R.EL.T7H.

01

Repair Manual
-T7H Electrical system

SINOTRUK No. 777 Hua'ao Road Jinan,

INTERNATIONAL Shandong Province, China, 250101
AFTER SALES SERVICE DEPARTMENT T7H Electrical System
1st Edition -English-
 R.EL.T7H.01

T7H Truck

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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 description of the bolt specification in this repair manual: M nominal diameter (×fine
thread pitch) ×length-performance grade, for example: M8×40-10.9, nominal diameter is
8mm, standard pitch, the length is 40mm, and performance grade is 10.9.
M8×0.75×40-8.8 means nominal diameter is 8mm, fine thread pitch 0.75mm, length is
40mm, and performance grade is 8.8.

In this repair manual, there are two codes for repair tools and fixture, for example : the
Piston ring compressor’s code : JD6805-0018 and 80.99602-0016，the former code is
SINOTRUK tool code, the latter is MAN tools code, it will be convenient for you to
purchase the tools.

The repair jobs are divided up into chapters and sections. Each section 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.

This manual is edited by SINOTRUK IMPORT＆EXPORT CO., LTD.

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

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.

Best wishes from

SINOTRUK (Hong Kong) LIMITED

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Content Page
CHAPTER ONE INTRODUCTION ...................................................................................... 5
SECTION I SAFETY INSTRUCTIONS ........................................................................ 5
SECTION II THE OVERVIEW OF T7H TRUCK ........................................................ 10
CHAPTER TWO THE EXPLANATION OF CIRCUIT DIAGRAM ...................................... 12
SECTION I THE EXPLANATION OF CIRCUIT DIAGRAM ....................................... 12
SECTION II THE VEHICLE CIRCUIT DIAGRAM ...................................................... 12
CHAPTER THREE THE LAYOUT OF CAB ROOF AND FLOOR HARNESS WIRE ........ 29
SECTION I THE OUTLAY OF THE CAB CEILING HARNESS WIRE....................... 29
SECTION II THE OUTLAY OF CAB FLOOR HARNESS WIRE ................................ 33
CHAPTER FOUR THE INTRODUCTION OF DOOR ELETRIC EQUIPMENTS .............. 34
SECTION I THE DOOR ELETRIC EQUIPMENTS .................................................... 34
SECTION II THE LAYPOUT OF DOOR ELETRIC EQUIPMENTS ........................... 34
CHAPTER FIVE THE LAYOUT OF CAB LEFT/RIGHT DISTRIBUTOR BOX .................. 37
SECTION I THE INSTALLATION OF DISTRIBUTOR BOX....................................... 37
SECTION II THE OUTLAY OF JUNCTION BOX INTERIOR CONNECTORS .......... 38
CHAPTER SIX THE CAB INTERIOR ELECTRIC EQUIPMENTS.................................... 38
SECTION I THE CAB INTERIOR LIGHTING LAMP ................................................. 38
SECTION II THE CAB HARNESS WIRE ................................................................... 40
SECTION III THE CAB ELETRIC EQUIPMENT ........................................................ 42
CHPATER SEVEN THE INTRODUCTION OF THE CAB EXTERNAL ELECTRIC
EQUIPMENTS .................................................................................... 49
SECTION I THE AIR HORN SOLENOID VALVE AND THE AIR49
PRESSURE SIGNAL SWITCH .................................................................................. 49
SECTION II THE HARNESS WIRE AT THE FRONT OF CAB .................................. 49
SECTION III THE WIPER MOTOR AND THE ELETRIC HORN ............................... 50
SECTION IV THE SIDE STEERING LAMPS,OUTLINE LAMPS AND THE HEIGHT
LAMPS .................................................................................................. 51
SECTION V THE FRONT COMBINATION HEADLAMP ........................................... 53
CHAPTER EIGHT THE CHASSIS ELETRIC EQUIPMENTS ........................................... 54
SECTION I THE INTRODUCTION OF CHASSIS HARNESS WIRE ........................ 54
SECTION II THE BATTERY BOX ELECTRIC EQUIPMENT AND WIRE .................. 56
SECTION III THE ENGINE AND STARTER MOTOR WIRE ..................................... 59
SECTION IV THE AIR DRYER AND THE INTER-AXLE DIFFERENTIAL LOCK ..... 60
SECTION V THE AIR FILTER WIRE AND FUEL SENSOR WIRE ............................ 61
SECTION VI THE SIDE POSITION LAMP,SOLENOID VALVE
AND TRAILER WIRE ........................................................................... 62
SECTION VII THE REAR LAMP AND WIRE,THE ABS HARNESS WIRE ............... 66
SECTION VIII THE ELETRIC OVERTURN DEVICE,AIR PRESSURE SENSOR AND
THE RELATED WIRE ......................................................................... 69

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CHAPTER ONE INTRODUCTION

SECTION I SAFETY INSTRUCTIONS

General
Only trained personnel are allowed to perform operating, maintenance and repair work on
trucks, buses and coaches

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. 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.

Operating the engine

– Only authorized personnel are permitted to start and operate an engine.
– Do not approach moving parts 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.

Working on high-pressure lines

– 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 vapour. Ensure that there is adequate ventilation.
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Working on the vehicle electrical system

– Do not disconnect batteries whilst 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°C 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 (EDC).

Electric welding
– 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. Otherwise it will
damage the engine electrical equipment, such as EDC, etc.
–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 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.

Painting
– If paint spraying is to be carried out, do not expose the electronic components to high
temperatures (max. 95 °C) for more than brief periods; a time of up to 2 hours is
permissible at a maximum of 85 °C. 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.

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

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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 plugged.
– Never run a unit dry, in other words always make sure that it has been fled with oil
before running it.
– Never run engines without coolant.
– Apply a suitable information sign to units that are not ready to be operated.
– Only use service products as per the SINOTRUK Recommended Service Products,
otherwise the manufacturer warranty will be invalidated.
– 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.
– Engine running angle shall not exceed the maximum allowable angle.

3. Limited liability for parts and accessories

Only use accessories and genuine SINOTRUK parts that have been expressly approved
by SINOTRUK for your SINOTRUK vehicle. SINOTRUK accepts no liability for any other
products.

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.

Service products and excipients

Do not use food or drink containers for draining and storing service products or excipients.

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.

