehicle frame with the bolts.
b. Connect the lamp wire harness to the combination lamp.
Fig 8-1 The Front Lamp (the left one)
After replaced the long and short beam lamp,check the setting situation of the front
combination lamp.
Don’t use the bare hands to teach the lamp bulb directly.
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8.2 THE REAR LAMP

There is a number-plate light under the left combination lamp.If the tractor with the
trailer,the lamps of tractor and trailer will light at the same time.
Fig 8-2 The Rear Combination Lamp (L)
8.3THE INNER LIGHTING LAMPS AND READING LAMP
8.3.1 The Inner Lighting Lamps
When the switch at positionⅠ，the inner lighting lamps will be turned on/off following with
the door is closed/open.
When the switch at position 0，the inner lighting lamps are off.
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Fig 8-3 The Inner Lighting lamps
8.3.2 The Reading Lamp
Turn the switch at the positionⅠ，the reading lamp is on.
Turn the switch at the position 0，the reading lamp is off.
Fig 8-4 The Reading lamp
8.4 THE POSITION LAMP AND STEERING LAMP
The layout of signal lamps,shown as the following diagram:
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Fig 8-5 The Steering lamp and Position Lamp
Fig 8-6 The layout of The Front Outline lamp
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9.THE CHASSIS ELECTRIC EQUIPMENTS

9.1 THE INTRODUCTION OF CHASSIS HARNESS WIRE
Install the chassis harness wire
a. Smear the gum on the mounting hole,and install the plastic protection bushing.
b. Install and tighten the harness wire bracket.
c. Install the harness wire along the frame as the diagram shown,the ABS wire cross
through the third process hole.The AMT wire cross through the furth process hole,the
chassis harness wire cross through the third process hole of right side of frame,the engine
wire cross through the second process hole of the right side of frame.Fix the wire as the
diagram shown.There is one fix point every 30-40cm.
d.The connecting mothed:connect the X101/1,X101/7,X101/8,X101/13,X101/14,the

power B07,the GND line B07 with the related sockets of front-right junction box.The B101
mileage sensor,S204 connects the creeping gear switch（yellow），S205 connect the
neutral switch（red）,S206 connects the reverse gear switch(green),Y201 connects the AC
electromagnetic clutch,S212 connects the coolant level switch,G103 connects the
generator,X5 connects the trailer socket(7 holes),S213 connects the air filter blocking
switch,E225 connects the front-left mark lamp,E226 connects the front-right mark
lamp,E227 connects the rear-left mark lamp,E228 connects the rear-right mark
lamp,Y106 connects the inter-axle differential solenoid valve,Y107 connects the exhaust
brake solenoid valve,B106 connects the fuel sensor,K301 connects the starting relay
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valve,K302 connects the preheater,F301.2 connects the 200A fuse,F304 connects the 5A
fuse,D2 connects the diode,X201/1 connects the air pressure sensor 1,X201/2 connects
the air pressure sensor 2,R101 connects the sir dryer,G1- connects the battery negative
electrode.
Fig 9-1 The Installation Diagram of Chassis Harness Wire
Fig 9-2 The Installation Diagram of Chassis Wire
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Fig 9-3 The Installation Diagram of Chassis Harness Wire
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9.2 THE BATTERY BOX ELECTRIC EQUIPMENT AND WIRE
Install the battery box electric equipment and wire
a. Install the main switch:fix the main switch on the right side of battery box by 2 bolts and
sealing shims.
b. Install the connected plate:Fix the stating relay on the mounting plate by 2 bolts and
spring shims.Install the 200A fuse,50A fuse on the connected plate,shown as the diagram.
c. Install the protection sleeve on the mounting holes of chassis,The starter harness wire
cross through the front mounting hole of battery box and chassis,the GND wire of chassis
harness wire cross through the rear mounting hole of battery.
d. Lay the rubber plate at the top and bottom side of battery,assemble 6 rubber blocks on
the long bolts,install the battery G1 and G2 as the diagram shown.Cover the upper plate
and tighten it.
e.Connect the starting wire(the wave type tube port) with the main switch port
S4.2,connect the other port with the positive electrode of starter.The other wire connects
the main switch port S4.1 and the positive electrode of G2,connect the G1 positive
electrode and the G2 negative electrode by one short and thick wire.The black wire
connects the G1 negative electrode with the starter negative electrode directly. Connect
the main switch S4.2 with the 200A fuse by one red wire,then connect the starter relay
A8.1 with the 200A fuse by one wire.The pin A8.1 of starter relay valve connects the pin
50 of starter,connect the starter relay connectors and the diode D5,connect the chassis
GND line with the G1 negative electrode.Then fix the harness wire.
f. Connect and tighten every electrode of battery,then smear the grease and cover the
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protection sleeve.
Fig 9-6 The Outlay of Battery Box Wire
Fig 9-7 The Installation Diagram of Main Switch and The Battery Negative Electrode
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Fig 9-8 The Outlay of Battery Wire
Fig 9-9 The Installation Diagram of Battery
9.3 THE ENGINE AND STERTER MOTOR WIRE
Install the Engine Wire
a. Install the generator wire as the diagram shown.

