---===WSE_1506_00001_0001.djvu===--- Shop Manual electrical Pub.No.00ELT0080, FEBRUARY 2015 ( EURO 5 b+. EURO VI ) ---===WSE_1506_00001_0001.djvu===--- Shop Manual electrical Pub.No.00ELT0080, FEBRUARY 2015 ( EURO 5 b+. EURO VI ) ---===WSE_1506_00001_0002.djvu===--- GROUP INDEX 54-00B 54-00C 54-00D 54-01 54-02 54-03 54-04 54-05 54-06 54-07 54-09 54-10 54-11 54-12 54-13 54-14 54EA 54-08 54EC 54EI 54EM 54ES 54-00A FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi Fuso CANTER series trucks, and includes pro- cedures for adjustment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage. Kindly note that the specifications and maintenance ser- vice figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. FEBRUARY 2015 Applicable models FE.FG ( EURO 5 b+. EURO VI ) ©2015 Mitsubishi Fuso Truck & Bus Corporation GENERAL ................................................ SPECIFICATIONS .................................... STRUCTURE AND OPERATION............. TROUBLESHOOTING ............................. POWER, CHARGE AND EARTH CIRCUIT ................................................... ENGINE STARTING, STOPPING AND PREHEATING CIRCUIT .................. LIGHTING CIRCUIT ................................. METER CIRCUIT...................................... INDICATOR AND WARNING LAMP CIRCUIT ........................................ CAB SIDE ELECTRICAL CIRCUIT ......... CHASSIS SIDE ELECTRICAL CIRCUIT ................................................... ENGINE AND GEARBOX SIDE ELECTRICAL CIRCUIT ........................... OTHER CIRCUIT...................................... ELECTRICAL EQUIPMENT INSTALLATION POSITIONS ................... INSPECTION OF ELECTRICAL EQUIPMENT ............................................ STARTER AND ALTERNATOR ............... ON-VEHICLE INSPECTION AND ADJUSTMENT ......................................... CONNECTOR CONFIGURATION CHART ..................................................... IDLING STOP AND START SYSTEM...... LDWS (LANE DEPARTURE WARNING SYSTEM) ............................... IMMOBILISER .......................................... METER CLUSTER ................................... SIGNAL DETECTED AND ACTUATION MODULES .......................... ---===WSE_1506_00001_0003.djvu===--- This Shop Manual contains the information classified into the following groups. If any system or equipment has two or more variations with significantly different construction, the variations are handled as different groups. These groups are identified by different alphabets preceded by the same number. 1. ENGINE volume (Pub.No.00ELT0078) 2. CHASSIS volume (Pub.No.00ELT0079) Group No. Group subject 00 GENERAL 11 ENGINE 12 LUBRICATION 13 FUEL AND ENGINE CONTROL 13E COMMON RAIL SYSTEM 14 COOLING 15 INTAKE AND EXHAUST 17 EMISSION CONTROL 17E BlueTec ® SYSTEM Group No. Group subject 00 GENERAL 21 CLUTCH 22A GEARBOX <M038: DUONIC ® > 22B GEARBOX <M038> 22E DUONIC ® 24 TRANSFER 25 PROPELLER SHAFT 26A FRONT AXLE <RIGID LEAF SUSPENSION (FE)> 26B FRONT AXLE <RIGID LEAF SUSPENSION (FG)> 26C FRONT AXLE <INDEPENDENT SUSPENSION> 27 REAR AXLE 31 WHEEL, TYRE 33A FRONT SUSPENSION <RIGID LEAF TYPE> 33B FRONT SUSPENSION <INDEPENDENT TYPE> 34 REAR SUSPENSION 35 BRAKE 35E ABS/ESP ® /ASR (ABS: ANTI-LOCK BRAKE SYSTEM, ESP ® : ELECTRONIC STABILITY PROGRAM, ASR: ANTI SPIN REGULATOR) 36 PARKING BRAKE 37A STEERING <RIGID LEAF SUSPENSION> 37B STEERING <INDEPENDENT SUSPENSION> 41 BUMPER, FRAME 42 CAB MOUNTING, TILT 43 DOOR 51 EXTERIOR 52 INTERIOR 52E SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 55 HEATER, AIR-CONDITIONER 55E FULL AUTO AIR-CONDITIONER ---===WSE_1506_00001_0004.djvu===--- 3. ELECTRICAL volume (Pub.No.00ELT0080) Group No. Group subject 54 ELECTRICAL 54EA IDLING STOP AND START SYSTEM 54EC LDWS (LANE DEPARTURE WARNING SYSTEM) 54EI IMMOBILISER 54EM METER CLUSTER 54ES SIGNAL DETECTED AND ACTUATION MODULES ---===WSE_1506_00001_0005.djvu===--- CONTENTS 54-00A GENERAL VEHICLE MODEL CODING SYSTEM .. 54-00A-2 EQUIPMENT TYPE CODES LIST ........ 54-00A-3 POWER TRAIN TABLE ........................ 54-00A-4 HOW TO READ THIS MANUAL ........... 54-00A-8 VEHICLE IDENTIFICATION NUMBER, ENGINE NUMBER AND NAME PLATE............ 54-00A-16 PRECAUTIONS FOR MAINTENANCE OPERATION ....................................... 54-00A-18 1. Handling Precautions for Electric Circuits ......................................... 54-00A-25 2. Service Precautions for Alternators..................................... 54-00A-28 3. Intermittent Faults........................... 54-00A-29 4. Precautions for Arc Welding............. 54-00A-30 5. Cautions When Handling AdBlue ® ........................................ 54-00A-31 6. Precautions When Repainting........... 54-00A-31 7. Precautions When Handling a Vehicle with DUONIC ® System............................ 54-00A-31 8. Precautions on Cleaning When Servicing the Engine and Gearbox .................. 54-00A-32 JACKING UP THE VEHICLE.............. 54-00A-36 DIAGNOSIS CODES 1. Diagnosis Codes ............................ 54-00A-38 2. Reading and Erasing the Diagnosis Code ............................................. 54-00A-44 TABLE OF STANDARD TIGHTENING TORQUES........................................... 54-00A-48 54-00B SPECIFICATIONS SPECIFICATIONS ................................ 54-00B-2 54-00C STRUCTURE AND OPERATION 1. Starter............................................. 54-00C-2 2. Alternator ........................................ 54-00C-3 3. Headlamps ...................................... 54-00C-5 4. Battery Equaliser .............................. 54-00C-7 54-00D TROUBLESHOOTING TROUBLESHOOTING .......................... 54-00D-2 54-01 POWER, CHARGE AND EARTH CIRCUIT HIGH-CURRENT FUSE BOX .................. 54-01-2 FUSE BOX ............................................... 54-01-4 SAM INTERNAL CIRCUIT ............. 54-01-6 POWER CIRCUIT ........................... 54-01-8 RESERVE POWER CIRCUIT....... 54-01-24 BATTERY CHARGING CIRCUIT........................................ 54-01-26 EARTH.......................................... 54-01-28 54-02 ENGINE STARTING, STOPPING AND PREHEATING CIRCUIT ENGINE STARTING CIRCUIT ....... 54-02-2 ISS (IDLING STOP AND START SYSTEM) CIRCUIT........................................ 54-02-10 105 110 115 125 130 210 275 ---===WSE_1506_00001_0006.djvu===--- 54-03 LIGHTING CIRCUIT HEADLAMP CIRCUIT .................... 54-03-2 HEADLAMP LEVELING CIRCUIT.......................................... 54-03-3 DAYTIME RUNNING LAMP CIRCUIT.......................................... 54-03-4 FOG LAMP CIRCUIT...................... 54-03-6 TAIL, POSITION AND LICENSE PLATE LAMPS CIRCUIT ............................ 54-03-8 STOP LAMP CIRCUIT.................. 54-03-10 TURN SIGNAL AND HAZARD LAMP CIRCUIT........................................ 54-03-12 BACKUP LAMP CIRCUIT ............ 54-03-14 CAB LAMP CIRCUIT.................... 54-03-18 ILLUMINATION LAMP CIRCUIT........................................ 54-03-20 END-OUTLINE MARKER LAMP CIRCUIT........................................ 54-03-21 54-04 METER CIRCUIT METER CLUSTER INTERNAL CIRCUIT.......................................... 54-04-2 TACHOMETER CIRCUIT ............... 54-04-4 SPEEDOMETER CIRCUIT ............. 54-04-8 TACHOGRAPH CIRCUIT ............. 54-04-10 FUEL GAUGE CIRCUIT ............... 54-04-12 WATER TEMPERATURE GAUGE CIRCUIT........................................ 54-04-14 54-05 INDICATOR AND WARNING LAMP CIRCUIT PARKING BRAKE INDICATOR CIRCUIT.......................................... 54-05-2 BRAKE WARNING CIRCUIT ......... 54-05-3 ENGINE OIL PRESSURE WARNING CIRCUIT.......................................... 54-05-4 OVERHEATING WARNING CIRCUIT.......................................... 54-05-8 CAB TILT WARNING CIRCUIT.... 54-05-11 STARTER KEY REMOVAL REMINDER ALARM CIRCUIT.......................... 54-05-12 FUEL FILTER CIRCUIT................ 54-05-14 54-06 CAB SIDE ELECTRICAL CIRCUIT CIGARETTE LIGHTER CIRCUIT ... 54-06-2 AUDIO CIRCUIT ............................. 54-06-3 WIPER AND WASHER CIRCUIT ... 54-06-4 HORN CIRCUIT .............................. 54-06-5 HEATER AND AIR-CONDITIONER CIRCUIT.......................................... 54-06-6 POWER WINDOW AND CENTRAL DOOR LOCK CIRCUIT ............................ 54-06-16 MIRROR HEATER CIRCUIT ........ 54-06-17 SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG CIRCUIT ........................ 54-06-18 KEYLESS ENTRY CIRCUIT......... 54-06-19 54-07 CHASSIS SIDE ELECTRICAL CIRCUIT ANTI-LOCK BRAKE SYSTEM CIRCUIT.......................................... 54-07-2 310 312 313 315 320 325 330 340 345 348 349 401 410 412 415 420 425 510 515 536 537 550 554 566 610 612 614 616 620 622 629 631 654 790 ---===WSE_1506_00001_0007.djvu===--- 54-08 ENGINE AND GEARBOX SIDE ELEC- TRICAL CIRCUIT FOUR-WHEEL DRIVE CIRCUIT .... 54-08-2 GEARBOX POWER TAKE-OFF CIRCUIT.......................................... 54-08-4 DUONIC ® SYSTEM ELECTRIC CIRCUIT.......................................... 54-08-8 COMMON RAIL SYSTEM ELECTRIC CIRCUIT........................................ 54-08-10 54-09 OTHER CIRCUIT JOINT CONNECTOR (J/C)............. 54-09-2 LDWS (LANE DEPARTURE WARNING SYSTEM) CIRCUIT ...... 54-09-7 54-10 ELECTRICAL EQUIPMENT INSTALLATION POSITIONS Cab side SWITCH AND SENSOR ..................... 54-10-2 RELAY AND ELECTRONIC CONTROL UNIT.................................................. 54-10-10 METER AND MOTOR ...................... 54-10-16 HEATER AND AIR-CONDITIONER ......................... 54-10-18 DOOR AND MIRROR ....................... 54-10-24 ROOF................................................ 54-10-26 CAB .................................................. 54-10-27 TILT .................................................. 54-10-28 JOINTS OF MAIN HARNESS CONNECTORS ................................ 54-10-30 OTHERS ........................................... 54-10-36 Engine and gearbox ENGINE ............................................ 54-10-38 GEARBOX ........................................ 54-10-40 Chassis side SWITCH AND SENSOR................... 54-10-44 FUSE, RELAY AND ELECTRONIC CONTROL UNIT............................... 54-10-52 MAGNETIC VALVE, MOTOR AND BUZZER ........................................... 54-10-54 JOINTS OF MAIN HARNESS CONNECTORS ................................ 54-10-56 OTHERS ........................................... 54-10-60 54-11 INSPECTION OF ELECTRICAL EQUIPMENT #001 to #179 SWITCH ............................. 54-11-2 #180 to #249 RELAY ............................... 54-11-7 #250 to #349 SENSOR ............................ 54-11-8 #350 to #409 CONTROL UNIT .............. 54-11-19 #410 to #509 MOTOR............................ 54-11-20 #510 to #539 ACTUATOR ..................... 54-11-25 #560 to #609 MAGNETIC VALVE ......... 54-11-27 #610 to #649 BUZZER, HORN .............. 54-11-29 #650 to #699 LAMP ............................... 54-11-30 #750 to #859 OTHER ............................ 54-11-31 #860 BATTERY ..................................... 54-11-35 #890 METER .......................................... 54-11-38 54-12 STARTER AND ALTERNATOR #930 STARTER ....................................... 54-12-2 #940 ALTERNATOR.............................. 54-12-18 810 850 873 880 905 959 A B C D E F G H J P R S T U V W X ---===WSE_1506_00001_0008.djvu===--- 54-13 ON-VEHICLE INSPECTION AND ADJUSTMENT #950 INSPECTION OF ALTERNATOR ... 54-13-2 #951 INSPECTION OF REGULATOR..... 54-13-3 #960 HEADLAMP AIMING ...................... 54-13-4 #961 FOG LAMP AIMING........................ 54-13-6 54-14 CONNECTOR CONFIGURATION CHART CONNECTOR CONFIGURATION CHART ..................................................... 54-14-2 ---===WSE_1506_00001_0009.djvu===--- 54-00A-1 54-00A GENERAL ---===WSE_1506_00001_0010.djvu===--- 54-00A-2 1 Basic vehicle type F Cab over truck 2 Driving wheels E4 2 G4 4 3 Cab/frame type, development sequence A Standard width cab, frame width: 700mm B Wide cab, frame width: 750mm C Wide cab, frame width: 850mm 4 Chassis, suspension (front/rear), classification of GVW 0 Independent/rigid, GVW: 3.5 tons 5 Rigid/rigid, GVW: 5 -- 6 tons 7 Rigid/rigid, GVW: 6.05 -- 7.5 tons X Rigid/rigid, GVW: 8.55 tons 5 Engine 1 4P10 6 Wheelbase B 2500 mm C 2800 mm E 3400 mm G 3850 mm H 4300 mm K 4750 mm 7S t e e r i n g R RHD LL H D 8 Floor height, gearbox type 3 High floor, DUONIC ® 4 High floor, Manual gearbox 9 Cab configuration S Single cab W Crew cab 10 11 Country code EA EU 12 Engine class W 4P10(T2) 96 kW X 4P10(T4) 110 kW Y 4P10(T6) 129 kW 1 7 4 35 2 9 810 6 FEA01BL S 11 12 4E A W VEHICLE MODEL CODING SYSTEM ---===WSE_1506_00001_0011.djvu===--- 54-00A-3 54-00A Component Name plate marking Code description Engine 4P10T2 4 P 1 0 T 2 Power version number Turbocharged Order of development within same series Order of development among different series Diesel engine No. of cylinders (4) Gearbox M038S5W M 038 S 5 W Variation (W: With directly-mounted transfer) Forward speeds Type of mesh (S: Synchromesh) Load capacity (in tonnes) of main model Initial letter of the gearbox Propeller shaft P3 P 3 Load capacity (in tonnes) of main model Initial letter of the propeller shaft Front axle F100TI F 100 T I Axle type Vehicle type (T: Truck) Load capacity of main model Initial letter of the front axle Rear axle R035T R 03 5 T Vehicle type (T: Truck) Order of development within same series Load capacity (in tonnes) of main model Initial letter of the rear axle Reduction and differential D035H D 03 5 H Tooth profile (H: Hypoid gear) Order of development within same series Load capacity (in tonnes) of main model Initial letter of the reduction & differential EQUIPMENT TYPE CODES LIST ---===WSE_1506_00001_0012.djvu===--- 54-00A-4 Vehicle model Engine Clutch Gearbox Propeller shaft Front axle Rear axle Reduction & differential FEA01BL4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEA01BL4SEAX 4P10-T4 C3W30 M038S5 P3 F100TI R015T D1H FEA01CL4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEA01CL4SEAX 4P10-T4 C3W30 M038S5 P3 F100TI R015T D1H FEA01EL4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEA01EL4SEAX 4P10-T4 C3W30 M038S5 P3 F100TI R015T D1H FEA51BL4SEAX 4P10-T4 C3W30 M038S5 P3 F200T R030T D3H FEA51CL4SEAX 4P10-T4 C3W30 M038S5 P3 F200T R030T D3H FEA51EL4SEAX 4P10-T4 C3W30 M038S5 P3 F200T R030T D3H FEB01BL4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEB01BL4SEAX 4P10-T4 C3W30 M038S5 P3 F100TI R015T D1H FEB01BL4SEAY 4P10-T6 C3W30 M038S5 P3 F100TI R015T D1H FEB01CL4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEB01CL4SEAX 4P10-T4 C3W30 M038S5 P3 F100TI R015T D1H FEB01CL4SEAY 4P10-T6 C3W30 M038S5 P3 F100TI R015T D1H FEB01EL4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEB01EL4SEAX 4P10-T4 C3W30 M038S5 P3 F100TI R015T D1H FEB01EL4SEAY 4P10-T6 C3W30 M038S5 P3 F100TI R015T D1H FEB01EL4WEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEB01EL4WEAX 4P10-T4 C3W30 M038S5 P3 F100TI R015T D1H FEB01GL4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEB01GL4SEAX 4P10-T4 C3W30 M038S5 P3 F100TI R015T D1H FEB01GL4SEAY 4P10-T6 C3W30 M038S5 P3 F100TI R015T D1H FEB71CL4SEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEB71EL4SEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEB71EL4SEAY 4P10-T6 C3W30 M038S5 P3 F350T R035T D035H FEB71GL4SEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEB71GL4SEAY 4P10-T6 C3W30 M038S5 P3 F350T R035T D035H FEB71GL4WEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEB71GL4WEAY 4P10-T6 C3W30 M038S5 P3 F350T R035T D035H FEC71HL4SEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEC71HL4SEAY 4P10-T6 C3W30 M038S5 P3 F350T R035T D035H FEC71KL4SEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEC71KL4SEAY 4P10-T6 C3W30 M038S5 P3 F350T R035T D035H POWER TRAIN TABLE ---===WSE_1506_00001_0013.djvu===--- 54-00A-5 54-00A Vehicle model Engine Clutch Gearbox Propeller shaft Front axle Rear axle Reduction & differential FEB01BR4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEB01CR4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEB01ER4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEB01ER4WEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEB01GR4SEAW 4P10-T2 C3W28 M038S5 P3 F100TI R015T D1H FEB71CR4SEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEB71ER4SEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEB71GR4SEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEB71GR4WEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEC71HR4SEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H FEC71KR4SEAX 4P10-T4 C3W30 M038S5 P3 F350T R035T D035H Vehicle model Engine Clutch Gearbox Propeller shaft Front axle Rear axle Reduction & differential FEA01BL3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEA01BL3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEA01CL3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEA01CL3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEA01EL3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEA01EL3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB01BL3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEB01BL3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB01CL3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEB01CL3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB01EL3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEB01EL3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB01EL3WEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB01GL3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEB01GL3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB71CL3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FEB71EL3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FEB71EL3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FEB71GL3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FEB71GL3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FEB71GL3WEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FECX1EL3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FECX1GL3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FECX1HL3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H ---===WSE_1506_00001_0014.djvu===--- 54-00A-6 FECX1EL3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FECX1GL3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FECX1HL3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FECX1KL3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FEC71HL3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FEC71HL3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FEC71KL3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FEC71KL3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FEC71KL3WEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FEB01BR3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEB01BR3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB01CR3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEB01CR3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB01ER3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEB01ER3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB01ER3WEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB01GR3SEAW 4P10-T2 – M038S6 P3 F100TI R015T D1H FEB01GR3SEAX 4P10-T4 – M038S6 P3 F100TI R015T D1H FEB71CR3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FEB71ER3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FEB71ER3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FEB71GR3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FEB71GR3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FECX1ER3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FECX1ER3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FECX1GR3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FECX1HR3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FECX1KR3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FEC71HR3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FEC71HR3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FEC71KR3SEAX 4P10-T4 – M038S6 P3 F350T R035T D035H FEC71KR3SEAY 4P10-T6 – M038S6 P3 F350T R035T D035H FEC71KR3WEAY 4P10-T6 – M038S6 P3 F350T R035T D035H Vehicle model Engine Clutch Gearbox Propeller shaft Front axle Rear axle Reduction & differential POWER TRAIN TABLE ---===WSE_1506_00001_0015.djvu===--- 54-00A-7 54-00A Vehicle model Engine Clutch Gearbox Propeller shaft Front axle Rear axle Reduction & differential FGB71EL6SEAY 4P10-T6 C4W30 M038S5W Front: P2 Rear: P3 F200TW R035T Front: D1H Rear: D035H FGB71EL6WEAY 4P10-T6 C4W30 M038S5W Front: P2 Rear: P3 F200TW R035T Front: D1H Rear: D035H FGB71GL6SEAY 4P10-T6 C4W30 M038S5W Front: P2 Rear: P3 F200TW R035T Front: D1H Rear: D035H FGB71GL6WEAY 4P10-T6 C4W30 M038S5W Front: P2 Rear: P3 F200TW R035T Front: D1H Rear: D035H FGB71ER6SEAY 4P10-T6 C4W30 M038S5W Front: P2 Rear: P3 F200TW R035T Front: D1H Rear: D035H FGB71ER6WEAY 4P10-T6 C4W30 M038S5W Front: P2 Rear: P3 F200TW R035T Front: D1H Rear: D035H FGB71GR6SEAY 4P10-T6 C4W30 M038S5W Front: P2 Rear: P3 F200TW R035T Front: D1H Rear: D035H ---===WSE_1506_00001_0016.djvu===--- 54-00A-8 This manual consists of the following parts: Specifications Structure and Operation Troubleshooting Circuits Electrical Equipment Installation Positions Inspection of Electrical Equipment On-vehicle Inspection and Adjustment Service procedures Connector configuration chart On-vehicle Inspection and Adjustment Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de- scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for looseness, play, backlash, crack, damage, etc. Service procedures Procedures for servicing components and parts off the vehicle are described centring on key points in their remov- al, installation, disassembly, reassembly, inspection, etc. Inspection Check items subject to "acceptable/unacceptable" judgement on the basis of service standards are all given. Some routine visual checks and cleaning of some reused parts are not described but must always be included in actual service work. Caution This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information: Terms and Units Front and rear The forward running direction of the vehicle is referred to as the front and the reverse running direction is referred to as the rear. Left and right Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and right. Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear- ance between two parts when assembled, and the standard value for an assembly part, as the case may be. Limit When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired. DANGER Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives. WARNING Precautionary instructions, which, if not observed, could result in serious injury or death. CAUTION Precautionary instructions, which, if not observed, could result in damage to or de- struction of equipment or parts. NOTE Suggestions or supplementary information for more efficient use of equipment or better understanding. HOW TO READ THIS MANUAL ---===WSE_1506_00001_0017.djvu===--- 54-00A-9 54-00A Tightening torque Values are directly specified for out-of-standard tightening torques for bolts and nuts. Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. (Values for standard tightening torques are based on thread size and material.) When the item is to be tightened in a wet state, "wet" is indicated. Where there is no indication, read it as dry. Units Tightening torques and other parameters are given in SI* units with metric units added in brackets { }. *SI: Le Système International d'Unités Unit SI unit {metric unit} Conversion factor Force N {kgf} 9.80665 N {1 kgf} Moment of force N·m {kgf·m} 9.80665 N·m {1 kgf·m} Pressure Positive pressure kPa {kgf/cm 2 } 98.0665 kPa {1 kgf/cm 2 } Vacuum pressure kPa {mmHg} 0.133322 kPa {1 mmHg} Pa {mmH 2 O} 9.80665 Pa {1 mmH 2 O} Volume dm 3 {L} 1dm 3 {1 L} Heat quantity J {kcal} 4186.05 J {1 kcal} Heat flow W {kcal/h} 1.16279 W {1 kcal/h} Power kW {PS} 0.7355 kW {1 PS} Example: 390 N·m {40 kgf·m} Metric unit SI unit ---===WSE_1506_00001_0018.djvu===--- 54-00A-10 Illustrated Parts Breakdown and Service Procedures Symbol Denotation Application Remarks Tightening torque Parts not tightened to standard torques (standard torques specified where neces- sary for servicing) Specified values shown in table See Table of Standard Tightening Torques for parts for which no tightening torques are speci- fied. Locating pin Parts to be positioned for installation Non-reusable parts Parts not to be reused Lubricant and/or sealant Parts to be coated with lubricant or sealant for assembly or installation Necessary lubricant and/or sealant, quantity re- quired, etc. are specified in table. Special tool Parts for which special tools are required for service operation Tool name/shape and part number are shown in table. *a Associated part Parts associated with those removed/disas- sembled for servicing HOW TO READ THIS MANUAL ---===WSE_1506_00001_0019.djvu===--- 54-00A-11 54-00A ---===WSE_1506_00001_0020.djvu===--- 54-00A-12 How to Read Circuits (Electrical) HOW TO READ THIS MANUAL ---===WSE_1506_00001_0021.djvu===--- 54-00A-13 54-00A 1.1 Index number: to Index numbers are used as reference numbers for electrical circuits. Each electrical circuit has been assigned its own index number. 1.2 Key number: A01 to Z99 Key numbers indicate electrical equipment installation locations. The installation location of an electrical equip- ment can be easily found using its key number shown in a circuit diagram. All of the electrical equipment installation locations are listed in Gr54-10. 1.3 Part name 1.4 Connector type (type indication) A list of the connectors used is included in Gr54-14. 1.5 Connector terminal number 1.6 Major harness division Major harness divisions are shown. 1.7 Wiring variations between different specifications Variations in wiring/circuit between different vehicle specifications are clearly indicated as shown. 1.8 Circuit number, wire diameter, wire colour 1.9 Code number: #001 to #999 Code numbers are reference numbers to find individual electrical equipment inspection procedures. The inspec- tion procedure for an electrical equipment can be found using its code number shown in a circuit diagram. 1.10Earthing point: [1] to [99] Locations where wires are earthed to the vehicle. All of the earthing points are listed in . 1.11 Harness connection The arrow in the wiring diagram indicates where harnesses are connected, and NOT the flow of electricity. 100 999 130 ---===WSE_1506_00001_0022.djvu===--- 54-00A-14 Wire colour Wire colour Base colour + tracer BB l a c k BW Black/ white BY Black/ yellow BR Black/red BG Black/ green BL Black/ blue BO Black/ orange BP Black/ pink BV Black/ violet BBr Black/ brown Br Brown BrW Brown/ white BrB Brown/ black BrY Brown/ yellow BrR Brown/ red BrG Brown/ green BrL Brown/ blue BrGr Brown/ grey BrV Brown/ Violet GG r e e n GW Green/ white GR Green/ red GY Green/ yellow GB Green/ black GL Green/ blue GO Green/ orange GGr Green/ grey GBr Green/ brown GV Green/ violet Gr, Gy Grey GrL, GyL Grey/ blue GrR, GyR Grey/ red GrB, GyB Grey/ black GrG, GyG Grey/ green GrW, GyW Grey/ white GrY Grey/ yellow GrG Grey/ green GrBr Grey/ brown LB l u e LW Blue/ white LR Blue/red LY Blue/ yellow LB Blue/ black LO Blue/ orange LG Blue/ green LGr Blue/grey LBr Blue/ brown Lg Light green LgR Light green/ red LgY Light green/ yellow LgB Light green/ black LgW Light green/ white O Orange OL Orange/ blue OB Orange/ black OG Orange/ green PP i n k P B Pink/ black PG Pink/ green PL Pink/ blue PW Pink/ white PGr Pink/grey PV Pink/ violet Pu Purple RR e d RW Red/ white RB Red/ black RY Red/ yellow RG Red/ green RL Red/blue RO Red/ orange RBr Red/ brown Rgr Red/ Grey Sb Sky blue V Violet VY Violet/yel- low VW Violet/ white VR Violet/red VG Violet/ green VGr Violet/ grey VB Violet/ black WW h i t e WR White/ red WB White/ black WL White/ blue WG White/ green WO White/ orange WV White/ violet WBr White/ brown WY White/ yellow Y Yellow YR Yellow/ red YB Yellow/ black YG Yellow/ green YL Yellow/ blue YW Yellow/ white YO Yellow/ orange YP Yellow/ pink YV Yellow/ violet YGr Yellow/ grey YBr Yellow/ brown HOW TO READ THIS MANUAL ---===WSE_1506_00001_0023.djvu===--- MEMO 54-00A-15 54-00A ---===WSE_1506_00001_0024.djvu===--- 54-00A-16 Vehicle identification and engine numbers are assigned to the vehicles and engines in manufacturing sequence. Every vehicle and engine has its own number. These numbers are required for registration and related inspection of the vehicle. Vehicle identification number (V.I.N) Engine number Name plate Name plate contains the following information. Whole vehicle type-approval number Vehicle identification number Maximum permitted laden mass of the vehicle Maximum permitted laden mass of the combination Maximum permitted load mass for 1st axle Maximum permitted load mass for 2nd axle Example: Vehicle model Serial No. TY B FEB01BLD T 00001 Model Code* T: 2005~ Plant D: MFTE A: Right-Hand Drive B: Left-Hand Drive Europe, Portugal, Mitsubishi Fuso Truck Europe S.A. *: This code will be changed due to model change. VEHICLE IDENTIFICATION NUMBER, ENGINE NUMBER AND NAME PLATE ---===WSE_1506_00001_0025.djvu===--- MEMO 54-00A-17 54-00A ---===WSE_1506_00001_0026.djvu===--- 54-00A-18 Before performing service operations, inquire into the customer's complaints and ascertain the condition by checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors on the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently. Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be removed or dis- assembled. Then, follow the service procedure given in this manual. Perform service operations on a level surface. Before starting, take the following preparatory steps: To prevent soiling and damage, place covers over the seats, trim and floor in the cab and over the paintwork of the body. Prepare all the general and special tools necessary for the job. WARNING Special tools must be used wherever specified in this man- ual. Do not attempt to use other tools since they could cause injuries and/or vehicle damage. After manually tilting the cab, be sure to engage the stopper with the lock lever to secure the cab stay in a rigid state. Take extreme care when removing/installing heavy items such as engine, gearbox and axle. When lifting heavy items using a cable etc., observe the following precautions. Identify the weight of the item being lifted. Use the cable that is strong enough to support the weight. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1506_00001_0027.djvu===--- 54-00A-19 54-00A If lifting eyes are not provided on the item being lifted, tie a ca- ble around the item taking into account the item's centre of gravity. Do not allow anyone to pass or stay under a lifted item which may possibly fall. Never work in shoes that have oily soles. When working with a partner or in a group, use pre-arranged sig- nals and pay constant attention to safety. Be careful not to touch switches and levers unintentionally. Inspect for oil leakage etc. before washing the vehicle. If the or- der is reversed, any oil leakage or fault that may exist could go unnoticed during inspection. Prepare replacement parts ready for installation. ---===WSE_1506_00001_0028.djvu===--- 54-00A-20 Oil seals, packings, O-rings and other rubber parts, gaskets, and split pins must be replaced with new ones after removal. Use only genuine MITSUBISHI replacement parts. When disassembling parts, visually check them for wear, cracks, damage, deformation, deterioration, rust, corrosion, defective ro- tation, fatigue, clogging and any other possible defect. To facilitate correct reassembly of parts, make alignment marks on them before disassembly and arrange disassembled parts neatly. Make punch marks and other alignment marks where they will not detract from parts' functionality and appearance. After removing parts from the vehicle, cover the area to keep it free of dust. CAUTION Be careful not to mix up identical parts, similar parts and parts that have left/right alignments. Keep new replacement parts and original (removed) parts separately. Apply the specified oil or grease to U-seals, oil seals, dust seals and bearings before reassembly. Always use the specified oils and greases when performing in- spection or replacement. Immediately wipe away any excess oil or grease with a rag. To prevent trouble, do not spill engine oil on the belts and starter. Wear safety goggles when using a grinder or welder. Wear gloves when necessary, and watch out for sharp edges and oth- er items that might wound your hands. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1506_00001_0029.djvu===--- 54-00A-21 54-00A Before working on the electrical system, disconnect the (--) bat- tery cable to prevent short circuits. CAUTION Make sure that the starter switch and lighting switches are OFF before disconnecting or connecting battery cable. (Semiconductor components may otherwise be damaged.) Be sure to place the starter switch into the LOCK or OFF po- sition and wait for about 2 minutes before disconnecting battery cables, harnesses or connectors. (This is because the BlueTec ® system is still in operation.) Disconnect the (--) battery cable, then insulate the (--) termi- nal of the battery and (--) battery cable with insulating tape or the like. If the (--) battery cable is not disconnected, battery voltage will remain constantly applied to the B terminal, inviting danger of electric shock. CAUTION Make sure that the starter switch and lighting switches are OFF before disconnecting or connecting bat- tery cable. (Semiconductor components may otherwise be damaged.) The BlueTec ® system remains in operation for about 2 minutes after the starter switch is set to the LOCK position. Before disconnecting battery cables, harnesses or connectors, be sure to wait for at least 2 min- utes after turning the starter switch to the LOCK or OFF position. Connect the (+) and (--) battery cables correctly. If the polarity of the battery connections was reverse, the power switch and SAM would be damaged, leading to a vehicle fire. Removal and installation of the battery cover <Vehicle with one battery> Press the stopper A at the arrow to release the battery cover from the stopper A. Draw the battery cover toward you to detach it from the stop- pers B. To install the battery cover, follow the removal sequence in re- verse. After installing, make sure that the battery cover is se- curely attached. <Vehicle with two batteries> Remove the two wing bolts. Draw the battery cover toward you to detach it from the stop- pers A. To install the battery cover, follow the removal sequence in re- verse. After installing, make sure that the battery cover is se- curely attached. ---===WSE_1506_00001_0030.djvu===--- 54-00A-22 Removal and installation of battery <Vehicle without battery equaliser> Disconnect the battery cables at the battery terminals in the following sequence. Disconnect the battery cable at the (--) terminal (1). Disconnect the battery cable at the (+) terminal (2). To connect battery cable, follow the disconnection sequence in reverse. Press in the terminal of the battery cable all the way to the bottom of the battery terminal post and tighten the nut to secure the cable. Tightening torque: 5 to 7 N·m {0.5 to 0.7 kgf·m} Remove the nuts holding the battery, then remove the battery support. Remove the battery. To install the battery, follow the removal sequence in reverse. Af- ter installing, make sure that the battery is securely held in place. Carefully handle sensors relays, and other items that are sensi- tive to shock and heat. Do not remove or paint the cover of any control unit. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1506_00001_0031.djvu===--- 54-00A-23 54-00A When separating connectors, grasp the connectors themselves rather than the harnesses. To separate locking connectors, first push them in the direction of the arrows. To reconnect locking connectors, push them to- gether until they click. Removal and installation of batteries <Vehicle with battery equaliser> CAUTION Do not disconnect battery cable terminals from the battery equaliser located near the battery box unless it is neces- sary to service the battery equaliser. When cable terminals should be disconnected from or reconnected to the battery equaliser for the equaliser service, the procedure shown below should be followed. (See "Removal and installation of battery equaliser.") CAUTION Do not separate the battery terminal connectors from ca- bles Disconnect battery cables from the battery terminals in the fol- lowing order. Disconnect the battery cable at the (--) terminal A of 12V bat- tery (main). Disconnect battery cable at the (--) terminal B of 12V battery (for body building) Disconnect battery cable at the (+) terminal C of 12V battery (main) Disconnect battery cable at the (+) terminal D of 12V battery (for body building.) To reconnect the battery, follow the disconnecting sequence in reverse. When connecting battery cables, press battery ca- ble terminals in all the way to the lower end of corresponding terminal posts, then tighten nuts to the specified torque. Tightening torque 5 to 7 N·m {0.5 to 0.7 kgf·m} ---===WSE_1506_00001_0032.djvu===--- 54-00A-24 Remove nuts to remove the battery support. Remove the batteries. To install the batteries, follow the removal sequence in re- verse. After installing it, make sure that the batteries are se- cured and the battery support is not in contact with any battery terminal. Removal and installation of battery equaliser. Lubricant and/or sealant Disconnect a battery cable from the battery equaliser terminal 10 minutes after disconnecting the battery cable from the battery terminal. A battery cables for the battery equaliser should be connected to the equaliser using the following procedure with the cable disconnected from the battery terminal. CAUTION Connecting a battery cable to a wrong battery equaliser terminal can damage to the on-vehicle electronic parts. Take extra care to connect a cable to the correct terminal. Place the battery equaliser on a level surface with the terminals up. Connect the battery cables for the battery equaliser to the correct equaliser terminals. Apply sealant to the battery equaliser terminals for battery cables to be connected to 12V batteries (Main) and (for body building) so that the equaliser terminals and metal parts of the battery cable terminals will be covered with the sealant. When air bubbles are found in the sealant, remove it and apply new one again. CAUTION Be sure to apply sealant again since air bubbles in sealant will cause poor waterproof effect. Leave the battery equaliser on the level surface with terminals facing upward to dry the sealant for approx. 8 hours (ambient temperature: 10 degrees, humidity: 50%). Install the battery equaliser with the terminals directed upward and placed in the same height as that of the battery. Mark Points of application Specified lubricant and/or sealant Quantity Battery equaliser terminals and metal parts of battery cable terminals Three bond TB1530P As required PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1506_00001_0033.djvu===--- 54-00A-25 54-00A Before washing the vehicle, cover electrical parts to keep them dry. (Use plastic sheets or equivalent.) Keep water away from harness connectors and sensors and immediately wipe off any water that gets on them. When applying a voltage to a part for inspection purposes, check that the (+) and (--) cables are connected properly then gradually increase the voltage from zero. Do not exceed the specified voltage. Remember that control units and sensors do not necessarily op- erate on the battery voltage. 1. Handling Precautions for Electric Circuits CAUTION Do not pierce wire insulation with test probes or alligator clips when performing electrical inspections. Doing so can, particularly with the chassis harness, hasten corrosion. 1.1 Inspection of harnesses (1) Inspections with connectors fitted together (1.1) Waterproof connectors Connect an inspection harness and connector A between the connectors B of the circuit to be inspected. Perform the inspec- tion by applying a test probe C to the connectors of the inspec- tion harness. Do not insert the test probe C into the wire-entry sides of the waterproof connectors since this would damage their waterproof seals and lead to rust. (1.2) Non-waterproof connectors Perform the inspection by inserting a test probe C into the wire- entry sides of the connectors. An extra-narrow probe is required for control unit connectors, which are smaller than other types of connector. Do not force a regular-size probe into control unit connectors since this would cause damage. ---===WSE_1506_00001_0034.djvu===--- 54-00A-26 (2) Inspections with connectors separated (2.1) Inspections on female terminals Perform the inspection by carefully inserting a test probe into the terminals. Do not force the test probe into the terminals since this could deform them and cause poor connections. (2.2) Inspections on male terminals Perform the inspection by applying test probes directly to the pins. CAUTION . Be careful not to short-circuit pins together with the test probes. With control unit connectors, short-circuiting of pins can cause damage to the control unit's internal circuit- ry. When using a multimeter to check continuity, do not allow the test probes to touch the wrong terminals. 1.2 Inspection of connectors (1) Visual inspection Check that the connectors are fitted together securely. Check whether wires have been separated from their terminals due to pulling of the harness. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1506_00001_0035.djvu===--- 54-00A-27 54-00A Check that male and female terminals fit together tightly. Check for defective connections caused by loose terminals, by rust on terminals, or by contamination of terminals by foreign substances. (2) Checking for loose terminals If connector terminal retainers become damaged, male and fe- male terminals may not mate with each other when the connec- tor bodies are fitted together. To check for such terminals, gently pull each wire and see whether any terminals slip out of their connector housings. 1.3 Inspections when a fuse blows Remove the fuse, then measure the resistance between earth and the fuse's load side. Next, close the switch of each circuit connected to the fuse. If the resistance measurement between any switch and earth is zero, there is a short circuit between the switch and the load. If the resistance measurement is not zero, the circuit is not cur- rently short-circuited; the fuse probably blew due to a momen- tary short circuit. The main causes of short circuits are as follows: Harnesses trapped between chassis parts Harness insulation damage due to friction or heat Moisture in connectors or circuitry Human error (accidental short-circuiting of components) 1.4 Inspection of chassis earth A special earth bolt is used to tighten an earth terminal. When servicing the earth point, be sure to follow the procedures de- scribed below: When reinstalling the earth bolt Tighten the earth bolt to the specified torque. When relocating the earth point A special earth bolt must be used. Spot-weld a nut to a frame and tighten the earth bolt to the specified torque. Be sure to apply touch-up paint to the welded point. ---===WSE_1506_00001_0036.djvu===--- 54-00A-28 2. Service Precautions for Alternators When servicing alternators, observe the following precautions: Never reverse the polarity of battery connections. If the polarity of the battery connections were to be reversed, a large current would flow from the battery to the alternator, damaging the diodes and regulator. Never disconnect the battery cables with the engine running. Disconnection of the battery cables during engine operation would cause a surge voltage, leading to deterioration of the di- odes and regulator. Never perform inspections using a high-voltage multimeter. The use of a high-voltage multimeter could damage the diodes and regulator. Keep alternators dry. Water on alternators can cause internal short circuits and dam- age. Never operate an alternator with the B and L terminals short-cir- cuited. Operation with the B and L terminals connected together would damage the diode trio. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1506_00001_0037.djvu===--- 54-00A-29 54-00A Disconnect the battery cables before quick-charging the battery with a quick charger. Unless the battery cables are disconnected, quick-charging can damage the diodes and regulator. 3. Intermittent Faults An intermittent fault typically occurs only under certain operating conditions. Once these conditions have been identified, the cause of the intermittent fault can be ascertained easily. First, ask the customer about the vehicle operating conditions and weather conditions under which the fault occurs. Also ask about the frequency with which the fault occurs and about the fault symptoms. Then, reproduce the fault based on this information. In accordance with the conditions under which the fault occurs, determine whether the fault is caused by vibration, heat or other factors. if vibration is a possible factor, see if the fault can be re- produced by performing the following checks on individual con- nectors and other parts: Gently move connectors up and down and to left and right. Gently move wiring harnesses up and down and to left and right. Gently wiggle sensors and other devices by hand. Gently wiggle wiring harnesses on suspension systems and other moving parts. Connectors and other parts to be checked are those included or given as likely fault locations in inspection procedures corre- sponding to diagnosis codes and/or fault symptoms. ---===WSE_1506_00001_0038.djvu===--- 54-00A-30 4. Precautions for Arc Welding When arc welding is performed, current from the welder flows to earth via the vehicle's metal parts. Unless appro- priate steps are taken, this current can damage control units, other electrical devices and wiring harnesses. And any electrical device near the point on the vehicle to which the (--) cable of the welder is connected, might be largely damaged. Current flows backward as shown below. 4.1 From battery (--) cable To prevent damage to the battery and to electrical devices that are connected directly to the battery, it is essential to disconnect the battery's (--) cable. 4.2 Procedure Turn the starter switch to the LOCK position. Disconnect the battery's (--) cable. Cover all parts of the vehicle that may be damaged by welding sparks. Connect the welder's (--) cable to the vehicle as close as possi- ble to the area being welded. Do not connect the welder's (--) ca- ble to the cab if the frame is being welded, and vice versa. Set the welding current in accordance with the part being weld- ed. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1506_00001_0039.djvu===--- 54-00A-31 54-00A 5. Cautions When Handling AdBlue ® AdBlue ® is a colourless, transparent, odorless and harmless water solution (urea 32.5%, water 67.5%; freezing temperature --11°C), so no problem will occur if you get it on your skin. However, some persons with delicate skin may in very rare cases get a rash, so carry out the following procedure. If AdBlue ® gets into your eyes, immediately wash your eyes with a large amount of water, then see a physician to receive treatment. If AdBlue ® gets on your skin, wash it off with water. If there is any change in your skin or it is painful, promptly see a physician to receive treatment. Be sure to use AdBlue ® that conforms to ISO 22241 (International Organisation for Standardization). Do not dilute the AdBlue ® nor mix the AdBlue ® with another reagent. This may cause a malfunction of the selec- tive catalytic reduction system. When starting the engine, make sure that there is sufficient amount of AdBlue ® in the urea tank. If the urea tank is empty, the engine restart will be restricted by the engine restart inhibit control of the urea selec- tive catalytic reduction system. AdBlue ® : Registered trademark of the Verband der Automobilindustrie e.V. (VDA) ISO: International organisation for standardization 6. Precautions When Repainting When repainting, cover the following electronic control components with a masking material. If paint get on these components, functional reliability could be deteriorated as a result of the poor connection of connectors, internal circuit failure caused by heat build-up due to poor heat dissipation, erroneous sensor values due to clogged venti- lation holes. Engine electronic control unit, DUONIC electronic control unit, and other electronic control units Sensors 7. Precautions When Handling a Vehicle with DUONIC ® System 7.1 Test driving When rotating only the rear wheels for a certain period of time with the front wheels held using a chassis dyna- mometer, etc., set the DUONIC ® drive mode to the manual mode (manual shift mode in the hold range). At this time, the anti-lock brake system warning and DUONIC ® warning are displayed and the DUONIC electronic control unit will shift gears normally due to failure mode control, but there is no problem in test driving in the man- ual mode. NOTE Test driving cannot be performed in the drive range because normal shifting is not possible due to failure mode control. Even if the test driving is normally completed, be sure to erase the diagnosis codes for the anti-lock brake system and DUONIC ® system. This is because the diagnosis codes generated at the time of failure remains recognised by the electronic control unit as past diagnosis codes. 7.2 How to release shift lock If normal shifting is not possible because the electrical system is not properly connected or the battery has run out, operate the shift lock release lever to make gear shifting possible as follows. ---===WSE_1506_00001_0039.djvu===--- 54-00A-31 54-00A 5. Cautions When Handling AdBlue ® AdBlue ® is a colourless, transparent, odorless and harmless water solution (urea 32.5%, water 67.5%; freezing temperature --11°C), so no problem will occur if you get it on your skin. However, some persons with delicate skin may in very rare cases get a rash, so carry out the following procedure. If AdBlue ® gets into your eyes, immediately wash your eyes with a large amount of water, then see a physician to receive treatment. If AdBlue ® gets on your skin, wash it off with water. If there is any change in your skin or it is painful, promptly see a physician to receive treatment. Be sure to use AdBlue ® that conforms to ISO 22241 (International Organisation for Standardization). Do not dilute the AdBlue ® nor mix the AdBlue ® with another reagent. This may cause a malfunction of the selec- tive catalytic reduction system. When starting the engine, make sure that there is sufficient amount of AdBlue ® in the urea tank. If the urea tank is empty, the engine restart will be restricted by the engine restart inhibit control of the urea selec- tive catalytic reduction system. AdBlue ® : Registered trademark of the Verband der Automobilindustrie e.V. (VDA) ISO: International organisation for standardization 6. Precautions When Repainting When repainting, cover the following electronic control components with a masking material. If paint get on these components, functional reliability could be deteriorated as a result of the poor connection of connectors, internal circuit failure caused by heat build-up due to poor heat dissipation, erroneous sensor values due to clogged venti- lation holes. Engine electronic control unit, DUONIC electronic control unit, and other electronic control units Sensors 7. Precautions When Handling a Vehicle with DUONIC ® System 7.1 Test driving When rotating only the rear wheels for a certain period of time with the front wheels held using a chassis dyna- mometer, etc., set the DUONIC ® drive mode to the manual mode (manual shift mode in the hold range). At this time, the anti-lock brake system warning and DUONIC ® warning are displayed and the DUONIC electronic control unit will shift gears normally due to failure mode control, but there is no problem in test driving in the man- ual mode. NOTE Test driving cannot be performed in the drive range because normal shifting is not possible due to failure mode control. Even if the test driving is normally completed, be sure to erase the diagnosis codes for the anti-lock brake system and DUONIC ® system. This is because the diagnosis codes generated at the time of failure remains recognised by the electronic control unit as past diagnosis codes. 7.2 How to release shift lock If normal shifting is not possible because the electrical system is not properly connected or the battery has run out, operate the shift lock release lever to make gear shifting possible as follows. ---===WSE_1506_00001_0039.djvu===--- 54-00A-31 54-00A 5. Cautions When Handling AdBlue ® AdBlue ® is a colourless, transparent, odorless and harmless water solution (urea 32.5%, water 67.5%; freezing temperature --11°C), so no problem will occur if you get it on your skin. However, some persons with delicate skin may in very rare cases get a rash, so carry out the following procedure. If AdBlue ® gets into your eyes, immediately wash your eyes with a large amount of water, then see a physician to receive treatment. If AdBlue ® gets on your skin, wash it off with water. If there is any change in your skin or it is painful, promptly see a physician to receive treatment. Be sure to use AdBlue ® that conforms to ISO 22241 (International Organisation for Standardization). Do not dilute the AdBlue ® nor mix the AdBlue ® with another reagent. This may cause a malfunction of the selec- tive catalytic reduction system. When starting the engine, make sure that there is sufficient amount of AdBlue ® in the urea tank. If the urea tank is empty, the engine restart will be restricted by the engine restart inhibit control of the urea selec- tive catalytic reduction system. AdBlue ® : Registered trademark of the Verband der Automobilindustrie e.V. (VDA) ISO: International organisation for standardization 6. Precautions When Repainting When repainting, cover the following electronic control components with a masking material. If paint get on these components, functional reliability could be deteriorated as a result of the poor connection of connectors, internal circuit failure caused by heat build-up due to poor heat dissipation, erroneous sensor values due to clogged venti- lation holes. Engine electronic control unit, DUONIC electronic control unit, and other electronic control units Sensors 7. Precautions When Handling a Vehicle with DUONIC ® System 7.1 Test driving When rotating only the rear wheels for a certain period of time with the front wheels held using a chassis dyna- mometer, etc., set the DUONIC ® drive mode to the manual mode (manual shift mode in the hold range). At this time, the anti-lock brake system warning and DUONIC ® warning are displayed and the DUONIC electronic control unit will shift gears normally due to failure mode control, but there is no problem in test driving in the man- ual mode. NOTE Test driving cannot be performed in the drive range because normal shifting is not possible due to failure mode control. Even if the test driving is normally completed, be sure to erase the diagnosis codes for the anti-lock brake system and DUONIC ® system. This is because the diagnosis codes generated at the time of failure remains recognised by the electronic control unit as past diagnosis codes. 7.2 How to release shift lock If normal shifting is not possible because the electrical system is not properly connected or the battery has run out, operate the shift lock release lever to make gear shifting possible as follows. ---===WSE_1506_00001_0040.djvu===--- 54-00A-32 Operating procedure Remove the lower centre panel. (See Gr52.) Push the shift lock release lever of the shift lever unit approxi- mately 2 mm forward in the illustrated direction to unlock the shift lever, then perform gear shifting. 7.3 Towing Before towing the vehicle, be sure to remove the propeller shaft to prevent possible damage to the DUONIC ® sys- tem. 8. Precautions on Cleaning When Servicing the Engine and Gearbox When servicing the engine or gearbox (DUONIC ® ), care needs to taken with the following to prevent failures caused by dust and foreign objects. Works that require care to prevent the entry of dust and foreign objects are marked with and indicated as "Work that requires dust protection". 8.1 Work area The working place needs to be well organised and kept clean. Do not work outdoors. Take dust prevention measures when working indoors. Do not place parts directly on the floor. Put covers on parts to protect them from dust. Keep the over head doors closed unless necessary such as when a vehicle comes in or goes out. When servicing components related to the hydraulic circuit of the gearbox (DUONIC ® ), it is recommended that the work be done in an enclosed environment with a cleanliness level equivalent to that of meeting rooms. If these environmental requirements cannot be satisfied, establish a special procedure to protect the work area for servicing these components from dust. (See Gr22A.) 8.2 Clothing and protective wear Wear clean working clothes. Do not wear shoes smudged with oil or dirt when working. If oil gets on your clothes, immediately wipe it off. When a working glove or protective wear becomes dirty or ragged, immediately change it. Use of an apron is recommended. (For vehicles with DUONIC ® system.) Do not use cotton work gloves. Use rubber or plastic gloves that cover the lower part of your arms. (For vehicles with DUONIC ® system.) PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1506_00001_0041.djvu===--- 54-00A-33 54-00A 8.3 Tools Common tools, special tools and workbenches used for servicing should be cleaned with a cleaner and rags in advance. Whenever a tool or workbench gets damaged or dirty during servicing, immediately clean or replace it. Do not use air tools on components related to the hydraulic circuit of the gearbox (DUONIC ® ). (See Gr22A.) 8.4 Washing and drying Thoroughly wash the outside of the engine before removing sub-assemblies from the engine. After that, remove and disassemble sub-assemblies, then wash each part. The detailed instructions on washing and drying are given in the sections describing washing and inspection procedures and precautions in the engine service manual. Carefully read these instructions to ensure the correct procedures are followed. Thoroughly wash the clutch housing before servicing components related to the hydraulic circuit of the gearbox (DUONIC ® ). Use the specified cleaner when washing. After washing, dry with compressed air to make sure that foreign objects (such as broken bristles of a cleaning brush) do not remain on parts. 8.5 Rust prevention and removal of rust-preventive agent (for engine) If parts are not used immediately after washing, apply the specified rust-preventive agent (such as engine oil). Remove rust-preventive agent when installing a part on the engine. When installing a new part to which rust-preventive agent has been applied (such as a crankcase), thoroughly wash it to remove rust and rust-preventive agent. Pay special attention to the fuel and oil lines in particular. Follow the procedure given in the engine service manual for the removal of rust-preventive agent. 8.6 New parts (MITSUBISHI genuine parts) Have new parts ready in advance. To prevent dust from attaching a new part, unpack immediately before the replacement work. Oil seals, packings, O-rings and other rubber parts, gaskets and split pins need to be replaced with new parts after each disassembly. Use MITSUBISHI FUSO genuine parts for replacement. Since cleanliness assurance requirements are specified to each part and quality is assured for the delivered parts, handle new parts with care so as not to allow the entry of foreign objects. 8.7 Reused parts 8.7.1 Precautions on removal Parts removed from engines as well as places where the parts have been removed (intake, exhaust, fuel, lubrica- tion, coolant and other systems) need to be covered with clean paper, rag, plastic sheet, etc. secured with a clean plastic tape if necessary, to prevent the entry of dust. Be sure to handle the gearbox (DUONIC ® ) properly by carefully reading the instructions given in the chassis ser- vice manual. Since it is not possible to visually check for dust that has entered pipes in particular, cover both ends of a pipe im- mediately after washing it. 8.7.2 Handling reused parts Put removed parts in order for each engine to allow efficient inspection and installation. Parts with machined surfaces should not be put directly on the floor. Put these parts on an appropriate wood sur- face so that the machined surfaces are not damaged. Also, other sub-assemblies removed should not be put directly on the floor. Put the sub-assemblies on a clean surface. Be sure to handle the gearbox (DUONIC ® ) properly by carefully reading the instructions given in the chassis ser- vice manual. ---===WSE_1506_00001_0042.djvu===--- 54-00A-34 8.8 Installation Install parts by following the instructions given in the engine and chassis service manuals. To prevent the entry of dust and foreign objects during installation, thoroughly check that the parts to be installed are clean and free of foreign objects before installation. Blow air into reused parts (piping in the intake and injection systems, etc.) again before installation. 8.9 Fuel Use the specified fuel. Use only clean fuel. Do not use contaminated fuel. Be sure to observe the following if fuel is stored on the service site. Cover the filler cap of the storage tank to prevent water contamination. Keep the tank clean. In particular, the filler cap and area around the filler port should be kept clean. Position the tank so that it is slightly inclined toward the bottom drain. This facilitates discharging of accumulat- ed water and deposits. Drain off water at least once a month. Keep the tank as full as possible to minimize condensation. After filling the fuel storage tank, wait for a few hours before filling the equipment's tank. This allows contamina- tion to deposit. 8.10Oils Use MITSUBISHI genuine products for the engine oil, gearbox gear oil and automatic transmission fluid. Use only clean oils. Do not use contaminated oils. It is not recommended to reuse drained oil or automatic transmission fluid. If it is judged that drained oil or auto- matic transmission fluid can be reused because it is within the replacement interval and is not excessively con- taminated, be sure to observe the following. Store the drained oil or automatic transmission fluid in a clean, dedicated container. Do not use containers that were used to store fuel or water. Make sure that the container is appropriately stored so as to prevent the entry of dust and foreign objects. 8.11 Coolant Use MITSUBISHI genuine products for the coolant. Use only clean coolant. Do not use contaminated coolant. It is not recommended to reuse drained coolant. If it is judged that coolant can be reused because it is within the replacement interval and is not excessively contaminated, be sure to observe the following. Store the drained coolant in a clean, dedicated container. Do not use containers that were used to store fuel or oil. Make sure that the container is appropriately stored so as to prevent the entry of dust and foreign objects. 8.12 Miscellaneous Thoroughly wash the vehicle before servicing. Do not service a dust covered vehicle. The garage air must be clean. Blow air onto white paper to check for the presence of water and/or oil in the air flow. If a problem is found, immediately check the compressor. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1506_00001_0043.djvu===--- MEMO 54-00A-35 54-00A ---===WSE_1506_00001_0044.djvu===--- 54-00A-36 <Front of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Jack up the front of the vehicle with a bottle jack or garage jack. 3 If you use a bottle jack, set it at the jack-up point shown in the figure. If you use a garage jack, set it at the centre of the front axle or suspension crossmember <Independent suspension>. 4 Support the front of the vehicle frame on jack stands. WARNING Chock the wheels firmly to prevent the vehicle from rolling away. Do not attempt to remove the chocks until the operation is completed. It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition- ally support the front of the vehicle frame on jack stands. Never attempt to remove the bottle jack, garage jack, or jack stands until the operation is completed. JACKING UP THE VEHICLE ---===WSE_1506_00001_0045.djvu===--- 54-00A-37 54-00A <Rear of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Jack up the rear of the vehicle using a bottle jack or garage jack as illustrated above. 3 Support the vehicle frame on jack stands on both sides. WARNING Chock the wheels firmly to prevent the vehicle from rolling away. Do not attempt to remove the chocks until the operation is completed. It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition- ally support the vehicle frame on jack stands on both sides. Never attempt to remove the bottle jack, garage jack, or jack stands until the operation is completed. ---===WSE_1506_00001_0046.djvu===--- 54-00A-38 1. Diagnosis Codes The diagnosis system consists of electronic control unit functions to detect failures of electrical components, com- municate with diagnosis tools, and update various data. When an electronic control unit detects a failure, it stores the failure information as a diagnosis code (that de- scribes a failure of the vehicle) and alerts the user by displaying a warning. By reading diagnosis codes and checking for problems accordingly (troubleshooting), failures in electronically controlled systems can be efficiently identified and remedied. Diagnosis codes (fault codes) can be displayed in the following two methods: Using the FUSO Diagnostics. (See later section.) Using the multi-information display in the meter cluster. (See later section.) 1.1 Reference Gr list for diagnosis codes 1.2 Types of diagnosis codes There are two types of diagnosis codes: current codes and past codes 1.2.1 Current diagnosis code The current failures in the vehicle can be checked by reading the current diagnosis codes. When a current diagnosis code is generated, the warning (or indicator) from the failed system is displayed and its electronic control unit initiates failure mode control such as stopping control or exercising backup control. 1.2.2 Past diagnosis code The past failures in the vehicle can be checked by reading the past diagnosis codes. When the indication changes from the current diagnosis codes to the past diagnosis codes, the warning (or indi- cator) showing a failure goes off and the electronic control unit recovers from failure mode control to normal con- trol. (The recovery timing varies depending on the diagnosis code.) If the failure has not been resolved, the electronic control unit will detect it again and generate a current diagnosis code. Warning System Reference Gr Common rail 13E, 17E BlueTec ® system DUONIC ® 22E Anti-lock brake system 35E Electronic stability program 35E Anti spin regulator system 35E Supplemental restraint system (SRS) 52E Idling stop and start system 54EA Lane departure warning system 54EC Immobiliser 54EI Meter cluster 54EM Signal detected and actuation modules 54ES -- Full auto air conditioner 55E DIAGNOSIS CODES ---===WSE_1506_00001_0046.djvu===--- 54-00A-38 1. Diagnosis Codes The diagnosis system consists of electronic control unit functions to detect failures of electrical components, com- municate with diagnosis tools, and update various data. When an electronic control unit detects a failure, it stores the failure information as a diagnosis code (that de- scribes a failure of the vehicle) and alerts the user by displaying a warning. By reading diagnosis codes and checking for problems accordingly (troubleshooting), failures in electronically controlled systems can be efficiently identified and remedied. Diagnosis codes (fault codes) can be displayed in the following two methods: Using the FUSO Diagnostics. (See later section.) Using the multi-information display in the meter cluster. (See later section.) 1.1 Reference Gr list for diagnosis codes 1.2 Types of diagnosis codes There are two types of diagnosis codes: current codes and past codes 1.2.1 Current diagnosis code The current failures in the vehicle can be checked by reading the current diagnosis codes. When a current diagnosis code is generated, the warning (or indicator) from the failed system is displayed and its electronic control unit initiates failure mode control such as stopping control or exercising backup control. 1.2.2 Past diagnosis code The past failures in the vehicle can be checked by reading the past diagnosis codes. When the indication changes from the current diagnosis codes to the past diagnosis codes, the warning (or indi- cator) showing a failure goes off and the electronic control unit recovers from failure mode control to normal con- trol. (The recovery timing varies depending on the diagnosis code.) If the failure has not been resolved, the electronic control unit will detect it again and generate a current diagnosis code. Warning System Reference Gr Common rail 13E, 17E BlueTec ® system DUONIC ® 22E Anti-lock brake system 35E Electronic stability program 35E Anti spin regulator system 35E Supplemental restraint system (SRS) 52E Idling stop and start system 54EA Lane departure warning system 54EC Immobiliser 54EI Meter cluster 54EM Signal detected and actuation modules 54ES -- Full auto air conditioner 55E DIAGNOSIS CODES ---===WSE_1506_00001_0047.djvu===--- 54-00A-39 54-00A 1.3 Follow the flowchart below to inspect the system. ---===WSE_1506_00001_0048.djvu===--- 54-00A-40 1.4 Precautions on troubleshooting Check the charging state and specific gravity of the battery before measuring voltage. If inspection is performed with insufficient charging or specific gravity, accurate measurements may not be displayed. Be sure to place the starter switch to the LOCK or OFF position and wait for about 5 minutes before removing bat- tery cables, harnesses or connectors. (This is because the BlueTec ® system is still in operation.) When installing battery cables, harnesses or connectors, place the starter switch and lighting switch to the LOCK or OFF position. Otherwise, electrical components could be damaged. When measuring with a multimeter, carefully handle the test bars so that the bars do not short-circuit between connector pins or with the body. Otherwise, electronic control units' internal circuits and electrical components could be damaged. Since resistance values are affected by temperature, refer to the descriptions on temperature in this manual as a guideline for pass/fail judgment. If temperature is not specified, normal temperature (10 to 35°C) is assumed. 1.5 Inspecting the input and output signals at the electronic control unit connector This inspection is to confirm that signals from electronic control units and electrical components are correctly transmitted to the harnesses and connectors on the vehicle side. This inspection includes the following checks: Measure the input voltage of switches and sensors and the output voltage of relays to check for open circuit and short cir- cuit to battery or earth by inserting the test bars from the back side of the connector with the harness (on the electronic con- trol unit connector) on the vehicle side connected. Measure the resistance of temperature sensors, rotation sen- sors and solenoids to check for open circuit by disconnecting the electronic control unit connector and inserting the test bars into the harness on the vehicle side. Check the operation of magnetic valves for open circuit and valve failure by disconnecting the electronic control unit con- nector and applying a voltage from the harness on the vehicle side. Some electronic unit connectors are equipped with water- or dust-proofing treatment and do not allow test probes to be in- serted from the back side of the connectors. 1.6 Inspecting the electrical components This inspection is to check that electrical components are operating normally. This inspection includes the following checks: Check if electrical components actually operate. Check the internal circuits of electrical components for open and short circuit. Check the characteristics of the output signals from electrical components. Operation or signal characteristics checking is not easy on some electrical components, for which only electrical checking for open and short circuit is performed. As a result, there may be cases where a mechanical failure exists in these components even if they are electrically normal. Therefore, it is necessary to make a pass/fail judgment on these electrical components by checking the overall system operation and the related compo- nents such as harnesses and connectors. DIAGNOSIS CODES ---===WSE_1506_00001_0049.djvu===--- 54-00A-41 54-00A 1.7 Inspecting the harnesses This inspection is to check for faulty sections of harnesses and connectors. 1.7.1 Open circuit An open circuit means a harness is broken. [Inspection example 1] Measure the resistance between components to confirm that that there is continuity. Gently shake the harness up and down while measuring. If the connectors to be measured are far apart from each other, chassis earth may be used. Standard value: Less than 5 Ω If the measurement is out of the standard value, there is an open circuit in the harness or a poor connection of pins in the connec- tor. [Inspection example 2] Measure voltage from the back side of each connector. Gently shake the harness up and down while measuring. If there is a voltage drop, there is an open circuit in the harness in that section or a poor connection of pins in the connector. [Inspection example 3] Connect a wire or equivalent to the component side and mea- sure the resistance between adjacent harnesses. Gently shake the harnesses up and down while measuring. If the measurement is out of the standard value shown above, there is an open circuit in the harnesses or a poor connection of pins in the connector. 