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 produced 32.5 % urea/water solution which is used as a NOx
reduction additive for diesel engines with SCR catalytic converter. AdBlue® is not a
hazardous substance but does decompose into ammonium hydroxide and carbon dioxide
when stored for prolonged periods. For this reason, AdBlue® is classified as a water
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hazard and is not allowed to enter sewage or the ground. 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°C. Soak up leaked or split AdBlue® using binding agent and dispose of in
the correct manner.

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 whilst the engine is running (high-pressure line from the high-pressure pump
to/on the rail and on the cylinder head to the injector). Whilst the engine is running, the
lines are constantly carrying fuel under a pressure of 1800 bar 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.
– Do not touch the live parts at the injector electrical connection whilst the engine is
running.
– Any changes to the original wiring can lead to the limit values specified being exceeded.
Examples of such changes include non-twisted injector wiring or the addition of the test
box (contact box).
– A jet of fuel can cut through the skin. Risk of fire due to fuel atomization.
– Avoid standing near the running engine.

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 0.002 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.
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– 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 fakes off when connections are loosened (e.g. if they have been painted
over), these paint fakes 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.
– 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 remove the rail connections completely once the injectors have been removed so
that no dirt can fall into the injectors from above.
– After removal, rinse out the injectors with a cleaning fluid, making sure that the
high-pressure connection hole is facing downwards.

6. Limp-home program for units with electronic control units

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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.
The malfunctions should be remedied immediately.
– If SINOTRUK EOL is used, the fault code is output directly.

7. Installation instructions
Installation of piping
– Mechanical deformation of piping is not permitted when performing installation work -
risk of fracture!

Installation of gaskets and O-rings

–
 Only use genuine SINOTRUK gaskets and O-rings.
–
 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 little grease to stick the seal to the part to be mounted.
– Tighten the bolts evenly to the specified tightening torque.

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

SECTION II THE OVERVIEW OF T7H TRUCK

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T7H truck is the new product of SITRAK, which developed by the operation of SINOTRUK
and MAN. It is positioned as the high level product in domestic and international market.
In the domestic market, it will lead the truck trend, replace the imported truck products and
expend the exports. The electrical system adopts the Mini controller that made by the
famous army manufacturers Fanhua, the VDO instrument and the ABS system of
WABCO.

The composition of repair manual

This repair manual is fit to the T7H product of SINOTRUK, and it can be used as the
reference of the HOWO-A7 and other styling vehicle. The repair manual contains:

（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, especially 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, and 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 contain 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
locks, and solenoid valve and air pressure sensors.

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CHAPTER TWO THE EXPLANATION OF CIRCUIT

DIAGRAM
SECTION I THE EXPLANATION OF CIRCUIT DIAGRAM
In order 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

Light Flat
Color Red Black White Yellow Grey Green Purple Orange Blue Brown Pink
blue copper

SECTION II THE VEHICLE CIRCUIT DIAGRAM

The complete vehicle circuit diagram is composed of every partial circuit diagrams. In
order to understand the circuits 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 2-1: The Vehicle Circuit Diagram

(1)The basic electric equipment symbols:

There are many symbols in the circuit diagram, as the following:

The symbol The component The symbol The component

The relay valve The key switch

The fuse The lighting diode

The main switch The switch

(mechanical type)

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The motor The rocker switch

The battery The GND line

The alternator The sensor

(resistance type)

The diode The sensor

(electric type)

The horn The lamp

The solenoid valve The air pressure

switch

The inductance The

electromagnetic
clutch

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CAN line The heater

The controller It is the 7th pin of 4th

connector.

This line connects

with the 4th line of 1.5--the line size
page 19. AGC--the colors

The 1st pin of

X101/3 connector.

Fig 2-2: The Electric Equipment Symbol Table

Table 1: The electric letter symbol and the rated electric equipment

No. Series The rated electric equipment

1 A series The controller
2 B series The sensor
3 D series The diode
4 E series The lamp
5 F series The fuse
6 G series The battery, generator
7 H series The electric horn
8 K series The relay vale
9 M series The motor
10 R series The heater, resistance
11 S series The switch
12 V series The distributor
13 X series The connector
14 Y series The solenoid valve, actuator

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Table 2: The symbols and the rated electric equipments of T7H:

No. Symbol Name

1 A101 The junction box
2 A102 Mini controller
3 A103 The combination instrument
4 A110 The over-voltage alarming device
5 A111 ADR controller
6 A152 The electric hoist device
7 A187 The front-left combination lamp ass
8 A188 The front-right combination lamp ass
9 A189 The rear-left combination lamp ass
10 A190 The rear-right combination lamp ass
11 A201 The AC controller
12 A202 The speed controller
13 A301 The main door controller(driver side)
14 A302 The auxiliary door controller(the other side)
15 A303 The door control panel(driver side)
16 A304 The auxiliary door control panel(the other side)
17 A305 The rear-view mirror ass(driver side)
18 A306 The auxiliary rear-view mirror ass(the other side)
19 A401 ECU
20 A402 The accelerator pedal
21 A411 The remote accelerator
22 A412 The chassis junction box
23 A502 The retarder control unit
24 A601 ABS controller
25 A701 ECAS controller
26 A710 ECAS remote controller
27 A802 VDR
28 A805 MTCO（the paper disc recorder）
29 A806 The vehicle monitor
30 A808 The radio with MP5
31 B101 The vehicle speed sensor

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32 B101 The oil temperature sensor of retarder

33 B102 The water temperature sensor of retarder
34 B103 The pressure sensor of retarder
35 B106 The fuel sensor
36 B107 The air pressure sensor of brake circuit 1
37 B108 The air pressure sensor of brake circuit 2
38 B111 The MTCO vehicle speed sensor
39 B201 The indoor temperature sensor
40 B202 The outdoor temperature sensor
41 B203 The temperature sensor of evaporator
42 B269 The cyclic temperature sensor
43 B401 The accelerator sensor Ⅰ
44 B402 The accelerator sensor Ⅱ
45 B440 The remote accelerator sensor Ⅰ
46 B487 The common rail pressure sensor
47 B488 The NE sensor
48 B489 The G sensor
49 B601 The front-left wheel sensor
50 B602 The front-right wheel sensor
51 B603 The rear-left wheel sensor
52 B604 The rear-right wheel sensor
53 B605 The EBL sensor
54 B701 The height sensor of front axle
55 B702 The airbag pressure sensor of front axle
56 B703 The air pressure sensor of lifting axle left airbag
57 B704 The air pressure sensor of lifting axle right airbag
58 B705 The left height sensor of driving axle
59 B706 The right height sensor of driving axle
60 B707 The left pressure sensor of driving axle
61 B708 The right pressure sensor of driving axle
62 B709 The main airbag sensor of lifting axle
63 B801 The left door speaker
64 B802 The right door speaker
65 D1 The voltage-regulator diode of 30＃ power line
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66 D2 The voltage-regulator diode of 15＃power line

