Harness Manufacturing Specifications for Vehicle with Yuchai Bosch Common Rail (EDC7 +

Sanli Post-treatment System) under Euro IV Emission Standard _V1.1

Revisions
Version No. Prepared by Date Reason for change
V1.0 Chen Junhong 2010-11-11 First version
and Ye Yu
V1.1 Chen Junhong 2010-11-17 Exchange the male and female positions of 48-terminal
connectors
I. Harness Manufacturing Specifications
1. The Specifications define the schematic diagram of vehicle harness connection.
2. The Specifications define the model of connectors to be connected in the harness.
3. The detailed parameters for sensors, switches and actuators required for the vehicle are
included in the technical agreement. The selected electrical parts shall meet the
requirements specified in the technical agreement. Among which, the accelerator is a key
part concerning safety. An accelerator which is not provided along the engine by Yuchai
can be used only after certification of Yuchai and Bosch.
4. Adblue liquid level sensor applied by the vehicle is involved in OBD diagnosis and torque
reduction. A sensor other than Adblue liquid level sensor provided along the engine by
Yuchai can be used only after certification of Yuchai.
5. CAN bus network has 120Ω resistance integrated inside ECU. DCU also has 120Ω
resistance integrated, but the resistance is not enabled by default. If it is confirmed that
there is no other terminal resistance for the vehicle, it shall be added depending on the
arrangement of other controls in the vehicle.
6. ECU and DCU have to carry out subsequent processing on some actuators (such as
Adblue injection pump) after the engine stops and send relevant operating data to the
memory, so normal power supply for ECU, DCU and Adblue pump is required in 30
seconds after the engine stops. It is recommended that power supply of ECU and Adblue
pump is directly connected to the battery. After DCU is connected to the main relay
controlled by ECU, the built-in relays of ECU and Adblue pump will control the power
supply automatically.
7. Conductors shall be connected with connectors and welding connection is prohibited.
Special tools shall be used in a correct way to ensure the connection between the
conductor and the pin is firm and reliable. Meanwhile, the waterproof plug and blind plug
of conductor shall be installed in place to guarantee the waterproofness of vehicle
harnesses.
8. The arrangement of vehicle harness shall be optimized reasonably combining with the
structure of the vehicle. If it is classified depending on the object, reasonable branch can
be made as per the positions of objects.
9. The harness shall be away from high-temperature parts such as exhaust pipe, starter and
engine. The engine harness shall keep a certain distance from such parts as vehicle
crossbeam so as to avoid interference with each other in the process of use.
10. The harness shall be fixed with snap springs or nails for fear of looseness or wear. The
interval between two adjacent fixed points shall not exceed 500mm.
11. The harness shall not be tightened too tight, especially at the corner. When laid at the
sharp corners or passing through metal holes, harness shall be protected with rubber or
sleeve; otherwise, short circuit or grounding may be caused due to wear of harness,
resulting in destroy of the entire harness and even fire.
12. Manufacturing and installation of the vehicle harness shall meet the requirements stated in
QC/T 29106-2004 Technical Specification of Low-voltage Electric Harness for Motor
Vehicles.
13. Welding is prohibited when ECU is connected to each connector. If welding is required, it
can be carried out after the vehicle connector to the engine and the engine connector are
 disconnected.
14. If CAN instrument will not be used, it is required to install SCR system fault indicator
lamp (red) and OBD MIL (yellow) on the dashboard. The driving voltage is 24V, so that
the incandescent lamp bulb can be connected directly. If light emitting diode (LED) is
used, the current-limiting resistance is about 5.1kΩ.
15. Under the circumstances that the instrument panel would not receive and display CAN
Adblue liquid level message, it is required to install Adblue liquid level display instrument
on the dashboard. YCDCU provides the corresponding Adblue liquid level PWM signal,
with open-collector output, pull-up voltage of 5-31V, and square wave output frequency
of 0-300Hz (the corresponding liquid level is 0~100%).
16. The connection of the positive and negative electrodes and ground of vehicle power shall
be arranged reasonably to avoid forming of potential difference between ECU and body
which will damage ECU. It is recommended to install as per the requirements of Bosch as
shown in the figure below:
II. ECU Harness Connector List
Drawing No. of Drawing number Quantity per
Name of connectors Description
manufacturer of Yuchai set
Vehicle signal adapter
(male)
192991-0648 J6A00-3900541 1
48-terminal connectors (including sealing ring
(Vehicle side) and retainer)
Vehicle signal wiring Choose as
192990-2530 J6A00-3900543
terminal (female pin) required
Vehicle power adapter
2-terminal power (with O-ring and locking DJ70217-6.3-11 G6000-3900551 1
connectors clip)
(Vehicle side) Vehicle power wiring
DJ612-6.3C G6000-3900553 2
terminal
Adapter 174262-2 G6000-3900571 1
6-terminal accelerator Terminal 171662-1 G6000-3900572 6
connectors
(Vehicle side) Waterproof plug J00150011 G6000-3900573 6
Retaining member 174263-7 G6000-3900574 1
Vehicle signal adapter 15326861 L4700-3900541 1
Choose as
14-terminal vehicle Vehicle signal terminal 15326269 L4700-3900543
required
signal connectors
(Vehicle side) Vehicle signal waterproof Choose as
15366021 L4700-3900542
plug required
Terminal lock 15430904 L4700-390054L 1