1.7.2 Short circuit A short circuit means a harness is in contact with another har- ness. A large current may occur if the power supply harness di- rectly touches an earthing harness without going through a load. A short circuit to power refers to a short circuit to the power sup- ply line carrying the same voltage as the battery voltage. A short circuit to earth refers to a short circuit to an earthing line. [Inspection example] Check the following to confirm that there is no continuity. Gently shake the harness up and down while measuring. Measure the resistance between the pins to be inspected. Measure the resistance between the pin to be inspected and a power line. (short circuit to power) Measure the resistance between the pin to be inspected and an earthing line or chassis earth. (short circuit to earth) Standard value: More than 1 MΩ If the measurement is out of the standard value, there is a short circuit in the harness or in the connector. ---===WSE_1506_00001_0050.djvu===--- 54-00A-42 1.8 Intermittent faults An intermittent fault typically occurs only under certain operating conditions. Once these conditions have been identified, the cause of the intermittent fault can be ascertained easily. First, ask the customer about the vehicle operating conditions and weather conditions under which the fault occurs. Also ask about the frequency with which the fault occurs and about the fault symptoms. Then, reproduce the fault based on this information. In accordance with the conditions under which the fault occurs, determine whether the fault is caused by vibration, heat or other factors. if vibration is a possible factor, see if the fault can be re- produced by performing the following checks on individual con- nectors and other parts: Gently move connectors up and down and to left and right. Gently move wiring harnesses up and down and to left and right. Gently wiggle sensors and other devices by hand. Gently wiggle wiring harnesses on suspension systems and other moving parts. Connectors and other parts to be checked are those included or given as likely fault locations in inspection procedures corre- sponding to diagnosis codes and/or fault symptoms. DIAGNOSIS CODES ---===WSE_1506_00001_0051.djvu===--- 54-00A-43 54-00A 1.9 Diagnosis tool functions and available tests 1.9.1 Basic functions The basic functions of the diagnosis tools include the readout of diagnosis codes and control information from electronic control units. Efficient troubleshooting can be made by using these functions. A writing function is also provided to allow registering or changing information on electronic control units. If you perform a short test with the FUSO Diagnostics, the systems on the vehicle that support the FUSO Diag- nostics are automatically determined and a list of the current diagnosis codes (fault codes) is displayed. Failures can be efficiently identified and removed by reading diagnosis codes and taking actions (troubleshooting) accordingly. (1) Reading diagnosis codes By reading diagnosis codes, failures in the vehicle can be efficiently identified and remedied. (2) Reading service data (measured values) Service data shows the values and information used for control by an electronic control unit, allowing you to check if the switches, sensors, harnesses or connectors that provide the information are operating normally. The following types of service data are available (which varies depending on the electronic control unit): Input or calculated values from switches, sensors and other electronic control units Output values to relays and actuators Vehicle specifications stored in the electronic control unit If backup values are displayed as service data, the electrical component or harness associated with the service data is faulty. Since some systems store related service data when a diagno- sis code is generated as freeze frame data, there may be cases where the cause of a failure can be presumed without reproduc- ing the failure. (3) Performing the actuator test (control) By performing an actuator test, functions of an electrical component or electronic control unit can be easily acti- vated to check if the component or unit is faulty or not. Since operation checks can be performed without driving the vehicle, greater efficiency and safety of troubleshooting are assured. The following types of actuator tests are available (which varies depending on the electronic control unit): Make an electrical component operate to determine and check failures. Input pseudo signals to an electronic control unit (e.g. a signal that tells the unit that a switch is set to ON regardless of the actual position of the switch). In actuator tests, service data may be displayed as "Operating" even if the electrical component is not operating normally. Therefore, also check for operation sound, etc. to make sure. When an electronic control unit is exercising failure mode con- trol, the unit may not activate the actuator even if an actuator test is performed (depending on the electronic control unit and failure conditions). (4) Registering, changing and resetting the specifications and parameters of electronic control units and coding such as calibration It is possible to check the specifications and parameters stored in electronic control units, register, change, or re- set the parameters or data upon replacement of related components, and update learned values. ---===WSE_1506_00001_0052.djvu===--- 54-00A-44 2. Reading and Erasing the Diagnosis Code 2.1 Using the FUSO Diagnostics Special tools (1) Connecting the FUSO Diagnostics Turn the starter switch to the LOCK position. Connect , , and LAN cable (cross cable; category 5 or higher). Connect the diagnostic connector to the connector. (2) Operating instructions for FUSO diagnostics See the instruction manual for FUSO diagnostics. Mark Tool name and shape Part No. Application PC FDS-R15-1 or higher (FUSO Diagnostics version) Data gearbox between FUSO con- nect and PC FUSO Connect MH064036 Data gearbox between electronic control unit and PC FUSO Diagnostics test harness MH062998 Power supply to FUSO connect and communication with electronic control unit DIAGNOSIS CODES ---===WSE_1506_00001_0053.djvu===--- 54-00A-45 54-00A (3) Description of diagnosis code (fault code) screen. [CURRENT and STORED F] shown at the right end denote diagnosis codes issued presently and in the past re- spectively. [STORED f] denotes diag- nosis code issued in the past. 2.2 When FUSO diagnostics is not used Even if the FUSO Diagnostics is not available, you can display or erase diagnosis codes by using the multi-infor- mation display on the meter cluster as follows. (1) Preparations for system inspec- tion Stop the vehicle. Turn the starter switch ON. Press the SELECT, MODE and SET/ RES switches simultaneously. The multi-information display in the meter cluster enters the diagnosis mode. ---===WSE_1506_00001_0054.djvu===--- 54-00A-46 (2) System (electronic control unit) selection mode Press the SELECT switch to select the system (electronic con- trol unit) to be checked. Press the SET/RES switch to enter the function selection mode. (3) Function selection mode Press the SELECT switch to select the desired mode. Press the SET/RES switch to enter one of the following modes: Current diagnosis code display mode Past diagnosis code display mode Diagnosis code erase mode When the MODE switch is pressed, the system (electronic con- trol unit) selection mode will be entered. DIAGNOSIS CODES ---===WSE_1506_00001_0055.djvu===--- 54-00A-47 54-00A (4) Current and past diagnosis code display modes Generated diagnosis codes are displayed. When two or more di- agnosis codes have been generated, they are displayed in turns at 3-second intervals. If there is no diagnosis code, "NO DTC" is displayed. If "ERROR" or "CANNOT RECEIVE" is displayed during commu- nication, perform the operation again. When the MODE switch is pressed, the function selection mode will be entered. NOTE For the engine electronic control unit, check the diagnosis code shown in the "RQ CONFIRMED" screen. For the engine electronic control unit, "RQ ACTIVE" is not a diagnosis code indicating a failure. (5) Diagnosis code erase mode If the SET/RES switch is pressed in the "ERASE YES" screen, all diagnosis codes stored in the selected electronic control unit will be erased and "ERASE COMPLETE" will be displayed. If "CANNOT ERASE" or "ERROR" screen is displayed, connect the FUSO Diagnostics to check each system and take neces- sary actions. When the MODE switch is pressed, the function selection mode will be entered. When the SET/RES switch is pressed in the "ERASE NO" screen, the function selection mode will be entered. ---===WSE_1506_00001_0056.djvu===--- 54-00A-48 Use specified bolts and nuts. Tighten them to the torques shown below as appropriate, unless otherwise speci- fied. Threads and bearing surfaces shall be dry. If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the bolt. Hexagon Head Bolts and Stud Bolts (Unit: N·m {kgf·m}) Hexagon Head Flange Bolts (Unit: N·m {kgf·m}) Strength 4T 7T 8T Identification symbol Nominal diameter (stud) (stud) (stud) M5 2to3 {0.2 to 0.3} -- 4to6 {0.4 to 0.6} -- 5to7 {0.5 to 0.7} -- M6 4to6 {0.4 to 0.6} -- 7to10 {0.7 to 1.0} -- 8to12 {0.8 to 1.2} -- M8 9to13 {0.9 to 1.3} -- 16to24 {1.7 to 2.5} -- 19to28 {2.0 to 2.9} -- M10 18to27 {1.8 to 2.7} 17to25 {1.8 to 2.6} 34to50 {3.5 to 5.1} 32to48 {3.3 to 4.9} 45to60 {4.5 to 6.0} 37to55 {3.8 to 5.7} M12 34to50 {3.4 to 5.1} 31to45 {3.1 to 4.6} 70to90 {7.0 to 9.5} 65to85 {6.5 to 8.5} 80 to 105 {8.5 to 11} 75to95 {7.5 to 10} M14 60to80 {6.0 to 8.0} 55to75 {5.5 to 7.5} 110 to 150 {11 to 15} 100 to 140 {11 to 14} 130 to 170 {13 to 17} 120 to 160 {12 to 16} M16 90 to 120 {9 to 12} 90 to 110 {9 to 11} 170 to 220 {17 to 23} 160 to 210 {16 to 21} 200 to 260 {20 to 27} 190 to 240 {19 to 25} M18 130 to 170 {14 to 18} 120 to 150 {12 to 16} 250 to 330 {25 to 33} 220 to 290 {23 to 30} 290 to 380 {30 to 39} 250 to 340 {26 to 35} M20 180 to 240 {19 to 25} 170 to 220 {17 to 22} 340 to 460 {35 to 47} 310 to 410 {32 to 42} 400 to 530 {41 to 55} 360 to 480 {37 to 49} M22 250 to 330 {25 to 33} 230 to 300 {23 to 30} 460 to 620 {47 to 63} 420 to 560 {43 to 57} 540 to 720 {55 to 73} 490 to 650 {50 to 67} M24 320 to 430 {33 to 44} 290 to 380 {29 to 39} 600 to 810 {62 to 83} 540 to 720 {55 to 73} 700 to 940 {72 to 96} 620 to 830 {63 to 85} Strength 4T 7T 8T Identification symbol Nominal diameter M6 4to6 {0.4 to 0.6} -- 8to12 {0.8 to 1.2} -- 10to14 {1.0 to 1.4} -- M8 10to15 {1.0 to 1.5} -- 19to28 {2.0 to 2.9} -- 22to33 {2.3 to 3.3} -- M10 21to31 {2.1 to 3.1} 20to29 {2.0 to 3.0} 45to55 {4.5 to 5.5} 37to54 {3.8 to 5.6} 50to65 {5.0 to 6.5} 50to60 {5.0 to 6.0} M12 38to56 {3.8 to 5.5} 35to51 {3.5 to 5.2} 80 to 105 {8.0 to 10.5} 70to95 {7.5 to 9.5} 90 to 120 {9 to 12} 85 to 110 {8.5 to 11} TABLE OF STANDARD TIGHTENING TORQUES ---===WSE_1506_00001_0057.djvu===--- 54-00A-49 54-00A Hexagon Nuts (Unit: N·m {kgf·m}) Hexagon Flange Nuts (Unit: N·m {kgf·m}) Strength 4T 6T Identification symbol Nominal diameter Standard screw thread Coarse screw thread Standard screw thread Coarse screw thread M5 2to3 {0.2 to 0.3} -- 4to6 {0.4 to 0.6} -- M6 4to6 {0.4 to 0.6} -- 7to10 {0.7 to 1.0} -- M8 9to13 {0.9 to 1.3} -- 16to24 {1.7 to 2.5} -- M10 18to27 {1.8 to 2.7} 17to25 {1.8 to 2.6} 34to50 {3.5 to 5.1} 32to48 {3.3 to 4.9} M12 34to50 {3.4 to 5.1} 31to45 {3.1 to 4.6} 70to90 {7.0 to 9.5} 65to85 {6.5 to 8.5} M14 60to80 {6.0 to 8.0} 55to75 {5.5 to 7.5} 110 to 150 {11 to 15} 100 to 140 {11 to 14} M16 90 to 120 {9 to 12} 90 to 110 {9 to 11} 170 to 220 {17 to 23} 160 to 210 {16 to 21} M18 130 to 170 {14 to 18} 120 to 150 {12 to 16} 250 to 330 {25 to 33} 220 to 290 {23 to 30} M20 180 to 240 {19 to 25} 170 to 220 {17 to 22} 340 to 460 {35 to 47} 310 to 410 {32 to 42} M22 250 to 330 {25 to 33} 230 to 300 {23 to 30} 460 to 620 {47 to 63} 420 to 560 {43 to 57} M24 320 to 430 {33 to 44} 290 to 380 {29 to 39} 600 to 810 {62 to 83} 540 to 720 {55 to 73} Strength 4T Identification symbol Nominal diameter Standard screw thread Coarse screw thread M6 4to6 {0.4 to 0.6} -- M8 10to15 {1.0 to 1.5} -- M10 21to31 {2.1 to 3.1} 20to29 {2.0 to 3.0} M12 38to56 {3.8 to 5.6} 35to51 {3.5 to 5.2} ---===WSE_1506_00001_0058.djvu===--- 54-00A-50 Tightening Torque for General-Purpose Flare Nut (Unit: N·m {kgf·m}) Tightening Torque for General-Purpose Air Piping Nylon Tube (DIN Type) (Unit: N·m {kgf·m}) Tightening Torque for General-Purpose Air Piping Nylon Tube (SAE Type) (Unit: N·m {kgf·m}) Pipe diameter φ4.76 mm φ6.35 mm φ8 mm φ10 mm φ12 mm φ15 mm Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10} Nominal diameter wall thickness 6 1mm 10 1.25mm 12 1.5mm 15 1.5mm Tightening torque 20 {2.0 } 34 {3.5 } 49 {5.0 } 54 {5.5 } Nominal diameter 1/4 in. 3/8 in. 1/2 in. 5/8 in. Tightening torque 13 {1.3 } 29 {3.0 } 49 {5.0 } 64 {6.5 } +6 0 +0.6 0 +10 0 +1.0 0 +10 0 +1.0 0 +5 0 +0.5 0 +4 0 +0.4 0 +5 0 +0.5 0 +5 0 +0.5 0 +5 0 +0.5 0 TABLE OF STANDARD TIGHTENING TORQUES ---===WSE_1506_00001_0059.djvu===--- 54-00B-1 54-00B SPECIFICATIONS ---===WSE_1506_00001_0060.djvu===--- 54-00B-2 Battery Alternator Starter and Preheat System Item Specifications Model 100AH-760A (EN) 62AH-480A (EN) Voltage Quantity V 12 11 2 21 2 1 Capacity (5-hour rating) Ah 100 (20-hour rating) 62 (5-hour rating) Item Specifications Manufacturer Bosch Type Alternator with built-in regulator Model 0 124 525 216 0 124 555 063 0 124 655 091 Output V-A 12-140 24-80 24-90 Item Specifications Starter Manufacturer MITSUBISHI ELECTRIC Model M001T31072 Output V-kW 12-2.0 Reduction gear mechanism Planetary gears Magnetic switch operating voltage V 8 or less Starter relay Model U001TE3072 Excitation current V-A 12-4 Closing voltage V 8 or less Opening voltage V 3.5 or less Allowable cutoff current A 200 Glow elec- tronic con- trol unit Manufacturer Bosch Glow plug Model Sheathed type Excitation current V-A 11-18 (reference value) SPECIFICATIONS ---===WSE_1506_00001_0061.djvu===--- 54-00B 54-00B-3 Lighting All bulbs in the lamps shown above have voltage rating of 12 volts. *: The types of bulbs are shown in parentheses. Relay, Radio, Motor, Horn, Buzzer Item Specifications Model Unconventional, 2-lamp-system Type Reflector type Headlamp Main beam (high) W 60/55 (H4)* (high/low) Dipped beam (low) W Position lamp W 5 (W5W)* Fog lamp and daytime running lamp Fog lamp W 55 (H3)* Daytime running lamp W 21 (P21W)* Front and side turn signal lamp (serving also as hazard warning lamp) W 21 (W21W)* End-outline marker lamp <Wide cab> W 5 (R5W)* Rear combi- nation lamp Stop lamp W 21 (P21W)* Tail lamp W 10 (R10W)* Rear turn signal lamp (serving also as hazard warning lamp) W 21 (P21W)* Backup lamp W 21 (P21W)* Rear fog lamp W 21 (P21W)* Step lamp W 5 (W5W)* License plate lamp W 5 (C5W)* Cab lamp W 10 Cab and spot lamp W 8 Item Specifications Relay Rated voltage V 12 Minimum operating voltage V 8 or less Relay in signal detect and actua- tion modules Rated voltage V 12V 12 24V 24 Minimum operating voltage V 12V 7.2 or less 24V 14 or less Loudspeaker Rated input W 15 Maximum input W 25 Impedance Ω 4±0.6 Wiper motor Rated voltage V 12 No-load current A 4 or less Bound current A 30 or less Washer motor Rated voltage V 12 Rated current A 3.8 or less Power window motor Rated voltage V 12 Rated current A 5 or less Electric horn Rated voltage V 12 Current consumption A 3.5 Sound pressure dB 110±5(at2m) Back buzzer <Option> Rated voltage V 12 Rated current mA 50 or less Sound pressure dB 85±10(at1m) ---===WSE_1506_00001_0062.djvu===--- 54-00C-1 54-00C STRUCTURE AND OPERATION ---===WSE_1506_00001_0063.djvu===--- 54-00C-2 1. Starter This starter uses planetary gears as its reduction gearing mech- anism. STRUCTURE AND OPERATION ---===WSE_1506_00001_0063.djvu===--- 54-00C-2 1. Starter This starter uses planetary gears as its reduction gearing mech- anism. STRUCTURE AND OPERATION ---===WSE_1506_00001_0064.djvu===--- 54-00C 54-00C-3 2. Alternator <12V-140A (0 124 525 216)> ---===WSE_1506_00001_0065.djvu===--- 54-00C-4 <24V-80A (0 124 555 063)>, <24V-90A (0 124 655 091)> STRUCTURE AND OPERATION ---===WSE_1506_00001_0066.djvu===--- 54-00C 54-00C-5 3. Headlamps (Left headlamps are shown in this illustration.) ---===WSE_1506_00001_0067.djvu===--- 54-00C-6 3.1 Headlamp leveling system The headlamp leveling system enables the headlamp reflectors' aim to be vertically adjusted using the leveling actuators. This allows the optimum aim to be set when the vehicle is loaded or unloaded. In the headlamp leveling system, the headlamp leveling switch is used to adjust the headlamps' aim. The "0" position is for the normal condition. The headlamps' aim can be lowered in 5 steps (1 to 5) in accordance with the weight of the vehicle's load. (The illustration shows the right-hand drive vehicle.) STRUCTURE AND OPERATION ---===WSE_1506_00001_0068.djvu===--- 54-00C 54-00C-7 4. Battery Equaliser 4.1 Overview A battery equaliser is equipped on ve- hicles that have two batteries (12 V × 2). It converts output voltage from 24Vto12V. The battery equaliser controls the electrical balance between the main battery and battery for body builder power source so as to enhance bat- tery life and protect the main battery. 4.2 Wiring diagram ---===WSE_1506_00001_0069.djvu===--- 54-00C-8 (1) Engine ON When the engine is ON, the alternator generates a voltage of 24 V. Part of this voltage is used for the 12 V load by the battery equaliser. (2) Engine OFF When the engine is OFF, the battery equaliser controls the voltage for the 12 V load from the main battery and battery for body builder power source. Both batteries are maintained at the same voltage. STRUCTURE AND OPERATION ---===WSE_1506_00001_0070.djvu===--- 54-00D-1 54-00D TROUBLESHOOTING ---===WSE_1506_00001_0071.djvu===--- 54-00D-2 1. Power and Charging Possible causes Symptoms Reference Gr Connector connection faulty, harness broken, earthing faulty O O Fuse blown OOO High-current fuse blown OOO Belt tension insufficient O O Gr14 Belt cut off O O Gr14 Defective battery O O Defective battery equaliser <Vehicle with battery equaliser> OOOOOO Signal detect and actuation modules malfunctioning <24V Vehicle> O O Communication failure of controller area network (Controller area network communication) O Alternator Open-circuited stator coil O Short circuit between stator coil and core O Open-circuited field coil O Defective rectifier O Defective regulator OOO Brush worn O Permanent set of brush spring in fa- tigue O Improper wiring O Power is not supplied to alter- nator R terminal Relay "Optional power supply (IGN)" inoperative OO O Gr54ES (Performing in- spections based on di- agnosis codes; check of FUSO Diagnostics ser- vice data (actual values) (039/067/071); inspec- tion and disconnection/ connection of relay (D)) Fuse blown O OO Gr54-01 (Inspection and removal/installa- tion of fuse (F04)) Defective meter cluster O TROUBLESHOOTING ---===WSE_1506_00001_0072.djvu===--- 54-00D 54-00D-3 2. Engine Starting, Stopping and Preheating Symptoms Starter is activat- ed but engine does not start Reference Gr Possible causes Connector connection faulty, harness broken, earthing faulty O OOOOO High current fuse blown O O O Fuse blown O O O Signal detect and actuation modules malfunctioning O O O Battery capacity insufficient O O Starter Magnet switch contact stuck, fused O Magnet switch coil open cir- cuited O Overrunning clutch malfunc- tioning O Pinion worn, damaged O Defective starter relay O Defective starter switch O O Flywheel ring gear worn, damaged O Gr11 Common rail system malfunctioning O OOOOOGr13E Faulty starter relay (for drive) O Faulty shift lever unit relay <DUONIC ® >O DUONIC ® system malfunctioning O Gr22E Gear shift lever in other position than P or N O Gr22E Defective glow plug OOOG r 1 1 Glow electronic control unit malfunctioning OOOGr13E Connecting plate poorly fitted OOOGr11 Defective water temperature sensor OO Exhaust brake system malfunctioning O Gr35E Combination switch Defective exhaust brake switch O Defective warming-up switch O Immobiliser system malfunctioning O Engine immobiliser starter key not registered in immobiliser electronic control unit is in use O Warning lamp (red) for signal detect and actuation module is il- luminating. OG r 5 4 E S Communication failure (Controller area network / Local intercon- nect network) OO O G r 5 4 E S ---===WSE_1506_00001_0073.djvu===--- 54-00D-4 Power is not supplied to starter switch. O Gr54-01 (Inspection and removal/instal- lation of fuse (F13)); Gr54ES (Inspec- tion and disconnec- tion/connection of signal detect and actuation module connector (3B)) Starter switch signal is not received. O Gr54ES (Inspec- tion and disconnec- tion/connection of signal detect and actuation module connectors (15B/ 18B); perform in- spections based on diagnosis codes; check of FUSO Di- agnostics service data (actual val- ues) (063 - 066); performing FUSO Diagnostics actua- tor test (actuations) (002)) Output conditions are not satisfied <DUONIC ® models> O Gr13E, Gr22E, Gr54EI (Check of each inhibit condi- tion for electronic control mod- ule);Gr22E (Check of FUSO Diagnos- tics service data (actual values) (021));Gr54-01 (In- spection and re- moval/installation of fuses (F15/ F24));Gr54ES (In- spection and dis- connection/ connection of signal detect and actua- tion module con- nector (18B);Check of coding data for signal detect and actuation module) Symptoms Starter is activat- ed but engine does not start Reference Gr Possible causes TROUBLESHOOTING ---===WSE_1506_00001_0074.djvu===--- 54-00D 54-00D-5 Power is not supplied to relat- ed electronic control units/com- ponents Blown fuse O Gr54-01 (Inspection and removal/instal- lation of fuses (F01/ F04/F09/F13/F19/ F28/F31/F34)) Starter signal relay (ACC) inop- erative O Gr54ES (Perform- ing inspections based on diagnosis codes; check of FUSO Diagnostics service data (actu- al values) (036/ 068)) Starter signal relay (IGN) inop- erative O Gr54ES (Perform- ing inspections based on diagnosis codes; check of FUSO Diagnostics service data (actu- al values) (038/070/ 071); inspection and removal/instal- lation of relay (E)) Fuel pump relay inoperative O Gr54ES (Inspec- tion and removal/in- stallation of relay (F)) Output conditions are satisfied but S signal is not outputted Faulty communication of con- troller area network O Gr54ES (Inspec- tion and disconnec- tion/connection of signal detect and actuation module connector (17B); performing inspec- tions based on di- agnosis codes) Low input voltage O Gr54ES (Check of input terminals (8C/ 9C/10C) of signal detect and actua- tion module; per- forming inspections based on diagnosis codes; check of FUSO Diagnostics service data (actu- al values) (087)) Low output voltage O Inspect by replac- ing with a known- good signal detect and actuation mod- ule. Communication failure (Controller area network / Local intercon- nect network) OO G r 5 4 E S Symptoms Starter is activat- ed but engine does not start Reference Gr Possible causes ---===WSE_1506_00001_0075.djvu===--- 54-00D-6 Power is not supplied to Combination switch. O O Gr54-01 (Inspection and removal/instal- lation of fuse (F09)); Gr54ES (In- spection and dis- connection/ connection of signal detect and actua- tion module con- nector (2B)) Combination switch signal is not received. O O Gr54ES (Inspec- tion and disconnec- tion/connection of signal detect and actuation module connector (18B); performing inspec- tions based on di- agnosis codes) Faulty controller area network function of signal detect and actu- ation module OO Gr54ES (Inspec- tion and disconnec- tion/connection of signal detect and actuation module connector (17B); performing inspec- tions based on di- agnosis codes) Symptoms Starter is activat- ed but engine does not start Reference Gr Possible causes TROUBLESHOOTING ---===WSE_1506_00001_0076.djvu===--- 54-00D 54-00D-7 3. Lighting Symptoms Headlamp Reference Gr Possible causes Connector connection faulty, harness broken, earthing faulty O OOOOO High current fuse blown O OOOOO Signal detect and actuation modules malfunctioning O OOOOOOOO Battery insufficient in capacity O Defective alternator O Bulb blown out O OOOO Combination switch Defective lighting switch O OO Defective dimmer switch OO Defective headlamp leveling switch O Defective headlamp leveling actuator O Defective starter switch O Defective front fog lamp switch O Defective rear fog lamp switch O Signal detect and actuation modules malfunctioning O Failure of combination switch O Warning lamp (amber) for signal detect and actuation module is illu- minating. OO G r 5 4 E S Power is not supplied to combination switch. O OO Gr54-01 (Inspection and removal/installa- tion of fuse (F09)); Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (2B)) Combination switch is not received. OO OO O Gr54-01 (Inspection and removal/installa- tion of fuse (F09)); Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (18B); performing in- spections based on diagnosis codes; check of FUSO Diag- nostics service data (actual values) (002); performing FUSO Di- agnostics actuator test (actuations) (002)) ---===WSE_1506_00001_0077.djvu===--- 54-00D-8 Combination switch signal is not received. O Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (18B); performing in- spections based on diagnosis codes) Outputting although the output conditions are not satisfied. External factor O Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (18B)); Gr54-03 (Check and removal of additional wiring) Internal factor of signal detect and actuation module O Inspection by replac- ing with a known- good signal detect and actuation module Low voltage Low input voltage O Gr54ES (Check of in- put terminals (8C/9C/ 10C) of signal detect and actuation mod- ule; performing in- spections based on diagnosis codes; check of FUSO Diag- nostics service data (actual values) (087)) Low output voltage O Inspection by replac- ing with a known- good signal detect and actuation module Changeover conditions are not satisfied. Combination switch signal is not received. OO Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (18B); performing in- spections based on diagnosis codes) Symptoms Headlamp Reference Gr Possible causes TROUBLESHOOTING ---===WSE_1506_00001_0078.djvu===--- 54-00D 54-00D-9 Output conditions are satisfied. Key switch position OO Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connectors (15B/18B); perform- ing inspections based on diagnosis codes; check of FUSO Diagnostics service data (actual values) (038/063 - 071)) O Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connectors (15B/18B); perform- ing inspections based on diagnosis codes; check of FUSO Diagnostics service data (actual values) (063 - 066)) Request to turn off the lamp <vehicle with idling stop and start system> OO O Gr54EA (Check of FUSO Diagnostics service data (actual values) (048)) Fog lamp switch signal is not re- ceived. O Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (15B); check of FUSO Diagnostics service data (actual values) (053)) Combination switch signal is not received. O Gr54-01 (Inspection and removal/installa- tion of fuse (F09)); Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (18B); performing in- spections based on diagnosis codes; check of FUSO Diag- nostics service data (actual values) (002/ 038)) Symptoms Headlamp Reference Gr Possible causes ---===WSE_1506_00001_0079.djvu===--- 54-00D-10 Output conditions are satisfied. Combination switch ON signal is received. O Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (18B); performing in- spections based on diagnosis codes) Output conditions are satisfied but output is halted. External factor O Gr54ES (Check of signal detect and ac- tuation module con- nectors (12C/13C); performing inspec- tions based on diag- nosis codes; check of FUSO Diagnostics service data (actual values) (018/019/ 053)) O Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connectors (14B/16B); perform- ing inspections based on diagnosis codes; check of FUSO Diagnostics service data (actual values) (000 - 001); performing FUSO Di- agnostics actuator test (actuations) (000)) OO Gr54ES (Check of signal detect and ac- tuation module con- nectors (15B); performing inspec- tions based on diag- nosis codes; check of FUSO Diagnostics service data (actual values) (017)) Internal factor of signal detect and actuation module OO O O Inspection by replac- ing with a known- good signal detect and actuation mod- ule. Symptoms Headlamp Reference Gr Possible causes TROUBLESHOOTING ---===WSE_1506_00001_0080.djvu===--- 54-00D 54-00D-11 Output conditions are not satis- fied. Head lamps are illuminating. O Gr54ES (Inspection of signal detect and actuation module connectors (14B/ 16B/18B); check of FUSO Diagnostics service data (actual values) (000 - 001, 008 - 013); perform- ing FUSO Diagnos- tics actuator test (actuation) (000)) Key switch position (when stop- ping) O Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connectors (15B/18B); perform- ing inspections based on diagnosis codes; check of FUSO Diagnostics service data (actual values) (038/063 - 071)) Fog lamp switch is in ON posi- tion. O Gr54ES (Inspection of signal detect and actuation module connectors (14B/ 16B/18B); check of FUSO Diagnostics service data (actual values) (000 - 001, 008 - 013); perform- ing FUSO Diagnos- tics actuator test (actuation) (000)) Power is not supplied to combi- nation switch. O Gr54-01 (Inspection and removal/installa- tion of fuse (F09)); Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (2B)) Combination switch signal is not received. O Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (18B); performing in- spections based on diagnosis codes) Symptoms Headlamp Reference Gr Possible causes ---===WSE_1506_00001_0081.djvu===--- 54-00D-12 Output conditions are not satis- fied. Key switch position O Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (15B/18B); perform- ing inspections based on diagnosis codes; check of FUSO Diagnostics service data (actual values) (063 - 071)) Output is halted. External factor O Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module connector (14B); check of FUSO Diagnostics service data (actual values) (016)) Over current O Check of installed af- termarket parts; in- spection of illumination condi- tions of other night il- luminations Internal factor of signal detect and actuation module O Inspection by replac- ing with a known- good signal detect and actuation module Faulty controller area network communication O Gr13E (Inspection of engine electronic control unit); Gr54ES (Inspection and dis- connection/connec- tion of signal detect and actuation module connector (17B); per- forming inspections based on diagnosis codes) Symptoms Headlamp Reference Gr Possible causes TROUBLESHOOTING ---===WSE_1506_00001_0082.djvu===--- 54-00D 54-00D-13 Symptoms Turn signal lamp (also used as haz- ard lamp) Reference Gr Possible causes Connector connection faulty, harness broken, earthing faulty OOOO OO High-current fuse blown OOOO OO Signal detect and actuation modules malfunctioning OOOOOOOOOO Battery insufficient in capacity O Defective alternator O Bulb blown out OOOO O O Defective stop lamp switch O Bulb lower than specified in wattage O Combination switch Defective lighting switch OO Defective turn signal switch O Defective hazard switch O Defective backup lamp switch OO Defective back buzzer O DUONIC ® system malfunctioning O O Gr22E Warning lamp (amber) for signal detect and actuation module is il- luminating. OOO G r 5 4 E S Faulty signal detect and actua- tion module Internal factor of signal detect and actuation module OO Inspection by replacing with a known-good signal detect and actuation module Power is not supplied to combination switch O O Gr54-01 (In- spection and removal/instal- lation of fuse (F09)); Gr54ES (Inspection and disconnection/ connection of signal detect and actuation module con- nector (2B)) combination switch signal is not received. O O O Gr54ES (In- spection and disconnection/ connection of signal detect and actuation module con- nector (18B); performing in- spections based on diag- nosis codes) ---===WSE_1506_00001_0083.djvu===--- 54-00D-14 Stop lamp switch signal is not received. O Gr54ES (In- spection and disconnection/ connection of signal detect and actuation module con- nector (18B); check of FUSO Diagnostics service data (actual values) (079)) Output is halted. External factor O Gr54ES (In- spection of sig- nal detect and actuation mod- ule connectors (15B/18B/12C/ 13C); perform- ing inspections based on diag- nosis codes; check of FUSO Diagnostics service data (actual values) (006/007/078/ 079)) Symptoms Turn signal lamp (also used as haz- ard lamp) Reference Gr Possible causes TROUBLESHOOTING ---===WSE_1506_00001_0084.djvu===--- 54-00D 54-00D-15 Output is halted. External factor O Gr54ES (In- spection of sig- nal detect and actuation mod- ule connec- tors (14B/16B/ 18B/12C/13C); performing in- spections based on diag- nosis codes; check of FUSO Diagnostics service data (actual values) (002 - 005/023/ 024); perform- ing FUSO Di- agnostics actuator test (actuations) (000)) O Gr54ES (In- spection of sig- nal detect and actuation mod- ule connectors (17B/18B/ 13C); perform- ing inspections based on diag- nosis codes; check of FUSO Diagnostics service data (actual values) (044/080)) Symptoms Turn signal lamp (also used as haz- ard lamp) Reference Gr Possible causes ---===WSE_1506_00001_0085.djvu===--- 54-00D-16 Output is halted. External factor (broken wire de- tected) O Gr54ES (In- spection of sig- nal detect and actuation mod- ule connectors (14B/16B/18B/ 12C/13C); per- forming inspec- tions based on diagnosis codes; check of FUSO Diag- nostics service data (actual values) (002 - 005/023/024)) Internal factor of signal detect and actuation module OO OO Inspection by replacing with a known-good signal detect and actuation module Symptoms Turn signal lamp (also used as haz- ard lamp) Reference Gr Possible causes TROUBLESHOOTING ---===WSE_1506_00001_0086.djvu===--- 54-00D 54-00D-17 Output conditions are not satis- fied. Key switch position O Gr54ES (In- spection and disconnection/ connection of signal detect and actuation module con- nectors (15B/ 18B); perform- ing inspections based on diag- nosis codes; check of FUSO Diagnostics service data (actual values) (063 - 071); performing FUSO Diag- nostics actua- tor test (actuation) (000)) Reverse signal is not received. O Gr54ES (In- spection and disconnection/ connection of signal detect and actuation module con- nector (18B); check of FUSO Diagnostics service data (actual values) (045/080); check of cod- ing data for sig- nal detect and actuation mod- ule) Symptoms Turn signal lamp (also used as haz- ard lamp) Reference Gr Possible causes ---===WSE_1506_00001_0087.djvu===--- 54-00D-18 Output signals are satisfied but output is halted. External factor O Gr54ES (In- spection of sig- nal detect and actuation mod- ule connectors (15B/18B); per- forming inspec- tions based on diagnosis codes; check of FUSO Diag- nostics service data (actual values) (010/ 011); perform- ing FUSO Di- agnostics actuator test (actuation) (000)) Internal factor of signal detect and actuation module O Inspection by replacing with a known-good signal detect and actuation module Symptoms Turn signal lamp (also used as haz- ard lamp) Reference Gr Possible causes TROUBLESHOOTING ---===WSE_1506_00001_0088.djvu===--- 54-00D 54-00D-19 Possible causes Symptoms Reference Gr Connector connection faulty, harness broken, earthing faulty OOOOO High-current fuse blown OOOOO Signal detect and actuation modules malfunctioning OOOOO Bulb burnt-out O OOO Defective starter switch OO Defective cab and spot lamp OO Defective door switch OOOO Defective power window switch O Defective rear cab lamp (crew cab) O Defective meter cluster O Defective lighting switch O Power is not supplied. O Gr54-01 (Inspection and removal/installa- tion of fuse (F12)); Gr54ES (Inspection and disconnection/con- nection of signal detect and actuation module connectors (3B/17B)) Illumination conditions are not satis- fied. Door switch information O Gr54ES (Inspection of signal detect and actu- ation module connec- tor (15B); check of FUSO Diagnostics ser- vice data (actual val- ues) (058 - 060)) A certain duration has passed after opening a door. O Open and close the door to check reproduc- ibility. ---===WSE_1506_00001_0089.djvu===--- 54-00D-20 Output is halted. External factor O Gr54ES (Inspection of signal detect and actu- ation module connec- tor (17B); performing inspections based on diagnosis codes; check of FUSO Diagnostics service data (actual val- ues) (048)) O Gr54ES (Inspection of signal detect and actu- ation module connec- tor (14B); check of FUSO Diagnostics ser- vice data (actual val- ues) (016)) Over current O Gr54-01 (Check of in- stalled aftermarket parts; inspection of illu- mination condition of other night illumina- tions) Internal failure of the signal detect and actuation module OO Inspection by replacing with a known-good sig- nal detect and actua- tion module Illumination turning-off conditions are not satisfied. O Gr54ES (Inspection of signal detect and actu- ation module connec- tors (15B/17B); check of FUSO Diagnostics service data (actual val- ues) (048/058/059)) Output conditions are not satisfied. O Gr54ES (Inspection of signal detect and actu- ation module connec- tor (15B); check of FUSO Diagnostics ser- vice data (actual val- ues) (014/015/058 - 060)) Possible causes Symptoms Reference Gr TROUBLESHOOTING ---===WSE_1506_00001_0090.djvu===--- 54-00D 54-00D-21 Output conditions are not satisfied. Power is not supplied to the combina- tion switch. O Gr54-01 (Inspection and removal/installa- tion of fuse (F09)); Gr54ES (Inspection and disconnection/con- nection of signal detect and actuation module connector (2B)) Combination switch is not received. O Gr54ES (Inspection and disconnection/con- nection of signal detect and actuation module connector (18B); per- forming inspections based on diagnosis codes) Key switch position O Gr54ES (Inspection and disconnection/con- nection of signal detect and actuation module connectors (15B/18B); performing inspections based on diagnosis codes; check of FUSO Diagnostics service data (actual values) (063 - 071)) Possible causes Symptoms Reference Gr ---===WSE_1506_00001_0091.djvu===--- 54-00D-22 4. Meter Symptoms Reference Gr Possible causes Connector connection faulty, harness broken, earthing faulty OOO O Fuse blown OO Signal detect and actuation modules malfunctioning OOO O Gr54ES Defective meter cluster OOOOO Odometer and trip meter The coding data for electrical control unit is im- proper. OG r 5 4 E M Tachometer Defective tachometer OOOO Engine speed sensor poorly fitted OOO Gr11 Defective engine speed sensor O Defective engine electronic control unit OOO Gr13E Speedometer Defective speedometer OOOO Defective vehicle speed sensor OOO Vehicle speed sensor poorly fitted OOO Gr22E Tyre not as specified O Gr31 Tyre worn and tyre pressure not as specified O Gr31 The coding data for electrical control unit is im- proper. OG r 5 4 E M Water temperature gauge Defective water temperature sensor OOO Defective engine electronic control unit OOO Gr13E Fuel level gauge Defective fuel level gauge OOOO Defective fuel level sensor OOO Defective buzzer (built in meter) O Controller area network communication faulty OOO O Faulty controller area network communication OOO O Gr54ES (Inspec- tion and disconnec- tion/connection of signal detect and actuation module connector (17B); perform inspec- tions based on di- agnosis codes) Power is not supplied. OOO O Gr54-01 (Inspection and removal/instal- lation of fuses (F09/ F22)); Gr54ES (In- spection and dis- connection/ connection of signal detect and actua- tion module con- nectors (1B/2B)) TROUBLESHOOTING ---===WSE_1506_00001_0092.djvu===--- 54-00D 54-00D-23 Switch signal is not received. OOO O Gr54ES (Inspec- tion and disconnec- tion/connection of signal detect and actuation module connectors (15B/ 18B); performing in- spections based on diagnosis codes; check of FUSO Di- agnostics service data (actual val- ues) (063 - 071)) Symptoms Reference Gr Possible causes ---===WSE_1506_00001_0093.djvu===--- 54-00D-24 Symptoms Indicator and warning display function Reference Gr Possible causes Controller area network communication faulty OOOO Initialization of meter cluster is not done yet OOOO Signal detect and actuation modules malfunctioning OOOO Related system electronic control unit malfunctioning OOOO Faulty controller area network communication OOOO Gr54ES (Inspec- tion and disconnec- tion/connection of signal detect and actuation module connector (17B); perform inspec- tions based on di- agnosis codes) Power is not supplied. OOOO Gr54-01 (Inspection and removal/instal- lation of fuses (F09/ F22)); Gr54ES (In- spection and dis- connection/ connection of signal detect and actua- tion module con- nectors (1B/2B)) Switch signal is not received. OOOO Gr54ES (Inspec- tion and disconnec- tion/connection of signal detect and actuation module connectors (15B/ 18B); performing in- spections based on diagnosis codes; check of FUSO Di- agnostics service data (actual val- ues) (063 - 071)) TROUBLESHOOTING ---===WSE_1506_00001_0094.djvu===--- 54-00D 54-00D-25 5. Cigarette Lighter and Audio Symptoms Cigarette light- er Audio Reference Gr Possible causes Connector connection faulty, harness broken, earthing faulty O OO O Fuse blown O Signal detect and actuation modules malfunctioning O O Defective cigarette lighter OO Antenna and antenna feeder poorly connected O Defective speaker OOOO Left and right speakers are different in impedance O Starter switch signal is not received. O Gr54ES (Inspection and disconnection/connec- tion of signal detect and actuation module con- nectors (15B/18B); per- forming inspections based on diagnosis codes; check of FUSO Diagnostics service data (actual values) (063 - 071)) Power is not supplied. Blown fuse O Gr54-01 (Inspection and removal/installation of fuse (F16)) ACC relay inoperative O Gr54ES (Performing in- spections based on diag- nosis codes; check of FUSO Diagnostics ser- vice data (actual values) (036/068); inspection and removal/installation of relay (J)) ---===WSE_1506_00001_0095.djvu===--- 54-00D-26 Output conditions are not sat- isfied Power is not supplied to the combination switch. O Gr54-01 (Inspection and removal/installation of fuse (F09)); Gr54ES (In- spection and disconnec- tion/connection of signal detect and actuation module connector (2B)) combination switch signal is not received. O Gr54ES (Inspection and disconnection/connec- tion of signal detect and actuation module con- nector (18B); performing inspections based on di- agnosis codes) Key switch position O Gr54ES (Inspection of disconnection/connec- tion of signal detect and actuation module con- nectors (15B/18B); per- forming inspections based on diagnosis codes; check of FUSO Diagnostics service data (actual values) (063 - 066)) Output is halted. External factor O Gr54ES (Inspection of signal detect and actua- tion module connector (14B); check of FUSO Diagnostics service data (actual values) (016)) Over current O Gr54-01 (Check of in- stalled aftermarket parts; inspection of illumination condition of other night il- luminations) Internal factor of signal de- tect and output module O Inspection by replacing with a known-good signal detect and actuation module Symptoms Cigarette light- er Audio Reference Gr Possible causes TROUBLESHOOTING ---===WSE_1506_00001_0096.djvu===--- 54-00D 54-00D-27 Source of accessory noise 6. Horn Accessory Noise Status Alternator Beep-beep High-pitched sound that occurs when accelerator pedal is quickly pressed. (Sound stops as soon as engine is stopped.) Fuel level sensor Scratchy sound Heard when engine is suddenly revved up, vehicle is running on rough road or starter switch is turned ON Horn Hushing sound Heard when horn button is pressed or released Wiper motor Whizzing sound Heard depending on windshield wiper speed Washer motor Whizzing sound Heard when washer is operating on front windshield Symptoms Horn Reference Gr Possible causes Connector connection faulty, harness broken, earthing faulty O Fuse blown O Defective horn switch OO Defective horn relay OO Signal detect and actuation modules malfunctioning OO Defective horn O OO Horn stay bent OO Battery insufficient in capacity O O Horn switch signal is not received. O Gr54ES (Inspection and disconnection/connec- tion of signal detect and actuation module con- nector (15B)) Horn switch signal is received. O Power is not supplied. Blown fuse O Gr54-01 (Inspection and removal/installa- tion of fuse (F14)) Horn relay inoperative O Gr54ES (Inspection and removal/installation of relay (B)) Power is supplied continuously. Fused horn relay O ---===WSE_1506_00001_0097.djvu===--- 54-01-1 54-01 POWER, CHARGE AND EARTH CIRCUIT ---===WSE_1506_00001_0098.djvu===--- 54-01-2 54-L10040HF-1 HF03 HF04 HF01 * HF22 * HF21 HF05 HF06 HF08 F42 * F41 F40 F38 F37 F36 High-current fuse box Cover Lock ● ● ● ● ● WARNING To prevent possible injury, be sure to disconnect the negative (-) cable of the battery and insulate it with tape before removing high-current fuses. (See Gr54-00A.) With the negative (-) cable of the battery connected, some high-current fuses are always under battery voltage. An arc will be generated when any of these high-current fuses is replaced without disconnecting the battery negative cable, and this could cause the related electric devices to be damaged. If replace the fuse, remove the high-current fuse box from the vehicle. If a fuse blows out, identify and remedy the cause, then replace the fuse. Be sure to use the fuse with the specified ampere. CAUTION * The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V HF02 HF07 F43 * F39 HIGH-CURRENT FUSE BOX ---===WSE_1506_00001_0099.djvu===--- 54-01 54-01-3 54-L10040HF-2 Main load SAM - SAM - Hydraulic unit Hydraulic unit Rear condenser fan <Crew cab> Condenser fan Main relay 2 Alternator <Vehicle with battery equaliser> - - Glow ECU - Starter relay Rear blower fan <Crew cab> DUONIC ECU SAM : Signal detect and actuation modules ECU : Electronic control unit SAM High-current fuse box * The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V Capacity - 140A 80A - - 60A 40A 40A 20A 10A 15A 20A 30A 10A 20A 50A - - Fuse No. HF01 HF02 HF03 HF04 HF05 HF06 HF07 HF08 HF21* HF22* F36 F37 F38 F39 F40 F41 F42* F43* ---===WSE_1506_00001_0100.djvu===--- 54-01-4 54-L10040FUSE-1 <Inside of SAM> Removal of spare fuse * * Spare fuse SAM : Signal detect and actuation modules ● ● ● ● WARNING To prevent possible injury, be sure to disconnect the negative (-) cable of the battery and insulate it with tape before removing fuses. (See Gr54-00A.) If a fuse blows out, identify and remedy the cause, then replace the fuse. Be sure to use the fuse with the specified ampere. Insert the fuse puller into the gap on the outer side of the fuse holder wall to remove the spare fuse. Do not force the puller into the gap on the inner side of the fuse holder wall. Doing so will break the SAM and cause malfunctions or a fire. CAUTION * The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V <Left-hand drive vehicle> <Right-hand drive vehicle> Wall Wall Fuse puller Fuse FUSE BOX ---===WSE_1506_00001_0101.djvu===--- 54-01 54-01-5 54-L10040FUSE-2 Main load Starter - SRS airbag Trailer tail lamp relay, LH Alternator <Vehicle with battery equaliser>, Opt (IGN) Trailer rear fog lamp relay, trailer back lamp relay Cigarette lighter Starter switch, immobiliser, tachograph Audio, DUONIC ECU Horn Fuel filter ABS ECU Engine ECU ISS ECU (IGN), four-wheel drive magnetic valve - Meter cluster, air-conditioner control Trailer tail lamp relay, RH DUONIC ECU Opt (ACC) Opt (B) Engine fan clutch Engine ECU Engine ECU Air-conditioner - Fuel pump Meter cluster, diagnosis connector, combination switch Power window (driver's seat side) Power window (assistant driver's seat side) Audio, cab lamp Blower fan ABS : Anti-lock brake system ECU : Electronic control unit SAM : Signal detect and actuation modules SRS : Supplemental restraint system ISS : Idling stop and start system ISS ECU or ISS DC/DC converter Fuse box BlueTec exhaust gas aftertreatment R BlueTec exhaust gas aftertreatment R * The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V Capacity - 10A 10A 10A 10A - - 30A 30A 10A 30A 30A 15A 10A 10A 10A 20A 20A 10A 15A 10A 15A 10A 10A 10A 20A 15A 20A 20A 20A 10A 15A 20A 10A Fuse No. F01 F02 F03 F04* F05 F06 F07 F08 F09 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 F23 F24 F25* F26* F27 F28 F29 F30 F31 F32 F33 F34 ---===WSE_1506_00001_0102.djvu===--- 54-01-6 * * * The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V 105-C10040SAM-1 (1/2) 18B-16 18B-16 CAN H DIAGNOSTICS POSITION LAMP LH POSITION LAMP RH FRONT TURN LH FRONT TURN RH STEP LAMP ASSISTANT STEP LAMP DRIVER ILLUMINATION MIRROR HEATER ASSISTANT FUEL LEVEL SEN. GND BACK BUZZER PTO M/V OPT. SIDE TURN LH OPT. SIDE TURN RH BACKUP LAMP STOP LAMP LH STOP LAMP RH TAIL LAMP LH TAIL LAMP RH REAR TURN LAMP LH REAR TURN LAMP RH FRONT FOG LAMP RH LICENSE PLATE LAMP CENTRE OR LH FRONT FOG LAMP LH WIPER MOTOR LOW WIPER MOTOR HI WIPER WASHER MOTOR(+) WIPER WASHER MOTOR(-) CAB LAMP(-) OPT. ILL. CHASSIS (12V/24V) BACKUP ALARM SW PTO SW(CHASSIS) ALTERNATOR L(12V/24V) FUEL LEVEL SEN. CAN L DIAGNOSTICS CAN H CAB CAN L CAB CAN H CHASSIS CAN L CHASSIS COMB. SW LIN SIG P/W DRIVER SW LIN SIG P/W ASSISTANT SW LIN SIG KEYLESS ENTRY LIN SIG CLU LIN SIG LIN GND BRK. SW(N. O.) HAZARD SW FRONT DOOR SW DRIVER FRONT DOOR SW ASSISTANT REAR DOOR SW STARTER SW(ACC) STARTER SW(MAIN) KEY INSERTED SW HORN SW PTO SW(CAB) BRK. SW(N.C.) PARK BRK. SW BRK. FLUID LEVEL SW VAC. SW MIRROR HEAT SW FRONT FOG SW CAB TILT LOCK SW CLUTCH SW(UPPER) DPF SW A/C SW STARTER SW(START) WIPER PARKED SW KEY INTERLOCK SOL(+) KEY INTERLOCK SOL(-) MIRROR HEATER SW ILL. MIRROR HEATER DRIVER HEADLAMP HI LH HEADLAMP LOW LH GND HEADLAMP LOW LH HEADLAMP LOW RH GND HEADLAMP LOW RH SPARE INPUT SWITCH DIG1 HEADLAMP HI RH XT01H 15B-10 CL01L 15B-11 CL01R 16B-4 TR01FL 14B-4 TR01FR 15B-12 SE01A 15B-14 SE01D 14B-8 IL01 14B-5 MH01A 11C-1 FE01S TRANSFER FOUR-WHEEL DRIVE SW 11C-7 FG03A 11C-3 FE01G 11C-2 RE01 11C-9 PT01 11C-8 GE01L 11C-6 BZ01 13C-10 VP01M 12C-7 TR01SL 13C-4 TR01SR 13C-6 BL01 12C-1 SL01L 13C-7 SL01R 13C-8 TL01L 12C-3 TL01R LICENSE PLATE LAMP RH 12C-5 LL01R 12C-4 TR01RL 13C-5 TR01RR 12C-6 FL01R 13C-9 LL01L 13C-2 FL01L 16B-1 WI01L 16B-5 WI01H 17B-5 WM01V DRL LAMP LH 12C-9 DR01L DRL LAMP RH 13C-3 DR01R REAR FOG LAMP LH/RH 12C-2 RF01 TRAILER STOP LAMP 12C-8 SL01CD TRAILER TURN LAMP LH 13C-1 TR01CL TRAILER TURN LAMP RH 12C-10 TR01CR 17B-6 WM01G 17B-15 RL01 6X-4 OP02IL 18B-1 XT01L 18B-14 CB1HIM 18B-27 CB1LIM 17B-1 CN1HCM 17B-11 CN1LCM 18B-21 CS01LS 18B-20 PW01SD 18B-19 PW01SA 18B-22 KL01LS 18B-24 CH01LS 18B-23 EAB1LG 18B-4 BS01NO 15B-4 HZ01 15B-18 DS01FD 15B-3 DS01FA 15B-2 DS01R 18B-17 KE01A 18B-3 KE01M 18B-18 KS02 15B-24 HN01 18B-5 PT02J 15B-19 BS01NC 18B-6 PB01 18B-7 BF01 15B-1 VC01 18B-11 MH02 15B-16 FL02 18B-10 TT01 REAR FOG LAMP SW 15B-8 RF02 18B-9 CU01 15B-20 DF01 15B-17 AC02 15B-15 KE01ST 17B-16 WI01P 17B-17 KI01V BACKUP ALARM SW 15B-28 BL02 17B-8 KI01G 15B-27 MH03 14B-1 MH01D 16B-2 HL01HL HEADLAMP LEVELING ACT. 15B-13 ML01VJ 14B-3 HLE1LL 14B-2 HL01LL 14B-7 HL01HR 16B-7 HLE1LR 16B-8 HL01LR 15B-21 LD01 1B HH18B HQ10A HQ8A HQ8C HH18A HH28A HH28B HN14B HN14A HN14D HN6A HN14C HQ2A HQ1A HQ10C 2B 3B 5C 6X 7C 8C 9C 11C 1 2 3 4 5 6 6 5 4 3 2 1 2 1 1 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 13C 14B 15B 18B 16B 17B 1 2 3 4 5 6 7 8 9 10 HQ10B 12C 1 3 4 5 6 7 8 9 10 2 4X-5 4X-7 4X-6 4X-8 OPT. ILL. BODY OPT. GEARBOX NEUTRAL SW OPT. PTO OPT. PARK. BRK. CUT HQ8B 4X 4 8 3 7 2 6 1 5 SAM SAM:Signal detect and actuation modules SAM connector (harness side) Number of terminal Connector classification To SAM internal circuit (2/2) A part of this circuit is omitted. B40 SAM INTERNAL CIRCUIT 105 ---===WSE_1506_00001_0103.djvu===--- 54-01 54-01-7 * * ** * * * * * * * The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V 105-C10040SAM-2 (2/2) 2B-2 2B-2 SW(SIGNAL)GND POWER GND ECU GND POWER GND CLU ACC. SAM Relay LSD SAM Relay LSD SAM Relay LSD SAM Relay LSD SAM Relay LSD SAM Relay LSD AUDIO ACC. DUONIC ACC. CIGAR. LIGHTER ACC. F15 F30 F29 F28 F31 F25 F16 F22 F18 F19 F03 F24 F01 F17 F10 F07 F05 ACC RELAY J ENGINE RELAY H 12V/24V ACC RELAY C IGN RELAY E COMB. METER MAIN EQUALISER MAIN ABS MAIN ENG. ECU MAIN AIR BAG MAIN DUONIC ECU MAIN 1 DUONIC ECU MAIN 2 DUONIC SHIFT LEVER MAIN 1 DUONIC SHIFT LEVER MAIN 2 STARTER CONT. MAIN FUEL HEATER BATT. FUEL HEATER RELAY CONTROL ISS DC/DC CONVERTER POWER WINDOW ASSIST. GND POWER WINDOW DRIVER GND POWER WINDOW ASSIST. BATT. POWER WINDOW DRIVER BATT. BODY BUILDER POWER SOURCE(12V/24V) ENGINE POWER SOURCE(12V) GND ENG. MAIN RLY CONT. ENG. ECU B1 ENG. ECU B2 ENG. ECU B3 OPT. ACC. CHASSIS F04 F26 12V/24V IGN RELAY D A/C BLOWER RELAY A OPT. MAIN CHASSIS OPT. BATT. CHASSIS CAB LAMP BATT. DIAG. CONN. GND 1 DIAG. CONN. GND 2 ALT. R F09 DIAG. CONN. BATT. COMB. SW BATT. COMB. METER BATT. F12 AUDIO BATT. F13 IMMOBI. BATT. 2 F06 F11 BLOWER MOTOR BATT. BLOWER MOTOR GND A/C COMP COND. RELAY G F32 COND. MTR. RLY. DRIVE COMP. M/C BATT. HORN RELAY B F14 F34 HORN BATT. FUEL PUMP RELAY F FUEL PUMP BATT. FUEL PUMP CONT. IMMOBI. BATT. 1 STARTER SW BATT. SCR HEAT. POWER 2 SCR HEAT. POWER 1 ENG. CONT. ACT. VEHICLE POWER SOURCE(12V) EAB1S 1B-18 EAB1PL 1B-3 EAB1E 1B-9 EAB1PR 3B-8 FA15CH 3B-10 FA15RA 7C-8 FA15AM 3B-13 FA16CI 1B-11 FM22CM 5C-1 FM22EQ 5C-2 FM18AB 5C-4 FM19ED 1B-15 FM3AG 5C-11 FM24A1 5C-9 FM24A2 1B-1 FM24AM 1B-4 FM20FG FM24FG, FM24CH 1B-5 FM1ST 3B-14 FB17FH 2B-4 (FUSE F28) SAM 12V/24V BAT HORN SW (FUSE F28) SAM 12V/24V BAT FR28FH 2B-11 FB10DC 2B-6 PWE1A 2B-10 PWE1D 2B-3 FB7A 1B-7 FB5D 9C-1 10C HF22 8C-2 HF03 8C-1 EAB1 5C-5 ED01 7C-7 FR31B1 7C-10 FR31B2 7C-9 FR31B3 7C-2 FR28 7C-4 FR29 7C-6 FR30 6X-1 FA25C 5C-3 FM4R 6X-5 FM4C 6X-3 FB26C 2B-9 FB9CM F08 TRAILER REAR FOG LAMP 2B-5 FB8RF 2B-7 FB9XT 2B-8 FB9CS 2B-12 XTE1 1B-2 XTE2 3B-1 FB12RA 3B-2 FB12RL 3B-6 FB13I2 3B-7 FB13I1 3B-3 FB13KE 3B-5 FB13TG 2B-1 FB6L 2B-14 FB11BW 3B-4 BWE1 7C-11 FB32CF 7C-12 FB32AC 7C-3 FP01 7C-13 FB34FP 7C-5 FB14HN HF01 1B HH18B HQ10A HQ8A HQ8C HH18A HH28A HH28B HN14B HN14A HN14D HN6A HN14C HQ2A HQ1A HQ10C HQ10B 12C 2B 3B 5C 6X 7C 8C 9C 11C 1 2 3 4 5 6 6 5 4 3 2 1 2 1 1 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 13C 14B 15B 18B 16B 17B 1 2 3 4 5 6 7 8 9 10 F20 4WD M/V, IGN ISS ECU MAIN 1B-13 FM20LD SPARE OUTPUT, IGN3 1B-14 1B-17 FM20DC FM20IS *1 *1 *2 IS01, IS01, TACHOGRAPH BATT. TRAILER TAIL LAMP LH F23 TRAILER TAIL LAMP RH 5C-14 FB23R F27 FAN CLU RELAY 2B-13 FB27F1 HQ8B 4X 4 8 3 7 2 6 1 5 4X-1 4X-2 4X-3 4X-4 OPT. ACC. BODY OPT. BATT. BODY OPT. BODY. GND OPT. MAIN. BODY SAM SAM:Signal detect and actuation modules M/G:Manual gearbox ISS : Idling stop and start system SAM connector (harness side) Number of terminal Connector classification To SAM internal circuit (1/2) Inspection of relay in SAM: (See Gr54-00C.) A part of this circuit is omitted. *1 : DUONIC *2:M/G R B40 ---===WSE_1506_00001_0104.djvu===--- 54-01-8 * * * * * * * *: 24V 110-C10040ALL-1 Battery → high-current fuse → SAM <Vehicle with battery equaliser> 24V 12V GND + - + - BA24 BE24 3-BL 15-BY BA12A 20-W F41 F40 FB40CF 1.25-WR F38 FB38CF 1.25-RL F39 FB39 1.25-LR F37 FB37 1.25-WL F43 F42 F36 Fuse F28 to F31 Fuse F04, F25, F26 HF08 HF07 HF04 HF02 HF08 5-RB HF06 HF06A 3-RW HF05 HF05 5-BW HF03 HF03 8-Y ENGINE POWER SOURCE (12V) VEHICLE POWER SOURCE (12V) BODY BUILDER POWER SOURCE (24V) 8C-2 HF01 HF01 15-R HF21 HF22 HF22 FB42BS BG24 W 20-BL BT01 BTE1 60-BR 60-BY 3-L W FB42BS 10C 9C-1 FB41AB 3-G HQ2A HQ1A 8C 9C 2 1 1 FB36A1 1.25-O FB36CH 0.85-O FB36A2 1.25-O Fuse F01 to F03, F05 to F20, F22 to F24, F27, F32, F34 To hydraulic unit <ABS> To hydraulic unit <ABS> 210 880 To starter relay To glow ECU 620 To rear condenser fan relay 880 To main relay 2 620 790 To condenser fan relay 620 790 873 873 To rear blower motor relay To starter 210 To alternator High-current fuse box 125 105 SAM Battery equaliser Battery Battery SAM connector (harness side) 130 [16] ECU : Electronic control unit ABS : Anti-lock brake system To DUONIC ECU To shift lever unit relay U03 B40 U02 POWER CIRCUIT 110 ---===WSE_1506_00001_0105.djvu===--- 54-01 54-01-9 110-C10040ALL-2 Battery → high-current fuse → SAM <Vehicle without battery equaliser> + - + - BA12A 20-W 60-BR 60-BY F41 F40 FB40CF 1.25-WR F38 FB38CF 1.25-RL F39 F37 FB37 1.25-WL F43 F42 F36 Fuse F28 to F31 Fuse F04, F25, F26 HF08 HF07 HF04 HF02 HF08 5-RB HF06 HF06A 3-RW HF05 HF05 5-BW HF03 HF03 8-Y ENGINE POWER SOURCE (12V) VEHICLE POWER SOURCE (12V) BODY BUILDER POWER SOURCE (12V) 8C-2 HF01 HF01 15-R HF21 HF22 HF22 BG12 30-BL BT01 BTE1 60-BR 60-BY 3-L 10C 9C-1 FB41AB 3-G HQ2A HQ1A 8C 9C 2 1 1 * * Fuse F01 to F03, F05 to F20, F22 to F24, F27, F32, F34 FB36A1 1.25-O FB36CH 0.85-O FB36A2 1.25-O FB39 1.25-LR 130 [16] 210 To alternator High-current fuse box 125 105 SAM Battery Battery <*> SAM connector (harness side) To starter ECU: Electronic control unit ABS: Anti-lock brake system To hydraulic unit <ABS> To hydraulic unit <ABS> 210 790 880 To starter relay To glow ECU 620 To rear condenser fan relay 620 790 To condenser fan relay 620 873 873 To rear blower motor relay * : Option To DUONIC ECU To shift lever unit relay 880 To main relay 2 B40 U02 ---===WSE_1506_00001_0106.djvu===--- 54-01-10 110-C10040-2412 The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V B40 SAM (12V/24V BAT) OP02IL HF22 3-L OB 6X-4 9C-1 HN6A HQ1A 6X 9C 6 5 4 3 2 1 1 105 SAM To high-current fuse (HF22) 115 To optional connector SAM connector (harness side) POWER CIRCUIT 110 ---===WSE_1506_00001_0107.djvu===--- 54-01 54-01-11 ---===WSE_1506_00001_0108.djvu===--- 54-01-12 110-C10040-12-1 SAM (12V BAT)1/4 CL01L BL 15B-10 CL01R BR 15B-11 TR01FL YL 16B-4 TR01FR YR 14B-4 SE01A V 15B-12 SE01D VR 15B-14 MH01A 0.85-LR 14B-5 MH01D 0.85-RL 14B-1 MH03 0.3-RW 15B-27 BL02 0.3-RL 15B-28 BZ01 BP 11C-6 VP01M RL 13C-10 BL01L BO BL01R BO 13C-6 TR01SL GrL 12C-7 TR01SR GrR BL01 BO 13C-7 SL01R GR 13C-8 TL01L L 7 13C-4 HF01 15-R 10C HQ10C HQ10B 12C 11C 1 2 3 4 5 6 7 8 9 10 1 3 4 5 6 7 8 9 10 2 HQ10A HQ8C HH28A 5 1 6 2 7 3 8 4 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 13C 15B 16B 1 2 3 4 5 6 7 8 9 10 HQ8A 5 1 6 2 7 3 8 4 14B 105 SAM 320 To headlamp, LH (position) 320 To headlamp, RH (position) 330 To front and side turn signal lamp, LH 330 To front and side turn signal lamp, RH 345 To step lamp, As 345 To step lamp, Dr 629 To mirror heater, As 629 To mirror heater, Dr 629 To mirror heater switch 340 To trailer back lamp relay 340 To back buzzer 850 To gearbox PTO 3-way M/V 340 To rear combination lamp, LH (back) 325 To rear combination lamp, RH (stop) 320 To rear combination lamp, LH (tail) 340 To rear combination lamp, RH (back) SAM connector (harness side) 115 To optional connector Rear chassis Chassis To high-current fuse (HF01) PTO: Power take-off M/V: Magnetic valve Dr: Driver's seat side As: Assistant driver's seat side W03 B40 POWER CIRCUIT 110 ---===WSE_1506_00001_0109.djvu===--- 54-01 54-01-13 110-C10040-12-2 SAM (12V BAT)2/4 HF01 15-R FL01R WR 12C-6 FL01L WL 13C-2 LL01L OL 13C-9 WM01V L 17B-5 KI01V LR 12 3 4 17B-17 HL01HL 1.25-WL HL01HR 1.25-WR 16B-2 13C-5 TR01RR YR RF01R RY RF01L RY DR01L YL 12C-9 RF03 RY 12C-2 RF01 RY SL01CD RG 12C-8 TR01CR RB 12C-10 TR01CL LB 13C-1 13C-3 DR01R YR 14B-2 HL01LL 1.25-RL 14B-7 ML01VJ RG ML01V 0.3-RG ML01VL 0.3-RG ML01VR 0.3-RG 15B-13 WI01L 0.85-LR 16B-1 WI01H 0.85-LB 16B-5 10C HQ10B 12C 1 3 4 5 6 7 8 9 10 2 HQ10A HQ8C HH18A HH28A 5 1 6 2 7 3 8 4 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 13C 15B 16B 17B 1 2 3 4 5 6 7 8 9 10 HQ8A 5 1 6 2 7 3 8 4 14B 11 105 SAM 315 To fog lamp and daytime running lamp, RH (fog) 315 To fog lamp and daytime running lamp, LH (fog) 614 To wiper motor 320 To license plate lamp, LH 614 873 To windscreen washer motor To key interlock solenoid 310 To headlamp, LH (Main) 330 To rear combination lamp, RH (turn) 315 To rear fog lamp, RH To rear fog lamp, LH 313 To fog lamp and daytime running lamp, LH (daytime running) To fog lamp and daytime running lamp, RH (daytime running) 315 To trailer rear fog lamp relay 315 310 To headlamp, LH (Dipped) 310 To headlamp, RH (Main) 312 To headlamp leveling switch 312 905 To headlamp leveling actuator SAM connector (harness side) J/C (ML01VJ) <Headlamp leveling> To high-current fuse (HF01) DRL : Daytime running lamp 325 To coupling device (stop) 330 330 To coupling device (turn LH) To coupling device (turn RH) 313 Rear chassis Chassis B40 J07a W03 ---===WSE_1506_00001_0110.djvu===--- 54-01-14 POWER CIRCUIT 110 ---===WSE_1506_00001_0111.djvu===--- 54-01 54-01-15 110-C10040-12-4 SAM (12V BAT)4/4 IL01HZ O IL01RA O IL01AA 0.3-O IL01HC O IL01AM O IL01PT 0.3-O IL01FL 0.3-O IL01RF IL01TG 0.3-O IL01AB 0.3-O 0.3-O IL01F2 0.3-O IL01CC 0.3-O IL01F1 0.3-O IL01 0.85-O JOINT (IL01) 330 To hazard swith 612 To radio To air-conditioner ECU and control panel 620 620 873 To heater control panel To ECO mode switch 850 To gearbox PTO switch 315 315 790 415 To fog lamp switch 810 To T/F HIGH/LOW changeover switch 880 To cruse control main switch 810 To front drive switch To tachograph To rear fog lamp switch To ESP/ASR cutoff switch ECU: Electronic control unit PTO: Power take-off ESP: Electronic stability program ASR: Anti spin regulator T/F: Transfer ---===WSE_1506_00001_0112.djvu===--- 54-01-16 * * * *The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V * 110-C10040F01 SAM (Fuse F01 to F10) FM1ST RB F01 F03 F05 F04 1B-5 FM3AG OL 1B-15 FM4R R 5C-3 FM4C LR FM4CD LR 6X-5 FB5D 2-O 1B-7 F06 FB6L PL 2B-1 F08 FB8RF 0.85-WR FB8BL 0.85-WR 0.85-YL FB27BL 2B-5 F07 FB7A 2-OB 2B-3 F10 F09 FB9CM OL 2B-9 FB9CS LW 2B-8 2B-11 FB10DC 2-R 2B-7 FB9XT PL 1 3 1B HH18B HN14B HN14D HN6A 2B 5C 6X 1 2 3 4 5 6 6 5 4 3 2 1 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 105 SAM 210 631 125 <Vehicle with battery equaliser> 325 622 315 320 401 310 320 330 614 275 SAM connector (harness side) To alternator To coupling device 115 To optional connector To trailer rear fog lamp relay 622 To power window switch, As To power window switch, Dr To airbag ECU To starter relay (for drive) To trailer tail lamp relay, LH 340 To trailer back lamp relay To DC/DC converter To meter cluster To combination switch Diagnosis connector ECU: Electronic control unit Dr: Driver's seat side As: Assistant driver's seat side Trailer lamp Cab J21 J04a B40 POWER CIRCUIT 110 ---===WSE_1506_00001_0113.djvu===--- 54-01 54-01-17 110-C10040F11 SAM (Fuse F11 to F14) FB11BW 2-RW 2-RW F11 F12 2B-14 FB12RA PG 3B-1 F13 F14 HORN RELAY 7C-5 FB14HN BL 3B-5 FB13TG BR 3B-2 FB12RL RW 4 FB12RA PG FB12AA PG FB12KL PG FB12RL RW FB12RR RW FB13IS BR 3B-3 FB13KE G 3B-7 FB13I1 BY 3B-6 FB13I2 BL KS01 G 22 RB03 2-RW RB03H 2-RW RB03M 2-RW 1 HN14B HN14A 2B 3B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 HN14C 7C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 FB13TG FB13KE 105 SAM To blower motor 612 To radio 654 620 To keyless entry ECU To air-conditioner ECU and control panel 345 To cab lamp 345 To rear cab lamp 275 To ISS ECU 210 To starter switch To immobiliser ECU 554 654 To starter switch 616 To electric horn 415 To tachograph SAM connector (harness side) Instrument panel Cab 620 110 620 To rear blower motor relay <Rear air-conditioner> JOINT (FB11RB) 620 To rear blower motor relay (middle) 620 To rear blower motor relay (high) Rear air-conditioner Cab Roof Cab 210 ECU: Electronic control unit ISS: Idling stop and start system J07 J13 J32 B40 ---===WSE_1506_00001_0114.djvu===--- 54-01-18 POWER CIRCUIT 110 ---===WSE_1506_00001_0115.djvu===--- 54-01 54-01-19 110-C10040F18 SAM (Fuse F18 to F20) FM18AB PL F18 F20 5C-2 FM19ED 0.75-Lg F19 5C-4 FM20FG *1 BY FM20LD YL FM20DC *2 PG FM20IS *3 PG 1B-13 1B-14 1B-17 IS01 PG 1B HH18B HN14D 5C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 AB07 PL AB06 PL CC01 Lg AB09V PL AB07 PL 10 5 AB05 PL AB05 PL 105 SAM To hydraulic unit To ESP sensor <FE> To four-wheel drive relay To steering wheel angle sensor <FE> G sensor <FG> To DC/DC converter <DUONIC > To ISS ECU To ISS cutoff switch To lane recognition camera 275 275 275 959 880 810 790 To engine ECU 880 To cruse control relay SAM connector (harness side) Instrument panel Chassis Cab Cab ECU : Electronic control unit ISS : Idling stop and start system ESP : Electronic stability program ASR : Anti spin regulator M/G : Manual gearbox To ESP/ASR cutoff switch <FE> *1:FG *2 : DUONIC *3:M/G R R B40 J13 W09a ---===WSE_1506_00001_0116.djvu===--- 54-01-20 110-C10040F22 SAM (Fuse F22 to F24) FM22EQ YL F22 5C-1 FB23R WR F23 5C-14 FM24A1 RY 5C-11 FM24A2 5C-9 FM24AM 1B-1 FM24CH RL RW RG 1B-4 FM22CM YG 1B-11 F24 FM22CM YG AA02V YG FM22AA YG FM22HC YG SS02V RY FG04 RW FM24FG RW HC01V YG FM22TG YG 9 1B HH18B HN14D 5C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 *1 FM24FG *2 RW 105 SAM To battery equaliser To DUONIC ECU To DUONIC ECU To G sensor To shift lever unit To vehicle speed sensor 401 620 620 125 To trailer tail lamp relay, RH 320 873 To meter cluster 620 To heater control panel 620 To fresh/recirculation changeover motor 415 To tachograph To fresh/recirculation changeover motor To air-conditioner ECU and control panel SAM connector (harness side) Instrument panel Cab ECU: Electronic control unit T/F: Transfer To T/F ECU 810 To four-wheel drive relay 810 *1:FE *2:FG J14 B40 POWER CIRCUIT 110 ---===WSE_1506_00001_0117.djvu===--- 54-01 54-01-21 * * * * *The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V ** 110-C10040F25 SAM (Fuse F25 to F27) F25 FB26C 6X-3 FA25C WR GR 6X-1 F26 HN6A 6X 6 5 4 3 2 1 FB27F1 1.25-YL 1.25-YL FB27F1 1.25-YL FB27F2 F27 2B-13 FB26CD GR FB26C 1.25-GR 9 HN14B 2B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 105 SAM To optional connector 115 SAM connector (harness side) To fan clutch relay 1 To fan clutch relay 2 880 880 To coupling device 330 Coupling device Chassis B40 W03a ---===WSE_1506_00001_0118.djvu===--- 54-01-22 110-C10040F28 To fan clutch relay 1 To fan clutch relay 2 To NOx sensor and NH3 sensor SAM (Fuse F28 to F31) F28 FR28 FR28 GL01 0.75-G LA01HV 0.75-G VG01V 1.25-G WS01V 0.75-G AF01V 0.75-G NT01 0.75-G <M/G> PR01V 0.75-G PR01V 0.75-R 2-G 7C-2 F29 F30 F31 7C-4 FR29 2-RB 2B-4 FR28FH GY 7C-6 FR30 2-LR 7C-7 FR31B1 2.5-RY 7C-10 FR31B2 2.5-RW 7C-9 FR31B3 2.5-RB 8 HN14C HN14B 2B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 *1 FR28FC 0.75-G FR28F1 0.75-G 0.75-G 0.85-G FR28F2 FR28ED *1 *1 3 *1 105 SAM JOINT (FR28) To urea heater power unit To fuel heater relay To engine ECU To glow ECU To lambda sensor To vacuum modulator 566 880 880 880 880 880 880 880 880 880 880 880 To fuel filter To air flow and intake air temperature sensor To gearbox neutral switch To urea supply module (motor and heater) To urea tank level unit To urea reverting valve SAM connector (harness side) Chassis Urea tank Chassis Cab ECU: Electronic control unit M/G: Manual gearbox *1:With BlueTec exhaust gas aftertreatment R 880 B40 W17 J04 POWER CIRCUIT 110 ---===WSE_1506_00001_0119.djvu===--- 54-01 54-01-23 ---===WSE_1506_00001_0120.djvu===--- 54-01-24 *The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V * * * * * * 115-C10040 BATT(12V/24V) ACC(12V/24V) MAIN(12V/24V) GND ILL(12V/24V) IDLE UP(SW to GND) FB26C FA25C FM4C OPE2 OP02IL OP02UP GR WR FB26CD FM4CD GR LR LR 0.85-B OB RB IDLE UP(SW to GND) OP01UP RB OP01UP RB 1 1 2 3 5 6 4 F26 F25 F04 9C-1 6X-3 FB26C GR 6X-1 FA25C WR 6X-5 FM4C LR 6X-4 OP02IL OB EAC1 1.25-B 6X 9C 6 5 4 3 2 1 1 HN6A HQ1A TURN RH(12V) TURN LH(12V) TR01SR TR01SL GrR GrL 2 1 10C 13C-4 12C-7 TR01SR GrR TR01SL GrL 12C 1 2 3 4 5 6 7 8 9 10 13C 1 2 3 4 5 6 7 8 9 10 HQ10B HQ10A [12] 130 130 315 105 SAM 110 To high- current fuse (HF22) Optional connector JOINT (EAC1) To engine ECU SAM connector (harness side) ECU: Electronic control unit 110 To high- current fuse (HF01) Optional connector To coupling device 320 325 330 880 340 B40 J05 W07 W06 RESERVE POWER CIRCUIT 115 ---===WSE_1506_00001_0121.djvu===--- MEMO 54-01-25 54-01 ---===WSE_1506_00001_0122.djvu===--- 54-01-26 125-C10040-1 Multi- information display BAT EQ <Vehicle with battery equaliser> F04 * F13 F42* HF22* HF01 Battery - + Battery equaliser GND IND MAIN 12V 24V Battery - + FM4R FM4R RR GE01L L FB42BS W BG24 20-BL FB9CM OL FM22CM YG CN1HCM Y CN1LCM L CM01H Y CM01L L EAB1E 0.85-B CME1 B EQ01 0.3-Sb EQ01 Sb KE01M Y FB13KE EQ01 FM22EQ HF01 15-R HF22 BA12A BA24 3-L 20-W 3-BL FB42BS W KE01M 5C-3 11C-8 9C-1 3B-3 F22 F09 5C-1 18B-3 1B-11 17B-1 17B-11 13 13 CAN(L) 1B-3 8C-1 CAN(H) * ALT. L STARTER SW(M) 2B-9 DD10B 9 AK22A 679 1 0 17 5V CPU LED DRIVER 18913 2 105 6 2 1 4 5 6 3 2 3 HM5A 4 BS B+ 15 L 10C 12345 1B HH18B HH18A HH28B HN14B HN14A HN14D HQ2A HQ1A HQ10C 2B 3B 5C 8C 9C 11C 1 2 3 4 5 6 2 1 1 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18B 17B 123456789 101112131415161718 12 12 110 SAM High-current fuse box Starter switch JOINT (EAB1E) Meter cluster J/C(CAN-H) J/C(CAN-L) Alternator <24V> *:24V Alternator connector (harness side) 105 130 130 401 905 905 [13] 130 [16] Chassis Cab Instrument panel Cab Instrument panel Cab SAM connector (harness side) Meter cluster connector (harness side) HH18C J/C(CAN-H) J/C(CAN-L) 905 905 B40 U02 R07 J04 U03 A18 #002 J14 J20 J20 C01 J13 J29 J29 BATTERY CHARGING CIRCUIT 125 ---===WSE_1506_00001_0123.djvu===--- 54-01 54-01-27 125-C10040-2 <Vehicle without battery equaliser> F13 HF01 Battery - + GE01L L BG12 30-BL FB9CM OL FM22CM YG CN1HCM Y CN1LCM L CM01H Y CM01L L EAB1E 0.85-B CME1 B Y HF01 15-R KE01M 11C-8 3B-3 F22 F09 18B-3 1B-11 17B-1 17B-11 13 13 CAN(L) 1B-3 8C-1 CAN(H) ALT. L STARTER SW(M) 2B-9 AK22A 679 1 0 17 5V CPU LED DRIVER 18913 2 10 4 5 6 3 HH2A 1 B+ L 10C 1 2 1B HH18B HH18A HH28B HN14B HN14A HQ2A HQ10C 2B 3B 8C 11C 2 1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18B 17B 123456789 101112131415161718 + - 60-BY 60-BR * * 12 12 110 SAM High-current fuse box Starter switch JOINT (EAB1E) Meter cluster J/C(CAN-H) J/C(CAN-L) Alternator Alternator connector (harness side) 105 130 130 401 905 905 [13] 130 [16] SAM connector (harness side) Meter cluster connector (harness side) HH18C Battery <*> Instrument panel Cab * : Option J/C(CAN-H) J/C(CAN-L) 905 905 B40 U02 R07 A18 #002 J14 J20 J20 C01 J29 J29 ---===WSE_1506_00001_0124.djvu===--- 54-01-28 54-L10040GND-1 [1]-[2] Destination Remarks JOINT (EAB2) Frame earth ([12]) Cab earth [1] [2] <Left-hand drive vehicle> [1] [2] <Right-hand drive vehicle> Location [1] [2] Circuit No. EAB2 EAB3 Wire diameter - wire colour 1.25-B 1.25-B EARTH 130 ---===WSE_1506_00001_0125.djvu===--- 54-01 54-01-29 54-L10040GND-2 [11] - [16] [16] * [16] * [16] <Vehicle with battery equaliser> (View a) (View a) <Vehicle without battery equaliser> [12] [13] [14] [15] a * : The installation position is different depending on the specification. [11] Front Front Front or Front Chassis earth ---===WSE_1506_00001_0126.djvu===--- 54-01-30 54-L10040GND-3 Destination Remarks Frame earth ([12]) Horn Condenser fan motor Rear air-conditioner Cab earth ([2]) JOINT (EAR1) JOINT (EAC1) Fog lamp Horn earth Urea tank ABS Vehicle with battery equaliser : 24V Vehicle without battery equaliser : 12V SAM Hydraulic unit DUONIC ECU NOx sensor 1, 2 Fuel filter Fan clutch coupling Engine ECU Starter Battery ABS : Anti-lock brake system ECU : Electronic control unit ESP:Electronic Stability Program SAM : Signal detect and actuation modules BlueTec exhaust gas aftertreatment R BlueTec exhaust gas aftertreatment R Wire diameter - wire colour 1.25-B 1.25-B 1.25-B 1.25-B 0.85-B B 1.25-B 2-B 2-B 8-B 3-B 3-B 1.25-B 1.25-B 2.5-B B 2.5-B 2.5-B 30-BY 1.25-B 60-BY Circuit No. HNE1 CFE3 CFE1 EAB3 EAC1 FLE1L HNE1 HSE1 ABE1 ABE2 AME1 HSE2 EAB1 EDE2 EDE3 NXE1 EAR1 FCE1 EDE1 AME2 BTE3 BTE2 FHE1 FPE1 BTE1 Location [12] [11] [13] [14] [15] [16] EARTH 130 ---===WSE_1506_00001_0127.djvu===--- 54-01 54-01-31 130-C10040ALL Entire earth EAB1 8-B ☆ EAB2 1.25-B ☆ FLE1L B ☆ EAC1 1.25-B ☆ EAB3 1.25-B CFE3 FCE1 1.25-B 1.25-B HNE1 1.25-B HSE1 2-B ☆ ☆ ☆ HSE2 2-B EDE3 2.5-B EDE2 2.5-B NXE1 B NXE1 *2 B *3 0.75-B *1 BTE1 60-BY EDE1 2.5-B AME2 1.25-B AME1 873 1.25-B ABE2 3-B ABE1 3-B EAR1 1.25-B 30-BY or BTE2 30-BY BTE3 -+ ☆ ☆ FHE1 1.25-B FPE1 0.85-B FHE1 1.25-B FPE1X 0.75-B FHE1S FHE1S 1.25-B 1.25-B 10 3 9 1 CFE1 1.25-B NXE1 0.75-B 0.75-B *1 1 ☆ <*3> <*2> 105 To SAM(GND) 315 To fog lamp and daytime running lamp, LH To JOINT(EAC1) 616 880 Horn To JOINT(EAB2) ・This diagram indicates earthing points. ・See the following pages for branching of earthing (wiring for ☆). (in circuit No. order) [1] [12] [14] [15] [2] 880 620 790 880 880 To fan clutch magnet To rear condenser fan motor <rear air-conditioner> To hydraulic unit To JOINT(HSE1) [11] [13] ECU: Electronic control unit ABS: Anti-lock brake system To JOINT(EAR1) To engine ECU To NOx sensor 1 210 To starter To DUONIC ECU Battery [16] To fuel filter 880 To fuel pump Fuel Chassis ATS Rear chassis Chassis 620 To condenser fan motor <FE> ★ ATS Chassis <FG> ★ *1:With BlueTec exhaust gas aftertreatment *2:Wheelbase type C *3:Except *2 R W16 W19 W19 ---===WSE_1506_00001_0128.djvu===--- 54-01-32 130-C10040EAB1-1 Circuit No. EAB1 earth (1/8) RL01 0.3-WB RL01 0.3-WB RR01 0.3-WB 17B-15 KI01G LB WM01G BL 17B-6 17B-8 BWE1 2-B 3B-4 2B-10 PWE1A 2-B PWE1A 2-B SEE1A B MHE1A 0.85-B PWE1D 2-B DLE1 B SEE1D B 2B-6 16B-7 HLE1LL 1.25-B HLE1LR 1.25-B 14B-3 1B-2 11C-3 8C-1 FE01G BL 2B-12 XTE1 B XTE2 B EAB1 8-B 13 12 1 PWE1D 2-B 1 5 1B HH18B HQ8C HH18A HN14B HN14A HQ2A HQ10C 2B 3B 8C 11C 2 1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 16B 17B HQ8A 5 1 6 2 7 3 8 4 14B MHE1D 0.75-B 105 SAM 345 To cab lamp 345 To rear cab lamp 614 To key interlock solenoid To windscreen washer motor To power window switch, As 620 873 To heater control panel or To power MOS-FET (transistor) 622 To power window switch, Dr 622 To step lamp, As 345 To mirror heater, As 629 To door lock actuator, Dr 622 To step lamp, Dr 345 To head lamp, LH Diagnosis connector 310 To head lamp, RH 310 To fuel level sensor 420 [13] SAM connector (harness side) Door, Dr Cab Roof Cab Door, As Cab To mirror heater, Dr 629 Dr: Driver's seat side As: Assistant driver's seat side J21 J10 J19 J07 B40 EARTH 130 ---===WSE_1506_00001_0129.djvu===--- 54-01 54-01-33 130-C10040EAB1-2 Circuit No. EAB1 earth (2/8) <JOINT(EAB1E)> 1B-3 8C-1 EAB1E 0.85-B CME1 B AGE1 B CHE1E B DCE1 B BME2 B ISE1 B IME1 B IME2 B BME3 B BME1 B ABE5 0.3-B ABE6 0.3-B CME1 B AME4 0.3-B LDE1 0.3-B KLE1 B ILEITG B TGE1 B EAB1 8-B 17 1B HH18B HQ2A 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 105 SAM JOINT (EAB1E) 401 To ECO mode switch To ESP sensor To steering wheel angle sensor To airbag ECU To shift lever unit To DC/DC converter 275 873 To brake control valve relay 1 275 To ISS ECU 275 To immobiliser ECU 210 To brake control valve relay 2 275 790 631 To keyless entry ECU To meter cluster 654 To tachograph 873 To lane recognition camera 959 415 [13] SAM connector (harness side) Instrument panel Cab ECU: Electronic control unit ISS: Idling stop and start system ESP: Electronic stability program J14 B40 ---===WSE_1506_00001_0130.djvu===--- 54-01-34 130-C10040EAB1-3 Circuit No. EAB1 earth (3/8) <J/C(EAB1LG)> HH28B HQ2A 8C 2 1 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 18B 18B-23 8C-1 EAB1LG B CSE1LG B CHE1LG 3 2 1 B EAB1 8-B SAM connector (harness side) 105 905 SAM J/C (EAB1LG) 310 873 315 320 330 To shift lever unit To combination switch [13] B40 J01 EARTH 130 ---===WSE_1506_00001_0131.djvu===--- MEMO 54-01-35 54-01 ---===WSE_1506_00001_0132.djvu===--- 54-01-36 130-C10040EAB1-4 Circuit No. EAB1 earth (4/8) <JOINT(EAB1PL), JOINT(EAI1)> 1B-18 8C-1 EAB1PL 0.85-B RLE1 0.3-B CFE2 0.3-B ILE1DF 0.3-B MKE1L 0.3-B MLE1L 0.3-B FGE5 B ILE1MH 0.3-B CHE2 0.3-B ILE1IS 0.3-B MKE1R 0.3-B MKE1L 0.3-B BLE2 0.3-B RFE3 0.3-B CHE1 EDE4 B B TRE1FL B CLE1L B ILE1ML 0.3-B MLE1 0.3-B EAB1 8-B EAI1 TLE2 0.3-B TLE2L 0.3-B 8 TLE2R 0.3-B 6 1B HH18B HQ2A 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 EAI1 0.85-B EAI1 0.85-B 16 105 SAM JOINT (EAB1PL) To cab and spot lamp 345 To condenser fan relay <RHD> <RHD> To head lamp leveling switch <LHD> 620 873 To DPF cleaning switch <RHD> To end-outline marker lamp, LH To end-outline marker lamp, RH 349 To headlamp leveling actuator, LH 312 To T/F ECU <FG> 810 To mirror heater switch <RHD> 629 To shift lever unit relay <RHD> To ISS cut switch <RHD> 275 To main relay 2 <RHD> 880 To front and side turn signal lamp, LH 330 To headlamp, LH (position) 320 880 873 To trailer tail lamp relay, LH 320 To trailer tail lamp relay, RH 349 320 To trailer back lamp relay 340 To rear fog lamp relay 315 312 [13] SAM connector (harness side) Trailer lamp Cab RHD: Right-hand drive vehicle LHD: Left-hand drive vehicle ESP: Electronic stability program ECU: Electronic control unit ISS: Idling stop and start system DPF: Diesel particulate filter PTO: Power take-off ASR: Anti spin regulator T/F: Transfer Instrument panel Cab To shift lever unit <RHD> B40 J07 J04a J14 EARTH 130 ---===WSE_1506_00001_0133.djvu===--- 54-01 54-01-37 130-C10040EAB1-5 Circuit No. EAB1 earth (5/8) <JOINT(EAB1PL), JOINT(EAI1)> HCE1 0.3-B ILE1F2 0.3-B ILE1AM 0.3-B AAE1 B HZE1 B ILE1AB 0.3-B EAI1 0.85-B ILE1HZ B RFE2 0.3-B ILE1RF 0.3-B FLE2 0.3-B ILE1FL 0.3-B PTE3 0.3-B ILE1PT 0.3-B ILE1F1 0.3-B FGE4 B CCE1 B ILE1CC B EAI1 JOINT(EAI1) To heater control panel 620 To T/F HIGH/LOW changeover switch <FG> 810 873 620 790 To ECO mode switch To air-conditioner ECU and control panel To hazard switch 330 To rear fog lamp switch 315 To fog lamp switch 315 To gearbox PTO switch 850 To front drive switch <FG> 810 To cruse control main switch 880 To ESP/ASR cutoff switch <RHD> ---===WSE_1506_00001_0134.djvu===--- 54-01-38 130-C10040EAB1-6 Circuit No. EAB1 earth (6/8) <JOINT(EAB1PR), JOINT(EAI1)> 1B-9 8C-1 EAB1PR 0.85-B CFE2 0.3-B ILE1DF 0.3-B MLE1R 0.3-B ILE1MH 0.3-B ILE1LD 0.3-B CHE2 0.3-B ILE1IS 0.3-B TLE2R 0.3-B BLE2 0.3-B RFE3 0.3-B CHE1 B TRE1FR EDE4 B B CLE1R B ILE1ML 0.3-B MLE1 0.3-B EAB1 8-B EAI1 TLE2 0.3-B TLE2L 0.3-B 6 1B HH18B HQ2A 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 FGE5 B EAI1 0.85-B EAI1 0.85-B 16 105 SAM JOINT (EAB1PR) To condenser fan relay <LHD> <LHD> To head lamp leveling switch <RHD> 620 To DPF cleaning switch <LHD> To headlamp leveling actuator, RH 312 To mirror heater switch <LHD> 629 To LDWS cutoff switch 959 873 To shift lever unit relay <LHD> To ISS cut switch <LHD> 275 To shift lever unit <LHD> To main relay 2 <LHD> To front and side turn signal lamp, RH 880 330 To headlamp, RH (position) 320 880 873 To trailer tail lamp relay, LH 320 To trailer tail lamp relay, RH 320 To trailer back lamp relay 340 To rear fog lamp relay 315 312 [13] SAM connector (harness side) Trailer lamp Cab RHD: Right-hand drive vehicle LHD: Left-hand drive vehicle ESP: Electronic stability program ECU: Electronic control unit ISS: Idling stop and start system DPF: Diesel particulate filter PTO: Power take-off ASR: Anti spin regulator T/F: Transfer LDWS: Lane departure warning system To T/F ECU <FG> 810 Instrument panel Cab J04a B40 J14 EARTH 130 ---===WSE_1506_00001_0135.djvu===--- 54-01 54-01-39 130-C10040EAB1-7 Circuit No. EAB1 earth (7/8) <JOINT(EAB1PR), JOINT(EAI1)> HCE1 0.3-B ILE1AM 0.3-B AAE1 B HZE1 B ILE1AB 0.3-B 0.85-B ILE1HZ B CCE1 B ILE1CC B RFE2 0.3-B ILE1RF 0.3-B FLE2 0.3-B ILE1FL 0.3-B PTE3 0.3-B ILE1PT 0.3-B EAI1 EAI1 ILE1F2 0.3-B ILE1F1 0.3-B FGE4 B JOINT (EAI1) To heater control panel 620 620 873 To ECO mode switch To air-conditioner ECU and control panel To hazard switch 330 790 To rear fog lamp switch 315 To fog lamp switch 315 To gearbox PTO switch 850 To ESP/ASR cutoff switch To cruse control main switch 880 <LHD> To T/F HIGH/LOW changeover switch <FG> 810 To front drive switch <FG> 810 ---===WSE_1506_00001_0136.djvu===--- 54-01-40 130-C10040EAB1-8 Circuit No. EAB1 earth (8/8) <JOINT(EAB1S)> 2B-2 8C-1 EAB1S B BFE1 0.3-B LDE2 0.3-B TTE1 0.3-B CUE1 0.3-B MHE2 0.3-B DFE1 0.3-B BSE1NO 0.3-B BSE1NC 0.3-B EAB1 8-B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 105 SAM JOINT (EAB1S) To brake fluid level switch To stop lamp switch 515 To LDWS cutoff switch 959 To cab tilt lock switch 550 To clutch switch <M/G> 850 To DPF cleaning switch 275 629 To mirror heater switch 325 880 873 880 [13] SAM connector (harness side) M/G: Manual gearbox DPF: Diesel particulate filter LDWS: Lane departure warning system B40 EARTH 130 ---===WSE_1506_00001_0137.djvu===--- 54-01 54-01-41 130-C10040EAB2 Circuit No. EAB2 earth CIE1 0.85-B WIE1 0.85-B EAB2 1.25-B RAE1 0.85-B RAE1 0.85-B 20 JOINT (EAB2) To cigarette lighter To wiper motor 614 610 To radio 612 [1] Instrument panel Cab J13 ---===WSE_1506_00001_0138.djvu===--- 54-01-42 130-C10040EAC1 Circuit No. EAC1 earth STE1X B STE1Y STE1Y B GLE1 B AME3 B TQE1 B OPE2 0.85-B CDE1 1.25-B CDE1 1.25-B PTE1 B VPE1 B ADE3 0.3-B ADE2 0.3-B ADE1 0.3-B ILE1AD 0.3-B CDE3 CDE2 CDE1 1.25-B 1.25-B 1.25-B RBE1H 1.25-B RBE1M 0.85-B RBE1L B CFE4 0.3-B REE1 B EAC1 1.25-B 8 RBE1 1.25-B RBE1 1.25-B 1 JOINT (EAC1) JOINT (RBE1) 210 To starter relay To glow ECU To parking gear switch To torque limit switch <M/G> 115 To optional connector 315 325 320 330 340 To coupling device 850 To PTO control switch 850 To gearbox PTO 3-way M/V 620 To rear heater temperature motor 620 To control panel (rear air-conditioner switch) 620 To rear blower motor relay (high) 620 To rear blower motor relay (middle) 620 To rear blower resistor 620 To rear condenser fan relay 340 880 880 873 To backup lamp switch <M/G> 210 To diode (for starter relay) [12] Coupling device Chassis Rear air-conditioner Chassis ECU: Electronic control unit PTO: Power take-off M/V: Magnetic valve M/G: Manual gearbox J31 W03a EARTH 130 ---===WSE_1506_00001_0139.djvu===--- 54-01 54-01-43 130-C10040EAR1 Circuit No. EAR1 earth TLE1R 0.85-B TLE1L 0.85-B LLE1L B LLE1R B BZE1 B FGE1 B FGE1X B FGE1Y B FGE7 B FGE3 B FGE2X B FGE2Y B FG6HX B FG6HY B 3 6 12 AB16A FGE3 B EAR1 1.25-B <FG> <FG> <FG> <FG> JOINT (EAR1) 320 325 330 340 To rear combination lamp, RH 320 315 315 325 330 340 To rear combination lamp, LH 320 To license plate lamp, RH 320 To back buzzer 340 To license plate lamp, LH To two-wheel drive 3-way M/V 810 To diode 810 To four-wheel drive 3-way M/V 810 810 To high 3-way M/V To diode 810 To diode 810 T/F control Chassis Transfer Chassis Rear chassis Chassis 810 810 [15] T/F: Transfer M/V: Magnetic valve To T/F low switch To T/F four-wheel drive switch W29 W21 W03 ---===WSE_1506_00001_0140.djvu===--- 54-01-44 130-C10040FLE1 Circuit No. FLE1 earth FLE1L B B FLE1L FLE1R B [12] To fog lamp and daytime running lamp, LH 313 To fog lamp and daytime running lamp, RH 313 315 315 EARTH 130 ---===WSE_1506_00001_0141.djvu===--- 54-01 54-01-45 130-C10040HSE1 Circuit No. HSE1, HSE2 earth HSE1TH 2-B HSE1IH 2-B HSE1PH 1.5-B PRE1 B HSE2 2-B 3 HSE1 2-B HSE2 2-B HSE1 2-B 4 JOINT (HSE1) To urea line heater To urea supply module (motor and heater) To urea temperature sensor and urea tank heater [12] Chassis Urea tank 880 880 880 W18 ---===WSE_1506_00001_0142.djvu===--- 54-01-46 130-C10040FPE1 Circuit No. FPE1 earth WSE1 To Fuel filter To Fuel pump 0.3-B 3 FPE1X 0.75-B FPE1 0.85-B [12] Chassis Fuel 880 W16 EARTH 130 ---===WSE_1506_00001_0143.djvu===--- 54-01 54-01-47 130-C10040NXE1 Circuit No. NXE1 earth *1 B *2 0.75-B NHE1 NXE2 B NXE2S B 1 NXE1 *1 B *2 0.75-B NXE1 B NHE1 0.75-B NXE2 0.75-B NXE2S B 1 NXE1 0.75-B NXE1 0.75-B <*2> <*1> *1:Wheelbase type C *2:Except *1 [14] Rear chassis Chassis To NH3 sensor ECU To NOx senor 1 To NOx senor 2 To NH3 sensor ECU To NOx senor 1 To NOx senor 2 ATS 880 <With BlueTec exhaust gas aftertreatment> <FE> [14] Chassis ATS 880 <FG> R ECU: Electronic control unit W19 W19 ---===WSE_1506_00001_0144.djvu===--- 54-02-1 54-02 ENGINE STARTING, STOPPING AND PREHEATING CIRCUIT ---===WSE_1506_00001_0145.djvu===--- 54-02-2 210-C10040M-1 - + HF06 HF01 BT01 60-BR BA12A 20-W HF01 15-R BTE1 60-BY 30-BY BTE2 HF06A 3-RW ST01Y RW HF06B 3-R STE1X B STE1Y B EAC1 1.25-B 1 2 1 1 BBB5B 3-R ST02 FM1ST ST03 ST01 ST02 RB LR RW Br ST03 LR ST01X ST02 Br ST03 Br RW LR 53 STRTH 27 STRTL 24 CAN1 (H) 25 4 8 CAN1 (L) FM1ST F01 10 9 11 4 1 5 3 RB HF01 15-R 2 ST B M M BS 1B-5 10C <Manual gearbox> (1/3) 1B HH18B HH18A HH28A HH28B HN14A 3B 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 15B 18B 17B 6 5 94 72 50 28 73 51 29 7 4 3 2 1 