67 D4 The signal diode of reverse gear
68 D6 The diode of wiper high gear
69 E101 The indoor lighting lamp（left)
70 E102 The indoor lighting lamp(right)
71 E103 The left reading lamp
72 E104 The right reading lamp
73 E105 The upper sleeper reading lamp
74 E107 The nether sleeper reading lamp
75 E109 The left lighting lamp of left groceries box
76 E110 The right lighting lamp of left groceries box
77 E111 The left lighting lamp of right groceries box
78 E112 The right lighting lamp of right groceries box
79 E201 The left short beam lamp
80 E202 The right short beam lamp
81 E203 The left high beam lamp
82 E204 The right high beam lamp
83 E205 The left auxiliary high beam lamp
84 E206 The right auxiliary high beam lamp
85 E207 The front-left position lamp
86 E208 The front-right position lamp
87 E209 The front-left steering lamp
88 E210 The front-right steering lamp
89 E211 The front-left fog lamp
90 E212 The front-right fog lamp
91 E213 The front-left height position lamp
92 E214 The front-right height position lamp
93 E215 The front-left outline lamp
94 E216 The front-right outline lamp
95 E217 The left step lamp
96 E218 The right step lamp
97 E219 The left side steering lamp
98 E220 The right side steering lamp
99 E221 The rear-left outline lamp of cab
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100 E222 The rear-right outline lamp of cab

101 E225 The front-left marker lamp
102 E226 The front-right marker lamp
103 E227 The rear-left marker lamp
104 E228 The rear-right marker lamp
105 E231 The rear-left steering lamp
106 E232 The rear-right steering lamp
107 E233、E234 The left and right brake lamp
108 E235 The rear-left position lamp
109 E236 The rear-right position lamp
110 E237 The rear-left fog lamp
111 E238 The rear-right fog lamp
112 E239 The left reverse lamp
113 E240 The right reverse lamp
114 E241 The warning lamp
115 F1 The cigarette lighter fuse
116 F10 The relay valve of high beam lamp
117 F11 The fuse of door controller
118 F12 The fuse of the reverse relay valve
119 F13 The fuse of starting switch
120 F14 The backup relay fuse
121 F15 The backup power fuse
122 F150 The fuse of main power line
123 F151 The one-time fuse
124 F152 The fuse of electric lift device
125 F16 The fuse of electric horn relay valve
126 F17 The backup fuse
127 F18 The fuse of position lamp relay valve
128 F19 The fuse of right position lamp
129 F2 The backup relay fuse
130 F20 The backup relay fuse
131 F21 The left position lamp
132 F22 The fuse of starting key
133 F23 The left door controller fuse
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134 F24 The right door controller fuse

135 F25 The fuse of tractor ABS
136 F26 The fuse of trailer ABS
137 F27 The backup power fuse
138 F28 The AC fuse
139 F29 The fuse of brake lamp relay valve
140 F3 The fuse of interior lighting lamp,VDR,MP5
141 F30 The fuse of tractor ABS
142 F31 The fuse of trailer ABS
143 F32 The VDR fuse
144 F33 The fuse of vehicle monitor, Mini controller
145 F34 The fuse of working lamp, differential locks
146 F35 The fuse of combination switch
147 F36 The fuse of emergency alarming switch
148 F37 The wiper fuse
149 F38 The air dryer fuse
150 F39 The fuse of ECAS, the backup fuse
151 F4 The fuse of front fog lamp relay
152 F40 The fuse of combination instrument
153 F41 The fuse of seat heater, ECU
154 F451 The fuse(200A) of preheater
155 F5 The fuse of door lamp switch, Mini controller
156 F6 The fuse of wiper relay valve
157 F7 The fuse of combination instrument
158 F8 The fuse of short beam lamp relay
159 F813 The fuse of CD
The fuses of vehicle monitor, the diagnosis, the
160 F9
rocker switches
161 F901 The fuse of SCR main relay valve
162 F902 The fuse of urea pipe heater
163 F903 The fuse of urea injector heater
164 F904 The fuse of urea pumping pipe heater
165 F905 The fuse of urea pump heater

20
 R.EL.T7H.01

166 F906 The backup fuse

167 F907 The fuse of ECU-30 power line
168 F908 The one-time fuse
169 G101 The battery Ⅰ
170 G102 The battery Ⅱ
171 G103 The generator
172 H111 The indicator of ADR
173 H202 The electric horn
174 INJ11 The injector #1
175 INJ12 The injector #2
176 INJ13 The injector #3
177 INJ21 The injector #4
178 INJ22 The injector #5
179 INJ23 The injector #6
180 K1 The backup relay
181 K10 The horn relay
182 K11 The backup relay
183 K12 The brake lamp relay
184 K13 The relay of 15＃ power line
185 K152 The relay of electric lift device
186 K2 The wiper relay
187 K3 The high beam lamp relay
188 K4 The backup relay
189 K451 The preheated relay
190 K5 The position lamp relay
191 K52 The relay (double solenoid）
192 K6 The relay of wiper low speed switch
193 K7 The relay of front fog lamp
194 K8 The relay of short beam lamp
195 K9 The relay of reverse lamp
196 K901 The SCR main relay
197 K902 The relay of urea pipe heater
198 K903 The relay of urea injector heater
199 K904 The relay of urea pumping pipe heater
21
 R.EL.T7H.01