b. Install the AC wire as the diagram shown.
c. Install the expansion tank coolant level sensor sire.
Install the Engine Starter Wire
a. Connect the starter wire and cover the protection sleeve.
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Fig 9-10 The Installation Diagram of Generator Wire
Fig 9-11 The Installation Diagram of Expansion Tank Coolant Level Switch
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Fig 9-12 The Connection Diagram of Engine Starter
9.4 THE AIR DRYER AND THE INTER-AXLE DIFFERENTIAL LOCK

Install the air dryer wire
a. Install the air dryer wire.
Install the differential locks wire
a. The installation of double axle wire.

b. The installation of single axle wire.
Fig 9-13 The Connection of Air Dryer
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Fig 9-14 The Installation Diagram of Double Axle Differential Locks
Fig 9-15 The Installation Diagram of Single Axle Differential Lock
9.5 THE AIR FILTER WIRE AND FUEL SENSOR WIRE

Install the air filter block alarming wire
a.Install the alarming sensor on the air filter cover.

b. Install the alarming wire shown as the diagram.
c. Connect the connector S213.
Install the fuel sensor wire
A.Install the fuel sensor wire as the diagram shown.

b. Connect the fuel sensor connector B106.
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Fig 9-16 The Diagram of Air Filter Block Alarming Switch
Fig 9-17 The Installation Diagram of Fuel Sensor Wire
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9.6 THE SIDE POSITION LAMP,SOLENOID VALVE AND TRAILER
WIRE
Install the side position lamp wire
a. Install the side position lamp wire as the diagram shown

b. Connect the front-left,front-right,rear-left,rear-right lamp withe the connector
E225,E226,E227,E228.
Install the solenoid valve wire
a. Install the solenoid valve wire as the diagram shown

Install the trailer wire（contains the working lamp and trailer ABS）
a. Fix the trailer socket( 7 holes) on the bracket and connect the X5 connector shown as
the diagram ,then cover the protection cap.
b.Fix the ABS power socket on the bracket with 2 screws,and connect the trailer ABS
socket,shown as the diagram.
c. Fix the working lamp on the bracket by the hex bolts,then connect the wire and
connector E23,cover the protection sleeve.Shown as the following diagram.
Fig 9-18 The Installation Diagram of Front Position Lamp
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Fig 9-19 The Installation Diagram of Rear Position Lamp
Annotation: The res wire is inter-axle differential lock wire.

The white wire is inter-wheel differential lock wire.
The green wire is the exhaust brake switch wire.
Fig 9-20 The Installation Diagram of Solenoid Valve
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The PTO neutral

gear solenoid valve
The PTO solenoid

valve
Fig 9-21 The Installation Diagram of Solenoid Valve
Fig 9-22 The Installation Diagram of The Trailer ABS Socket,The Trailer Socket(7 holes)
and The Working Lamp
Fig 9-23 The Installation Diagram of The Trailer Socket (7 holes)
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1--The GND line ; 2--The outline lamps (grey/green); 3--The steering lamps( purple,green/green); 4--The brake
lamp(black/yellow) ; 5--The steering lamp(purple/red) ; 6--The outline lamp (grey/red); 7--The reverse lamp(black/white).
Fig 9-24 The Installation Diagram of Working Lamp Wire
9.7 THE REAR LAMP AND WIRE,THE ABS HARNESS WIRE
Install the rear lamp and wire
a. Install the rear lamp wire as the diagram shown.

b. Connect the connector A189/A190 with the left and right rear lamp.
Install the ABS chassis harness wire
a. Cover the corrugated pipe on the ABS sensor wire and tighten it every 20cm，and
tighten the ends of the corrugated pipe.
b. Install the ABS chassis wire along the left side of the vehicle frame and fix them，then
install the front-left,front-right,rear-left and rear-right wire at the related wheel.
c. Cross the ABS front-left wire through the vehicle frame,connect the sensor wire,the
solenoid valve.Tighten the wire with the air pipe.The installation of the right side wire is
same as the left one.
d. Install the ABS wire along the air pipe to the rear-rear wheel,connect the speed sensor
wire and the solenoid valve.Install the right wire same as the left one.
e. Connect the EBL sensor wire（shown as the diagram).
f. Connect the ASR solenoid valve wire（shown as the diagram).
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Fig 9-25 The Installation Diagram of Tractor Rear Combination Lamp
Fig 9-26 The Installation Diagram of First Axle ABS Sensor Wire
Fig 9-27 The Installation Diagram of Front Axle ABS Solenoid Valve Wire
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Fig 9-28 The Installation Diagram of Rear Axle Left/Right Side ABS Valve Wire
Fig 9-29 The Installation Diagram of Rear Axle ABS Sensor Wire
Fig 9-30 The Installation Diagram of ASR Solenoid Valve,EBL Sensor
1st Edition 87
R.EL.T5G.01
Note：
a. The installation position of ABS sensors：For 4╳2,4╳4 the sensors are installed on the
first and second axle.For 6╳4,the sensors are installed on the first and third axle.For 6╳4
（double steering axles）,the sensors are installed on the second and third axle.For
8╳4,10╳4（the last axle is liftable axle）,the sensors are installed on the second and furth
axle.For 10╳4（the middle axle is liftable axle）,the sensors are installed on the second and
fifth axle.
b. Fix the ABS sensor wire with the air pipe（one fixing belt every 10-15cm），note the
outlay direction,avoid the wheel and the plate spring to ensure there is no interference
between wheels when the vehicle steering.
c. Do not fix the ABS sensor wire too tightened to avoid snapping the wire when the
vehicle in bumpy or steering condition.
d. According to the marks of ABS wire,make the ABS connectors outlay at the right wheel
positions.
e. Fix the ABS solenoid valve and sensor wire along the vehicle frame and air pipe,the
ABS wire should put on the protection bushing or bellow through the vehicle holes.
9.8 THE ELETRIC OVERTURN DEVICE,AIR PRESSURE SENSOR
AND RATED WIRE