Engine ECU side connector HJ94A CN1LCM CN1HCM 17B-1 17B-11 CHASSIS CAN-H CHASSIS CAN-L Y L F13 3 6 4 5 M B A S STARTER SW (MAIN) STARTER SW (ACC) STARTER SW (START) KE01ST FB13KE KE01M KE01A R G Y WG 3B-3 18B-3 15B-15 18B-17 30-BY BTE3 *1 *2 *1:Vehicle with battery equaliser *2:Vehicle without battery equaliser 1 2 1 3 3 1 2 2 1 2 CN2HIS Y CN2LIS L CN3H Y CN3L L IS01H Y IS01L L 7 CAN(H) CAN(L) 8 2 5 1 4 12345678 9101112 13 141516 Starter Battery Starter relay JOINT (EAC1) Starter Chassis Starter relay (for drive) SAM Engine ECU Cab Chassis Cab Chassis 110 880 130 SAM connector (harness side) 130 130 [12] [16] 105 Starter switch High-current fuse box ECU: Electronic control unit ISS: Idling stop and start system Refer to (3/3) for other specifications. J/C(CAN-H) J/C(CAN-L) 905 905 J/C(CAN-H) J/C(CAN-L) 905 905 ISS ECU 275 J/C(CAN) 905 <Without BlueTec exhaust gas aftertreatment> R HH16A ISS ECU connector (harness side) #187 U06 B40 W26 U05 U01 U02 W08 W08 #201 B19 #002 A18 #930 R15 J09 J09 J20 J20 B07 W01 ENGINE STARTING CIRCUIT 210 ---===WSE_1506_00001_0146.djvu===--- 54-02 54-02-3 210-C10040M-2 <Manual gearbox> (2/3) A part of immobiliser circuit is omitted. BATT 1 ECU GND CABIN CAN-H CABIN CAN-L BATT 2 GND 1 GND 2 CAN-H CAN-L F13 (+) (-) Starter switch Immobiliser antenna Immobiliser ECU DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L Diagnosis connector CHASSIS CAN-H CHASSIS CAN-L CAN-H CAN-L Meter cluster SAM 105 ECU: Electronic control unit Engine ECU C01 U01 #771 P06 B05 B40 J21 ---===WSE_1506_00001_0147.djvu===--- 54-02-4 210-C10040M-3 CN6HNX Y CN6LNX L Y CN8HNH CN8LNH L 12 CN5HNX Y CN5LNX L 905 CN6LNX L CN6HNX Y CN5HNX CN5LNX Y L 2 3 21 54 21 5 Y L CN4HAB 905 CN4LAB 4 11 12 45 12 45 CN9HED Y CN9LED L CN9HED CN9LED L Y 905 905 <FG> 905 < FE with BlueTec exhaust gas aftertreatment > R <Manual gearbox> (3/3) CN7HNX Y CN7LNX L CN7HNX CN7LNX Y L 2 3 10 9 21 54 12 45 905 CN8HNH CN8LNH Y L CN9HED Y CN9LED L CN9HED CN5HNX Y L Y CN5LNX L 21 54 CN4HAB CN4LAB 905 CN5HNX Y CN5LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y <*2> <*1> *1:Wheelbase type C *2:Except *1 J/C(CAN) J/C(CAN) J/C (CAN) ATS Chassis J/C (CAN) CAN : Controller area network J/C(CAN) J/C (CAN) J/C (CAN) J/C (CAN) ATS Rear chassis Chassis W19 W01 W23 W24 W22 W19 W01 W23 W24 W22 ENGINE STARTING CIRCUIT 210 ---===WSE_1506_00001_0148.djvu===--- MEMO 54-02-5 54-02 ---===WSE_1506_00001_0149.djvu===--- 54-02-6 210-C10040D-1 - + HF06 HF01 BT01 60-BR BA12A 20-W HF01 15-R BTE1 60-BY 30-BY HF06A 3-RW ST01Y RW HF06B 3-R STE1X B STE1Y B EAC1 1.25-B 1 2 1 1 HF06B 3-R ST02 FM1ST ST03 ST01 ST02 RB LR RW Br ST03 LR ST01X ST02 Br ST03 Br RW LR 53 STRTL CAN1 (L) CAN1 (H) STRTH 27 24 25 FM1ST F01 10 9 11 4 1 5 3 RB HF01 15-R 2 ST B M M BS 1B-5 10C <DUONIC > (1/3) 1B HH18B HH18A HH28A HH28B HN14A 3B 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 15B 18B 17B 6 5 94 72 50 28 73 51 29 7 4 3 2 1 Engine ECU side connector HJ94A CN1LCM CN1HCM 17B-1 17B-11 CHASSIS CAN-H CHASSIS CAN-L Y L F13 3 6 4 5 M B A S STARTER SW (MAIN) STARTER SW (ACC) STARTER SW (START) KE01ST FB13KE KE01M KE01A R G Y WG 3B-3 18B-3 15B-15 CLU LIN SIG CH01LS YR 18B-24 18B-17 30-BY *1 *2 *1:Vehicle with battery equaliser *2:Vehicle without battery equaliser BTE2 BTE3 Y CN6HED L CN6LED Y CN5HAM L CN5LAM CN4HAB CN4LAB Y L 4 8 1 2 4 5 1 2 5 4 3 6 Y AM01H L AM01L 880 1 2 1 3 3 1 2 2 1 2 CN2HIS Y CN2LIS L CN3H Y CN3L L IS01H Y IS01L L 12345678 9 101112 13 141516 7 CAN(H) CAN(L) 8 < Without BlueTec exhaust gas aftertreatment > R Refer to (3/3) for other specifications. Starter Battery Starter relay JOINT (EAC1) High-current fuse box DUONIC Chassis Starter relay (for drive) SAM Engine ECU Cab Chassis 110 130 SAM connector (harness side) 130 130 [12] [16] 105 Starter switch 873 To shift lever unit R *3:Without BlueTec exhaust gas aftertreatment *4:With BlueTec exhaust gas aftertreatment R R Cab Chassis J/C(CAN) J/C (CAN) To DUONIC ECU J/C(CAN-H) J/C(CAN-L) 905 905 J/C(CAN-H) J/C(CAN-L) 905 905 905 873 905 HH16A ISS ECU 275 ISS ECU connector (harness side) ECU: Electronic control unit ISS: Idling start and stop system #187 U06 #930 R15 B40 W27 U05 U01 U02 W08 #201 B19 #002 A18 W08 W01 W02 J09 J09 J20 J20 B07 ENGINE STARTING CIRCUIT 210 ---===WSE_1506_00001_0150.djvu===--- 54-02 54-02-7 210-C10040D-2 <DUONIC > (2/3) A part of immobiliser circuit is omitted. BATT 1 ECU GND CABIN CAN-H CABIN CAN-L BATT 2 GND 1 GND 2 CAN-H CAN-L F13 (+) (-) DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L CHASSIS CAN-H CHASSIS CAN-L CAN-H CAN-L SAM 105 Starter switch Immobiliser antenna Immobiliser ECU Diagnosis connector Meter cluster ECU: Electronic control unit Engine ECU R C01 U01 #771 P06 B05 B40 J21 ---===WSE_1506_00001_0151.djvu===--- 54-02-8 210-C10040D-3 <DUONIC > (3/3) R 905 905 < DUONIC with BlueTec exhaust gas aftertreatment > R Y CN8HNH CN7HNX CN7LNX Y L CN7HNX CN7LNX Y L CN8LNH L 2 3 10 9 21 54 2 1 5 4 CN9HED Y CN9LED L CN9HED CN5HAM Y L L CN5LAM Y 21 54 CN4LAB CN4HAB 905 AM01H Y AM01L L CN6HNX Y CN6LNX L 3 6 21 54 873 905 CN6HNX Y CN6LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y <*2> <*1> *1:Wheelbase type C *2:Except *1 CAN : Controller area network ECU : Electronic control unit J/C(CAN) J/C (CAN) To DUONIC ECU J/C (CAN) J/C (CAN) J/C (CAN) ATS Rear chassis Chassis W19 W01 W02 W23 W24 W22 ENGINE STARTING CIRCUIT 210 ---===WSE_1506_00001_0152.djvu===--- MEMO 54-02-9 54-02 ---===WSE_1506_00001_0153.djvu===--- 54-02-10 275-C10040-1 4 3 1 2 #042 A21 2-RB FB10IS V DC01ST WL DC01DI FM20IS PG *4 3 6 7 V OUT ST SIG IN DIAG OUT *3 *3 *3 FB10DC 2-R FM20DC PG IS01 PG FM20IS PG *3 *3 *4 *3 *3 *4 2-R FB10DC PG FM20DC PG FM20IS B DCE1 0.3-O IL01IS EAB1PL 0.85-B *2 IL01 0.85-O ILE1IS 0.3-B 1B-18 EAB1PR 0.85-B *1 1B-9 14B-8 11 1 3 13 12 XT01H R XT01L V PB01 0.3-BW VC01 WB DS01FD 0.3-WR DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L PARKING BRAKE SW VAC SW DRIVER FRONT DOOR SW FB32AC LR 5 2 1 7 3 9 1 10 IGN SW SIG VIN GND BR FB13IS B ISE1 RW IS02 0.3-WR IS03 FB13TG BR HL01LR 1.25-R HF03 8-Y EAB1E 0.85-B PG IS01 1 9 2 15 16 13 10 BATT MAIN ST ON/OFF SIG DC/DC DIAG GND ISS CUT SW ISS CUT IND 1 2 3 4 5 6 7 8 9 10 1 2345 6 7 891 0 RW IS02 0.3-WR IS03 0.3-B ILE1IS 3B-5 FL01R WR 12C-6 FL01L WL 13C-2 16B-8 8C-2 HL01LL 1.25-RL HF01 15-R 14B-2 2B-11 1B-17 1B-3 CS01LS YG COMB. SW LIN SIG 18B-21 HZ01 VW HAZARD SW 15B-4 7C-12 FB32CF RG 7C-11 18B-16 FB9XT PL 2B-7 XTE1 B 2B-12 XTE2 B EAB1 8-B 1B-2 18B-1 18B-6 15B-1 2B-2 8C-1 TT01 0.3-LW CAB TILT LOCK SW 18B-10 15B-19 18B-4 15B-18 DS01FA 0.3-LR ASSIST 15B-3 FB11BW 2-RW 2B-14 (1/5) F13 F20 F10 F32 F09 F11 12345678 91 01 11 21 31 41 51 6 10C EAB1S B BS01NO 0.3-Lg BS01NC 0.3-Gr BRAKE SW NO BRAKE SW NC BSE1NO Brake pedal pressed : 1-2:ON 3-4 : OFF 0.3-B BSE1NC 0.3-B 1B HH18B HQ10A HQ8C HH28A HH28B HN14B HN14A HN14C HQ2A 2B 3B 7C 8C 2 1 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 13C 15B 18B 16B 1 2 3 4 5 6 7 8 9 10 HQ10B 12C 1 3 4 5 6 7 8 9 10 2 HQ8A 5 1 6 2 7 3 8 4 14B JOINT (EAB1PR) *1 (EAB1PL) *2 130 *1 : Left-hand drive vehicle *2 : Right-hand drive vehicle *3 : DUONIC *4:M/G *3 Diagnosis connector To front door switch (Dr) To front door switch (As) To Vacuum switch To blower motor (to magnetic clutch) To dual pressure switch To condenser fan relay ISS cut switch SAM DC/DC converter Harness side connector HH10B HH10A HH16A ISS cutoff switch connector (harness side) JOINT (EAB1E) To parking brake switch SAM connector (harness side) ISS ECU To high-current fuse (HF03) 510 515 To cab tilt lock switch 550 620 To head lamp, RH (dipped) To head lamp, LH (dipped) To combination switch 330 310 315 345 130 130 To hazard switch 620 620 105 110 To high-current fuse (HF01) To fog lamp, RH To fog lamp, LH 110 ISS ECU connector (harness side) [13] JOINT (EAB1S) Stop lamp switch ECU : Electronic control unit ISS : Idling stop and start system M/G : Manual gearbox Dr : Driver's seat side As : Assistant driver's seat side R #354 B03 #089 A11 B40 J21 B07 ISS (IDLING STOP AND START SYSTEM) CIRCUIT 275 ---===WSE_1506_00001_0154.djvu===--- 54-02 54-02-11 275-C10040-2 1 HF06B *3 <*3> <*4> BBB5B *4 3-R *3:DUONIC *4:M/G BRAKE CONTROL VALVE + 6 BRAKE CONTROL VALVE FR 4 BRAKE CONTROL VALVE RR 5 BM01V YR BM01GF BY 1 2 3 BM01GR BR YR BM01VR BR BM01GR RB FM1ST LR ST03 RW ST01 Br ST02 LR ST03 Br ST02 53 STRLYH 27 STRLYL RB FM1ST 24 25 CAN-H CAN-L 9 18 IS01H Y HH16A HH18C IS01L L CM01H Y CM01L L Y CN1HCM L CN1LCM 7 6 3 2 1 3 2 1 3 2 1 1 3 2 CHASSIS CAN-H CHASSIS CAN-L CN2HIS Y CN3H CN3L CN2LIS L Y L 7 8 CAN-H CAN-L 123456789 101112131415161718 AB16A 48 10 11 12345678 91 01 11 21 31 41 51 6 17B-1 8C-1 17B-11 1B-5 13 10 CME1 FM22CM CME1 EAB1E FM22CM B YG B 0.85-B YG 9 17 1B-11 1B-3 2B-9 FB9CM 10 2 OL FB9CM OL CPU 2 1 BM01VF BM01GF YR BY 2 1 (2/5) SPEAKER - + HF06 BT01 60-BR BTE1 60-BY BTE3 30-BY HF06A 3-RW ST01Y RW HF06B 3-R STE1X B STE1Y B EAC1 1.25-B 1 2 1 ST01X RW ST01 RW 9 ST B M M BS 6 5 94 72 50 28 73 51 29 7 4 3 2 1 Engine ECU side connector SAM connector (harness side) HJ94A 30-BY *1 *2 *1:Vehicle with battery equaliser *2:Vehicle without battery equaliser BTE2 5V LED DRIVER F09 F22 F01 1B HH18B HH18A HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17B 4 1 5 3 2 BM01VF CM01LA CM01HA Y L 1 1 2 2 CM01LB CM01HB Y L 12 Y CN5HED L CN5LED 5 4 CN4HAB CN4LAB Y L DUONIC STARTER Chassis ESP: Electronic stability program ECU: Electronic control unit ISS: Idling stop and start system M/G: Manual gearbox Refer to (3/5, 4/5) for other specifications. Refer to (5/5) for other specification. Cab (Front) Brake control valve (Rear) Brake control valve Starter relay (for drive) Cab Chassis Engine ECU Meter cluster Harness side connector J/C (CAN-H) J/C (CAN-H) J/C (CAN-L) J/C (CAN-L) Cab Instrument panel ISS ECU ISS ECU connector (harness side) 105 130 905 130 130 130 110 905 880 JOINT (EAB1E) 401 Starter SAM Battery Starter relay JOINT (EAC1) High-current fuse box Cab Chasis [12] [16] 130 [13] 905 905 905 <M/G without BlueTec exhaust gas aftertreatment> <DUONIC without ESP > R R R J/C (CAN-H) J/C (CAN-L) J/C (CAN) 905 #930 R15 W26 <*4> W27 <*3> #587 X06 W12 X07 B40 U01 W08 J20 J14 J09 J20 J09 B07 #201 B19 #187 U06 U05 U02 C01 W08 J29 J29 W01 ---===WSE_1506_00001_0155.djvu===--- 54-02-12 275-C10040-3 CN6HNX Y CN6LNX L Y CN8HNH CN8LNH L 12 CN5LNX L CN5HNX Y 905 CN6HNX Y CN6LNX L CN5LNX CN5HNX L Y 3 2 54 21 54 2 L Y CN4LAB 905 CN4HAB 1 11 12 45 12 45 CN9HED Y CN9LED L CN9HED CN9LED L Y 905 905 <FG> 905 < FE, M/G with BlueTec exhaust gas aftertreatment > R (3/5) CN7HNX Y CN7LNX L CN7HNX CN7LNX Y L 2 3 10 9 21 54 12 45 905 CN8HNH CN8LNH Y L CN9HED Y CN9LED L CN9HED Y L 12 45 CN4HAB CN4LAB 905 CN5HNX Y CN5LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y <*2> <*1> *1:Wheelbase type C *2:Except *1 J/C(CAN) J/C(CAN) J/C (CAN) ATS Chassis J/C (CAN) CAN : Controller area network J/C(CAN) J/C (CAN) J/C (CAN) J/C (CAN) Rear chassis ATS Chassis W19 W01 W23 W24 W22 W19 W01 W23 W24 W22 ISS (IDLING STOP AND START SYSTEM) CIRCUIT 275 ---===WSE_1506_00001_0156.djvu===--- 54-02 54-02-13 ---===WSE_1506_00001_0157.djvu===--- 54-02-14 ISS (IDLING STOP AND START SYSTEM) CIRCUIT 275 ---===WSE_1506_00001_0158.djvu===--- 54-03-1 54-03 LIGHTING CIRCUIT ---===WSE_1506_00001_0159.djvu===--- 54-03-2 HEADLAMP CIRCUIT 310 ---===WSE_1506_00001_0160.djvu===--- 54-03 54-03-3 HEADLAMP LEVELING CIRCUIT 312 ---===WSE_1506_00001_0161.djvu===--- 54-03-4 DAYTIME RUNNING LAMP CIRCUIT 313 ---===WSE_1506_00001_0162.djvu===--- MEMO 54-03-5 54-03 ---===WSE_1506_00001_0163.djvu===--- 54-03-6 FOG LAMP CIRCUIT 315 ---===WSE_1506_00001_0164.djvu===--- 54-03 54-03-7 315-C10040-2 4 1 4 1 6X-5 1B-9 1B-18 2B-5 12C-2 6X-3 F26* F04* F08 FB26CD FB26C CDE1 1.25-B FM4C CDE2 1.25-B CDE3 1.25-B RFE3 0.3-B RF03 RY RY RF03 FB8RF 0.85-WR RF01CD 0.85-RW RF01CD GR FB26C GR FM4CD LR FM4C LR RF01 RY FB8RF 0.85-WR EAB1PL FB8RF TLE2 0.3-B 0.85-B EAB1PR 0.85-B CDE1 1.25-B EAC1 1.25-B FB26C 1.25-GR FM4C 1.25-LR CDE1 1.25-B RF01CD 1.25-RW 10 8 7 9 3 1 1 6 11 12 7 10 13 6 8 1 10C 8C-1 1B HH18B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 HQ10B 12C 1 3 4 5 6 7 8 9 10 2 (2/2) *2 *1 TLE1L 0.85-B EAR1 1.25-B RF01L RY TLE1R 0.85-B RF01R RY RF01L RY RF01 RY EAR1 1.25-B HN6A 6X 6 5 4 3 2 1 *3 TLE2L 0.3-B FB8RF 1 4 5 2 3 SAM connector (harness side) 130 130 JOINT (EAC1) 130 JOINT (EAB1PL) 130 JOINT (EAB1PR) 105 SAM 110 To high-current fuse (HF01) 130 [13] Chassis Coupling device Chassis Trailer lamp Cab Trailer lamp Chassis Rear chassis Rear combination lamp, LH Rear combination lamp, RH [12] Trailer rear fog lamp relay Coupling device 130 JOINT (EAR1) 130 [15] *The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V *1 : Right-hand drive vehicle *2 : Left-hand drive vehicle *3 : With coupling device B40 W03a J04a W03 B21 #201 W30 J05a ---===WSE_1506_00001_0165.djvu===--- 54-03-8 TAIL, POSITION AND LICENSE PLATE LAMPS CIRCUIT 320 ---===WSE_1506_00001_0166.djvu===--- 54-03 54-03-9 320-C10040-2 6X-5 1B-9 1B-18 14B-8 2B-1 5C-14 6X-3 F26* F04* F06 F23 FB26CD FB26C CDE1 1.25-B FM4C CDE2 1.25-B CDE3 1.25-B TLE2R 0.3-B 0.3-O TL02R WR FB23R GR TL01CR GW TL01CL FB23R TL01CR TL01CR GR FB26C GR FM4CD LR FM4C LR FB23R WR IL01 0.85-O EAB1PL TL02 FB6L 0.3-O TLE2 0.3-B 0.85-B EAB1PR 0.85-B CDE1 1.25-B EAC1 1.25-B FB26C 1.25-GR FM4C 1.25-LR CDE1 1.25-B TL01CR 1.25-GR 10 8 2 9 2 6 5 5 2 6 7 10 2 TL01CL TL01CL 1.25-GW 14 6 8 1 10C 8C-1 1B HH18B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 (2/2) 1 4 5 2 3 TLE2L 0.3-B 0.3-O TL02L PL FB6L PL FB6L TL02L FB6L TL01CL TLE2L 1 4 5 2 3 *2 *1 HN6A 6X 6 5 4 3 2 1 *3 HN14D 5C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 HQ8A 5 1 6 2 7 3 8 4 14B SAM connector (harness side) 130 130 JOINT (EAC1) 130 JOINT (EAB1PL) 130 JOINT (EAB1PR) 105 SAM 110 To high- current fuse (HF01) 130 [13] Chassis Coupling device Chassis Trailer lamp Cab Trailer lamp [12] Trailer tail lamp relay, RH Trailer tail lamp relay, LH *The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V Coupling device *1 : Right-hand drive vehicle *2 : Left-hand drive vehicle *3 : With coupling device B40 W03a J04a J05a B22 #201 B23 #201 W30 ---===WSE_1506_00001_0167.djvu===--- 54-03-10 325-C10040 [12] SL01R SL01R GR SL01L 13C-7 SL01L FB26C FM4C FB26CD FM4CD SL01CD SL01CD CDE1 1.25-B GR LR GR LR RG G 12C-1 6X-3 6X-5 12C-8 8C-2 EAB1S B 1.25-B EAR1 EAR1 1.25-B 2B-2 BS01NO 0.3-Lg 18B-4 BRAKE SW NO 8C-1 10C GK7A 4 3 6 12 5 BSE1NO Brake pedal pressed:ON 0.3-B HQ10A HH28B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 13C 18B 1 2 3 4 5 6 7 8 9 10 HQ10B 12C 1 3 4 5 6 7 8 9 10 2 Stop GK7A 3 4 Stop *F26 *F04 SL01CD CDE1 FM4C FB26C SL01CD CDE3 FM4C CDE2 CDE1 FB26C 1.25-RG 1.25-B 1.25-B 1.25-B 1.25-B 1.25-LR 1.25-GR 9 3 10 8 6 1 3 7 8 10 HN6A 6X 6 5 4 3 2 1 1 3 42 AN4B [13] JOINT (EAB1S) Stop lamp switch Coupling device *1 SAM 105 To high-current fuse(HF01) 110 To high-current fuse(HF03) 110 130 JOINT (EAR1) 130 130 [15] 130 SAM connector (harness side) Chassis Rear chassis Chassis Coupling device Rear combination lamp, RH Rear combination lamp, LH JOINT (EAC1) *1 : With coupling device *The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V 130 130 B40 W03 #042 A21 W03a W30 STOP LAMP CIRCUIT 325 ---===WSE_1506_00001_0168.djvu===--- MEMO 54-03-11 54-03 ---===WSE_1506_00001_0169.djvu===--- 54-03-12 TURN SIGNAL AND HAZARD LAMP CIRCUIT 330 ---===WSE_1506_00001_0170.djvu===--- 54-03 54-03-13 330-C10040-2 HQ10A 13C 1 2 3 4 5 6 7 8 9 10 HQ10B 12C 1 3 4 5 6 7 8 9 10 2 (2/2) 6X-5 6X-3 F26* F04* FB26CD FB26C CDE1 1.25-B FM4C CDE2 1.25-B TR01CR CDE3 1.25-B TR01CL GR FB26C GR FM4CD LR FM4C LR 12C-10 TR01CR TR01CR RB 13C-1 TR01CL TR01CL LB CDE1 1.25-B EAC1 1.25-B FB26C 1.25-GR FM4C 1.25-LR TR01CR 1.25-RB TR01CL 1.25-LB CDE1 1.25-LB 10 6 5 8 9 7 11 10 12 6 8 1 10C *1 SAM HN6A 6X 6 5 4 3 2 1 SAM connector (harness side) Chassis Coupling device 130 130 JOINT (EAC1) [12] 110 To high-current fuse (HF01) Coupling device 105 *The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V *1 : With coupling device B40 W03a W30 ---===WSE_1506_00001_0171.djvu===--- 54-03-14 340-C10040M-1 BL01 BO Back Back BZ01 BL01L BO BP 13C-6 BZ01 BP 11C-6 EAR1 1.25-B EAR1 1.25-B KE01M Y 18B-3 STARTER SW(M) REVERSE SW COMB. SW LIN SIG RE01 BW RE01 BW REE1 Gearbox reverse position:ON B EAC1 1.25-B 11C-2 CS01LS YG 18B-21 8C-1 10C GK7A 4 7 GK7A 4 7 7 8 2 1 1 2 <Manual gearbox> (1/2) FM22CM YG 1B-11 FB9CM OL 2B-9 F09 F22 17 10 EAB1E 0.85-B CME1 B CME1 B 91 3 FM22CM YG 10 2 FB9CM OL 9 18 CM01H Y CM01L L 1B-3 6 7 CN1HCM Y 17B-1 CN1LCM L 17B-11 CAN(L) CAN(H) 3 1 3 1 CPU SPEAKER 5V Intermittent circuit Sound unit 123456789 101112131415161718 1B HH18B HQ10A HH18A HH28B HN14B HQ2A HQ10C 2B 8C 11C 2 1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 13C 18B 17B 1 2 3 4 5 6 7 8 9 10 12 L Y Y 2 1 2 1 L [13] SAM 105 To high-current fuse (HF01) 110 JOINT (EAR1) Back buzzer Backup lamp switch 130 To starter switch 210 To combination switch 310 130 [15] 130 [12] 130 130 Rear combination lamp, RH Rear combination lamp, LH Chassis Rear chassis Meter cluster JOINT(EAC1) SAM connector (harness side) J/C(CAN-L) J/C(CAN-H) 130 905 905 401 JOINT(EAB1E) Instrument panel Cab Meter cluster connector (harness side) HH18C J/C(CAN-L) 905 J/C(CAN-H) 905 B40 W03 J29 J29 J14 #614 V06 #054 S01 C01 J20 J20 BACKUP LAMP CIRCUIT 340 ---===WSE_1506_00001_0172.djvu===--- 54-03 54-03-15 340-C10040M-2 6X-5 2B-5 1B-18 1B-9 6X-3 F26* F04* F08 FB26CD FB26C CDE1 1.25-B FM4C CDE2 1.25-B CDE3 1.25-B 0.85-BO BL01CD BL01CD GR FB26C GR FM4CD LR FM4C LR CDE1 1.25-B EAC1 1.25-B FB26C 1.25-GR FM4C 1.25-LR CDE1 1.25-B BL01CD 1.25-BO 10 8 4 9 4 7 10 5 6 8 1 10C 8C-1 1B HH18B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 <Manual gearbox> (2/2) HN6A 6X 6 5 4 3 2 1 15B-28 EAB1PL 0.85-B EAB1PR 0.85-B TLE2 0.3-B BL02 *1 *2 6 4 3 BLE2 0.3-B BL02 0.3-RL BL02 0.3-RL BL02 FB8BL FB27BL 0.85-YL 0.85-WR 0.85-WR FB8RF 0.3-B TLE2L FB27BL BL01CD 1 4 5 2 3 HH28A 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 15B SAM connector (harness side) JOINT (EAC1) SAM 110 To high-current fuse (HF01) [13] Chassis Coupling device Chassis Trailer lamp [12] Coupling device *The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V 130 JOINT (EAB1PL) 130 JOINT (EAB1PR) Cab Trailer back lamp relay Trailer lamp *3 *1 : Right-hand drive vehicle *2 : Left-hand drive vehicle *3 : With coupling device 130 130 130 105 W03a J05a W30 J04a B24 #201 B40 ---===WSE_1506_00001_0173.djvu===--- 54-03-16 340-C10040D-1 BL01 BO BZ01 BL01L BO BP 13C-6 BZ01 BP 11C-6 EAR1 1.25-B KE01M Y 18B-3 STARTER SW(M) CLU LIN SIG COMB. SW LIN SIG CH01LS YR 18B-24 CS01LS YG 18B-21 8C-1 10C 7 8 2 1 <DUONIC > (1/2) FM22CM YG 1B-11 FB9CM OL 2B-9 F09 F22 17 10 EAB1E 0.85-B CME1 B CME1 B 91 3 FM22CM YG 10 2 FB9CM OL 9 18 CM01H Y L CN2LIS CN2HIS Y CM01L L 1B-3 6 7 CN1HCM Y 17B-1 CN1LCM L 17B-11 CAN(L) CAN(H) 3 1 2 3 1 2 CPU SPEAKER Multi- information display 5V 123456789 101112131415161718 1B HH18B HQ10A HH18A HH28B HN14B HQ2A HQ10C 2B 8C 11C 2 1 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 13C 18B 17B 1 2 3 4 5 6 7 8 9 10 Sound unit Intermittent circuit Back Back GK7A 4 7 GK7A 4 7 12 EAR1 1.25-B L YY 2 1 2 1 L R [13] SAM 105 To high-current fuse (HF01) 110 JOINT (EAR1) 130 To starter switch 210 873 To shift lever unit To combination switch 310 130 Chassis Rear chassis Meter cluster To DUONIC circuit J/C(CAN-L) J/C(CAN-H) 130 873 905 905 401 JOINT (EAB1E) SAM connector (harness side) Meter cluster connector (harness side) HH18C Back buzzer Instrument panel Cab Rear combination lamp, RH Rear combination lamp, LH [15] 130 J/C (CAN-L) 905 J/C (CAN-H) 905 B40 W03 J14 C01 J29 J29 J20 J20 #614 V06 BACKUP LAMP CIRCUIT 340 ---===WSE_1506_00001_0174.djvu===--- 54-03 54-03-17 340-C10040D-2 <DUONIC > (2/2) 6X-5 2B-5 1B-18 1B-9 6X-3 F26* F04* F08 FB26CD FB26C CDE1 1.25-B FM4C CDE2 1.25-B CDE3 1.25-B 0.85-BO BL01CD BL01CD GR FB26C GR FM4CD LR FM4C LR CDE1 1.25-B EAC1 1.25-B FB26C 1.25-GR FM4C 1.25-LR CDE1 1.25-B BL01CD 1.25-BO 10 8 4 9 4 7 10 5 6 8 1 10C 8C-1 1B HH18B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 HN6A 6X 6 5 4 3 2 1 15B-28 EAB1PL 0.85-B EAB1PR 0.85-B TLE2 0.3-B BL02 *1 *2 6 4 3 BLE2 0.3-B BL02 0.3-RL BL02 0.3-RL BL02 FB8BL 0.85-WR FB27BL 0.85-YL 0.85-WR FB8RF 0.3-B TLE2L FB27BL BL01CD 1 4 5 2 3 HH28A 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 15B R SAM connector (harness side) JOINT (EAC1) SAM 110 To high-current fuse (HF01) [13] Chassis Coupling device Chassis Trailer lamp [12] Coupling device *The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V 130 JOINT (EAB1PL) 130 JOINT (EAB1PR) Cab Trailer back lamp relay Trailer lamp *3 *1 : Right-hand drive vehicle *2 : Left-hand drive vehicle *3 : With coupling device 130 130 130 105 W03a J05a W30 J04a B24 #201 B40 ---===WSE_1506_00001_0175.djvu===--- 54-03-18 CAB LAMP CIRCUIT 345 ---===WSE_1506_00001_0176.djvu===--- 54-03 54-03-19 ---===WSE_1506_00001_0177.djvu===--- 54-03-20 ILLUMINATION LAMP CIRCUIT 348 ---===WSE_1506_00001_0178.djvu===--- 54-03 54-03-21 END-OUTLINE MARKER LAMP CIRCUIT 349 ---===WSE_1506_00001_0179.djvu===--- 54-04-1 54-04 METER CIRCUIT ---===WSE_1506_00001_0180.djvu===--- 54-04-2 1 HH18C 23456789 101112131415161718 Meter cluster connector (harness side) 401-C10040-1 10 CME1 GND FM22CM STARTER SW(M) FB9CM BATT 13 2 SS01VM SPEED SENSOR(+) 3 SS01GM SPEED SENSOR(GND) 4 SS01SM SPEED SENSOR(SIG) 12 ILE1AA, ILE1HC ILL, OUTPUT 1 EQ01 SPEED OUTPUT FOR ECU EQUALISER 5 FG06SS 7 AM02SS SPEED OUTPUT CAN(L) CAN(H) 16 CM01LB 18 CM01HB Level 1 Level 2 Level 3 Level 4 9 Urea level warning (1/2) SENSOR SUPPLY Urea level indicator POWER SUPPLY 5V Speedo- meter CPU Tachometer Fuel gauge SPEAKER METER CLUSTER INTERNAL CIRCUIT 401 ---===WSE_1506_00001_0181.djvu===--- 54-04 54-04-3 ---===WSE_1506_00001_0182.djvu===--- 54-04-4 410-C10040-1 (1/3) F09 F22 FB9CM OL 2B-9 FM22CM YG FB9CM OL FM22CM YG 1B-11 EAB1E 0.85-B 1B-3 8C-1 10 9 2 13 CME1 CPU B CME1 B 17 10 79 CM01H Y CM01L L CN2HIS Y 3 2 3 2 CN2LIS L 61 8 6 5 94 46 60 31 45 16 30 15 1 72 50 28 73 51 29 7 4 3 2 1 5V 1B HH18B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 123456789 101112131415161718 4 8 24 25 CAN-H CAN-L GND SIG 59 44 HH60A 2 1 5 1 2 GND SIG 4 1 2 CN3H Y 1 2 CN3L L CN5LED L CN5HED Y WR GrB 21 CM01HB Y TG01L L TG01H Y CM01LB L CM01HA Y CM01LA L 2 1 3 2 1 3 HH60A HJ94A SAM JOINT(EAB1E) J/C(CAN-H) J/C(CAN-L) 905 905 [13] 130 130 105 401 HH18C Meter cluster Tacho- meter Meter cluster connector (harness side) Engine ECU side connector SAM connector (harness side) ECU: Electronic control unit M/G: Manual gearbox Instrument panel Cab J/C(CAN-H) 905 J/C(CAN-L) 905 880 J/C(CAN) 905 Chassis Engine speed sensor Harness side connector (backward view connector) Cab Engine ECU HJ2C 415 To TACHOGRAPH J/C(CAN-L) J/C(CAN-H) 905 905 <M/G without BlueTec exhaust gas aftertreatment> R Refer to (2/3, 3/3) for other specifications. B40 J20 J20 J14 C01 J09 J09 W08 W01 R06 #263 U01 J29 J29 TACHOMETER CIRCUIT 410 ---===WSE_1506_00001_0183.djvu===--- 54-04 54-04-5 ---===WSE_1506_00001_0184.djvu===--- 54-04-6 TACHOMETER CIRCUIT 410 ---===WSE_1506_00001_0185.djvu===--- MEMO 54-04-7 54-04 ---===WSE_1506_00001_0186.djvu===--- 54-04-8 SPEEDOMETER CIRCUIT 412 ---===WSE_1506_00001_0187.djvu===--- 54-04 54-04-9 ---===WSE_1506_00001_0188.djvu===--- 54-04-10 415-C10040-1 F09 F22 CAN(H) CAN(L) FB9CM OL 2B-9 FM22CM YG FB9CM OL FM22CM YG FB9CM FM22CM YG 1B-11 F13 3B-5 B 1B-3 14B-8 8C-1 10 9 7 6 2 13 9 18 CPU 8 5V SENSOR SUPPLY CME1 B 17 (+) (-) DATA SIG 2 4 1 3 10 SS01VM YG CME1 B CME1 IL01 IL01 B 0.3-O B 0.85-O TGE1 FB13TG FB13TG FB13TG BR BR ILE1TG SS01SM G IL01TG 8 3 SS01SM W 12 SS01GM BY SS01VT YG 4 SS01DT L SS01V YG SS01DT L SS01G BY SS01S W 1 2 3 S/S V S/S SIG OUT S/S DATA S/S GND S/S SIG IN 4 SS01V YG SS01DT L SS01G BY SS01S W SS01V YG SS01DT L SS01G BY SS01S SS01V SS01DT SS01G SS01S W 1 2 3 1 4 3 2 SS01GT BY SS01ST W 4 2 1 YG FM22TG 6 4 3 2 5 8 4 6 ILL E ILL B GND MAIN BATT TG01H 8 CAN-H TG01L Y L 7 CAN-L 14 2 3 1B HH18B HN14B 2B HQ2A 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 123456789 101112131415161718 AK4A 234 *1 : Right-hand drive vehicle *2 : Left-hand drive vehicle (1/2) 10C HN14A 3B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 HQ8A 5 1 6 2 7 3 8 4 14B EAB1E 0.85-B IL01 0.85-O HH18A 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 17B CN1HCM Y 17B-1 CN1LCM L Y L 17B-11 CM01H CM01L 3 1 3 1 CM01HA Y CM01LA L CM01HB Y CM01LB L 2 1 3 2 1 3 Vehicle speed sensor Harness side connector Refer to (2/2) for other specification. SAM Meter cluster Cab Cab [13] 130 JOINT(IL01) 110 JOINT(EAB1E) 130 J/C(CAN-H) J/C(CAN-L) 905 905 905 905 401 105 SAM connector (harness side) HH18C Meter cluster connector (harness side) Tachograph Tachograph Cab Cab Chassis Instrument panel Instrument panel Instrument panel Instrument panel Instrument panel Cab <FE> Tachograph To high-current fuse(HF01) 110 Instrument panel J/C (CAN-L) J/C (CAN-H) B40 J14 J13 C01 S04 #265 J28 J14 W10a J12 J28 J29 J29 J20 J20 P02 TACHOGRAPH CIRCUIT 415 ---===WSE_1506_00001_0189.djvu===--- 54-04 54-04-11 ---===WSE_1506_00001_0190.djvu===--- 54-04-12 FUEL GAUGE CIRCUIT 420 ---===WSE_1506_00001_0191.djvu===--- MEMO 54-04-13 54-04 ---===WSE_1506_00001_0192.djvu===--- 54-04-14 425-C10040-1 F09 (1/3) F22 FB9CM OL 2B-9 FM22CM YG FB9CM OL FM22CM YG 1B-11 EAB1E 0.85-B 1B-3 8C-1 10 9 2 13 CME1 CPU B CME1 B 17 4 8 CAN-H CAN-L GND SIG 57 58 HH60A 10 7 2 1 GND SIG 9 CM01H Y CM01L L LR GrG 6 18 21 5V 6 5 94 46 60 31 45 16 30 15 1 72 50 28 73 51 29 7 4 3 2 1 1B HH18B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 123456789 101112131415161718 Multi- information display 24 25 CN2HIS Y 1 2 1 2 3 2 3 2 CN3H Y CN2LIS L CN3L L 2 1 5 4 CN5HED Y < M/G without BlueTec exhaust gas aftertreatment > R CN5LED L Refer to (2/3, 3/3) for other specifications. Y 2 1 2 1 Water temperature sensor Harness side connector (backward view connector) SAM JOINT(EAB1E) Meter cluster Instrument panel Cab [13] 130 Engine ECU side connector 130 401 105 HH60A HJ94A HJ2C SAM connector (harness side) ECU: Electronic control unit M/G: Manual gearbox Meter cluster connector (harness side) HH18C Chassis Cab J/C(CAN-H) 905 J/C(CAN-L) 905 J/C(CAN-H) J/C(CAN-L) 905 905 905 880 905 Engine ECU J/C(CAN) 905 J/C (CAN-L) J/C (CAN-H) B40 J14 C01 W08 R11 #262 U01 J09 J09 J20 J20 W01 J29 J29 WATER TEMPERATURE GAUGE CIRCUIT 425 ---===WSE_1506_00001_0193.djvu===--- 54-04 54-04-15 425-C10040-2 CN6HNX Y CN6LNX L Y CN8HNH CN8LNH L 12 CN5LNX L CN5HNX Y 905 CN6HNX Y CN6LNX L CN5LNX CN5HNX L Y 3 2 54 21 54 2 L Y CN4LAB 905 CN4HAB 1 11 12 45 12 45 CN9HED Y CN9LED L CN9HED CN9LED L Y 905 905 <FG> 905 < FE, M/G with BlueTec exhaust gas aftertreatment > R (2/3) CN7HNX Y CN7LNX L CN7HNX CN7LNX Y L 2 3 10 9 21 54 12 45 905 CN8HNH CN8LNH Y L CN9HED Y CN9LED L CN9HED Y L 12 45 CN4HAB CN4LAB 905 CN5HNX Y CN5LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y <*2> <*1> *1:Wheelbase type C *2:Except *1 J/C(CAN) J/C(CAN) J/C (CAN) ATS Chassis J/C (CAN) CAN : Controller area network J/C(CAN) J/C (CAN) J/C (CAN) J/C (CAN) Rear chassis ATS Chassis W19 W01 W23 W24 W22 W19 W01 W23 W24 W22 ---===WSE_1506_00001_0194.djvu===--- 54-04-16 425-C10040-3 CN4HAB Y CN4LAB L 1 2 5 4 Y CN6HED L CN6LED L CN5LAM 1 2 5 4 3 6 Y CN5HAM Y AM01H L AM01L 873 905 905 < DUONIC without BlueTec exhaust gas aftertreatment > R (3/3) 905 905 < DUONIC with BlueTec exhaust gas aftertreatment > R Y CN8HNH CN7HNX <*2> <*1> Rear chassis ATS Chassis CN7LNX Y L CN7HNX CN7LNX Y L CN8LNH L 2 3 10 9 21 54 2 1 5 4 CN9HED Y CN9LED L *1:Wheelbase type C *2:Except *1 CN9HED CN5HAM Y L L CN5LAM Y 12 45 CN4LAB CN4HAB 905 AM01H Y AM01L L 3 6 12 45 873 905 CN6HNX Y CN6LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y J/C(CAN) J/C (CAN) To DUONIC ECU CAN : Controller area network ECU : Electronic control unit J/C(CAN) J/C (CAN) To DUONIC ECU J/C (CAN) J/C (CAN) J/C (CAN) W01 W02 W19 W01 W02 W23 W24 W22 WATER TEMPERATURE GAUGE CIRCUIT 425 ---===WSE_1506_00001_0195.djvu===--- 54-05-1 54-05 INDICATOR AND WARNING LAMP CIRCUIT ---===WSE_1506_00001_0196.djvu===--- 54-05-2 PARKING BRAKE INDICATOR CIRCUIT 510 ---===WSE_1506_00001_0197.djvu===--- 54-05 54-05-3 BRAKE WARNING CIRCUIT 515 ---===WSE_1506_00001_0198.djvu===--- 54-05-4 536-C10040-1 (1/3) F09 F22 FB9CM OL 2B-9 FM22CM YG FB9CM OL FM22CM YG 1B-11 EAB1E 0.85-B 1B-3 8C-1 10 9 2 13 CME1 CPU LED DRIVER B CME1 B 17 CAN-H CAN-L SIG 54 HH60A 10 79 CM01H Y CM01L L GrR 61 8 5V 123456789 101112131415161718 1B HH18B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 6 5 94 46 60 31 45 16 30 15 1 72 50 28 73 51 29 7 4 3 2 1 24 25 4 8 CN2HIS Y 1 2 1 2 3 2 3 2 CN3H Y CN2LIS L CN3L L 2 1 5 4 CN5HED Y < M/G without BlueTec exhaust gas aftertreatment > R CN5LED L Refer to (2/3, 3/3) for other specifications. Y Y 2 1 2 1 Oil pressure switch Engine stop:ON SAM JOINT(EAB1E) 130 401 105 HH18C HH60A HJ94A Meter cluster Meter cluster connector (harness side) Engine ECU side connector Instrument panel Cab SAM connector (harness side) ECU: Electronic control unit M/G: Manual gearbox [13] 130 Engine ECU Chassis Cab J/C(CAN-H) 905 J/C(CAN-L) 905 J/C(CAN-H) J/C(CAN-L) 905 905 905 905 880 J/C(CAN) 905 J/C (CAN-L) J/C (CAN-H) B40 J14 C01 R16 #044 U01 W08 J09 J09 J29 J20 J20 W01 ENGINE OIL PRESSURE WARNING CIRCUIT 536 ---===WSE_1506_00001_0199.djvu===--- 54-05 54-05-5 536-C10040-2 CN6HNX Y CN6LNX L Y CN8HNH CN8LNH L 12 CN5LNX L CN5HNX Y 905 CN6HNX Y CN6LNX L CN5LNX CN5HNX L Y 3 2 54 21 54 2 L Y CN4LAB 905 CN4HAB 1 11 12 45 12 45 CN9HED Y CN9LED L CN9HED CN9LED L Y 905 905 <FG> 905 < FE, M/G with BlueTec exhaust gas aftertreatment > R (2/3) CN7HNX Y CN7LNX L CN7HNX CN7LNX Y L 2 3 10 9 21 54 12 45 905 CN8HNH CN8LNH Y L CN9HED Y CN9LED L CN9HED Y L 12 45 CN4HAB CN4LAB 905 CN5HNX Y CN5LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y <*2> <*1> *1:Wheelbase type C *2:Except *1 J/C(CAN) J/C(CAN) J/C (CAN) ATS Chassis J/C (CAN) CAN : Controller area network J/C(CAN) J/C (CAN) J/C (CAN) J/C (CAN) ATS Rear chassis Chassis W19 W01 W23 W24 W22 W19 W01 W23 W24 W22 ---===WSE_1506_00001_0200.djvu===--- 54-05-6 ENGINE OIL PRESSURE WARNING CIRCUIT 536 ---===WSE_1506_00001_0201.djvu===--- MEMO 54-05-7 54-05 ---===WSE_1506_00001_0202.djvu===--- 54-05-8 537-C10040-1 (1/3) F09 F22 FB9CM OL 2B-9 FM22CM YG FB9CM OL FM22CM YG 1B-11 EAB1E 0.85-B 1B-3 8C-1 10 9 2 13 CME1 LED DRIVER (Red) B CME1 B 17 CAN-H CAN-L GND SIG 57 58 HH60A 10 7 2 1 GND SIG 9 LR GrG 6 HH60A HJ94A 18 21 6 5 94 46 60 31 45 16 30 15 1 72 50 28 73 51 29 7 4 3 2 1 5V 1B HH18B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 123456789 101112131415161718 Multi- information display 24 25 4 8 CM01H Y CM01L L CN2HIS Y 1 2 1 2 3 2 3 2 CN3H Y CN2LIS L CN3L L 2 1 5 4 CN5HED Y < M/G without BlueTec exhaust gas aftertreatment > R CN5LED L Refer to (2/3, 3/3) for other specifications. Y 2 1 2 1 Engine ECU side connector SAM JOINT(EAB1E) Meter cluster [13] 130 880 130 105 401 SAM connector (harness side) HH18C Instrument panel Cab Meter cluster connector (harness side) Harness side connector (backward view connector) ECU: Electronic control unit M/G: Manual gearbox Engine ECU HJ2C Water temperature sensor Chassis Cab J/C(CAN-H) 905 J/C(CAN-L) 905 J/C(CAN-H) J/C(CAN-L) 905 905 J/C(CAN) 905 905 905 J/C (CAN-L) J/C (CAN-H) B40 C01 J14 U01 R11 #262 W08 J09 J09 J20 J20 W01 J29 J29 OVERHEATING WARNING CIRCUIT 537 ---===WSE_1506_00001_0203.djvu===--- 54-05 54-05-9 537-C10040-2 CN6HNX Y CN6LNX L Y CN8HNH CN8LNH L 12 CN5LNX L CN5HNX Y 905 CN6HNX Y CN6LNX L CN5LNX CN5HNX L Y 3 2 54 21 54 2 L Y CN4LAB 905 CN4HAB 1 11 12 45 12 45 CN9HED Y CN9LED L CN9HED CN9LED L Y 905 905 <FG> 905 < FE, M/G with BlueTec exhaust gas aftertreatment > R (2/3) CN7HNX Y CN7LNX L CN7HNX CN7LNX Y L 2 3 10 9 21 54 12 45 905 CN8HNH CN8LNH Y L CN9HED Y CN9LED L CN9HED Y L 12 45 CN4HAB CN4LAB 905 CN5HNX Y CN5LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y <*2> <*1> *1:Wheelbase type C *2:Except *1 J/C(CAN) J/C(CAN) J/C (CAN) ATS Chassis J/C (CAN) CAN : Controller area network J/C(CAN) J/C (CAN) J/C (CAN) J/C (CAN) ATS Rear chassis Chassis W19 W01 W23 W24 W22 W19 W01 W23 W24 W22 ---===WSE_1506_00001_0204.djvu===--- 54-05-10 OVERHEATING WARNING CIRCUIT 537 ---===WSE_1506_00001_0205.djvu===--- 54-05 54-05-11 CAB TILT WARNING CIRCUIT 550 ---===WSE_1506_00001_0206.djvu===--- 54-05-12 STARTER KEY REMOVAL REMINDER ALARM CIRCUIT 554 ---===WSE_1506_00001_0207.djvu===--- MEMO 54-05-13 54-05 ---===WSE_1506_00001_0208.djvu===--- 54-05-14 566-C10040-1 WATER SEPR F09 F22 F28 (1/3) FB9CM OL 2B-9 FM22CM YG FB9CM OL FM22CM YG 1B-11 EAB1E 0.85-B 1B-3 FR28 2-G 7C-2 8C-1 10 9 2 13 CME1 CPU Multi- information display B CME1 B 17 CAN-H CAN-L SIG 30 5 3 6 HJ94A 10 7 1 11 WSG 6 WSV WS IND 9 WS01S 0.3-Gr WS01S 0.3-Gr WS01S WS01V 0.75-G WSE1 FPE1X FPE1 0.75-B 0.85-B WS01V 0.75-G FR28 2-G 0.3-B 8-B 61 8 5V 1 2345 6 7 891011 12 123456789 101112131415161718 6 5 94 72 50 28 73 51 29 7 4 3 2 1 1B HH18B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 24 25 HN14C 7C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 1 5 4 CN5HED Y R < M/G without BlueTec exhaust gas aftertreatment > CN5LED L Refer to (2/3, 3/3) for other specifications. 4 8 CN2HIS Y 1 2 1 2 3 2 3 2 CN3H Y CN2LIS L CN3L L 2 1 2 1 Fuel filter SAM JOINT(EAB1E) [13] 130 [12] 130 130 JOINT (FR28) 110 105 Meter cluster connector (harness side) HH18C HJ94A HH12B Chassis Instrument panel Cab Fuel Meter cluster 401 ECU: Electronic control unit M/G: Manual gearbox SAM connector (harness side) Harness side connector Engine ECU side connector 880 Engine ECU J/C(CAN) 905 Chassis Cab J/C(CAN-H) 905 J/C(CAN-L) 905 J/C(CAN-H) J/C(CAN-L) 905 905 905 905 J/C(CAN-L) J/C(CAN-H) B40 J14 W16 T12 #323 U01 C01 W01 W08 J09 J09 J20 J20 J29 J29 FUEL FILTER CIRCUIT 566 ---===WSE_1506_00001_0209.djvu===--- 54-05 54-05-15 566-C10040-2 CN6HNX Y CN6LNX L Y CN8HNH CN8LNH L 12 CN5LNX L CN5HNX Y 905 CN6HNX Y CN6LNX L CN5LNX CN5HNX L Y 3 2 54 21 54 2 L Y CN4LAB 905 CN4HAB 1 11 12 45 12 45 CN9HED Y CN9LED L CN9HED CN9LED L Y 905 905 <FG> 905 < FE, M/G with BlueTec exhaust gas aftertreatment > R (2/3) CN7HNX Y CN7LNX L CN7HNX CN7LNX Y L 2 3 10 9 21 54 12 45 905 CN8HNH CN8LNH Y L CN9HED Y CN9LED L CN9HED Y L 12 45 CN4HAB CN4LAB 905 CN5HNX Y CN5LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y <*2> <*1> *1:Wheelbase type C *2:Except *1 J/C(CAN) J/C(CAN) J/C (CAN) ATS Chassis J/C (CAN) CAN : Controller area network J/C(CAN) J/C (CAN) J/C (CAN) J/C (CAN) ATS Rear chassis Chassis W19 W01 W23 W24 W22 W19 W01 W23 W24 W22 ---===WSE_1506_00001_0210.djvu===--- 54-05-16 FUEL FILTER CIRCUIT 566 ---===WSE_1506_00001_0211.djvu===--- 54-06-1 54-06 CAB SIDE ELECTRICAL CIRCUIT ---===WSE_1506_00001_0212.djvu===--- 54-06-2 CIGARETTE LIGHTER CIRCUIT 610 ---===WSE_1506_00001_0213.djvu===--- 54-06 54-06-3 AUDIO CIRCUIT 612 ---===WSE_1506_00001_0214.djvu===--- 54-06-4 614-C10040 COMB SW LIN SIG STARTER SW(M) WI01H 0.85-LB 16B-5 F09 FB9CS LW EAB1LG CSE1LG BB 2B-8 KE01M Y 18B-3 18B-23 12 CS01LS YG 18B-21 WM01V L 17B-5 WM01G BL 17B-6 16B-1 17B-16 WIPER PARKED SW 0.85-B LW 0.85-LR 1 2 4 1 5 3 LO HI WIE1 WI01P WI01L WI01P WI01L WI01H 2 1 3 LIN SIG GND BATT M 5 3 1 4 LO HI WIE1 WI01P WI01L WI01H M M EAB2 1.25-B 10C 8C-1 123 HQ8C HH18A HH28B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 18B 16B 17B Wiper motor Windscreen washer motor <*1> Wiper motor <*2> Combination switch JOINT(EAB2) 130 J/C(EAB1LG) 905 [1] 130 To starter switch 210 SAM 105 110 [13] 130 To high-current fuse (HF01) HU3A SAM connector (harness side) Combination switch connector (harness side) *1 : Right-hand drive vehicle *2 : Left-hand drive vehicle #428 C02 A17 #001 J01 C03 #422 C03 #422 B40 WIPER AND WASHER CIRCUIT 614 ---===WSE_1506_00001_0215.djvu===--- 54-06 54-06-5 HORN CIRCUIT 616 ---===WSE_1506_00001_0216.djvu===--- 54-06-6 HEATER AND AIR-CONDITIONER CIRCUIT 620 ---===WSE_1506_00001_0217.djvu===--- MEMO 54-06-7 54-06 ---===WSE_1506_00001_0218.djvu===--- 54-06-8 620-C10040M-1 M M M <Manual air-conditioner> (1/3) A/C SW CAN(L) CAN(H) STARTER SW(M) F22 F11 F32 F40 FM22CM YG 1B-11 9 AC02 0.3-GR 15B-17 15 IL01 FM22CM AC02 IL01 0.85-O 14B-8 EAB1PL EAI1 EAI1 HCE1 0.85-B 0.85-B IL01 0.85-O FM22CM FM22HC +12V A/C COMP SIG A/C IND GND ILL(+) EVA SEN SEN GND F-R GND RECIRC FRESH A/C GND HI MH ML LO AC02 AC02 AC04A IL01HC ILL(-) ILE1HC AC04B BWE1 BW01HI HCE1 HC01V BW01MH BW01ML BW01LO YG 1 2 0.3-GR 0.3-L O 0.3-B W 2-B 2-BW 0.3-B 1.25-L 0.85-Y G BWE1 BW01HX BW01MH BW01ML BW01LO BW01HY 2-BW BW01HX 2-BW FB11BW 2-RW FB11BW 2-RW BWE1 2-B BW01MH BW01ML BW01LO 2-B 2-BW 1.25-L 0.85-Y G YG 0.85-B 1B-18 EAB1PR 0.85-B *1 *2 1B-9 BWE1 2-B 3B-4 FB11BW 2-RW 2B-14 EAB1PL 0.85-B 1B-18 EAB1PR 0.85-B *1 *2 1B-9 FB32AC LR 7C-12 FB32CF FB32CF RG 7C-11 KE01M Y CF01 1.25-GR FB40CF 1.25-WR 18B-3 8 16 2 1 7 8 5 1 2 3 4 1 4 7 6 5 12 8 11 10 9 3 1 5 6 3 2 4 3 2 1 2 1 8C-1 GA2B 2 1 10 4 5 5 3 12 4 EQ5A 24 25 CAN-H CAN-L CAN(H) CAN(L) 12 AR2E CN1HCM Y 17B-1 CN1LCM L 17B-11 4 8 2 1 2 3 3 1 2 1 2 1 CN2HIS Y CN2LIS L CN4LAB L CN4HAB Y CN3L L IS01L L IS01H Y CN3H Y CFE1 1.25-B 6 5 94 72 50 28 73 51 29 7 4 3 2 1 MH LOW ML AC01 RY 10C 123456 789101112 123 12 12 34 HH18B HH18A HH28A HH28B HN14B HN14A HN14C HQ2A 2B 3B 7C 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15B 18B 17B HQ8A 5 1 6 2 7 3 8 4 14B HC01RE HC01FR AC03S AC03G HC01RE HC01FR HC01RE HC01V YG GB LR 0.3-WG 0.3-VR HC01FR REC FRE AC03S AC03G AC03S AC03G 0.3-WG 0.3-VR LR GB 2 1 1 2 3 5 4 3 2 1 *1 : Right-hand drive vehicle *2 : Left-hand drive vehicle 1B 2 1 5 4 CN5HED Y < M/G without BlueTec exhaust gas aftertreatment > R CN5LED L Refer to (2/3, 3/3) for other specifications. JOINT (EAB1PL) (EAB1PR) *1 *2 Heater control panel 12pin connector (harness side) HH12A HS3A HS2A HS4A Harness side connector Harness side connector Harness side connector 130 JOINT(EAI1) To meter cluster JOINT(IL01) 130 401 JOINT (EAB1PL) *1 (EAB1PR) *2 130 110 Engine ECU HJ94A Cab Cab Chassis Cab Air-conditioner Air-conditioner Chassis Cab J/C(CAN-H) J/C(CAN-L) 905 J/C(CAN-H) 905 ISS ECU 275 905 J/C(CAN-L) 905 880 110 [13] 130 130 To starter switch High-current fuse box Condenser fan motor Condenser fan relay 210 Blower resistor Blower motor Fresh/ recirculation changeover motor Magnetic clutch Dual pressure switch SAM 105 110 SAM connector (harness side) ECU: Electronic control unit M/G: Manual gearbox To high- current fuse (HF01) Instrument panel Instrument panel Engine ECU side connector Thermostat [15] J/C(CAN) 905 J14 D01 J14 J11 J15 J13 U02 U01 J04 W08 J20 J09 J20 J09 B07 D03 #750 D04 #411 D02 #415 R08 T02 #201 B16 V01 #431 B40 J11a D05 #751 D09 W01 HEATER AND AIR-CONDITIONER CIRCUIT 620 ---===WSE_1506_00001_0219.djvu===--- 54-06 54-06-9 620-C10040M-2 <Manual air-conditioner> (2/3) CN6HNX Y CN6LNX L Y CN8HNH CN8LNH L 12 CN5LNX L CN5HNX Y 905 CN6HNX Y CN6LNX L CN5LNX CN5HNX L Y 3 2 54 21 54 2 L Y CN4LAB 905 CN4HAB 1 11 12 45 12 45 CN9HED Y CN9LED L CN9HED CN9LED L Y 905 905 <FG> 905 < FE, M/G with BlueTec exhaust gas aftertreatment > R CN7HNX Y CN7LNX L CN7HNX CN7LNX Y L 2 3 10 9 21 54 12 45 905 CN8HNH CN8LNH Y L CN9HED Y CN9LED L CN9HED Y L 12 45 CN4HAB CN4LAB 905 CN5HNX Y CN5LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y <*2> <*1> *1:Wheelbase type C *2:Except *1 J/C(CAN) J/C(CAN) J/C (CAN) ATS Chassis J/C (CAN) CAN : Controller area network J/C(CAN) J/C (CAN) J/C (CAN) J/C (CAN) ATS Rear chassis Chassis W19 W01 W23 W24 W22 W19 W01 W23 W24 W22 ---===WSE_1506_00001_0220.djvu===--- 54-06-10 HEATER AND AIR-CONDITIONER CIRCUIT 620 ---===WSE_1506_00001_0221.djvu===--- MEMO 54-06-11 54-06 ---===WSE_1506_00001_0222.djvu===--- 54-06-12 HEATER AND AIR-CONDITIONER CIRCUIT 620 620-C10040A-1 OUTSIDE 8℃ 18B 8 4 AB16A Cab Chassis 27 20 39 ILL (+) CAN-H CAN-L CM01H Y CN3H CN3L Y L Y CN2HIS Y IS01H L CN2LIS L IS01L 1 2 3 1 2 CM01L L 3 1 3 2 1 3 2 1 2 CB3H G CB3L W CB2HAG G CB2LAG W G CB3H W CB3L 0.3-O IL01AA 0.85-O IL01 0.85-O IL01 AA01H AA01L G W CABIN CAN-H CABIN CAN-L 14 13 8 12 12 CB1HIM G 12 12 CB1LIM W CN1HCM Y CN1LCM L CHASSIS CAN-H CHASSIS CAN-L 14B-8 18B-14 18B-27 17B-1 17B-11 <Fully automatic air-conditioner> (1/3) 1B HH18B HH18A HH28B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 17B 9 18 7 6 CM01H Y CM01L L 1 ILE1AA 0.3-B ILL(-) 28 13 10 CME1 FM22CM CME1 EAB1E FM22CM B YG B 0.85-B YG 9 17 1B-11 1B-3 CPU 2B-9 FB9CM OL FB9CM OL 10 2 123456789 101112131415161718 F09 F22 DIAG CAN-H DIAG CAN-L F09 2B-7 18B-16 18B-1 2B-12 1B-2 XT01L XT01H R V XTE2 B XTE1 FB9XT PL B 1 13 12 11 3 Multi- information display 5V HF01 15-R 10C EAB1 8-B 8C-1 12 34 5 6 7 8 91011121314151617181920 2122232425262728293031323334353637383940 HQ8A 5 1 6 2 7 3 8 4 14B 1 2 Y CN5HED L CN5LED 5 4 CN4HAB CN4LAB Y L 2 1 2 1 J/C (CAN-H) J/C (CAN-L) J/C (CAN-H) J/C (CAN-L) J/C (CAN-H) J/C (CAN-L) J/C (CAN-H) SAM J/C (CAN-L) To ISS ECU Air-conditioner ECU and control panel CAN resistor Cab Instrument panel 905 905 275 105 905 905 905 905 JOINT (IL01) 110 Meter cluster JOINT (EAB1E) 130 401 905 905 Meter cluster connector (harness side) HH18C HH40B Diagnosis connector 905 To high-current fuse (HF01) 110 130 [13] Air-conditioner ECU and control panel connector (harness side) Cab Instrument panel ECU: Electronic control unit M/G: Manual gearbox ISS: Idling stop and start system To engine ECU < M/G without BlueTec exhaust gas aftertreatment > Refer to (3/3) for other specifications. J/C (CAN) 905 880 J/C (CAN-L) J/C (CAN-H) R SAM connector (harness side) #828 B12 B40 J14 J02 J17 J17 J20 J20 J09 J09 J02 J13 J21 C01 J29 J29 J14 D09 W08 W01 ---===WSE_1506_00001_0223.djvu===--- 54-06 54-06-13 ---===WSE_1506_00001_0224.djvu===--- 54-06-14 HEATER AND AIR-CONDITIONER CIRCUIT 620 620-C10040A-3 L CN4LAB L CN5LAM CN6HNX Y CN6LNX L Y CN8HNH Y CN8HNH CN8LNH L 2 1 5 4 CN9HED Y CN7HNX < DUONIC without BlueTec exhaust gas aftertreatment > R <*2> <*1> CN7LNX Y L CN7HNX CN7LNX Y L 2 3 10 9 21 54 CN9HED CN5HAM Y L CN5LAM 2 5 21 54 CN6HNX Y CN6LNX L 21 54 CN9LED L Y 905 905 L Y 1 4 CN4LAB CN4HAB 905 CN6HED 880 Y CN6LED L 2 1 4 5 Y CN4HAB 2 1 4 5 Y CN5HAM 905 905 905 905 880 CN9LED L < DUONIC with BlueTec exhaust gas aftertreatment > R CN8LNH L 12 CN5HNX Y CN5LNX L 905 CN6LNX L CN6HNX Y CN5HNX CN5LNX Y L 2 3 21 54 21 5 Y L CN4HAB 905 CN4LAB 4 11 12 45 12 45 CN9HED Y CN9LED L 880 CN9HED CN9LED L Y 905 905 <FG> 905 <Fully automatic air-conditioner> (3/3) < FE, M/G with BlueTec exhaust gas aftertreatment > R CN7HNX Y CN7LNX L CN7HNX CN7LNX Y L 2 3 10 9 21 54 12 45 905 CN8HNH CN8LNH Y L CN9HED Y CN9LED L CN9HED Y L 21 54 880 CN4HAB CN4LAB 905 CN5HNX Y CN5LNX L 21 54 905 CN9LED L Y <*2> <*1> *1:Wheelbase type C *2:Except *1 J/C(CAN) J/C(CAN) J/C (CAN) ATS To engine ECU J/C(CAN) J/C (CAN) J/C (CAN) J/C(CAN) J/C (CAN) To engine ECU J/C (CAN) J/C (CAN) ATS Rear chassis Chassis To engine ECU Chassis J/C (CAN) CAN : Controller area network ECU : Electronic control unit J/C(CAN) J/C (CAN) J/C (CAN) J/C (CAN) ATS Rear chassis Chassis To engine ECU W01 W02 W02 W01 W23 W24 W19 W22 W19 W01 W23 W24 W22 W19 W01 W23 W24 W22 ---===WSE_1506_00001_0225.djvu===--- 54-06 54-06-15 ---===WSE_1506_00001_0226.djvu===--- 54-06-16 622-C10040 + - - + M M + - - + M M BATT GND P/W MOTOR UP REAR DOOR P/W MOTOR DOWN LIN SIG P/W DRIVER SW LIN SIG F05 FB5D 2-O 1B-7 PWE1D 2-B 2 1 7 2B-10 PW01SD 1 10 11 2 3 2 1 DD14A GY FB5D 2-O PWE1D 2-B PW01SD GY 1 2 6 7 DOOR LOCK 8 DOOR UNLOCK 9 DOOR POSITION LOCK 4 DOOR POSITION UNLOCK 5 PW02UR 2-R PW02DR 2-G 2 1 PW02UL 2-R PW02DL 2-G 1 2 DL02L 1.25-RB DL02U 1.25-WB DL02L 1.25-RB DL02U 1.25-WB DL01L Y DL01U G DLE1 B 18B-20 BATT GND P/W MOTOR UP P/W MOTOR DOWN LIN SIG P/W ASSISTANT SW LIN SIG F07 FB7A 2-OB 2B-3 PWE1A 2-B 2 1 7 2B-6 PW01SA 1 2 3 LY FB7A 2-OB PWE1A 2-B PW01SA LY 6 7 DOOR LOCK 8 DOOR UNLOCK 9 18B-19 Switch 2 3 4 5 1 LOCK UN- LOCK LOCK UN- LOCK actu- ator actu- ator + + - - 2 3 DL03L 1.25-R DL03U 1.25-W DL03L 1.25-RG DL03U 1.25-WG LOCK LOCK UN- LOCK UNLOCK actu- ator + + - - 2 1 2 3 DL03L 1.25-R DL03U 1.25-W LOCK UN- LOCK actu- ator + + - - 8C-1 1B HH18B HH28B HN14B HQ2A 2B 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18B UP DOWN UP DOWN 2 1 PW02UL PW02DL 1 2 PW02UR PW02DR DL02L DL02U DL01L DL01U DLE1 Switch 3 4 2 1 5 LOCK UN- LOCK actu- ator UP DOWN UP DOWN *1 : Right-hand drive vehicle *2 : Left-hand drive vehicle ★ ★ Power window motor, Dr Power window motor, As Door, As Cab Door, Dr Cab Door, Dr Rear door Door lock actuator, Dr Power window motor, Dr Power window motor, As Door lock actuator, Dr Door lock actuator, As Rear door lock actuator, Dr <Crew cab> <Crew cab> Door, As Rear door Rear door lock actuator, As Power window switch, As Power window switch, Dr [13] 130 SAM 105 SAM connector (harness side) Dr : Driver's seat side As : Assistant driver's seat side <*1> <*2> E11 #423 E06 E13 E08 #423 J19 J19 J10 E12 #511 E11 #423 E08 #423 E12 #511 E15 E14 E07 J10 B40 #512 #510 #512 #027 #027 POWER WINDOW AND CENTRAL DOOR LOCK CIRCUIT 622 ---===WSE_1506_00001_0227.djvu===--- 54-06 54-06-17 MIRROR HEATER CIRCUIT 629 ---===WSE_1506_00001_0228.djvu===--- 54-06-18 SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG CIRCUIT 631 ---===WSE_1506_00001_0229.djvu===--- 54-06 54-06-19 KEYLESS ENTRY CIRCUIT 654 ---===WSE_1506_00001_0230.djvu===--- 54-07-1 54-07 CHASSIS SIDE ELECTRICAL CIRCUIT ---===WSE_1506_00001_0231.djvu===--- 54-07-2 790-C10040-1 9 18 10 13 30 MAIN 5 6 CAN-H CAN-L CHASSIS CAN-H CHASSIS CAN-L 4 8 FM18AB PL CM01H CM01L Y L ASR OFF ASR ESP OFF ASR SYS CPU ABS CME1 B YG FM22CM EAB1E 0.85-B CME1 FM22CM B YG CN1HCM CN1LCM Y L FM18AB PL 1 3 1 3 2 2 1 1 2 2 Y CN2HIS L CN2LIS CN3H CN3L Y L 6 7 9 17 1B-11 1B-3 17B-11 17B-1 5C-2 2B-9 FB9CM 10 2 OL FB9CM OL FM22CM YG FB9CM OL (1/4) F18 F22 F09 HH18C 123456789 101112131415161718 LED DRIVER 5V 1 2 3 4 5 6 7 8 9 10 11 12 13 HH38A 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 11 1 3 13 12 XT01H R XT01L V DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L 18B-16 FB9XT PL 2B-7 XTE1 B 2B-12 XTE2 B EAB1 8-B 1B-2 18B-1 8C-1 15B-19 18B-4 F09 BS01NO 0.3-Lg BS01NC 0.3-Gr BRAKE SW NO BRAKE SW NC 1B HH18B HH18A HH28A HH28B HN14B HN14D HQ2A 2B 5C 8C 1 2 3 4 5 6 2 1 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 15B 18B 17B BF01 0.3-GY BRK. FLUID LEVEL SW 18B-7 3 2 1 GND SIG V 13 14 15 AB09V PL AB09S W AB09G G *1: FG *1 *1 *1 *1 *1 *1 AB09V PL AB09S W AB09G G 31 34 G-SENSOR SIG G-SENSOR GND Multi- information display 2 5 3 1 6 4 CN4HAB CN4LAB AB03H Y CN5HED Y L Y < M/G without BlueTec exhaust gas aftertreatment > R AB03L L CN5LED L Refer to (3/4, 4/4) for other specifications. 1 1 2 2 CM01HA CM01HB CM01LB Y Y L CM01LA L Hydraulic unit Meter cluster To engine ECU J/C (CAN-H) SAM J/C (CAN-L) J/C (CAN-H) J/C (CAN-L) SAM connector (harness side) Cab Chassis JOINT (EAB1E) 905 401 905 880 105 130 905 905 Meter cluster connector (harness side) Hydraulic unit connector (harness side) Diagnosis connector 130 [13] To stop lamp switch To brake fluid level switch 515 325 ECU: Electronic control unit M/G: Manual gearbox ISS : Idling stop and start system G sensor <FG> Cab Chassis J/C(CAN) 905 J/C (CAN-H) J/C (CAN-L) 905 905 Cab Instrument panel B40 J09 X05 J09 J20 J20 W08 C01 J21 #327 A43 W08 W01 J29 J29 J14 ANTI-LOCK BRAKE SYSTEM CIRCUIT 790 ---===WSE_1506_00001_0232.djvu===--- 54-07 54-07-3 790-C10040-2 1 2 3 4 5 6 7 8 9 10 11 12 13 HH38A 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 3 34 33 29 4 27 28 11 10 36 35 SPEED SENSOR Fr RH+ VAC SENSOR GND VAC SENSOR SIG 31 CUT SW 30 MAIN VAC SENSOR V 9 8 CAN-L CAN-H SPEED SENSOR Fr RH- SPEED SENSOR Fr LH+ SPEED SENSOR Fr LH- SPEED SENSOR Rr RH+ SPEED SENSOR Rr RH- SPEED SENSOR Rr LH+ SPEED SENSOR Rr LH- AB01SR AB01GR AB01SL AB01GL AB02SR AB02GR AB02SL 15 16 13 14 AB02GL R G L P W O WL OL AB01SR AB01GR AB01SL AB01GL AB02SR AB02GR AB02SL AB02GL R G L P W O WL OL 2 1 1 2 1 2 ★ 1 2 F41 HF08 25 1 13 38 COIL/ECU B+ PUMP MOTOR B+ PUMP MOTOR GND COIL/ECU GND FB41AB 3-G HF08 5-RB ABE2 3-B ABE1 3-B (2/4) EAB1 8-B 10C F18 8C-1 AK22B 8 4 3 2 1 7 6 5 10 9 AK22A 8 16 1B-18 1B-9 14B-8 5C-2 1B-3 10 1 OFF ON 37 1 2 3 4 5 6 7 8 9 10 *1 : Left-hand drive vehicle *2 : Right-hand drive vehicle V SIG GND V GND CAN-H CAN-L CAN-H CAN-L V GND CAN-H CAN-L 3 1 2 1 6 2 3 4 5 1 4 2 3 Sb AB08 V AB05H Gr AB05L R AB04V W AB04S B AB04G B AB04SE AB04V R AB04S W AB04G B AB04SE B AB08 Sb PL AB05 AB05H V AB05L Gr FM18AB PL AB04V R AB04S W AB04G B AB04SE B W AB04S B AB04G PL AB05 0.3-B ABE5 V AB05H Gr AB05L VR AB06H GrR AB06L PL AB06 0.3-B ABE6 VR AB06H GrR AB06L R AB04V AB05 PL 0.85-O 0.85-B EAB1PR 0.85-B EAB1PL *1 *2 0.85-B EAB1E 0.85-O IL01 ILE1AB 0.3-B IL01AB 0.3-O AB08 Sb AB05H V AB05L Gr 1234 123 456 1 2 3 SHIELD SHIELD 1B HH18B HN14D 5C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 HQ8A 5 1 6 2 7 3 8 4 14B ★:AB2A or AB2C HQ2A 8C 2 1 Hydraulic unit connector (harness side) RH LH RH Front wheel speed sensor Rear wheel speed sensor LH Chassis Rear chassis High-current fuse box 110 130 Hydraulic unit [14] ECU: Electronic control unit SAM 130 [13] 105 110 To high- current fuse (HF01) Cab Chassis Cab Instrument panel Cab JOINT (EAI1) JOINT (IL01) JOINT (EAB1PR) *1 JOINT (EAB1PL) *2 JOINT (EAB1E) ESP/ASR cutoff switch <FE> ESP/ASR cutoff switch connector (harness side) HH10A Instrument panel Vacuum Sensor ESP Sensor Steering wheel angle sensor ESP: Electronic stability program ASR: Anti spin regulator HU4A (harness side connector) HH6A (harness side connector) HN3B (harness side connector) 130 130 130 130 110 SAM connector (harness side) <FE> <FE> <FE> #329 #329 U02 X01 X04 X02 W03 X03 X05 B40 A14 #089 W09a P09 #250 A47 #282 A46 #348 J14 J13 ---===WSE_1506_00001_0233.djvu===--- 54-07-4 790-C10040-3 CN6HNX Y CN6LNX L Y CN8HNH CN8LNH L 12 CN5LNX L CN5HNX Y 905 CN6HNX Y CN6LNX L CN5LNX CN5HNX L Y 3 2 54 21 5 6 4 2 L Y L Y AB03L AB03H CN4LAB 905 CN4HAB 3 1 11 12 45 12 45 CN9HED Y CN9LED L CN9HED CN9LED L Y 905 905 <FG> 905 < FE, M/G with BlueTec exhaust gas aftertreatment > R (3/4) CN7HNX Y CN7LNX L CN7HNX CN7LNX Y L 2 3 10 9 21 54 12 45 905 CN8HNH CN8LNH Y L AB03H Y AB03L L CN9HED Y CN9LED L CN9HED Y L 1 3 2 4 6 5 CN4HAB CN4LAB 905 CN5HNX Y CN5LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y <*2> <*1> *1:Wheelbase type C *2:Except *1 J/C(CAN) J/C(CAN) J/C (CAN) ATS Chassis J/C (CAN) CAN : Controller area network J/C(CAN) J/C (CAN) J/C (CAN) J/C (CAN) ATS Rear chassis Chassis W19 W01 W23 W24 W22 W19 W01 W23 W24 W22 ANTI-LOCK BRAKE SYSTEM CIRCUIT 790 ---===WSE_1506_00001_0234.djvu===--- 54-07 54-07-5 ---===WSE_1506_00001_0235.djvu===--- 54-08-1 54-08 ENGINE AND GEARBOX SIDE ELECTRICAL CIRCUIT ---===WSE_1506_00001_0236.djvu===--- 54-08-2 810-C10040-1 8C-1 1B HH18B HQ2A 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 FM22CM YG 1B-11 FB9CM OL 2B-9 (1/2) F09 F22 17 10 EAB1E 0.85-B CME1 B CME1 B 91 3 FM22CM YG 10 2 FB9CM OL 9 18 CM01H Y CM01L L 1B-3 6 7 CN1HCM Y 17B-1 CN1LCM L 17B-11 CAN(L) CAN(H) 3 1 3 1 CPU LED DRIVER 5V 123456789 101112131415161718 HH18A 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 17B HN14B 2B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 1 2 1 HH18C 105 SAM 130 [13] Meter cluster J/C(CAN-L) J/C(CAN-H) 130 905 905 905 J/C (CAN-L) 905 401 JOINT(EAB1E) Instrument panel Cab Meter cluster connector (harness side) J/C (CAN-H) SAM connector (harness side) B40 C01 J14 J20 J20 J29 J29 FOUR-WHEEL DRIVE CIRCUIT 810 ---===WSE_1506_00001_0237.djvu===--- 54-08 54-08-3 ---===WSE_1506_00001_0238.djvu===--- 54-08-4 V02 #565 850-C10040M-1 8C-1 <Manual gearbox>(1/2) FM22CM YG 1B-11 FB9CM OL 2B-9 F09 F22 17 10 EAB1E 0.85-B CME1 B CME1 B 91 3 FM22CM YG 10 2 FB9CM OL 9 18 CM01H Y CM01L L 1B-3 6 7 CN1HCM Y 17B-1 CN1LCM L 17B-11 CAN(L) CAN(H) 3 1 2 3 1 2 CPU Multi- information display 5V 123456789 101112131415161718 PT01 BY 11C-9 VP01M RL 13C-10 PTO SW (CHASSIS) CU01 0.3-GY 18B-9 EAB1S B 2B-2 CLUTCH SW (UPPER) CU01 CUE1 0.3-B 2 1 PT01 PTE1 B EAC1 1.25-B 2 1 Meter cluster connector (harness side) HH18C 4 8 AB16A 25 24 CAN-L CAN-H 6 5 94 72 50 28 73 51 29 7 4 3 2 1 Engine ECU side connector HJ94A 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 AP02V AP02S AP02G V SIG GND 12 56 34 V PTOAPP S PTOAPP G PTOAPP AP02V 0.3-L AP02S 0.3-G AP02G 0.3-BW AP02V 0.3-L AP02S 0.3-G AP02G 0.3-BW 4 5 6 1 2 3 0.3-L 0.3-G 0.3-BW 1 2 3 4 5 6 7 8 9 10 EAB1PL 0.85-B EAB1PR 0.85-B *1 *2 14B-8 1B-18 1B-9 IL01PT PT03M 0.3-P 2 IL01 0.85-O IL01 0.85-O IL01 0.85-O EAI1 0.85-B PT03 0.3-P 8 EAI1 0.85-B 16 1 10 3 7 OFF ON 1 2 3 4 5 6 7 8 9 10 10C PT02J 0.3-P 18B-5 PTO SW (CAB) 3 1 1 2 VP01M VPE1 B 13C 1 2 3 4 5 6 7 8 9 10 HQ8A 5 1 6 2 7 3 8 4 14B 2 1 2 1 CN2LIS L CN2HIS Y 2 1 5 4 CN5HED Y CN5LED L Refer to (2/2) for other specifications. < M/G without BlueTec exhaust gas aftertreatment > R 2 1 2 1 [13] 130 [12] 130 Meter cluster J/C(CAN-L) J/C(CAN-H) 130 905 905 401 JOINT (EAB1E) SAM 105 130 JOINT(EAB1S) 130 JOINT(EAC1) Clutch pedal pressed :OFF Clutch switch PTO control switch Engine ECU Chassis Cab SAM connector (harness side) 1B HH18B HH18A HH28B HN14B HQ2A HQ10C HQ10A 2B 8C 17B 18B PTO load sensor (for cab back) 11C 110 JOINT(IL01) 130 130 JOINT(EAI1) Gearbox PTO switch Gearbox PTO switch connector (harness side) HH10A To high-current fuse (HF01) 110 J/C(PT02J) 905 Gearbox PTO 3-way M/V Chassis PTO load sensor Instrument panel Cab Instrument panel Cab 905 J/C (CAN-H) 905 J/C (CAN-L) M/G: Manual gearbox PTO: Power take-off ECU: Electronic control unit M/V: Magnetic valve JOINT(EAB1PL) (EAB1PR) *1 *2 *1 : Right-hand drive vehicle *2 : Left-hand drive vehicle 880 J/C(CAN) 905 905 905 J/C(CAN-L) J/C(CAN-H) C01 J20 J20 B40 #031 A20 #054 S05 W08 J14 U01 #317 T13 J14 #089 A06 J01 W05 J09 J09 W01 J29 J29 GEARBOX POWER TAKE-OFF CIRCUIT 850 ---===WSE_1506_00001_0239.djvu===--- 54-08 54-08-5 850-C10040M-2 CN6HNX Y CN6LNX L Y CN8HNH CN8LNH L 12 CN5LNX L CN5HNX Y 905 CN6HNX Y CN6LNX L CN5LNX CN5HNX L Y 3 2 54 21 54 2 L Y CN4LAB 905 CN4HAB 1 11 12 45 12 45 CN9HED Y CN9LED L CN9HED CN9LED L Y 905 905 <FG> 905 < FE with BlueTec exhaust gas aftertreatment > R <Manual gearbox>(2/2) CN7HNX Y <*2> <*1> CN7LNX L CN7HNX CN7LNX Y L 2 3 10 9 21 54 12 45 905 CN8HNH CN8LNH Y L CN9HED Y CN9LED L CN9HED Y L 12 45 CN4HAB CN4LAB 905 CN5HNX Y CN5LNX L 12 45 CN7HNX Y L CN7LNX 905 CN9LED L Y *1:Wheelbase type C *2:Except *1 J/C(CAN) J/C(CAN) J/C (CAN) ATS Chassis J/C (CAN) CAN : Controller area network J/C(CAN) J/C (CAN) J/C (CAN) J/C (CAN) ATS Rear chassis Chassis W19 W01 W23 W24 W22 W19 W01 W23 W24 W22 ---===WSE_1506_00001_0240.djvu===--- 54-08-6 850-C10040D-1 8C-1 <DUONIC > (1/2) R FM22CM YG 1B-11 FB9CM OL 2B-9 F09 F22 17 10 EAB1E 0.85-B CME1 B CME1 B 91 3 FM22CM YG 10 2 FB9CM OL 9 18 CM01H Y CM01L L 1B-3 6 7 CN1HCM Y 17B-1 CN1LCM L 17B-11 CAN(L) CAN(H) 3 1 2 3 1 2 CPU Multi- information display 5V 123456789 101112131415161718 Meter cluster connector (harness side) HH18C HH40A HH81A 41 2 8 AB16A 25 24 CAN-L CAN-H CAN 32 19 HH40A HH40A 24 (H) (L) 6 5 94 72 50 28 73 51 29 7 4 3 2 1 Engine ECU side connector DUONIC ECU connector (harness side) HJ94A 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 14B-8 1B-18 58 HH81A IL01PT PT03 0.3-P 2 IL01 0.85-O IL01 0.85-O IL01 0.85-O EAI1 0.85-B PT03 0.3-P 8 EAI1 0.85-B 16 1 10 3 7 OFF ON 1 2 3 4 5 6 7 8 9 10 10C PT01 BY 11C-9 PTO SW (CHASSIS) PT01 PTE1 B EAC1 1.25-B 2 1 AP02V AP02S AP02G V SIG GND 12 56 34 V PTOAPP S PTOAPP G PTOAPP AP02V 0.3-L AP02S 0.3-G AP02G 0.3-BW AP02V 0.3-L AP02S 0.3-G AP02G 0.3-BW 4 5 6 1 2 3 0.3-L 0.3-G 0.3-BW 1 2 3 4 5 6 7 8 9 10 3231302928272625 2423222120191817 16151413121110 9 87654321 403938 37 36 353433 EAC1 1.25-B 1 2 VP01A RL VPE1 B 5 1 6 2 7 3 8 4 EAB1PL 0.85-B EAB1PR 0.85-B *3 *4 1B-9 *3 : Right-hand drive vehicle *4 : Left-hand drive vehicle 2 1 2 1 CN2LIS L CN2HIS Y 2 1 2 1 1 2 5 4 L CN6LED Y CN6HED L CN5LAM 1 2 5 4 3 6 Y CN5HAM Y AM01H L AM01L 905 905 Refer to (2/2) for other specifications. < Without BlueTec exhaust gas aftertreatment > R 54 3 21 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 1B HH18B HH18A HN14B HQ2A 2B 8C 17B HQ10C 11C HQ8A 14B [13] 130 Meter cluster J/C(CAN-L) J/C(CAN-H) 130 905 905 401 JOINT (EAB1E) SAM 105 Engine ECU Chassis Cab DUONIC ECU SAM connector (harness side) 110 JOINT(IL01) 130 JOINT(EAI1) Gearbox PTO switch Gearbox PTO switch connector (harness side) HH10A To high-current fuse (HF01) 110 [12] 130 130 JOINT(EAC1) PTO control switch PTO load sensor (for cab back) [12] 130 873 880 130 JOINT(EAC1) Gearbox PTO 3-way M/V Instrument panel Cab Instrument panel Cab Chassis PTO load sensor ECU: Electronic control unit PTO: Power take-off M/V: Magnetic valve 130 905 J/C (CAN-H) 905 J/C (CAN-L) JOINT(EAB1PL) (EAB1PR) *3 *4 905 905 J/C(CAN-L) J/C(CAN-H) J/C(CAN) J/C (CAN) C01 J20 J20 B40 W08 J14 U01 U07 J14 #089 A06 #054 S05 #317 T13 W05 J09 J09 W01 W02 J29 J29 V02 #565 GEARBOX POWER TAKE-OFF CIRCUIT 850 ---===WSE_1506_00001_0241.djvu===--- 54-08 54-08-7 ---===WSE_1506_00001_0242.djvu===--- 54-08-8 DUONIC ® SYSTEM ELECTRIC CIRCUIT 873 ---===WSE_1506_00001_0243.djvu===--- 54-08 54-08-9 3231302928272625 2423222120191817 161514131211109 8765432 1 403938 37 36 353433 54 3 21 81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 873-C10040-2 10 2 AM03S W AM03G G G-SEN S G-SEN G 14 15 0.85-B EAB1PL 1B-18 0.85-B EAB1PR *2 *1 1B-9 SIP V SIP G SS02V SS02S SS02G VP01A VPE1 AM09 24 62 23 61 22 60 12 50 69 49 48 46 65 21 4 1 5 2 20 27 29 21 25 9 1 58 3 6 2 5 1 4 6 3 5 2 1 8 7 3 2 6 1 5 4 2 3 7 4 8 1 5 6 2 1 3 2 1 3 2 1 1 2 MV1F MV1R MV2F MV2R MV3F MV3R SIP1S SIP2 S SIP3 S TEMP S TEMP G MVC CLSOL1 V CLSOL1 G CLSOL2 V CLSOL2 G MVR P GEAR SW S/S SIG GND BRKP + BRKP S BRKP G PTO M/V GS01V GS01S GS01G GS02S GS03S AM04S AM04G AM06V AM06G AM07V AM07G AM05V SS02S BrW SS02G Gr AM10V RY AM10S BrW AM10G Gr GM01F GM01R GM02F GM02R GM03F GM03R VP01A RL AM09 OB AM08V Bush connector V SIG GND V SIG GND V SIG GND SIG GND V G V G V G 1 2 MV1F MV1R MV2F MV2R MV3F MV3R V G V SIG GND V SIG G AME3 EAC1 RY BrW Gr RL B OB RW YG BR LR WL Br BO 0.75-L 0.75-R W O WL OL 0.5-Y 0.5-G 0.5-R 0.5-B Lg YB GB RG WB VW RB PG B 1.25-B 5C-11 5C-9 38 39 FM24A1 RY FM24A2 RL FM24A1 FM24A2 MAIN MAIN RY RL 35 3 AME2 1.25-B AME1 1.25-B GND GND 7C-8 3 7 10 1 2 40 19 1 2 3 4 5 6 7 8 9 10 0.3-B PTE3 PT03 0.3-P FA15AM P PT03 P FA15AM ACC PTO SW P 1B-1 3 2 1 V SIG GND FM24AM RW AM03S W AM03G FM24AM G 12 RW EAI1 0.85-B 16 0.85-B EAI1 PT03 0.3-P ILE1PT 0.3-B IL01PT 0.3-O SS02V SS02S SS02G RY BrW Gr 2 1 3 1 2 3 4 14B-8 8 0.85-O IL01 IL01 0.85-O PTO SW(chassis) FRONT DOOR SW DRIVER FRONT DOOR SW ASIST BRAKE SW NC BRAKE SW NO 1 2 1 1 3 1 4 2 2 1 12 LR KI01V LB KI01G 0.3-WR DS01FD 0.3-LR DS01FA BY PT01 PTE1 EAC1 1.25-B BS01NC 0.3-Gr BS01NO 0.3-Lg B EAB1S BSE1NC 0.3-B BSE1NO 0.3-B B 0.3-Gr BS01NC 0.3-Lg BS01NO 17B-17 17B-8 15B-18 15B-3 15B-19 18B-4 2B-2 11C-9 (2/2) HF01 15-R 10C 11 1 3 13 12 XT01H R XT01L V DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L 18B-16 FB9XT PL 2B-7 XTE1 B 2B-12 XTE2 B EAB1 8-B 1B-2 18B-1 8C-1 F09 F24 F15 F24 1B HH18B HH18A HH28A HH28B HN14B HN14D HN14C HQ2A HQ10C 2B 5C 7C 8C 11C 1 2 3 4 5 6 2 1 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15B 18B 17B HQ8A 5 1 6 2 7 3 8 4 14B P position : OPEN Except P position : CLOSE *1 : Left-hand drive vehicle *2 : Right-hand drive vehicle Front door switch, (driver's seat side) Front door switch, (Assistant driver's seat side) JOINT (EAC1) Vehicle speed sensor (DUONIC) Brake fluid pressure sensor Oil temperature sensor Harness side connector Gearbox PTO 3-way M/V Sensor 1 Sensor 2 Sensor 3 Linear solenoid valve (for inner clutch drive) Linear solenoid valve (for outer clutch drive) Solenoid valve (relief) Gear shift unit Shift stroke sensor Parking gear switch Cab Instrument panel Gearbox PTO switch connector (harness side) HH10A JOINT (EAI1) Gearbox PTO switch G sensor JOINT (EAB1PR) *1 (EAB1PL) *2 SAM Chassis DUONIC ECU Solenoid valve (cooling) Valve body 130 130 130 130 JOINT (IL01) 110 Cab [12] [14] Key interlock solenoid Stop lamp switch JOINT (EAB1S) PTO control switch JOINT (EAC1) Harness side connector HU2C 130 130 130 [12] Starter switch 105 DUONIC Chassis Brake pedal pressed : 1-2:ON 3-4:OFF To high-current fuse (HF01) 110 Diagnosis connector 130 [13] SAM connector (harness side) DUONIC ECU connector (harness side) HH81A HH40A ECU: Electronic control unit PTO: Power take-off M/V: Magnetic valve Instrument panel #089 A06 B40 J14 U07 W27 #054 S15 S12 S11 J14 #327 A43 #265 S14 #302 T06 #565 V02 #534 S13 #296 #535 #002 A18 #035 A31 #035 A33 #042 A21 #054 S05 J21 W08 ---===WSE_1506_00001_0244.djvu===--- 54-08-10 880-C10040-1 M M CUE1 0.3-B DF01 0.3-GO DFE1 0.3-B IL01DF 0.3-O ILE1DF 0.3-B G W AG04H AG04L CB2HAG CB2LAG CABIN CAN-H CABIN CAN-L PARKING CLUTCH SW BRAKE SW N.C BRAKE SW N.O DPF SW BSE1NO 0.3-B BSE1NC 0.3-B 2B-2 14B-8 15B-20 15B-19 18B-4 18B-9 18B-6 18B-14 11C-2 11C-9 11C-3 11C-1 7C-13 7C-12 1B-18 7C-11 18B-27 1 2 1 2 1 2 3 1 3 2 7 3 1 10 2 1 1 2 3 4 PB01 1 2 3 4 5 6 7 8 9 10 FB34FP 0.85-WL FE01S FE01G Y BL PT01 RE01 BY BW FB32AC LR FB32CF RG FB32CF RG FB34FX 0.75-WL FPE1 0.85-B FPE1X 0.75-B FE01S Y FE01G BL CF01 CFE1 1.25-GR 1.25-B CF01 1.25-GR FB40CF 1.25-WR FB40CF 1.25-WR AC01 RY FUEL SENSOR SIG PTO SW (chassis) REVERSE SW 4 + 3 GND 1 2 PTE1 B REE1 B EAB1PL 0.85-B *2 1B-9 EAB1PR 0.85-B *1 JOINT (EAC1) 5 4 3 8 7 4 1 2 1 2 2 1 1 CFE2 0.3-B 10 1 F40 53 2 41 EQ5A 1 2 3 4 5 6 CB1HIM CB1LIM PB01 CU01 BS01NC BS01NO DF01 EAB1S G W 0.3-BW 0.3-GY 0.3-Gr 0.3-Lg 0.3-GO IL01 0.85-O B 2 EAB1PL 1B-18 0.85-B EAB1PR 1B-9 0.85-B *2 *1 (1/10) F32 F32 F34 SIG GND 11 1 3 13 12 XT01H R XT01L V DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L 18B-16 FB9XT PL 2B-7 XTE1 B 2B-12 XTE2 B EAB1 1B-2 18B-1 8C-1 F09 HF01 15-R 10C 1B HH18B HH28A HH28B HN14B HN14C HQ10C 2B 7C 11C 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15B 18B HQ2A 8C 2 1 HQ8A 5 1 6 2 7 3 8 4 14B EAC1 1.25-B G W AA01H AA01L G W CB3H CB3L G W G W CB3H CB3L 1 2 14 13 8-B Clutch switch Parking brake switch Park:ON Stop lamp switch Brake pedal pressed : 1-2:ON 3-4:OFF DPF cleaning switch <M/G> <M/G> To Airbag ECU To air-conditioner ECU and control panel J/C (CAN-L) J/C (CAN-H) J/C (CAN-L) J/C (CAN-H) JOINT (EAB1S) DPF cleaning switch connector (harness side) SAM connector (harness side) HH10A Fuel tank unit Fuel pump Fuel level sensor Magnetic clutch Condenser fan motor PTO control switch Backup lamp switch (at gearbox reverse position : ON) Fuel Fuel tank unit connector (harness side) HK6A Chassis Dual pressure switch Condenser fan relay JOINT (EAB1PL) *2 (EAB1PR) *1 Cab Chassis High-current fuse box Chassis Cab 110 130 905 631 620 905 130 130 SAM [15] 130 130 JOINT (EAB1PL) *2 (EAB1PR) *1 130 130 905 905 105 Diagnosis connector 130 [13] To high-current fuse (HF01) 110 DPF : Diesel particulate filter ECU : Electronic control unit PTO : Power take-off M/G : Manual gearbox *1 : Left-hand drive vehicle *2 : Right-hand drive vehicle Cab Instrument panel [12] [13] CAN resistor #431 V01 #258 T11 #497 T11 #038 A36 #089 A13 #031 A20 #042 A21 #054 S05 #054 S01 #201 B16 U02 J04 J04 R08 T02 W16 J17 J17 J02 J13 J02 B40 J21 #828 B12 COMMON RAIL SYSTEM ELECTRIC CIRCUIT 880 ---===WSE_1506_00001_0245.djvu===--- 54-08 54-08-11 880-C10040-2 AP02V AP02S AP02G AP01V1 AP01S1 AP01G1 AP01V2 AP01S2 AP01G2 V SIG GND 12 56 34 16 60 38 17 61 39 V PTOAPP S PTOAPP G PTOAPP V APP1 S APP1 G APP1 V APP2 S APP2 G APP2 6 4 5 3 1 2 AP02V AP02S AP02G AP02V 0.3-L AP02S 0.3-G AP02G 0.3-BW AP01V1 YG + SIG GND + SIG GND AP01S1 WB AP01G1 GR AP01V2 YR AP01S2 LR AP01G2 RG 4 5 6 1 2 3 1 2 3 5 6 7 OP01UP 0.3-L 0.3-G 0.3-BW YG WB GR YR LR RG RB OP01UP RB 11 IDUPSW OP02UP RB 4 1 8-Y HF03 HF03 HF03 8-Y FR31B1 2.5-RY FR31B2 2.5-RW FR31B3 2.5-RB ED01 YR FM19ED 0.75-Lg FP01 LW FR31B1 FR31B2 FR31B3 ED01 FM19ED FP01 2.5-RY 2.5-RW 2.5-RB YR 0.75-Lg LW 1 BATT1 3 BATT2 5 BATT3 28 MRLY 54 T15(MAIN) 91 FPSP HF05 11 6 10 9 7 FR28 2-G 5-BW HF05 GL01 0.75-G GL01ST 0.75-PG GL01DI 0.75-BW GLE1 B NT02 0.75-R WB TQ01 NT01 0.75-G TQE1 B 1.5-B 1.5-G 1.5-RG 1.5-O 2-W GLG1 2-Y GLG2 2-RY GLG3 2-O GLG4 1 2 3 4 86 ST DI 31 GNT SW 88 TQL SW 44 GLW ST GLW DI 26 67 GL01ST GL01DI 0.75-PG 0.75-BW 1 2 3 4 EAC1 1.25-B 2 1 2 1 1 2 3 4 5 6 7 8 9 10 11 7C-2 7C-7 7C-10 7C-9 7C-3 5C-5 5C-4 8C-2 5-BW HF05 BATT LIN SIG GND B CSE1LG COMB.SW LIN SIG AC02 0.3-GR A/C SW 18B-23 18B-21 2B-8 15B-17 12 3 2 1 23 1 FB9CS CS01LS EAB1LG LW YG B (2/10) ENGINE RELAY H F28 F31 F09 F19 FUEL PUMP RELAY EAB1 8-B 8C-1 HH28A HH28B HN14B HN14D HN14C HQ2A 2B 5C 7C 8C 1 2 3 4 5 6 2 1 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15B 18B 6 5 94 72 50 28 73 51 29 7 4 3 2 1 SAM PTO load sensor (for cab back) Accelerator pedal position sensor PTO load sensor Chassis Cab Chassis Sensor 1 Sensor 2 Optional connector Optional connector High-current fuse box When in neutral:ON Glow plug 1 Glow plug 2 Glow plug 3 Glow plug 4 Torque limit switch When in gearbox 1st : ON Glow ECU JOINT(EAC1) Engine Chassis Glow ECU connector (harness side) HK11A Engine ECU JOINT (FR28) Engine ECU side connector HJ94A Gearbox neutral switch <M/G> <M/G C4 clutch> 110 130 130 110 Heater control panel <Manual air-conditioner> Air-conditioner ECU and control panel <Fully automatic air-conditioner> J/C(EAB1LG) Combination switch connector (harness side) HU3A Combination switch 905 or 620 105 130 [13] SAM connector (harness side) M/G : Manual gearbox ECU : Electronic control unit [12] #764 R13 #054 S03 U02 U01 B40 U04 W04 #056 S02 #324 A42 #317 T13 #001 A17 J01 W08 W05 J05 W07 ---===WSE_1506_00001_0246.djvu===--- 54-08-12 880-C10040-3 AdBlue AUTO CN2HIS CN2LIS Y L CN3H CN3L Y L IS01L IS01H L Y 9 18 13 10 CM01H CM01L Y L CME1 FM22CM CME1 EAB1E FM22CM B YG B 0.85-B YG CPU ENG SYS ENG OIL WATER SEPR DPF FULL 5V LED DRIVER Multi-infomation Display 24 25 CAN-H CAN-L CHASSIS CAN H CHASSIS CAN L CN1HCM Y CN1LCM L 1 3 2 1 3 2 1 3 2 1 3 2 7 6 9 17 1 2 1 2 SIG GND SIG GND 4 3 1 5 2 6 V LSH LSCP LSCA LSVG LSVN CATTSPRE S CATTSPRE G CATTSPOST S CATTSPOST G 78 65 82 81 LSH LSCP LSCA 7 64 LSVG LSVN 85 CA01S CA01G CA02S CA02G CA01S LW CA01G WL CA02S YB CA02G BY CA01S LW CA01G WL CA02S YB CA02G BY LA01HV 0.75-G LA01HG 0.75-LB LA01CP BR LA01CA RW LA01VG W LA01VN R LA01HG LA01CP LA01VG LA01VN LW WL YB BY *1 *1 *1 *1 *1 *1 *1 *1 0.75-LB BR 86 LA01CA RW W R 7 8 5 6 8 7 6 4 9 5 *3 *2 *2 *2 *2 *2 *2 *3 *3 *3 *3 *3 *3 *3 *3 *3 *3 *3 1 2 3 4 5 6 1 2 1 2 63 LA01HV 0.75-G FR28 2-G 7C-2 1B-11 1B-3 17B-1 17B-11 Level 4 Level 3 Level 2 Level 1 Urea level warning 2B-9 FB9CM 10 2 OL FB9CM OL (3/10) HH18C 123456789 101112131415161718 F28 F09 F22 EAB1 8-B 8C-1 1B HH18B HH18A HN14B HN14C HQ2A 2B 7C 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17B SPEAKER Y CN5HED L CN5LED CN4HAB CN4LAB Y L 4 8 1 3 2 4 6 5 AB03H Y AB03L L CM01HA Y 2 1 2 1 CM01LA L <*7> <*6> 6 5 94 72 50 28 73 51 29 7 4 3 2 1 HJ94A Meter cluster To ISS ECU J/C (CAN-L) J/C (CAN-H) J/C(CAN-H) J/C(CAN-L) Cab Lambda sensor HK2B HK2A HJ6A Sensor connector (harness side) ATS Rear chassis Chassis DUONIC Chassis Engine ECU JOINT (FR28) JOINT (EAB1E) SAM connector (harness side) 905 905 905 905 401 905 275 SCR temperature sensor 1 SCR temperature sensor 2 SAM 110 130 Urea level indicator 105 Meter cluster connector (harness side) 130 [13] Engine ECU side connector Instrument panel M/G : Manual gearbox ECU : Electronic control unit SCR : Selective catalytic reduction ISS : Idling stop and start system *1: With BlueTec exhaust gas aftertreatment *2:M/G *3 : DUONIC *4:FE *5:FG *6 : Wheelbase type C *7 : Except *6 R < M/G without BlueTec exhaust gas aftertreatment > R Refer to (8/10, 9/10, 10/10) for other specifications. Cab Chassis 790 To hydraulic unit J/C(CAN) 905 J/C(CAN-L) J/C(CAN-H) #336 X19 B40 #297 T21 J20 J20 J29 J29 J14 W27 W19 U01 C01 J09 J09 #336 X17 W08 W01 COMMON RAIL SYSTEM ELECTRIC CIRCUIT 880 ---===WSE_1506_00001_0247.djvu===--- 54-08 54-08-13 ---===WSE_1506_00001_0248.djvu===--- 54-08-14 880-C10040-5 4 (5/10) F19 F28 F27 1B HH18B HN14B 2B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 HQ2A 8C 2 1 HQ8A 5 1 6 2 7 3 8 4 14B HN14C 7C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 HN14D 5C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 7 3 1 10 6 4 9 4 1 5 3 2 CC03 Lg CC01 Lg CC04 LW CC05 LW CC06 BW CC06 BW CC02 LW CC03 Lg IL01 *1 *2 0.85-O EAI1 0.85-B CC01 Lg CC02 LW CC02 FM19ED LW 0.75-Lg FC01C 0.75-W FC02C 0.75-GW FM19ED 0.75-Lg IL01 0.85-O EAB1PR 0.85-B *1 EAB1PL 0.85-B FR28 2-G FB27F1 1.25-YL EAB1 8-B *2 HF01 15-R IL01 EAI1 0.85-O 0.85-B CC02 LW CC03 Lg CC06 BW CCE1 B CC07 LW ILE1CC B IL01CC 0.3-O CC06 CC02 CC03 BW LW Lg 4 3 2 11 12 8 16 1 2 3 4 5 6 7 8 9 10 Instrument Harness side connector HH10A J13 J14 6 5 8 7 AB8A 3 DD10B 2 3 1 1 4 5 2 3 1.25-YL FB27F1 0.75-W FC01C 0.75-G FR28F1 1.25-RW FC01 1 4 5 2 3 1.25-YL FB27F2 0.75-GW FC02C 0.75-G FR28F2 1.25-RL FC02 1.25-RW FC01 2-G FR28 1.25-RL FC02 1.25-B FCE1 Fan clutch magnet Cab Chassis FAN1 73 76 54 CRCMN T15 (MAIN) 50 FAN2 Engine ECU side connector HJ94A 6 5 94 72 50 28 73 51 29 7 3 2 1 5C-4 14B-8 10C 1B-9 1B-18 7C-2 2B-13 8C-1 SAM connector (harness side) SAM 105 130 [13] panel Chassis Cab Cab Cruise control relay Cruise control main switch 130 110 130 130 110 130 Cab Chassis Fan cluch relay 1 Fan cluch relay 2 To high-current fuse (HF01) [15] Engine ECU *1:Left-hand drive vehicle *2:Right-hand drive vehicle ECU: Electronic control unit B40 JOINT (IL01) JOINT (EAI1) JOINT (EAB1PR) (EAB1PL) #201 B18 #089 A02 W09a JOINT (FR28) R10 W10a J04 #201 B25 #201 B27 U01 COMMON RAIL SYSTEM ELECTRIC CIRCUIT 880 ---===WSE_1506_00001_0249.djvu===--- 54-08 54-08-15 ---===WSE_1506_00001_0250.djvu===--- 54-08-16 880-C10040-7 5 3 4 2 1 2 1 3 4 5 4 3 2 1 2 1 3 4 1 2 3 1 2 HS2 HS1 TANKHV PUMOHV PRINLHV HH1 DIAG H1 HH2 DIAG H2 FR30 FR29 HSE2 2-B HSE1 2-B TOP MID LOW GND 3 1 2 V GND V GND SIG V GND SIG GND V SIG GND V GND V PWM GND OP LEVEL:4 MID LEVEL:3 LOW LEVEL:2 GND:1 HS01S OL HS01DI RL HS02S GrB HS02DI PG PR01S V TH01S VY IC01G LgB LgB TH01G PS01V GY PS01S VR PS01G BL RV01G 0.75-LgR Sb LS01S VW LS01G WL L 0.75-G PR01V FR30 2-LR FR29 2-RB HSE2 2-B HSE1 2-B HS01S OL HS01DI RL HS02S GrB HS02DI PG PR01V 0.75-R PR01S W TH01S VY TH01G LgB PS01V R PS01S W PS01G B RV01G 0.75-B LS01S Sb LS01G VW FR30 FR29 HS01TH HS01PH HS01IH HS01S HS01DI HS02S HS02DI HS01IH HSE1IH HS01PH HSE1PH PR01V PRE1 PR01SR HS01TH HSE1TH TH01S TH01G PS01VR PS01SR PS01GR RV01V RV01GR LS01V LS01S LS01G 2-LR 2-RB 2-L 1.5-W 2-R OL RL GrB PG 2-R 2-B 1.5-W 1.5-B 0.75-R B W 2-L 2-B VY LgB R W B 0.75-R 0.75-B 0.75-R Sb VW 1 2 4 3 4 3 1 2 8 7 6 5 12 11 10 9 16 15 1 2 3 12 123 1 2 3 4 12345 1 2 3 4 1 2 3 4 5 HH1 74 SENS 8 DIAG1 9 HH2 92 DIAG2 10 RAPMP 48 TRATS S SEN G PRAS V PRAS S PRAS G RARV 87 89 15 55 33 49 RALS1 S RALS1 G 21 22 - + HF06 BT01 60-BR BTE1 60-BY BTE2 30-BY *1:M/G *2:DUONIC *3:Vehicle with battery equaliser : 24V *4:Vehicle without battery equaliser : 12V HF06A ST01X 3-RW RW ST01Y RW HF06B 3-R STE1X B STE1Y B STE1Y B EAC1 1.25-B 1 2 1 1 1 BBB5B 3-R HF06B 3-R *2 *1 *2 *1 *3 BTE3 30-BY *4 ST02 FM1ST ST03 ST01 ST02 RB LR RW Br ST03 LR ST01X ST02 Br ST03 Br RW LR 53 STRTH 27 STRTL FM1ST 10 9 11 4 3 5 1 3 6 4 5 KEY SW ACC KEY SW MAIN KEY SW START KE01ST KE01A KE01M FB13KE RB R WG Y G 2 FR28 2-LR 2-RB 2-G ST B M M BS 1B-5 18B-17 18B-3 15B-15 3B-3 7C-6 7C-4 7C-2 M B A S (7/10) F01 F28 F29 F13 F30 1B HH18B HH28A HH28B HH2B HN14A HN14C 3B 7C 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15B 18B 1 2 V GND 4 5 W IC01S IC01S W LgB IC01G WY BG 6 7 1 2 SIG GND 12 <*6> <*6> <*6> 6 5 94 72 50 28 73 51 29 7 4 3 2 1 46 60 31 45 16 30 15 1 *5:With BlueTec exhaust gas aftertreatment *6:Single cab (Except wheel base C, E), Crew cab R Urea line heater HQ5A HQ4A HQ5B HQ4B HJ3A HJ2A HN3A Urea supply module (motor and heater) Urea heater power unit Urea pressure sensor Urea temperature sensor and urea heater Urea reverting valve Urea level sensor Urea tank level unit JOINT(HSE1) Harness side connector Urea tank Chassis Starter Battery Starter relay JOINT (EAC1) High-current fuse box DUONIC Chassis Starter Chassis Starter relay (for drive) Starter switch Engine ECU JOINT(FR28) Cab Chassis 130 110 130 SAM SAM connector (harness side) 110 130 [16] [12] 130 130 [12] 105 <*5> ECU: Electronic control unit M/G: Manual gearbox <*5> <*5> <*5> <*5> <*5> <*5> Engine ECU side connector HH60A HJ94A Engine Chassis Engine Intercooler outlet temperature sensor Harness side connector (backward view connector) #339 X23 #002 A18 #187 U06 R15 W27 W26 #201 B19 U05 B40 W18 #773 X21 X22 X24 X26 X27 X25 W17 U02 U01 W08 W04 W04 R14a COMMON RAIL SYSTEM ELECTRIC CIRCUIT 880 ---===WSE_1506_00001_0251.djvu===--- 54-08 54-08-17 880-C10040-8 (8/10) 110 110 105 130 130 [13] 130 [14] 905 HN5A 905 *1: Wheelbase type C *2: Except *1 HH4A < DUONIC with BlueTec exhaust gas aftertreatment > R FR28 2-G 7C-2 8C-1 1B-9 F28 EAB1 8-B 1B-18 EAB1PL 0.85-B *2 EAB1PR 0.85-B *1 2 3 4 1 NX01V NX01V EDE4 B 3 2 4 1.25-GR FB39 1.25-LR 1.25-GR FB39 1.25-LR FR28ED FR28F1 FR28FC 0.85-G 0.75-G 0.75-G 5 0.75-GR NX01V NXE1 *1 B *2 0.75-B CN7HNX Y CN7LNX L CN7HNX Y CN7LNX L Y CN8HNH 1.25-GR NX01V NXE1 B CN7HNX CN7LNX Y L CN8LNH L 1 2 V HEATER + HEATER - TEMP SEN SIG GND TRIM RESISTOR TRIM RES. GND EMF 2 EMF 1 V CAN-H GND HH8B 5 1 6 2 7 3 8 4 CAN-L HEATER + HEATER - TEMP SEN SIG GND TRIM RESISTOR TRIM RES. GND EMF 2 EMF 1 NH01H Y NHE1 NH01L *1 B *2 0.75-B L NH01H Y NH01L L 1 2 4 3 GND 3 CAN-L NX01V NXE1 4 CAN-H NX01H NX01L Pu Y T B W G Br Gr NH01V 0.75-GR 0.75-GR Y NX01H Y L 4 1 2 3 10 9 24 25 NX01L L 1 3 2 4 6 5 1 2 3 4 5 31 2 64 5 CN8HNH Y CN9HED Y CN8LNH L <*2> <*1> CN9LED L CN9HED AB03L L CN5HAM L Y CN3L CN3H L Y Y AB03H CN5LAM Y L 54 6 21 3 CN4LAB CN4HAB 905 CN5HAM Y CN6HNX Y L Y CN5LAM CN6LNX L L 23 1 56 4 AM01H AM01L 905 CN6HNX Y CN6LNX L 12 3 45 6 CN7HNX NX02H Y L CN7LNX NX02L 905 4 8 790 CN9LED L Y CAN-H 1 2 4 5 V GND CAN-H GND 3 CAN-L NX02V NXE2 0.75-GR B NX02H Y NXE2S NX02L B L 1 2 3 4 5 Harness side connector HN5A CAN-L F39 4 1 2 3 873 SAM : Signal detect and actuation modules CAN : Controller area network ECU : Electronic control unit JOINT (FR28) SAM JOINT (EAB1PR) *1 JOINT (EAB1PL) *2 Cab Chassis J/C(CAN) Main relay 2 (NOx sensor and NH3 sensor) High-current fuse box NOx sensor 1 NH3 sensor ECU NH3 sensor J/C (CAN) J/C (CAN) J/C (CAN) Cab Chassis To hydraulic unit To DUONIC ECU NOx sensor 2 J/C (CAN) ATS Rear chassis Chassis Engine ECU B40 J04 J04 W19 U02 W01 W02 W23 W08 #298 X18a U01 W24 #201 B14 #298 X18 X20 W22 #252 X17a ---===WSE_1506_00001_0252.djvu===--- 54-08-18 880-C10040-9 110 110 105 130 130 [13] 130 [14] 905 HN5A 905 (9/10) < FE, M/G with BlueTec exhaust gas aftertreatment > R FR28 2-G 7C-2 8C-1 1B-9 F28 EAB1 8-B 1B-18 EAB1PL 0.85-B *2 EAB1PR 0.85-B *1 2 3 4 1 NX01V NX01V EDE4 B 3 2 4 1.25-GR FB39 1.25-LR 1.25-GR FB39 1.25-LR FR28ED FR28F1 FR28FC 0.85-G 0.75-G 0.75-G 5 0.75-GR NX01V NXE1 *1 B *2 0.75-B CN7HNX Y CN7LNX L CN7HNX Y CN7LNX L Y CN8HNH 1.25-GR NX01V NXE1 B CN7HNX CN7LNX Y L CN8LNH L 1 2 V HEATER + HH4A HH8B 5 1 6 2 7 3 8 4 4 1 2 3 HEATER - TEMP SEN SIG GND TRIM RESISTOR TRIM RES. GND EMF 2 EMF 1 V CAN-H GND CAN-L HEATER + HEATER - TEMP SEN SIG GND TRIM RESISTOR TRIM RES. GND EMF 2 EMF 1 NH01H Y NHE1 NH01L *1 B *2 0.75-B L NH01H Y NH01L L 1 2 4 3 GND 3 CAN-L NX01V NXE1 4 CAN-H NX01H NX01L Pu Y T B W G Br Gr NH01V 0.75-GR 0.75-GR Y NX01H Y L 4 1 2 3 10 9 24 25 NX01L L 1 3 2 4 6 5 1 2 3 4 5 31 2 64 5 CN8HNH Y CN9HED Y CN8LNH L CN9LED L CN9HED AB03L L CN5HNX L Y Y AB03H CN5LNX 790 Y L 54 6 21 3 L Y CN3L CN3H CN4LAB CN4HAB 905 CN5HNX Y CN5LNX L 12 3 45 6 Y L CN7HNX NX02H CN7LNX NX02L 905 4 8 CN9LED L Y CAN-H 1 2 4 5 V GND CAN-H GND 3 CAN-L NX02V NXE2 0.75-GR B NX02H Y NXE2S NX02L B L 1 2 3 4 5 Harness side connector HN5A CAN-L F39 <*2> <*1> *1: Wheelbase type C *2: Except *1 SAM : Signal detect and actuation modules CAN : Controller area network ECU : Electronic control unit M/G : Manual gearbox JOINT (FR28) SAM JOINT (EAB1PR) *1 JOINT (EAB1PL) *2 Cab Chassis J/C(CAN) Main relay 2 (NOx sensor and NH3 sensor) High-current fuse box NH3 sensor ECU NOx sensor 1 NH3 sensor J/C (CAN) J/C (CAN) Cab Chassis To hydraulic unit NOx sensor 2 J/C (CAN) ATS Rear chassis Chassis Engine ECU #252 X17a B40 J04 J04 W19 U02 W01 W23 W08 #298 X18a U01 W24 #201 B14 #298 X20 X18 W22 COMMON RAIL SYSTEM ELECTRIC CIRCUIT 880 ---===WSE_1506_00001_0253.djvu===--- 54-08 54-08-19 ---===WSE_1506_00001_0254.djvu===--- 54-09-1 54-09 OTHER CIRCUIT ---===WSE_1506_00001_0255.djvu===--- 54-09-2 905-C10040-1 4 3 2 1 CB3H CB2HAG SRS airbag(CAN-H) SRS airbag(CAN-L) Meter cluster(CAN-H) Meter cluster(CAN-L) AG04H - G CB2HAG G CB3H G AG04H 3 1 2 4 W CB2LAG W CB3L W AG04L 3 1 2 4 4 3 2 1 CB3L CB2LAG AG04L - -- 4 3 2 1 CB2HAG CB1HIM Immobiliser(CAN-H) Immobiliser(CAN-L) IM01H - G CB1HIM G CB2HAG G IM01H 3 1 2 4 W CB1LIM W CB2LAG W IM01L 3 1 2 4 4 3 2 1 CB2LAG CB1LIM IM01L - 4 3 2 1 CN1HCM CN2HIS CM01H Y CN1HCM Y CN2HIS 2 Y CM01H 3 1 4 4 3 2 1 CN1LCM CN2LIS CM01L L CN1LCM L CN2LIS L CM01L 2 1 3 4 (1/5) 210 880 880 210 SRS: Supplemental restraint system 631 631 JOINT CONNECTOR (J/C) 905 ---===WSE_1506_00001_0256.djvu===--- 54-09 54-09-3 ---===WSE_1506_00001_0257.djvu===--- 54-09-4 JOINT CONNECTOR (J/C) 905 ---===WSE_1506_00001_0258.djvu===--- 54-09 54-09-5 905-C10040-4 Y CN6HNX Y CN8HNH Y NX01H L CN6LNX L CN8LNH L Y CN5HNX, CN6HNX Y CN7HNX Y NX02H L CN5LNX, CN6LNX L CN7LNX L NX02L 3 1 2 4 5 6 1 CN6HNX CN5HNX 2 CN7HNX 3 NX02H 4 CN6LNX CN5LNX 5 CN7LNX 6 NX02L CONNECT NX01L 3 1 2 4 5 6 Y CN5HNX Y CN6HNX Y NX02H L CN5LNX L CN6LNX L NX02L 3 1 2 4 5 6 (4/5) 1 CN6HNX 23 NX01H 4 CN6LNX 5 CN8HNH CN8LNH 6 NX01L CONNECT CONNECT 1 CN5HNX 2 CN6HNX 3 NX02H 4 CN5LNX 5 CN6LNX 6 NX02L NOx sensor 1(CAN) <FG> 880 NOx sensor 2(CAN) <FE> 880 NOx sensor 2(CAN) <FG> 880 ---===WSE_1506_00001_0259.djvu===--- 54-09-6 905-C10040-5 4 3 2 1 CSE1LG EAB1LG Earth(EAB1LG) CHE1LG - B EAB1LG B CSE1LG B CHE1LG 3 1 2 4 4 3 2 1 - PT02J PTO(PT02J) <M/G> Rear door switch(040) PT03M - 0.3-P PT02J 0.3-P PT03M 3 1 2 4 4 3 2 1 ML01V ML01VJ Headlamp leveling(ML01VJ) ML01VL ML01VR RG ML01VJ 0.3-RG ML01V 0.3-RG ML01VL 0.3-RG ML01VR 3 1 2 4 0.3-BY DS01R 0.3-BY DS01RL 0.3-BY DS01RR 3 1 2 4 4 3 2 1 DS01RL DS01R DS01RR - (5/5) NH3 sensor ECU(CAN) Y CN8HNH Y CN9HED Y NH01H L CN8LNH L CN9LED L NH01L 3 1 2 4 5 6 1 CN8HNH 2 CN9HED 3 NH01H 4 CN8LNH 5 CN9LED 6 NH01L CONNECT PTO: Power take-off M/G: Manual gearbox 130 873 310 313 315 320 330 850 312 345 880 JOINT CONNECTOR (J/C) 905 ---===WSE_1506_00001_0260.djvu===--- 54-09 54-09-7 959-C10040 F09 F22 CAN(H) CAN(L) FB9CM OL 2B-9 FM22CM YG FB9CM OL FM22CM YG FB9CM FM22CM YG 1B-11 F20 1B-14 B 1B-3 10C 10 9 7 6 7 17 CME1 B CME1 FM20LD FM20LD YL YL FM20LD YL LD01H LD01L LDE1 Y L 0.3-B 1B HH18B HN14B 2B HQ2A 8C 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 HQ8A 5 1 6 2 7 3 8 4 14B EAB1E 0.85-B IL01 0.85-O EAB1PR 0.85-B EAB1S B LD01 0.3-LW EAB1 8-B SPARE INPUT SWITCH DIG1 HF01 15-R HH18A 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 17B CN1HCM Y 17B-1 14B-8 1B-9 2B-2 15B-21 8C-1 CN1LCM L Y L 17B-11 CM01H CM01L 3 1 3 1 CM01HA Y CM01LA L CM01HB Y CM01LB L 2 1 4 2 1 4 HH28A 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 15B 2 13 18 CME1 B 10 9 4 3 2 1 +B CAN-H CAN-L GND HH18C 123456789 101112131415161718 731 1 0 ON OFF 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 LED DRIVER Multi- information display 5V SAM Cab Cab JOINT(EAB1E) 130 JOINT(EAB1S) JOINT (EAB1PR) 130 130 J/C(CAN-H) J/C(CAN-L) 905 905 905 905 110 130 105 401 SAM connector (harness side) Instrument panel Instrument panel Cab Instrument panel J/C (CAN-L) J/C (CAN-H) Meter cluster Lane recognition camera Lane recognition camera side connector To high-current fuse (HF01) Meter cluster connector (harness side) LDWS cutoff switch LDWS cutoff switch connector (harness side) HH10A [13] LDWS: Lane departure warning system B40 C01 P10 #350 J14 J13 J14 J29 J29 J20 J20 A10 #089 LDWS (LANE DEPARTURE WARNING SYSTEM) CIRCUIT 959 ---===WSE_1506_00001_0261.djvu===--- 54-10-1 54-10 ELECTRICAL EQUIPMENT