200 K905 The relay of urea pump heater

201 K906 The backup relay
202 KD The relay of engine controller
203 M101 The starter motor
204 M102 The wiper motor
205 M103 The wishing motor
206 M104 The electric lift motor
207 M201 The electric motor of AC
208 M202 The brushless motor
209 M203 The loop motor
210 M204 The model motor
211 M205 The water valve motor Ⅰ
212 M206 The water valve motor Ⅱ
The adjusting(up/down) motor of wide-view
213 M301
mirror(the driver side)
The adjusting(up/down) motor of wide-view
214 M302
mirror(the auxiliary driver side)
The adjusting(left/right) motor of wide-view
215 M303
mirror(the driver side)
The adjusting(left/right) motor of wide-view
216 M304
mirror(the auxiliary driver side)
The adjusting(up/down) motor of rear-view
217 M305
mirror(the driver side)
The adjusting(left/right) motor of rear-view
218 M307
mirror(the driver side)
The adjusting(up/down) motor of rear-view
219 M308
mirror(the auxiliary driver side)
220 M309 The glass lifting motor of door(the driver side)
The glass lifting motor of door(the auxiliary driver
221 M310
side)
222 M311 The lock motor of door(driver side)
223 M312 The lock motor of door(the auxiliary driver side)
224 R101 The air dryer
225 R102 The cigarette lighter(24V)

22
 R.EL.T7H.01

226 R103 The defroster of rear-view mirror

227 R104 The defroster of auxiliary rear-view mirror
228 R105 The seat heater
229 R106 The auxiliary seat preheater
230 R106 The preheater
231 R109 The beam adjusting switch of headlamp
232 R114 The resistance 120Ω
233 R115 The resistance 120Ω
234 R116 The resistance 120Ω
235 S102/Ⅰ The combination switch of headlamp
236 S102/Ⅱ The wiper switch
237 S103 The right combination switch
238 S104 The lighting rotary switch
239 S106 The rocker switch of electric lifting device
240 S107 The horn over-change switch
241 S108 The inter-wheel differential lock switch
242 S109 The inter-axle differential lock switch
243 S110 The emergency alarming switch
244 S112 The switch of working lamp
245 S113 The PTO switch
246 S114 The neutral switch of PTO
247 S115 The lifting axle switch
248 S119 The switch of remote accelerator
249 S122 The diagnosis switch of engine
250 S124 The diagnosis switch of ABS
251 S126 The driving-assist switch
252 S127 The ASR switch
253 S131 The heater switch of main seat
254 S132 The heater switch of auxiliary seat
255 S133 The ABS switch(the cross-country mode)
256 S134 The switch of ECAS (the lift axle)
257 S138 The polymorphic switch
The emergency switch of cab interior power
258 S139
source
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 R.EL.T7H.01

259 S140 The ADR power switch

260 S140 The retarder switch
261 S141 The warning lamp switch
262 S143 The emergency power switch(outside of cab)
263 S151 The brake lamp switch
264 S152 The clutch switch
265 S153 The left door lamp switch
266 S154 The right door lamp switch
267 S155 The locking signal switch of safety belt
268 S157 The horn button
269 S158 The lamp switch of right groceries box door
270 S161 The operation panel (the driver side)
271 S163 The pressure switch
272 S201 The mechanical main switch of power source
273 S202 The signal switch of hand brake
274 S203 The signal switch of brake circuit 4
275 S204 The signal switch of transmission low gears
276 S205 The neutral switch of transmission（not AMT）
277 S206 The signal switch of reverse gear
278 S208 The signal switch of PTO
The signal switch of front axle inter-axle
279 S209
differential lock
The signal switch of middle axle inter-axle
280 S210
differential lock
The signal switch of rear axle inter-axle
281 S211
differential lock
The signal switch of front axle 1 inter-wheel
282 S212
differential lock
The signal switch of front axle 2 inter-wheel
283 S213
differential lock
The signal switch of rear axle 1 inter-wheel
284 S214
differential lock
The signal switch of rear axle 2 inter-wheel
285 S215
differential lock

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 R.EL.T7H.01

286 S217 The signal switch of cross-country mode

287 S217 The start button of electric lifting device
288 S218 The coolant level sensor switch
289 S219 The blocking alarming switch of air
290 S220 The signal sensor of cab lock device
291 S221 The locking signal switch of cab
292 S225 The Start button under the vehicle
293 S226 The Stop button under the vehicle
294 S228 The oil-water separator switch
295 S232 The adjustable vehicle speed limited switch
296 X101/5 The 30＃ power line connector of cab
The GND line connector of cab and the front-right
297 X101/6
connector
298 X102/2 The front-left GND line connector of cab
299 X102/4 The power port of backup lamps
300 X102/5 The backup power
301 X12 The connector of rear junction box
302 X130/2 The 30＃ power distributor of rocker switch
303 X131/1 The junction box for GND lines
The distributor of working lamps, differential
304 X150/1
locks
305 X158/1 The power distributor of marker lighting lamps
The power distributor of small lighting power
306 X158/2
source
307 X240 The backup power socket (24V)
308 X430/2 The output power line of ECU
309 X5 The trailer connector (with 7 holes)
310 X6 The trailer ABS connector (with 7 holes)
311 XOBD The diagnosis port
312 Y101 The air horn solenoid valve
313 Y101 The proportional valve
314 Y102 The PTO solenoid valve
315 Y103 The solenoid valve of inter-wheel differential lock
316 Y105 The neutral gear solenoid valve of PTO
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 R.EL.T7H.01

317 Y106 The solenoid valve of inter-axle differential lock

318 Y107 The exhaust brake solenoid valve
319 Y108 The lifting axle solenoid valve
320 Y201 The electric clutch
321 Y601 The solenoid valve of front-left wheel
322 Y602 The solenoid valve of front-right wheel
323 Y603 The solenoid valve of rear-left wheel
324 Y604 The solenoid valve of rear-right wheel
325 Y605 The EBL solenoid valve
326 Y701 The solenoid valve of front axle airbag
327 Y702 The main solenoid valve of lifting axle
328 Y703 The solenoid valve of lifting axle left airbag
329 Y704 The solenoid valve of lifting axle right airbag
330 Y705 The left airbag solenoid valve of driving axle
331 Y706 The right airbag solenoid valve of driving axle
332 Y707 The central solenoid valve

Table 3: The codes of T7H rated connector

No. The code The connected name

1 X101/1 The connector of chassis harness wire
2 X101/3
The connector of suspension
3 X101/4
4 X101/7 The trailer lamp connector（the chassis harness
wire connector）
5 X101/8 The connector of working, right position lamp
(the chassis harness wire connector)
6 X101/11
The front-right connector of cab
7 X101/12
8 X101/15 The connector of electric overturning device
9 X101/19 The connector of MTCO sensor
10 X101/23 The connector of vehicle recorder, original fuel
filter heater
11 X101/24 The steering connector