6-terminal Electronic Accelerator Connector (Vehicle Side)

2-terminal Vehicle Power Connector (Vehicle Side)

48-terminal Vehicle Signal Connector (Vehicle Side)

14-terminal Vehicle Signal Connector (Vehicle Side)

III. List of Post-processing DCU Harness Connector
S/N Name Drawing No. Terminal and waterproof plug Quantity Manufacturer
Model Qty. for each
vehicle
(set)
1 DCU L4400-3900581 DCU adapter 1 1 AMP
connectors 1-1418883-1
L4400-3900582 DCU wiring terminal (big) 8
1-968857-1
L4400-3900583 DCU wiring terminal 18
(small)
1241380-3
G6000-3900542 Vehicle signal waterproof 8
plug
J00150017
J5600-3900545 Vehicle signal waterproof 18
plug
J00150005
L4400-3900584 Big blind plug 4
J00150020
J5600-3900546 Small blind plug 45
J00150026
L4400-3900585 DCU end frame 1
0-1418882-1
2 OBD L6400-3900531 OBD adapter 1 1 AMP
connectors 179631-1
L6400-3900532 OBD connecting terminal 6
776001
3 Front L4400-3900591 Temperature sensor adapter 1 1 AMP
temperature 1-967325-3 (female)
sensor L4400-3900592 Temperature sensor wiring 3
connectors of terminal
catalytic
converter 929973-1
L4400-3900593 Temperature sensor end 1
frame
965784-1
L4400-3900597 Temperature sensor 4
waterproof plug
828920-1
4 Rear L6400-3900591 Temperature sensor adapter 1 1 DEUTSCH
temperature DT06-2S
sensor L6400-3900592 Temperature sensor wiring 2
connectors of terminal
catalytic
1062-16-0122
converter
L6400-3900597 Temperature sensor 1
retaining plug
W2S
5 UDS L4400-3900511 UDS main electric adapter 1 1 ITT-Cannon
compressed air 121583-0002
solenoid valve L4400-3900512 UDS main electric wiring 3
connectors terminal
 121668-0125
L4400-3900513 UDS main electric adapter 3
waterproof plug
121668-0032
L4400-3900514 Blind plug 3
121668-0034
L4400-3900515 End frame 1
058-8578-103
6 UDS main L4400-3900521 UDS main electric adapter 1 1 ITT-Cannon
electric 121583-0058
interface L4400-3900522 UDS main electric wiring 10
connectors terminal
121668-0222
L4400-3900523 UDS main electric adapter 10
waterproof plug
273-8506-009
L4400-3900524 UDS main electric adapter 32
blind plug
121667-0025
L4400-3900525 UDS main electric adapter 1
end frame
044-8597-000
7 NOx sensor L6400-39005A1 NOx sensor adapter 1 1 Hirschmann
connectors 872-860-501
L6400-39005A2 NOx sensor wiring terminal 4
50253207/88
L6400-39005A3 Waterproof plug 4 Herth+Buss
50282021
L6400-39005A4 Blind plug 1

1. DCU Connector

DCU adapter 1-1418883-1 DCU wiring terminal (big) DCU wiring terminal (small)
DCU end frame 1-968857-1 1241380-3
0-1418882-1

Vehicle signal waterproof Vehicle signal waterproof

plug J00150017 plug J00150005
Big blind plug J00150020 Small blind plug J00150026
2. Front Temperature Sensor Connector of Catalytic Converter

Temperature sensor Temperature sensor Temperature sensor Temperature sensor

adapter end frame wiring terminal waterproof plug
1-967325-3 (female) 965784-1 929973-1 828920-1

3. Rear Temperature Sensor Connector of Catalytic Converter

Temperature sensor adapter Temperature sensor wiring Temperature sensor retaining

terminal plug
DT06-2S
1062-16-0122 W2S

4. Compressed Air Valve Connector

5. 37-pin Connector for Measuring and Injection Unit

6. OBD Connector
OBD adapter OBD adapter terminal
179631-1 776001
L6400-3900531 L6400-3900532

7. NOx Sensor Connector

NOx sensor connector NOx sensor wiring terminal Waterproof plug

872-860-501 50253207/88 50282021
L6400-39005A1 L6400-39005A2 L6400-39005A2