INSTALLATION POSITIONS ---===WSE_1506_00001_0262.djvu===--- 54-10-2 54-L10040A-1 A01-14 A13 A14 A14 A12 A11 A09 A06 A04 A05 A01 A02 A03 A04 A05 A06 A09 A10 A11 A12 A13 A14 ASR : Anti-spin regulator DPF : Diesel particulate filter ESP : Electronic stability program ISS : Idling stop and start system LDWS : Lane departure warning system ECO mode switch <DUONIC >, Transfer HIGH/LOW changover switch <FG> Front drive switch <FG>, Cruise control main switch Hazard switch Front fog lamp switch Rear fog lamp switch Gearbox power take-off switch Headlamp leveling switch LDWS cutoff switch ISS cut switch Mirror heater switch DPF cleaning switch ESP/ASR cutoff switch <FE> A03 A01 A02 (Switch) <Right-hand drive vehicle> A13 A12 A11 A09 A06 A05 A04 A03 A01 A02 <Left-hand drive vehicle> R A10 A10 SWITCH AND SENSOR A ---===WSE_1506_00001_0262.djvu===--- 54-10-2 54-L10040A-1 A01-14 A13 A14 A14 A12 A11 A09 A06 A04 A05 A01 A02 A03 A04 A05 A06 A09 A10 A11 A12 A13 A14 ASR : Anti-spin regulator DPF : Diesel particulate filter ESP : Electronic stability program ISS : Idling stop and start system LDWS : Lane departure warning system ECO mode switch <DUONIC >, Transfer HIGH/LOW changover switch <FG> Front drive switch <FG>, Cruise control main switch Hazard switch Front fog lamp switch Rear fog lamp switch Gearbox power take-off switch Headlamp leveling switch LDWS cutoff switch ISS cut switch Mirror heater switch DPF cleaning switch ESP/ASR cutoff switch <FE> A03 A01 A02 (Switch) <Right-hand drive vehicle> A13 A12 A11 A09 A06 A05 A04 A03 A01 A02 <Left-hand drive vehicle> R A10 A10 SWITCH AND SENSOR A ---===WSE_1506_00001_0263.djvu===--- 54-10 54-10-3 54-L10040A-2L A16-23 A21 A22 A21 Stop lamp switch A22 Brake fluid level switch A23 Clutch switch (lower) <FG> A16 Horn switch A17 Combination switch A18 Starter switch A20 Clutch switch <M/G> M/G : Manual gearbox Front (Switch) <Left-hand drive vehicle> A16 A18 A17 A23 A20 ---===WSE_1506_00001_0264.djvu===--- 54-10-4 54-L10040A-2R A16-23 A21 A22 A20 A23 A16 Front A18 A17 (Switch) <Right-hand drive vehicle> A16 Horn switch A17 Combination switch A18 Starter switch A20 Clutch switch <M/G> A21 Stop lamp switch A22 Brake fluid level switch A23 Clutch switch (lower) <FG> M/G : Manual gearbox SWITCH AND SENSOR A ---===WSE_1506_00001_0265.djvu===--- 54-10 54-10-5 54-L10040A-3L A31-38 A33 A33 A37 A38 A36 A31 A31 A31 Front door switch, Dr A33 Front door switch, As A36 Parking brake switch A37 Rear door switch, RH <Crew cab> A38 Rear door switch, LH <Crew cab> Dr : Driver's seat side As : Assistant driver's seat side <Except crew cab> <Crew cab> a a <Parking brake lever> (View a) (Switch) <Left-hand drive vehicle> ---===WSE_1506_00001_0266.djvu===--- 54-10-6 54-L10040A-3R A31-38 A33 (Switch) A31 A36 A31 Front door switch, Dr A33 Front door switch, As A36 Parking brake switch A37 Rear door switch, RH <Crew cab> A38 Rear door switch, LH <Crew cab> Dr : Driver's seat side As : Assistant driver's seat side <Except crew cab> <Crew cab> <Parking brake lever> (View a) a a A31 A37 A33 A38 <Right-hand drive vehicle> SWITCH AND SENSOR A ---===WSE_1506_00001_0267.djvu===--- 54-10 54-10-7 54-L10040A-4L A41-44 (Sensor) A43 Front A41 <Left-hand drive vehicle> Front A44 A41 Photo sensor <Fully automatic air-conditioner> A42 Accelerator pedal position sensor A43 G sensor <DUONIC , FG> A44 Sub G sensor <SRS airbag> SRS : Supplemental restraint system R A42 Front ---===WSE_1506_00001_0268.djvu===--- 54-10-8 54-L10040A-4R A41-44 A41 Photo sensor <Fully automatic air-conditioner> A42 Accelerator pedal position sensor A43 G sensor <DUONIC , FG> A44 Sub G sensor <SRS airbag> SRS : Supplemental restraint system (Sensor) A42 A43 Front Front Front A44 A41 <Right-hand drive vehicle> R SWITCH AND SENSOR A ---===WSE_1506_00001_0269.djvu===--- 54-10 54-10-9 54-L10040A-5 A46-47 <Left-hand drive vehicle> <FE> A46 A46 A47 A47 A46 ESP sensor <ESP > A47 Vacuum sensor <ESP > ESP : Electronic stability program <Wide cab> <Standard cab> <Right-hand drive vehicle> R R ---===WSE_1506_00001_0270.djvu===--- 54-10-10 54-L10040B-1L B02-07 B02 B05 Front Front <Left-hand drive vehicle> Front B07 ECU : Electronic control unit ISS : Idling stop and start system SRS : Supplemental restraint system B02 Keyless entry ECU B03 DC/DC converter <DUONIC and ISS> B05 Immobiliser ECU B06 Airbag ECU B07 ISS ECU B06 B03 Front R RELAY AND ELECTRONIC CONTROL UNIT B ---===WSE_1506_00001_0271.djvu===--- 54-10 54-10-11 54-L10040B-1R B02-07 B03 B02 B06 B05 B07 Front Front Front Front B02 Keyless entry ECU B03 DC/DC converter <DUONIC and ISS> B05 Immobiliser ECU B06 Airbag ECU B07 ISS ECU ECU : Electronic control unit ISS : Idling stop and start system SRS : Supplemental restraint system <Right-hand drive vehicle> R ---===WSE_1506_00001_0272.djvu===--- 54-10-12 B11-35 54-L10040B-2L a <View a> (Meter cluster backward view) B11 B33 B34 B35 B11 B12 B14 B15 B16 B17 B18 B19 B21 Shift lever unit <DUONIC > CAN resistor Main relay 2(NOx sennsor and NH3 sensor) Fuel heater relay Condenser fan relay Shift lever unit relay <DUONIC >, Four-wheel drive relay<FG> Cruise control relay Starter relay (for drive) Trailer rear fog lamp relay B12 Front Front <Left-hand drive vehicle> B15 B16 B19 B14 B17 B25 B26 B27 B28 B24 B23 R R B22 B23 B24 B25 B26 B27 B28 B33 B34 B35 CAN : Controller area network ECU : Electronic control unit Trailer tail lamp relay, RH Trailer tail lamp relay, LH Trailer back lamp relay Fan clutch relay 1 Brake control valve relay 1 Fan clutch relay 2 Brake control valve relay 2 Transfer ECU <FG> Diode <FG> Diode <FG> B21 B22 B18 RELAY AND ELECTRONIC CONTROL UNIT B ---===WSE_1506_00001_0273.djvu===--- 54-10 54-10-13 54-L10040B-2R B11-35 B11 B33 <View a> Front (Meter cluster backward view) a Front <Right-hand drive vehicle> B12 B35 B34 B14 B23 B24 B22 B21 B15 B16 B19 B17 B25 B26 B27 B28 B18 B11 B12 B14 B15 B16 B17 B18 B19 B21 Shift lever unit <DUONIC > CAN resistor Main relay 2(NOx sennsor and NH3 sensor) Fuel heater relay Condenser fan relay Shift lever unit relay <DUONIC >, Four-wheel drive relay<FG> Cruise control relay Starter relay (for drive) Trailer rear fog lamp relay R R B22 B23 B24 B25 B26 B27 B28 B33 B34 B35 CAN : Controller area network ECU : Electronic control unit Trailer tail lamp relay, RH Trailer tail lamp relay, LH Trailer back lamp relay Fan clutch relay 1 Brake control valve relay 1 Fan clutch relay 2 Brake control valve relay 2 Transfer ECU <FG> Diode <FG> Diode <FG> ---===WSE_1506_00001_0274.djvu===--- 54-10-14 0 54-L10040B-3 B40 B40 B40 B40 SAM ** SAM : Signal detect and actuation modules A/C BLOWER RELAY * 12V/24V ACC RELAY * 12V/24V IGN RELAY IGNITION RELAY FUEL PUMP RELAY A/C COMP COND. RELAY ACC RELAY ENGINE RELAY HORN RELAY * The voltage is different depending on the specification of the vehicle. ・Vehicle with battery equaliser : 24V ・Vehicle without battery equaliser : 12V <Right-hand drive vehicle> <Left-hand drive vehicle> <View a (front side)> <View a (back side)> a a RELAY AND ELECTRONIC CONTROL UNIT B ---===WSE_1506_00001_0275.djvu===--- 54-10 54-10-15 54-L10040B-4 B46-49 <Crew cab (rear air-conditioner)> B46 B47 B49 B48 B46 Rear condenser fan relay B47 Rear blower motor relay (high) B48 Rear blower motor relay B49 Rear blower motor relay (middle) ---===WSE_1506_00001_0276.djvu===--- 54-10-16 54-L10040C-L C01-04 C03 C01 C02 Front C01 Meter cluster C02 Windscreen washer motor C03 Wiper motor C04 Headlamp leveling actuator <Left-hand drive vehicle> <View a> <View b> C04 a b METER AND MOTOR C ---===WSE_1506_00001_0277.djvu===--- 54-10 54-10-17 54-L10040C-R C01-04 C03 a b <View a> <View b> C01 C02 C04 Front <Right-hand drive vehicle> C01 Meter cluster C02 Windscreen washer motor C03 Wiper motor C04 Headlamp leveling actuator ---===WSE_1506_00001_0278.djvu===--- 54-10-18 54-L10040D-1L D01-09 D01 Diode D02 Fresh/recirculation changeover motor D03 Blower resistor D04 Blower motor D05 Thermostat D09 Heater control panel ECU : Electronic control unit D05 <Manual air-conditioner (left-hand drive vehicle)> D03 D02 D04 D09 (Panel backward view) <View a> <View b> Front Front b a b <Standard cab> <Wide cab> D02 D03 D04 D01 HEATER AND AIR-CONDITIONER D ---===WSE_1506_00001_0279.djvu===--- 54-10 54-10-19 54-L10040D-1R D01-09 D01 Diode D02 Fresh/recirculation changeover motor D03 Blower resistor D04 Blower motor D05 Thermostat D09 Heater control panel ECU : Electronic control unit D05 D02 D03 D09 D04 D01 Front Front (Panel backward view) <Manual air-conditioner (right-hand drive vehicle)> ---===WSE_1506_00001_0280.djvu===--- 54-10-20 54-L10040D-2L D02-09 D05 <Fully automatic air-conditioner (left-hand drive vehicle)> D02 D06 D03 D04 a a D07 D09 D08 D02 Fresh/recirculation changeover motor D03 Power MOS-FET (transistor) D04 Blower motor D05 Thermostat D06 Air inlet sensor D07 Mode motor D08 Air mixing motor D09 Air-conditioner ECU and control panel ECU : Electronic control unit Front D02 D06 D03 D04 <Standard cab> <Wide cab> <View a> HEATER AND AIR-CONDITIONER D ---===WSE_1506_00001_0281.djvu===--- 54-10 54-10-21 54-L10040D-2R D02-09 D05 <Fully automatic air-conditioner (right-hand drive vehicle)> D02 D06 D03 D04 D07 D08 D09 Front D02 Fresh/recirculation changeover motor D03 Power MOS-FET (transistor) D04 Blower motor D05 Thermostat D06 Air inlet sensor D07 Mode motor D08 Air mixing motor D09 Air-conditioner ECU and control panel ECU : Electronic control unit ---===WSE_1506_00001_0282.djvu===--- 54-10-22 54-L10040D-3 D20-25 D22 D23 D24 D25 Front D20 D24 Rear mode motor D25 Rear blower resistor D20 Control panel (rear air-conditioner switch) D22 Rear heater temperature motor D23 Rear blower motor <Rear air-conditioner> HEATER AND AIR-CONDITIONER D ---===WSE_1506_00001_0283.djvu===--- MEMO 54-10-23 54-10 ---===WSE_1506_00001_0284.djvu===--- 54-10-24 54-L10040E-1 E01-15 Speaker E13 E12 E11 E10 <Front door, LH> <Front door, RH> Speaker E06 E07 E08 E09 E10 Step lamp, Dr E11 Power window motor, Dr E12 Door lock actuator, Dr E13 Power window switch, Dr E14 Rear door lock actuator, As <Crew cab> E15 Rear door lock actuator, Dr <Crew cab> E01 Mirror heater, Dr E04 Mirror heater, As E06 Power window switch, As E07 Door lock actuator, As E08 Power window motor, As E09 Step lamp, As E14 E15 <Rear door, RH> <Rear door, LH> <Left-hand drive vehicle> Dr : Driver's seat side As : Assistant driver's seat side E01 E04 DOOR AND MIRROR E ---===WSE_1506_00001_0285.djvu===--- 54-10 54-10-25 54-L10040E-2 E01-15 Speaker E06 E07 E08 E09 <Front door, LH> <Front door, RH> Speaker E13 E12 E11 E10 E10 Step lamp, Dr E11 Power window motor, Dr E12 Door lock actuator, Dr E13 Power window switch, Dr E14 Rear door lock actuator, As <Crew cab> E15 Rear door lock actuator, Dr <Crew cab> E01 Mirror heater, Dr E04 Mirror heater, As E06 Power window switch, As E07 Door lock actuator, As E08 Power window motor, As E09 Step lamp, As E15 E14 <Rear door, RH> <Rear door, LH> <Right-hand drive vehicle> Dr : Driver's seat side As : Assistant driver's seat side E01 E04 ---===WSE_1506_00001_0286.djvu===--- 54-10-26 54-L10040F F01-04 F01 F01a F01a F02 F04a F04a F01 Cab lamp, cab and spot lamp F01a End-outline marker lamp, RH <Wide cab> F02 In car sensor <Fully automatic air-conditioner> F04 Rear cab lamp <Crew cab> F04a End-outline marker lamp, LH <Wide cab> F04 F01 <Except crew cab> <Crew cab> ROOF F ---===WSE_1506_00001_0287.djvu===--- 54-10 54-10-27 54-L10040G G01-06 G01 Front and side turn signal lamp, LH G02 Headlamp, LH G03 Fog lamp and daytime running lamp, LH G04 Fog lamp and daytime running lamp, RH G05 Headlamp, RH G06 Front and side turn signal lamp, RH G01 G02 G03 G04 G05 G06 CAB G ---===WSE_1506_00001_0288.djvu===--- 54-10-28 54-L10040H H01 H01 H01 Cab tilt lock switch <Except crew cab> TILT H ---===WSE_1506_00001_0289.djvu===--- MEMO 54-10-29 54-10 ---===WSE_1506_00001_0290.djvu===--- 54-10-30 J01-17 54-L10040J-1L J01 J04 J04a J05 J05a J07 J10 Front Front J15 J12 J14 J11 J10a J11a J13 Indicate by connector type [ ]. CAN : Controller area network ISS : Idling stop and start system PTO : Power take-off SRS : Supplemental restraint system <Left-hand drive vehicle> J09 J07a J02, J17 J01 J02 J04 J04a J05 J05a J07 J07a J09 J10 J10a J11 J11a J12 J13 J14 J15 J17 Joint connector (Earth : EAB1LG), Joint connector (PTO : PT02J) Joint connector (SRS airbag : CAN-H), Joint connector (SRS airbag : CAN-L) Connection of cab harness and chassis harness : [AN4A], [DD10B] Connection of cab harness and trailer lamp harness : [AK6A] Optional connector : [AK2A] Connection of chassis harness and trailer lamp harness : [AK6A] Connection of cab harness and roof harness : [AK8A] Joint connector (Headlamp leveling : ML01VJ) Joint connector (ISS : CAN-H), Joint connector (ISS : CAN-L) Connection of cab harness and door harness, (assistant driver's seat side) : [DD7A], Connection of door harness, (assistant driver's seat side) and rear door harness : [DD2A] <Crew cab> Connection of instrument panel harness and air-conditioner harness : [AK18A] <Fully automatic air-conditioner> Connection of cab harness and air-conditioner harness : [AN2A] Connection of instrument panel harness and air-conditioner harness : [AK6A] <Manual air-conditioner> Connection of cab harness and instrument panel harness : [AK4A] Connection of cab harness and instrument panel harness : [AK22B] Connection of cab harness and instrument panel harness : [AK22A] Connection of instrument panel harness and air-conditioner harness : [AN6A] <Manual air-conditioner> Joint connector (Immobiliser : CAN-H), Joint connector (Immobiliser : CAN-L) JOINTS OF MAIN HARNESS CONNECTORS J ---===WSE_1506_00001_0291.djvu===--- 54-10 54-10-31 J01-17 54-L10040J-1R J01 J04a J07 J10 J09, J07a Front Front <Right-hand drive vehicle> J15 J13 J14 J11 J12 J10a J11a J05 J05a J04 J17 J02 J01 J02 J04 J04a J05 J05a J07 J07a J09 J10 J10a J11 J11a J12 J13 J14 J15 J17 Joint connector (Earth : EAB1LG), Joint connector (PTO : PT02J) Joint connector (SRS airbag : CAN-H), Joint connector (SRS airbag : CAN-L) Connection of cab harness and chassis harness : [AN4A], [DD10B] Connection of cab harness and trailer lamp harness : [AK6A] Optional connector : [AK2A] Connection of chassis harness and trailer lamp harness : [AK6A] Connection of cab harness and roof harness : [AK8A] Joint connector (Headlamp leveling : ML01VJ) Joint connector (ISS : CAN-H), Joint connector (ISS : CAN-L) Connection of cab harness and door harness, (assistant driver's seat side) : [DD7A], Connection of door harness, (assistant driver's seat side) and rear door harness : [DD2A] <Crew cab> Connection of instrument panel harness and air-conditioner harness : [AK18A] <Fully automatic air-conditioner> Connection of cab harness and air-conditioner harness : [AN2A] Connection of instrument panel harness and air-conditioner harness : [AK6A] <Manual air-conditioner> Connection of cab harness and instrument panel harness : [AK4A] Connection of cab harness and instrument panel harness : [AK22B] Connection of cab harness and instrument panel harness : [AK22A] Connection of instrument panel harness and air-conditioner harness : [AN6A] <Manual air-conditioner> Joint connector (Immobiliser : CAN-H), Joint connector (Immobiliser : CAN-L) CAN : Controller area network ISS : Idling stop and start system PTO : Power take-off SRS : Supplemental restraint system Indicate by connector type [ ]. ---===WSE_1506_00001_0292.djvu===--- 54-10-32 54-L10040J-2L J19-21 J19 Connection of cab harness and door harness, (driver's seat side) : [DD7A], Connection of door harness, (driver's seat side) and rear door harness : [DD2A] <Crew cab> J20 Joint connector (Meter cluster : CAN-H), Joint connector (Meter cluster : CAN-L) J21 Diagnosis connector CAN : Controller Area Network Indicate by connector type [ ]. J19 Front J20 J21 Front <Left-hand drive vehicle> JOINTS OF MAIN HARNESS CONNECTORS J ---===WSE_1506_00001_0293.djvu===--- 54-10 54-10-33 54-L10040J-2R J19-21 J20 J19 Connection of cab harness and door harness, (driver's seat side) : [DD7A], Connection of door harness, (driver's seat side) and rear door harness : [DD2A] <Crew cab> J20 Joint connector (Meter cluster : CAN-H), Joint connector (Meter cluster : CAN-L) J21 Diagnosis connector CAN : Controller area network Indicate by connector type [ ]. J19 J21 Front Front <Right-hand drive vehicle> ---===WSE_1506_00001_0294.djvu===--- 54-10-34 54-L10040J-3 J28-29 J28 Connector [AK4A] <Without tachograph>, Connection of instrument panel harness and tachograph harness [AK4A] <With tachograph> J29 Joint connector (Tachograph : CAN-H), Joint connector (Tachograph : CAN-L) <Left-hand drive vehicle> J28 Front (Panel backward view) J28 Front (Panel backward view) J29 (Meter cluster backward view) <Right-hand drive vehicle> (Meter cluster backward view) Front J29 Front JOINTS OF MAIN HARNESS CONNECTORS J ---===WSE_1506_00001_0295.djvu===--- 54-10 54-10-35 54-L10040J-4 J31-33 <Crew cab (right-hand drive vehicle)> J32 J33 J31 Front <View b> <View a> b a J31 Front <Crew cab (left-hand drive vehicle)> J32 J33 J31 Connection of chassis harness and rear air-conditioner harness : [DD5A] J32 Connection of cab harness and rear door switch harness : [AK3A], Connection of cab harness and rear air-conditioner harness : [AK3A] <With rear air-conditioner> J33 Joint connector (Rear door switch : 040) Indicate by connector type [ ]. ---===WSE_1506_00001_0296.djvu===--- 54-10-36 54-L10040P P01-10 P01 P01 P02 P07,P08 P07,P08 P01 Airbag module (assistant driver's seat side) <*1> P02 Tachograph P03 Cigarette lighter P04 Airbag module (driver's seat side) <*1> P05 Clock spring <*1> P06 Immobiliser antenna P07 Seat belt with pre-tensioner (assistant driver's seat side) <*1> P08 Seat belt with pre-tensioner (driver's seat side) <*1> P09 Steering wheel angle sensor <ESP > P10 Lane recognition camera P04 P03 P05 P09 Front *1 : SRS airbag ESP:Electronic Stability Program SRS : Supplemental restraint system <Right-hand drive vehicle> P02 P03 <Left-hand drive vehicle> R P06 P10 P10 OTHERS P ---===WSE_1506_00001_0297.djvu===--- MEMO 54-10-37 54-10 ---===WSE_1506_00001_0298.djvu===--- 54-10-38 R01-10 54-L10040R-1 (Right side view) (Upper view) R04 R04a R06 R07 R10 R08 R03 R02 R05 R01 R02 R03 R04 R04a R05 Injector Camshaft timing sensor EGR actuator Exhaust brake valve EGR water temperature sensor VGT position sensor R06 R07 R08 R10 EGR : Exhaust gas recirculation VGT : Variable geometry turbocharger Engine speed sensor Alternator Magnetic clutch Fan clutch magnet R01 ENGINE R ---===WSE_1506_00001_0298.djvu===--- 54-10-38 R01-10 54-L10040R-1 (Right side view) (Upper view) R04 R04a R06 R07 R10 R08 R03 R02 R05 R01 R02 R03 R04 R04a R05 Injector Camshaft timing sensor EGR actuator Exhaust brake valve EGR water temperature sensor VGT position sensor R06 R07 R08 R10 EGR : Exhaust gas recirculation VGT : Variable geometry turbocharger Engine speed sensor Alternator Magnetic clutch Fan clutch magnet R01 ENGINE R ---===WSE_1506_00001_0299.djvu===--- 54-10 54-10-39 R11-18 54-L10040R-2 (Left side view) R11 R17 R18 R12 R13 R15 R16 R11 Water temperature sensor R12 Pressure regulation valve R13 Glow plug R14 Pressure sensor R14a Intercooler outlet temperature sensor R15 Starter R16 Oil pressure switch R17 FMU (fuel metering unit) R18 Boost pressure and temperature sensor R14 R14a ---===WSE_1506_00001_0300.djvu===--- 54-10-40 54-L10040S-1 S01-05 S01 S03 S02 S05 S04 S01 Backup lamp switch S02 Torque limit switch <C4 clutch> S03 Gearbox neutral switch S04 Vehicle speed sensor S05 PTO control switch PTO : Power take-off <Manual gearbox> (Upper view) (Left side view) GEARBOX S ---===WSE_1506_00001_0301.djvu===--- 54-10 54-10-41 54-L10040S-2 S04-15 S04 S12 S13 S14 PTO : Power take-off S11 S15 <DUONIC > S04 Vehicle speed sensor S05 PTO control switch S11 Valve body (connector) S12 Shift stroke sensor (connector) S13 Gear shift unit S14 Vehicle speed sensor <DUONIC > S15 Parking gear switch <Vacuum PTO> S05 (Right side view) (Left side view) R R ---===WSE_1506_00001_0302.djvu===--- 54-10-42 54-L10040S-3 S04-22 S04 S21 S22 <Transfer (FG)> (Upper view) (Left side view) S04 Vehicle speed sensor S21 Transfer four-wheel drive switch S22 Transfer low switch GEARBOX S ---===WSE_1506_00001_0303.djvu===--- MEMO 54-10-43 54-10 ---===WSE_1506_00001_0304.djvu===--- 54-10-44 54-L10040T-1 T01-02 T01 Vacuum switch T02 Dual pressure switch <Air-conditioner> (Switch) T02 <FE (except crew cab), FG> <FE (crew cab)> T02 T01 T01 Front Front Front Vacuum tank Vacuum tank <Left-hand drive vehicle> <Wide cab> <Standard cab> T02 T01 Vacuum tank (Driver's seat floor under) (Driver's seat floor under) <Right-hand drive vehicle> SWITCH AND SENSOR T ---===WSE_1506_00001_0304.djvu===--- 54-10-44 54-L10040T-1 T01-02 T01 Vacuum switch T02 Dual pressure switch <Air-conditioner> (Switch) T02 <FE (except crew cab), FG> <FE (crew cab)> T02 T01 T01 Front Front Front Vacuum tank Vacuum tank <Left-hand drive vehicle> <Wide cab> <Standard cab> T02 T01 Vacuum tank (Driver's seat floor under) (Driver's seat floor under) <Right-hand drive vehicle> SWITCH AND SENSOR T ---===WSE_1506_00001_0305.djvu===--- 54-10 54-10-45 54-L10040T-2 T06 T06 Brake fluid pressure sensor <DUONIC > (Sensor) <FEB■, FEC7, FG> <FEA0> T06 R Front Front Front ---===WSE_1506_00001_0306.djvu===--- 54-10-46 54-L10040T-3 T11-13 T11 Fuel level sensor,fuel pump T12 Fuel filter T13 PTO load sensor (for cab back) T12 <*1> T12 <*2> T11 T13 T12 <*3> *1 : Fuel tank front side *2 : Fuel tank rear side *3 : Frame left side (Sensor) Front PTO : Power take-off T11 T12 <FG> <FE> Front The installation position is different depending on the specification. SWITCH AND SENSOR T ---===WSE_1506_00001_0307.djvu===--- 54-10 54-10-47 54-L10040T-4 T16 T16 Air flow and intake air temperature sensor (Sensor) Front Front Front T16 <FEA0> <FE> <FEB■, FEC7 (except crew cab)> T16 <FEB■ (crew cab)> T16 ---===WSE_1506_00001_0308.djvu===--- 54-10-48 54-L10040T-5 T16 T16 Air flow and intake air temperature sensor (Sensor) Front Front <Crew cab> <Except crew cab> <FG> T16 T16 SWITCH AND SENSOR T ---===WSE_1506_00001_0309.djvu===--- 54-10 54-10-49 54-L10040T-6 T21-24 T21 Lambda sensor T22 Exhaust gas temperature sensor 1 T23 Exhaust gas temperature sensor 2 T24 DPF differential pressure sensor DPF : Diesel particulate filter (Sensor) <FE> T22 T23 T24 Front T21 ---===WSE_1506_00001_0310.djvu===--- 54-10-50 54-L10040T-7 T21-24 T21 Lambda sensor T22 Exhaust gas temperature sensor 1 T23 Exhaust gas temperature sensor 2 T24 DPF differential pressure sensor (Sensor) <FG> DPF : Diesel particulate filter SCR : Selective catalytic reduction T22 T23 T24 T21 SWITCH AND SENSOR T ---===WSE_1506_00001_0311.djvu===--- MEMO 54-10-51 54-10 ---===WSE_1506_00001_0312.djvu===--- 54-10-52 54-L10040U-1 U01-06 U01 U02 U03 U06 U06 <FEA0> <FEB■, FEC7, FG> U05 U05 U04 U04 Front Front U01 U02 U01 Engine ECU U02 High-current fuse box U03 Battery equaliser U04 Glow ECU U05 Diode (for starter relay) U06 Starter relay ECU : Electronic control unit FUSE, RELAY AND ELECTRONIC CONTROL UNIT U ---===WSE_1506_00001_0313.djvu===--- 54-10 54-10-53 54-L10040U-2 U07-08 U07 DUONIC ECU U08 Diode <FG> ECU : Electronic control unit U07 <FE> Front U08 ---===WSE_1506_00001_0314.djvu===--- 54-10-54 54-L10040V-1 V01-06 V05 Front Front V02 V03 V01 V06 V04 V01 Condenser fan motor V02 Gearbox power take-off 3-way magnetic valve V03 Electric horn V04 Rear condenser fan motor <Rear air-conditioner > V05 Vacuum modulator V06 Back buzzer <Left-hand drive vehicle> <Right-hand drive vehicle> V01 <FE (crew cab)> MAGNETIC VALVE, MOTOR AND BUZZER V ---===WSE_1506_00001_0315.djvu===--- 54-10 54-10-55 54-L10040V-2 V11-14 V1 1 Two-wh eel drive 3-w ay magnetic valve V1 2 Four-wh eel drive 3-w ay magnetic valve V1 3 Transfe r low 3-way m agnetic valv e V1 4 Transfe r high 3-way magnetic valv e V13 V14 V11 V12 <FG> ---===WSE_1506_00001_0316.djvu===--- 54-10-56 54-L10040W-1 W01-12 <FEA0> <FEB■, FEC7, FG> W03 W03a W02 W01 W01 Joint connector (ABS, ABS and ESP : CAN) W02 Joint connector (DUONIC : CAN) W03 Connection of chassis harness and rear chassis harness : [AB2A], [AB16A] W03a Connection of chassis harness and coupling device harness : [AB12A] W04 Connection of chassis harness and engine harness : [AB12A], [GA4A] W05 Connection of chassis harness and PTO load sensor harness : [CT3A] W06 Optional connector : [AB2A] W07 Optional connector : [AB6A] W08 Connection of cab harness and chassis harness : [AB16A] W09a Connection of cab harness and chassis harness <ABS and ESP > : [AB12A] W10a Connection of cab harness and chassis harness : [AB8A] W12 Connection of cab harness and brake control valve harness <ISS and DUONIC > : [AB6A] W09a W10a W08 W04 W06 W05 W07 W12 (Under view) Front Front Front Front W06 W05 W07 W04 ABS : Anti-lock brake system CAN : Controller area network ESP : Electronic stability program ISS : Idling stop and start system PTO : Power take-off Indicate by connector type [ ]. R R R R JOINTS OF MAIN HARNESS CONNECTORS W ---===WSE_1506_00001_0317.djvu===--- 54-10 54-10-57 W16-23 54-L10040W-2 <FEA0, FEB■> <FEC7> W16 W17 W16 W17 W18 W18 W19 W19 W23 <*1> <*1> <*1> <*1> <*1> <*1> <*1> <*1> W23 W16 W17 W18 W19 W19a W21 W22 W23 Connection of chassis harness and fuel harness : [AB12A] Connection of chassis harness and urea tank harness : [AB16A] Connection of chassis harness and urea tank harness : [AC4A] Connection of chassis harness and ATS harness : [AB14A] <FE>, [AB12A] <FG> Connection of chassis harness and ATS harness : [AB8A] Connection of chassis harness and transfer control harness : [AB6A] <FG> Joint connector (NH3 sensor : CAN) Joint connector (NOx sensor 2 : CAN) Front Front W17 W19a W18 W16 <FG> W21 <FG> W22 W19 Front *1 : With BlueTec exhaust gas aftertreatment CAN : Controller area network Indicate by connector type [ ]. R ---===WSE_1506_00001_0318.djvu===--- 54-10-58 54-L10040W-3 W22-24 W22 Joint connector (NH3 sensor : CAN) W23 Joint connector (NOx sensor 2 : CAN) W24 Joint connector (NOx sensor 1 : CAN) CAN : Controller area network <FG> W24 W22 W24 W22 a W24 W23 Front Front (View a) <FEB7C> <FE■■E, FE■■G, FEC7> JOINTS OF MAIN HARNESS CONNECTORS W ---===WSE_1506_00001_0319.djvu===--- 54-10 54-10-59 W26-30 54-L10040W-4 <M/G (FE)> <M/G (FG)> <DUONIC > W26 W27 W29 W30 Indicate by connector type [ ]. M/G : Manual gearbox Connection of chassis harness and starter harness : [AC1A] Connection of chassis harness and DUONIC harness : [AB12A], [AC1A] Connection of chassis harness and transfer harness : [AB8A] <FG> Coupling device W26 W29 W26 W27 Front Front W30 R ---===WSE_1506_00001_0320.djvu===--- 54-10-60 X01-10 54-L10040X-1 X01 X04 X05 X06 X07 X03 X10 (Upper view) X02 X09 Front X01 X02 X03 X04 X05 X06 X07 X09 X10 Front wheel speed sensor, RH Rear wheel speed sensor, RH Rear wheel speed sensor, LH Front wheel speed sensor, LH Hydraulic unit Brake control valve (front) <DUONIC without ESP > Brake control valve LH (front) <DUONIC with ESP > Brake control valve (rear) <DUONIC without ESP > Brake control valve RH (front)<DUONIC with ESP > Brake control valve, RH (rear) <DUONIC with ESP > Brake control valve, LH (rear) <DUONIC with ESP > ABS : Anti-lock brake system ESP : Electronic stability program ISS : Idling stop and start system <ABS, ABS and ESP > R R R R R R R R R R R R R OTHERS X ---===WSE_1506_00001_0321.djvu===--- 54-10 54-10-61 54-L10040X-2 X16-20 Front Front <FEB7■C> <BlueTec exhaust gas aftertreatment> R X17 X17a X16 Dosing module X17 SCR temperature sensor 2 X17a NH3 sensor X18 NOx sensor 1 X18a NOx sensor 2 X19 SCR temperature sensor 1 X20 NH3 sensor ECU ECU : Electronic control unit SCR : Selective catalytic reduction X18a X20 (Veiw a) a Front X16 X18 X19 ---===WSE_1506_00001_0322.djvu===--- 54-10-62 54-L10040X-3 X16-20 Front a X16 X18 X19 X20 X18a (Veiw a) <FE■■E, FE■■G, FEC7> <BlueTec exhaust gas aftertreatment> R X16 Dosing module X17 SCR temperature sensor 2 X17a NH3 sensor X18 NOx sensor 1 X18a NOx sensor 2 X19 SCR temperature sensor 1 X20 NH3 sensor ECU ECU : Electronic control unit SCR : Selective catalytic reduction Front Front X17 X17a OTHERS X ---===WSE_1506_00001_0323.djvu===--- 54-10 54-10-63 \ 54-L10040X-4 X16-20 X16 Dosing module X17 SCR temperature sensor 2 X17a NH3 sensor X18 NOx sensor 1 X18a NOx sensor 2 X19 SCR temperature sensor 1 X20 NH3 sensor ECU ECU : Electronic control unit SCR : Selective catalytic reduction <FG> X19 X20 X18a X17 X17a X18 X16 <BlueTec exhaust gas aftertreatment> R ---===WSE_1506_00001_0324.djvu===--- 54-10-64 54-L10040X-5 X21-27 1:FE<Fram e right side> 2:FE<Fram e left side> 3:FG a <*1> a <*2> a <*3> <View a> X21 X22 X23 X24 X25 X26 X27 X21 Urea heater power unit X22 Urea line heater X23 Urea temperature sensor and urea tank heater X24 Urea supply module (motor and heater) X25 Urea tank level unit X26 Urea pressure sensor X27 Urea reverting valve OTHERS X ---===WSE_1506_00001_0325.djvu===--- 54-11-1 54-11 INSPECTION OF ELECTRICAL EQUIPMENT ---===WSE_1506_00001_0326.djvu===--- 54-11-2 #001 Inspection of combination switch Because it is not easy to independently check the switch for the function, determine the quality of the switch indirectly by check- ing the related parts, such as the harness, horn switch, etc. in the system. If there is nothing abnormal in the related parts, but the problem remains in the system, then replace the switch. (See Gr37.) Inspection of horn switch with SRS airbag. (See #762.) #002 Inspection of starter switch Perform the following checks, and if any fault is found, replace the switch. (See Gr37.) (1) Starter switch (2) Key interlock solenoid <DUONIC ® > Confirm that applying battery voltage between the terminals 1 and 2 prevents the key from turning toward the LOCK position. #008 Inspection of headlamp leveling switch Measure the resistance between terminals 1 and 6 at each switch position. If any fault found, replace the switch. Switch position Continuity terminal LOCK without key -- with key (1)--(2) ACC (1)--(2), 4--5 ON (1)--(2), 4--5--6 START (1)--(2), 3--4--5--6 Switch position Standard value Night illumination 0 Approx. 1265  (+) 4--3 (--) 1 Approx. 1145  2 Approx. 1025  3 Approx. 905  4 Approx. 785  5 Approx. 665  #001 to #179 SWITCH ---===WSE_1506_00001_0327.djvu===--- 54-11 54-11-3 #023 Inspection of vacuum switch Perform the following checks, and if any fault is found, replace the switch. (See Gr35.) (1) Inspection without applying negative pressure Make sure that there is continuity between terminals 1 and 2 (body). (2) Inspection by applying negative pressure Gradually apply negative pressure to the switch starting from 0 kPa {0 kgf/cm 2 }. Measure the degree of air pressure at the moment when conti- nuity is not detected between terminals 1 and 2 (body), and make sure to confirm if the value meets the standard. #027 Inspection of power window switch Because it is not easy to check these switches individually, de- termine the quality of the switches indirectly by checking related parts, such as harnesses, power window motor, etc. in the sys- tem. If there is nothing abnormal in related parts, but there is still something wrong with the system, then replace the switches. (See Gr43.) #031 Inspection of clutch switch If any fault is found, replace the switch. (See Gr21.) #035 Inspection of door switch If any fault is found, replace the switch. (See Gr43.) #038 Inspection of parking brake switch Measure continuity between terminals 1 and 2 (body) earth. If any fault is found, replace the switch. (See Gr36.) Standard value --(47 ) kPa {--(350 ) mmHg} Switch position Continuity terminal OFF -- ON 1--2 Switch position Continuity terminal OFF -- ON 1-body, 2-body Pull the parking brake lever Continuity exists Release the parking brake lever Continuity does not exist +3.3 --4.0 +25 --30 ---===WSE_1506_00001_0328.djvu===--- 54-11-4 #039 Inspection of cab tilt lock switch If any fault is found, replace the switch. (See Gr42.) #041 Inspection of brake fluid level switch Gradually drain brake fluid from the brake fluid reservoir. CAUTION Brake fluid contains ingredients that dissolve the vehicle's paint. Quickly wipe off brake fluid when it is spilled. Measure height of the switch when continuity is detected be- tween terminals 1 and 2. If the measured value deviates from the standard value, replace the brake fluid reservoir. (See Gr52.) #042 Inspection of stop lamp switch If any fault is found, replace the switch. (See Gr35.) #044 Inspection of oil pressure switch Perform the following checks, and if any fault is found, replace the switch. (See Gr12.) (1) Inspection without applying air pressure Make sure that there is continuity between terminals 1 and the body. (2) Inspection by applying air pressure Gradually apply air pressure to the switch starting from 0 kPa {0 kgf/cm 2 }. Measure the degree of air pressure at the moment when conti- nuity is not detected between terminals 1 and body, and make sure to confirm if the value meets the standard. Switch position Continuity terminal OFF -- ON 1--2 Standard value 18to20mm Switch position Continuity terminal A 1--2 B 3--4 Standard value (operating pressure) 50 ± 10 kPa {0.5 ± 0.1 kgf/cm 2 } #001 to #179 SWITCH ---===WSE_1506_00001_0329.djvu===--- 54-11 54-11-5 #054 Inspection of switch Perform the following checks, and if any fault is found, replace the switch. Transfer four-wheel drive switch. <FG> Transfer low switch. <FG> Backup lamp switch. (See Gr22.) Parking gear switch. (See Gr22.) Power take-off control switch. (See Gr22.) Gearbox neutral switch. (See Gr22.) #056 Inspection of torque limit switch If any fault is found, replace the switch. (See Gr22.) Switch position Continuity terminal OFF -- ON 1--2 Switch position Continuity terminal OFF -- ON 1--2 ---===WSE_1506_00001_0330.djvu===--- 54-11-6 #081 Inspection of hazard switch If any fault is found, replace the switch. (See Gr52.) #089 Inspection of switch Perform the following checks, and if any fault is found, replace the switch. Front fog lamp switch Rear fog lamp switch DPF cleaning switch Gearbox power take-off switch ISS cutoff switch Mirror heater switch Front drive switch ECO mode switch ESP/ASR cutoff switch Transfer high/low changeover switch Cruise control main switch Switch position Continuity terminal Night illumination OFF -- (+) 4-1 (--) ON 2--3 Switch position Continuity terminal Night illumination OFF -- (+) 1--10 (--) ON 3--7 Switch position Continuity terminal Operation illumination Night illumination OFF -- -- (+) 1--10 (--) ON 3--7 (+) 9--10 (--) Switch position Continuity terminal Night illumination OFF 5--7 (+) 1--10 (--) ON 3--7 Switch position Continuity terminal Operation illumination Night illumination LOW 3--7 (+) 9--10 (--) (+) 1--10 (--) HIGH 4--8 -- Switch position Continuity terminal Operation illumination Night illumination OFF 4--8, 5--7 -- (+) 1--10 (--) Neutral 4--6, 5--7 -- ON 3--7, 4--6 (+) 9--10 (--) #001 to #179 SWITCH ---===WSE_1506_00001_0331.djvu===--- 54-11 54-11-7 #187 Inspection of starter relay Perform continuity and operation checks, and if any fault is found, replace the relay. #201 Inspection of relay (normally open type 5 pin) Perform continuity and operation checks, and if any fault is found, replace the relay. #180 to #249 RELAY ---===WSE_1506_00001_0332.djvu===--- 54-11-8 #250 Inspection of steering wheel angle sensor Because it not easy to independently check the switch for the function, determine the quality of the switch indirectly by check- ing the related parts, such as the harness, horn switch, etc. in the system. If there is nothing abnormal in the related parts, but the problem remains in the system, then replace the combination switch. #251 Inspection of photo sensor With the photo sensor connected to the control panel at the sen- sor connector, turn the starter switch ON. With the exposed portion of the sensor exposed to light, mea- sure the output voltage between terminal 2 and body earth. If the measured value deviates from the standard value, replace the sensor. (See Gr52.) #252 Inspection of sensor Because it is not easy to check these switches individually, de- termine quality of the sensors indirectly by checking related parts, such as harnesses, etc. in the system. If any fault is not found in the related parts, and the problem still remains in the system, replace the sensors. Standard value Inspection condition: Move a lit bulb of about 60 watts toward and away from right above the photo sensor (approx. 150 mm from sensor at closest point). 1to5V (voltage lowers as light nears sensor) #250 to #349 SENSOR ---===WSE_1506_00001_0333.djvu===--- 54-11 54-11-9 #253 Inspection of air inlet sensor Change the ambient temperature of the sensor and measure the resistance between terminals 1 and 2. If the measured value deviates from the characteristic shown in the table at left, replace the sensor. (See Gr55.) ---===WSE_1506_00001_0334.djvu===--- 54-11-10 #256 Inspection of in car sensor Change the ambient temperature of the sensor and measure the resistance between terminals 1 and 2. If the measured value deviates from the characteristics shown in the table at left, replace the sensor. (See Gr52.) #258 Inspection of fuel level sensor Measure resistance values between terminals 1 and 2 when bringing the float arm into contact with stoppers (at A and C po- sitions) and placing it at B position. If the measured value deviates from the standard value, replace the sensor. (See Gr13.) #262 Inspection of water temperature sensor Dip the sensor in a container filled with engine oil. Raise the oil temperature to each specification below while stir- ring the oil. Measure resistance values between terminals 1 and 2. If the measured value deviates from the standard value, replace the sensor. (See Gr14.) #263 Inspection of engine speed sensor Measure the resistance value between terminals 1 and 2. If the measured value deviates from the standard value, replace the sensor. (See Gr11.) Standard value at D position 9±2 at C position 50±2 at B position 130±3.5 at A position 135±3.5 Standard value --30C 22.307 to 310.194 k 20C 2.262 to 2.760 k 80C 0.304 to 0.342 k 120C 0.106 to 0.119 k Standard value (at 20C) 860±86 #250 to #349 SENSOR ---===WSE_1506_00001_0335.djvu===--- 54-11 54-11-11 #265 Inspection of vehicle speed sensor While applying a voltage of 6.5 to 9 V between terminals 1 and 2, rotate the pulse rotor. Check the signals of terminal 3 (SPEED SIG IN) and terminal 4 (SPEED DATA). If no signals are found, replace the sensor. (See Gr22.) #282 Inspection of vacuum sensor Apply 5 volts DC to terminals 2 and 3. Apply negative pressure and measure the output voltage occur- ring at terminals 1 and 2. If the measurement is out of specification, replace the vacuum sensor. #296 Inspection of shift stroke sensor Because it is not easy to independently check the sensor for the functions, check the FUSO Diagnostics service data using the FUSO Diagnostics. Replace the gear shift unit if there is any fault in the sensor. #297 Inspection of lambda sensor Because it is not easy to check these sensor individually, deter- mine quality of the sensor indirectly by checking related parts, such as harnesses, etc. in the system. If any fault is not found in the related parts, and the problem still remains in the system, replace the sensor. (See Gr15.) #298 Inspection of NOx sensor Because it is not easy to check these sensor individually, deter- mine quality of the sensor indirectly by checking related parts, such as harnesses, etc. in the system. If any fault is not found in the related parts, and the problem still remains in the system, replace the sensor. (See Gr17.) NOx sensor 1 NOx sensor 2 Standard value -100 kpa {-1 kgm/cm 2 } 4.5 V 0 kpa {0 kgm/cm 2 } 0.5 V ---===WSE_1506_00001_0336.djvu===--- 54-11-12 #302 Inspection of brake fluid pressure sensor Apply 5 volts DC to terminals 1 and 3. Measure the output voltage occurring at terminals 2 and 3. If the measured value deviates from the standard value, replace the sensor. #306 Inspection of air flow and intake air temperature sensor <Inspection of on-vehicle condition> Using the FUSO Diagnostics, check if its service data changes in accordance with changes in the engine speed. Replace the sensor if the service data is not changed. (See Gr15.) <Inspection of standalone condition> Connect the air flow and intake air temperature sensor, multime- ter capable of measuring frequency output, resistor and batter- ies as shown in the illustration. Blow air against the sensor and check if the frequency is changed. Replace the sensor if the frequencies not changed. (See Gr15.) #317 Inspection of power take-off load sensor Apply 5 volts DC between terminals 4 and 6 for the power take- off load sensor. Measure the output voltage between terminals 5 and 6 when the lever is in the idling position A and when it is in the full load posi- tion B. If the measurement in the full load position is out of the standard value, adjust with the full load stopper bolt. If the measurement in the idling position is out of the standard value, replace the PTO load sensor. Standard value 0.5 V Standard value Lever position Output voltage Idling position B 0.85±0.1V Full load position A 3.0±0.1V #250 to #349 SENSOR ---===WSE_1506_00001_0337.djvu===--- 54-11 54-11-13 #320 Inspection of camshaft timing sensor Apply 5 volts DC to terminals 3 and 1 and measure, using a mul- timeter the output from terminal 2 and 1. With no metallic part close to sensor tip the output should be 5 V. Approach the sensor tip to a metallic part. The output should be- come 0V when it comes to approx.1mm to the part. If the measurement is out of specification, replace the sensor. (See Gr11.) This kind of test is made in static condition, and it isn't able to detect all sensor failure mode on the engine during normal func- tioning. #323 Inspection of fuel filter (1) Inspection of fuel temperature sensor Measure the resistance between terminals 8 and 9. If the measurement is out of specification, replace the fuel filter. (See Gr13.) (2) Inspection of water separator sensor Drain water from fuel filter. Apply 12 volts DC between the terminal 6 and 1. Measure the output voltage of terminal 11 and 1. If the measured value deviates from the standard value, replace the fuel filter. (See Gr13.) (3) Inspection of fuel heater Perform continuity check, and if any fault is found, replace the fuel filter. (See Gr13.) Standard value --30C 26.114 ± 2.533  0C 5.896 ± 0.430  25C 2.057 ± 0.115  60C 596 ± 22.648  100C 186 ± 3.720  110C 144 ± 3.456  Standard value 11.8 V or more ---===WSE_1506_00001_0338.djvu===--- 54-11-14 #324 Inspection of accelerator pedal position sensor Apply 5 volts DC to terminals 6 and 5 (sensor 1) and terminals 3 and 2 (sensor 2) of the accelerator pedal position sensor. Measure the output voltage at terminals 4 and 5 (sensor 1) and the output voltage at terminals 1 and 2 (sensor 2) with the accel- erator lever in each specified position. If the measurement is out of specification, replace the sensor. #327 Inspection of G sensor Apply a 12 volts DC across terminals 3 and 1 of the G sensor. Measure the G sensor output voltage between terminals 2 and 1 for both when the sensor is in a horizontal position and when it is in a vertical position. If any of the measurements is not within the standard value range, replace the sensor. Standard value Lever position Output voltage Full load position A Sensor 1 4.5±0.05V Sensor 2 2.25 ± 0.05 V Idling position B Sensor 1 1.2±0.05V Sensor 2 0.6±0.05V Standard value Horizontal position 2.3to2.7V Vertical position 3.3to3.7V #250 to #349 SENSOR ---===WSE_1506_00001_0339.djvu===--- 54-11 54-11-15 #329 Inspection of wheel speed sensor <FE> Perform the following check. Replace the wheel speed sensor if any fault is found. CAUTION The wheel speed sensor has a magnet in it. Be careful not to allow metal pieces to attach the sensor. (1) Output voltage Because output check using the anti-lock brake system rotor is required, follow the steps below to measure the output voltage with the sensor mounted on the vehicle. Jack up the wheel to be measured, then remove the connector of the wheel speed sensor. Connect the terminals of the removed connector to an oscillo- scope as shown in the circuit diagram, then check the voltage on the oscilloscope while rotating the wheel by hand at a constant speed. (2) Insulation resistance Measure the resistance between terminal 1 and body and be- tween terminal 2 and body. (3) Open circuit If there is an open circuit, remove the clamp on the harness from the vehicle, then check for transient open circuit while bending and stretching the harness at the clamp. Also, check the con- nection conditions of the connector terminals. <FG> Carry out the following checks. If faulty, replace the wheel speed sensor. CAUTION The pole piece is magnetized by the magnet housed in the wheel speed sensor. Be careful not to allow metal parts to stick onto the pole piece. (1) Resistance between terminals (2) Insulation resistance (between the sensor body and each terminal) (3) Open circuit If open circuit is suspected, remove the harness clamps and wiggle the harness to determine whether it is an intermittent fault or not. Check also the connector terminals for proper connec- tion. Standard value High 1.05 V Low 0.53 V Standard value 5 M or above Standard value 1.4±0.2k Standard value 1 M or above +0.21 -0.16 +0.10 -0.09 ---===WSE_1506_00001_0340.djvu===--- 54-11-16 #334 Inspection of DPF differential pressure sensor Apply 5 volts DC to terminals 1 and 2. Apply air pressure (gauge pressure) and measure the output voltage occurring at terminals 2 and 3 (left figure). If the measurement is out of specification, replace the sensor. (See Gr17.) #336 Exhaust gas temperature sensor 1, 2, SCR temperature sensor 1, 2 Measurement must be carried out with DPF (diesel particulate filter) cooled enough. Unplug electrical connector, but do not remove sensor from DPF and SCR (selective catalytic reduction). Measure the resistance between terminals 1 and 2. See the chart below for normal resistance versus temperature. Check if the measured value is within the standard value by comparing the measured value with the value according to the chart and outside temperature. Measure resistance between each pin to sensor body. Resis- tance should be greater than 1 M (open circuit). If the measurement is out of standard value, replace the sensor. (See Gr17.) #339 Inspection of urea temperature sensor and urea tank heater Unplug electrical connector, but do not remove sensor from urea tank. Measure the resistance between terminals 3 and 4 while chang- ing surrounding temperature of the urea level and temperature sensor. If the measurement is out of standard value, replace the DEF tank. (See Gr17.) Standard value 0 kPa {0 kgf/cm 2 } 0.5 V 100 kPa {1.02 kgf/cm 2 } 4.5 V Standard value --20C 185.6  0C 201.0  25C 220.1  50C 239.0  Standard value 15C 13.75 to 17.76 k 20C 11 to 14.09 k 25C 8.83 to 11.21 k 30C 7.08 to 9.03 k 35C 5.75 to 7.35 k #250 to #349 SENSOR ---===WSE_1506_00001_0341.djvu===--- 54-11 54-11-17 #345 Inspection of VGT position sensor Apply 5 volts DC between terminals 3 and 1. Make sure that the actuator rod is not displaced. Measure the output voltage between terminals 2 and 1. Using vacuum pump kit (MH063724), apply negative pres- sure until the rod mechanically stops. The pressure should be approximately 60 kPa {0.6 kgf/cm 2 }. Measure the output voltage between terminals 2 and 1. If the measurement is out of the standard value, replace the tur- bocharger. (See Gr15.) If the purpose of this inspection is only to check the diaphragm for damage, you can determine that it is damaged if the rod does not move when negative pressure (60 kPa {0.6 kgf/ cm 2 }) is applied to the actuator capsule. (If the actuator operates normally, the rod will move with a minimum amount of flow.) #346 Inspection of boost pressure and temperature sensor (1) Boost pressure sensor inspection Apply 5 volts DC to terminals 3 and 1. Apply air pressure and gradually increase it, measuring the out- put voltage occurring at terminals 2 and 1. If the measured value deviates from the standard value, replace the sensor. (See Gr15.) (2) Boost temperature sensor inspection Place the sensor in ambient with temperature controlled to 20C for 15 min. Measure the resistance between terminals 2 and 1. If the measured value deviates from the standard value, replace the sensor. (See Gr15.) Standard value 1±0.2V Standard value 3.7±0.2V Standard value Air pressure (gauge) Voltage 100 kPa {1 kgf/cm 2 }3 V 250 kPa {2.5 kgf/cm 2 }4 . 3 5 V Standard value 0C 5895±250 20C 2499±80 40C 1174±30 +2.7 0 +0.03 0 ---===WSE_1506_00001_0342.djvu===--- 54-11-18 #348 Inspection of ESP sensor Since the units alone cannot be readily checked off the vehicle. Check the harness, switch and other related parts in each sys- tem. If faults are not found in the related parts, and the problem still remains the system, replace the control units or other units. #250 to #349 SENSOR ---===WSE_1506_00001_0343.djvu===--- 54-11 54-11-19 #350 Inspection of control unit and other units Since the units alone cannot be readily checked off the vehicle, check the harness, switch and other related parts in each sys- tem. If any unit is found giving out diagnosis output, checked the is- sued diagnosis code to identify the cause of existing fault, and replace such unit or electronic control unit, if its malfunction is determined. If faults are not found in the related parts, and the problem still remains in the system, replace the control units or other units. #354 Inspection of DC/DC converter While applying 12 volts DC between terminals 2 and 1 and ter- minals 5 and 1 simultaneously, measure the voltage output from terminal 3. If the measured value deviates from the standard value, replace the DC/DC converter. Standard value Input voltage at terminal 2 ± 1 V (when idling stop and start system is not operating) #350 to #409 CONTROL UNIT ---===WSE_1506_00001_0344.djvu===--- 54-11-20 #411 Inspection of blower motor Make sure that the motor operates when 12 volts DC is applied between each terminal. If any fault is found, replace the motor. (See Gr55.) #413 Inspection of air mixing motor Perform the following checks, and if any fault is found, replace the motor. (See Gr55.) (1) Inspection of motor Make sure that the motor operates when 12 volts DC is applied between each terminal. CAUTION Stop voltage application when the lever stops. After inspection of the motor, return the lever to a position within the range of MAX HOT to MAX COOL. (2) Inspection of potentiometer Apply 5 volts DC between the terminals 1 and 3 and measure the voltage between the terminals 1 and 5. Lever position Continuity terminal MAX HOT (+) 6--7 (--) MAX COOL (+) 7--6 (--) Lever position Standard value MAX HOT 1±0.03 MAX COOL 4±0.03 #410 to #509 MOTOR ---===WSE_1506_00001_0345.djvu===--- 54-11 54-11-21 #414 Inspection of mode motor Perform the following checks, and if any fault is found, replace the motor. (See Gr55.) <Fully automatic air-conditioner> (1) Inspection of motor Make sure that the motor operates when 12 volts DC is applied between each terminal. CAUTION Stop voltage application when the lever stops. After inspection of the motor, return the lever to a position within the range of FACE to DEF. (2) Inspection of potentiometer Apply 5 volts DC between the terminals 1 and 3 and measure the voltage between the terminals 1 and 5. <Rear air-conditioner> Make sure that the motor operates when 12 volts DC is applied between each terminal. CAUTION Stop applying 12 volts DC if the lever stops spontaneously at the VENT, BI LEVEL or FOOT position. #415 Inspection of fresh/recirculation changeover motor Perform the following checks, and if any fault is found, replace the motor. (See Gr55.) Make sure that the motor operates when 12 volts DC is applied between each terminal. CAUTION Stop applying 12 volts DC if the lever stops spontaneously at the REC or FRE position. Lever position Continuity terminal FACE (+) 6--7 (--) <LHD>, (+) 7--6 (--) <RHD> DEF (+) 7--6 (--) <LHD>, (+) 6--7 (--) <RHD> Lever position Standard value FACE 4.5 ± 0.03 DEF 0.5 ± 0.03 Lever position Continuity terminal VENT (+) 4--7 (--) BI LEVEL (+) 4--6 (--) FOOT (+) 4--5 (--) Lever position Continuity terminal REC (inside air) (+) 3--2 (--) FRE (outside air) (+) 3--1 (--) ---===WSE_1506_00001_0346.djvu===--- 54-11-22 #422 Inspection of wiper motor Because it is not easy to check these switches individually, de- termine the quality of the motor indirectly by checking related parts, such as harnesses, power window motor, etc. in the sys- tem. If there is nothing abnormal in related parts, but there is still something wrong with the system, then replace the motor. (See Gr51.) #410 to #509 MOTOR ---===WSE_1506_00001_0347.djvu===--- 54-11 54-11-23 #423 Inspection of power window motor Make sure that the motor operates when 12 volts DC is applied between each terminal. If any fault is found, replace the motor and the regulator as a set. (See Gr43.) #428 Inspection of windshield washer motor Make sure that the motor operates when 12 volts DC is applied between each terminal. If any fault is found, replace the motor. (See Gr51.) #431 Inspection of condenser fan motor Make sure that the motor operates when 12 volts DC is applied between each terminal. If any fault is found, replace the condenser. (See Gr55.) #436 Inspection of rear heater temperature motor (water valve) <Rear air-conditioner> Perform the following checks, and if any fault is found, replace the motor. (1) Inspection of motor Make sure that the motor operates when 12 volts DC is applied between each terminal. CAUTION Stop voltage application when the valve opens (HOT) or closes (COOL). (2) Inspection of potentiometer Apply 5 volts DC between the terminals 2 and 3 and measure the voltage between the terminals 3 and 6. Rotation direction Continuity terminal Left (+) 2--1 (--) Right (+) 1--2 (--) Lever position Continuity terminal Open (HOT) (+) 7--5 (--) Close (COOL) (+) 5--7 (--) Lever position Standard value Open (HOT) 4.8 V Close (COOL) 0.2 V ---===WSE_1506_00001_0348.djvu===--- 54-11-24 #497 Inspection of fuel pump Make sure that the motor operates when battery voltage is ap- plied between terminals 3 and 4. If any fault is found, replace the fuel pump. (See Gr13.) #410 to #509 MOTOR ---===WSE_1506_00001_0349.djvu===--- 54-11 54-11-25 #510 Inspection of door lock actuator (passenger's seat side) Make sure that the actuator operates when 12 volts DC is ap- plied between each terminal. If any fault is found, replace the actuator. (See Gr43.) #511 Inspection of door lock actuator (driver's seat side) Make sure that the actuator operates when 12 volts DC is ap- plied between each terminal. <LHD> <RHD> If any fault is found, replace the actuator. (See Gr43.) #512 Inspection of rear door lock actuator Make sure that the actuator operates when 12 volts DC is ap- plied between each terminal. If any fault is found, replace the actuator. (See Gr43.) #530 Inspection of EGR actuator Because it is not easy to check these actuator individually, deter- mine quality of the actuator indirectly by checking related parts, such as harnesses, power window motor, etc. in the system. If any fault is not found in the related parts, and the problem still remains in the system, replace the EGR actuator. (See Gr17.) #534 Inspection of gear shift unit Because it is not easy to independently check the sensor for the functions, check the FUSO Diagnostics service data using the FUSO Diagnostics. (See Gr22.) Replace the gear shift unit if there is any fault in the sensor. (See Gr22.) Switch position Terminal LOCK (+) 1--2 (--) UNLOCK (+) 2--1 (--) Switch position Continuity terminal Terminal LOCK 1--2 (+) 3--4 (--) UNLOCK 1--5 (+) 4--3 (--) Switch position Continuity terminal Terminal LOCK 4--5 (+) 2--3 (--) UNLOCK 1--5 (+) 3--2 (--) Switch position Terminal LOCK (+) 2--3 (--) UNLOCK (+) 3--2 (--) #510 to #539 ACTUATOR ---===WSE_1506_00001_0350.djvu===--- 54-11-26 #535 Inspection of valve body (connector) (1) Inspection of solenoid valve 1, 2 Measure the resistance between terminals 3 and 7, and termi- nals 4 and 8. If the measured value deviates from the standard value, replace the valve body. (See Gr22.) (2) Inspection of solenoid valve (cooling) and solenoid valve (relief) Gradually apply DC current between each terminals starting from 0 V. Measure the voltage at which the cooling valve and relief valve operates. If the measured value deviates from the standard value, replace the valve body. (3) Inspection of oil temperature sensor Measure the resistance between terminals 5 and 6. If the measured value deviates from the standard value, replace the valve body. (See Gr22.) #536 Inspection of vacuum modulator Apply battery voltage between each terminals confirm that the vacuum modulator operates. If any fault is found, replace the vacuum modulator. (See Gr15.) Standard value (at 20°C) 5.3±0.5 Standard value (minimum operat- ing voltage) Solenoid valve (relief) 1-body 8Vorless Solenoid valve (cooling) 2-body Standard value (at 20°C) 2.262 to 2.760 k #510 to #539 ACTUATOR ---===WSE_1506_00001_0351.djvu===--- 54-11 54-11-27 #565 Inspection of 3-way magnetic valve <Type-1> Perform the following checks, and if any fault is found, replace the 3-way magnetic valve. (1) Operation check Gradually apply DC current between each terminal starting from 0V. Measure the voltage when the 3-way magnetic valve operates. (Determine ON/OFF of the magnetic valve by operating noises.) (2) Inspection of continuity and air tightness Negative pressure when inspected: --99.99 kPa {--750 mmHg} <Type-2> Perform the following checks, and if any fault is found, replace the 3-way magnetic valve. (1) Operation check Gradually apply DC current between each terminal starting from 0V. Measure the voltage at which the 3-way magnetic valve oper- ates. (Determine ON/OFF of the magnetic valve by operating noises.) (2) Inspection of continuity and air tightness Negative pressure when inspected: --60 kPa {--450 mmHg} #572 Inspection of FMU (fuel metering unit) Because it is not easy to check these FMU (fuel metering unit) individually, determine quality of the FMU (fuel metering unit) in- directly by checking related parts, such as harnesses, etc. in the system. If any fault is not found in the related parts, and the problem still remains in the system, replace the FMU (fuel metering unit). #582 Inspection of injector Measure the resistance between terminals 1 and 2. If the measurement is out of specification, replace the injector. (See Gr13.) If an injector was replaced with a new one, the data must be writ- ten and reset in the engine electronic control unit. Perform the data writing and resetting work, using the diagnostic tool. Standard value (minimum operating voltage) 11Vorless Standard value (minimum operating voltage) 8Vorless Standard value (at 20C) 0.39 ± 0.04  #560 to #609 MAGNETIC VALVE ---===WSE_1506_00001_0352.djvu===--- 54-11-28 #587 Inspection of brake control valve (front, rear, left, right) Measure the resistance between terminals 1 and 2. If the measurement is out of specification, replace the brake control valve. Standard value (at 20C) 14±0.7 #560 to #609 MAGNETIC VALVE ---===WSE_1506_00001_0353.djvu===--- 54-11 54-11-29 #614 Inspection of back buzzer [Inspection] Make sure to confirm if the buzzer intermittently sounds by ap- plying the 12 volts DC between each terminal. If any fault is found, replace the buzzer. [Installation] Install the back buzzer to the frame in the range of angles as il- lustrated. CAUTION Be aware that if the installed angle of the buzzer is out of the range as illustrated, water in the buzzer will not drain normally. #615 Inspection of electric horn CAUTION Bending the stay changes the sound quality of the horn, de- grading the horn performance. Never bend or damage the stay. [Inspection] Make sure to confirm whether the horn sounds by applying the 12 volts DC between terminals 1 and body. Remove foreign substances adhered to the resonator and dia- phragm. If any fault is found, replace the horn. [Installation] Install in the direction as illustrated. #610 to #649 BUZZER, HORN ---===WSE_1506_00001_0354.djvu===--- 54-11-30 #656 Inspection of cab and spot lamp If any fault is found, replace the lamp. #650 to #699 LAMP ---===WSE_1506_00001_0355.djvu===--- 54-11 54-11-31 #750 Inspection of blower resistor <Front air-conditioner (manual)> Measure resistance values between each terminals. If the measured value deviates from the standard value, replace the blower resistor. (See Gr55.) <Rear air-conditioner> Measure resistance values between each terminal. If the measured value deviates from the standard value, replace the blower resistor. (See Gr55.) #751 Inspection of thermostat Measure the output voltage between terminals 1 and 2 at the specified temperatures. If the measured value deviates from the characteristic shown in the table at left, replace the sensor. (See Gr55.) Fan speed Terminal Standard value MEDIUM HIGH 2--4 0.56 ± 0.0392  MEDIUM LOW 3--4 1.56 ± 0.109  LOW 1--4 3.36 ± 0.235  Fan speed Terminal Standard value MEDIUM HIGH 1--4 0.77  MEDIUM LOW 1--2 1.54  LOW 1--3 5.38  #750 to #859 OTHER ---===WSE_1506_00001_0356.djvu===--- 54-11-32 #752 Inspection of power MOS-FET (transistor) Perform the following checks, and if any fault is found, replace the power transistor. (See Gr55.) Start the engine and operate the blower in the HI mode. Check that a high blower output equivalent to HI is obtained. Operate the control to step down the flow of air. Check that the blower output equally decreases gradually. Check that nothing is abnormal with the blower motor, wiring, air conditioner electronic control unit, control panel and relat- ed parts. If the blower motor is inoperative in that state, the power MOS-FET (transistor) should be faulty. #754 Inspection of cigarette lighter Perform the following checks, and if any fault is found, replace the cigarette lighter. (See Gr52.) Make sure that there is continuity between heater element and body. Make sure that when plug is pushed in by hand, it immediately returns to its original position. Place the starter switch at ACC or ON position. Push plug into the socket in the cab. Measure the time required for plug to automatically return. Check to see that heater element is red-hot. #756 Inspection of mirror heater Make sure that the rear view mirror gets warm when 12 volts DC is applied between each terminal. If any fault is found, replace the rear view mirror (the mirror and the holder). Standard value 15 ± 5 seconds #750 to #859 OTHER ---===WSE_1506_00001_0357.djvu===--- 54-11 54-11-33 #762 Inspection of squib and horn switches, and clock spring (See Gr52.) DANGER Never allow the tester to touch the connector. If the tester touches the connector any minute electric current given off by the tester may flow into the airbag ignition circuit. #763 Inspection of heater control panel Perform the following checks, and if any fault is found, replace the heater control panel. (See Gr52.) (1) Blower switch <AN6A connector> (2) Fresh/recirculation changeover switch (3) Air-conditioner switch #764 Inspection of glow plug Measure the resistance between the housing and the connec- tion pin using a multimeter. If the measured value deviates from the standard value, replace the glow plug. (See Gr11.) #771 Inspection of immobiliser antenna Measure the resistance between terminals 1 and 2. If the measured value deviates from the standard value, replace the immobiliser antenna. Switch position Continuity terminal 0: OFF -- 1: LO (LOW) 1--2--4 2: ML (MEDIUM LOW) 1--3--4 3: MH (MEDIUM HIGH) 1--4--6 4: HI (HIGH) 1--4--5 Switch position Continuity terminal Operation illumination Night illumination OFF: Fresh air 6--12 -- (+) 9--10 (--) ON: Recirculation air 5--12 (+) 1--12 (--) Switch position Continuity terminal Operation illumination Night illumination OFF -- -- (+) 9--10 (--) ON 3--7 (+) 1--7 (--) Standard value (at 20C) 0.6to1.0 Standard value (at 25C) 20±2 ---===WSE_1506_00001_0358.djvu===--- 54-11-34 #773 Inspection of urea heater power unit Because it is not easy to check these urea heater power unit in- dividually, determine quality of the urea heater power unit indi- rectly by checking related parts, such as harnesses, etc. in the system. If any fault is not found in the related parts, and the problem still remains in the system, replace the urea heater power unit. (See Gr17.) #825 Inspection of shift lever unit Because it is not easy to check these shift lever unit individually, determine quality of shift lever unit indirectly by checking related parts, such as harnesses, etc. in the system. If any fault is not found in the related parts, and the problem still remains in the system, replace the shift lever unit. (See Gr22.) #828 Inspection of controller area network resistor Measure the resistance of the resistor number marked on the controller area network resistor. If the measurement is out of specification, replace the controller area network resistor with one that has the same resistor num- ber and same specified resistance. CAUTION The controller area network resistor are matched to the en- gine. If you replace any of them, be sure to replace it with one that has the same resistor number. Standard value (at 20C) Resistor No. 1 270±13.5 2 510±25.5 3 820±41 4 1300±65 5 2000±100 6 3300±165 7 5600±280 8 15000 ± 750  9 390±19.5 10 4300±215 11 9100±455 12 120±6 #750 to #859 OTHER ---===WSE_1506_00001_0359.djvu===--- 54-11 54-11-35 DANGER Since flammable hydrogen gas is generated by the battery be sure to obey the following warnings: Do not short-circuit the (+) and (--) terminals on the battery. Keep sparks and lit cigarettes away from the battery. Do not wear metal objects on your arms and lean over battery. Because the battery electrolyte is made of diluted sulfuric acid and is corrosive, when handling battery wear safety glasses and rubber gloves to protect the eyes and hands. WARNING Make sure that you disconnect battery cable (--) first when you disconnect battery cables. CAUTION Make sure that all electrical switches of the vehicle are OFF before connecting battery cables. Make sure that you connect battery cable (+) before you connect battery cable (--). To prevent a short-circuit be sure that disconnected battery cables do not accidentally touch the battery terminals. Service standards Location Maintenance item Standard value Limit Remedy -- Specific gravity of battery electrolyte (20C) 1.280 1.220 Charge or replace #860 BATTERY ---===WSE_1506_00001_0360.djvu===--- 54-11-36 Service procedure Inspection: Battery (1) Visual inspection If terminal is corroded, scrub off the corrosion from it using a wire brush. If cracks or defects are found on battery, replace it since the cracks or defects can cause liquid spills. (2) Inspection of fluid level Check the battery electrolyte level using the indicator on top of the battery. If the indicator is black, the electrolyte level is proper. If the indi- cator is white, the electrolyte level is low. Replace the battery. #860 BATTERY ---===WSE_1506_00001_0361.djvu===--- 54-11 54-11-37 (3) Charging Although, as a rule, battery charging should be done with the battery removed from the vehicle, if you have to charge the bat- tery while it is on the vehicle, make sure that you stop the engine and disconnect battery cable (--). Remove vent plug before charging the battery. For the recommended charge time and current, see the follow- ing table to avoid overcharging. Use the graph shown on the left to calculate the amount of dis- charge (%). Use diluted sulfuric acid, made up of sulfuric acid and refined or distilled water, as the battery electrolyte. DANGER Keep open flame away from the battery while charging to prevent explosion. It is dangerous to generate sparks while charging the bat- tery. Do not charge battery if the electrolyte level is below min level, since it can cause early deterioration, heating, or ex- plosion. Make sure to add the fluid to the specified level be- fore charging. WARNING Do not let the battery electrolyte level rise and overflow while charging the battery. After charging the battery, tighten vent plug, wash away sul- furic acid from the battery using water, and dry the surface. Charge current (A) Charge time (H) Upper limit of fluid temperature (C) Normal charge Value of 5-hour rating capacity 10 *Amount of discharge (Ah) Charge current (A) 1.2 (to 1.5) 45 Quick charge Value of 5-hour rating capacity 1.5 0.5 55 * Amount of discharge (Ah) = 5-hour rating capacity (Ah)  Amount of 100 discharge(%) ---===WSE_1506_00001_0362.djvu===--- 54-11-38 #890 Meter cluster Check the meter cluster by the actuator test of FUSO Diagnos- tics.(See Gr54EM.) Check for meter cluster faults with diagnosis codes. (See Gr54EM.) When the meter cluster is replaced, be sure to rewrite data in the electronic control unit using FUSO Diagnostics. CAUTION The replacement of the meter cluster should be performed only when the meter cluster is judged as faulty after per- forming the following inspections. Check the connectors, harnesses and fuses. Perform the actuator test. Temporarily install the said meter cluster to other vehicle and check if the same problem occurs. #890 METER ---===WSE_1506_00001_0363.djvu===--- 54-12-1 54-12 STARTER AND ALTERNATOR ---===WSE_1506_00001_0364.djvu===--- 54-12-2 WARNING Before removing the starter, dis- connect the (--) battery cable and in- sulate the cable and the (--) battery terminal with tape. It is dangerous to leave the (--) bat- tery cable connected since the bat- tery cable voltage is always present at terminal B. Tightening torque (Unit: N·m {kgf·m}) Assembly procedure Assembly: Bracket Install the bracket at the angle shown in the illustration. Work after installation In vehicles with an idling stop and start system, clear the idling stop and start system cycle number stored in the idling stop and start system electronic control unit with the FUSO Diagnostics after replacing the starter. (See Gr54EA.) Mark Parts to be tightened Tightening torque Remarks Bolt (starter mounting) 22 to 30 {2.2 to 3.1} -- Bolt (harness mounting) 2.25 to 4.08 {0.2 to 0.4} -- Nut (battery cable mounting) 9.8 to 11.8 {1.0 to 1.2} -- #930 STARTER ---===WSE_1506_00001_0365.djvu===--- MEMO 54-12-3 54-12 ---===WSE_1506_00001_0366.djvu===--- 54-12-4 Disassembly sequence CAUTION When the armature is removed, the ball may come out with it. Take care not to lose the ball. Do not remove the rear bearing unless defects are evident. 1 Magnetic switch 2 Shim 3 Rear bracket 4 Rear bearing 5 Brush holder 6 Armature 7 Ball 8 Yoke 9 Packing A 10 Planetary gear 11 Packing B 12 Plate 13 Lever 14 Snap ring 15 Stop ring 16 Overrunning clutch 17 Internal gear 18 Planetary gear holder 19 Front bracket : Non-reusable parts #930 STARTER ---===WSE_1506_00001_0367.djvu===--- 54-12-5 54-12 Assembly sequence Follow the disassembly sequence in reverse. CAUTION Do not immerse parts in any kind of solvent for cleaning. Immersing the armature in a solvent will damage the insulation. Wipe parts clean with a cloth. Immersion cleaning of the drive unit is prohibited. The overrunning clutch is filled with grease at the factory. Immersion cleaning will wash away the grease from the clutch. To clean the drive unit, use a cleaning solvent-moistened brush and then wipe it dry with a cloth. Whenever the magnetic switch is replaced, the pinion gap must be adjusted. The packing A is serviceable if any defect is not found. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy -- Pinion gap 0.5 to 2.0 -- Replace -- No-load char- acteristics With 11 V applied Current 120 A or less -- Correct or replace Rotation speed 2870 rpm or higher -- 4,6 Difference between inside diameter of rear bearing and outside diameter of armature shaft 0.1 or less -- Replace 5 Brush spring pressure 23.4 to 31.6 N {2.4 to 3.2 kgf} 10N {1.0 kgf} Replace Brush length 17.6 12.1 Replace 6 Commutator outside diameter 29.4 28.8 Replace Runout of commutator periphery -- 0.1 or higher Mold depth between segments 0.5 0.2 or less Correct or replace 13 Overrunning clutch contact surface of lever 8 or higher -- Replace Mark Parts to be tightened Tightening torque Remarks Screw (magnetic switch mounting) 4.1 to 7.6 {0.4 to 0.8} -- Through bolt (rear bracket mounting) 5.0 to 7.1 {0.5 to 0.7} -- Screw (rear bracket mounting) 2.4 to 4.4 {0.2 to 0.4} -- Nut (tightening cable to terminal M) 9.8 to 11.8 {1.0 to 1.2} -- ---===WSE_1506_00001_0368.djvu===--- 54-12-6 Lubricant and/or sealant Work before disassembly Mating mark: Front bracket and yoke CAUTION Make sure that the motor body is free of damage and that the magnet switch terminals S, B and M are normal. CAUTION A permanent magnet is used in the field section. Do not strike at the yoke hard with a hammer or equivalent, drop it nor squeeze it with a vise. Disassembly procedure Disassembly: Magnet switch Remove the terminal M nut from the magnet switch and discon- nect the field coil line. Remove screws and remove the magnet switch. Mark Points of application Specified lubricant and/or sealant Quantity Armature contact surface of rear bearing Multipurpose grease [NLGI No. 2 (Li soap)] As required Sliding surfaces of lever and overrunning clutch and lever supporting point Internal gear contact surface and spline of planetary gear holder Gear shaft contact surface of front bracket Sliding surfaces of armature and gear shaft Molykote AG650 As required Ball Teeth of planetary gear Internal gear and gear shaft contact surfaces Splines of planetary gear holder Multemp OA-171 (Kyodo Yushi Co., Ltd.) As required #930 STARTER ---===WSE_1506_00001_0369.djvu===--- 54-12-7 54-12 Disassembly: Rear bracket Remove through bolts and screws, and then remove the rear bracket. Disassembly: Rear bearing To remove the rear bearing, press it out of the rear bracket using a round bar slightly thinner than the bearing and a hand press to apply force from outside of the rear bracket. Disassembly: Brush holder, armature and yoke Separate the brushes from the commutator. Then, hold each brush with the brush spring applied against the flank of brush. Pull the brush spring at A to draw up the brush. Hold the drawn-up brush with the brush spring as shown. ---===WSE_1506_00001_0370.djvu===--- 54-12-8 With the brushes held, remove in this order: the brush holder, ar- mature and yoke. Disassembly: Packing A, B, plate and planetary gear Remove packing A, three planetary gears, packing B and plate from the front bracket. Disassembly: Planetary gear holder, internal gear, overrun- ning clutch and lever Remove the planetary gear holder, internal gear, overrunning clutch and lever from the front bracket. CAUTION Confirm the lever direction before removal. Apply a pipe of the same size to the stop ring, and then hammer the pipe moderately to release the stop ring from the snap ring. Remove the snap ring, stop ring, overrunning clutch and internal gear from the planetary gear holder. #930 STARTER ---===WSE_1506_00001_0371.djvu===--- 54-12-9 54-12 Inspection procedure Inspection: Magnetic switch Perform the following checks, and if any fault is found, replace the switch. (1) Test for coil open circuit Confirm that continuity exists between terminals S and M. Confirm that continuity exists between terminal M and the body. (2) Test for fused-together contacts Confirm that continuity does not exist between terminals B and M. (3) Test for contact-to-contact continuity Push in the end of the magnetic switch to close the internal con- tacts. Then, confirm that continuity exists between terminals B and M. ---===WSE_1506_00001_0372.djvu===--- 54-12-10 Inspection: Brush holder (1) Test for insulation Thoroughly clean the (+) side connector and (--) side base and check for continuity between them. If continuity exists, there is a short circuit and the brush holder must be replaced. (2) Manual and visual inspections Perform the following inspections. If any fault is found, replace the brush holder. The brush holder should be free of deformation, cracks, loos- ening of swaged joints and rusted base. The brushes should be able to move smoothly in the brush holder. The brush springs should be free of rust. Inspection: Brush spring Using new brushes, measure the load required to separate each brush spring from its brush. If either measurement is lower than the specified limit, replace the brush springs. Inspection: Brush (+) (--) If either brush is shorter than the limit, it must be replaced. #930 STARTER ---===WSE_1506_00001_0373.djvu===--- 54-12-11 54-12 Inspection: Armature (1) Test for coil short circuit Hold an iron rod parallel with the armature. Slowly rotate the armature by hand. If the iron rod vibrates or is pulled toward the armature, the coil is short-circuited and the armature must be replaced. (2) Test for coil earthing Confirm that continuity does not exist between the commutator and the core (or shaft). If continuity exists, the coil is earthed and the armature must be replaced. (3) Test for coil open circuit Check for continuity between commutator segments. If continuity does not exist, replace the armature. (4) Commutator outside diameter If the measurement is out of specification, replace the armature. (5) Runout of commutator periphery If the reading exceeds the specified limit, replace the armature. (6) Condition of commutator surface If the surface is rough or has stepped wear, rectify it with emery paper (#300 to 500). After rectifying the surface, check the extent of commutator run- out. ---===WSE_1506_00001_0374.djvu===--- 54-12-12 (7) Undercut depth between segments If the measurement is lower than the specified limit, rectify or re- place the armature. To rectify the armature, grind the illustrated portions. If the undercut is worn as illustrated, rectify or replace the arma- ture. : Acceptable  : Unacceptable Inspection: Yoke Inspect the ferrite magnet in the yoke for damages and cracks. If any fault is found, replace the yoke. Inspection: Overrunning clutch If the following inspections reveal any abnormality, replace the overrunning clutch. While holding the housing, give a turn to the pinion. The pinion should not turn at all in one direction but should turn smoothly in the other direction with some resistance felt. Confirm that the pinion teeth are free of chips and not abnormal- ly worn. Confirm that the pinion metal is not abnormally worn. CAUTION The overrunning clutch is filled with grease inside. Do not use immersion cleaning. #930 STARTER ---===WSE_1506_00001_0375.djvu===--- 54-12-13 54-12 Inspection: Lever Measure the overrunning clutch contact surface of the lever to see if it meets the standard value. If the measurement is out of the standard value, replace the le- ver. Inspection: Rear bearing Confirm that the difference between the inside diameter of the rear bearing and outside diameter of the armature shaft meets the standard value. If the measurement is out of the standard value, replace the rear bearing. Assembly procedure Assembly: Planetary gear holder, internal gear and overrun- ning clutch Install the internal gear, overrunning clutch and stop ring onto the planetary gear holder. Set a new snap ring in the groove of the planetary gear holder. Using a puller, draw the stop ring toward the snap ring and then fit the snap ring into the stop ring by pressing with a screwdriver. Assembly: Lever Paying attention to its direction, install the lever onto the over- running clutch. ---===WSE_1506_00001_0376.djvu===--- 54-12-14 Assembly: Front bracket Install the planetary gear holder, internal gear, overrunning clutch and lever on the front bracket. Assembly: Packing A, B, plate and planetary gear Install in this order: plate, packing B, three planetary gears and packing A. Assembly: Front bracket and yoke Using the mating marks provided before disassembly for align- ment, install the yoke to the front bracket. Assembly: Ball and armature Insert the ball, and then install the armature on the planetary gear holder side. Assembly: Brush holder Install the brush holder on the armature. Set the brush springs in the regular state. #930 STARTER ---===WSE_1506_00001_0377.djvu===--- 54-12-15 54-12 Assembly: Rear bearing and rear bracket Install the rear bearing to the rear bracket. Install the rear bracket on the yoke. Make sure that the parts are fitted at the grommet section of the rear bracket. Tighten the through bolts and screws. Assembly: Magnetic switch Install the magnet switch onto the lever with its terminal S in the illustrated direction. Tighten the screws. Connect the field coil line to terminal M of the magnet switch, and then tighten the nut. ---===WSE_1506_00001_0378.djvu===--- 54-12-16 Inspection after assembly Inspection: Performance and pinion gap After assembling the starter, perform inspections with current supplied to it. WARNING When the starter is energized, the pinion will spring out and rotate. Be careful not to touch it with your hands. The magnetic switch may become very hot during inspec- tions. Be careful when touching it. CAUTION Do not energize the pull-in coil P for longer than 10 sec- onds, and do not energize the holding coil H for longer than 30 seconds. If these periods are exceeded, the coils may overheat and burn out. When current is supplied to the starter, a large current (100 A or higher) will flow. For inspection purposes, booster ca- bles or similarly thick cables must therefore be used. It is also important to ensure that all connections are secure. (1) Performance test Connect the starter as illustrated. Set the voltage to 11 volts DC. CAUTION The voltage applied must not exceed 12 V. The following operations are performed with current supplied to the starter. Thus, the entire test (consisting of measurement of the current flowing through the starter and measurement of the starter's rotational speed) must be completed within 30 seconds. Turn ON the switch to supply current to the starter. The pinion will spring out and rotate. CAUTION When the switch is turned ON, the pull-in coil P and holding coil H are both energized. When the large current from the DC power supply flows from terminal B to terminal M, the supply of current to the pull-in coil P is cut; only the holding coil H remains energized. To prevent the holding coil from burning out, it is essential to complete all operations within 30 seconds. Measure the current, then measure the starter's rotational speed with a digital tachometer. Turn OFF the switch to de-energize the starter. If either measurement is out of specification, disassemble and inspect the starter again. #930 STARTER ---===WSE_1506_00001_0379.djvu===--- 54-12-17 54-12 (2) Pinion gap Connect the starter as illustrated. The following operations are performed with current supplied to the starter. Thus, the entire procedure for measurement of the pinion gap must be completed within 30 seconds. Turn ON switches 1 and 2 to supply current to the starter. The pinion will spring out and rotate. After the pinion starts to rotate, quickly (within five seconds) turn OFF switch 2 to stop the pinion's rotation. CAUTION When switches 1 and 2 are turned ON, the pull-in coil P and holding coil H are both energized. The circuit is connected such that no voltage is applied to starter terminal B, so cur- rent flows to the pull-in coil while the pinion rotates. To pre- vent the pull-in coil from burning out, it is essential to turn OFF switch 2 quickly (within five seconds) after the pinion starts to rotate. Pull out the end of the pinion by hand, and then lightly push it back by hand. Measure the amount of axial movement (pinion gap). Turn OFF switch 1 to de-energize the starter. If the measurement is out of specification, replace the lever. ---===WSE_1506_00001_0380.djvu===--- 54-12-18 Removal sequence 1 Belt 2 Alternator WARNING Before removing the alternator, disconnect the (--) battery cable and insulate the cable and the (--) battery terminal with tape. It is dangerous to leave the (--) battery cable connected since the battery cable voltage is always present at terminal B. Installation sequence Follow the removal sequence in reverse. Service standards <12 V> * The hot condition occurs after the alternator has been running at normal ambient temperature at 6000 rpm and maximum output for 30 minutes. <24 V> * The hot condition occurs after the alternator has been running at normal ambient temperature at 6000 rpm and maximum output for 30 minutes. Location Maintenance item Standard value Limit Remedy 2 Alternator output current (*when alternator is hot and producing 13.5 V) 140A At 1800 rpm 75Aormore -- Correct or replace At 6000 rpm 140 A or more -- Adjustment voltage of regulator (at 6000 rpm, 5 A is loaded) 14.5 ± 0.25 V -- Replace Location Maintenance item Standard value Limit Remedy 2 Alternator output current (*when alternator is hot and producing 27 V) 80A At 1800 rpm 35Aormore -- Correct or replace At 6000 rpm 80Aormore -- 90A At 1800 rpm 40Aormore -- At 6000 rpm 90Aormore -- Adjustment voltage of regulator (at 6000 rpm, 5 A is loaded) 28.3±0.3V -- Replace #940 ALTERNATOR ---===WSE_1506_00001_0381.djvu===--- 54-12-19 54-12 Inspection procedure Inspection: Alternator (1) Alternator output current (bench test) Connect the alternator as illustrated. CAUTION Wires with sufficient thickness should be used for wiring and each connection should be securely fastened. Increase load resistance to the maximum (condition under which the load current hardly flows). Turn switch 1 and 2 ON. Run alternator at 6000 rpm for 30 minutes by adjusting load re- sistance so that electric current can conform to the following standard. Alternator nominal current Measure the current at each specified revolution of alternator. If the measured value is lower than the standard value, disas- semble and check alternator. (2) Adjustment voltage of regulator (bench test) Connect the alternator as illustrated. Turn switch ON. Run alternator at low speeds. Increase the speed of alternator to 6000 rpm and measure the voltage (adjustment voltage) at this speed. At the same time, make sure that the current is 5 amperes or less at 6000 rpm. If the measured value deviates from the standard value, do as follows: If higher than the standard value: Replace the regulator. If lower than the standard value: Inspect the alternator related parts before replacing the regulator. Alternator Current 80A Approx. 