26
 R.EL.T7H.01

12 X102/1 The front-left connector of cab

13 X103/1 The connector of cab upper ceiling
14 X103/2 The connector of cab nether ceiling
15 X103/3 The connector of groceries box
16 X104 The connector of cab floor harness wire
17 X105 The connector of left seat heater wire
18 X106 The connector of right seat heater wire
19 X201
The connector of AC harness wire
20 X202
21 X301 The left door harness wire connector
22 X302 The right door harness wire connector
23 X401/1
24 X401/2 The connector of engine harness wire
25 X401/3
26 X501 The connector of AMT harness wire
27 X601/1
The connector of ABS harness wire
28 X601/2
29 X601/3 The connector of EBL harness wire
30 X602/1 The connector of trailer ABS harness wire
31 X701/1 The connector of ECAS harness wire
32 GL The connector of vehicle monitor

Table 4: The abbreviated names of some T7H electric equipments

No. The abbreviated The full name

name
1 ABS Anti-skid brake system
2 ADR The dangerous goods vehicle
3 AMT The automated mechanical transmission
4 ASR Acceleration Slip Regulation
5 CBCU Central body control unit
6 EBL Electric brake force distribution

27
 R.EL.T7H.01

7 ECAS The electronic air suspension

8 ECU The engine control unit
9 EGR Exhaust gas recirculation
10 MTCO The paper disc recorder
11 SCR Selective catalytic reduction
12 TPM Tire pressure monitoring
13 VDR Vehicle traveling data recorder

(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 24 V.
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.
g、The single line, ground line(GND)
In the vehicle electrical 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 shows the H control circuit, and the fig 4 shows the L control circuit.

28
 R.EL.T7H.01

Fig 2-3: The H Control

The CAN-H is control the positive line.

Fig 2-4: The L Control

The CAN-L is control the negative line.

CHAPTER THREE THE LAYOUT OF CAB ROOF AND

FLOOR HARNESS WIRE

SECTION I THE OUTLAY OF THE CAB CEILING HARNESS

WIRE

1. The Ceiling and Reading Lamp Harness Wire of Extended Cab

a. The cab ceiling harness wire is fixed on the left A column from upper side to the bottom

29
 R.EL.T7H.01

by the belt, then it is fixed along the by the sundry box from left side to the right. When
finished the fixing, connect the connector ZM08A3 of X103/1 with the connector ZN08A3
of X103/1.

b. Install and fix the interior lamp wire and the rear outline lamp wire along the cab ceiling
from left side to right side. Show as the following diagram.

c. Fix the left and right GND line on the GND points of the windscreen upper bracket,
tighten them by the screws and shims.

d. Traverse the left and right lamp wires out to the outside of cab through the related
mounting holes. Then block the mounting holes by the sealing gum.

e. When install the cab lining, move the reading lamp connector to the mounting and
connecting position.

Fig 3-1: The Ceiling Wire Outlay of Extended Cab

Fig 3-2: The Ceiling Wire Outlay of Extended Cab

2. The outlay of high cab ceiling wire and sundry box wire
30
 R.EL.T7H.01

a. Fix the cab ceiling harness wire on the left side of windscreen bracket along the left a
column from the bottom to upper side. Then fix the wire along the bracket from left side to
right side. Finish the wire installation, connect the connector ZM08A3 of X103/1 with the
ZN08A3 of X103/1 的 ZN08A3.

b. Traverse the front-left outline lamp wire to the outside of cab through the top steel
bracket and the mounting holes.

c. Fix the cab interior lighting lamp wire on the middle position of lining along the middle
line by the belt.

d. Install and fix the rear outline lamps wire, the sleeper reading lamp wire on the rear-left
side of the cab. Show as the diagram.

e. Install and fix the sleeper reading lamp wire from the rear-left side of cab to the reading
lamp mounting position.

f. Fix the left and right GND line on the related GND point by the cross screws and
tightening shim.

g. Install the sundry box wire as the diagram shown. Install the sundry box lamp, switch
and the related wire at the accurate mounting position. Connect the wire connector
WM06B1 of X103/3 with the ceiling wire connector WN06B1 of X103/3.

h. When installing the cab lining, move the interior lamp and reading lamp wire to the
mounting and connecting position.

Fig 3-3: The Outlay Diagram of High Cab Ceiling Harness Wire

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 R.EL.T7H.01

Fig 3-4: The Outlay Diagram of Cab Ceiling Harness Wire

Fig 3-5: The Installation Diagram of Cab Glove Box Electric Equipments

Fig 3-6: The Outlay of Glove Box Wire

Note：

a. Remove the paint of the GND point to ensure the wire connected well.
b. Keep the wire not too tightened to protect the wire.

32
 R.EL.T7H.01

c. Use the few belt to fix the wire for temporary fixed.

SECTION II THE OUTLAY OF CAB FLOOR HARNESS WIRE

1. The Cab Floor Harness Wire
A. Fix the cab floor harness wire on the cab floor, shown as the diagram.

B. Connect the connector ZN08A1 of X104 with the connector ZM08A1 of X104 的
ZM08A1, then install the left and right wires to the left and right bottom of engine cover,
and to the accurate mounting position.

C. Finish the installation, the connector marks:

S159—the left door lamp switch,S160—the right door lamp switch,E219—the left steering
lamps,E220—the right steering lamps,S214—the left locking switch,S215—the right
locking switch,S218—the trailer brake switch（connect the ZN02A1 and short circuit it，if
there is trailer brake connector, cut off the connector ZN02A1）.

Fig 3-7: The Outlay of Cab Floor Harness Wire

Note：
a. Install the cab floor harness wire and tighten it.
b. Install the rubber protection article.
C. During the installing, avoid the bolts and the mounting holes.