Install the cab overturn device
a. Install the fuse(50A) in the battery box,and install the control button of cab overturning
lifting motor on the outside of battery box.
b. Install the overturning wire along the vehicle frame beams,the connector F303.1
connects the fuse(200A),the connector F301.1 connect the fuse(50A),the connector
F301.2 connect the fuse(50A),the G1- connect the battery G1(the negative electrode),all
of them are connected in the box.The K303 connects the electric lifting motor.
c.Install the control harness wire：the S227 connects the overturn button,the X101/15
connects the X101/15 of the cab harness wire.
Install the air pressure sensor of brake system
a. Install the air pressure sensor on the air tanks(the front axle air tank and the rear axle
air tank).
b.Connect the X201/1(red）and X201/2（green）of chassis harness wire with the related
air tanks.
88 1st Edition
R.EL.T5G.01
Fig 9-31 The Installation Diagram of Lifting Motor
Fig 9-32 The Installation Diagram of Air Pressure Sensor
1st Edition 89

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R.EL.T5G.

The Repair Manual of T5G

SINOTRUK No. 777 Hua'ao Road Jinan,

The T5G Truck

We reserve the right to make modifications in the course of further development.

Best wishes from

8. THE INTRODUCTION OF LIGHTING SYSTEM .......................................................... 68

1.1 SAFETY INSTRUCTIONS

The following sections include summaries of important regulations, listed according to

1.1.1 Regulations for Preventing Accidents Leading to Injury to Personnel

Working on the brake system

Working on vehicles with compressed natural gas (CNG) system

-Compressed-gas tanks are only allowed to be exposed to temperatures up to 60℃ in

Working on the compressed natural gas (CNG) system

Operating the engine

Attachments and special bodies

Working on high-pressure lines

Checking injector nozzles

Working on the vehicle electrical system

Be careful as battery gases are explosive!

Caution! Battery acid is poisonous and corrosive!

Working on plastic tubes–Danger of damage and fire!

permissible at a maximum of 85℃. Disconnect the batteries.

Working with the cab tilted

Working on the air-conditioning system

Working on the independent heater

1.1.2 Notes on Preventing Damage and Premature Wear on Units

1.1.3 Limited Liability for Parts and Accessories

1.1.4 Regulations for Avoiding Injury and Environmental Contamination

Service products and excipients

Cleaning the cooling circuit

Cleaning the filter insert

Used engine/gear oil

1.1.5 Special Information for Working on The Common-rail System

Danger of damage due to dirt ingress

Before commencing work on the clean side

After opening the clean side

Danger of damage due to dirt ingress

1.1.6 Limp-home Program for Units with Electronic Control Units

-Output of a fault message with fault code.

1.1.7 Installation Instructions

little grease to stick the seal to the part to be mounted.

THE COMPOSITION OF THE REPAIR MANUAL

（1）The explanation of principle circuit

（2）The layout of cab harness wire

（3）The introduction of door electric equipment

（4）The layout of junction boxes and connectors

（5）The introduction of the cab interior electric equipments

（6）The introduction of the cab external electric equipments

There mainly contains the lamps,switch and some wires.

（7）The introduction of chassis electric equipments

locks,solenoid valve and air pressure sensors.

3. THE EXPLANTION OF PRINCIPLE CIRCUIT DIAGRAM

3.1THE PRINCIPLE CIRCUIT DIAGRAM

3.2 READING THE CIRCUIT DIAGRAM

Fig 3-1 The Complete Circuit Diagram

3.2.1 The Basic Electric Equipment Symbols

The relay valve The key switch

The fuse The lighting diode

The main switch The switch

The motor The roker switch

The battery The GND line

The alternator The sensor