80A 90A Approx. 90A 140A Approx. 140A ---===WSE_1506_00001_0382.djvu===--- 54-13-1 54-13 ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1506_00001_0383.djvu===--- 54-13-2 Performance test The on-vehicle inspection is only a simplified check. Use a test bench for accurate checking. Connect the meters to the alternator as shown. WARNING To prevent possible injury, be sure to disconnect the nega- tive battery cable and insulate the cable and the negative battery terminal with tape before working on the wiring. With the negative (--) battery cable connected, battery volt- age is always applied to terminal B. To connect to switch, use a lead wire with the same or larg- er diameter than that of the chassis harness connected to terminal B. Turn on switch and make sure that voltmeter indicates battery voltage. Start the engine. Immediately turn on the switches for all lamps on the vehicle. Immediately accelerate the engine to the speed indicated below and measure the alternator's output current. Approx. 2200 rpm The alternator is considered to be good if the measured value is 70% or more of the nominal output current. Alternator nominal output Alternator Voltage Output current 8 0 A2 4 V8 0 A 90A 24V 90A 140 A 12V 140 A #950 INSPECTION OF ALTERNATOR ---===WSE_1506_00001_0384.djvu===--- 54-13 54-13-3 Service standards Connect the meters to the alternator as shown. WARNING To prevent possible injury, be sure to disconnect the nega- tive battery cable and insulate the cable and the negative battery terminal with tape before working on the wiring. With the negative (--) battery cable connected, battery volt- age is always applied to terminal B. To connect to switch, use a lead wire with the same or larg- er diameter than that of the chassis harness connected to terminal B. Turn off the switches for lamps, heater, etc. so that electric loads may not be applied during the inspection. Turn on switch and then start the engine. If the output current is 5 amperes or less when the engine speed is raised to the appropriate speed indicated below, then mea- sure the voltage at terminal B. Approx. 2200 rpm If the output current is not less than 5 amperes, the measured value (regulated voltage) will be slightly lower. If the output current is 5 amperes or more, do one of the follow- ing: Run the engine for a while to charge the battery. Replace the battery with a fully-charged one. If the measured value deviates from the standard value, conduct checking again on the test bench. Location Maintenance item Standard value Limit Remedy -- Adjusting voltage 24V 28.3±0.3V --R e p l a c e 12V 14.5 ± 0.25 V #951 INSPECTION OF REGULATOR ---===WSE_1506_00001_0385.djvu===--- 54-13-4 1. Preparation before Adjustment Park the vehicle on a level flat place and apply chocks to the wheels. Empty the vehicle. Adjust the tyre inflation pressure to the specified value. Place a mass of 75 kg (corresponding to a mean weight of one man) on the driver's seat. On vehicles with headlamp leveling device, set the headlamp leveling switch to 0. Start the engine to charge the battery. Locate a lamp tester at a place opposite to the vehicle front end face as illustrated. Turn on the headlamps and aim the headlamps such that the passing beam lamp centre is aligned with the beam convergent lens centre of the lamp tester. (Shown here is the left-hand headlamp.) Mask other lamps than that next subjected to adjustment in such a way that no light may leak. CAUTION Headlamp lenses are made of plastic. Do not keep the masked headlamps illuminated for longer than 2 minutes. Sustained illumination of these lamps can cause heat gen- eration, possibly resulting in deformed headlamp lens. 2. Adjustment Turn on the passing beam. Perform the following procedure to adjust the passing beam such that the elbow point of the cut-off line between the lighted and shaded areas is positioned as shown in the figure: Adjustment in vertical direction: Turn screws A and B the same amount in this order. Adjustment in horizontal direction: Turn screw B. The position of the cut-off line between the lighted and shaded areas must correspond to the adjustment value. Cut-off line position Adjustment value 0.57° <FE> 0.86° <FG> #960 HEADLAMP AIMING ---===WSE_1506_00001_0386.djvu===--- 54-13 54-13-5 CW: Clockwise CCW: Counter-clockwise Beam adjustment direction Right-hand headlamp Left-hand headlamp Up Down Left Right Up Down Left Right Screw A CCW CW -- -- CCW CW -- -- Screw B CCW CW CCW CW CCW CW CW CCW ---===WSE_1506_00001_0387.djvu===--- 54-13-6 1. Preparation before Adjustment Park the vehicle on a level flat place and apply chocks to the wheels. Empty the vehicle. Adjust the tyre inflation pressure to the specified value. Place a mass of 75 kg (corresponding to a mean weight of one man) on the driver's seat. Start the engine to charge the battery. Locate a lamp tester at a place opposite to the vehicle front end face as illustrated. With the fog lamp turned on, align the centre of fog lamp bulb and the centre of convergent lens of convergent lamp tester. (Shown here is the left-hand fog lamp.) Mask other lamps than that next subjected to adjustment in such a way that no light may leak. CAUTION Fog lamp lenses are made of plastic. Do not keep the masked fog lamp illuminated for longer than 2 minutes. Sustained illumination of these lamps can cause heat gen- eration, possibly resulting in deformed fog lamp lens. 2. Adjustment Turn on fog lamp. Make adjustment with the aiming gear to bring for lamp cut-off line into the illustrated position. Cut-off line position Standard value 1.5% or less Adjusting direction for optical axis Upward Downward Screwdriver rotation direction Clockwise Counter-clockwise #961 FOG LAMP AIMING ---===WSE_1506_00001_0388.djvu===--- 54-14-1 54-14 CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0389.djvu===--- 54-14-2 AA type Number shows number of pins Female connector Male connector AA1A AA2A AA2B AA3A AA3B AA4A AA4B AA6A AA6B CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0390.djvu===--- 54-14 54-14-3 AB type AA8A AA10A AA12A Number shows number of pins Female connector Male connector AB1A AB2A AB2B AB2C AB3A AB3B Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0391.djvu===--- 54-14-4 AB4A AB6A AB6B AB8A AB8B AB12A AB12B AB14A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0392.djvu===--- 54-14 54-14-5 AC type AB14B AB16A AB16B AB52A AB52B Number shows number of pins Female connector Male connector AC1A AC1B AC2A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0393.djvu===--- 54-14-6 AD type AC2B AC2C AC2D AC3A AC4A AC4B Number shows number of pins Female connector Male connector AD1A AD2A AD2B Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0394.djvu===--- 54-14 54-14-7 AE type Number shows number of pins Female connector Male connector AE2A AE3A AE5A AE7A AE9A AE11A AE13A AE15A AE16A ---===WSE_1506_00001_0395.djvu===--- 54-14-8 AG type AH type AE16B AE16C AE17A Number shows number of pins Female connector Male connector AG16A AG20A Number shows number of pins Female connector Male connector AH10A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0396.djvu===--- 54-14 54-14-9 AH12A AH12B AH16A AH18A AH18B Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0397.djvu===--- 54-14-10 AJ type AH22A AH24A AH26A Number shows number of pins Female connector Male connector AJ2A AJ4A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0398.djvu===--- 54-14 54-14-11 AJ8A AJ10A AJ12A AJ16A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0399.djvu===--- 54-14-12 AK type AJ20A Number shows number of pins Female connector Male connector AK2A AK3A AK4A AK6A AK8A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0400.djvu===--- 54-14 54-14-13 AK10A AK12A AK14A AK18A AK20A AK20B Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0401.djvu===--- 54-14-14 AL type AK22A AK22B Number shows number of pins Female connector Male connector AL1A AL2A AL2B Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0402.djvu===--- 54-14 54-14-15 AL3A AL3B AL3C AL3D AL3E Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0403.djvu===--- 54-14-16 AL4A AL4B AL6A AL6B AL8A AL8B Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0404.djvu===--- 54-14 54-14-17 AM type Number shows number of pins Female connector Male connector AM1A AM1B AM2A AM2B AM2C AM4A AM4B AM6A AM6B ---===WSE_1506_00001_0405.djvu===--- 54-14-18 AN type AM8A AM8B AM10A AM10B Number shows number of pins Female connector Male connector AN1A AN2A AN2B AN3A AN4A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0406.djvu===--- 54-14 54-14-19 AP type AN4B AN6A AN6B AN8A AN8B Number shows number of pins Female connector Male connector AP1A AP1B AP2A AP2B Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0407.djvu===--- 54-14-20 AQ type AP2C Number shows number of pins Female connector Male connector AQ1A AQ3A AQ3B AQ5A AQ6A AQ8A AQ12A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0408.djvu===--- 54-14 54-14-21 AR type Number shows number of pins Female connector Male connector AR2A AR2B AR2C AR2D AR2E AR2F AR2G AR2H AR3A ---===WSE_1506_00001_0409.djvu===--- 54-14-22 AS type AT type AU type Number shows number of pins Female connector Male connector AS1A AS2A AS2B Number shows number of pins Female connector Male connector AT4A Number shows number of pins Female connector Male connector AU2A AU6A AU8A AU10A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0410.djvu===--- 54-14 54-14-23 AV type AW type AU12A AU13A AU16A AU16B AU16C Number shows number of pins Female connector Male connector AV1A AV2A Number shows number of pins Female connector Male connector AW1A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0411.djvu===--- 54-14-24 AX type AY type AW1B AW1C AW2A Number shows number of pins Female connector Male connector AX2A AX3A AX4A Number shows number of pins Female connector Male connector AY2A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0412.djvu===--- 54-14 54-14-25 AZ type BA type BB type BC type BD type Number shows number of pins Female connector Male connector AZ2A Number shows number of pins Female connector Male connector BA3A Number shows number of pins Female connector Male connector BB2A BB3A Number shows number of pins Female connector Male connector BC3A Number shows number of pins Female connector Male connector BD6A ---===WSE_1506_00001_0413.djvu===--- 54-14-26 BE type BF type BD8A BD12A BD16A BD20A Number shows number of pins Female connector Male connector BE6A Number shows number of pins Female connector Male connector BF6A BF8A BF10A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0414.djvu===--- 54-14 54-14-27 BG type BJ type BF12A Number shows number of pins Female connector Male connector BG10A BG12A BG16A Number shows number of pins Female connector Male connector BJ5A BJ7A BJ9A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0415.djvu===--- 54-14-28 BM type BN type BQ type Number shows number of pins Female connector Male connector BM2A BM2B BM2C BM3A BM4A Number shows number of pins Female connector Male connector BN1A Number shows number of pins Female connector Male connector BQ1A BQ2A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0416.djvu===--- 54-14 54-14-29 BR type BS type BQ3A BQ3B Number shows number of pins Female connector Male connector BR1A BR2A BR4A BR4B Number shows number of pins Female connector Male connector BS1A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0417.djvu===--- 54-14-30 BT type BS2A BS3A BS4A BS6A BS8A Number shows number of pins Female connector Male connector BT2A BT3A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0418.djvu===--- 54-14 54-14-31 BT4A BT6A BT8A BT10A BT12A BT16A BT16B BT16C BT20A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0419.djvu===--- 54-14-32 BU type BW type BT20B BT20C Number shows number of pins Female connector Male connector BU4A BU6A Number shows number of pins Female connector Male connector BW2A BW2B BW3A BW3B Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0420.djvu===--- 54-14 54-14-33 BX type BW4A BW4B BW6A BW6B BW8A BW10A Number shows number of pins Female connector Male connector BX2A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0421.djvu===--- 54-14-34 BX3A BX5A BX7A BX9A BX11A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0422.djvu===--- 54-14 54-14-35 BY type BX13A BX15A BX17A BX19A Number shows number of pins Female connector Male connector BY4A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0423.djvu===--- 54-14-36 BZ type CA type CB type Number shows number of pins Female connector Male connector BZ12A BZ16A BZ22A BZ26A Number shows number of pins Female connector Male connector CA2A Number shows number of pins Female connector Male connector CB16A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0424.djvu===--- 54-14 54-14-37 CD type CE type Number shows number of pins Female connector Male connector CD35A CD55A Number shows number of pins Female connector Male connector CE2A CE4A CE12A CE16A CE20A ---===WSE_1506_00001_0425.djvu===--- 54-14-38 CF type CH type CK type CL type Number shows number of pins Female connector Male connector CF21A Number shows number of pins Female connector Male connector CH2A CH2B CH3A Number shows number of pins Female connector Male connector CK3A Number shows number of pins Female connector Male connector CL14A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0426.djvu===--- 54-14 54-14-39 CM type CN type Number shows number of pins Female connector Male connector CM28A CM30A CM35A Number shows number of pins Female connector Male connector CN2A CN12A CN16A ---===WSE_1506_00001_0427.djvu===--- 54-14-40 CP type CQ type Number shows number of pins Female connector Male connector CP40A CP40B CP80A Number shows number of pins Female connector Male connector CQ2B CQ3A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0428.djvu===--- 54-14 54-14-41 CR type CS type CT type CQ8A Number shows number of pins Female connector Male connector CR16A Number shows number of pins Female connector Male connector CS2A Number shows number of pins Female connector Male connector CT3A CT3B CT10A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0429.djvu===--- 54-14-42 CU type CV type CW type Number shows number of pins Female connector Male connector CU6A CU9A CU12A CU15A CU17A CU18A Number shows number of pins Female connector Male connector CV8A Number shows number of pins Female connector Male connector CW16A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0430.djvu===--- 54-14 54-14-43 CX type CY type CW25A CW31A CW32A Number shows number of pins Female connector Male connector CX30A CX32A CX32B CX32C Number shows number of pins Female connector Male connector CY17A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0431.djvu===--- 54-14-44 DA type DB type CY22A CY24A CY28A CY31A Number shows number of pins Female connector Male connector DA20A DA22A DA25A Number shows number of pins Female connector Male connector DB2A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0432.djvu===--- 54-14 54-14-45 DC type DD type Number shows number of pins Female connector Male connector DC3A Number shows number of pins Female connector Male connector DD1A DD2A DD2B DD2C DD2E DD2F DD3A ---===WSE_1506_00001_0433.djvu===--- 54-14-46 DD4A DD4C DD5A DD6A DD6B DD6C DD6E DD7A DD8A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0434.djvu===--- 54-14 54-14-47 DD9A DD10A DD10B DD11A DD12A DD12B DD12C DD13A DD13B Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0435.djvu===--- 54-14-48 DD14A DD14B DD15A DD15B DD16A DD16B DD18A DD20A DD22A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0436.djvu===--- 54-14 54-14-49 DE type DF type DG type Number shows number of pins Female connector Male connector DE3A DE7A Number shows number of pins Female connector Male connector DF3A Number shows number of pins Female connector Male connector DG1A DG1B DG1C DG1D DG2A ---===WSE_1506_00001_0437.djvu===--- 54-14-50 DG2B DG2C DG2D DG2E DG2F DG2G DG2H DG2J DG2K Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0438.djvu===--- 54-14 54-14-51 DG2L DG2M DG3A DG3B DG4A DG4B DG4C DG5A DG5B Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0439.djvu===--- 54-14-52 DG5C DG5D DG6A DG6B DG6C DG8A DG8B DG10A DG12A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0440.djvu===--- 54-14 54-14-53 DH type Number shows number of pins Female connector Male connector DH2A DH5A DH6A DH10A DH14A DH18A DH20A DH22A ---===WSE_1506_00001_0441.djvu===--- 54-14-54 DJ type DK type DL type Number shows number of pins Female connector Male connector DJ10A DJ10B Number shows number of pins Female connector Male connector DK2A DK2B DK3A DK4A Number shows number of pins Female connector Male connector DL4A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0442.djvu===--- 54-14 54-14-55 DM type DN type DP type DQ type Number shows number of pins Female connector Male connector DM3A DM4A Number shows number of pins Female connector Male connector DN4A Number shows number of pins Female connector Male connector DP5A Number shows number of pins Female connector Male connector DQ2A DQ2B DQ2C ---===WSE_1506_00001_0443.djvu===--- 54-14-56 DQ2D DQ2E DQ2F DQ3A DQ3B DQ3D DQ4A DQ4B DQ4C Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0444.djvu===--- 54-14 54-14-57 DR type DS type DT type DQ8A Number shows number of pins Female connector Male connector DR2A Number shows number of pins Female connector Male connector DS2A DS6A Number shows number of pins Female connector Male connector DT1A DT2A DT3A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0445.djvu===--- 54-14-58 DU type DV type DW type DX type DT4A Number shows number of pins Female connector Male connector DU2A Number shows number of pins Female connector Male connector DV4A Number shows number of pins Female connector Male connector DW2A Number shows number of pins Female connector Male connector DX2A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0446.djvu===--- 54-14 54-14-59 DY type DZ type EA type EB type Number shows number of pins Female connector Male connector DY1A DY1B Number shows number of pins Female connector Male connector DZ1A Number shows number of pins Female connector Male connector EA8A EA8B Number shows number of pins Female connector Male connector EB8A ---===WSE_1506_00001_0447.djvu===--- 54-14-60 EC type ED type EE type EF type EG type Number shows number of pins Female connector Male connector EC2A Number shows number of pins Female connector Male connector ED2A Number shows number of pins Female connector Male connector EE2A Number shows number of pins Female connector Male connector EF2A Number shows number of pins Female connector Male connector EG4A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0448.djvu===--- 54-14 54-14-61 EH type EJ type EK type EL type EM type Number shows number of pins Female connector Male connector EH2A Number shows number of pins Female connector Male connector EJ9A Number shows number of pins Female connector Male connector EK2A Number shows number of pins Female connector Male connector EL2A Number shows number of pins Female connector Male connector EM40A EM81A ---===WSE_1506_00001_0449.djvu===--- 54-14-62 EN type EP type EQ type Number shows number of pins Female connector Male connector EN4A EN5A Number shows number of pins Female connector Male connector EP34A Number shows number of pins Female connector Male connector EQ4A EQ4B EQ5A EQ5B CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0450.djvu===--- 54-14 54-14-63 ER type ES type Number shows number of pins Female connector Male connector ER2A ER6A ER8A Number shows number of pins Female connector Male connector ES2A ES2B ES2C ES3A ES3B ---===WSE_1506_00001_0451.djvu===--- 54-14-64 ET type ES4A Number shows number of pins Female connector Male connector ET1A ET1B ET1D ET2A ET2B ET2C ET2D ET2F Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0452.djvu===--- 54-14 54-14-65 ET2G ET2L ET3A ET3B ET3C ET4A ET4B ET5A ET5B Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0453.djvu===--- 54-14-66 EU type ET5D ET6A ET6B ET6C ET8A ET8B ET10A ET32A Number shows number of pins Female connector Male connector EU1A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0454.djvu===--- 54-14 54-14-67 EV type EW type EX type EY type EZ type Number shows number of pins Female connector Male connector EV2A Number shows number of pins Female connector Male connector EW12A Number shows number of pins Female connector Male connector EX5A Number shows number of pins Female connector Male connector EY3A Number shows number of pins Female connector Male connector EZ3A ---===WSE_1506_00001_0455.djvu===--- 54-14-68 FA type FB type GA type Number shows number of pins Female connector Male connector FA2B FA3A FA5A Number shows number of pins Female connector Male connector FB55A Number shows number of pins Female connector Male connector GA1A GA2A GA2B CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0456.djvu===--- 54-14 54-14-69 GA3A GA3B GA4A GA4B GA6A GA6B GA8A GA10A GA12A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0457.djvu===--- 54-14-70 GB type Number shows number of pins Female connector Male connector GB1A GB2A GB2B GB3A GB3B GB4A GB4B GB6A GB6B CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0458.djvu===--- 54-14 54-14-71 GC type GD type GB8A GB10A GB12A Number shows number of pins Female connector Male connector GC32A Number shows number of pins Female connector Male connector GD1A GD2A GD3A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0459.djvu===--- 54-14-72 GE type GF type GD3B Number shows number of pins Female connector GE58A GE96A Number shows number of pins Female connector Male connector GF31A GF32A GF34A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0460.djvu===--- 54-14 54-14-73 GG type GH type GF35A GF35B Number shows number of pins Female connector Male connector GG12A GG16A GG22A GG26A Number shows number of pins Female connector Male connector GH3A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0461.djvu===--- 54-14-74 GJ type GK type GL type GM type GN type Number shows number of pins Female connector Male connector GJ2A GJ2B Number shows number of pins Female connector Male connector GK7A Number shows number of pins Female connector Male connector GL2A Number shows number of pins Female connector Male connector GM2A Number shows number of pins Female connector Male connector GN2A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0462.djvu===--- 54-14 54-14-75 GP type GQ type GR type GS type Number shows number of pins Female connector Male connector GP8A GP8B Number shows number of pins Female connector Male connector GQ9A Number shows number of pins Female connector Male connector GR13A GR15A Number shows number of pins Female connector Male connector GS2A GS2B ---===WSE_1506_00001_0463.djvu===--- 54-14-76 GT type GU type GS2C GS2D GS3A Number shows number of pins Female connector Male connector GT24A GT28A GT32A Number shows number of pins Female connector Male connector GU24A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0464.djvu===--- 54-14 54-14-77 GV type GW type Number shows number of pins Female connector Male connector GV12A GV16A GV20A Number shows number of pins Female connector Male connector GW3A GW3B GW4A ---===WSE_1506_00001_0465.djvu===--- 54-14-78 GX type GY type GZ type HA type Number shows number of pins Female connector Male connector GX1A GX2A Number shows number of pins Female connector Male connector GY4A Number shows number of pins Female connector Male connector GZ2A Number shows number of pins Female connector Male connector HA2A HA4A HA7A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0466.djvu===--- 54-14 54-14-79 HB type HC type HD type HA15A HA36A HA46A Number shows number of pins Female connector Male connector HB4A Number shows number of pins Female connector Male connector HC11A Number shows number of pins Female connector Male connector HD2A HD2B Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0467.djvu===--- 54-14-80 HE type HF type HD3A HD4A HD4B HD5A Number shows number of pins Female connector Male connector HE2A HE3A Number shows number of pins Female connector Male connector HF3A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0468.djvu===--- 54-14 54-14-81 HG type HH type Number shows number of pins Female connector Male connector HG2A HG3A HG3B HG4A Number shows number of pins Female connector Male connector HH1A HH2A HH2B HH2C ---===WSE_1506_00001_0469.djvu===--- 54-14-82 HH3A HH3B HH3C HH4A HH6A HH6B HH6C HH8A HH8B Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0470.djvu===--- 54-14 54-14-83 HH10A HH10B HH12A HH12B HH16A HH18A HH18B HH18C HH20A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0471.djvu===--- 54-14-84 HJ type HH28A HH28B HH38A HH40A HH40B HH60A HH81A Number shows number of pins Female connector Male connector HJ2A HJ2B Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0472.djvu===--- 54-14 54-14-85 HJ2C HJ3A HJ3B HJ3C HJ4A HJ4B HJ6A HJ94A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0473.djvu===--- 54-14-86 HK type HL type HM type HN type Number shows number of pins Female connector Male connector HK2A HK2B HK6A HK11A Number shows number of pins Female connector Male connector HL3A Number shows number of pins Female connector Male connector HM5A Number shows number of pins Female connector Male connector HN3A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0474.djvu===--- 54-14 54-14-87 HN3B HN4A HN5A HN5B HN6A HN14A HN14B HN14C HN14D Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0475.djvu===--- 54-14-88 HP type HQ type Number shows number of pins Female connector Male connector HP23A Number shows number of pins Female connector Male connector HQ1A HQ2A HQ4A HQ4B HQ5A HQ5B HQ8A CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0476.djvu===--- 54-14 54-14-89 HR type HS type HQ8B HQ8C HQ10A HQ10B HQ10C Number shows number of pins Female connector Male connector HR3A Number shows number of pins Female connector Male connector HS2A HS3A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0477.djvu===--- 54-14-90 HT type HU type HS4A HS5A HS5B Number shows number of pins Female connector Male connector HT7A Number shows number of pins Female connector Male connector HU2A HU2B HU2C HU2D Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0478.djvu===--- 54-14 54-14-91 HV type PC type PE type HU3A Number shows number of pins Female connector Male connector HV3A Number shows number of pins Female connector Male connector PC4A Number shows number of pins Female connector Male connector PE8A PE10A PE10B Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0479.djvu===--- 54-14-92 PE12A PE12B PE14A Number shows number of pins Female connector Male connector CONNECTOR CONFIGURATION CHART ---===WSE_1506_00001_0480.djvu===--- 54-14 54-14-93 PE18A PE20A Number shows number of pins Female connector Male connector ---===WSE_1506_00001_0481.djvu===--- 54EA-1 54EA IDLING STOP AND START SYSTEM STRUCTURE AND OPERATION 1. Overview........................................................................................... 54EA-2 2. Electronic Control System.............................................................. 54EA-4 3. Electronic Control Unit Circuit Diagram ...................................... 54EA-10 TROUBLESHOOTING 1. Inspection Based on Diagnosis Codes ....................................... 54EA-12 2. FUSO Diagnostics Service Data (Actual Values) ........................ 54EA-18 3. FUSO Diagnostics Actuator Test (Actuations) ........................... 54EA-24 4. Electronic Control Unit Coding .................................................... 54EA-25 5. Electronic Control Unit Input/Output Table ................................. 54EA-25 INSPECTION OF ELECTRICAL PARTS . ................................(See Gr54.) INSTALLED LOCATIONS OF PARTS .....................................(See Gr54.) ELECTRIC CIRCUIT DIAGRAM ..............................................(See Gr54.) MEMO Contents of the "54-00C 8. Idling Stop and Start System Electronic Control Unit" (00ELT0035) and "54-13 #990 INSPECTION OF IDLING STOP AND START SYSTEM" (00ELT0035) has been described as same group to Gr54EA. Content other than change bar is same as 00ELT0035. ---===WSE_1506_00001_0482.djvu===--- 54EA-2 1. Overview The idling stop and start system automatically stops the engine when the vehicle is stopped and automatically starts the engine when the vehicle is started, thus reducing exhaust emissions and improving fuel consumption. (The illustration shows the left-hand drive vehicle.) When the idling stop and start system is operating, vehicle equipment is operated or controlled as follows: When the engine is automatically stopped while the headlights (dipped beam) or fog lamps are on, the lights will be automatically turned off. Even when the engine is automatically stopped while the audio system is operating, the system will keep oper- ating. Even when the engine is automatically stopped while the air conditioning system is operating, the system will keep operating for 1 minute. When the engine has been automatically stopped for more than 1 minute, the air conditioner magnet clutch will be cut off to stop the air-conditioning system. The idling stop and start system does not operate under any of the following conditions: The specific gravity of the battery has dropped. The driver's door or assistant driver's door is open. The cab is raised. The idling stop and start system cutoff switch is ON. Power take-off is being used. Automatic or parked diesel particulate filter regeneration is under way. The brake warning is illuminated. (The brake fluid pressure has dropped.) The coolant temperature indicator shows 4 segments or less, or 9 segments or more. STRUCTURE AND OPERATION ---===WSE_1506_00001_0482.djvu===--- 54EA-2 1. Overview The idling stop and start system automatically stops the engine when the vehicle is stopped and automatically starts the engine when the vehicle is started, thus reducing exhaust emissions and improving fuel consumption. (The illustration shows the left-hand drive vehicle.) When the idling stop and start system is operating, vehicle equipment is operated or controlled as follows: When the engine is automatically stopped while the headlights (dipped beam) or fog lamps are on, the lights will be automatically turned off. Even when the engine is automatically stopped while the audio system is operating, the system will keep oper- ating. Even when the engine is automatically stopped while the air conditioning system is operating, the system will keep operating for 1 minute. When the engine has been automatically stopped for more than 1 minute, the air conditioner magnet clutch will be cut off to stop the air-conditioning system. The idling stop and start system does not operate under any of the following conditions: The specific gravity of the battery has dropped. The driver's door or assistant driver's door is open. The cab is raised. The idling stop and start system cutoff switch is ON. Power take-off is being used. Automatic or parked diesel particulate filter regeneration is under way. The brake warning is illuminated. (The brake fluid pressure has dropped.) The coolant temperature indicator shows 4 segments or less, or 9 segments or more. STRUCTURE AND OPERATION ---===WSE_1506_00001_0483.djvu===--- 54EA 54EA-3 The idling stop and start system indicator is illuminated. The turn signal is ON or the hazard lamp switch is pressed. <Vehicles with DUONIC ® system> To prevent the automatic engine stop function from activating too frequently when the vehicle is repeatedly stopped or slowed down in a traffic jam or at intersections, the engine is not automatically stopped by the idling stop and start system when the vehicle is stopped after it has been driven at a speed of 10 km/h or less. In other words, the engine is automatically stopped by the idling stop and start system when the vehicle is stopped after it has been driven at a speed of 10 km/h or more. ---===WSE_1506_00001_0484.djvu===--- 54EA-4 2. Electronic Control System 2.1 System block diagram <With ESP ® > STRUCTURE AND OPERATION ---===WSE_1506_00001_0485.djvu===--- 54EA 54EA-5 <Without ESP ® > ---===WSE_1506_00001_0486.djvu===--- 54EA-6 Part name Main function/operation Idling stop and start system cutoff switch Idling stop and start system control stop switch FUSO Diagnostics (diagnosis connector) Communication between FUSO Diagnostics and idling stop and start system electronic control unit Door switch Detects whether driver's door and assistant driver's door are open or closed. Condenser fan relay Air conditioning control by signal detect and actuation modules when idling stop and start system is operating Blower motor Magnetic clutch Starter Starter control by engine electronic control unit when idling stop and start system is operating Meter cluster System warning Warning when idling stop and start system is faulty Operation indicator Indications when preparing for automatic engine stop and when automatically stopping engine Buzzer Sounds when engine is automatically stopped and driver's door or assistant driver's door is open. Idling stop and start system electronic control unit Requests idling stop and start system control (automatic en- gine stop and start) to engine electronic control unit via control- ler area network communication when input signals satisfy idling stop and start system actuation conditions. Sends or receives idling stop and start system control related signals to and from signal detect and actuation modules via controller area network communication. Signal detect and actuation modules Controls power supply to various equipment. Relays signals input or output to and from signal detect and ac- tuation modules in response to signals received from idling stop and start system electronic control unit via controller area network communication. Engine electronic control unit Inputs or outputs idling stop and start system control related signals. Sends or receives idling stop and start system request/cancel signal from idling stop and start system electronic control unit via controller area network communication. DUONIC electronic control unit <Vehicles with DUONIC ® system> Determines whether or not to allow idling stop and start system control (automatic engine stop and start). Headlamp (dipped), fog lamp Lamp ON/OFF control by signal detect and actuation modules when idling stop and start system is operating Brake control valve <Vehicles with DUONIC ® system> Brake control when idling stop and start system is operating DC/DC converter Power supply to idling stop and start system electronic control unit Combination switch, hazard switch Detects turn signal operation status. <Vehicles with DUONIC ® system> Stop lamp switch Detects brake pedal operation status. STRUCTURE AND OPERATION ---===WSE_1506_00001_0487.djvu===--- 54EA 54EA-7 2.2 Automatic engine stop <Manual gearbox> <DUONIC ® > Head lamps (low beam) OFF Fog lamps OFF Idling stop and start system cutoff switch OFF After driving at 10 km/h or more Release clutch pedal Engine coolant temperature indication is between 4 segments and 9 segments Specific gravity of battery is normal Driver's door and assistant driver's door are closed Power-take off, diesel particulate filter or cab tilt are not operating Idling stop and start system cancellation signal does not exist Vehicle speed is 2 km or less Engine idling Engine stops AND Air conditioning system continues to operate (Stops after operating for 1 minute) Idling stop and start system operation indicator ON Gear shift control lever is in "N" position Head lamps (dipped beam) OFF Fog lamps OFF Idling stop and start system cutoff switch OFF After driving at 10 km/h or more Gearshift lever is in "D" (manual mode posi- tion), "N" or "P" position Press brake pedal (Strongly press it during driving on a steep slope.) Engine coolant temperature indication is between 4 segments and 9 segments Specific gravity of battery is normal Driver's door and assistant driver's door are closed Power take-off, diesel particulate filter or cab tilt are not operating Idling stop and start system cancellation signal does not exist Vehicle speed is 2 km or less Engine idling Engine stops AND Air conditioning system continues to operate (Stops after operating for 1 minute) Idling stop and start system operation indicator ON Brake control valve is activated (Braking power is maintained if gear- shift lever is in "D" (manual mode po- sition) or "N" position.) Turn signal switch OFF Hazard switch OFF ---===WSE_1506_00001_0488.djvu===--- 54EA-8 2.3 Automatic engine start <Manual gearbox> <DUONIC ® > If idling stop function is activated with gearshift lever in "D" (or manual mode) position: <DUONIC ® > If idling stop function is activated with gearshift lever in "N" or "P" position: Idling stop and start system cutoff switch OFF Idling stop by idling stop and start system Engine starts Idling stop and start system control unit operation indicator OFF Air conditioning system operates nor- mally Head lamps (low beam) ON Fog lamps ON Press clutch pedal Gear shift control lever is in "N" position Driver's door and assistant driver's door are closed AND OR AND AND Idling stop and start system cutoff switch OFF Idling stop by idling stop and start system Driver's door and assistant driver's door are closed Gearshift lever is in "D" (or manual mode) posi- tion Release brake pedal Engine starts AND Idling stop and start system control unit operation indicator OFF Brake control valve is released Air conditioning system operates nor- mally Head lamps (dipped beam) ON Fog lamps ON Gearshift lever is moved from "D" to "+"/ "--" or "A/M" (manual mode) position Press brake pedal OR AND AND Idling stop and start system cutoff switch OFF Idling stop by idling stop and start system Driver's door and assistant driver's door are closed Engine starts AND Idling stop and start system operation indicator OFF Air conditioning system operates nor- mally Head lamps (dipped beam) ON Fog lamps ON Gearshift lever is moved from "N" or "P" position to "D" or "R" position Release brake pedal Gearshift lever is in "N" position Press brake pedal STRUCTURE AND OPERATION ---===WSE_1506_00001_0489.djvu===--- 54EA 54EA-9 2.4 Diagnostic function While the starter switch is ON, the idling stop and start system control unit continuously monitors the conditions of communications with other electronic control units and whether various sensors and relays operate normally. In the event the idling stop and start system electronic control unit find fault, it sends fault information to the meter cluster to alert the driver. At the same time, it stores the fault information in the form of a diagnosis code and starts executing control under failure conditions. While control under failure conditions is being executed, the system's functionality is limited to ensure vehicle and driver safety. The stored diagnosis codes can be displayed on the FUSO Diagnostics system and on the meter cluster. ---===WSE_1506_00001_0490.djvu===--- 54EA-10 3. Electronic Control Unit Circuit Diagram <With ESP ® > C10040-ECU-54EA-1 A/C BLOWER RELAY A A/C COMP COND. RELAY G POWER GND ECU GND CHASSIS CAN-H CHASSIS CAN-L POWER GND ILL CABIN FRONT DOOR SW(RH,LH) VAC SW(FLOW SW) PARKING BRAKE SW F13 F01 F20 F10 F11 F32 DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L IGN RELAY E ISS CUT SW ISS CUT IND BRAKE M/V BRAKE M/V FRONT-L BRAKE M/V FRONT-R (RH,LH) CAB TILT LOCK SW M 1 9 2 15 16 13 10 6 4 5 7 8 BATT CAN-H MAIN ST ON/OFF SIG DC/DC DIAG GND CAN-L IGN SW SIG VIN GND V OUT ST SIG DIAG HH16A M 12345678 9 10111213141516 SAM Relay LSD SAM Relay LSD BRAKE SW NO GND BRAKE SW NC COMB. SW BATT COMB. SW LIN SIG HAZARD SW LIN GND BATT LIN SIG GND SAM Relay LSD SPEAKER Battery High-current fuse box Vacuum switch Parking brake switch ISS cutoff switch Front door switch Cab tilt lock switch Dual pressure switch Magnetic clutch Blower motor To power MOS-FET(transistor) or To blower resistor Diagnosis connector Condenser fan motor Condenser fan relay Brake control Valve (Front LH) Brake control valve relay 1 Starter relay (solenoid type) DUONIC ECU Hydraulic unit (ABS ECU) Harness side connector To starter ISS ECU DC/DC converter <DUONIC > Combination switch To headlamp, RH(dipped) To headlamp, LH (dipped) To fog lamp, RH To fog lamp, LH Hazard switch Engine ECU Meter cluster Starter relay (for drive) SAM: Signal detect and actuation modules ECU: Electronic control unit ISS: Idling stop and start system ABS: Anti-lock brake system M/G: Manual gearbox <M/G> <DUONIC > R R Brake control valve relay 2 Brake control Valve (Front RH) Brake control Valve (Rear LH) Brake control Valve (Rear RH) Stop lamp switch SAM STRUCTURE AND OPERATION ---===WSE_1506_00001_0491.djvu===--- 54EA 54EA-11 <Without ESP ® > C10040-ECU-54EA-2 A/C BLOWER RELAY A A/C COMP COND. RELAY G POWER GND ECU GND CHASSIS CAN-H CHASSIS CAN-L POWER GND ILL CABIN FRONT DOOR SW(RH,LH) VAC SW(FLOW SW) PARKING BRAKE SW F13 F01 F20 F10 F11 F32 DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L IGN RELAY E ISS CUT SW ISS CUT IND BRAKE M/V BRAKE M/V FRONT BRAKE M/V REAR CAB TILT LOCK SW M 1 9 2 15 16 13 10 6 4 5 7 8 BATT CAN-H MAIN ST ON/OFF SIG DC/DC DIAG GND CAN-L IGN SW SIG VIN GND V OUT ST SIG DIAG M 12345678 9 10111213141516 SAM Relay LSD SAM Relay LSD COMB. SW BATT COMB. SW LIN SIG HAZARD SW LIN GND BATT LIN SIG GND SAM Relay LSD BRAKE SW NO GND BRAKE SW NC SPEAKER Battery High-current fuse box Vacuum switch Parking brake switch ISS cutoff switch Front door switch (RH,LH) Cab tilt lock switch Dual pressure switch Magnetic clutch Blower motor To power MOS-FET(transistor) or To blower resistor Diagnosis connector Condenser fan motor Condenser fan relay Starter relay (solenoid type) DUONIC ECU Hydraulic unit (ABS ECU) HH16A Harness side connector To starter ISS ECU DC/DC converter <DUONIC > Combination switch To headlamp, RH(dipped) To headlamp, LH (dipped) To fog lamp, RH To fog lamp, LH Hazard switch Engine ECU Meter cluster Starter relay (for drive) SAM: Signal detect and actuation modules ECU: Electronic control unit ISS: Idling stop and start system ABS: Anti-lock brake system M/G: Manual gearbox <M/G> <DUONIC > Brake control valve (Front) Brake control valve (Rear) R R SAM Stop lamp switch ---===WSE_1506_00001_0492.djvu===--- 54EA-12 1. Inspection Based on Diagnosis Codes The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. When the FUSO Diagnostics is connected, perform the interac- tive troubleshooting with the following procedure. Select the code from the diagnostics code list  Click the test button  Start the interactive troubleshooting 1.1 List of Diagnosis Codes Code Message Warning indication Remarks 521752-2 CAN signal from control unit 'Combustion engine Control unit' FAULTY O 521753-2 CAN signal from control unit 'Signal & ActuatorModule' FAULTY O 521754-2 CAN signal from control unit 'Electronic transmission control' FAULTY O 521756-4 The supply voltage of component 'Automatic engine start/stop Control unit' is too low (undervoltage). O 521757-3 The supply voltage of component 'Automatic engine start/stop Control unit' is too high (overvoltage). O 521758-7 Hill Start valve voltage-No supply O 521759-7 Hill Start valve voltage-No intercept O 521760-7 Component 'Control valve "Front axle service brake"' has an open cir- cuit or short circuit. O 521761-7 Component 'Control valve "Rear axle service brake"' has an open cir- cuit or short circuit. O 521762-7 Component 'DC/DC converter' is defective. O 521763-19 The coding is implausible. O 521764-19 Faulty variant coding O 521765-13 The number of start/stop cycles of the automatic engine start/stop function exceeds 150,000. O 521766-13 The value is outside the permissible range. -- 521767-4 Pin 21 at control unit 'Automatic engine start/stop Control unit' has an open circuit. O 521768-19 Error reading EEPROM O 521770-2 CAN bus OFF fault O TROUBLESHOOTING ---===WSE_1506_00001_0492.djvu===--- 54EA-12 1. Inspection Based on Diagnosis Codes The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. When the FUSO Diagnostics is connected, perform the interac- tive troubleshooting with the following procedure. Select the code from the diagnostics code list  Click the test button  Start the interactive troubleshooting 1.1 List of Diagnosis Codes Code Message Warning indication Remarks 521752-2 CAN signal from control unit 'Combustion engine Control unit' FAULTY O 521753-2 CAN signal from control unit 'Signal & ActuatorModule' FAULTY O 521754-2 CAN signal from control unit 'Electronic transmission control' FAULTY O 521756-4 The supply voltage of component 'Automatic engine start/stop Control unit' is too low (undervoltage). O 521757-3 The supply voltage of component 'Automatic engine start/stop Control unit' is too high (overvoltage). O 521758-7 Hill Start valve voltage-No supply O 521759-7 Hill Start valve voltage-No intercept O 521760-7 Component 'Control valve "Front axle service brake"' has an open cir- cuit or short circuit. O 521761-7 Component 'Control valve "Rear axle service brake"' has an open cir- cuit or short circuit. O 521762-7 Component 'DC/DC converter' is defective. O 521763-19 The coding is implausible. O 521764-19 Faulty variant coding O 521765-13 The number of start/stop cycles of the automatic engine start/stop function exceeds 150,000. O 521766-13 The value is outside the permissible range. -- 521767-4 Pin 21 at control unit 'Automatic engine start/stop Control unit' has an open circuit. O 521768-19 Error reading EEPROM O 521770-2 CAN bus OFF fault O TROUBLESHOOTING ---===WSE_1506_00001_0493.djvu===--- 54EA 54EA-13 1.2 Details of Diagnosis Codes 521752-2: CAN signal from control unit 'Combustion engine Control unit' FAULTY 521753-2: CAN signal from control unit 'Signal & ActuatorModule' FAULTY 521754-2: CAN signal from control unit 'Electronic transmission control' FAULTY 521756-4: The supply voltage of component 'Automatic engine start/stop Control unit' is too low (undervolt- age). Generation condition There is no controller area network signal from engine electronic control unit. Recoverability System recovers when starter switch is turned OFF. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Electronic control fuel system is faulty. Open circuit, battery short circuit, earth short circuit, or short circuit in con- troller area network communication line. Resistor in idling stop and start system electronic control unit is faulty. Engine electronic control unit is faulty. Idling stop and start system electronic control unit is faulty. Generation condition There is no controller area network signal from signal detect and actuation module. Recoverability System recovers when starter switch is turned OFF. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Signal detect and actuation module system is faulty. Open circuit, battery short circuit, earth short circuit, or short circuit in con- troller area network communication line. Resistor in idling stop and start system electronic control unit is faulty. Signal detect and actuation module is faulty. Idling stop and start system electronic control unit is faulty. Generation condition There is no controller area network signal from DUONIC electronic control unit. Recoverability System recovers when starter switch is turned OFF. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes DUONIC system is faulty. Open circuit, battery short circuit, earth short circuit, or short circuit in con- troller area network communication line. Resistor in idling stop and start system electronic control unit is faulty. DUONIC electronic control unit is faulty. Idling stop and start system electronic control unit is faulty. Generation condition Idling stop and start system electronic control unit battery power has been less than 8 V for 15 seconds. Recoverability System recovers when idling stop and start system electronic control unit battery power becomes 8 V or more. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Open circuit or earth short circuit in harness between battery and idling stop and start system electronic control unit. Battery is faulty. Alternator is faulty. Signal detect and actuation module is faulty. Idling stop and start system electronic control unit is faulty. ---===WSE_1506_00001_0494.djvu===--- 54EA-14 521757-3: The supply voltage of component 'Automatic engine start/stop Control unit' is too high (overvolt- age). 521758-7: Hill Start valve voltage-No supply <With ESP ® > * When this code is displayed, inspect the brake control valve (Rear RH/LH) also. <Without ESP ® > 521759-7: Hill Start valve voltage-No intercept <With ESP ® > * When this code is displayed, inspect the brake control valve (Rear RH/LH) also. <Without ESP ® > Generation condition Idling stop and start system electronic control unit battery power has been 16 V or higher for 15 seconds. Recoverability System recovers when idling stop and start system electronic control unit battery power becomes less than 16 V. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Alternator is faulty. Idling stop and start system electronic control unit is faulty. Generation condition Power is not supplied to brake control valve when direct battery power to idling stop and start system electronic control unit is more than 8 V and start- er switch is ON. Recoverability System recovers when starter switch is turned OFF. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is forced release. Possible causes Earth short circuit in power harness between idling stop and start system electronic control unit and brake control valve (Front RH or LH). Brake control valve (Front RH or LH) is faulty. Idling stop and start system electronic control unit is faulty. Generation condition Power is not supplied to brake control valve when direct battery power to idling stop and start system electronic control unit is more than 8 V and start- er switch is ON. Recoverability System recovers when starter switch is turned OFF. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is forced release. Possible causes Earth short circuit in power harness between idling stop and start system electronic control unit and brake control valve. Brake control valve is faulty. Idling stop and start system electronic control unit is faulty. Generation condition Power supply to brake control valve cannot be interrupted when direct bat- tery power to idling stop and start system electronic control unit is more than 8 V and starter switch is ON. Recoverability System recovers when brake control valve operates normally. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Battery short circuit in brake control valve (Front RH or LH). Brake control valve is faulty (Front RH or LH). Idling stop and start system electronic control unit is faulty. Generation condition Power supply to brake control valve cannot be interrupted when direct bat- tery power to idling stop and start system electronic control unit is more than 8 V and starter switch is ON. Recoverability System recovers when brake control valve operates normally. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Battery short circuit in brake control valve. Brake control valve is faulty. Idling stop and start system electronic control unit is faulty. TROUBLESHOOTING ---===WSE_1506_00001_0495.djvu===--- 54EA 54EA-15 521760-7: Component 'Control valve "Front axle service brake"' has an open circuit or short circuit. <With ESP ® > * When this code is displayed, inspect the brake control valve (Rear RH/LH) also. <Without ESP ® > 521761-7: Component 'Control valve "Rear axle service brake"' has an open circuit or short circuit. <With ESP ® > * When this code is displayed, inspect the brake control valve (Rear RH/LH) also. <Without ESP ® > Generation condition Output to brake control valve (Front LH) and feedback are not consistent. Recoverability System recovers when starter switch is turned OFF. System recovers when output to brake control valve (Front LH) and feed- back are consistent. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Open circuit, battery short circuit, earth short circuit, or short circuit in earth harness between idling stop and start system electronic control unit and brake control valve (Front LH). Brake control valve (Front LH) is faulty. Idling stop and start system electronic control unit is faulty. Generation condition Output to brake control valve (Front) and feedback are not consistent. Recoverability System recovers when starter switch is turned OFF. System recovers when output to brake control valve (Front) and feedback are consistent. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Open circuit, battery short circuit, earth short circuit, or short circuit in earth harness between idling stop and start system electronic control unit and brake control valve (Front). Brake control valve (Front) is faulty. Idling stop and start system electronic control unit is faulty. Generation condition Output to brake control valve (Front RH) and feedback are not consistent. Recoverability System recovers when starter switch is turned OFF. System recovers when output to brake control valve (Front RH) and feed- back are consistent. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Open circuit, battery short circuit, earth short circuit, or short circuit in earth harness between idling stop and start system electronic control unit and brake control valve (Front RH). Brake control valve (Front RH) is faulty. Idling stop and start system electronic control unit is faulty. Generation condition Output to brake control valve (Rear) and feedback are not consistent. Recoverability System recovers when starter switch is turned OFF. System recovers when output to brake control valve (Rear) and feedback are consistent. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Open circuit, battery short circuit, earth short circuit, or short circuit in earth harness between idling stop and start system electronic control unit and brake control valve (Rear). Brake control valve (Rear) is faulty. Idling stop and start system electronic control unit is faulty. ---===WSE_1506_00001_0496.djvu===--- 54EA-16 521762-7: Component 'DC/DC converter' is defective. 521763-19: The coding is implausible. 521764-19: Faulty variant coding 521765-13: The number of start/stop cycles of the automatic engine start/stop function exceeds 150,000. 521766-13: The value is outside the permissible range. 521767-4: Pin 21 at control unit 'Automatic engine start/stop Control unit' has an open circuit. Generation condition Abnormal signal is sent from DC-DC converter 10 seconds after engine is started with starter switch. The voltage in an abnormal signal from the DC-DC converter remains 12 V for 15 seconds. Recoverability System recovers when starter switch is turned OFF or when abnormal signal is not sent from DC-DC converter. System recovers when idling stop and start system cutoff switch is turned ON with communication from DC-DC converter alive. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Open circuit, battery short circuit, or earth short circuit in harness between idling stop and start system electronic control unit and DC-DC converter. DC-DC converter is faulty. Idling stop and start system electronic control unit is faulty. Generation condition At least one item of "0: As-shipped condition" exists in EEPROM. Recoverability System recovers when normal vehicle information is written by coding func- tion. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Coding is not done. Generation condition Out-of-standard data exists in coding in EEPROM. Recoverability System recovers when normal vehicle information is written by coding func- tion. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Out-of-range value was written when coding. Generation condition Idling stop and start system activation count has exceeded 150,000. Recoverability Idling stop and start system operation status memory delete function recov- ers system when starter switch is turned OFF after performing one of the fol- lowing. Delete all data. Delete idling stop and start system auto start count data only. Control effected by electronic control unit Normal control of idling stop and start system Possible causes Idling stop and start system activation count has exceeded 150,000. Generation condition Count-up value has exceeded calculation range. Recoverability Idling stop and start system operation status memory delete function recov- ers system when starter switch is turned OFF after deleting all data. Control effected by electronic control unit Normal control of idling stop and start system Possible causes Count-up value has exceeded calculation range. Generation condition Battery power is turned OFF after backup power was turned ON. Recoverability System recovers when idling stop and start system electronic control unit power is turned OFF. Control effected by electronic control unit Normal control of idling stop and start system Possible causes Open circuit or earth short circuit in harness between battery and idling stop and start system electronic control unit. Battery is faulty. Alternator is faulty. Signal detect and actuation module is faulty. Idling stop and start system electronic control unit is faulty. TROUBLESHOOTING ---===WSE_1506_00001_0497.djvu===--- 54EA 54EA-17 521768-19: Error reading EEPROM 521770-2: CAN bus OFF fault Generation condition Abnormal data is found when reading data stored in EEPROM. Recoverability System recovers when idling stop and start system electronic control unit power is turned OFF. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Idling stop and start system electronic control unit is faulty. Generation condition Bus-off status has continued for 0.5 seconds. Recoverability System recovers when recovered from bus-off status. Control effected by electronic control unit Idling stop and start system control is stopped. Operation is disabled after brake control valve is released. Possible causes Bus-off status has continued for 0.5 seconds. ---===WSE_1506_00001_0498.djvu===--- 54EA-18 2. FUSO Diagnostics Service Data (Actual Values) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. [Current value group: Voltage values] [Current value group: Vehicle speed] [Current value group: Temperature values] No. Description Value Explanation 000 Supply voltage of compo- nent 'Starter Switches' V Shows voltage of signal detect and actua- tion modules (Starter switch (M-terminal power)). 12V (Shows voltage equivalent to bat- tery.) [Related parts] Battery Signal detect and actuation modules Starter switch 001 Battery voltage V Shows voltage of signal detect and actua- tion modules (Battery (B direct power)). 12V (Shows voltage equivalent to bat- tery.) [Related parts] Battery Signal detect and actuation modules No. Description Value Explanation 002 Current engine speed 1/min Shows engine speed received from engine electronic control unit (controller area net- work communication). Synchronizes with tachometer. [Related parts] Engine speed sensor Engine electronic control unit 003 Current vehicle speed km/h Shows engine speed received from meter cluster (controller area network communi- cation). Synchronizes with speedometer. [Related parts] Vehicle speed sensor Meter cluster 004 Braking deceleration km/h/s Shows vehicle deceleration received from engine electronic control unit (controller area network communication). Range: 0 to 60km/h/100ms [Related parts] Engine electronic control unit No. Description Value Explanation 005 Coolant temperature °C Shows coolant temperature received from meter cluster (controller area network com- munication). Synchronizes with coolant temperature gauge on the meter cluster. Range: -- 40 to 220°C [Related parts] Water temperature sensor Meter cluster TROUBLESHOOTING ---===WSE_1506_00001_0499.djvu===--- 54EA 54EA-19 [Current value group: Other actual values] [Current value group: Switch status] No. Description Value Explanation 006 Operating state of compo- nent 'Automatic engine start/ stop Control unit' Automatic engine stop Mode1/ Automatic engine stop Mode2/ Automatic engine stop indication Mode1/ Automatic engine stop indication Mode2/ Engine start standby Mode/ Engine stop standby Mode/ Normal Mode/ Automatic engine stop Timer Mode/ Automatic engine start Mode/ Automatic engine start indication Mode/ Automatic engine stop hold Mode/ Shows states of current control by idling stop and start system electronic control unit. 007 Original vehicle identifica- tion number Shows originally VIN (vehicle identification number) received from signal detect and actuation modules (controller area network communication). [Related parts] Signal detect and actuation modules 008 Current VIN Shows currently VIN (vehicle identification number) received from signal detect and actuation modules (controller area network communication). [Related parts] Signal detect and actuation modules 009 Detection of on-board elec- trical system status Shows calculated value based on source voltage judgment logic. Range: --2550 to 2550 [Related parts] Battery Signal detect and actuation modules 010 Vehicle model I1/ I2/ I3/ I4/ L1/ L2/ Default Shows vehicle model registered in idling stop and start system electronic control unit. I1/ : Manual gearbox I2/ : DUONIC I3/:HEV I4/:-- L1/:-- L2/:-- Default : No registration No. Description Value Explanation 011 Status of switch 'Automatic engine start/stop Control unit' ON/OFF Shows ON/OFF status of idling stop and start system. ON: Idling stop and start cutoff switch is OFF. OFF: Idling stop and start cutoff switch is ON. [Related parts] Idling stop and start cutoff switch 012 Status of switch 'Driver door' ON/OFF Shows ON/OFF status of driver door. ON: Driver's door opened OFF: Driver's door closed [Related parts] Front door switch (Driver's) Signal detect and actuation modules 013 Status of switch 'Passenger door' ON/OFF Shows ON/OFF status of passenger door. ON: Passenger's door opened OFF: Passenger's door closed [Related parts] Front door switch (Passenger's) Signal detect and actuation modules ---===WSE_1506_00001_0500.djvu===--- 54EA-20 014 Automatic engine start/stop Control unit: DISABLED ON/OFF Shows ON/OFF status of cancel signal of idling stop and start system. ON: Idling stop and start system has a cancel signal. OFF: Idling stop and start system has no cancel signal. 015 Automatic engine start/stop Control unit: CANCELED by DUONIC Control unit ON/OFF Shows ON/OFF status of cancel signal of idling stop and start system received from DUONIC engine electronic control unit. ON: Idling stop and start system has a cancel signal. OFF: Idling stop and start system has no cancel signal. [Related parts] DUONIC electronic control unit 016 Status of switch 'Power take-off' ON/OFF Shows ON/OFF status of gearbox power- take off switch. ON: Gearbox power-take off switch is ON. OFF: Gearbox power-take off switch is OFF. [Related parts] Gearbox power-take off switch Signal detect and actuation modules 017 Status of switch 'Cold start' ON/OFF Shows ON/OFF status of exhaust brake switch. ON: Exhaust brake switch is ON. OFF: Exhaust brake switch is OFF. [Related parts] Combination switch Engine electronic control unit Signal detect and actuation modules 018 Status of switch 'Pressure differential in diesel particu- late filter' ON/OFF Shows ON/OFF status of diesel particulate filter regeneration. ON: Regeneration is in progress in the diesel particulate filter. OFF: Regeneration is not in progress in the diesel particulate filter. [Related parts] Engine electronic control unit 019 Status of switch 'Locking of cab tilt system Switches' ON/OFF Shows ON/OFF status of cab tilt lock switch. ON: Cab tilt is not locked. OFF: Cab tilt is locked. [Related parts] Cab tilt lock switch Signal detect and actuation modules 020 Status of switch 'Left turn signal lamp' ON/OFF Shows ON/OFF status of left turn signal lamp. ON: Left turn signal lamp illuminates. OFF: Left turn signal lamp does not illu- minate. [Related parts] Signal detect and actuation modules 021 Status of switch 'Right turn signal lamp' ON/OFF Shows ON/OFF status of right turn signal lamp. ON: Right turn signal lamp illuminates. OFF: Right turn signal lamp does not il- luminate. [Related parts] Signal detect and actuation modules No. Description Value Explanation TROUBLESHOOTING ---===WSE_1506_00001_0501.djvu===--- 54EA 54EA-21 022 Status of indicator lamps (Engine diagnosis (Orange)) YES/NO Shows YES/NO status of indicator lamps (Engine diagnosis (Orange)). YES:Indicator lamps (Orange) illumi- nates. NO: Indicator lamps (Orange) does not illuminate. [Related parts] Meter cluster Engine electronic control unit 023 Status of switch 'Starter Switches' ON/OFF Shows ON/OFF status of starter switch. ON: Starter switch (ON or START) OFF: Starter switch (LOCK or ACC) [Related parts] Starter switch Signal detect and actuation modules 024 Status of switch 'Parking brake' ON/OFF Shows ON/OFF status of parking brake switch. ON: Parking brake lever is pulled. OFF: Parking brake lever is released. [Related parts] Parking brake switch Signal detect and actuation modules 025 Status of switch 'Transmis- sion Neutral position Switch- es' ON/OFF Shows ON/OFF status of gearbox neutral position. ON: Gearbox is in neutral position. OFF: Gearbox is not in neutral position. [Related parts] Gearbox neutral switch <M/T> Engine electronic control unit DUONIC electronic control unit 026 Status of switch 'Clutch ped- al' ON/OFF Shows ON/OFF status of clutch pedal. ON: Clutch pedal is pressed. OFF: Clutch pedal is released. [Related parts] Clutch switch Signal detect and actuation modules 027 Status of switch 'Brake ped- al' ON/OFF Shows ON/OFF status of brake pedal. ON: Brake pedal is pressed. OFF: Brake pedal is released. [Related parts] Stop lamp switch Signal detect and actuation modules 028 Automatic ENGINE STOP: PERMISSIBLE ON/OFF Shows ON/OFF status of engine stop per- mission signal of idling stop and start sys- tem. ON: Engine stop is permitted. OFF: Engine stop is not permitted. 029 Automatic ENGINE STOP: COMPLETED ON/OFF Shows ON/OFF status of engine stop oper- ation of idling stop and start system. ON: Engine stop is in operation. OFF: Engine stop is not in operation. 030 Automatic ENGINE START: PERMISSIBLE ON/OFF Shows ON/OFF status of engine start per- mission signal of idling stop and start sys- tem. ON: Engine start is permitted. OFF: Engine start is not permitted. 031 Automatic ENGINE START: COMPLETED ON/OFF Shows ON/OFF status of automatic engine start operation of idling stop and start sys- tem. ON: Engine start is in operation. OFF: Engine start is not in operation. 032 Automatic ENGINE START: General error ON/OFF Shows ON/OFF status of engine start error signal of idling stop and start system. ON: Engine start can not operate. OFF: Engine start can operate. No. Description Value Explanation ---===WSE_1506_00001_0502.djvu===--- 54EA-22 033 ENGINE START demanded by TCM (Transmission con- trol unit) ON/OFF Shows ON/OFF status of engine stop re- quest signal from DUONIC electronic con- trol unit. ON: Signal of engine stop request is transmitted. OFF: Signal of engine stop request is not transmitted. 034 ENGINE STOP permitted by TCM ON/OFF Shows ON/OFF status of engine stop per- mission signal from DUONIC electronic control unit. ON: Signal of engine stop permission is transmitted. OFF: Signal of engine stop permission is not transmitted. [Related parts] DUONIC electronic control unit 035 Status of switch 'Main switch 'Hill Start Assist'' ON/OFF Shows ON/OFF status of brake control valve operation. ON: Brake control valve is in operation. OFF: Brake control valve is not in opera- tion. [Related parts] Brake control valve (Front, Rear) <Without ESP ® > Brake control valve (Front RH/LH) <With ESP ® > 036 Hill holder system is re- quested by TCM ON/OFF Shows ON/OFF status of hill start assist system operation request signal from DU- ONIC electronic control unit. ON: Signal of hill start assist system op- eration request is transmitted. OFF: Signal of hill start assist system operation request is not transmitted. [Related parts] DUONIC electronic control unit 037 Hill holder system is re- leased by TCM ON/OFF Shows ON/OFF status of hill start assist system operation request signal from DU- ONIC electronic control unit. ON: Signal of hill start assist system cancellation request is transmitted. OFF: Signal of hill start assist system operation request is not transmitted. [Related parts] DUONIC electronic control unit 038 Automatic ENGINE STOP: STANDBY mode ON/OFF Shows ON/OFF status of idling stop and start system standby information. ON: Idling stop and start system has standby information. OFF: Idling stop and start system has no standby information. 039 Status of indicator lamps (Automatic engine start/ stop) ON/OFF Shows ON/OFF status of idling stop and start system indicator lamp. ON: Idling stop and start system indica- tor lamp illuminates. OFF: Idling stop and start system indica- tor lamp does not illuminate. [Related parts] Meter cluster 040 Status of switch 'Warning lamp' ON/OFF Shows ON/OFF status of idling stop and start system warning lamp. ON: Idling stop and start system warning lamp illuminates. OFF: Idling stop and start system warn- ing lamp does not illuminate. [Related parts] Meter cluster No. Description Value Explanation TROUBLESHOOTING ---===WSE_1506_00001_0503.djvu===--- 54EA 54EA-23 041 Automatic ENGINE STOP: Work information ON/OFF Shows ON/OFF status of gearbox of idling stop and start system information signal. ON: Information signal of idling stop and start system status is transmitted. OFF: Information signal of idling stop and start system status is not transmit- ted. 042 Status of switch 'Warning buzzer' ON/OFF Shows ON/OFF status of idling stop and start system warning buzzer. ON: Idling stop and start system warning buzzer sounds. OFF: Idling stop and start system warn- ing buzzer does not sound. [Related parts] Buzzer (built in meter cluster) 043 Request for function 'Auto- matic ENGINE STOP' ON/OFF Shows ON/OFF status of engine stop re- quest of idling stop and start system. ON: Idling stop and start system has en- gine stop request. OFF: Idling stop and start system has no engine stop request. 044 Request for function 'Auto- matic ENGINE START' ON/OFF Shows ON/OFF status of engine start re- quest of idling stop and start system. ON: Idling stop and start system has en- gine start request. OFF: Idling stop and start system has no engine start request. 045 Releasing automatic engine start/stop is demanded ON/OFF Shows ON/OFF status of idling stop and start system cancellation request. ON: Idling stop and start system has cancellation request. OFF: Idling stop and start system has no cancellation request. 046 Status of component 'DC/ DC converter' ON/OFF Shows ON/OFF status of DC/DC converter error. ON: DC/DC converter has an error. OFF: DC/DC converter has no error. [Related parts] DC/DC converter 047 Status of component 'Blow- er motor Relays' ON/OFF Shows ON/OFF status of idling stop and start system load cut relay 1 signal. ON: Idling stop and start system load cut relay 1 signal is on. Blower motor is not in operation. OFF: Idling stop and start system load cut relay 1 signal is off. Blower motor is in operation. [Related parts] Blower motor Signal detect and actuation modules 048 Status of component 'Refrig- erant compressor Relays' ON/OFF Shows ON/OFF status of idling stop and start system load cut relay 2 signal. ON: Idling stop and start system load cut relay 2 signal is on. Air compressor is not in operation. OFF: Idling stop and start system load cut relay 2 signal is off. Air compressor is in operation. [Related parts] Magnetic clutch Dual pressure switch Signal detect and actuation modules No. Description Value Explanation ---===WSE_1506_00001_0504.djvu===--- 54EA-24 3. FUSO Diagnostics Actuator Test (Actuations) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. The basic conditions for performing the actuator test: Vehicle stopped, engine stopped and starter switch ON. <With ESP ® > <Without ESP ® > 049 Status of component 'Head- lamps and foglamps' ON/OFF Shows ON/OFF status of idling stop and start system load cut relay 3 signal. ON: Idling stop and start system load cut relay 3 signal is on. Headlamp and fog lamp does not illumi- nate. OFF: Idling stop and start system load cut relay 3 signal is off. Headlamp and fog lamp illuminate. [Related parts] Headlamp Fog lamp Signal detect and actuation modules No. Selection Explanation 000 Control valve "Rear axle service brake" Drives brake control valve (Front RH and Rear LH/RH) power supply and brake control valve (Front RH and Rear LH/RH). 