33
 R.EL.T7H.01

CHAPTER FOUR THE INTRODUCTION OF DOOR

ELETRIC EQUIPMENTS

SECTION I THE DOOR ELETRIC EQUIPMENTS

There are many electric equipments in the door system of T7H truck,they contains:
a. The door controller
b. The central-control door lock
c. The electric lifting device of door window
d. The electric driving rear-view mirror
e. The heater
f. The radio speaker
g. The step lamp

Fig 4-1: The Partial Schematic Diagram of Door Electric Equipment

SECTION II THE LAYPOUT OF DOOR ELETRIC EQUIPMENTS

a. Thread the door wire through the door and the cab installation holes, mark the
connector as X301（the right door one X302） and connect it with the related connector of
the cab, then amount the protective bushing at the hole correctly.

b. Bind the rear-view mirror wire on the cab pillar as the diagram shown, when installation
the mirror, connect the connector X303/1、X303/2（the right side X304/1、X304/2）.

c. Use the cross screws（Q2300520） to mount the speaker, then connect the speaker

34
 R.EL.T7H.01

connector B801（the right one is B802).

d. After mounted the glass lifting device, bind the wire as the diagram shown. Connect the
connector X305（the right one is X306） with the door lock connector, and connect the
connector M309（the right one is M310）with the lifting motor connector.

e. Mount the door controller and speaker on the installation plate as the diagram shown，
then bind the harness wire. Connect the connector A301/1、A301/2、A301/3（the right ones
are A302/1、A302/2、A302/3） with the related door controller ports（the low-level
configuration vehicle no connector A301/2,A302/2).

f. Mount the operation panel, and connect the connector A303（the right one is A304).

g. Thread the door wire through the installation hole, connect the connector S159（the
right lamp wire is S160）with the door switch connector.

h. Tighten the door lamp switch（WG9918790001）on the cab through the cross screw-C
（Q2764816F31).

，then mount
i. Connect the left door lamp and the connector E217（the right one is E218）
the door lamp on the door as the diagram shown.

Fig 4-2: The Layout of Rear-view and Lifting Device Harness Wire

Fig 4-3: The Layout of Speaker and Wiper Harness Wire

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 R.EL.T7H.01

Fig 4-4 The Layout of Door Operation Panel and Harness Wire

Fig 4-5 The Layout of Door Lamp Switch and Step Lamp

36
 R.EL.T7H.01

CHAPTER FIVE THE LAYOUT OF CAB LEFT/RIGHT

DISTRIBUTOR BOX

SECTION I THE INSTALLATION OF DISTRIBUTOR BOX

Fix the left junction box(WG9925771003) on the combination penal assembly by 6 sets
cross screws（Q2715516）,shim（Q40006）and spring shim（Q40306).Finish the connecting,
install the cover （WG9925771007） at the inside of the junction box by 2 cross screws
（Q2140412） and fix the cover（WG9925771002）on the outside of junction box by 2
cross screws（Q2140412）.

Fix the right junction box (WG9925771006) on the right-front side of cab by 6 sets cross
screws（Q2715516）,shim（Q40006）and the spring shim（Q40306）.Finish the connection,
install the cover（WG9925771002） on the outside of box by 2 cross screws（Q2140412）.

Fig 5-1 The Installation Diagram of Junction Box Cover

37
 R.EL.T7H.01

Fig 5-2 The Installation Diagram of Junction Box Cover

SECTION II THE OUTLAY OF JUNCTION BOX INTERIOR

CONNECTORS
The right junction box contains the engine connector X401/1,X401/2,X401/3，the chassis
wire connector X101/1,X101/7,X101/8，the vehicle frame wire connector X101/3,X101/4，
the power connector X101/5,X101/6，the trailer ABS connector，shown as the Fig 19 (left).

The left junction box contains the connector X102/1,the AMT connector X501,the ABS
connector X601/1,X601/2,and the front-right GND connector X102/2.The outlay as the Fig
19 (right) shown.

Fig 5-3 The Outlay of Junction Box Interior Connectors

The left and right junction boxes of cab are the important device for connection, there
mainly contains the connectors of the cab and chassis wire, the whole vehicle and engine
wire. There is simple for mechanic to dismantle and measure the failure. Open the cover
and measure the failure related pin to solve the failure according to the electric principle
diagram.

CHAPTER SIX THE CAB INTERIOR ELECTRIC EQUIPMENTS

SECTION I THE CAB INTERIOR LIGHTING LAMP

The standard and extended cab

a. Install the cab interior lighting lamp (the standard and extended cab)

Connect the left lighting lamp with the ceiling wire connector E101，and fix it at the ceiling

38
 R.EL.T7H.01

left mounting hole. Connect the right lighting lamp with the ceiling wire connector E102，
and fix it at the ceiling right mounting hole.

b. Install the reading lamp(the standard and extended cab)

Connect the left reading lamp with the ceiling wire connector E103,and fix it at the ceiling
front-left mounting hole.

The high cab

a. Install the cab interior lighting lamp（the high cab）

Connect the left interior lighting lamp with the ceiling wire connector E101,and fix it at the
ceiling left mounting hole. Connect the right interior lighting lamp with the ceiling wire
connector E102，and fix it at ceiling right mounting hole.

b. Install the reading lamp（the high cab）

Connect the left reading lamp with the connector E103 of left sundry box, and fix it at the
left-nether mounting hole. Connect the right reading lamp with the connector E104 of the
sundry box, and fix it at the right-nether mounting hole. Connect the upper sleeper reading
lamp with the ceiling wire connector E105，and fix it at the cab ceiling left-rear mounting
hole. Connect the upper lighting lamp with the ceiling wire connector E106, and fix it at the
cab ceiling left-rear mounting hole. Connect the ceiling wire connector X103/2 with the
nether sleeper lamp connector. Connect the nether reading lamp with the connector
E107,and fix it at the mounting hole. Connect the nether lighting lamp with the connector
E108,and fix it at the mounting hole.

Fig 6-1 The Cab Interior Lighting Lamp and Reading Lamp

39
 R.EL.T7H.01

Fig 6-2 The Installation Diagram of Interior Lighting Lamp and Reading Lamp

Fig 6-3 The Interior Lighting Lamp and Upper Sleeper Lamp

Fig 6-4 The Sleeper Lamp Wire

SECTION II THE CAB HARNESS WIRE

The cab harness wire

a. Install the protection article at the right position of steering column, shown as the
40
 R.EL.T7H.01

diagram.

b. As the diagram shown, tighten the harness wire orderly and use the saw tooth lock
washer to tighten the GND points.

The ABS harness wire

a. Install the cab harness wire and ABS wire, then tighten the wires on the bracket of
steering column.

b. Install the connectors and tighten the wire orderly.

c. Install the 120Ω resistance for R114 R115.

d. Tighten the ABS wire orderly, and make the related connector AF01 AF08,

X601ABS-CAN 14PINS and 18PINS connected well.

Fig 6-5 The Harness Wire Protection Article

Fig 6-6 The Installation Diagram of Cab Harness Wire and ABS Wire

41
 R.EL.T7H.01

Fig 6-7 The Installation Diagram of ABS Wire

Fig 6-8 The Installation Diagram of Cab Left/Right GND Points and The 120Ω Resistance

SECTION III THE CAB ELETRIC EQUIPMENT

Install the electric accelerator assembly

Install the electric accelerator on the mounting hole, and connect the connector A402 with
the accelerator sensor.