001 Control valve "Front axle service brake" Drives brake control valve (Front RH and Rear LH/RH) power supply and brake control valve (Front RH and Rear LH/RH). 002 Actuation of component 'load cut indicator' Turn on/off idling stop and start system cutoff switch indicator lamp output. 003 Actuation of component 'Automatic engine start/ stop indicator lamp' Turn on/off idling stop and start system indicator lamp output. 004 Actuation of component 'Warning lamp' Turn on/off idling stop and start system indicator lamp output. 005 Actuation of component 'Blower motor Relays' Turn on/off load cut relay 1 (blower motor) output. 006 Actuation of component 'Headlamps and foglamps' Turn on/off load cut relay 3 (headlamp and fog lamp) output. 007 Actuation of component 'Warning buzzer' Turn on/off idling stop and start system warning buzzer output. No. Selection Explanation 000 Control valve "Rear axle service brake" Drives brake control valve (Rear) power supply and brake control valve (Rear). 001 Control valve "Front axle service brake" Drives brake control valve (Front) power supply and brake control valve (Front). 002 Actuation of component 'load cut indicator' Turn on/off idling stop and start system cutoff switch indicator lamp output. 003 Actuation of component 'Automatic engine start/ stop indicator lamp' Turn on/off idling stop and start system indicator lamp output. 004 Actuation of component 'Warning lamp' Turn on/off idling stop and start system indicator lamp output. 005 Actuation of component 'Blower motor Relays' Turn on/off load cut relay 1 (blower motor) output. 006 Actuation of component 'Headlamps and foglamps' Turn on/off load cut relay 3 (headlamp and fog lamp) output. 007 Actuation of component 'Warning buzzer' Turn on/off idling stop and start system warning buzzer output. No. Description Value Explanation TROUBLESHOOTING ---===WSE_1506_00001_0505.djvu===--- 54EA 54EA-25 4. Electronic Control Unit Coding 4.1 Overview The idling stop and start system electronic control unit has various kinds of information such as technical data of vehicle and equipment registered as coding data. Therefore, each time the meter cluster is replaced or some specification changes are made, the coding data must surely be rewritten using the diagnostic tool. Otherwise, the data stored in the idling stop and start system elec- tronic control unit could deviate from the actual conditions of the vehicles, resulting in incorrect alarms. 4.2 Rewriting of Coding Data If specification changes have been made, be sure to rewrite the relevant coding data. Perform the data writing and resetting work, using the diagnostic tool. 5. Electronic Control Unit Input/Output Table See the Electronic Control Unit Schematic Diagram for the pin locations of each signal and earth. Rewriting coding data required Standards for rewriting idling stop and start system electronic control unit internal data Delete all items. Update is required when electronic control unit is replaced. Delete only automatic engine start count data of idling stop and start system. Deletes only automatic engine start count data of idling stop and start system. Deletes idling stop and start system activation count data when starter is re- placed. Deletes idling stop and start system activation count data when diagnosis code "521765-13 (Idling stop and start system activation count has exceeded 150,000)" has occurred. Devices to be connected Terminal Input/ output Voltage and wave form Signal detect and actuation module (Starter switch (M-terminal power)) 9-Earth Input [Judgment criteria] Normal: Equivalent to battery voltage Abnormal: 0 V Signal detect and actuation module (Battery (B direct power)) 1-Earth Input [Judgment criteria] Normal: Equivalent to battery voltage Abnormal: 0 V Idling stop and start system cutoff switch 13-Earth Input [Judgment criteria] Idling stop and start system cutoff switch OFF: Equivalent to battery voltage Idling stop and start system cutoff switch ON: 0 V Idling stop and start system cutoff switch (Internal indicator lamp) 10-Earth Output [Judgment criteria] Idling stop and start system cutoff switch OFF: 0V Idling stop and start system cutoff switch ON: Equivalent to battery voltage Brake control valve (Front), (Rear) 6-Earth Output [Judgment criteria] Idling stop and start system OFF: 0 V When the Idling stop and start system is operat- ing: Equivalent to battery voltage ---===WSE_1506_00001_0505.djvu===--- 54EA 54EA-25 4. Electronic Control Unit Coding 4.1 Overview The idling stop and start system electronic control unit has various kinds of information such as technical data of vehicle and equipment registered as coding data. Therefore, each time the meter cluster is replaced or some specification changes are made, the coding data must surely be rewritten using the diagnostic tool. Otherwise, the data stored in the idling stop and start system elec- tronic control unit could deviate from the actual conditions of the vehicles, resulting in incorrect alarms. 4.2 Rewriting of Coding Data If specification changes have been made, be sure to rewrite the relevant coding data. Perform the data writing and resetting work, using the diagnostic tool. 5. Electronic Control Unit Input/Output Table See the Electronic Control Unit Schematic Diagram for the pin locations of each signal and earth. Rewriting coding data required Standards for rewriting idling stop and start system electronic control unit internal data Delete all items. Update is required when electronic control unit is replaced. Delete only automatic engine start count data of idling stop and start system. Deletes only automatic engine start count data of idling stop and start system. Deletes idling stop and start system activation count data when starter is re- placed. Deletes idling stop and start system activation count data when diagnosis code "521765-13 (Idling stop and start system activation count has exceeded 150,000)" has occurred. Devices to be connected Terminal Input/ output Voltage and wave form Signal detect and actuation module (Starter switch (M-terminal power)) 9-Earth Input [Judgment criteria] Normal: Equivalent to battery voltage Abnormal: 0 V Signal detect and actuation module (Battery (B direct power)) 1-Earth Input [Judgment criteria] Normal: Equivalent to battery voltage Abnormal: 0 V Idling stop and start system cutoff switch 13-Earth Input [Judgment criteria] Idling stop and start system cutoff switch OFF: Equivalent to battery voltage Idling stop and start system cutoff switch ON: 0 V Idling stop and start system cutoff switch (Internal indicator lamp) 10-Earth Output [Judgment criteria] Idling stop and start system cutoff switch OFF: 0V Idling stop and start system cutoff switch ON: Equivalent to battery voltage Brake control valve (Front), (Rear) 6-Earth Output [Judgment criteria] Idling stop and start system OFF: 0 V When the Idling stop and start system is operat- ing: Equivalent to battery voltage ---===WSE_1506_00001_0506.djvu===--- 54EC-1 54EC LDWS (Lane departure warning system) STRUCTURE AND OPERATION 1. Overview........................................................................................... 54EC-2 2. Electronic Control System.............................................................. 54EC-3 3. Electronic Control Unit Circuit Diagram ........................................ 54EC-6 TROUBLESHOOTING 1. Inspection Based on Diagnosis Codes ......................................... 54EC-8 2. FUSO Diagnostics Service Data (Actual Values) ........................ 54EC-13 3. Coding Data in Electronic Control Unit ....................................... 54EC-15 4. Electronic Control Unit Input/Output Table ................................. 54EC-16 5. Lane departure warning system adjustment .............................. 54EC-16 6. Troubleshooting by Symptom ...................................................... 54EC-16 INSPECTION OF ELECTRICAL PARTS . ................................(See Gr54.) INSTALLED LOCATIONS OF PARTS .....................................(See Gr54.) ELECTRIC CIRCUIT DIAGRAM ..............................................(See Gr54.) ---===WSE_1506_00001_0507.djvu===--- 54EC-2 1. Overview The lane departure warning system alerts the driver with a warning display and buzzer if the driver has left their lane unintentionally. Based on the following information input, the electronic control unit outputs a multi-information display and buzzer alarm (in meter cluster) if the vehicle veers out of its lane. (The illustration shows a left-hand drive vehicle.) STRUCTURE AND OPERATION ---===WSE_1506_00001_0507.djvu===--- 54EC-2 1. Overview The lane departure warning system alerts the driver with a warning display and buzzer if the driver has left their lane unintentionally. Based on the following information input, the electronic control unit outputs a multi-information display and buzzer alarm (in meter cluster) if the vehicle veers out of its lane. (The illustration shows a left-hand drive vehicle.) STRUCTURE AND OPERATION ---===WSE_1506_00001_0508.djvu===--- 54EC 54EC-3 2. Electronic Control System 2.1 System block diagram Part name Main function/operation Lane departure warning system electronic control unit (cam- era-integrated) Detects centre line and lane separation markings. Lane departure warning system cutoff switch Activates/deactivates the lane departure warning system func- tion. Buzzer (in meter cluster) Lane departure warning alarm Meter cluster (Multi-information display) Displays the lane departure warning system warning when leaving the lane. Displays the lane departure warning system malfunctions. FUSO Diagnostics (diagnosis connector) Communicates with the lane departure warning system elec- tronic control unit. Combination switch (turn signal switch) Detects operation of turn signal. Vehicle speed sensor Senses vehicle speed. Lane departure warning system inactive indicator lamp Illuminates when the lane departure warning system is inacti- vated by the lane departure warning system cutoff switch. Illuminates when the lane departure warning system malfunc- tions. ---===WSE_1506_00001_0509.djvu===--- 54EC-4 2.2 Input signal Lane departure warning system cutoff switch Lane recognition camera (centre line and lane separation markings recognition) Combination switch (turn signal switch) Vehicle speed sensor 2.3 Output signal Multi-information display, Buzzer alarm (in meter cluster) If a malfunction is found in the lane departure warning system electronic control system, the system warns this by multi-information display and indicator lamp. 2.4 Multi-information display, Indicator lamp, Buzzer alarm (1) Conditions when the lane departure warning system does not operate When the turn signal lamp is operated When the lane departure warning system malfunctions When the lane departure warning system cutoff switch is on When the vehicle speed is lower than 60 km/h (37 MPH) When the camera cannot recognise the lane (2) Indications when the system is inactivated Pressing the lane departure warning system cutoff switch lights the lane departure warning system inactive indicator lamp. When the lane departure warning system malfunctions, the lane departure warning system inactive indicator lamp lights and the lane departure warning system warning is displayed. 2.5 Lane departure warning system warning display (1) Left side lane departure warning display Displayed when leaving the lane on the left side of the vehicle without activating the left turn signal lamp. A buzzer also sounds at the same time. STRUCTURE AND OPERATION ---===WSE_1506_00001_0510.djvu===--- 54EC 54EC-5 (2) Right side lane departure warning display Displayed when leaving the lane on the right side of the vehicle without activating the right turn signal lamp. A buzzer also sounds at the same time. (3) When the white lane markings cannot be recognised The screen currently displayed remains unchanged and a buzzer does not sound. 2.6 Lane recognition camera The lane recognition camera inputs an image of the surface of the road to detect the white lane markings, centre line, and other lane separation markings. 2.7 Diagnostic functions When the starter switch is in the ON position, the system continuously monitors the sensors and other system components. If any fault is detected, the system warns the driver of this by displaying the relevant fault information on the meter cluster. At the same time, the system also stores a relevant diagnosis code in the memory and starts operation in the fault mode. In the fault-mode operation, the system functions are limited to ensure safety for the driver and the vehicle. Stored diagnosis codes can be displayed on the FUSO Diagnostics system and on the meter cluster. ---===WSE_1506_00001_0511.djvu===--- 54EC-6 3. Electronic Control Unit Circuit Diagram C10040-ECU-54EC 18 Multi-information display CAN(H) CAN(L) ECU GND 9 2 13 10 SPARE INPUT SWITCH DIGI SW (SIGNAL) GND SPARE OUTPUT ING3 POWER GND +B GND CAN-H CAN-L CAN(H) CAN(L) CAN(L) CAN(H) LED F09 F22 1 2 3 4 5 6 7 8 4 1 3 2 SAM Meter cluster LDWS cutoff switch Lane recognition camera LDWS:Lane departure warning system SAM:Signal detect and actuation modules Lane recognition camera side connector STRUCTURE AND OPERATION ---===WSE_1506_00001_0512.djvu===--- 54EC-7 54EC MEMO ---===WSE_1506_00001_0513.djvu===--- 54EC-8 1. Inspection Based on Diagnosis Codes The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. When the FUSO Diagnostics is connected, perform the interac- tive troubleshooting with the following procedure. Select the code from the diagnostics code list  Click the test button  Start the interactive troubleshooting 1.1 List of Diagnosis Codes Diagnosis code Indications made by FUSO diagnosis Warning given at occurrence of diagnosis code Remarks 158-0 Supply Voltage too high O O 158-1 Supply Voltage too low O O 639-3 Vehicle CAN electrical error O O 639-9 Vehicle CAN timeout O O 639-11 Vehicle CAN Bus Off O O 523000-12 ECU Malfunction O O 523001-13 Camera out of Calibration O O 523008-13 Camera not configured O O 523010-31 Camera Blockage O O 524000-9 ECU CPC timeout O O 524000-19 ECU CPC data error O O 524023-9 ECU ICUC timeout O O 524023-19 ECU ICUC data error O O 524033-9 ECU SCA timeout O O 524033-19 ECU SCA data error O O 524049-9 ECU MSF timeout O O 524049-19 ECU MSF data error O O TROUBLESHOOTING ---===WSE_1506_00001_0513.djvu===--- 54EC-8 1. Inspection Based on Diagnosis Codes The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. When the FUSO Diagnostics is connected, perform the interac- tive troubleshooting with the following procedure. Select the code from the diagnostics code list  Click the test button  Start the interactive troubleshooting 1.1 List of Diagnosis Codes Diagnosis code Indications made by FUSO diagnosis Warning given at occurrence of diagnosis code Remarks 158-0 Supply Voltage too high O O 158-1 Supply Voltage too low O O 639-3 Vehicle CAN electrical error O O 639-9 Vehicle CAN timeout O O 639-11 Vehicle CAN Bus Off O O 523000-12 ECU Malfunction O O 523001-13 Camera out of Calibration O O 523008-13 Camera not configured O O 523010-31 Camera Blockage O O 524000-9 ECU CPC timeout O O 524000-19 ECU CPC data error O O 524023-9 ECU ICUC timeout O O 524023-19 ECU ICUC data error O O 524033-9 ECU SCA timeout O O 524033-19 ECU SCA data error O O 524049-9 ECU MSF timeout O O 524049-19 ECU MSF data error O O TROUBLESHOOTING ---===WSE_1506_00001_0514.djvu===--- 54EC 54EC-9 1.2 Details of Diagnosis Codes 158-0: Supply Voltage too high 158-1: Supply Voltage too low 639-3: Vehicle CAN electrical error 639-9: Vehicle CAN timeout 639-11: Vehicle CAN Bus Off 523000-12: ECU Malfunction Generation condition When the input of the lane departure warning system electronic control unit supply voltage becomes more than 32 V. Recoverability System recovers when the input of the lane departure warning system elec- tronic control unit supply voltage becomes less than 32 V. Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Malfunction of each connector. Malfunction of battery. Defective lane departure warning system electronic control unit. Generation condition When the input of the lane departure warning system electronic control unit supply voltage is less than 8 V. Recoverability System recovers when the input of the lane departure warning system elec- tronic control unit supply voltage becomes 8 V or more. Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Malfunction of each connector. Malfunction of battery. Defective lane departure warning system electronic control unit. Generation condition No controller area network communication line signals are received. Recoverability System recovers on recognition of normal status. Control effected by electronic control unit Normal control is effected. Possible causes Controller area network communication line open or shorted. Malfunction of each connector. Defective lane departure warning system electronic control unit. Generation condition No controller area network communication line signals are received (time- out). Recoverability System recovers on recognition of normal status. Control effected by electronic control unit Lane departure warning system warning system warning is not generated. Possible causes Controller area network communication line open or shorted. Malfunction of each connector. Defective lane departure warning system electronic control unit. Generation condition Controller area network communication bus off condition is detected. Recoverability System recovers on recognition of normal status. Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Controller area network communication line open or shorted. Malfunction of each connector. Defective lane departure warning system electronic control unit. Generation condition Internal abnormality occurs in lane departure warning system electronic con- trol unit. Recoverability System has recovered if signal becomes normal after starter switch is turned OFF and then ON (thus reenergizing electronic control unit). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Defective lane departure warning system electronic control unit. ---===WSE_1506_00001_0515.djvu===--- 54EC-10 523001-13: Camera out of Calibration 523008-13: Camera not configured 523010-31: Camera Blockage 524000-9: ECU CPC timeout 524000-19: ECU CPC data error Generation condition When faulty lane recognition camera installation or faulty adjustment is de- tected. Recoverability After adjusting and securing the lane recognition camera, turn the starter switch OFF and then ON. System recovers if it is normal (turning the power to the electronic control unit off and then on). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Lane recognition camera or bracket installation is incorrect. Coding was done incorrectly. Defective lane departure warning system electronic control unit. Generation condition When faulty lane recognition camera height setting (1 m) is detected. Recoverability After setting the height of the lane recognition camera, turn the starter switch OFF and then ON. System recovers if it is normal (turning the power to the electronic control unit off and then on). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Coding has not been done. Coding was done incorrectly. Generation condition When the lane recognition camera is obstructed or the windscreen is dirty or frosty, so that the camera cannot identify the lane (while the vehicle speed is 60 km/h or higher). Recoverability Remove any obstructions, wipe off any dirt, and turn the starter switch OFF and then ON. System recovers if it is normal (turning the power to the elec- tronic control unit off and then on). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes An obstruction has been installed near the lane recognition camera. Windscreen is dirty. Windscreen is frosty. Generation condition No controller area network communication line signal from engine electronic control unit are received (timeout). Recoverability System has recovered if signal becomes normal after starter switch is turned OFF and then ON (thus reenergizing electronic control unit). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Open-circuit or short-circuit in controller area network communication line between lane departure warning system electronic control unit and engine electronic control unit. Malfunction of each connector. Defective engine electronic control unit. Defective lane departure warning system electronic control unit. Generation condition Controller area network communication signal received from engine elec- tronic control unit is abnormal. Recoverability System has recovered if signal becomes normal after starter switch is turned OFF and then ON (thus reenergizing electronic control unit). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Open-circuit or short-circuit in controller area network communication line between lane departure warning system electronic control unit and engine electronic control unit. Malfunction of each connector. Defective engine electronic control unit. Defective lane departure warning system electronic control unit. TROUBLESHOOTING ---===WSE_1506_00001_0516.djvu===--- 54EC 54EC-11 524023-9: ECU ICUC timeout 524023-19: ECU ICUC data error 524033-9: ECU SCA timeout 524033-19: ECU SCA data error Generation condition No controller area network communication line signal from meter cluster are received (timeout). Recoverability System has recovered if signal becomes normal after starter switch is turned OFF and then ON (thus reenergizing electronic control unit). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Open-circuit or short-circuit in controller area network communication line between lane departure warning system electronic control unit and meter cluster. Malfunction of each connector. Defective meter cluster. Defective lane departure warning system electronic control unit. Generation condition Controller area network communication line signal from meter cluster are ab- normal. Recoverability System has recovered if signal becomes normal after starter switch is turned OFF and then ON (thus reenergizing electronic control unit). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Open-circuit or short-circuit in controller area network communication line between lane departure warning system electronic control unit and meter cluster. Malfunction of each connector. Defective meter cluster. Defective lane departure warning system electronic control unit. Generation condition No controller area network communication line signal SCA_E2 from signal detect and actuation modules are received (timeout). Recoverability System has recovered if signal becomes normal after starter switch is turned OFF and then ON (thus reenergizing electronic control unit). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Open-circuit or short-circuit in controller area network communication line between lane departure warning system electronic control unit and signal detect and actuation modules. Malfunction of each connector. Defective signal detect and actuation modules. Defective lane departure warning system electronic control unit. Generation condition Controller area network communication signal (ignition) received from signal detect and actuation modules is abnormal. Recoverability System has recovered if signal becomes normal after starter switch is turned OFF and then ON (thus reenergizing electronic control unit). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Open-circuit or short-circuit in controller area network communication line between lane departure warning system electronic control unit and signal detect and actuation modules. Malfunction of each connector. Defective signal detect and actuation modules. Defective lane departure warning system electronic control unit. ---===WSE_1506_00001_0517.djvu===--- 54EC-12 524049-9: ECU MSF timeout 524049-19: ECU MSF data error Generation condition No controller area network communication line signal from signal detect and actuation modules are received (timeout). Recoverability System has recovered if signal becomes normal after starter switch is turned OFF and then ON (thus reenergizing electronic control unit). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Open-circuit or short-circuit in controller area network communication line between lane departure warning system electronic control unit and signal detect and actuation modules. Malfunction of each connector. Defective signal detect and actuation modules. Defective lane departure warning system electronic control unit. Generation condition Controller area network communication signal (turn signal) received from signal detect and actuation modules is abnormal. Recoverability System has recovered if signal becomes normal after starter switch is turned OFF and then ON (thus reenergizing electronic control unit). Control effected by electronic control unit Lane departure warning system warning is not generated. Possible causes Open-circuit or short-circuit in controller area network communication line between lane departure warning system electronic control unit and signal detect and actuation modules. Malfunction of each connector. Defective signal detect and actuation modules. Defective lane departure warning system electronic control unit. TROUBLESHOOTING ---===WSE_1506_00001_0518.djvu===--- 54EC 54EC-13 2. FUSO Diagnostics Service Data (Actual Values) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. [Current value group: Voltages] No. Current Value Group Description Value Comment 001 Voltage Supply Voltage V Supply voltage to lane departure warning system elec- tronic control unit is indicated. Normal voltage: 8 to 16 V [Related parts] Lane departure warning system electronic control unit 003 Tempera- tures Inside temperature of component 'Multifunction camera' °C Shows the lane recognition camera temperature. [Related parts] Lane departure warning system electronic control unit. 004 Tempera- tures Outside temperature °C Shows the outside air temperature detected by the out- side air temperature sensor. [Related parts] Outside air temperature sensor. 006 Driver Ac- tivities Left turn signal lamp ON/OFF Turn signal lamp (left) status is indicated by ON/OFF. [Related parts] Turn signal lamp switch Signal detect and actuation modules 007 Driver Ac- tivities Right turn signal lamp ON/OFF Turn signal lamp (right) status is indicated by ON/OFF. [Related parts] Turn signal lamp switch Signal detect and actuation modules 008 Driver Ac- tivities Status 'Main switch' Lane keeping assist'' ON/OFF Lane departure warning system cutoff switch status is in- dicated by ON/OFF. ON: Lane departure warning system cutoff switch is ON. OFF: Lane departure warning system cutoff switch is OFF. [Related parts] Lane departure warning system cutoff switch Signal detect and actuation modules 010 Driver Ac- tivities Kickdown ON/OFF Kickdown status of accelerator pedal is indicated. ON: Status of Kickdown. OFF: Other than kickdown status. [Related parts] Engine electronic control unit Accelerator pedal position sensor 011 Driver Ac- tivities Accelerator Pedal ON/OFF Operating status of accelerator pedal is indicated. ON: Accelerator pedal is operated. OFF: Accelerator pedal is not operated. [Related parts] Engine electronic control unit Accelerator pedal position sensor 012 Driver Ac- tivities Brake Pedal ON/OFF Operating status of brake pedal is indicated. ON: Brake pedal depressed. OFF: Brake pedal released. [Related parts] Stop lamp switch 013 Teaching in the cam- era Lane recognition (Left side of vehicle) none/ dashed/ continuous/ s.n.a. Shows the lane's left side status and type identified by the camera. none: No lane dashed: Dashed line continuous: Continuous line s.n.a: No signal [Related parts] Lane departure warning system electronic control unit 014 Teaching in the cam- era Lane recognition (Right side of vehicle) none/ dashed/ continuous/ s.n.a. Shows the lane's right side status and type identified by the camera. none: No lane dashed: Dashed line continuous: Continuous line s.n.a: No signal [Related parts] Lane departure warning system electronic control unit ---===WSE_1506_00001_0519.djvu===--- 54EC-14 015 Teaching in the cam- era Lane Change not changing lane/ changing lane/ error/ s.n.a. Shows the lane change status as identified by the cam- era. not changing lane: Not changing lane. changing lane: Changing lane. error: Error is detected. s.n.a: No signal [Related parts] Lane departure warning system electronic control unit 018 Teaching in the cam- era Distance from left lane marking m Shows the space (distance) from the left side of the lane to the vehicle, as calculated by the image from the cam- era. [Related parts] Lane departure warning system electronic control unit 019 Teaching in the cam- era Distance from right lane marking m Shows the space (distance) from the right side of the lane to the vehicle, as calculated by the image from the camera. [Related parts] Lane departure warning system electronic control unit 020 Teaching in the cam- era Width of left lane marking m Shows the width of the line on the left side of the lane, as calculated by the image from the camera. [Related parts] Lane departure warning system electronic control unit 021 Teaching in the cam- era Width of right lane mark- ing m Shows the width of the line on the right side of the lane, as calculated by the image from the camera. [Related parts] Lane departure warning system electronic control unit 022 Teaching in the cam- era Curve radius m Shows the curve of the lane (radius), as identified by the camera. [Related parts] Lane departure warning system electronic control unit 023 Teaching in the cam- era Angle relative to the lane for vehicle ° Shows the difference between the lane and the angle in which the vehicle is advancing, as identified by the cam- era. [Related parts] Lane departure warning system electronic control unit 024 Teaching in the cam- era Lateral velocity m/s Shows the speed in which the vehicle is moving laterally, as identified by the camera. [Related parts] Lane departure warning system electronic control unit 025 Calibra- tion of camera Calibration of compo- nent 'Multifunction cam- era' (Yaw angle) no t calibration/ 1/2/3/4/5 Shows the calibration status and the operation mode (right and left (horizontality)) of camera not calibration:NG 1-5:OK [Related parts] Lane departure warning system electronic control unit 026 Calibra- tion of camera Calibration of compo- nent 'Multifunction cam- era' (Pitch angle) not calibration/ 1/2/3/4/5 Shows the calibration status and the operation mode (up and down (verticality)) of camera not calibration:NG 1-5:OK [Related parts] Lane departure warning system electronic control unit 027 Calibra- tion of camera Calibration of compo- nent 'Multifunction cam- era' (Roll angle) not calibration/ 1/2/3/4/5 Shows the calibration status and the operation mode (in- clination (levelness)) of camera not calibration:NG 1-5:OK [Related parts] Lane departure warning system electronic control unit 029 Calibra- tion of camera Offset value of compo- nent 'Multifunction cam- era' (Pitch angle) ° Shows the optical axial angle deviation of camera (up and down (verticality)). [Related parts] Lane departure warning system electronic control unit 030 Calibra- tion of camera Offset value of compo- nent 'Multifunction cam- era' (Roll angle) ° Shows the optical axial angle deviation of camera (incli- nation (levelness)). [Related parts] Lane departure warning system electronic control unit No. Current Value Group Description Value Comment TROUBLESHOOTING ---===WSE_1506_00001_0520.djvu===--- 54EC 54EC-15 3. Coding Data in Electronic Control Unit 3.1 Overview The lane departure warning system electronic control unit has various kinds of information such as technical data of vehicle and equipment registered as coding data. Therefore, each time the lane departure warning system electronic control unit is replaced or some specification changes are made, the coding data must surely be rewritten using the diagnostics tool. 3.2 Rewriting of Coding Data If specification changes have been made, be sure to rewrite the relevant coding data. Perform the data writing and resetting work, using the diagnostic tool. Input the parameter above for calibration of camera. Service data for inspection The coding data has been rewritten, if the values of service data are set to 1 or over, when you drive the vehicle ac- tually (at a speed of 60 km/h or higher more than 10 minutes) after inputting the calibration parameter. (If the values of service data does not change even after the vehicle is moving for a certain period of time, check again the assembled state of camera, and perform the calibration.) Remedy LDWS electronic control unit data Overall data Remarks Coding Replacement of electronic control unit O- Coding parameter Value Remarks Height for camera installation (m) Optional Measure and input actually Calibration Value (Provisional Value) Yaw (deg) 0 - Pitch (deg) 0 - Roll (deg) 0 - Stage Yaw not calibration/ 1/2/3/4/5 Calibration status and operation mode of camera (right and left (horizontal direction)) Stage Pitch not calibration/ 1/2/3/4/5 Calibration status and operation mode of camera (up and down (vertical direction)) Stage Roll not calibration/ 1/2/3/4/5 Calibration status and operation mode of camera (inclination (levelness)) ---===WSE_1506_00001_0521.djvu===--- 54EC-16 4. Electronic Control Unit Input/Output Table See the Electronic Control Unit Schematic Diagram for the pin locations of each signal and earth. 5. Lane departure warning system adjustment If any of the following service is performed, initial adjustment of the lane departure warning system must be per- formed. Replacement of the lane departure warning system electronic control unit (camera integrated) Display of diagnostics code (fault codes) [523001-13: Camera out of Calibration] or [523008-13: Camera not configured] 5.1 Vehicle information registration (update various data) to the lane departure warning system electronic control unit (camera integrated) This service is intended to be registered information of the vehicle to the lane departure warning system electronic control unit (camera integrated). Vehicle information is registered using the FUSO Diagnostics. Stop the vehicle. Apply the parking brake, and chocks to wheels. Connect the FUSO Diagnostics. Turn the starter switch ON. (the engine is not started) Select [Lane departure warning system electronic control unit] from control unit list. Click [adaptations] tab from [Lane departure warning system electronic control unit] screen. Update the various data in accordance with instructions and points on the FUSO Diagnostics display. 6. Troubleshooting by Symptom 6.1 Inspection if camera does not identify the lane The camera may not identify the lane if the lines are not clearly visible, such as on snowy roads or in heavy rain. If the lane cannot be identified continuously, even though the lanes on the road are visible, the camera's lens may be very dirty. Inspect and clean the lens. Devices to be connected Terminal Input/ output Voltage and wave form Power Supply 4-Earth In [Measurement condition] Disconnect the electronic control unit and harness, then perform inspection on the vehicle-side connec- tor. [Judgment criteria] Continuously: About 12 V (battery voltage) TROUBLESHOOTING ---===WSE_1506_00001_0521.djvu===--- 54EC-16 4. Electronic Control Unit Input/Output Table See the Electronic Control Unit Schematic Diagram for the pin locations of each signal and earth. 5. Lane departure warning system adjustment If any of the following service is performed, initial adjustment of the lane departure warning system must be per- formed. Replacement of the lane departure warning system electronic control unit (camera integrated) Display of diagnostics code (fault codes) [523001-13: Camera out of Calibration] or [523008-13: Camera not configured] 5.1 Vehicle information registration (update various data) to the lane departure warning system electronic control unit (camera integrated) This service is intended to be registered information of the vehicle to the lane departure warning system electronic control unit (camera integrated). Vehicle information is registered using the FUSO Diagnostics. Stop the vehicle. Apply the parking brake, and chocks to wheels. Connect the FUSO Diagnostics. Turn the starter switch ON. (the engine is not started) Select [Lane departure warning system electronic control unit] from control unit list. Click [adaptations] tab from [Lane departure warning system electronic control unit] screen. Update the various data in accordance with instructions and points on the FUSO Diagnostics display. 6. Troubleshooting by Symptom 6.1 Inspection if camera does not identify the lane The camera may not identify the lane if the lines are not clearly visible, such as on snowy roads or in heavy rain. If the lane cannot be identified continuously, even though the lanes on the road are visible, the camera's lens may be very dirty. Inspect and clean the lens. Devices to be connected Terminal Input/ output Voltage and wave form Power Supply 4-Earth In [Measurement condition] Disconnect the electronic control unit and harness, then perform inspection on the vehicle-side connec- tor. [Judgment criteria] Continuously: About 12 V (battery voltage) TROUBLESHOOTING ---===WSE_1506_00001_0521.djvu===--- 54EC-16 4. Electronic Control Unit Input/Output Table See the Electronic Control Unit Schematic Diagram for the pin locations of each signal and earth. 5. Lane departure warning system adjustment If any of the following service is performed, initial adjustment of the lane departure warning system must be per- formed. Replacement of the lane departure warning system electronic control unit (camera integrated) Display of diagnostics code (fault codes) [523001-13: Camera out of Calibration] or [523008-13: Camera not configured] 5.1 Vehicle information registration (update various data) to the lane departure warning system electronic control unit (camera integrated) This service is intended to be registered information of the vehicle to the lane departure warning system electronic control unit (camera integrated). Vehicle information is registered using the FUSO Diagnostics. Stop the vehicle. Apply the parking brake, and chocks to wheels. Connect the FUSO Diagnostics. Turn the starter switch ON. (the engine is not started) Select [Lane departure warning system electronic control unit] from control unit list. Click [adaptations] tab from [Lane departure warning system electronic control unit] screen. Update the various data in accordance with instructions and points on the FUSO Diagnostics display. 6. Troubleshooting by Symptom 6.1 Inspection if camera does not identify the lane The camera may not identify the lane if the lines are not clearly visible, such as on snowy roads or in heavy rain. If the lane cannot be identified continuously, even though the lanes on the road are visible, the camera's lens may be very dirty. Inspect and clean the lens. Devices to be connected Terminal Input/ output Voltage and wave form Power Supply 4-Earth In [Measurement condition] Disconnect the electronic control unit and harness, then perform inspection on the vehicle-side connec- tor. [Judgment criteria] Continuously: About 12 V (battery voltage) TROUBLESHOOTING ---===WSE_1506_00001_0522.djvu===--- 54EI-1 54EI IMMOBILISER STRUCTURE AND OPERATION 1. Overview ................................................................................... 54EI-2 2. Electronic Control System ......................................................... 54EI-3 3. Electronic Control Circuit Diagram ............................................ 54EI-4 TROUBLESHOOTING 1. Inspection Based on Diagnosis Codes ...................................... 54EI-6 2. FUSO Diagnostics Service Data (Measured Values) ................... 54EI-9 INITIAL SETTINGS OF IMMOBILISER 1. Connecting the FUSO Diagnostics .......................................... 54EI-10 2. Selection of the Setting of Immobiliser .................................... 54EI-10 3. Various Operations (Initial Key Registration, Additional Key Registration, Secret Key Registration, Key Information Deletion) .................................................................................. 54EI-11 4. Additional Starter Key Registration (Up to 6 Keys Can be Registered) .............................................................................. 54EI-15 5. New Starter Key Registration after All of Starter Keys Have Been Lost ................................................................................ 54EI-16 INSPECTION OF ELECTRICAL PARTS . ................................(See Gr54.) INSTALLED LOCATIONS OF PARTS .....................................(See Gr54.) ELECTRIC CIRCUIT DIAGRAM ..............................................(See Gr54.) MEMO Contents of the "54-00C 6. Immobilizer" (00ELT0035) and "54-13 #984 INSPECTION OF IMMOBILIZER" (00ELT0035) has been described as same group to Gr54EI. Content other than change bar is same as 00ELT0035. ---===WSE_1506_00001_0523.djvu===--- 54EI-2 1. Overview The immobiliser stops the supply of power to the starter and supply of fuel to the engine thereby to prevent im- proper vehicle control when any other key than the engine immobiliser starter key registered in the immobiliser electronic control unit is used in an attempt to start the engine. The immobiliser electronic control unit has the capacity enough to accept the registration of up to six starter keys for engine immobiliser. In case the registered starter key is lost, its registration is erased, then an available starter key is additionally registered. If all the registered starter keys are lost or damaged, the erasing of such keys and additional registration of new starter keys are impossible. In such case, the immobiliser electronic control unit is replaced in combination with the new starter keys. The immobiliser electronic control unit performs self-diagnosis of the system, and if there is any abnormality in the system, the immobiliser warning lamp is lit to inform the driver of the abnormality. STRUCTURE AND OPERATION ---===WSE_1506_00001_0523.djvu===--- 54EI-2 1. Overview The immobiliser stops the supply of power to the starter and supply of fuel to the engine thereby to prevent im- proper vehicle control when any other key than the engine immobiliser starter key registered in the immobiliser electronic control unit is used in an attempt to start the engine. The immobiliser electronic control unit has the capacity enough to accept the registration of up to six starter keys for engine immobiliser. In case the registered starter key is lost, its registration is erased, then an available starter key is additionally registered. If all the registered starter keys are lost or damaged, the erasing of such keys and additional registration of new starter keys are impossible. In such case, the immobiliser electronic control unit is replaced in combination with the new starter keys. The immobiliser electronic control unit performs self-diagnosis of the system, and if there is any abnormality in the system, the immobiliser warning lamp is lit to inform the driver of the abnormality. STRUCTURE AND OPERATION ---===WSE_1506_00001_0524.djvu===--- 54EI 54EI-3 2. Electronic Control System 2.1 System block diagram 2.2 Fault diagnosis function The status of the system is constantly monitored when the starter switch is put in the ON position, and if a fault is detected in the system, the driver is informed of the fault through warning lamp in the meter cluster. At the same time, the location of the fault is stored in the memory in the form of diagnosis code and appropriate fault-response control is effected. The diagnosis code stored in the memory can be called out on the multi-information display in the meter cluster and through the FUSO Diagnostics. (See Gr54-00A.) Part name Function or use Starter key for immobiliser Sending and receiving of ID No. signal Immobiliser antenna Sending and receiving of ID No. signal Starter switch Check of starter switch ON/OFF Immobiliser electronic control unit Identification of ID No. and enabling signal for engine start Starter Start of engine Immobiliser warning lamp (meter cluster) Lit for approx. 3 seconds after starter switch ON (with immobil- iser system in "set" status) Lit when immobiliser system becomes abnormal. FUSO Diagnostics (diagnosis connector) Communication between FUSO Diagnostics and immobiliser electronic control unit (controller area network communication via signal detect and actuation modules) Signal detect and actuation modules Junction for sent and received signals between immobiliser electronic control unit, engine electronic control unit, meter cluster and FUSO Diagnostics Sending of starter ON/OFF signal ---===WSE_1506_00001_0525.djvu===--- 54EI-4 3. Electronic Control Circuit Diagram C10040-ECU-54EI BATT 1 ECU GND CABIN CAN-H CABIN CAN-L BATT 2 GND 1 GND 2 CAN-H CAN-L F13 (+) (-) Immobiliser antenna DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L CHASSIS CAN-H CHASSIS CAN-L CAN-H CAN-L SAM Battery High-current fuse box Starter switch Immobiliser electronic control unit Diagnosis connector Meter cluster Engine electronic control unit STRUCTURE AND OPERATION ---===WSE_1506_00001_0526.djvu===--- MEMO 54EI-5 54EI ---===WSE_1506_00001_0527.djvu===--- 54EI-6 1. Inspection Based on Diagnosis Codes The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. When the FUSO Diagnostics is connected, perform the interac- tive troubleshooting with the following procedure. Select the code from the diagnostics code list  Click the test button  Start the interactive troubleshooting 1.1 List of Diagnosis Codes 1.2 Details of Diagnosis Codes 521742-12: Faulty component 'Immobilizer Control unit' 521742-31: Faulty component 'Immobilizer Control unit't Code Message Warning lamp indication Remarks 521742-12 Faulty component 'Immobilizer Control unit' O 521742-31 Faulty component 'Immobilizer Control unit' O 521743-2 Faulty component 'Transponder key, W1 (Receiving antenna of immo- bilizer)' O 521744-2 A transponder key which has not been taught in was detected O 521745-2 Faulty component 'Combustion engine Control unit' O 521746-2 Faulty component 'Immobilizer control unit, Combustion engine con- trol unit Authentication' O 521747-2 Faulty component 'Immobilizer control unit, Transponder key Authenti- cation' O 521748-2 The default settings have not yet been applied of Immobilizer Control unit O 521749-2 Faulty component 'Transponder key Data' O 521750-19 CAN fault O 521750-31 No CAN message received from component 'Signal & ActuatorMod- ule'. O Generation condition Some abnormality has occurred in immobiliser electronic control unit. Recoverability System recovers when relevant diagnosis code is erased. Control effected by electronic control unit Engine is disabled from starting. Possible causes Defective immobiliser electronic control unit Generation condition CPU has been reset. Recoverability System recovers if no abnormal conditions are present when starter switch is placed in ON again. Control effected by electronic control unit None Possible causes Defective immobiliser electronic control unit TROUBLESHOOTING ---===WSE_1506_00001_0527.djvu===--- 54EI-6 1. Inspection Based on Diagnosis Codes The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. When the FUSO Diagnostics is connected, perform the interac- tive troubleshooting with the following procedure. Select the code from the diagnostics code list  Click the test button  Start the interactive troubleshooting 1.1 List of Diagnosis Codes 1.2 Details of Diagnosis Codes 521742-12: Faulty component 'Immobilizer Control unit' 521742-31: Faulty component 'Immobilizer Control unit't Code Message Warning lamp indication Remarks 521742-12 Faulty component 'Immobilizer Control unit' O 521742-31 Faulty component 'Immobilizer Control unit' O 521743-2 Faulty component 'Transponder key, W1 (Receiving antenna of immo- bilizer)' O 521744-2 A transponder key which has not been taught in was detected O 521745-2 Faulty component 'Combustion engine Control unit' O 521746-2 Faulty component 'Immobilizer control unit, Combustion engine con- trol unit Authentication' O 521747-2 Faulty component 'Immobilizer control unit, Transponder key Authenti- cation' O 521748-2 The default settings have not yet been applied of Immobilizer Control unit O 521749-2 Faulty component 'Transponder key Data' O 521750-19 CAN fault O 521750-31 No CAN message received from component 'Signal & ActuatorMod- ule'. O Generation condition Some abnormality has occurred in immobiliser electronic control unit. Recoverability System recovers when relevant diagnosis code is erased. Control effected by electronic control unit Engine is disabled from starting. Possible causes Defective immobiliser electronic control unit Generation condition CPU has been reset. Recoverability System recovers if no abnormal conditions are present when starter switch is placed in ON again. Control effected by electronic control unit None Possible causes Defective immobiliser electronic control unit TROUBLESHOOTING ---===WSE_1506_00001_0528.djvu===--- 54EI 54EI-7 521743-2: Faulty component 'Transponder key, W1 (Receiving antenna of immobilizer)' 521744-2: A transponder key which has not been taught in was detected 521745-2: Faulty component 'Combustion engine Control unit' 521746-2: Faulty component 'Immobilizer control unit, Combustion engine control unit Authentication' 521747-2: Faulty component 'Immobilizer control unit, Transponder key Authentication' 521748-2: The default settings have not yet been applied of Immobilizer Control unit Generation condition No communication takes place between transponder key (starter key) and immobiliser electronic control unit. Recoverability System recovers if no abnormal conditions are present when starter switch is placed in ON again. Control effected by electronic control unit Engine is disabled from starting. Possible causes Defective transponder key (starter key) Defective harness between immobiliser antenna and immobiliser electronic control unit Defective immobiliser antenna Defective immobiliser electronic control unit Generation condition Secret key is not registered in immobiliser electronic control unit. Recoverability None Control effected by electronic control unit Engine is disabled from starting. Possible causes Defective immobiliser electronic control unit Generation condition Collation between engine electronic control unit and immobiliser electronic control unit is not successfully made. Recoverability System recovers if collation is made successfully when starter switch is placed in ON again. Control effected by electronic control unit Engine is disabled from starting. Possible causes Defective engine electronic control unit Incorrect engine electronic control unit in use Engine electronic control unit transferred from another vehicle Generation condition No communication is possible between engine electronic control unit and im- mobiliser electronic control unit. Recoverability System recovers if normal communication is established when starter switch is placed in ON again. Control effected by electronic control unit Engine is disabled from starting. Possible causes Defective engine electronic control unit Controller area network communication line is open or short-circuited to power, earth or another circuit. Incorrect engine electronic control unit in use Generation condition Collation between transponder key (starter key) and immobiliser electronic control unit is made unsuccessfully. Recoverability System recovers if collation is made successfully when starter switch is placed in ON again. Control effected by electronic control unit Engine is disabled from starting. Possible causes Unauthorised transponder key (starter key) is used. Transponder key (starter key) not registered yet is used. Generation condition Transponder key (starter key) ID is not stored in immobiliser electronic con- trol unit. Recoverability System recovers when initial key registration is executed. Control effected by electronic control unit Engine is disabled from starting. Possible causes Transponder key (starter key) used is not a one registered in immobiliser electronic control unit. ---===WSE_1506_00001_0529.djvu===--- 54EI-8 521749-2: Faulty component 'Transponder key Data' 521750-19: CAN fault 521750-31: No CAN message received from component 'Signal & ActuatorModule'. Generation condition Immobiliser electronic control unit has received an implausible data from transponder key (starter key) through communication line. Recoverability System recovers if a plausible data is obtained when starter switch is placed in ON again. Control effected by electronic control unit Engine is disabled from starting. Possible causes Faulty transponder key (starter key) Faulty immobiliser antenna Faulty immobiliser electronic control unit Generation condition Controller area network error message is received. Recoverability System recovers if any normal signal is received when starter switch is placed in ON position. Control effected by electronic control unit None Possible causes Controller area network communication line is open or shorted to power, earth or another circuit. Faulty controller area network resistor Faulty signal detect and actuation module Faulty immobiliser electronic control unit Generation condition No controller area network message is receivable. Recoverability System recovers if any normal signal is received when starter switch is placed in ON position. Control effected by electronic control unit None Possible causes Controller area network communication line is open or shorted to power, earth or another circuit. Faulty controller area network resistor Faulty signal detect and actuation module Faulty immobiliser electronic control unit TROUBLESHOOTING ---===WSE_1506_00001_0530.djvu===--- 54EI 54EI-9 2. FUSO Diagnostics Service Data (Measured Values) Since the contents of the FUSO Diagnostics are regularly updated, the descriptions and expressions may differ from those given in the service manuals. Check the latest information with the FUSO Diagnostics. [Current Value Group: Transponder key] [Current Value Group: Status of function "Immobilizer"] No. Description Value Explanation 000 Ignition status ON/OFF Indicates the ignition status ON: Starter switch is in ACC, ON or START position OFF: Starter switch is in LOCK position 001 Type of key used Transponder key/ Key not taught-in/ Vehicle key NOT INSERTED Indicates the type of the starter key (transponder key for engine immobiliser) currently inserted in the starter switch. Transponder key: Starter key registered in the immobiliser electronic control unit Key not taught-in: Starter key not registered in the immobilis- er electronic control unit Vehicle key NOT INSERTED: No key in the starter switch. 002 Number of keys taught in Indicates the number of registered starter keys 00to06 No. Description Value Explanation 003 Status of function 'Immobi- lizer' Indicates the current status of the immobiliser electronic control unit 00: Initial key registration completed 01: Initial key registration not completed 02: Additional key registration in progress 03: Deletion of registered key in progress 04: Secret key registration in progress 05: Standby 004 Immobilizer Warning lamp ON/OFF Indicates the status of the immobiliser indicator lamp ON: Indicator lamp is illuminating OFF: Indicator lamp is off 005 Immobilizer Operating con- dition ACTIVE/NOT ACTIVE Indicates the status of the immobiliser system ACTIVE: immobiliser system is active NOT ACTIVE: immobiliser system is inactive ---===WSE_1506_00001_0531.djvu===--- 54EI-10 1. Connecting the FUSO Diagnostics CAUTION The immobiliser can be set with FUSO Diagnostics Ver. FDS-R10-1 or higher. Display images will be applied to FUSO Diagnostics Ver. FDS-R12-1 or higher. Display images might look different according to the version of FUSO Diagnostics. Connect FUSO Diagnostics. (See Gr54-00A.) 2. Selection of the Setting of Immobiliser From the control unit list screen, select [IMMO - Immobilizer Control Unit (A12)]. Select "Actuations" tab. Select [Transponder key Teach-in process]. Press the "S" button of "Start teach-in process". INITIAL SETTINGS OF IMMOBILISER ---===WSE_1506_00001_0531.djvu===--- 54EI-10 1. Connecting the FUSO Diagnostics CAUTION The immobiliser can be set with FUSO Diagnostics Ver. FDS-R10-1 or higher. Display images will be applied to FUSO Diagnostics Ver. FDS-R12-1 or higher. Display images might look different according to the version of FUSO Diagnostics. Connect FUSO Diagnostics. (See Gr54-00A.) 2. Selection of the Setting of Immobiliser From the control unit list screen, select [IMMO - Immobilizer Control Unit (A12)]. Select "Actuations" tab. Select [Transponder key Teach-in process]. Press the "S" button of "Start teach-in process". INITIAL SETTINGS OF IMMOBILISER ---===WSE_1506_00001_0531.djvu===--- 54EI-10 1. Connecting the FUSO Diagnostics CAUTION The immobiliser can be set with FUSO Diagnostics Ver. FDS-R10-1 or higher. Display images will be applied to FUSO Diagnostics Ver. FDS-R12-1 or higher. Display images might look different according to the version of FUSO Diagnostics. Connect FUSO Diagnostics. (See Gr54-00A.) 2. Selection of the Setting of Immobiliser From the control unit list screen, select [IMMO - Immobilizer Control Unit (A12)]. Select "Actuations" tab. Select [Transponder key Teach-in process]. Press the "S" button of "Start teach-in process". INITIAL SETTINGS OF IMMOBILISER ---===WSE_1506_00001_0532.djvu===--- 54EI 54EI-11 3. Various Operations (Initial Key Registration, Additional Key Registration, Secret Key Registration, Key Information Deletion) Details of each function are as follows. CAUTION The secret key data can be registered in the memory only after the initial key has been previously regis- tered. (1) Initial key registration After replacement of the immobiliser electronic control unit, this function should be executed to allow the electron- ic control unit to identify the starter key data in the memory or load new data to the memory. (The procedure of initial key registration is identical with the procedure of additional key registration after pressing the button "R" for "Register Initial Key". See "(2) Additional key registration".) (2) Additional key registration At re-registration of starter key or addition of a new key, additional key registration function should be executed to allow the electronic control unit to identify the starter key data in the memory or load new data to the memory. Up to 6 sets of the key data can be registered in the immobiliser electronic control unit memory. (2.1) Registration procedure Insert the starter key registered in the immobiliser electronic control unit memory. Check that the actual value of "Type of key used" is "Transpon- der key". Press the "R" (red) button of "Register additional key". Function FUSO Diagnostics display Outline Initial key registration Button "R": Register Initial Key Used to allow the immobiliser electronic control unit to identify starter key data or to load new data to the memory after replacement of the electronic control unit. (See "(1) Initial key registration".) Additional key registration Button "R": Register Additional Key Used to allow the immobiliser electronic control unit to identify starter key data or to load new data to the memory at re-registration of starter key or ad- dition of a new key. (See "(2) Additional key registration".) Secret key registration Button "R": Perform teach-in process "security code". Used to allow the system to collate immobiliser electronic control unit ID with engine electronic control unit ID. (See "(3) Secret key registration".) Key information deletion Button "N": Delete key. Used to delete starter key data registered in the immobiliser electronic con- trol unit memory. (See "(4) Key information deletion".) ---===WSE_1506_00001_0533.djvu===--- 54EI-12 Press the "Continue" button. If an error occurs, or when work was interrupted in the middle, and then press the "Continue" button after the ON again to OFF once the starter switch Insert a new starter key to be registered in the immobiliser elec- tronic control unit memory into the starter switch. Press the "Continue" button. A message appears to show registration of additional starter key data in the immobiliser electronic control unit has been success- fully completed. Make sure that the number of the value of "Numbers of keys taught in" is increased. (3) Secret key registration Secret key registration function should be executed whenever the following operations have been done. Without secret key registration, the engine cannot be started because engine cannot find the same key ID in the memory. The immobiliser electronic control unit is replaced with new one. The engine electronic control unit is replaced with new one. The engine electronic control unit is replaced with one derived from other vehicles. CAUTION The immobiliser electronic control unit should never be replaced with one derived from other vehicles. The secret key registration function need not be executed after the starter key data is once deleted and registered again. INITIAL SETTINGS OF IMMOBILISER ---===WSE_1506_00001_0534.djvu===--- 54EI 54EI-13 (3.1) Registration procedure Press the "R" (black) button of "Perform teach-in process 'Secu- rity code'". Press the "Continue" button. Press the "Continue" button. A message appears to show that registration of the secret key in the engine electronic control unit memory has been successfully completed. ---===WSE_1506_00001_0535.djvu===--- 54EI-14 (4) Key information deletion Key information deletion function should be executed to delete the starter key data registered in the immobiliser electronic control unit memory. (4.1) Deletion procedure Press the "N" button of "Key Delete". Press the "Continue" button. Press the button "Continue" again. A message appears to show deletion of the starter key data reg- istered in the immobiliser electronic control unit memory has been successfully completed. Make sure that the value of "Number of keys taught in" is "01". (Only the starter key inserted in the starter switch has been taught in.) INITIAL SETTINGS OF IMMOBILISER ---===WSE_1506_00001_0536.djvu===--- 54EI 54EI-15 4. Additional Starter Key Registration (Up to 6 Keys Can be Registered) Follow the procedure below to register the additional starter key after checking its key number. When the key number is unavailable, the key cutouts must be cut as this starter key has no cutout on it. Key number is shown on the key number plate attached to one of two starter keys initially provided. Prepare the additional starter key to be registered with the key number confirmed. (If the key number is unavailable, the key cutouts must be cut as this starter key has no cutout on it.) Prepare the existing starter key and the new and additional starter key to be registered. Insert the existing starter key (other than the new and additional starter key to be registered) into the starter switch. Delete the starter key data with FUSO Diagnostics. (See "3. (4) Key information deletion".) After deletion of the starter key registration has been completed, all of the starter key data except the starter key in- serted into the starter switch is deleted. Register the additional starter key with FUSO Diagnostics. (See "3. (2) Additional key registration".) Any starter keys except the starter key inserted into the starter switch at deletion of key registration can be registered. Register the secret key with FUSO Diagnostics. (See "3. (3) Secret key registration".) End ---===WSE_1506_00001_0537.djvu===--- 54EI-16 5. New Starter Key Registration after All of Starter Keys Have Been Lost When the new starter key has to be registered after all of starter keys have been lost, firstly check the key number because the key parts to be prepared will differ according to availability of key number. Key number is shown on the key number plate attached to one of two starter keys initially provided. Follow the procedure below after checking if the key number is available or not. When the key number is unavailable Register the additional starter key. (See "4. Additional Starter Key Registration".) End When the key number is available Replace all the parts below with new ones. Starter key Starter switch Door lock cylinder Immobiliser electronic control unit Fuel cap Glove box with key <Glove box with key type> Replace all the parts below with new ones. (Provide the key number.) Starter key Immobiliser electronic control unit Insert the starter key into the starter switch. Register the initial starter key with FUSO Diagnostics. (See "3. (1) Initial key registration".) Register the secret key with FUSO Diagnostics. (See "3. (3) Secret key registration".) INITIAL SETTINGS OF IMMOBILISER ---===WSE_1506_00001_0538.djvu===--- 54EM-1 54EM METER CLUSTER SPECIFICATIONS.......................................................................... 54EM-2 STRUCTURE AND OPERATION 1. Overview ................................................................................. 54EM-4 2. Electronic Control System ....................................................... 54EM-5 3. Electronic Control Unit Circuit Diagram ................................. 54EM-16 TROUBLESHOOTING 1. Inspection Based on Diagnosis Codes .................................. 54EM-18 2. FUSO Diagnostics Service Data (Actual values) .................... 54EM-20 3. FUSO Diagnostics Actuator Test (Actuations) ....................... 54EM-20 4. Coding Data in Electronic Control Unit .................................. 54EM-20 5. Electronic Control Unit Input/Output Table ............................ 54EM-21 INSPECTION OF ELECTRICAL PARTS . ................................(See Gr54.) INSTALLED LOCATIONS OF PARTS .....................................(See Gr54.) ELECTRIC CIRCUIT DIAGRAM ..............................................(See Gr54.) MEMO Contents of the "54-00B Meter" (00ELT0035),"54-00C 4. Meter Cluster" (00ELT0035) and "54-13 #986 INSPECTION OF METER CLUSTER" (00ELT0035) has been described as same group to Gr54EM. Content other than change bar is same as 00ELT0035. ---===WSE_1506_00001_0539.djvu===--- 54EM-2 Item Specifications Manufacturer Continental Voltage V 12 Speedometer indicating range km/h {MPH} 0to160( at60km/h){0to100( at40MPH)} Tachometer indicating range rpm 0 to 5000 (±50 at 3000 rpm) Meter cluster Water temperature gauge indicating range Meter warning buzzer Sound pressure dB 55±3(at1m) Low vacuum pressure buzz- er Sound pressure dB 75±3(at1m) +3 0 +2 0 SPECIFICATIONS ---===WSE_1506_00001_0540.djvu===--- 54EM-3 54EM MEMO ---===WSE_1506_00001_0541.djvu===--- 54EM-4 1. Overview This meter cluster contains a central processing unit with the following functions. Instrument drive function (speedometer, tachometer, fuel level gauge) Vehicle speed output distribution function Indicator and warning indication function Multi-information display indication function Urea level indicator operation function Buzzer sound function Fault diagnosis function STRUCTURE AND OPERATION ---===WSE_1506_00001_0541.djvu===--- 54EM-4 1. Overview This meter cluster contains a central processing unit with the following functions. Instrument drive function (speedometer, tachometer, fuel level gauge) Vehicle speed output distribution function Indicator and warning indication function Multi-information display indication function Urea level indicator operation function Buzzer sound function Fault diagnosis function STRUCTURE AND OPERATION ---===WSE_1506_00001_0542.djvu===--- 54EM 54EM-5 2. Electronic Control System 2.1 Instrument drive function and vehicle speed output distribution function (1) System block diagram ---===WSE_1506_00001_0543.djvu===--- 54EM-6 2.2 Warning and indicator lamps indication function, multi-information display function, urea lev- el indicator operation function and fault diagnosis function (1) System block diagram STRUCTURE AND OPERATION ---===WSE_1506_00001_0544.djvu===--- 54EM 54EM-7 2.3 General description The warning and indicator lamps indication function indicates warning characters or graphical marks (LED), there- by adequately alerting the driver to abnormalities. Output data signals from respective systems are gathered in the central processing unit in the meter cluster and indicated through appropriate LED or the multi-information display. Alarm is sounded by the buzzer (speaker) in the meter cluster. The system features are as shown below. The multi-information display distinctly shows necessary information by changing display colours according to the degree of significance of the information. MODE switch, SELECT switch, SET/RES switch and ODO/TRIP switch are used to have option vehicle infor- mation (such as trip meter, clock, check and service data) and diagnosis codes for respective electronic control systems indicated by the multi-information display according to information gathered in the meter cluster. When there are two or more warning items, the display is switched to show them in every three seconds. ---===WSE_1506_00001_0545.djvu===--- 54EM-8 (1) Multi-information display indication transition diagram STRUCTURE AND OPERATION ---===WSE_1506_00001_0546.djvu===--- 54EM 54EM-9 (2) Indicator lamps (LED) Lamp Illuminating/ flashing Internal buzzer sounding Condition for illuminating/flashing Remarks FUEL LEVEL GAUGE • Illuminates -- Fuel level is low See Gr54 . Illuminates O Parking brake is engaged (Buzzer sounds when vehicle speed exceeds 12 km/h with parking brake engaged.) See Gr54 . -- Brake fluid level is low See Gr54 . Illuminates -- Vacuum in vacuum tank is low <Vacuum booster-equipped vehicle> See Gr54 . Illuminates O Engine is overheated See Gr54 . Illuminates -- Charging system is defective See Gr54 . Illuminates -- Engine fluid pressure is low See Gr54 . Illuminates -- Engine is being preheated See Gr54 . Illuminates -- Engine control system is defective Exhaust gas aftertreatment is defective See Gr54 . Flashes -- Urea tank is empty See Gr54 . (amber) Flashes -- Soot is accumulated in Diesel Particulate Filter (flashes at 0.5 second interval) See Gr54 . Flashes -- Diesel Particulate Filter requires cleaning (flashes at 0.25 second inter- val) Illuminates -- Manual regeneration is in progress in the Diesel Particulate Filter (green) Illuminates -- Automatic regeneration is in progress in the Diesel Particulate Filter See Gr54 . UREA LEVEL INDICA- TOR • Illuminates O Urea level decreases (10% or lower) See Gr54 . Flashes O Urea level decreases (5% or lower) Urea tank is empty Abnormality is detected by NOx sensor Quality of AdBlue ® refilled decreases Illuminates -- Headlamp high beam is on See Gr54 . Illuminates -- Fog lamp is on See Gr54 . Illuminates -- Rear fog lamp is on See Gr54 . Flashes O (turn signal sound) Turn signal lamp is on Hazard lamp is on See Gr54 . Illuminates -- Exhaust brake is on Warm-up system is on See Gr54 . Illuminates -- BlueTec ® exhaust gas aftertreatment is faulty. See Gr54 . 420 510 515 515 537 125 536 880 880 880 880 880 880 310 315 315 330 880 880 ---===WSE_1506_00001_0547.djvu===--- 54EM-10 Mark Illuminating/ flashing Internal buzzer sounding Condition for illuminating/flashing Remarks Illuminates -- Anti-lock brake system is abnormal See Gr54 . Illuminates -- Engine immobiliser starter key communication is defective Engine immobiliser system is defective See Gr54 . Illuminates -- Vehicle is running in four-wheel drive mode <FG> See Gr54 . Flashes -- Idling stop and start system is preparing for automatic engine stop (fast flashing: 0.5-second interval) See Gr54 . -- Idling stop and start system is automatically stopping the engine (slow flashing: 2-second interval) Illuminates O Idling stop and start system canceled automatic engine start (door open) -- Idling stop and start system is faulty Flashes -- Electronic stability program is operating See Gr54 . Illuminates -- Electronic stability program is faulty Illuminates -- Electronic stability program is off See Gr54 . Illuminates -- Vehicle is running in cruise control mode See Gr54 . Illuminates -- Lane departure warning system is faulty Lane departure warning system is turned off See Gr54 . 790 210 810 275 790 790 880 959 STRUCTURE AND OPERATION ---===WSE_1506_00001_0548.djvu===--- 54EM 54EM-11 (3) Multi-information display indications Mark Illuminating/ flashing Internal buzzer sounding Condition for illuminating/flashing Remarks (red) Illuminates -- Engine output is limited See Gr54 . Urea tank is empty See Gr54 . (amber) Illuminates -- Engine check is required Engine oil change is required (when the mark appears alternately with ) System is reset after engine oil change (indicated for 10 seconds) See Gr54 . Illuminates -- Automatic transmission fluid is too hot See Gr54 . (red) Illuminates O DUONIC ® system is faulty or abnormal in electric control system (The system malfunction causes gears to remain in the present shift posi- tion; lamp comes on and buzzer sounds.) See Gr54 . (amber) Illuminates -- DUONIC ® system is faulty or abnormal in electric control system (Automatic or manual gear shifting is enabled.) See Gr54 . (red) Illuminates -- Signal detect and actuation modules are faulty in electric control system -- (amber) Illuminates -- Signal detect and actuation modules are abnormal in electric control sys- tem (when outside light check is needed) -- Illuminates -- Meter cluster electric circuit is defective -- (amber) Illuminates -- Engine oil change is required (when quantity of fuel mixed in engine oil exceeds upper limit) See Gr54 . (green) Illuminates -- PCV (positive crankcase ventilation) filter regeneration must be per- formed or PCV (positive crankcase ventilation) filter must be replaced. See Gr13E. Illuminates -- Soot accumulation in Diesel Particulate Filter is excessive See Gr54 . Illuminates -- SRS airbag electrical circuit is defective See Gr54 . Illuminates -- Moisture in fuel filter becomes excessive See Gr54 . Illuminates -- Electrical balance between main battery and battery for body builder pow- er source is abnormal See Gr54 . Illuminates O Cab tilt lock is incomplete (Buzzer sounds at vehicle speed beyond 5 km/h.) See Gr54 . Illuminates -- Anti spin regulator system is faulty See Gr54 . Illuminates -- Anti spin regulator system is turned off See Gr54 . 880 880 880 873 873 873 880 880 631 566 125 550 790 790 ---===WSE_1506_00001_0549.djvu===--- 54EM-12 (4) Alarm with buzzer only (without warning lamp on) Illuminates -- Lane departure warning system is faulty See Gr54 . Illuminates -- Anti spin regulator system is operating See Gr54 . Illuminates -- Gearbox power take-off is connected <Vehicles with gearbox power take-off> See Gr54 . Illuminates -- Gearbox power take-off is ready for connection <Vehicles with DUONIC ® gearbox power take-off> See Gr54 . Illuminates -- Less than 1,000 km or one month remains before the next scheduled en- gine oil change interval -- Illuminates -- Less than 1,000 km or one month remains before the next scheduled en- gine oil filter replacement interval -- Illuminates -- Less than one month remains before the next scheduled fuel filter re- placement interval -- Illuminates -- Less than 1,000 km or one month remains before the next scheduled brake fluid change interval -- Illuminates -- Less than one month remains before the next scheduled air cleaner re- placement interval -- Illuminates -- Less than 1,000 km or one month remains before the next scheduled clutch fluid and gearbox fluid change interval (DUONIC ®) Less than 1,000 km or one month remains before the next scheduled gearbox fluid change interval (manual gearbox) -- Illuminates -- Less than 1,000 km or one month remains before the next scheduled wheel hub bearing grease change interval -- Illuminates -- Less than 1,000 km or one month remains before the next scheduled dif- ferential gear oil change interval -- Illuminates -- Less than 1,000 km or one month remains before the next scheduled power steering fluid change interval -- Illuminates -- Less than 1,000 km or one month remains before the next scheduled en- gine coolant change interval -- Buzzer Internal buzzer sounding Condition for buzzing Remarks Back buzzer O Shifter lever is put in the "R" position -- Key reminder buzzer O When all conditions below are established Starter key is left inserted Starter switch in the OFF position Driver's side door switch is in "OPEN" position -- Mark Illuminating/ flashing Internal buzzer sounding Condition for illuminating/flashing Remarks 959 790 850 850 STRUCTURE AND OPERATION ---===WSE_1506_00001_0550.djvu===--- 54EM 54EM-13 2.4 Fault diagnosis function The fault diagnosis function establish- es the diagnosis mode through simul- taneous push of the MODE, SELECT and SET/RES switches with the vehi- cle at a stop to perform the fault diag- nosis of respective systems. ---===WSE_1506_00001_0551.djvu===--- 54EM-14 (1) Fault diagnosis function (diagnosis mode) display transition diagram (anti-lock brake system electronic control unit (hydraulic unit)) STRUCTURE AND OPERATION ---===WSE_1506_00001_0552.djvu===--- 54EM-15 54EM MEMO ---===WSE_1506_00001_0553.djvu===--- 54EM-16 3. Electronic Control Unit Circuit Diagram C10040-ECU-54EM-1 ECU GND CHASSIS CAN-H CHASSIS CAN-L CAB CAN-H CAB CAN-L CAN-H CAN-L OIL PRESS SW W/T SEN SIG W/T SEPARATOR SEN SIG W/T SEN GND CRCMN WS IND WSV WS GND F04 F09 F22 F20 F19 12V/24V IGN RELAY D IGN RELAY E GND SIG GND L ILL(-) ILL(-) V SIG GND ALTERNATOR (12V/24V) BATT MAIN GND CAN-H CAN-L ENG. CONT. ACT. POWER GND 2 13 10 9 18 RHEOSTAT RHEOSTAT 3 1 16 S/S PULSE 7 S/S OUTPUT S/S V 12 S/S SIG 4 S/S GND V SIG GND S/S V S/S SIG OUT S/S SIG IN S/S GND DATA SIG S/S DATA SIG CAN-H CAN-L SAM Relay LSD GND L EQUALISER IND CAN-H CAN-L 5 CAN-H CAN-L CAN-H CAN-L R SAM Relay LSD 987654321 181716151413121110 SAM Alternator (24V) Engine ECU Lane recognition camera Oil pressure switch Water temperature sensor Air-conditioner electronic control unit and control panel (Auto) Heater control panel (Manual) Vehicle speed sensor <Without tachograph> Meter cluster Tachograph <With tachograph> Transfer ECU <FG> Vehicle speed sensor <With tachograph> Fuel filter DUONIC ECU Immobiliser electronic control unit Hydraulic unit Alternator (12V) Battery equaliser ISS ECU Airbag ECU Battery High current fuse box Battery ECU : Electronic control unit ISS : Idling stop and start system M/G : Manual gearbox SAM:Signal detect and actuation modules LDWS:Lane departure warning system Meter cluster connector Condenser fan relay Cruise control main switch STRUCTURE AND OPERATION ---===WSE_1506_00001_0554.djvu===--- 54EM 54EM-17 C10040-ECU-54EM-2 DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L FUEL LEVEL SENSOR SIG FUEL LEVEL SENSOR GND PTO SW(CHASSIS) CAB TILT SW BRAKE FLUID LEVEL SW KEY INSERTED SW VACUUM SW F13 FRONT DOOR SIG GND BATT(T30) PARKING BRAKE SW SW(SIGNAL)GND SPARE INPUT SWITCH DIGI STARTER SW BATT. REVERSE SW *1 *1 SAM Battery Front door switch Parking brake switch Vacuum switch Fuel level sensor Power take-off control switch Cab tilt lock switch Brake fluid level switch LDWS cutoff switch Keyless switch (starter switch) High current fuse box Starter switch Diagnosis connector Backup lamp switch *1:M/G ---===WSE_1506_00001_0555.djvu===--- 54EM-18 1. Inspection Based on Diagnosis Codes The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. When the FUSO Diagnostics is connected, perform the interac- tive troubleshooting with the following procedure. Select the code from the diagnostics code list ↓ Click the test button ↓ Start the interactive troubleshooting 1.1 List of Diagnosis codes 1.2 Details of Diagnosis codes 158-3: The battery voltage is too high. 158-4: The battery voltage is too low. Code Message Warning indication Remarks 158-3 The battery voltage is too high. O 158-4 The battery voltage is too low. O 629-31 Faulty part CPU inside component "Instrument panel" O 639-4 CAN bus OFF fault O 1213-14 There is an internal fault in component 'instrument panel'. O 521751-7 There is an internal fault in component 'instrument panel'. O 521768-19 Faulty part CPU inside component "Instrument panel" O Generation condition In meter cluster is indicated a battery voltage higher than 16 V for 10 sec- onds. Recoverability System recovers if normal reading is obtained when starter switch is turned to OFF and then to ON. Control effected by electronic control unit None Possible causes Faulty alternator Faulty signal detect and actuation module Defective meter cluster Generation condition In meter cluster is indicated a battery voltage lower than 10 V for 10 seconds Recoverability System recovers if normal reading is obtained when starter switch is turned to OFF and then to ON. Control effected by electronic control unit None Possible causes Open-circuit or short-circuit to earth in harness between battery and meter cluster Malfunction of battery Faulty alternator Faulty signal detect and actuation module Defective meter cluster TROUBLESHOOTING ---===WSE_1506_00001_0555.djvu===--- 54EM-18 1. Inspection Based on Diagnosis Codes The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. When the FUSO Diagnostics is connected, perform the interac- tive troubleshooting with the following procedure. Select the code from the diagnostics code list ↓ Click the test button ↓ Start the interactive troubleshooting 1.1 List of Diagnosis codes 1.2 Details of Diagnosis codes 158-3: The battery voltage is too high. 158-4: The battery voltage is too low. Code Message Warning indication Remarks 158-3 The battery voltage is too high. O 158-4 The battery voltage is too low. O 629-31 Faulty part CPU inside component "Instrument panel" O 639-4 CAN bus OFF fault O 1213-14 There is an internal fault in component 'instrument panel'. O 521751-7 There is an internal fault in component 'instrument panel'. O 521768-19 Faulty part CPU inside component "Instrument panel" O Generation condition In meter cluster is indicated a battery voltage higher than 16 V for 10 sec- onds. Recoverability System recovers if normal reading is obtained when starter switch is turned to OFF and then to ON. Control effected by electronic control unit None Possible causes Faulty alternator Faulty signal detect and actuation module Defective meter cluster Generation condition In meter cluster is indicated a battery voltage lower than 10 V for 10 seconds Recoverability System recovers if normal reading is obtained when starter switch is turned to OFF and then to ON. Control effected by electronic control unit None Possible causes Open-circuit or short-circuit to earth in harness between battery and meter cluster Malfunction of battery Faulty alternator Faulty signal detect and actuation module Defective meter cluster TROUBLESHOOTING ---===WSE_1506_00001_0556.djvu===--- 54EM 54EM-19 629-31: Faulty part CPU inside component "Instrument panel" 639-4: CAN bus OFF fault 1213-14: There is an internal fault in component "instrument panel". 521751-7: There is an internal fault in component "instrument panel". 521768-19: Faulty part CPU inside component "Instrument panel" Generation condition CPU in meter cluster is reset. Recoverability System recovers if any normal signal is received when starter switch is turned to OFF and then to ON. Control effected by electronic control unit None Possible causes Defective meter cluster Generation condition Controller area network communication bus off condition is detected. Recoverability System recovers if any normal signal is received when starter switch is turned to OFF and then to ON. Control effected by electronic control unit None Possible causes Controller area network communication bus is open or shorted to power, earth or another circuit. Faulty resistor in meter cluster Defective meter cluster Generation condition Internal circuit is malfunctioning. Recoverability System recovers if any normal signal is received when starter switch is turned to OFF and then to ON. Control effected by electronic control unit Error message is sent through controller area network. Possible causes Defective meter cluster Generation condition Internal circuit is malfunctioning. Recoverability System recovers if any normal signal is received when starter switch is turned to OFF and then to ON. Control effected by electronic control unit None Possible causes Defective meter cluster Generation condition Access to EEPROM is impossible. Recoverability System recovers if any normal signal is received when starter switch is turned to OFF and then to ON. Control effected by electronic control unit None Possible causes Defective meter cluster ---===WSE_1506_00001_0557.djvu===--- 54EM-20 2. FUSO Diagnostics Service Data (Actual values) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. 3. FUSO Diagnostics Actuator Test (Actuations) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. The basic conditions for performing the actuator test: Vehicle stopped, engine stopped and starter switch ON. 4. Coding Data in Electronic Control Unit 4.1 Overview The meter cluster has various kinds of information such as technical data of vehicle and equipment registered as coding data. Therefore, each time the meter cluster is replaced or some specification changes are made, the coding data must surely be rewritten using the diagnostic tool. Otherwise, the data stored in the meter cluster could deviate from the actual conditions of the vehicles, resulting in incorrect alarms. 4.2 Rewriting of Coding Data If specification changes have been made, be sure to rewrite the relevant coding data. Perform the data writing and resetting work, using the diagnostic tool. No. Current Value Group Description Value Explanation 000 -- Vehicle speed Tachograph km Shows the vehicle speed as determined by the ta- chograph. Synchronous with the speedometer 0.000 to 255.000 km/h {0.000 to 158.4 mph} [Related parts] vehicle speed sensor 001 -- Vehicle speed ECU km Shows the vehicle speed as determined by the option connector Synchronous with the speedometer 0.000 to 255.000 km/h {0.000 to 158.4 mph} [Related parts] vehicle speed sensor No. Selection Explanation 000 Instrument cluster [Test method] Operate each indication in the meter cluster. [Checking method] The speedometer operates from 0 to maximum. It stops on the way for about 5 seconds at the 40 km/h {24.9 mph} point. The tachometer operates from 0 to maximum. It stops on the way for about 5 seconds at the 2000 rpm point. The fuel level gauge operates from 0 to full. It stops on the way for about 5 seconds at the one half point. The indicator lamp, illumination, multi-information display and buzzer cycle ON/OFF every 1 second. [Note] The test stops automatically when three rounds of inspection are completed. (Or, terminated using the stop button.) Rewriting coding data required Standards for rewriting meter cluster internal data Final gear When the final gear is changed, the meter cluster internal data must be updated. Rear tyre When the tyre size is changed, the meter cluster internal data must be updated. Anti-lock brake system When specifications of this system are changed, the meter cluster internal data must be updated. Meter cluster replacement All data (entire set of the latest history data for the vehicle) TROUBLESHOOTING ---===WSE_1506_00001_0557.djvu===--- 54EM-20 2. FUSO Diagnostics Service Data (Actual values) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. 3. FUSO Diagnostics Actuator Test (Actuations) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. The basic conditions for performing the actuator test: Vehicle stopped, engine stopped and starter switch ON. 4. Coding Data in Electronic Control Unit 4.1 Overview The meter cluster has various kinds of information such as technical data of vehicle and equipment registered as coding data. Therefore, each time the meter cluster is replaced or some specification changes are made, the coding data must surely be rewritten using the diagnostic tool. Otherwise, the data stored in the meter cluster could deviate from the actual conditions of the vehicles, resulting in incorrect alarms. 4.2 Rewriting of Coding Data If specification changes have been made, be sure to rewrite the relevant coding data. Perform the data writing and resetting work, using the diagnostic tool. No. Current Value Group Description Value Explanation 000 -- Vehicle speed Tachograph km Shows the vehicle speed as determined by the ta- chograph. Synchronous with the speedometer 0.000 to 255.000 km/h {0.000 to 158.4 mph} [Related parts] vehicle speed sensor 001 -- Vehicle speed ECU km Shows the vehicle speed as determined by the option connector Synchronous with the speedometer 0.000 to 255.000 km/h {0.000 to 158.4 mph} [Related parts] vehicle speed sensor No. Selection Explanation 000 Instrument cluster [Test method] Operate each indication in the meter cluster. [Checking method] The speedometer operates from 0 to maximum. It stops on the way for about 5 seconds at the 40 km/h {24.9 mph} point. The tachometer operates from 0 to maximum. It stops on the way for about 5 seconds at the 2000 rpm point. The fuel level gauge operates from 0 to full. It stops on the way for about 5 seconds at the one half point. The indicator lamp, illumination, multi-information display and buzzer cycle ON/OFF every 1 second. [Note] The test stops automatically when three rounds of inspection are completed. (Or, terminated using the stop button.) Rewriting coding data required Standards for rewriting meter cluster internal data Final gear When the final gear is changed, the meter cluster internal data must be updated. Rear tyre When the tyre size is changed, the meter cluster internal data must be updated. Anti-lock brake system When specifications of this system are changed, the meter cluster internal data must be updated. Meter cluster replacement All data (entire set of the latest history data for the vehicle) TROUBLESHOOTING ---===WSE_1506_00001_0557.djvu===--- 54EM-20 2. FUSO Diagnostics Service Data (Actual values) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. 3. FUSO Diagnostics Actuator Test (Actuations) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. The basic conditions for performing the actuator test: Vehicle stopped, engine stopped and starter switch ON. 4. Coding Data in Electronic Control Unit 4.1 Overview The meter cluster has various kinds of information such as technical data of vehicle and equipment registered as coding data. Therefore, each time the meter cluster is replaced or some specification changes are made, the coding data must surely be rewritten using the diagnostic tool. Otherwise, the data stored in the meter cluster could deviate from the actual conditions of the vehicles, resulting in incorrect alarms. 4.2 Rewriting of Coding Data If specification changes have been made, be sure to rewrite the relevant coding data. Perform the data writing and resetting work, using the diagnostic tool. No. Current Value Group Description Value Explanation 000 -- Vehicle speed Tachograph km Shows the vehicle speed as determined by the ta- chograph. Synchronous with the speedometer 0.000 to 255.000 km/h {0.000 to 158.4 mph} [Related parts] vehicle speed sensor 001 -- Vehicle speed ECU km Shows the vehicle speed as determined by the option connector Synchronous with the speedometer 0.000 to 255.000 km/h {0.000 to 158.4 mph} [Related parts] vehicle speed sensor No. Selection Explanation 000 Instrument cluster [Test method] Operate each indication in the meter cluster. [Checking method] The speedometer operates from 0 to maximum. It stops on the way for about 5 seconds at the 40 km/h {24.9 mph} point. The tachometer operates from 0 to maximum. It stops on the way for about 5 seconds at the 2000 rpm point. The fuel level gauge operates from 0 to full. It stops on the way for about 5 seconds at the one half point. The indicator lamp, illumination, multi-information display and buzzer cycle ON/OFF every 1 second. [Note] The test stops automatically when three rounds of inspection are completed. (Or, terminated using the stop button.) Rewriting coding data required Standards for rewriting meter cluster internal data Final gear When the final gear is changed, the meter cluster internal data must be updated. Rear tyre When the tyre size is changed, the meter cluster internal data must be updated. Anti-lock brake system When specifications of this system are changed, the meter cluster internal data must be updated. Meter cluster replacement All data (entire set of the latest history data for the vehicle) TROUBLESHOOTING ---===WSE_1506_00001_0558.djvu===--- 54EM 54EM-21 5. Electronic Control Unit Input/Output Table For the signal and earth terminal positions, see the circuit diagram for the electronic control unit. Connected unit Terminal I/O Voltage or waveform SAM (Starter switch (M terminal voltage)) 13 - Earth Input [Judgment criteria] Starter switch ON: Approx. 12 V (battery voltage) Starter switch OFF: 0 V SAM (Battery direct (B terminal voltage)) 2 - Earth Input [Judgment criteria] Constant: Approx. 12 V (battery voltage) Vehicle speed sensor 12-4 Input [Judgment criteria] Lo:0.8Vmax. Hi: Approx. 6.0 V ---===WSE_1506_00001_0559.djvu===--- 54ES-1 54ES SIGNAL DETECTED AND ACTUATION MODULES STRUCTURE AND OPERATION 1. Overview ..................................................................................54ES-2 2. Electronic Control System ........................................................54ES-4 3. Electronic Control Unit Circuit Diagram ..................................54ES-12 4. Diagnosis Code Occurrence Condition Range (List of Output Current Threshold Values) ......................................................54ES-21 TROUBLESHOOTING 1. Inspection Based on Diagnosis Codes ...................................54ES-24 2. FUSO Diagnostics Service Data (Actual Values) .....................54ES-54 3. FUSO Diagnostics Actuator Test (Actuations) ........................54ES-63 4. Coding Data in Electronic Control Unit ...................................54ES-63 5. Electronic Control Unit Input/Output Table .............................54ES-65 6. Confirmation items before replacing the signal detect and actuation module ..................................54ES-67 7. Symptoms and inspection procedures when warning lamp (red or amber) illuminates .......................54ES-70 INSPECTION OF RELAYS IN SIGNAL DETECT AND ACTUATION MODULE .................................................................54ES-73 INSPECTION OF ELECTRICAL PARTS . ................................(See Gr54.) INSTALLED LOCATIONS OF PARTS .....................................(See Gr54.) ELECTRIC CIRCUIT DIAGRAM ..............................................(See Gr54.) MEMO Contents of the "54-00C 5.Signal Detect and Actuation Modules","54-13 #985 INSPECTION OF SIGNAL DETECT AND ACTUATION MODULES" has been described as same group to Gr54EM. Content other than change bar is same as 00ELT0035. ---===WSE_1506_00001_0560.djvu===--- 54ES-2 1. Overview (The illustration shows the left-hand drive vehicle.) Signal detect and actuation modules contains conventional relays and fuses in the central processing unit and ef- fects integrated control of electric parts and power distribution. Basically, it has the following functions. Power supply and power distribution functions Detection of various control switch output signals (starter switch, combination switch, etc.) Detection of various detection switch output signals (stop lamp switch, clutch switch, etc.) Detection of various sensor output signals (fuel level sensor, etc.) Junction for controller area network communication between electronic control units Fault diagnosis function Open circuit detection function Various lighting control functions (blown bulb detection) Wiper & washer control Mirror (mirror heater) control STRUCTURE AND OPERATION ---===WSE_1506_00001_0560.djvu===--- 54ES-2 1. Overview (The illustration shows the left-hand drive vehicle.) Signal detect and actuation modules contains conventional relays and fuses in the central processing unit and ef- fects integrated control of electric parts and power distribution. Basically, it has the following functions. Power supply and power distribution functions Detection of various control switch output signals (starter switch, combination switch, etc.) Detection of various detection switch output signals (stop lamp switch, clutch switch, etc.) Detection of various sensor output signals (fuel level sensor, etc.) Junction for controller area network communication between electronic control units Fault diagnosis function Open circuit detection function Various lighting control functions (blown bulb detection) Wiper & washer control Mirror (mirror heater) control STRUCTURE AND OPERATION ---===WSE_1506_00001_0561.djvu===--- 54ES 54ES-3 CAUTION Before replacing the signal detect and actuation modules, associated fuses and relays, be sure to discon- nect (--) battery cable and protect the (--) battery terminal and (--) battery cable with insulating tape or the like. When a fuse is blown, identify the cause and repair to remove it completely. Then, install a new fuse. Be sure to use the fuse of designated ampere. To remove a spare fuse, insert a fuse puller from outside the wall holding the spare fuse. Inserting the fuse puller from inside the wall may damage the signal detect and actuation modules, resulting in system malfunction or a fire. Connect the (+) and (--) cables to the battery at right terminals. Wrong connection causes an excessive current to the signal detect and actuation modules, damaging internal elements and circuits. ---===WSE_1506_00001_0562.djvu===--- 54ES-4 2. Electronic Control System 2.1 System block diagram STRUCTURE AND OPERATION ---===WSE_1506_00001_0563.djvu===--- 54ES 54ES-5 2.2 Input and output signals list by signal detect and actuation modules functions Function Input Output Remarks Back buzzer Starter switch Back light switch Back buzzer Buzzer in meter cluster Electronic control units See Gr54 . Gearbox neutral gear Starter switch Neutral signal (controller area network signal) Option connector: Gearbox neutral switch 12 V/24 V -- Power take-off subsystem Starter switch Gearbox power take-off switch (cab) Power take-off control switch (chassis), dump lever switch (cab) Clutch switch <Manual gearbox vehicles> Gearbox power take-off 3-way magnetic valve <Manual gear- box vehicles> Option connector: Power take- off 12 V/24 V Electronic control units See Gr54 . Backup switch signal output Starter switch Backup lamp switch Option connector: Backup light switch Trailer backup lamp relay -- Parking brake switch output Starter switch Parking brake switch Option connector: Parking brake switch cut-off -- Service brake switch Stop lamp switch N.O. (service brake switch 1) Stop lamp switch N.C. (service brake switch 2) Electronic control units See Gr54 , , , . Parking brake switch Parking brake switch Electronic control units See Gr54 . Brake fluid level switch Brake fluid level switch Electronic control units See Gr54 . Vacuum flow switch Vacuum switch Electronic control units See Gr54 . Air conditioner compressor clutch & condenser fan motor Starter switch Air conditioner cut-off signal (controller area network signal) Air conditioner main switch Air conditioner condenser fan motor Dual pressure switch (air condi- tioner compressor clutch) See Gr54 . Air conditioner blower motor con- trol Starter switch Air conditioner cut-off signal (controller area network signal) Air conditioner blower motor Air conditioner blower motor earthing point See Gr54 . Door switch status Driver's seat side door switch Assistant driver's seat side door switch Rear door switch (left-hand, right-hand) Starter switch Electronic control units See Gr54 . Keyless entry Answer back signal (local inter- connect network communica- tion) Driver's seat side door switch Assistant driver's seat side door switch Rear door switch (left-hand, right-hand) Starter key insert Rear turn signal lamp (left- hand) Rear turn signal lamp (right- hand) Front turn signal lamp (left- hand) Front turn signal lamp (right- hand) Option connector: Side turn sig- nal lamp (left-hand) Option connector: Side turn sig- nal lamp (right-hand) Interior lamp See Gr54 , . Diesel Particulate Filter Diesel Particulate Filter cleaning switch Engine electronic control unit See Gr54 . Fuel level sensor Fuel level sensor Meter cluster See Gr54 . 340 850 325 790 873 880 510 515 515 620 620 345 115 654 880 420 ---===WSE_1506_00001_0564.djvu===--- 54ES-6 Function Input Output Remarks Starter switch & relay control Starter switch ACC Starter switch ON Starter switch CRANK Starter switch inserted Electronic control units [In signal detect and actuation modules] IGN RELAY ACC RELAY 12 V/24 V IGN RELAY (OP- TION) 12 V/24 V ACC RELAY (OPTION) See Gr54 , . Backup lamp Backup lamp switch Backup lamp (left-hand, right- hand) See Gr54 . Headlamp Starter switch Combination switch Idling stop and start system electronic control unit Dipped beam (left-hand) Dipped beam (right-hand) See Gr54 . Starter switch Combination switch Main beam (left-hand) Main beam (right-hand) Meter cluster Stop lamp Stop lamp switch N.O. (service brake switch 1) Stop lamp (left-hand) Stop lamp (right-hand) See Gr54 . Position lamp, license plate lamp, tail lamp Starter switch Combination switch Position lamp (left-hand) Position lamp (right-hand) License plate lamp (left-hand) License plate lamp (right-hand) Tail lamp (left-hand) Tail lamp (right-hand) Trailer tail lamp relay (RH) Trailer tail lamp relay (LH) See Gr54 . End-outline marker lamp (right- hand) End-outline marker lamp (left- hand) See Gr54 . Turn signal lamp, hazard lamp Hazard lamp switch Combination switch Rear turn signal lamp (left- hand) Rear turn signal lamp (right- hand) Front turn signal lamp (left- hand) Front turn signal lamp (right- hand) Option connector: Side turn sig- nal lamp (left-hand) Option connector: Side turn sig- nal lamp (right-hand) Meter cluster See Gr54 , . Fog lamp Combination switch Fog lamp switch Idling stop and start system electronic control unit Fog lamp (left-hand) Fog lamp (right-hand) Meter cluster See Gr54 . Cab lamp Driver's seat side door switch Assistant driver's seat side door switch Rear door switch (left-hand, right-hand) Starter switch Cab lamp (battery) Cab lamp (control) See Gr54 . Step lamp Driver's seat side door switch Assistant driver's seat side door switch Step lamp (driver's seat side) Step lamp (assistant driver's seat side) See Gr54 . 105 110 340 310 325 320 349 115 330 315 345 345 STRUCTURE AND OPERATION ---===WSE_1506_00001_0565.djvu===--- 54ES 54ES-7 Illumination lamp Combination switch Air conditioner control panel illu- mination Audio illumination Various control switches illumi- nation Option connector: Illumination chassis 12 V/24 V Option connector: Illumination body 12 V/24 V See Gr54 , . Alternator (L terminal) Alternator (L terminal) Meter cluster See Gr54 . Clutch switch (upper) Clutch switch Electronic control units See Gr54 . Key interlock Gear shift signal (controller area network line) Starter switch Key interlock solenoid: control See Gr54 . Wiper & washer Starter switch Combination switch Wiper motor (LOW) Wiper motor (HIGH) Washer motor (CONTROL) See Gr54 . Battery monitor (12 V battery volt- age) Battery Limitation of various functions at low voltage and overvoltage -- Horn Horn switch Horn battery [In signal detect and actuation modules] Horn relay See Gr54 . Mirror heater Mirror heater switch Mirror heater switch illumination Mirror heater on driver's seat side Mirror heater on assistant driv- er's seat side See Gr54 . Transfer four-wheel drive switch status Transfer four-wheel drive switch Meter cluster Anti-lock brake electronic con- trol unit See Gr54 . Head lamp leveling actuator Head lamp leveling switch Head lamp leveling actuator, RH Head lamp leveling actuator, LH See Gr54 . Day time running lamp Combination switch Starter switch Front fog lamp switch Daytime running lamp, RH Daytime running lamp, LH See Gr54 . Rear fog lamp Combination switch Front fog lamp swich Rear fog lamp swich Rear fog lamp, RH Rear fog lamp, LH Trailer rear fog lamp relay Meter cluster See Gr54 . Cab tilt signal switch Cab tilt lock switch Meter cluster See Gr54 . Function Input Output Remarks 115 348 125 880 873 614 616 629 810 312 313 315 550 ---===WSE_1506_00001_0566.djvu===--- 54ES-8 Function Input Output Remarks Power distribu- tion module: J: accessory re- lay output Fuse F15 -- DUONIC electronic control unit accessory Audio accessory Shift lever unit relay drive See Gr54 , . Fuse F16 -- Cigarette lighter accessory Motor-driven retractable mirror Power distribu- tion module: E: IGN relay out- put Fuse F22 -- Meter cluster IGN Tachograph IGN Air conditioner IGN Rear air conditioner IGN Battery equaliser IGN See Gr54 , , . Fuse F18 -- Hydraulic unit (electronic control unit) IGN1 Fuse F19 -- Engine electronic control unit IGN Fuse F3 -- Airbag electronic control unit IGN Fuse F24 -- DUONIC electronic control unit IGN1 DUONIC electronic control unit IGN2 Shift lever 1 IGN1 Shift lever 2 IGN2 Fuse F20 -- Front drive switch Idling stop and start system electronic control unit IGN Fuse F1 -- Starter relay Power distribu- tion module: H: Engine relay output Fuse F31 -- Engine battery control 1 Engine battery control 2 Engine battery control 3 See Gr54 , . Fuse F28 -- Engine actuator battery control Fuel heater relay drive Fuel pump relay drive Fuse F29/F30 -- Selective catalytic reduction battery control 1 Selective catalytic reduction battery control 2 Power distribu- tion module: C:24V/12V ACC relay (OP- TION) output Fuse F25 -- Option connector: ACC chassis 24 V/12 V Option connector: ACC body 24 V/12 V See Gr54 , , . Power distribu- tion module: D:24V/12V IGN relay (OP- TION) output Fuse F04 -- Option connector: Main chassis 24 V/12 V Option connector: Main body 24 V/12 V Alternator terminal R (24 V) Coupling device See Gr54 , , . Power distribu- tion module: 24 V/12 V bat- tery output Fuse F26 -- Option connector: Battery body 24 V/12 V Option connector: Battery chas- sis 24 V/12 V Coupling device 105 110 105 115 110 105 110 105 115 110 105 115 110 STRUCTURE AND OPERATION ---===WSE_1506_00001_0567.djvu===--- 54ES 54ES-9 Function Input Output Remarks Power distribu- tion module: 12 V BAT output Fuse F23 -- Trailer tail lamp RH See Gr54 , . Fuse F9 -- Meter cluster BAT Diagnosis connector BAT Combination switch BAT Fuse F12 -- Audio BAT Interior lamp BAT Fuse F13 -- Tachograph BAT Immobiliser electronic control unit BAT 2 Immobiliser electronic control unit BAT 1 Idling stop and start electronic control unit BAT Starter switch BAT Fuse F6 -- Trailer tail lamp LH Fuse F17 -- Fuel heater BAT Fuse F8 -- Trailer rear fog lamp Trailer back lamp Fuse F27 -- Fan clutch relay 1, 2 Fuse F10 -- DC/DC converter <Vehicles with idling stop and start sys- tem> Power distribu- tion module: A: A/C BLOW- ER RELAY out- put Fuse F11 -- Air conditioner blower motor See Gr54 , . Power distribu- tion module: B: HORN RE- LAY output Fuse F14 -- Horn switch Horn BATT See Gr54 , . Power distribu- tion module: G: A/C COMP COND. RELAY output Fuse F32 -- Air conditioner condenser fan motor relay drive Air conditioner condenser fan clutch See Gr54 , . Power distribu- tion module: F: FUEL PUMP RELAY output Fuse F28 -- Fuel pump control Fuel heater control See Gr54 , . Fuse F34 -- Fuel pump BAT Power distribu- tion module: Power window supply Fuse F5 -- Power window BAT driver's seat side See Gr54 , . Fuse F7 -- Power window BAT assistant driver's seat side Communication Controller area network - Cabin Controller area network - Chas- sis Controller area network - Diag- nosis Various local interconnect net- work lines Controller area network - Cabin Controller area network - Chas- sis Controller area network - Diag- nosis Various local interconnect net- work lines -- Signal detect and actuation mod- ules supply Signal detect and actuation modules 12 V BAT Signal detect and actuation modules 24 V/12 V BAT Signal detect and actuation modules 12 V ENG BAT -- See Gr54 , , . Earthing Signal detect and actuation modules earth Earth, body harness, POWER Earth, body harness, SIGNAL Earth, central harness Earth, various electronic control units 105 110 105 110 105 110 105 110 105 110 105 110 105 110 130 ---===WSE_1506_00001_0568.djvu===--- 54ES-10 2.3 Fault diagnosis function The driver is informed of faults in the signal detect and actuation modules through the multi-information display in the meter cluster. Details of diagnosis codes can be called out through the multi-informa- tion display in the meter cluster and the FUSO Diagnostics (diagnosis con- nector). (See Gr54-00A.) STRUCTURE AND OPERATION ---===WSE_1506_00001_0569.djvu===--- 54ES-11 54ES MEMO ---===WSE_1506_00001_0570.djvu===--- 54ES-12 3. Electronic Control Unit Circuit Diagram C10040-ECU-54ES-1 OPT. SIDE TURN RH OPT. SIDE TURN LH FRONT TURN RH FRONT TURN LH POWER GND POWER GND HAZARD SW ILLUMINATION COMB. SW BATT. BATT. COMB. SW LIN SIG LIN GND PARK BRK. SW VAC. SW SW (SIGNAL) GND BRK.FLUID LEVEL SW STATER SW(START) STARTER SW BATT. FRONT DOOR SW DRIVER FRONT DOOR SW ASSISTANT REAR DOOR SW BODY BUILDER POWER SOURCE ENGINE POWER SOURCE VEHICLE POWER SOURCE STARTER CONT. MAIN GND ON OFF BATT LIN SIG GND 13C4 12C7 14B4 1B9 16B4 1B18 15B4 14B8 2B8 18B21 18B23 18B6 15B1 2B2 18B7 15B15 3B3 15B18 15B3 15B2 9C1 8C2 10C1 8C1 1B5 HF22 HF03 HF01 HF06 HF22 HF03 HF01 HF06 1B3 1B18 14B8 GND ILL E ILL B MAIN ECU GND <RHD> POWER GND COMB. METER MAIN ILLUMINATION 3B5 BATT 1B11 <LHD> POWER GND 1B9 18B17 18B3 18B18 STARTER SW (ACC) STARTER SW (MAIN) KEY INSERTED SW K2 LOCK ACC ON START BAMSK1 Keyless With a key High-current fuse box High-current fuse box To meter cluster To starter Starter relay (Solenoid type) Rear door switch RH Rear door switch LH Front door switch (Driver's seat side) Strarter switch Front door switch (Assistant driver's seat side) Parking brake switch Optional connector Optional connector Front and side turn signal lamp (Driver's seat side) Front and side turn signal lamp (Assistant driver's seat side) Hazard switch Engine electronic control unit Combination switch Vacuum switch Brake fluid level switch Signal detect and actuation modules Battery Starter relay (for drive) <Vehicle without battery equaliser> Battery <Vehicle with battery equaliser> Battery Tachograph STRUCTURE AND OPERATION ---===WSE_1506_00001_0571.djvu===--- 54ES 54ES-13 C10040-ECU-54ES-2 6 5 4 3 2 1 1 2 3 4 5 6 2 1 1 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 5 1 6 2 7 3 8 4 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 POSITION LAMP LH POWER GND CENTRE HARNESS GND POSITION LAMP RH FRONT FOG LAMP RH FRONT FOG SW POWER GND <RHD> FRONT FOG LAMP LH ILLUMINATION ON OFF Position Position 15B10 15B11 12C6 13C2 14B8 15B16 1B18 1B18 1B9 REAR FOG SW ON OFF 15B8 DAYTIME RUNNING LAMP RH DAYTIME RUNNING LAMP LH 13C3 12C9 POWER GND <LHD> 1B9 BACKUP LAMP STOP LAMP RH STOP LAMP LH TAIL LAMP RH TAIL LAMP LH REAR TURN LAMP RH REAR TURN LAMP LH LICENSE PLATE LAMP LH BACK BUZZER Backup Turn Stop 13C6 13C7 12C3 13C5 12C1 13C8 12C4 13C9 11C6 LICENSE PLATE LAMP RH 12C5 Fog Tail Backup Turn Stop Fog Tail 12C2 REAR FOG LAMP RH/LH 6X3 6X5 12C10 13C1 12C8 5C14 2B1 2B5 2B5 14B8 15B28 1B18 BATT GND(BATT) MAIN GND(MAIN) TURN RH TURN LH STOP LAMP GND(LAMP) TAIL RH TAIL LH BACK LAMP REAR FOG BODY BUILDER OPT BATT BODY BUILDER OPT MAIN TRAILER TURN LAMP RH TRAILER TURN LAMP LH TRAILER STOP LAMP TRAILER TAIL-L LH BATT TRAILER BACK-L BATT TRILER REAR FOG-L BATT ILLUMINATION REVERSE SW SIG POWER GND <RHD> TRAILER TAIL-L RH BATT 1B9 POWER GND <LHD> Harness connector Fog lamp switch Headlamp, LH Headlamp, RH Signal detect and actuation modules Fog lamp, RH Fog lamp, LH Rear fog lamp switch Daytime running lamp, RH Daytime running lamp, LH Rear combination lamp, RH Rear combination lamp, LH license plate lamp, LH Backup buzzer License plate lamp, RH Trailer tail lamp relay, RH Trailer tail lamp relay, LH Trailer back lamp relay Trailer rear fog lamp relay Coupling device 6X 1B 12C 2B 3B 5C 8C 9C 10C 11C 13C 14B 15B 18B 16B ---===WSE_1506_00001_0572.djvu===--- 54ES-14 C10040-ECU-54ES-3 <LHD> POWER GND 15B13 1B9 1B18 14B8 POWER GND POWER GND HEADLAMP LEVELING ACT. ILLUMINATION <RHD> <RHD> <LHD> <LHD> AUDIO BATT. BLOWER MOTOR BATT. BLOWER MOTOR GND 1B3 18B24 18B23 1B18 1B4 3B8 5C11 5C9 7C8 F36 F37 CLU ACC. DUONIC ACC. DUONIC ECU MAIN 1 DUONIC ECU MAIN 2 <RHD> POWER GND <RHD> POWER GND DUONIC SHIFT LEVER MAIN 2 ECU GND CLU LIN SIG LIN GND ILLUMINATION *12 *12 *12 *12 *13 *13 *13 *13 *13 *13 2B14 3B4 1B18 3B1 1B11 14B8 15B17 18B14 18B27 CABIN CAN-H CABIN CAN-L A/C SW COMB. METER MAIN 1B15 1B3 AIR BAG MAIN CAN CAN ECU GND 1B9 <LHD> POWER GND 1B9 Headlamp leveling actuator, RH Headlamp leveling actuator, LH Headlamp leveling switch *12:Fully automatic air conditioner *13:Manual air conditioner DUONIC electronic control unit Shift lever unit Shift lever unit relay ECO mode switch High current fuse box Signal detect and actuation modules Blower motor Fresh/recirculation changeover motor Air conditioner electronic control unit and control panel Power MOS-FET (Transistor) To meter cluster Controller area network resistor (120Ω) Rear blower motor relay Rear heater switch Rear heater blower motor Blower resistor Airbag electronic control unit Battery STRUCTURE AND OPERATION ---===WSE_1506_00001_0573.djvu===--- 54ES 54ES-15 C10040-ECU-54ES-4 <M/G> 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15B14 2B10 15B12 2B6 11C8 11C1 11C3 STEP LAMP DRIVER STEP LAMP ASSISTANT POWER WINDOW ASSIST. GND POWER WINDOW DRIVER GND ALTERNATOR L FUEL LEVEL SEN. GND FUEL LEVEL SEN. L GND CAN-H CAN-L CAN-H CAN-L CAN-H CAN-L SIG GND GND SIG V 17B1 17B11 15B21 2B2 14B8 1B9 1B14 17B1 17B11 1B3 1B1 CHASSIS CAN-H CHASSIS CAN-L SPARE INPUT SWITCH DIGI SW (SIGNAL) GND ILLUMINATION POWER GND SPARE OUTPUT, IGN3 CHASSIS CAN-H CHASSIS CAN-L POWER GND DUONIC SHIFT LEVER MAIN 1 5C3 ALTERNATOR R R L GND ECU GND ISS ECU MAIN ISS DC/DC CONVERTER BATT ISS BATT. POWER GND <RHD> ILLUMINATION VIN IGN SIG GND CAN-H CAN-L V OUT ST SIG DIAG 2B11 1B17 1B3 1B18 14B8 3B5 CAN-H CAN-L POWER GND <LHD> 1B9 ON OFF 5C 1B 2B 3B 7C 11C 14B 15B 18B 17B Step lamp (Driver's seat side) Step lamp (Assistant driver's seat side) Alternator (24V) Fuel level sensor Meter cluster Engine electronic control unit G sensor DUONIC eletronic control unit Signal detect and actuation modules Harness connector Alternator (12V) DC/DC converter <DUONIC > Idling stop and start system electronic control unit Idling stop and start system cutoff switch Hydraulic unit (electronic control unit) Lane departure warning system cutoff switch Lane recognition camera R ---===WSE_1506_00001_0574.djvu===--- 54ES-16 C10040-ECU-54ES-5 COMB. METER BATT. COMB. METER MAIN ECU GND CHASSIS CAN-H CHASSIS CAN-L CIGAR. LIGHTER ACC. CAB TILT LOCK SW SW(SIGNAL) GND 2B9 BATT IGN GND 1B11 1B3 17B1 17B11 3B13 18B10 2B2 EQUALISER MAIN MAIN IND EQUALISER IND 5C1 PTO SW POWER GND <RHD> 18B5 1B18 POWER GND <LHD> 1B9 AUDIO ACC. AUDIO BATT. DIAG. CONN. GND 1 DIAG. CONN. GND 2 DIAG. CONN. BATT. OPT. MAIN CHASSIS COMP. M/C BATT. DIAGNOSTIC CAN-H DIAGNOSTIC CAN-L BRK. SW(N.O.) BRK. SW(N.C.) ILLUMINATION OPT. ACC. CHASSIS OPT. BATT. CHASSIS OPT. ILL. CHASSIS HORN SW DPF SW KEY INTERLOCK SOL(+) KEY INTERLOCK SOL(-) SW(SIGNAL)GND 3B1 3B10 14B8 17B8 15B24 6X3 6X1 6X5 POWER GND ILLUMINETION 14B8 1B18 6X4 17B17 2B2 18B4 15B19 2B7 2B12 1B2 18B16 18B1 7C12 15B20 RH LH Meter cluster Cab tilt lock switch Cigarette lighter Battery equaliser Gearbox power take-off switch Optional connector Horn switch Diagnosis connector Diesel particulate filter cleaning switch Stop lamp switch Dual pressure switch Magnetic clutch Key interlock solenoid Audio Signal detect and actuation modules To illumination End-outline marker lamp STRUCTURE AND OPERATION ---===WSE_1506_00001_0575.djvu===--- 54ES 54ES-17 C10040-ECU-54ES-6 CAN-L CAN-H 1B9 1B18 14B8 1B3 OFF ON V GND CAN-H CAN-L CAN-H CAN-L V GND CAN-H CAN-L ILLUMINATION POWER GND <RHD> POWER GND <LHD> ECU GND ECU GND COND. MOTOR RELAY DRIVE POWER GND <RHD> CABIN CAN-H CABIN CAN-L CHASSIS CAN-H ABS MAIN CHASSIS CAN-L CAN-H CAN-L CAN-H CAN-L PTO M/V HEADLAMP HI LH HEADLAMP LOW RH GND HEADLAMP LOW RH HEADLAMP HI RH PTO SW(CHASSIS) HORN BATT. WIPER WASHER MOTOR(+) WIPER WASHER MOTOR(-) WIPER PARKED SW IMMOBI. BATT. 2 IMMOBI. BATT. 1 HEADLAMP LOW LH GND HEADLAMP LOW LH WIPER MOTOR LOW WIPER MOTOR HI 1 2 3 4 5 6 6 5 4 3 2 1 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 5 1 6 2 7 3 8 4 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 HI LO S B GND F40 Dipped/ Main Dipped/ Main 16B5 16B1 17B16 17B5 17B6 5C2 17B1 17B11 13C10 7C5 11C9 3B7 3B6 1B3 18B14 18B27 7C11 1B18 16B8 16B7 14B7 14B2 14B3 16B2 REVERSE SW 11C2 CUT SW 1B9 POWER GND <LHD> MAIN M M M ESP/ASR cutoff switch <ESP > ESP SENSOR <ESP > Steering Wheel Angle sensor <ESP > R R R 1B 2B 3B 5C 6X 7C 11C 13C 14B 15B 18B 16B 17B To rear condenser fan relay (crew cab) High-current fuse box Condenser fan relay Condenser fan motor Battery Headlamp RH Headlamp LH Wiper motor Windscreen washer motor Hydraulic unit (Electronic control unit) Immobiliser electronic control unit Gearbox power take-off 3-way magnetic valve <Vacuum type> Power take-off control switch (Gearbox) Horn Signal detect and actuation modules Harness connector Backup lamp switch <Manual gearbox> ---===WSE_1506_00001_0576.djvu===--- 54ES-18 C10040-ECU-54ES-7 AUDIO BATT. KEYLESS ENTRY LIN SIG ECU GND POWER WINDOW ASSIST. BATT. POWER WINDOW ASSIST. GND P/W ASSISTANT SW LIN SIG POWER WINDOW DRIVER BATT. POWER WINDOW DRIVER GND P/W DRIVER SW LIN SIG CHASSIS CAN-H CHASSIS CAN-L CAN-H CAN-L COND. MOTOR RELAY DRIVE. BLOWER MOTOR BATT. ILLUMINATION SCR HEAT. POWER1 SCR HEAT. POWER2 F38 F37 3B1 18B22 1B3 2B3 2B6 18B19 2B14 14B8 11C7 7C6 7C4 7C11 17B11 2B10 1B7 18B20 17B1 T/F 4WD SW M High-current fuse box NOx sensor Gearbox power take-off 3-way magnetic valve Rear condenser fan relay Rear condenser fan motor Rear blower motor relay Rear blower motor relay (high) Rear blower motor relay (middle) Battery DUONIC electronic control unit Control panel (Rear air conditioner switch) Blower motor Urea heater power unit Blower resistor Transfer four-wheel drive switch Keyless entry electronic control unit Power window switch (Assistant driver's seat side) Door lock actuator (Assistant driver's seat side) Door lock actuator (Driver's seat side) Rear door lock actuator (Assistant driver's seat side) Rear door lock actuator (Driver's seat side) Power window switch (Driver's seat side) Signal detect and actuation modules STRUCTURE AND OPERATION ---===WSE_1506_00001_0577.djvu===--- 54ES 54ES-19 C10040-ECU-54ES-8 3B14 2B13 2B4 5C4 5C5 7C3 7C7 7C10 7C9 7C13 7C2 CAB LAMP BATT POWER GND <RHD> CAB LAMP CONT CLTCH SW (UPPER) SW (SIGNAL) GND MIRROR HEATER DRIVER MIRROR HEAT SW SW (SIGNAL) GND MIRROR HEATER SW ILL. FUEL PUMP BATT ENG.CONT.ACT FUEL HEATER BATT. FUEL HEATER RELAY CONTROL FAN CLUTCH RELAY ENG. ECU MAIN ENG. MAIN RLY CONT FUEL PUMP CONT ENG. ECU B1 ENG. ECU B2 ENG. ECU B3 ILLUMINATION 1B18 17B15 3B2 14B8 2B2 15B27 18B11 18B9 FRONT DRIVE SW 1B13 ILLUMINATION 14B8 2B2 14B1 POWER WINDOW DRIVER GND 2B10 MIRROR HEATER ASSISTANT 14B5 POWER WINDOW ASSIST. GND 2B6 OFF ON DOOR OFF ON DOOR OFF ON N ON OFF ON OFF SPOT(LH) DOOR CAB SPOT(RH) OFF POWER GND <LHD> 1B9 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 5 1 6 2 7 3 8 4 5 1 6 2 7 3 8 4 9 10 11 12 13 14 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 21 7 20 6 19 5 18 4 17 3 16 2 15 1 28 14 27 13 26 12 25 11 24 10 23 9 22 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 7 15 6 18 9 17 8 14 5 13 4 12 3 11 2 10 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 11C 1B 2B 3B 5C 7C 14B 15B 18B 16B 17B Fuel tank unit Fan clucth Fuel heater relay Fan clutch relay 1 Fan clutch relay 2 Fuel filter Engine electronic control unit Rear cab lamp (crew cab) Mirror heater switch Front drive switch Clutch switch Mirror heater connector (Driver's seat side) Four-wheel drive 3-way magnetic valve Mirror heater connector (Assistant driver's seat side) Cruise control relay Cab lamp Cruise control main switch Cab and spot lamp Harness connector Two-wheel drive 3-way magnetic valve Signal detect and actuation modules ---===WSE_1506_00001_0578.djvu===--- 54ES-20 C10040-ECU-54ES-9 8C 9C 11C 12C 10C 13C 14B 17B 16B 15B 18B 7C 3B 2B 1B 4X 5C 6X STRUCTURE AND OPERATION ---===WSE_1506_00001_0579.djvu===--- 54ES 54ES-21 4. Diagnosis Code Occurrence Condition Range (List of Output Current Threshold Values) CAUTION Install genuine parts only. Mounting a non-genuine part may cause a diagnosis code to occur. Diagnosis code occurrence condition range of each connection device Connection device output current threshold values Terminal Devices to be connected Imin g (A) Imax g (A) Imin DTC (A) Imax DTC (A) 12C-7 Option connector (side turn lamp (LH)) *1 1.1 2.3 0.5 3.7 13C-4 Option connector (side turn lamp (RH)) *1 1.1 2.3 0.6 3.7 4X-5 Option connector (body illumination) *1 0 3.8 0 6.3 *2 7.3 *3 6X-4 Option connector (chassis illumination) *1 0 3.8 0 6.3 *2 7.3 *3 13C-10 Gearbox power take-off 3-way magnetic valve 0.4 1 0.2 1.7 14B-1 Mirror heater (RH) *1 2.7 7.7 0.7 13.5 13C-6 Backup lamp 2.2 4.7 1.1 8.2 16B-2 Head lamp high beam (LH) 2.9 6.5 0.8 11.7 14B-7 Head lamp high beam (RH) 2.9 6.5 0.8 11.7 14B-2 Head lamp low beam (LH) 2.9 6 0.8 10.9 16B-8 Head lamp low beam (RH) 2.9 6 0.8 10.9 12C-9 Daytime running lamp (RH) 1.1 2.3 0.5 4 13C-3 Daytime running lamp (LH) 1.1 2.3 0.5 4 12C-1 Stop lamp (LH) 1.1 2.3 0.5 3.7 13C-7 Stop lamp (RH) 1.1 2.3 0.5 3.7 15B-10 Parking lamp (LH) 0.3 0.5 0.1 1 15B-11 Parking lamp (RH) 0.3 0.5 0.1 1 13C-8 Tail lamp (LH) 0.3 1.3 0.1 2.4 ---===WSE_1506_00001_0580.djvu===--- 54ES-22 Terminal positions (See section 5.4) *1: Enabled when the option is mounted or parameters are set using coding. *2: Vehicle with battery equaliser. *3: Vehicle without battery equaliser. *4: Specify the limit at a battery voltage of 13 V. *5: Specify the limit at a battery voltage of 13 V and to a short-circuit to 10m earth. 12C-3 Tail lamp (RH) 0.3 1.3 0 2.2 12C-4 Rear turn lamp (LH) 1.1 2.3 0.5 3.7 13C-5 Rear turn lamp (RH) 1.1 2.3 0.5 3.7 16B-4 Front turn lamp (LH) 1.1 2.3 0.5 3.7 14B-4 Front turn lamp (RH) 1.1 2.3 0.5 3.9 12C-6 Front fog lamp (RH) 2.9 6 0.8 10.9 12C-2 Rear fog lamp (LH), (RH) 1.1 4.7 0.2 8.7 15B-13 Headlamp leveling actuator (LH), (RH) 0 1.5 0 2.4 15B-12 Step lamp (RH) 0.3 0.5 0.1 0.9 15B-14 Step lamp (LH) 0.3 0.5 0.1 0.9 14B-8 Illumination lamp 0 3.9 0 6.7 16B-5 Wiper motor (Hi) 0.7 11.6 0.1 19.2 16B-1 Wiper motor (Lo) 0.5 7.7 0 13.3 17B-5 Wiper washer motor 1.7 4.9 0.4 8.9 13C-9 License plate lamp 0.3 1.1 0.1 1.8 12C-5 License plate lamp (RH) 0.3 1.1 0 1.9 13C-2 Front fog lamp (LH) 2.9 6 0.8 10.9 12C-8 Coupling device (stop lamp) *1 2.2 4.5 0.6 8.4 13C-1 Coupling device (turn lamp (LH)) *1 1.1 2.3 0.5 3.9 12C-10 Coupling device (turn lamp (RH)) *1 1.1 2.3 0.5 3.7 14B-5 Mirror heater (LH) *1 2.7 7.7 0.7 13.5 11C-6 Backup buzzer *1 -- 0.4 *5 -- 0.9 *5 15B-27 Mirror heater switch illumination *1 -- 0.4 *5 -- 0.9 *5 17B-17 Key interlock solenoid -- 4.2 -- 7.4 17B-15 Cab lamp -- 6*4 -- 12 *4 16B-5 Wiper interval control switch -- 12 *4 -- 36 *4 Terminal Devices to be connected Imin g (A) Imax g (A) Imin DTC (A) Imax DTC (A) STRUCTURE AND OPERATION ---===WSE_1506_00001_0581.djvu===--- 54ES-23 54ES MEMO ---===WSE_1506_00001_0582.djvu===--- 54ES-24 1. Inspection Based on Diagnosis Codes The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. When the FUSO Diagnostics is connected, perform the interac- tive troubleshooting with the following procedure. Select the code from the diagnostics code list  Click the test button  Start the interactive troubleshooting 1.1 List of diagnosis codes Code Message Warning lamp indication Remarks (red) (amber) 2372-4 Left rear brake light - Insufficient voltage or short circuit to ground - O 2372-5 Left rear brake light - The current strength is too low or there is an open circuit. -O 2374-4 Right rear brake light - Insufficient voltage or short circuit to ground - O 2374-5 Right rear brake light - The current strength is too low or there is an open circuit. -O 521985-4 BBC Left turn signal lamp Short circuit to ground - Insufficient voltage or short circuit to ground -- 521985-5 BBC Left turn signal lamp Open circuit - The current strength is too low or there is an open circuit. -- 521986-4 BBC Right turn signal lamp Short circuit to ground - Insufficient volt- age or short circuit to ground -- 521986-5 BBC Right turn signal lamp Open circuit - The current strength is too low or there is an open circuit. -- 521987-4 Interior illumination - Insufficient voltage or short circuit to ground - - 521988-4 Exterior illumination - Insufficient voltage or short circuit to ground - - 521989-4 Switches BBC Backup warning system Short circuit to ground - Insuffi- cient voltage or short circuit to ground -- 521990-4 3/2-way valve 'Power take-off' - Insufficient voltage or short circuit to ground -- 521990-5 3/2-way valve 'Power take-off' - The current strength is too low or there is an open circuit. -- 521992-4 Mirror heater Driver side - Insufficient voltage or short circuit to ground - - 521994-4 Backup lamp - Insufficient voltage or short circuit to ground - - 521994-5 Backup lamp - The current strength is too low or there is an open cir- cuit. -- 521995-4 Left high beam - Insufficient voltage or short circuit to ground - - 521995-5 Left high beam - The current strength is too low or there is an open cir- cuit. -- 521996-4 Right high beam - Insufficient voltage or short circuit to ground - - 521996-5 Right high beam - The current strength is too low or there is an open circuit. -- TROUBLESHOOTING ---===WSE_1506_00001_0582.djvu===--- 54ES-24 1. Inspection Based on Diagnosis Codes The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. When the FUSO Diagnostics is connected, perform the interac- tive troubleshooting with the following procedure. Select the code from the diagnostics code list  Click the test button  Start the interactive troubleshooting 1.1 List of diagnosis codes Code Message Warning lamp indication Remarks (red) (amber) 2372-4 Left rear brake light - Insufficient voltage or short circuit to ground - O 2372-5 Left rear brake light - The current strength is too low or there is an open circuit. -O 2374-4 Right rear brake light - Insufficient voltage or short circuit to ground - O 2374-5 Right rear brake light - The current strength is too low or there is an open circuit. -O 521985-4 BBC Left turn signal lamp Short circuit to ground - Insufficient voltage or short circuit to ground -- 521985-5 BBC Left turn signal lamp Open circuit - The current strength is too low or there is an open circuit. -- 521986-4 BBC Right turn signal lamp Short circuit to ground - Insufficient volt- age or short circuit to ground -- 521986-5 BBC Right turn signal lamp Open circuit - The current strength is too low or there is an open circuit. -- 521987-4 Interior illumination - Insufficient voltage or short circuit to ground - - 521988-4 Exterior illumination - Insufficient voltage or short circuit to ground - - 521989-4 Switches BBC Backup warning system Short circuit to ground - Insuffi- cient voltage or short circuit to ground -- 521990-4 3/2-way valve 'Power take-off' - Insufficient voltage or short circuit to ground -- 521990-5 3/2-way valve 'Power take-off' - The current strength is too low or there is an open circuit. -- 521992-4 Mirror heater Driver side - Insufficient voltage or short circuit to ground - - 521994-4 Backup lamp - Insufficient voltage or short circuit to ground - - 521994-5 Backup lamp - The current strength is too low or there is an open cir- cuit. -- 521995-4 Left high beam - Insufficient voltage or short circuit to ground - - 521995-5 Left high beam - The current strength is too low or there is an open cir- cuit. -- 521996-4 Right high beam - Insufficient voltage or short circuit to ground - - 521996-5 Right high beam - The current strength is too low or there is an open circuit. -- TROUBLESHOOTING ---===WSE_1506_00001_0583.djvu===--- 54ES 54ES-25 521997-4 Left low beam - Insufficient voltage or short circuit to ground - - 521997-5 Left low beam - The current strength is too low or there is an open cir- cuit. -- 521998-4 Right low beam - Insufficient voltage or short circuit to ground - - 521998-5 Right low beam - The current strength is too low or there is an open circuit. -- 521999-4 Left daytime running light - Insufficient voltage or short circuit to ground -O 521999-5 Left daytime running light - The current strength is too low or there is an open circuit. -O 522000-4 Right daytime running light - Insufficient voltage or short circuit to ground -O 522000-5 Right daytime running light - The current strength is too low or there is an open circuit. -O 522003-4 Left standing light - Insufficient voltage or short circuit to ground - O 522003-5 Left standing light - The current strength is too low or there is an open circuit. -O 522004-4 Right standing light - Insufficient voltage or short circuit to ground - O 522004-5 Right standing light - The current strength is too low or there is an open circuit. -O 522005-4 Left taillamp - Insufficient voltage or short circuit to ground - O 522005-5 Left taillamp - The current strength is too low or there is an open cir- cuit. -O 522006-4 Right taillamp - Insufficient voltage or short circuit to ground - O 522006-5 Right taillamp - The current strength is too low or there is an open cir- cuit. -O 522007-4 Left rear turn signal lamp - Insufficient voltage or short circuit to ground -- 522007-5 Left rear turn signal lamp - The current strength is too low or there is an open circuit. -- 522008-4 Right rear turn signal lamp - Insufficient voltage or short circuit to ground -- 522008-5 Right rear turn signal lamp - The current strength is too low or there is an open circuit. -- 522009-4 Left turn signal lamp (front and side) - Insufficient voltage or short cir- cuit to ground -- 522009-5 Left turn signal lamp (front and side) - The current strength is too low or there is an open circuit. -- 522010-4 Right turn signal lamp (front and side) - Insufficient voltage or short cir- cuit to ground -- 522010-5 Right turn signal lamp (front and side) - The current strength is too low or there is an open circuit. -- 522011-4 Right front fog lamp - Insufficient voltage or short circuit to ground - - 522011-5 Right front fog lamp - The current strength is too low or there is an open circuit. -- 522012-4 Rear fog lamp - Insufficient voltage or short circuit to ground - O 522012-5 Rear fog lamp - The current strength is too low or there is an open cir- cuit. -O 522013-4 Electric motor "Left automatic headlamp adjustment", Electric motor "Right automatic headlamp adjustment" - Insufficient voltage or short circuit to ground -- Code Message Warning lamp indication Remarks (red) (amber) ---===WSE_1506_00001_0584.djvu===--- 54ES-26 522014-4 Passenger side Step illumination - Insufficient voltage or short circuit to ground -- 522014-5 Passenger side Step illumination - The current strength is too low or there is an open circuit. -- 522015-4 Driver side Step illumination - Insufficient voltage or short circuit to ground -- 522015-5 Driver side Step illumination - The current strength is too low or there is an open circuit. -- 522016-4 Cabin button illumination - Insufficient voltage or short circuit to ground - - 522017-4 Wiper motor - Insufficient voltage or short circuit to ground - - 522017-5 Wiper motor - The current strength is too low or there is an open cir- cuit. -- 522020-4 Left license plate lamp - Insufficient voltage or short circuit to ground - O 522020-5 Left license plate lamp - The current strength is too low or there is an open circuit. -O 522021-4 Right license plate lamp - Insufficient voltage or short circuit to ground - O 522021-5 Right license plate lamp - The current strength is too low or there is an open circuit. -O 522022-4 Left front fog lamp - Insufficient voltage or short circuit to ground - - 522022-5 Left front fog lamp - The current strength is too low or there is an open circuit. -- 522023-4 Brake light of trailer - Insufficient voltage or short circuit to ground - O 522023-5 Brake light of trailer - The current strength is too low or there is an open circuit. -O 522024-4 Left turn signal lamp for trailer - Insufficient voltage or short circuit to ground -- 522024-5 Left turn signal lamp for trailer - The current strength is too low or there is an open circuit. -- 522025-4 Right turn signal lamp for trailer - Insufficient voltage or short circuit to ground -- 522025-5 Right turn signal lamp for trailer - The current strength is too low or there is an open circuit. -- 522026-4 Mirror heater Passenger side - Insufficient voltage or short circuit to ground -- 522027-3 Interior lamp - Excessive voltage or short circuit to positive - - 522028-4 Mirror heater Switches - Insufficient voltage or short circuit to ground - - 522030-4 Warning buzzer (Backup warning system) - Insufficient voltage or short circuit to ground -- 522032-4 BBC Power take-off Short circuit to ground - Insufficient voltage or short circuit to ground -- 522033-4 BBC Switch 'TCM Neutral position' Short circuit to ground - Insufficient voltage or short circuit to ground -- 522034-4 BBC Switch 'Parking brake' Short circuit to ground - Insufficient volt- age or short circuit to ground -- 522038-5 Blower motor Relays - The current strength is too low or there is an open circuit. -O 522039-5 Relay 'Power supply for optional bodies' (ACC) - The current strength is too low or there is an open circuit. -O 522040-5 Starter signal Relays (IGN) - The current strength is too low or there is an open circuit. O- Code Message Warning lamp indication Remarks (red) (amber) TROUBLESHOOTING ---===WSE_1506_00001_0585.djvu===--- 54ES 54ES-27 522041-5 Starter signal Relays (ACC) - The current strength is too low or there is an open circuit. O- 522042-5 Relay 'Power supply for optional bodies' (IGN) - The current strength is too low or there is an open circuit. -O 522043-5 Refrigerant compressor Relays - The current strength is too low or there is an open circuit. -O 522064-25 DUONIC Control unit - The received data are implausible. - - 522066-25 Antilock brake system Control unit - The received data are implausi- ble. -- 522067-25 Combination switch - The received data are implausible. - O 522069-25 Combination switch - The received data are implausible. - - 522070-25 Combination switch - The received data are implausible. - - 522071-25 DUONIC Control unit - The received data are implausible. - - 522072-25 Automatic engine start/stop Control unit - The received data are im- plausible. -- 522073-25 Antilock brake system Control unit - The received data are implausi- ble. -- 522074-25 Combustion engine Control unit - The received data are implausible. - - 522075-25 Combustion engine Control unit - The received data are implausible. - - 522076-25 Combustion engine Control unit - The received data are implausible. - - 522077-25 Combination switch - The received data are implausible. - O 522078-25 Combination switch - The received data are implausible. - - 522079-25 Selector lever - The received data are implausible. - - 522080-25 Key less entry unit - The received data are implausible. - - 522081-25 Power window 'Driver door' Switches - The received data are implau- sible. -- 522082-25 Power window 'Front passenger door' Switches - The received data are implausible. -- 522097-2 Starter Switches (ACC) - Implausible data O - 522098-2 Starter Switches (ON) - Implausible data O - 522099-2 Starter Switches (START) - Implausible data O - 522112-3 The battery voltage is too high. - Excessive voltage or short circuit to positive O- 522112-4 The battery voltage is too low. - Insufficient voltage or short circuit to ground O- 522113-25 Combination switch - The received data are implausible. - - 522114-25 Combination switch - The received data are implausible. - - 522115-25 Power window 'Driver door' Switches - The received data are implau- sible. -- 522116-25 Power window 'Front passenger door' Switches - The received data are implausible. -- 522117-25 Key less entry unit - The received data are implausible. - - 522118-25 Selector lever - The received data are implausible. - - Code Message Warning lamp indication Remarks (red) (amber) ---===WSE_1506_00001_0586.djvu===--- 54ES-28 522133-17 Vacuum system Power take-off M/T - Activation Timeout error - - 522134-17 Vacuum system Power take-off M/T - Deactivation Timeout error - - 522135-17 Vacuum system Power take-off M/T - Deactivation No request - - 522136-17 Vacuum system Power take-off M/T - Activation No request - - 522138-25 Combination switch - The received data are implausible. - - 522139-25 Combination switch - The received data are implausible. - - 522140-25 Combination switch - The received data are implausible. - - 522141-25 Combination switch - The received data are implausible. - - 522142-4 Wiper motor - Insufficient voltage or short circuit to ground - - 522143-5 Wiper motor - The current strength is too low or there is an open cir- cuit. -- 522144-3 Wiper motor - Excessive voltage or short circuit to positive - - 522147-4 Ignition key Locking solenoid - Insufficient voltage or short circuit to ground -- 522148-17 Faulty part CPU inside component "Signal & ActuatorModule" - - 522149-17 Faulty part Memory inside component "Signal & ActuatorModule" O - 522150-17 Faulty component 'Signal & ActuatorModule' O - Code Message Warning lamp indication Remarks (red) (amber) TROUBLESHOOTING ---===WSE_1506_00001_0587.djvu===--- 54ES 54ES-29 1.2 Details of diagnosis codes 2372-4: Left rear brake light - Insufficient voltage or short circuit to ground 2372-5: Left rear brake light - The current strength is too low or there is an open circuit. 2374-4: Right rear brake light - Insufficient voltage or short circuit to ground 2374-5: Right rear brake light - The current strength is too low or there is an open circuit. 521985-4: BBC Left turn signal lamp Short circuit to ground - Insufficient voltage or short circuit to ground Generation condition Output current to stop lamp (left-hand) rises to range of 2.3 to 3.7 A or high- er. Recoverability System recovers when output current to stop lamp (left-hand) falls within range of 2.3 to 3.7 A or lower. Control effected by electronic control unit Output to stop lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between stop lamp (left-hand) and signal detect and actuation module Faulty stop lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to stop lamp (left-hand) falls to range of 0.5 to 1.1 A or lower. Recoverability System recovers when output current to stop lamp (left-hand) rises to range of 0.5 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between stop lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between stop lamp (left-hand) and signal detect and actuation module Faulty stop lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to stop lamp (right-hand) rises to range of 2.3 to 3.7 A or high- er. Recoverability System recovers when output current to stop lamp (right-hand) falls within range of 2.3 to 3.7 A or lower. Control effected by electronic control unit Output to stop lamp (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between stop lamp (right-hand) and signal detect and actuation module Faulty stop lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to stop lamp (right-hand) falls to range of 0.5 to 1.1 A or lower. Recoverability System recovers when output current to stop lamp (right-hand) rises to range of 0.5 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between stop lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between stop lamp (right-hand) and signal de- tect and actuation module Faulty stop lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to side turn signal lamp (left-hand) rises to range of 2.3 to 3.7 A or higher. Recoverability System recovers when output current to side turn signal lamp (left-hand) falls within range of 2.3 to 3.7 A or lower. Control effected by electronic control unit Output to side turn signal lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between side turn signal lamp (left-hand) and signal detect and actuation module Faulty side turn signal lamp (left-hand) Defective signal detect and actuation module ---===WSE_1506_00001_0588.djvu===--- 54ES-30 521985-5: BBC Left turn signal lamp Open circuit - The current strength is too low or there is an open circuit. 521986-4: BBC Right turn signal lamp Short circuit to ground - Insufficient voltage or short circuit to ground 521986-5: BBC Right turn signal lamp Open circuit - The current strength is too low or there is an open cir- cuit. 521987-4: Interior illumination - Insufficient voltage or short circuit to ground 521988-4: Exterior illumination - Insufficient voltage or short circuit to ground Generation condition Output current to side turn signal lamp (left-hand) falls to range of 0.5 to 1.1 A or lower. Recoverability System recovers when output current to side turn signal lamp (left-hand) ris- es to range of 0.5 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between side turn signal lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between side turn signal lamp (left-hand) and signal detect and actuation module Faulty side turn signal lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to side turn signal lamp (right-hand) rises to range of 2.3 to 3.7 A or higher. Recoverability System recovers when output current to side turn signal lamp (right-hand) falls within range of 2.3 to 3.7 A or lower. Control effected by electronic control unit Output to side turn signal lamp (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between side turn signal lamp (right-hand) and signal detect and actuation module Faulty side turn signal lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to side turn signal lamp (right-hand) falls to range of 0.5 to 1.1 A or lower. Recoverability System recovers when output current to side turn signal lamp (right-hand) rises to range of 0.5 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between side turn signal lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between side turn signal lamp (right-hand) and signal detect and actuation module Faulty side turn signal lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to body illumination lamp rises to range of 3.8 to 7.3 A or higher. Recoverability System recovers when output current to body illumination lamp falls within range of 3.8 to 7.3 A or lower. Control effected by electronic control unit Output to body illumination lamp is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between body illumination lamp (12 V) and signal detect and actuation module Faulty body illumination lamp (12 V) Defective signal detect and actuation module Generation condition Output current to chassis illumination lamp rises to range of 3.8 to 7.3 A or higher. Recoverability System recovers when output current to chassis illumination lamp falls within range of 3.8 to 7.3 A or lower. Control effected by electronic control unit Output to chassis illumination lamp is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between chas- sis illumination lamp (12 V) and signal detect and actuation module Faulty chassis illumination lamp (12 V) Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0589.djvu===--- 54ES 54ES-31 521989-4: Switches BBC Backup warning system Short circuit to ground - Insufficient voltage or short cir- cuit to ground 5521990-4: 3/2-way valve 'Power take-off' - Insufficient voltage or short circuit to ground 521990-5: 3/2-way valve 'Power take-off' - The current strength is too low or there is an open circuit. 521992-4: Mirror heater Driver side - Insufficient voltage or short circuit to ground 521994-4: Backup lamp - Insufficient voltage or short circuit to ground Generation condition Output current to backup lamp rises to range of 0.4 to 0.7 A or higher. Recoverability System recovers when output current to backup lamp falls within range of 0.4 to 0.7 A or lower. Control effected by electronic control unit Output to backup lamp is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between back- up lamp and signal detect and actuation module Faulty backup lamp Defective signal detect and actuation module Generation condition Output current to gearbox power take-off 3-way magnetic valve rises to range of 1.0 to 1.7 A or higher. Recoverability System recovers when output current to gearbox power take-off 3-way mag- netic valve falls within range of 1.0 to 1.7 A or lower. Control effected by electronic control unit Output to gearbox power take-off 3-way magnetic valve is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between gear- box power take-off 3-way magnetic valve and signal detect and actuation module Faulty gearbox power take-off 3-way magnetic valve Defective signal detect and actuation module Generation condition Output current to gearbox power take-off 3-way magnetic valve falls to range of 0.2 to 0.4 A or lower. Recoverability System recovers when output current to gearbox power take-off 3-way mag- netic valve rises to range of 0.2 to 0.4 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between gear- box power take-off 3-way magnetic valve and signal detect and actuation module Open-circuit in Plus harness between gearbox power take-off 3-way magnet- ic valve and signal detect and actuation module Faulty gearbox power take-off 3-way magnetic valve Defective signal detect and actuation module Generation condition Output current to mirror heater (driver side) rises to range of 7.7 to 13.5 A or higher. Recoverability System recovers when output current to mirror heater (driver side) falls with- in range of 7.7 to 13.5 A or lower. Control effected by electronic control unit Output to mirror heater (driver side) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between mirror heater (driver side) and signal detect and actuation module Faulty mirror heater (driver side) Defective signal detect and actuation module Generation condition Output current to backup lamp rises to range of 4.7 to 8.2 A or higher. Recoverability System recovers when output current to backup lamp falls within range of 4.7 to 8.2 A or lower. Control effected by electronic control unit Output to backup lamp is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between back- up lamp and signal detect and actuation module Faulty backup lamp Defective signal detect and actuation module ---===WSE_1506_00001_0590.djvu===--- 54ES-32 521994-5: Backup lamp - The current strength is too low or there is an open circuit. 521995-4: Left high beam - Insufficient voltage or short circuit to ground 521995-5: Left high beam - The current strength is too low or there is an open circuit. 521996-4: Right high beam - Insufficient voltage or short circuit to ground 521996-5: Right high beam - The current strength is too low or there is an open circuit. Generation condition Output current to backup lamp falls to range of 1.1 to 2.2 A or lower. Recoverability System recovers when output current to backup lamp rises to range of 1.1 to 2.2 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between back- up lamp and signal detect and actuation module Open-circuit in Plus harness between backup lamp and signal detect and ac- tuation module Faulty backup lamp Defective signal detect and actuation module Generation condition Output current to headlamp Hi (left-hand) rises to range of 6.5 to 11.7 A or higher. Recoverability System recovers when output current to headlamp Hi (left-hand) falls within range of 6.5 to 11.7 A or lower. Control effected by electronic control unit Output to headlamp Hi (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between head- lamp Hi (left-hand) and signal detect and actuation module Faulty headlamp Hi (left-hand) Defective signal detect and actuation module Generation condition Output current to headlamp Hi (left-hand) falls to range of 0.8 to 2.9 A or low- er. Recoverability System recovers when output current to headlamp Hi (left-hand) rises to range of 0.8 to 2.9 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between head- lamp Hi (left-hand) and signal detect and actuation module Open-circuit in Plus harness between headlamp Hi (left-hand) and signal de- tect and actuation module Faulty headlamp Hi (left-hand) Defective signal detect and actuation module Generation condition Output current to headlamp Hi (right-hand) rises to range of 6.5 to 11.7 A or higher. Recoverability System recovers when output current to headlamp Hi (right-hand) falls within range of 6.5 to 11.7 A or lower. Control effected by electronic control unit Output to headlamp Hi (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between head- lamp Hi (right-hand) and signal detect and actuation module Faulty headlamp Hi (right-hand) Defective signal detect and actuation module Generation condition Output current to headlamp Hi (right-hand) falls to range of 0.8 to 2.9 A or lower. Recoverability System recovers when output current to headlamp Hi (right-hand) rises to range of 0.8 to 2.9 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between head- lamp Hi (right-hand) and signal detect and actuation module Open-circuit in Plus harness between headlamp Hi (right-hand) and signal detect and actuation module Faulty headlamp Hi (right-hand) Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0591.djvu===--- 54ES 54ES-33 521997-4: Left low beam - Insufficient voltage or short circuit to ground 521997-5: Left low beam - The current strength is too low or there is an open circuit. 521998-4: Right low beam - Insufficient voltage or short circuit to ground 521998-5: Right low beam - The current strength is too low or there is an open circuit. 521999-4: Left daytime running light - Insufficient voltage or short circuit to ground Generation condition Output current to headlamp Lo (left-hand) rises to range of 6.0 to 10.9 A or higher. Recoverability System recovers when output current to headlamp Lo (left-hand) falls within range of 6.0 to 10.9 A or lower. Control effected by electronic control unit Output to headlamp Lo (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between head- lamp Lo (left-hand) and signal detect and actuation module Faulty headlamp Lo (left-hand) Defective signal detect and actuation module Generation condition Output current to headlamp Lo (left-hand) falls to range of 0.8 to 2.9 A or lower. Recoverability System recovers when output current to headlamp Lo (left-hand) rises to range of 0.8 to 2.9 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between head- lamp Lo (left-hand) and signal detect and actuation module Open-circuit in Plus harness between headlamp Lo (left-hand) and signal detect and actuation module Faulty headlamp Lo (left-hand) Defective signal detect and actuation module Generation condition Output current to headlamp Lo (right-hand) rises to range of 6.0 to 10.9 A or higher. Recoverability System recovers when output current to headlamp Lo (right-hand) falls with- in range of 6.0 to 10.9 A or lower. Control effected by electronic control unit Output to headlamp Lo (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between head- lamp Lo (right-hand) and signal detect and actuation module Faulty headlamp Lo (right-hand) Defective signal detect and actuation module Generation condition Output current to headlamp Lo (right-hand) falls to range of 0.8 to 2.9 A or lower. Recoverability System recovers when output current to headlamp Lo (right-hand) rises to range of 0.8 to 2.9 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between head- lamp Lo (right-hand) and signal detect and actuation module Open-circuit in Plus harness between headlamp Lo (right-hand) and signal detect and actuation module Faulty headlamp Lo (right-hand) Defective signal detect and actuation module Generation condition Output current to DRL lamp (left-hand) rises to range of 2.3 to 4.0 A or high- er. Recoverability System recovers when output current to DRL lamp (left-hand) falls within range of 2.3 to 4.0 A or lower. Control effected by electronic control unit Out put to DRL lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between DRL lamp (left-hand) and signal detect and actuation module Faulty DRL lamp (left-hand) Defective signal detect and actuation module ---===WSE_1506_00001_0592.djvu===--- 54ES-34 521999-5: Left daytime running light - The current strength is too low or there is an open circuit. 522000-4: Right daytime running light - Insufficient voltage or short circuit to ground 522000-5: Right daytime running light - The current strength is too low or there is an open circuit. 522003-4: Left standing light - Insufficient voltage or short circuit to ground 522003-5: Left standing light - The current strength is too low or there is an open circuit. Generation condition Output current to DRL lamp (left-hand) falls to range of 0.5 to 1.1 A or lower. Recoverability System recovers when output current to DRL lamp (left-hand) rises to range of 0.5 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between DRL lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between DRL lamp (left-hand) and signal detect and actuation module Faulty DRL lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to DRL lamp (right-hand) rises to range of 2.3 to 4.0 A or higher. Recoverability System recovers when output current to DRL lamp (right-hand) falls within range of 2.3 to 4.0 A or lower. Control effected by electronic control unit Out put to DRL lamp (right-hand) is stopped Possible causes Short-circuit to power, earth or another circuit in SIG harness between DRL lamp (right-hand) and signal detect and actuation module Faulty DRL lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to DRL lamp (right-hand) falls to range of 0.5 to 1.1 A or low- er. Recoverability System recovers when output current to DRL lamp (right-hand) rises to range of 0.5 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between DRL lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between DRL lamp (right-hand) and signal de- tect and actuation module Faulty DRL lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to parking lamp (left-hand) rises to range of 0.5 to 1.0 A or higher. Recoverability System recovers when output current to parking lamp (left-hand) falls within range of 0.5 to 1.0 A or lower. Control effected by electronic control unit Output to parking lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between park- ing lamp (left-hand) and signal detect and actuation module Faulty parking lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to parking lamp (left-hand) falls to range of 0.1 to 0.3 A or low- er. Recoverability System recovers when output current to parking lamp (left-hand) rises to range of 0.1 to 0.3 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between park- ing lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between parking lamp (left-hand) and signal de- tect and actuation module Faulty parking lamp (left-hand) Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0593.djvu===--- 54ES 54ES-35 522004-4: Right standing light - Insufficient voltage or short circuit to ground 522004-5: Right standing light - The current strength is too low or there is an open circuit. 522005-4: Left taillamp - Insufficient voltage or short circuit to ground 522005-5: Left taillamp - The current strength is too low or there is an open circuit. 522006-4: Right taillamp - Insufficient voltage or short circuit to ground Generation condition Output current to parking lamp (right-hand) rises to range of 0.5 to 1.0 A or higher. Recoverability System recovers when output current to parking lamp (right-hand) falls with- in range of 0.5 to 1.0 A or lower. Control effected by electronic control unit Output to parking lamp (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between park- ing lamp (right-hand) and signal detect and actuation module Faulty parking lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to parking lamp (right-hand) falls to range of 0.1 to 0.3 A or lower. Recoverability System recovers when output current to parking lamp (right-hand) rises to range of 0.1 to 0.3 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between park- ing lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between parking lamp (right-hand) and signal detect and actuation module Faulty parking lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to tail lamp (left-hand) rises to range of 1.3 to 2.4 A or higher. Recoverability System recovers when output current to tail lamp (left-hand) falls within range of 1.3 to 2.4 A or lower. Control effected by electronic control unit Output to tail lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between tail lamp (left-hand) and signal detect and actuation module Faulty tail lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to tail lamp (left-hand) falls to range of 0.1 to 0.3 A or lower. Recoverability System recovers when output current to tail lamp (left-hand) rises to range of 0.1 to 0.3 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between tail lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between tail lamp (left-hand) and signal detect and actuation module Faulty tail lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to tail lamp (right-hand) rises to range of 1.3 to 2.2 A or high- er. Recoverability System recovers when output current to tail lamp (right-hand) falls within range of 1.3 to 2.2 A or lower. Control effected by electronic control unit Output to tail lamp (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between tail lamp (right-hand) and signal detect and actuation module Faulty tail lamp (right-hand) Defective signal detect and actuation module ---===WSE_1506_00001_0594.djvu===--- 54ES-36 522006-5: Right taillamp - The current strength is too low or there is an open circuit. 