Install the brake switch and clutch switch

Install the switches on the combination plate, connect the S151（red）with the brake switch,
connect the S152（green） with the clutch switch. The AMT system no clutch switch.

Install the right/left combination switch and the key switch

Install the combination switch and tighten them on the steering column through 2 screws.
After installed the steering column assembly, connect the connectors S101、S102I、
S102II、S103.Install the horn and CD on the steering wheel, connect the connector S156
of cab, shown as the diagram.

Install the main junction box

Install the main junction box and tighten it through 4 screws at the middle of the instrument
desk, and connect the red power line and 30＃ power line of junction box. Plug the

42
 R.EL.T7H.01

connectors of A101/1—4 into the main junction box, and paste the nameplate.

Install the radio

a. Install the radio bracket (black color) on the instrument panel first, then install the
bracket on the black bracket and turn up the sheet iron to fix it.

b. Connect the connector A701/A,A701/B of CD wire and the connector X801/2 of cab CD
harness wire with the related socket, shown as the diagram.

Install the vehicle driving recorder device

a. Install the radio on the mounting bracket firstly, turn up the fixing sheet iron to fix the
bracket.

b. Connect the connector A802/A,A802/B,A802/D of cab harness wire with the vehicle
driving recorder device, shown as the diagram. Then push it into the bracket and lock it.

Assemble and install the instrument panel assembly

a. Connect the white connector X1,the black connector X2,the blue connector X3 and the
grey connector X4 with the related sockets of instrument, shown as the diagram.

b. Assemble every switches on the instrument panel. There contains rocker switches, the
computer diagnosis port, cover the 24V cigarette lighter, the 24V power socket, the AC
operation panel, the MCS menu rotary switch and the mounting plate.

c. The connector code of cab harness wire and the related rocker switches:

S104—the lamp lighting rotary switch；S105—MCS the menu rotary switch；S106—the

cab overturn switch ； S107—the horn over-change switch ； S108—the inter-wheel
differential lock switch；S109—the inter-axle differential switch；S110—the emergency
alarming switch；S111—the auxiliary high beam lamp；S112—the working lamp switch；
S113—the PTO switch；S114—the PTO neutral switch ；S119—the PTO switch；
S120—the engine preheater switch；S121—the double torque modes switch；S122—the
engine diagnosis switch；S124—the ABS diagnosis switch background lamp switch；
S128—the cargo truck testing switch；S129—the trailer diagnosis switch；S131—the left
seat heater switch；S132—the right seat heater switch: ABS—the ABS diagnosis switch；
16—the ASR switch；XOBD—the computer diagnosis port.

d. Finish the assembling work, install the instrument panel on the mounting bracket.

e. Select the 12V socket and install the 24V/12V converter on the instrument desk bracket
through 4 screws. Shown as the diagram.

43
 R.EL.T7H.01

Fig 6-9 The Installation Diagram of Brake Switch and Wire

Fig 6-10 The Installation Diagram of Brake Switch, Clutch Switch,

Electric Accelerator and The Related Wire

Fig 6-11 The Installation Diagram of Left/Right Combination Switch

44
 R.EL.T7H.01

Fig 6-12 The Installation Diagram of Key Switch and Left/Right Combination Switch

Fig 6-13 The Harness Wire of Horn and CD

Fig 6-14 The Junction Box and The Installation Nameplate

45
 R.EL.T7H.01

Fig 6-15 The Harness Wire of The Radio and The Vehicle Running Recorder

Fig 6-16 The Installation of Radio and Vehicle Running Recorder

Fig 6-17 The Rocker Switches

46
 R.EL.T7H.01

1.The PTO switch. 12.The emergency diagnoses switch

2.The lifting switch of axle. 13.The horn over-change switch
3.The testing switch of cargo truck load. 14.The ABS testing switch
4.The testing switch of trailer load. 15.The ASR switch
5.The switch of auxiliary high beam lamp. 16.The economic mode switch
6.The cab overturning button. 17.The working lamp switch
7.The lighting rotary switch. 18.The inter-differential lock switch
8.The diagnosis port. 19.The inter-axle differential lock switch
9.The backup switch. 20.The neutral gear switch of PTO
10.The engine preheater switch. 21.The PTO switch
11.The engine diagnose switch.

Fig 6-18 The Installation Diagram of Combination Instrument

Fig 6-19 The Installation Diagram of Rocker Switches

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Fig 6-20 The Installation Diagram of Rocker Switch Harness Wire

Fig 6-21 The Cigarette Lighter and The Socket(24V/12V)

Fig 6-22 The Diagram of Diagnosis Port

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CHPATER SEVEN THE INTRODUCTION OF THE CAB

EXTERNAL ELECTRIC EQUIPMENTS

SECTION I THE AIR HORN SOLENOID VALVE AND THE AIR

PRESSURE SIGNAL SWITCH

Install the horn solenoid valve and air pressure signal switch

a. Install the air horn solenoid valve on the bracket as the diagram shown.

b. Connect the connector Y101 with the solenoid valve, connect the connector S202 with
the air circuit 3 signal switch（common closed，there is one green point）,then cover the
W04.Connect the connector S203 with the air circuit 4 signal switch（common closed，
there is one green point）,then cover the W04.Connect the connector S216 with the stop
lamp signal switch（common closed，there is one red point）,then cover the W04.And
tighten them orderly.

Fig 7-1 The Installation Diagram of Air Horn Solenoid Valve and Pressure Signal Switch

SECTION II THE HARNESS WIRE AT THE FRONT OF CAB

Install the front cab harness wire

a. Connect the connector X102/1 well in the junction box, connect the A05 with the GND
point, then connect the connector Y101 with the air horn solenoid valve. Connect the
connector S202 with the air circuit 3 signal switch(common closed, there is one green
point)and cover the W04.Connect the connector S203 with the air circuit 4 signal
switch(common closed, there is one green point) and cover the W04.Connect the
connector S216 with the stop lamp signal switch(common open, there is one red point)
and cover the W04.Then tighten the wire orderly. Connect the M103 with the washing
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motor, connect the A187 with the front-left headlamp. Then tighten the wire orderly.

b. Connect the connector X101/1 well in the right junction box, and connect the A05 with
the GND point, and connect the connector H202 with the electric horn connector, connect
the connector A188 with the front-right headlamp. Then tighten the wire orderly.

Fig 7-2 The Harness Wire Installation Diagram Front of Cab

SECTION III THE WIPER MOTOR AND THE ELETRIC HORN

Install the wiper motor

a. Install the wiper motor on the cab mounting holes with 4 bolts.
b. Install the cab harness wire ,and connect the connector M102 with the wiper motor
connector, the tighten the wore orderly.

Install the electric horn

a. Install the triangle bracket on the mounting hole with the bolts（Q150B0818）,spring
shim（Q40308）and plate shim（Q40208）,it is shown as the following diagram.
b. Install the electric horn on the mounting hole with the bolts（Q340B08）and plate shim
（Q1460825）.It is shown as the following diagram.
c. Then connect the connector H202 with the electric horn wire,and tighten it orderly.

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Fig 7-3 The Installation Diagram of Wiper Motor

Fig 7-4 The Installation Diagram of Electric Horn

SECTION IV THE SIDE STEERING LAMPS, OUTLINE LAMPS

AND THE HEIGHT LAMPS

Install the side steering lamps

The left side

a. Install the left steering lamp(WG9925720012) on the mounting plate,as the diagram
shown.
b. Connect the connector E219（the right one is E220）with the steering lamp connector.

The right side

a. The installation process of right steering lamp(WG9925720013)is same with the left
one.

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Install the outline lamps and height lamps.

a.Install the right outline lamp on the sun shade with 1 bolt(Q150B0516）,1 cross screw
（Q2714816）,3 bolts（Q340B05）,4 spring shim（Q40305）and plate shim（Q40205）.Show
as the diagram.
b. Installed the sun shade, and connect the ceiling connector E215, E216 with the front
and rear outline lamp connectors, then smear the sealing gum.
c. Install the left/right height lamps on the windscreen with 2 cross screws（Q2140514）.
d. Installed the upper windscreen and connect the ceiling connector E213, E214 with the
left and right height lamp connectors.

Install the rear outline lamps of cab.

a. Firstly, assemble the left(right) rear outline lamps on the bracket with 2 cross screws
（Q2140520),plate shim（Q40105）and spring shim(Q40305）.Then install the bracket
assembly on the cab with 2 bolts（Q150B0816）.Shown as the diagram.
b. Installed the rear outline lamps, connect the ceiling connector E221,E222 with the
rear-left outline lamp connector, hen smear the sealing gum. Show as the following
diagram.

Fig 7-5 The Installation Diagram of Side Steering Lamps

Fig 7-6 The Installation Diagram of Outline Lamps

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Fig 7-7 The Installation Diagram of Rear Outline Lamps

SECTION V THE FRONT COMBINATION HEADLAMP

Install the front combination headlamp

a. Install the combination headlamp on the frame with the bolts.

b. Connect the connectors of left and right front combination headlamp.

Fig 7-8 The Installation Diagram of Combination Headlamp

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CHAPTER EIGHT THE CHASSIS ELETRIC EQUIPMENTS

SECTION I 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 fourth 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 method: 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
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 8-1 The Installation Diagram of Chassis Harness Wire

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Fig 8-2 The Installation Diagram of Chassis Wire

Fig 8-3 The Installation Diagram of Chassis Harness Wire

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Fig 8-4 The Installation Diagram of Chassis Wire

Fig 8-5 The Installation Diagram of Chassis Wire

SECTION II 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.

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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
protection sleeve.

Fig 8-6 The Outlay of Battery Box Wire

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Fig 8-7 The Installation Diagram of Main Switch and The Battery Negative Electrode

Fig 8-8 The Outlay of Battery Wire

Fig 8-9 The Installation Diagram of Battery

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SECTION III THE ENGINE AND STARTER 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.

Fig 8-10 The Installation Diagram of Generator Wire

Fig 8-11 The Installation Diagram of Expansion Tank Coolant Level Switch

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Fig 8-12 The Connection Diagram of Engine Starter

SECTION IV 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 8-13 The Connection of Air Dryer

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Fig 8-14 The Installation Diagram of Double Axle Differential Locks

Fig 8-15 The Installation Diagram of Single Axle Differential Lock

SECTION V 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 8-16 The Diagram of Air Filter Block Alarming Switch

Fig 8-17 The Installation Diagram of Fuel Sensor Wire

SECTION VI 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
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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. Be shown as the following diagram.

Fig 8-18 The Installation Diagram of Front Position Lamp

Fig 8-19 The Installation Diagram of Rear Position Lamp

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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 8-20 The Installation Diagram of Solenoid Valve

Fig 8-21 The Installation Diagram of Solenoid Valve

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Fig 8-22 The Installation Diagram of The Trailer ABS Socket,

The Trailer Socket(7 holes) and The Working Lamp

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 8-23 The Installation Diagram of The Trailer Socket (7 holes)

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Fig 8-24 The Installation Diagram of Working Lamp Wire

SECTION VII 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).

Fig 8-25 The Installation Diagram of Tractor Rear Combination Lamp

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Fig 8-26 The Installation Diagram of First Axle ABS Sensor Wire

Fig 8-27 The Installation Diagram of Front Axle ABS Solenoid Valve Wire

Fig 8-28 The Installation Diagram of Rear Axle Left/Right Side ABS Valve Wire

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Fig 8-29 The Installation Diagram of Rear Axle ABS Sensor Wire

Fig 8-30 The Installation Diagram of ASR Solenoid Valve, EBL Sensor

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

b. Fix the ABS last

8╳4,10╳4（the sensor
axlewire with the
is liftable air pipe（one
axle）,the sensorsfixing belt every
are installed on 10-15cm） ，note
the second the
and furth
outlay direction, avoid the wheel and the plate spring to ensure there is no interference
between
axle. For wheels when
10╳4（the the vehicle
middle axle issteering.
liftable axle）,the sensors are installed on the second

c.
andDo notaxle.
fifth fix the ABS sensor wire too tightened to avoid snapping the wire when the
vehicle in bumpy or steering condition.

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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.

SECTION VIII THE ELETRIC OVERTURN DEVICE,AIR

PRESSURE SENSOR AND THE RELATED 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.

Fig 8-31 The Installation Diagram of Lifting Motor

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Fig 8-32 The Installation Diagram of Air Pressure Sensor

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