522007-4: Left rear turn signal lamp - Insufficient voltage or short circuit to ground 522007-5: Left rear turn signal lamp - The current strength is too low or there is an open circuit. 522008-4: Right rear turn signal lamp - Insufficient voltage or short circuit to ground Generation condition Output current to tail lamp (right-hand) falls to range of 0.0 to 0.3 A or lower. Recoverability System recovers when output current to tail lamp (right-hand) rises to range of 0.0 to 0.3 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between tail lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between tail lamp (right-hand) and signal detect and actuation module Faulty tail lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to rear turn signal lamp (left-hand) rises to range of 2.3 to 3.7 A or higher. Recoverability System recovers when output current to rear turn signal lamp (left-hand) falls within range of 2.3 to 3.7 A or lower. Control effected by electronic control unit Output to rear turn signal lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between rear turn signal lamp (left-hand) and signal detect and actuation module Faulty rear turn signal lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to rear turn signal lamp (left-hand) falls to range of 0.5 to 1.1 A or lower. <In case of LED> Output current to rear turn signal lamp (left/right-hand) falls to range of 0.007 to 0.03 A or lower. Recoverability System recovers when output current to rear turn signal lamp (left-hand) ris- es to range of 0.5 to 1.1 A or higher. <In case of LED> System recovers when output current to rear turn signal lamp (left/right- hand) rises to range of 0.007 to 0.03 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between rear turn signal lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between rear turn signal lamp (left-hand) and signal detect and actuation module Faulty rear turn signal lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to rear turn signal lamp (right-hand) rises to range of 2.3 to 3.7 A or higher. Recoverability System recovers when output current to rear turn signal lamp (right-hand) falls within range of 2.3 to 3.7 A or lower. Control effected by electronic control unit Output to rear turn signal lamp (right-hand) is stopped Possible causes Short-circuit to power, earth or another circuit in SIG harness between rear turn signal lamp (right-hand) and signal detect and actuation module Faulty rear turn signal lamp (right-hand) Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0595.djvu===--- 54ES 54ES-37 522008-5: Right rear turn signal lamp - The current strength is too low or there is an open circuit. 522009-4: Left turn signal lamp (front and side) - Insufficient voltage or short circuit to ground 522009-5: Left turn signal lamp (front and side) - The current strength is too low or there is an open circuit. 522010-4: Right turn signal lamp (front and side) - Insufficient voltage or short circuit to ground Generation condition Output current to rear turn signal lamp (right-hand) falls to range of 0.5 to 1.1 A or lower. <In case of LED> Output current to rear turn signal lamp (left/right-hand) falls to range of 0.007 to 0.03 A or lower. Recoverability System recovers when output current to rear turn signal lamp (right-hand) rises to range of 0.5 to 1.1 A or higher. <In case of LED> System recovers when output current to rear turn signal lamp (left/right- hand) rises to range of 0.007 to 0.03 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between rear turn signal lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between rear turn signal lamp (right-hand) and signal detect and actuation module Faulty rear turn signal lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to front side turn signal lamp (left-hand) rises to range of 2.3 to 3.7 A or higher. Recoverability System recovers when output current to front side turn signal lamp (left- hand) falls within range of 2.3 to 3.7 A or lower. Control effected by electronic control unit Output to front side turn signal lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between front side turn signal lamp (left-hand) and signal detect and actuation module Faulty front side turn signal lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to front side turn signal lamp (left-hand) falls to range of 0.5 to 1.1 A or lower. Recoverability System recovers when output current to front side turn signal lamp (left- hand) rises to range of 0.5 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between front side turn signal lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between front side turn signal lamp (left-hand) and signal detect and actuation module Faulty front side turn signal lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to front side turn signal lamp (right-hand) rises to range of 2.3 to 3.9 A or higher. Recoverability System recovers when output current to front side turn signal lamp (right- hand) falls within range of 2.3 to 3.9 A or lower. Control effected by electronic control unit Output to front side turn signal lamp (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between front side turn signal lamp (right-hand) and signal detect and actuation module Faulty front side turn signal lamp (right-hand) Defective signal detect and actuation module ---===WSE_1506_00001_0596.djvu===--- 54ES-38 522010-5: Right turn signal lamp (front and side) - The current strength is too low or there is an open circuit. 522011-4: Right front fog lamp - Insufficient voltage or short circuit to ground 522011-5: Right front fog lamp - The current strength is too low or there is an open circuit. 522012-4: Rear fog lamp - Insufficient voltage or short circuit to ground 522012-5: Rear fog lamp - The current strength is too low or there is an open circuit. Generation condition Output current to front side turn signal lamp (right-hand) falls to range of 0.5 to 1.1 A or lower. Recoverability System recovers when output current to front side turn signal lamp (right- hand) rises to range of 0.5 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between front side turn signal lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between front side turn signal lamp (right-hand) and signal detect and actuation module Faulty front side turn signal lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to fog lamp (right-hand) rises to range of 6.0 to 10.9 A or high- er. Recoverability System recovers when output current to fog lamp (right-hand) falls within range of 6.0 to 10.9 A or lower. Control effected by electronic control unit Output to fog lamp (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between fog lamp (right-hand) and signal detect and actuation module Faulty fog lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to fog lamp (right-hand) falls to range of 0.8 to 2.9 A or lower. Recoverability System recovers when output current to fog lamp (right-hand) rises to range of 0.8 to 2.9 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between fog lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between fog lamp (right-hand) and signal detect and actuation module Faulty fog lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to rear fog lamp (left-hand, right-hand) rises to range of 4.7 to 8.7 A or higher. Recoverability System recovers when output current to rear fog lamp (left-hand, right-hand) falls within range of 4.7 to 8.7 A or lower. Control effected by electronic control unit Output to rear fog lamp (left-hand, right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between rear fog lamp (left-hand, right-hand) and signal detect and actuation module Faulty rear fog lamp (left-hand, right-hand) Defective signal detect and actuation module Generation condition Output current to rear fog lamp (left-hand, right-hand) falls to range of 0.2 to 1.1 A or lower. Recoverability System recovers when output current to rear fog lamp (left-hand, right-hand) rises to range of 0.2 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between rear fog lamp (left-hand, right-hand) and signal detect and actuation module Open-circuit in Plus harness between rear fog lamp (left-hand, right-hand) and signal detect and actuation module Faulty rear fog lamp (left-hand, right-hand) Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0597.djvu===--- 54ES 54ES-39 522013-4: Electric motor "Left automatic headlamp adjustment", Electric motor "Right automatic headlamp adjustment" - Insufficient voltage or short circuit to ground 522014-4: Passenger side Step illumination - Insufficient voltage or short circuit to ground 522014-5: Passenger side Step illumination - The current strength is too low or there is an open circuit. 522015-4: Driver side Step illumination - Insufficient voltage or short circuit to ground 522015-5: Driver side Step illumination - The current strength is too low or there is an open circuit. Generation condition Output current to headlamp leveling actuator rises to range of 1.5 to 2.4 A or higher. Recoverability System recovers when output current to headlamp leveling actuator falls within range of 1.5 to 2.4 A or lower. Control effected by electronic control unit Output to headlamp leveling actuator is stopped. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between rear headlamp leveling actuator and signal detect and actuation module Open-circuit in Plus harness between headlamp leveling actuator and signal detect and actuation module Faulty headlamp leveling actuator Defective signal detect and actuation module Generation condition Output current to step lamp (left-hand) rises to range of 0.5 to 0.9 A or high- er. Recoverability System recovers when output current to step lamp (left-hand) falls within range of 0.5 to 0.9 A or lower. Control effected by electronic control unit Output to step lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between step lamp (left-hand) and signal detect and actuation module Faulty step lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to step lamp (left-hand) falls to range of 0.1 to 0.3 A or lower. Recoverability System recovers when output current to step lamp (left-hand) rises to range of 0.1 to 0.3 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between step lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between step lamp (left-hand) and signal detect and actuation module Faulty step lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to step lamp (right-hand) rises to range of 0.5 to 0.9 A or high- er. Recoverability System recovers when output current to step lamp (right-hand) falls within range of 0.5 to 0.9 A or lower. Control effected by electronic control unit Output to step lamp (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between step lamp (right-hand) and signal detect and actuation module Faulty step lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to step lamp (right-hand) falls to range of 0.1 to 0.3 A or lower. Recoverability System recovers when output current to step lamp (right-hand) rises to range of 0.1 to 0.3 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between step lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between step lamp (right-hand) and signal de- tect and actuation module Faulty step lamp (right-hand) Defective signal detect and actuation module ---===WSE_1506_00001_0598.djvu===--- 54ES-40 522016-4: Cabin button illumination - Insufficient voltage or short circuit to ground 522017-4: Wiper motor - Insufficient voltage or short circuit to ground 522017-5: Wiper motor - The current strength is too low or there is an open circuit. 522020-4: Left license plate lamp - Insufficient voltage or short circuit to ground 522020-5: Left license plate lamp - The current strength is too low or there is an open circuit. Generation condition Output current to illumination lamp rises to range of 3.9 to 6.7 A or higher. Recoverability System recovers when output current to illumination lamp falls within range of 3.9 to 6.7 A or lower. Control effected by electronic control unit Output to illumination lamp is stopped. Possible causes Short-circuit to earth in harness between battery and signal detect and actu- ation module Malfunction of battery Faulty alternator Defective signal detect and actuation module Generation condition Output current to washer motor rises to range of 4.9 to 8.9 A or higher. Recoverability System recovers when output current to washer motor falls within range of 4.9 to 8.9 A or lower. Control effected by electronic control unit Output to washer motor is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between wash- er motor and signal detect and actuation module Faulty washer motor Defective signal detect and actuation module Generation condition Output current to washer motor falls to range of 0.4 to 1.7 A or lower. Recoverability System recovers when output current to washer motor rises to range of 0.4 to 1.7 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between wash- er motor and signal detect and actuation module Open-circuit in Plus harness between washer motor and signal detect and actuation module Faulty washer motor Defective signal detect and actuation module Generation condition Output current to license plate lamp (left-hand) rises to range of 1.1 to 1.8 A or higher. Recoverability System recovers when output current to license plate lamp (left-hand) falls within range of 1.1 to 1.8 A or lower. Control effected by electronic control unit Output to license plate lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between li- cense plate lamp (left-hand) and signal detect and actuation module Faulty license plate lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to license plate lamp (left-hand) falls to range of 0.1 to 0.3 A or lower. Recoverability System recovers when output current to license plate lamp (left-hand) rises to range of 0.1 to 0.3 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between li- cense plate lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between license plate lamp (left-hand) and sig- nal detect and actuation module Faulty license plate lamp (left-hand) Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0599.djvu===--- 54ES 54ES-41 522021-4: Right license plate lamp - Insufficient voltage or short circuit to ground 522021-5: Right license plate lamp - The current strength is too low or there is an open circuit. 522022-4: Left front fog lamp - Insufficient voltage or short circuit to ground 522022-5: Left front fog lamp - The current strength is too low or there is an open circuit. 522023-4: Brake light of trailer - Insufficient voltage or short circuit to ground Generation condition Output current to license plate lamp (right-hand) rises to range of 1.1 to 1.8 A or higher. Recoverability System recovers when output current to license plate lamp (right-hand) falls within range of 1.1 to 1.8 A or lower. Control effected by electronic control unit Output to license plate lamp (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between li- cense plate lamp (right-hand) and signal detect and actuation module Faulty license plate lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to license plate lamp (right-hand) falls to range of 0.1 to 0.3 A or lower. Recoverability System recovers when output current to license plate lamp (right-hand) rises to range of 0.1 to 0.3 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between li- cense plate lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between license plate lamp (right-hand) and signal detect and actuation module Faulty license plate lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to fog lamp (left-hand) rises to range of 6.0 to 10.9 A or high- er. Recoverability System recovers when output current to fog lamp (left-hand) falls within range of 6.0 to 10.9 A or lower. Control effected by electronic control unit Output to fog lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between fog lamp (left-hand) and signal detect and actuation module Faulty fog lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to fog lamp (left-hand) falls to range of 0.8 to 2.9 A or lower. Recoverability System recovers when output current to fog lamp (left-hand) rises to range of 0.8 to 2.9 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between fog lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between fog lamp (left-hand) and signal detect and actuation module Faulty fog lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to trailer stop lamp rises to range of 4.5 to 8.4 A or higher. Recoverability System recovers when output current to trailer stop lamp falls within range of 4.5 to 8.4 A or lower. Control effected by electronic control unit Output to trailer stop lamp is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between trailer stop lamp and signal detect and actuation module Faulty trailer stop lamp Defective signal detect and actuation module ---===WSE_1506_00001_0600.djvu===--- 54ES-42 522023-5: Brake light of trailer - The current strength is too low or there is an open circuit. 522024-4: Left turn signal lamp for trailer - Insufficient voltage or short circuit to ground 522024-5: Left turn signal lamp for trailer - The current strength is too low or there is an open circuit. 522025-4: Right turn signal lamp for trailer - Insufficient voltage or short circuit to ground 522025-5: Right turn signal lamp for trailer - The current strength is too low or there is an open circuit. Generation condition Output current to trailer stop lamp falls to range of 0.6 to 2.2 A or lower. Recoverability System recovers when output current to trailer stop lamp rises to range of 0.6 to 2.2 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between trailer stop lamp and signal detect and actuation module Open-circuit in Plus harness between trailer stop lamp and signal detect and actuation module Faulty trailer stop lamp Defective signal detect and actuation module Generation condition Output current to trailer turn lamp (left-hand) rises to range of 2.3 to 3.9 A or higher. Recoverability System recovers when output current to trailer turn lamp (left-hand) falls within range of 2.3 to 3.9 A or lower. Control effected by electronic control unit Output to trailer turn lamp (left-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between trailer turn lamp (left-hand) and signal detect and actuation module Faulty trailer turn lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to trailer turn lamp (left-hand) falls to range of 0.5 to 1.1 A or lower. Recoverability System recovers when output current to trailer turn lamp (left-hand) rises to range of 0.5 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between trailer turn lamp (left-hand) and signal detect and actuation module Open-circuit in Plus harness between trailer turn lamp (left-hand) and signal detect and actuation module Faulty trailer turn lamp (left-hand) Defective signal detect and actuation module Generation condition Output current to trailer turn lamp (right-hand) rises to range of 2.3 to 3.7 A or higher. Recoverability System recovers when output current to trailer turn lamp (right-hand) falls within range of 2.3 to 3.7 A or lower. Control effected by electronic control unit Output to trailer turn lamp (right-hand) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between trailer turn lamp (right-hand) and signal detect and actuation module Faulty trailer turn lamp (right-hand) Defective signal detect and actuation module Generation condition Output current to trailer turn lamp (right-hand) falls to range of 0.5 to 1.1 A or lower. Recoverability System recovers when output current to trailer turn lamp (right-hand) rises to range of 0.5 to 1.1 A or higher. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between trailer turn lamp (right-hand) and signal detect and actuation module Open-circuit in Plus harness between trailer turn lamp (right-hand) and sig- nal detect and actuation module Faulty trailer turn lamp (right-hand) Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0601.djvu===--- 54ES 54ES-43 522026-4: Mirror heater Passenger side - Insufficient voltage or short circuit to ground 522027-3: Interior lamp - Excessive voltage or short circuit to positive 522028-4: Mirror heater Switches - Insufficient voltage or short circuit to ground 522030-4: Warning buzzer (Backup warning system) - Insufficient voltage or short circuit to ground 522032-4: BBC Power take-off Short circuit to ground - Insufficient voltage or short circuit to ground Generation condition Output current to mirror heater (passenger side) rises to range of 7.7 to 13.5 A or higher. Recoverability System recovers when output current to mirror heater (passenger side) falls within range of 7.7 to 13.5 A or lower. Control effected by electronic control unit Output to mirror heater (passenger side) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between mirror heater (passenger side) and signal detect and actuation module Faulty mirror heater (passenger side) Defective signal detect and actuation module Generation condition Output current to room lamp rises to range of 6.0 to 12.0 A or higher. Recoverability System recovers when output current to room lamp falls within range of 6.0 to 12.0 A or lower. Control effected by electronic control unit Output to room lamp is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between room lamp and signal detect and actuation module Faulty room lamp Defective signal detect and actuation module Generation condition Output current to mirror heater switch (illuminated) rises to range of 0.4 to 0.9 A or higher. Recoverability System recovers when output current to mirror heater switch (illuminated) falls within range of 0.4 to 0.9 A or lower. Control effected by electronic control unit Output to mirror heater switch (illuminated) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between mirror heater switch (illuminated) and signal detect and actuation module Faulty mirror heater switch (illuminated) Defective signal detect and actuation module Generation condition Chip internal temperature rises abnormally high due to overcurrent generat- ed by full or partial short-circuit to earth. Recoverability System recovers when normal current flow is detected. Control effected by electronic control unit Output to back buzzer is stopped. Possible causes Open-circuit or short-circuit to power or earth in SIG harness between back buzzer and signal detect and actuation module Open-circuit in Plus harness between back buzzer and signal detect and ac- tuation module Faulty back buzzer Defective signal detect and actuation module Generation condition Output current to option connector (gearbox power take-off output) rises to range of 0.4 to 0.9 A or higher. Recoverability System recovers when output current to option connector (gearbox power take-off output) falls within range of 0.4 to 0.9 A or lower. Control effected by electronic control unit Output to option connector (gearbox power take-off output) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between option connector (gearbox power take-off output) and signal detect and actuation module Faulty option connector (gearbox power take-off output) Defective signal detect and actuation module ---===WSE_1506_00001_0602.djvu===--- 54ES-44 522033-4: BBC Switch 'TCM Neutral position' Short circuit to ground - Insufficient voltage or short circuit to ground 522034-4: BBC Switch 'Parking brake' Short circuit to ground - Insufficient voltage or short circuit to ground 522038-5: Blower motor Relays - The current strength is too low or there is an open circuit. 522039-5: Relay 'Power supply for optional bodies' (ACC) - The current strength is too low or there is an open circuit. 522040-5: Starter signal Relays (IGN) - The current strength is too low or there is an open circuit. 522041-5: Starter signal Relays (ACC) - The current strength is too low or there is an open circuit. Generation condition Output current to option connector (gearbox neutral switch signal) rises to range of 0.4 to 0.9 A or higher. Recoverability System recovers when output current to option connector (gearbox neutral switch signal) falls within range of 0.4 to 0.9 A or lower. Control effected by electronic control unit Output to option connector (gearbox neutral switch signal) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between option connector (gearbox neutral switch signal) and signal detect and actuation module Faulty option connector (gearbox neutral switch signal) Defective signal detect and actuation module Generation condition Output current to option connector (parking brake switch signal) rises to range of 0.4 to 0.9 A or higher. Recoverability System recovers when output current to option connector (parking brake switch signal) falls within range of 0.4 to 0.9 A or lower. Control effected by electronic control unit Output to option connector (parking brake switch signal) is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between option connector (parking brake switch signal) and signal detect and actuation module Faulty option connector (parking brake switch signal) Defective signal detect and actuation module Generation condition A/C blower relay in signal detect and actuation module is malfunctioning. Recoverability System recovers when A/C blower relay in signal detect and actuation mod- ule resumes normal control. Control effected by electronic control unit Normal control is effected. Possible causes Defective signal detect and actuation module (faulty A/C blower relay) Generation condition A/C relay in signal detect and actuation module is malfunctioning. Recoverability System recovers when A/C relay in signal detect and actuation module re- sumes normal control. Control effected by electronic control unit Normal control is effected. Possible causes Defective signal detect and actuation module (faulty A/C relay) Generation condition IGN relay in signal detect and actuation module is malfunctioning. Recoverability System recovers when IGN relay in signal detect and actuation module re- sumes normal control. Control effected by electronic control unit Normal control is effected. Possible causes Defective signal detect and actuation module (faulty IGN relay) Generation condition ACC relay in signal detect and actuation module is malfunctioning. Recoverability System recovers when ACC relay in signal detect and actuation module re- sumes normal control. Control effected by electronic control unit Normal control is effected. Possible causes Defective signal detect and actuation module (faulty ACC relay) TROUBLESHOOTING ---===WSE_1506_00001_0603.djvu===--- 54ES 54ES-45 522042-5: Relay 'Power supply for optional bodies' (IGN) - The current strength is too low or there is an open circuit. 522043-5: Refrigerant compressor Relays - The current strength is too low or there is an open circuit. 522064-25: DUONIC Control unit - The received data are implausible. 522066-25: Antilock brake system Control unit - The received data are implausible. 522067-25: Combination switch - The received data are implausible. 522069-25: Combination switch - The received data are implausible. Generation condition IGN relay (option) in signal detect and actuation module is malfunctioning. Recoverability System recovers when IGN relay (option) in signal detect and actuation module resumes normal control. Control effected by electronic control unit Normal control is effected. Possible causes Defective signal detect and actuation module (faulty IGN relay) Generation condition A/C compressor/condenser relay in signal detect and actuation module is malfunctioning. Recoverability System recovers when A/C compressor/condenser relay in signal detect and actuation module resumes normal control. Control effected by electronic control unit Normal control is effected. Possible causes Defective signal detect and actuation module (faulty A/C compressor/con- denser relay) Generation condition Controller area network communication data (gear information) from DUON- IC electronic control unit are abnormal. Recoverability System recovers when normal controller area network signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Controller area network line is open or shorted to power, earth or another cir- cuit. Faulty DUONIC electronic control unit Defective signal detect and actuation module Generation condition Controller area network communication data (gear information) from hydrau- lic unit (electronic control unit) are abnormal. Recoverability System recovers when normal controller area network signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Controller area network line is open or shorted to power, earth or another cir- cuit. Faulty hydraulic unit (electronic control unit) electronic control unit Defective signal detect and actuation module Generation condition Local interconnect network communication data (headlight and markers in- formation) from combination switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty combination switch Defective signal detect and actuation module Generation condition Local interconnect network communication data (high beam switch informa- tion) from combination switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty combination switch Defective signal detect and actuation module ---===WSE_1506_00001_0604.djvu===--- 54ES-46 522070-25: Combination switch - The received data are implausible. 522071-25: DUONIC Control unit - The received data are implausible. 522072-25: Automatic engine start/stop Control unit - The received data are implausible. 522073-25: Antilock brake system Control unit - Received network data is in error. 522074-25: Combustion engine Control unit - The received data are implausible. Generation condition Local interconnect network communication data (high beam flash switch in- formation) from combination switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty combination switch Defective signal detect and actuation module Generation condition Controller area network communication data from DUONIC electronic con- trol unit are abnormal. Recoverability System recovers when normal controller area network signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Controller area network line is open or shorted to power, earth or another cir- cuit. Faulty DUONIC electronic control unit Defective signal detect and actuation module Generation condition Controller area network communication data from automatic engine start stop control unit control unit are abnormal. Recoverability System recovers when normal controller area network signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Controller area network line is open or shorted to power, earth or another cir- cuit. Defective automatic engine start stop control unit Defective signal detect and actuation module Generation condition Controller area network communication data from anti-lock brake system control unit are abnormal. Recoverability System recovers when normal controller area network signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Controller area network line is open or shorted to power, earth or another cir- cuit. Defective anti-lock brake system control unit Defective signal detect and actuation module Generation condition Controller area network communication data from engine electronic control unit are abnormal. Recoverability System recovers when normal controller area network signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Controller area network line is open or shorted to power, earth or another cir- cuit. Defective engine electronic control unit Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0605.djvu===--- 54ES 54ES-47 522075-25: Combustion engine Control unit - The received data are implausible. 522076-25: Combustion engine Control unit - The received data are implausible. 522077-25: Combination switch - The received data are implausible. 522078-25: Combination switch - The received data are implausible. 522079-25: Selector lever - The received data are implausible. Generation condition Controller area network communication data from engine electronic control unit are abnormal. Recoverability System recovers when normal controller area network signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Controller area network line is open or shorted to power, earth or another cir- cuit. Defective engine electronic control unit Defective signal detect and actuation module Generation condition Controller area network communication data from engine electronic control unit are abnormal. Recoverability System recovers when normal controller area network signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Controller area network line is open or shorted to power, earth or another cir- cuit. Defective engine electronic control unit Defective signal detect and actuation module Generation condition Local interconnect network communication data (lighting information) from combination switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Headlamps and Marker Lights automatically turns on when IGN=ON. Possible causes Local interconnect network line is open or shorted to power, earth or another circuit. Defective combination switch Defective signal detect and actuation module Generation condition Local interconnect network communication data (wiper information) from combination switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Wiper slow mode automatically turns on when IGN=ON. Possible causes Local interconnect network line is open or shorted to power, earth or another circuit. Defective combination switch Defective signal detect and actuation module Generation condition Local interconnect network communication data from gear shift lever unit are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Local interconnect network line is open or shorted to power, earth or another circuit. Faulty gear shift lever unit Defective signal detect and actuation module ---===WSE_1506_00001_0606.djvu===--- 54ES-48 522080-25: Key less entry unit - The received data are implausible. 522081-25: Power window 'Driver door' Switches - The received data are implausible. 522082-25: Power window 'Front passenger door' Switches - The received data are implausible. 522097-2: Starter Switches (ACC) - Implausible data 522098-2: Starter Switches (ON) - Implausible data Generation condition Local interconnect network communication data from keyless entry electron- ic control unit are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Local interconnect network line is open or shorted to power, earth or another circuit. Faulty keyless entry electronic control unit Defective signal detect and actuation module Generation condition Local interconnect network communication data from power window switch driver side are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Local interconnect network line is open or shorted to power, earth or another circuit. Faulty power window switch right-hand Defective signal detect and actuation module Generation condition Local interconnect network communication data from power window switch passenger side are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Local interconnect network line is open or shorted to power, earth or another circuit. Faulty power window switch left-hand Defective signal detect and actuation module Generation condition Starter key position disagrees with starter switch signal (the key is OFF but the signal is ACC); there is a trouble in starter switch internal circuit. Starter key position corresponds with starter switch signal (both are ACC); there is a trouble in key reminder switch (stuck at OFF position). Recoverability System recovers when normal signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Faulty key reminder switch (sticking in OFF position or open-circuit) Open-circuit in harness between key reminder switch and signal detect and actuation module Short-circuit in harness between signal detect and actuation module and starter switch Faulty starter switch Defective signal detect and actuation module Generation condition Starter key position disagrees with starter switch signal (the key is OFF or ACC but the signal is ON); there is a trouble in starter switch internal circuit. Starter key position corresponds with starter switch signal (both are ON); there is a trouble in key reminder switch (stuck at OFF position). Recoverability System recovers when normal signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Faulty key reminder switch (sticking in OFF position or open-circuit) Open-circuit in harness between key reminder switch and signal detect and actuation module Short-circuit in harness between signal detect and actuation module and starter switch Faulty starter switch Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0607.djvu===--- 54ES 54ES-49 522099-2: Starter Switches (START) - Implausible data 522112-3: The battery voltage is too high. - Excessive voltage or short circuit to positive 522112-4: The battery voltage is too low. - Insufficient voltage or short circuit to ground 522113-25: Combination switch - The received data are implausible. 522114-25: Combination switch - The received data are implausible. Generation condition Starter key position disagrees with starter switch signal (the key is OFF, ACC or ON but the signal is ON); there is a trouble in starter switch internal circuit. Starter key position corresponds with starter switch signal (both are ON); there is a trouble in key reminder switch (stuck at OFF position). Recoverability System recovers when normal signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Faulty key reminder switch (sticking in OFF position or open-circuit) Open-circuit in harness between key reminder switch and signal detect and actuation module Short-circuit in harness between signal detect and actuation module and starter switch Faulty starter switch Defective signal detect and actuation module Generation condition Battery voltage (12 V) is too high. Recoverability System recovers when normal voltage is applied. Control effected by electronic control unit Normal control is effected. Possible causes Faulty alternator Defective signal detect and actuation module Generation condition Battery voltage (12 V) is too low. Recoverability System recovers when normal voltage is applied. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to earth in harness between battery and signal detect and actuation module Faulty alternator Defective signal detect and actuation module Generation condition Local interconnect network communication data (lighting information) from combination switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Headlamps and Marker Lights automatically turns on when IGN=ON. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty combination switch Defective signal detect and actuation module Generation condition Local interconnect network communication data from combination switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty combination switch Defective signal detect and actuation module ---===WSE_1506_00001_0608.djvu===--- 54ES-50 522115-25: Power window 'Driver door' Switches - The received data are implausible. 522116-25: Power window 'Front passenger door' Switches - The received data are implausible. 522117-25: Key less entry unit - The received data are implausible. 522118-25: Selector lever - The received data are implausible. 522133-17: Vacuum system Power take-off M/T - Activation Timeout error Generation condition Local interconnect network communication data from power window switch driver side are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty power window switch right-hand Defective signal detect and actuation module Generation condition Local interconnect network communication data from power window switch passenger side are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty power window switch left-hand Defective signal detect and actuation module Generation condition Local interconnect network communication data from keyless entry unit are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty keyless entry unit Defective signal detect and actuation module Generation condition Local interconnect network communication data from gear shift lever unit are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty gear shift lever unit Defective signal detect and actuation module Generation condition Power take-off switch dose not turn ON even in 5 seconds after gearbox power take-off switch is turned ON. Recoverability System recovers when normal signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit in signal harness between gearbox power take-off 3-way mag- netic valve and signal detect and actuation module Open-circuit in power harness between gearbox power take-off 3-way mag- netic valve and signal detect and actuation module Faulty gearbox power take-off 3-way magnetic valve Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0609.djvu===--- 54ES 54ES-51 522134-17: Vacuum system Power take-off M/T - Deactivation Timeout error 522135-17: Vacuum system Power take-off M/T - Deactivation No request 522136-17: Vacuum system Power take-off M/T - Activation No request 522138-25: Combination switch - The received data are implausible. 522139-25: Combination switch - The received data are implausible. Generation condition Gearbox power take-off switch (cabin switch) does not turn OFF even in 5 seconds after power take-off control switch (chassis switch) is turned OFF. Recoverability System recovers when normal signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Short-circuit to power or earth in signal harness between gearbox power take-off 3-way magnetic valve and signal detect and actuation module Faulty gearbox power take-off 3-way magnetic valve Defective signal detect and actuation module Generation condition Power take-off control switch turns OFF before gearbox power take-off switch is turned OFF with gearbox power take-off 3-way magnetic valve ON. Recoverability System recovers when normal signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit in signal harness between power take-off control switch and sig- nal detect and actuation module Open-circuit in power harness between power take-off control switch and signal detect and actuation module Faulty power take-off control switch Defective signal detect and actuation module Generation condition Power take-off control switch turns ON before gearbox power take-off switch is turned ON with gearbox power take-off 3-way magnetic valve OFF. Recoverability System recovers when normal signals are received. Control effected by electronic control unit Normal control is effected. Possible causes Short-circuit to power, earth or another circuit in signal harness between power take-off control switch and signal detect and actuation module Faulty power take-off control switch Defective signal detect and actuation module Generation condition Local interconnect network communication data (turn signal left-hand) from combination switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty combination switch Defective signal detect and actuation module Generation condition Local interconnect network communication data (turn signal right-hand) from combination switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty combination switch Defective signal detect and actuation module ---===WSE_1506_00001_0610.djvu===--- 54ES-52 522140-25: Combination switch - The received data are implausible. 522141-25: Combination switch - The received data are implausible. 522142-4: Wiper motor - Insufficient voltage or short circuit to ground 522143-5: Wiper motor - The current strength is too low or there is an open circuit. 522144-3: Wiper motor - Excessive voltage or short circuit to positive Generation condition Local interconnect network communication data (wiper signal) from combi- nation switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Wiper slow mode automatically turns on when IGN=ON. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty combination switch Defective signal detect and actuation module Generation condition Local interconnect network communication data (interval wiper signal) from combination switch are abnormal. Recoverability System recovers when normal local interconnect network signals are re- ceived. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit or short-circuit to power, earth or another circuit in local inter- connect network line between combination switch and signal detect and ac- tuation module Faulty combination switch Defective signal detect and actuation module Generation condition Voltage output to wiper motor is abnormal. Recoverability System recovers when normal voltage is applied. Control effected by electronic control unit Normal control is effected. Possible causes Short-circuit to earth in SIG harness between wiper motor and signal detect and actuation module Faulty wiper motor Defective signal detect and actuation module Generation condition Current output to wiper motor is abnormal. Recoverability System recovers when normal current is applied. Control effected by electronic control unit Normal control is effected. Possible causes Open-circuit in SIG harness between wiper motor and signal detect and ac- tuation module Open-circuit in Plus harness between wiper motor and signal detect and ac- tuation module Faulty wiper motor Defective signal detect and actuation module Generation condition Voltage input from wiper motor is abnormal. Recoverability System recovers when normal voltage is applied. Control effected by electronic control unit Normal control is effected. Possible causes Short-circuit to power in SIG harness between wiper motor and signal detect and actuation module Faulty wiper motor Defective signal detect and actuation module TROUBLESHOOTING ---===WSE_1506_00001_0611.djvu===--- 54ES 54ES-53 522147-4: Ignition key Locking solenoid - Insufficient voltage or short circuit to ground 522148-17: Faulty part CPU inside component "Signal & ActuatorModule" 522149-17: Faulty part Memory inside component "Signal & ActuatorModule" 522150-17: Faulty component 'Signal & ActuatorModule' Generation condition Output current to key interlock solenoid rises to range of 4.2 to 7.4 A or high- er. Recoverability System recovers when output current to key interlock solenoid falls within range of 4.2 to 7.4 A or lower. Control effected by electronic control unit Output to key interlock solenoid is stopped. Possible causes Short-circuit to power, earth or another circuit in SIG harness between key interlock solenoid and signal detect and actuation module Faulty key interlock solenoid Defective signal detect and actuation module Generation condition Watch dog of signal detect and actuation module generation condition is de- tected and resetting takes place. Recoverability Watch dog of signal detect and actuation module generation condition is cleared after resetting. Control effected by electronic control unit Normal control is effected. Possible causes Defective CPU of signal detect and actuation module Defective software of signal detect and actuation module Generation condition Checksum of signal detect and actuation module calculated at data rewriting is not correct. Recoverability Checksum of signal detect and actuation module calculated at data rewriting becomes correct. Control effected by electronic control unit Normal control is effected. Possible causes Abnormality of signal detect and actuation module Generation condition Memory unit is in an abnormal condition. Recoverability Normal operations of memory unit are resumed after restarting. Control effected by electronic control unit Normal control is effected. Possible causes Defective software of signal detect and actuation module ---===WSE_1506_00001_0612.djvu===--- 54ES-54 2. FUSO Diagnostics Service Data (Actual Values) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. [Current Value Group: Lighting: Outputs] No. Description Value Explanation 000 Right high beam ON/OFF Shows the ON/OFF state of the headlamp RH (high beam). ON: Illumination OFF: Extinction [Related parts] Headlamp RH (high beam) 001 Left high beam ON/OFF Shows the ON/OFF state of the headlamp LH (high beam). ON: Illumination OFF: Extinction [Related parts] Headlamp LH (high beam) 002 Right turn signal ON/OFF Shows the ON/OFF state of the front and side turn signal lamp RH. ON: Illumination OFF: Extinction [Related parts] Front and side turn signal lamp RH 003 Left turn signal ON/OFF Shows the ON/OFF state of the front and side turn signal lamp LH. ON: Illumination OFF: Extinction [Related parts] Front and side turn signal lamp LH 004 Right turn signal REAR ON/OFF Shows the ON/OFF state of the rear turn lamp RH. ON: Illumination OFF: Extinction [Related parts] Rear turn lamp RH 005 Left turn signal REAR ON/OFF Shows the ON/OFF state of the rear turn lamp LH. ON: Illumination OFF: Extinction [Related parts] Rear turn lamp LH 006 Right rear brake light ON/OFF Shows the ON/OFF state of the stop lamp RH. ON: Illumination OFF: Extinction [Related parts] Stop lamp RH 007 Left rear brake light ON/OFF Shows the ON/OFF state of the stop lamp LH. ON: Illumination OFF: Extinction [Related parts] Stop lamp LH 008 Right taillamp ON/OFF Shows the ON/OFF state of the tail lamp RH. ON: Illumination OFF: Extinction [Related parts] Tail lamp RH 009 Left taillamp ON/OFF Shows the ON/OFF state of the tail lamp LH. ON: Illumination OFF: Extinction [Related parts] Tail lamp LH 010 Right clearance lamps/Right side marker lamps ON/OFF Shows the ON/OFF state of the clearance lamp RH. ON: Illumination OFF: Extinction [Related parts] Clearance lamp RH 011 Left clearance lamps/Left side marker lamps ON/OFF Shows the ON/OFF state of the clearance lamp LH. ON: Illumination OFF: Extinction [Related parts] Clearance lamp LH TROUBLESHOOTING ---===WSE_1506_00001_0613.djvu===--- 54ES 54ES-55 012 Right license plate lamp ON/OFF Show the ON/OFF state of the License plate lamp (RH). ON: Illumination OFF: Extinction [Related parts] License plate lamp (RH) 013 Left license plate lamp ON/OFF Shows the ON/OFF state of the license plate lamp. ON: Illumination OFF: Extinction [Related parts] License plate lamp 014 Driver side Step illumination ON/OFF Shows the ON/OFF state of the step lamp, driver side. ON: Illumination OFF: Extinction [Related parts] Step lamp (driver side) 015 Passenger side Step illumi- nation ON/OFF Shows the ON/OFF state of the step lamp, passenger side. ON: Illumination OFF: Extinction [Related parts] Step lamp (passenger side) 016 Switch and controls illumi- nation ON/OFF Shows the ON/OFF state of the Illumination lamp. ON: Illumination OFF: Extinction [Related parts] Illumination lamp 017 Electric motor 'Automatic headlamp adjustment' ON/OFF Unused 018 Right front fog lamp ON/OFF Shows the ON/OFF state of the fog lamp RH. ON: Illumination OFF: Extinction [Related parts] Fog lamp RH 019 Left front fog lamp ON/OFF Shows the ON/OFF state of the fog lamp LH. ON: Illumination OFF: Extinction [Related parts] Fog lamp LH 020 Rear fog lamp ON/OFF Show the ON/OFF state of the rear fog lamp. ON: Illumination OFF: Extinction [Related parts] Rear fog lamp 021 Right daytime running lights ON/OFF Show the ON/OFF state of the Daytime running light (RH). ON: Illumination OFF: Extinction [Related parts] Daytime running light (RH) 022 Left daytime running lights ON/OFF Show the ON/OFF state of the Daytime running light (LH). ON: Illumination OFF: Extinction [Related parts] Daytime running light (LH) 023 Right turn signal on trailer ON/OFF Show the ON/OFF state of the Optional connector (Side turn signal lamp (RH)). ON: Illumination OFF: Extinction [Related parts] Optional connector (Side turn signal lamp (RH)) 024 Left turn signal on trailer ON/OFF Show the ON/OFF state of the Optional connector (Side turn signal lamp (LH)) ON: Illumination OFF: Extinction [Related parts] Optional connector (Side turn signal lamp (LH)) No. Description Value Explanation ---===WSE_1506_00001_0614.djvu===--- 54ES-56 [Current Value Group: Wipe and Wash: Outputs] [Current Value Group: Washer Pump Control Output] [Current Value Group: Door Outputs] 025 Brake light of trailer ON/OFF Show the ON/OFF state of the trailer stop lamp. ON: Illumination OFF: Extinction [Related parts] Trailer stop lamp 028 Interior illumination ON/OFF Shows the ON/OFF state of the optional connector (body illumi- nation lamp). ON: Illumination OFF: Extinction [Related parts] Optional connector (body illumination lamp) 029 Exterior illumination ON/OFF Shows the ON/OFF state of the optional connector (chassis illu- mination lamp). ON: Illumination OFF: Extinction [Related parts] Optional connector (chassis illumination lamp) No. Description Value Explanation 030 Windshield wiper Stage ON ON/OFF Shows the ON/OFF state of the wiper motor LO. ON: Operation OFF: Stopped [Related parts] Wiper motor 031 Windshield wiper Stage HIGH ON/OFF Shows the ON/OFF state of the wiper motor HI. ON: Operation OFF: Stopped [Related parts] Wiper motor No. Description Value Explanation 032 Windshield washer system ON/OFF Shows the ON/OFF state of the windshield washer motor. ON: Operation OFF: Stopped [Related parts] Windshield washer motor No. Description Value Explanation 033 Mirror heater Switches ON/OFF Shows the ON/OFF state of the mirror heater switch illumina- tion. ON: Mirror heater switch ON OFF: Mirror heater switch OFF [Related parts] Mirror heater switch 034 Driver side Mirror heater ON/OFF Shows the ON/OFF state of the mirror heater (driver side). ON: Operation OFF: Stopped [Related parts] Mirror heater (driver side) 035 Passenger side Mirror heat- er ON/OFF Shows the ON/OFF state of the mirror heater (passenger side). ON: Operation OFF: Stopped [Related parts] Mirror heater (passenger side) No. Description Value Explanation TROUBLESHOOTING ---===WSE_1506_00001_0615.djvu===--- 54ES 54ES-57 [Current Value Group: Ignition Relay Outputs] [Current Value Group: Air Conditioning Outputs] [Current Value Group: Brake Outputs] No. Description Value Explanation 036 Starter signal Relays (ACC) ON/OFF Shows the ON/OFF state of the ACC relay. ON: ACC RELAY ON OFF: ACC RELAY OFF [Related parts] Shift lever unit relay ETC ACC Audio ACC DUONIC ACC Cigarette lighter ACC Electric-powered mirror ACC 037 Relay 'Power supply for op- tional bodies' (ACC) ON/OFF Shows the ON/OFF state of the 12V/24V ACC relay. ON: 12V/24V ACC RELAY ON OFF: 12V/24V ACC RELAY OFF [Related parts] Optional connector (ACC body) Optional connector (ACC chassis) 038 Starter signal Relays (IGN) ON/OFF Shows the ON/OFF state of the ignition relay. ON: IGN RELAY ON OFF: IGN RELAY OFF [Related parts] Meter cluster (M power supply) Battery equaliser (M power supply) Anti-lock brake system electronic control unit (M power sup- ply) Engine electronic control unit (M power supply) Airbag system electronic control unit (M power supply) DUONIC electronic control unit (M power supply 1) DUONIC electronic control unit (M power supply 2) Shift lever unit (M power supply 1) Shift lever unit (M power supply 2) Lock brake electronic control unit (M power supply) Headlamp auto leveling system electronic control unit (M power supply) Idling stop and start system electronic control unit (M power supply) Starter relay 039 Relay 'Power supply for op- tional bodies' (IGN) ON/OFF Shows the ON/OFF state of the 12V/24V ignition relay. ON: 12V/24V IGN RELAY ON OFF: 12V/24V IGN RELAY OFF [Related parts] Optional connector (M power supply body) Optional connector (power supply chassis) Alternator (R terminal) No. Description Value Explanation 040 Refrigerant compressor Re- lays ON/OFF Shows the ON/OFF state of the air conditioner compressor- condenser relay. ON: A/C COMP COND.RELAY ON OFF: A/C COMP COND.RELAY OFF [Related parts] Dual pressure switch Condenser fan relay 041 Blower motor Relays ON/OFF Shows the ON/OFF state of the air conditioner blower relay. ON: A/C BLOWER RELAY ON OFF: A/C BLOWER RELAY OFF [Related parts] Blower motor relay No. Description Value Explanation 042 Parking brake Switches ON/OFF Shows the ON/OFF state of the optional connector (parking brake cut). ON: Optional connector (parking brake cut) ON OFF: Optional connector (parking brake cut) OFF [Related parts] Optional connector (parking brake cut) ---===WSE_1506_00001_0616.djvu===--- 54ES-58 [Current Value Group: Transmission: Outputs] [Current Value Group: PTO Outputs] [Current Value Group: PWM Actuation] No. Description Value Explanation 043 Transmission Neutral posi- tion Switches ON/OFF Shows the ON/OFF state of the optional connector (neutral sig- nal). ON: Optional connector (neutral signal) ON OFF: Optional connector (neutral signal) OFF [Related parts] Optional connector (neutral signal) 044 Backup light Switches ON/OFF Unused 045 Warning buzzer (Backup warning system) ON/OFF Shows the ON/OFF state of the backup buzzer. ON: Backup buzzer ON OFF: Backup buzzer OFF [Related parts] Backup buzzer No. Description Value Explanation 046 3/2-way valve Power take- off ON/OFF Shows the ON/OFF state of the gearbox power take-off 3-way magnetic valve <Vacuum>. ON: Gearbox power take-off 3-way magnetic valve ON (12V) OFF: Gearbox power take-off 3-way magnetic valve OFF (0V) [Related parts] Gearbox power take-off 3-way magnetic valve <Vacuum> 047 Power take-off Outputs ON/OFF Shows the ON/OFF state of the optional connector (power take- off magnetic valve). ON: Optional connector (power take-off magnetic valve) ON OFF: Optional connector (power take-off magnetic valve) OFF [Related parts] Optional connector No. Description Value Explanation 048 Interior lamp Shows the output state of cab lamp PWM (pulse width modula- tion) control 0-100% [Related parts] Cab lamp 049 Left low beam Shows the output state of headlamp LH (lower) PWM (pulse width modulation) control 0-100% [Related parts] Headlamp 050 Right low beam Shows the output state of headlamp RH (lower) PWM (pulse width modulation) control 0-100% [Related parts] Headlamp 051 Ignition key Locking sole- noid Shows the output state of interlock solenoid PWM (pulse width modulation) control 0-100% [Related parts] Key interlock solenoid % % % % TROUBLESHOOTING ---===WSE_1506_00001_0617.djvu===--- 54ES 54ES-59 [Current Value Group: Lighting Inputs] [Current Value Group: Washer Wiper Inputs] [Current Value Group: Door Inputs] No. Description Value Explanation 052 Rear fog lamp switches ON/OFF Shows the ON/OFF state of the rear fog lamp switch. ON: Rear fog lamp switch ON OFF: Rear fog lamp switch OFF [Related parts] Rear fog lamp switch 053 Front fog lamp Switches ON/OFF Shows the ON/OFF state of the fog lamp switch. ON: Fog lamp switch ON OFF: Fog lamp switch OFF [Related parts] Fog lamp switch 054 Hazard warning flasher Switches ON/OFF Shows the ON/OFF state of the hazard warning switch. ON: Hazard warning switch ON OFF: Hazard warning switch OFF [Related parts] Hazard warning switch 055 Blackout switch ON/OFF Unused No. Description Value Explanation 056 Windshield wiper Switch 'Rest position' ON/OFF Shows the ON/OFF state of the wiper switch. ON: Wiper switch ON OFF: Wiper switch OFF [Related parts] Wiper switch No. Description Value Explanation 057 Mirror heater ON/OFF Shows the ON/OFF state of the mirror heater switch. ON: Mirror heater switch ON OFF: Mirror heater switch OFF [Related parts] Mirror heater switch 058 Driver door OPEN/CLOSE Shows the OPEN/CLOSE state of the door switch LH. OPEN: Door switch RH ON CLOSE: Door switch RH OFF [Related parts] Front door switch RH 059 Passenger door OPEN/CLOSE Shows the OPEN/CLOSE state of the door switch LH. OPEN: Door switch RH ON CLOSE: Door switch RH OFF [Related parts] Front door switch RH 060 Right rear door / Left rear door OPEN/CLOSE Shows the OPEN/CLOSE state of the rear door switch (RH and LH) OPEN: Rear door switch (RH and LH) ON CLOSE: Rear door switch (RH and LH) OFF [Related parts] Rear door switch (RH and LH) 061 Driver door Lock Switches OFF ON/OFF Unused 062 Driver door Lock Switches ON ON/OFF Unused ---===WSE_1506_00001_0618.djvu===--- 54ES-60 [Current Value Group: Ignition Switch Inputs] No. Description Value Explanation 063 Starter Switches (LOCK) ON/OFF Shows the ON/OFF state of the starter switch (LOCK position). ON: Starter switch (LOCK position) OFF: Starter switch (any position except LOCK) [Related parts] Starter switch 064 Starter Switches (ACC) ON/OFF Shows the ON/OFF state of the starter switch (ACC position). ON: Starter switch (ACC position) OFF: Starter switch (any position except LOCK) [Related parts] Starter switch 065 Starter Switches (ON) ON/OFF Shows the ON/OFF state of the starter switch (ON position). ON: Starter switch (ON position) OFF: Starter switch (any position except ON) [Related parts] Starter switch 066 Starter Switches (START) ON/OFF Shows the ON/OFF state of the starter switch (START position). ON: Starter switch (START position) OFF: Starter switch (any position except START) [Related parts] Starter switch 067 Alternator ON/OFF Shows the ON/OFF state of the alternator operation. ON: Alternator in operation OFF: Alternator stopped [Related parts] Alternator 068 Starter signal Relays (ACC) ON/OFF Shows the ON/OFF state of the ACC relay. ON: ACC relay ON OFF: ACC relay OFF [Related parts] ACC relay (a relay within the signal detection and actuation module) 069 Relay 'Power supply for op- tional bodies' (ACC) ON/OFF Shows the ON/OFF state of the 12V/24V ACC relay. ON: 12V/24V ACC relay ON OFF: 12V/24V ACC relay OFF [Related parts] 12V/24V ACC relay (a relay within the signal detection and actuation module) 070 Starter signal Relays (IGN) ON/OFF Shows the ON/OFF state of the ignition relay. ON: Ignition relay ON OFF: Ignition relay OFF [Related parts] Ignition relay (a relay within the signal detection and actua- tion module) 071 Relay 'Power supply for op- tional bodies' (IGN) ON/OFF Shows the ON/OFF state of the 12V/24V ignition relay. ON: 12V/24V Ignition relay ON OFF: 12V/24V Ignition relay OFF [Related parts] 12V/24V ignition relay (a relay within the signal detection and actuation module) TROUBLESHOOTING ---===WSE_1506_00001_0619.djvu===--- 54ES 54ES-61 [Current Value Group: Air Conditioning Inputs] [Current Value Group: Brake Inputs] No. Description Value Explanation 072 Air conditioning Switches ON/OFF Shows the ON/OFF state of the air conditioner switch. ON: Air conditioner switch ON OFF: Air conditioner switch OFF [Related parts] Air conditioner switch (Air conditioner control unit and control panel) <Full automatic air conditioner> Air conditioner switch (heater control panel) <Manual air con- ditioner> 073 Refrigerant compressor Re- lays ON/OFF Shows the ON/OFF state of the compressor. ON: Compressor in operation OFF: Compressor stopped [Related parts] Magnetic clutch Dual pressure switch 074 Blower motor Relays ON/OFF Shows the ON/OFF state of the blower motor. ON: Blower motor in operation OFF: Blower motor stopped [Related parts] Blower motor Blower resistor <Manual air conditioner> Power MOS-FET <Full automatic air conditioner> No. Description Value Explanation 075 Vacuum Switches ON/OFF Shows the ON/OFF state of the vacuum switch. ON: Vacuum switch ON OFF: Vacuum switch OFF [Related parts] Vacuum switch 076 Bake fluid level Switches ON/OFF Shows the ON/OFF state of the brake fluid switch. ON: Brake fluid switch ON OFF: Brake fluid switch OFF [Related parts] Brake fluid switch 077 Parking brake Switches ON/OFF Shows the ON/OFF state of the parking brake switch. ON: Parking brake switch ON OFF: Parking brake switch OFF [Related parts] Parking brake switch 078 Brake light Switches 2 ON/OFF Shows the ON/OFF state of the stop lamp switch (N.C.). ON: Stop lamp switch (N.C.) ON OFF: Stop lamp switch (N.C.) OFF [Related parts] Stop lamp switch 079 Brake light Switches 1 ON/OFF Shows the ON/OFF state of the stop lamp switch (N.O.). ON: Stop lamp switch (N.O.) ON OFF: Stop lamp switch (N.O.) OFF [Related parts] Stop lamp switch ---===WSE_1506_00001_0620.djvu===--- 54ES-62 [Current Value Group: Transmission Inputs] [Current Value Group: Status of PTO Inputs] [Current Value Group: Fill Level of Fuel Tank] [Current Value Group: Battery Voltage] No. Description Value Explanation 080 Backup light Switches ON/OFF Shows the ON/OFF state of the backup lamp switch. ON: Backup lamp switch ON OFF: Backup lamp switch OFF [Related parts] Backup lamp switch 081 Transmission Neutral posi- tion Switches ON/OFF Shows the ON/OFF state of the optional connector (neutral sig- nal). ON: Optional connector (neutral signal) ON OFF: Optional connector (neutral signal) OFF [Related parts] Optional connector (neutral signal) 082 Clutch Switches ON/OFF Shows the ON/OFF state of the clutch switch. ON: Clutch switch ON OFF: Clutch switch OFF [Related parts] Clutch switch No. Description Value Explanation 083 Power take-off Inputs ON/OFF Shows the ON/OFF state of the optional connector (power-take off signal). ON: Optional connector (power-take off signal) available OFF: Optional connector (power-take off signal) unavailable [Related parts] Optional connector (power-take off signal) 084 Actuation of power take-off Switches ON/OFF Shows the ON/OFF state of the power take-off control switch. ON: Power take-off control switch ON OFF: Power take-off control switch OFF [Related parts] Power take-off control switch 085 Power take-off Switches ON/OFF Shows the ON/OFF state of the gearbox power take-off switch. ON: Gearbox power take-off switch ON OFF: Gearbox power take-off switch OFF [Related parts] Gearbox power take-off switch No. Description Value Explanation 086 Fuel level Shows fill level of the fuel tank. Approx. 0%: Fuel tank empty Approx. 100%: Fuel tank full [Related parts] Fuel level sensor No. Description Value Explanation 087 Battery Voltage Shows input voltage from the battery (high-current fuse box) to signal detection and actuation module. 0-25.4V(0-254) [Related parts] Battery High-current fuse box % V TROUBLESHOOTING ---===WSE_1506_00001_0621.djvu===--- 54ES 54ES-63 3. FUSO Diagnostics Actuator Test (Actuations) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. The basic conditions for performing the actuator test: Vehicle stopped, engine stopped and starter switch ON. 4. Coding Data in Electronic Control Unit 4.1 Overview The signal detect and actuation module has various kinds of information such as technical data of vehicle and equipment registered as coding data. Therefore, each time the signal detect and actuation module is replaced or some setting changes are made, the coding data must surely be rewritten using FUSO Diagnostics. Otherwise, the data stored in the signal detect and actuation module could deviate from the actual conditions of the vehicles, resulting in occurrence of diagnosis codes. No. Selection Explanation 000 Exterior illumination Illuminates the stop lamp (LH). Illuminates the headlamp high beam (LH). Illuminates the position lamp (LH). Illuminates the turn signal lamp (LH). Illuminates the stop lamp (RH). Illuminates the headlamp high beam (RH). Illuminates the position lamp (RH). Illuminates the turn signal lamp (RH). 001 Actuation of pump for windshield washer system "Windshield" Activates the windshield washer system. 002 Status of integrated ignition module Activates the ignition relay. [Additional condition for performing actuator test] Starter switch position: ACC Activates the 24 V/12 V ignition relay (option) [Additional condition for performing actuator test] Starter switch position: ACC Activates the accessory relay. Activates the accessory relay (option). 003 Air conditioning Activates the air conditioner compressor condenser relay. Activates the air blower relay. ---===WSE_1506_00001_0621.djvu===--- 54ES 54ES-63 3. FUSO Diagnostics Actuator Test (Actuations) The contents of FUSO Diagnostics are updated to improve without any notice. When there is any difference be- tween the FUSO Diagnostics and the workshop manual, check the latest information with the FUSO Diagnostics. The basic conditions for performing the actuator test: Vehicle stopped, engine stopped and starter switch ON. 4. Coding Data in Electronic Control Unit 4.1 Overview The signal detect and actuation module has various kinds of information such as technical data of vehicle and equipment registered as coding data. Therefore, each time the signal detect and actuation module is replaced or some setting changes are made, the coding data must surely be rewritten using FUSO Diagnostics. Otherwise, the data stored in the signal detect and actuation module could deviate from the actual conditions of the vehicles, resulting in occurrence of diagnosis codes. No. Selection Explanation 000 Exterior illumination Illuminates the stop lamp (LH). Illuminates the headlamp high beam (LH). Illuminates the position lamp (LH). Illuminates the turn signal lamp (LH). Illuminates the stop lamp (RH). Illuminates the headlamp high beam (RH). Illuminates the position lamp (RH). Illuminates the turn signal lamp (RH). 001 Actuation of pump for windshield washer system "Windshield" Activates the windshield washer system. 002 Status of integrated ignition module Activates the ignition relay. [Additional condition for performing actuator test] Starter switch position: ACC Activates the 24 V/12 V ignition relay (option) [Additional condition for performing actuator test] Starter switch position: ACC Activates the accessory relay. Activates the accessory relay (option). 003 Air conditioning Activates the air conditioner compressor condenser relay. Activates the air blower relay. ---===WSE_1506_00001_0622.djvu===--- 54ES-64 4.2 Rewriting of coding data If one of the following changes has been made, be sure to rewrite the relevant coding data. Perform the data writ- ing and resetting work, using the diagnostic tool. Depending on the specifications of the rear body to be mounted, coding data other than those listed below may have to be rewritten. Perform the data writing and resetting work, using the diagnostic tool. Rewriting coding data required Standards for rewriting signal detect and actuation module in- ternal data When signal detect and actuation module is replaced -- When additional turn signal lamps are installed -- When rear body is mounted If an optional connector for rear body mounting is used, the fol- lowing diagnosis/actuator functions must be set valid: Illumination Backup buzzer Power take-off Neutral switch Parking brake switch When additional LED rear lamps are installed If LED license plate lamp is used, the following diagnosis/actu- ator functions must be set valid. When additional mirror with heater is installed -- TROUBLESHOOTING ---===WSE_1506_00001_0623.djvu===--- 54ES 54ES-65 5. Electronic Control Unit Input/Output Table See the Electronic Control Unit Schematic Diagram for the pin locations of each signal and earth. (See Gr54- 00C.) Devices to be connected Terminal Input/ output Voltage and wave form License plate lamp 13C-9-Earth Output ON: 12 V/OFF: 0 V Parking lamp (RH) 15B-11-Earth Output ON: 12 V/OFF: 0 V Parking lamp (LH) 15B-10-Earth Output ON: 12 V/OFF: 0 V Head lamp high beam (RH) 14B-7-Earth Output ON: 12 V/OFF: 0 V Head lamp high beam (LH) 16B-2-Earth Output ON: 12 V/OFF: 0 V Option connector (side turn lamp (RH)) 13C-4-Earth Output ON: 12 V/OFF: 0 V Option connector (side turn lamp (LH)) 12C-7-Earth Output ON: 12 V/OFF: 0 V Rear turn lamp (RH) 13C-5-Earth Output ON: 12 V/OFF: 0 V Rear turn lamp (LH) 12C-4-Earth Output ON: 12 V/OFF: 0 V Front turn lamp (RH) 14B-4-Earth Output ON: 12 V/OFF: 0 V Front turn lamp (LH) 16B-4-Earth Output ON: 12 V/OFF: 0 V Front fog lamp (RH) 12C-6-Earth Output ON: 12 V/OFF: 0 V Front fog lamp (LH) 13C-2-Earth Output ON: 12 V/OFF: 0 V Stop lamp (RH) 13C-7-Earth Output ON: 12 V/OFF: 0 V Stop lamp (LH) 12C-1-Earth Output ON: 12 V/OFF: 0 V Tail lamp (RH) 12C-3-Earth Output ON: 12 V/OFF: 0 V Tail lamp (LH) 13C-8-Earth Output ON: 12 V/OFF: 0 V Step lamp (RH) 15B-12-Earth Output ON: 12 V/OFF: 0 V Step lamp (LH) 15B-14-Earth Output ON: 12 V/OFF: 0 V Illumination lamp 14B-8-Earth Output ON: 12 V/OFF: 0 V Option connector (chassis illumination) 6X-4-Earth Output ON: 12 V (or 24 V)/OFF: 0 V Wiper motor (Hi) 16B-5-Earth Output ON: 12 V/OFF: 0 V Wiper motor (Lo) 16B-1-Earth Output ON: 12 V/OFF: 0 V Wiper washer motor 17B-5-Earth Output ON: 12 V/OFF: 0 V Mirror heater switch illumination 15B-27-Earth Output ON: 12 V/OFF: 0 V Mirror heater (LH) 14B-5-Earth Output ON: 12 V/OFF: 0 V Mirror heater (RH) 14B-1-Earth Output ON: 12 V/OFF: 0 V Backup lamp 13C-6-Earth Output ON: 12 V/OFF: 0 V Backup buzzer 11C-6-Earth Output ON: 12 V/OFF: 0 V Gearbox power take-off 3-way magnetic valve <Vacuum type for manual gearbox> 13C-10-Earth Output ON: 12 V/OFF: 0 V Cab lamp 17B-15-Earth Output PWM Key interlock solenoid 17B-17-Earth Output PWM Front fog lamp switch 15B-16-Earth Input OFF: 12 V/ON: 0 V (Unlatched type) Hazard switch 15B-4-Earth Input OFF: 12 V/ON: 0 V (Unlatched type) Wiper motor stop position switch 17B-16-Earth Input OFF: 12 V/ON: 0 V Heater mirror switch 18B-11-Earth Input OFF: 12 V/ON: 0 V (Unlatched type) Rear door switch 15B-2-Earth Input OFF: 12 V/ON: 0 V Front door switch (assistant driver's seat side) 15B-3-Earth Input OFF: 12 V/ON: 0 V Front door switch (driver's seat side) 15B-18-Earth Input OFF: 12 V/ON: 0 V Starter switch (START position) 15B-15-Earth Input OFF: 0 V/ON: 12 V Starter switch (key insert switch) 18B-18-Earth Input OFF: 0 V/ON: 12 V Starter switch (ACC position) 18B-17-Earth Input OFF: 0 V/ON: 12 V Starter switch (M position) 18B-3-Earth Input OFF: 0 V/ON: 12 V Alternator (L terminal) 11C-8-Earth Input Engine running: 12 V/24 V Engine stopped: 0 V ---===WSE_1506_00001_0624.djvu===--- 54ES-66 Accessory relay 3B-8, 7C-8, 3B-10, 3B-13-Earth Output Activated: 12 V Not activated: 0 V 24 V/12V Accessory relay (option connector) 6X-1-Earth Output Activated: 12 V/24 V Not activated: 0 V Ignition relay 1B-11, 5C-2, 5C-4, 5C-11, 5C-9, 1B-1, 1B-4, 1B-5, 1B-13, 1B-14-Earth Output Activated: 12 V/24 V Not activated: 0 V 24 V/12V Ignition relay (option connector) 6X-5-Earth Output Activated: 12 V/24 V Not activated: 0 V Air conditioner switch 15B-17-Earth Input OFF: 12 V/ON: 0 V Air conditioner compressor condenser relay 7C-11, 7C-12-Earth Output Activated: 12 V Not activated: 0 V Air conditioner blower relay 2B-14-Earth Output Active (with air conditioner compres- sor operating): 12 V Not activated: 0 V Vacuum switch 15B-1-Earth Input OFF: 12 V/ON: 0 V Brake fluid level switch 18B-7-Earth Input OFF: 12 V/ON: 0 V Parking brake switch 18B-6-Earth Input OFF: 12 V/ON: 0 V Stop lamp switch (normal close) 15B-19-Earth Input OFF: 12 V/ON: 0 V Stop lamp switch (normal open) 18B-4-Earth Input OFF: 12 V/ON: 0 V Clutch switch 18B-9-Earth Input OFF: 12 V/ON: 0 V Power-take off control switch 11C-9-Earth Input OFF: 12 V/ON: 0 V Gearbox power take-off switch <Vacuum type for manual gearbox> 18B-5-Earth Input OFF: 12 V/ON: 0 V Cab tilt lock switch 18B-10-Earth Input OFF: 12 V/ON: 0 V Diesel particulate filter cleaning switch 15B-20-Earth Input OFF: 12 V/ON: 0 V (Unlatched type) Fuel level sensor 11C-1-Earth Input Fuel tank empty: 150 ± 3.5 or more Full:5±2 Battery voltage 10C-1-Earth Input Shows the battery voltage (12 V). Backup lamp switch <Manual gearbox> 11C-2-Earth Input OFF: 12 V/ON: 0 V Daytime running lamp (LH) 13C-3-Earth Output ON: 12 V/OFF: 0 V Daytime running lamp (RH) 12C-9-Earth Output ON: 12 V/OFF: 0 V Rear fog lamp (LH), (RH) 12C-2-Earth Output ON: 12 V/OFF: 0 V Headlamp leveling actuator (LH), (RH) 15B-13-Earth Output ON: 12 V/OFF: 0 V Headlamp leveling switch 15B-13-Earth Output ON: 12 V/OFF: 0 V Trailer tail lamp relay (LH) 2B-1-Earth Output ON: 12 V/OFF: 0 V Trailer tail lamp relay (RH) 5C-14-Earth Output ON: 12 V/OFF: 0 V Trailer back lamp relay 2B-13-Earth Output ON: 12 V/OFF: 0 V Trailer rear fog lamp relay 2B-5-Earth Output ON: 12 V/OFF: 0 V Coupling device (BATT) 6X-3-Earth Output ON: 12 V/OFF: 0 V Coupling device (turn lamp (LH)) 13C1-Earth Output ON: 12 V/OFF: 0 V Coupling device (turn lamp (RH)) 12C10-Earth Output ON: 12 V/OFF: 0 V Coupling device (stop lamp) 12C8-Earth Output ON: 12 V/OFF: 0 V Devices to be connected Terminal Input/ output Voltage and wave form TROUBLESHOOTING ---===WSE_1506_00001_0625.djvu===--- 54ES 54ES-67 6. Confirmation items before replacing the signal detect and actuation module 6.1 Diagnosis codes for signal detect and actuation module The diagnosis code for the signal detect and actuation module is generated when the signal detect and actuation module has normally performed self-diagnosis and has detected an abnormal load of the unit connected to the module. If a diagnosis code of the signal detect and actuation module is generated, first check the unit connected to the module before judging it as faulty signal detect and actuation module. 6.2 Troubleshooting before replacing the signal detect and actuation module Check the unit, harnesses and connectors related to the generated diagnosis code. Check if the system returns normal by disconnecting and connecting of the battery cable. Check the coding data in the signal detect and actuation module matches with the vehicle to which it is mounted. Temporarily replace the signal detect and actuation module with a known-good one and check if the same failure is detected. 6.3 Major symptoms and troubleshooting If the symptom is not observed currently, also check the past diagnosis codes. (1) Engine would not start Diagnosis code Cause Items to be inspected (See the "Electronic control unit circuit diagram" for the location of the sig- nal detect and actuation module connector.) 522074-25 (522074-19) Faulty communication to en- gine electronic control unit Check the engine electronic control unit. 522075-25 (522075-19) 522076-25 (522076-19) 522074-25 (522074-19) Faulty controller area network communication Check the controller area network-related connectors (17B/18B) and harnesses of the signal detect and actuation module, including discon- nection and connection of the connectors. Check the controller area network-related harnesses and connectors of the electronic control unit indicated by the diagnosis code, including disconnection and connection of the connectors. If the problem reappears after the above check (and repair, if neces- sary), the cause of the problem may be an internal failure of the signal detect and actuation module. Replace the signal detect and actuation module. 522075-25 (522075-19) 522076-25 (522076-19) 522064-25 (522064-19) 522071-25 (522071-19) 522073-25 (522073-19) 522040-5 Relay in signal detect and ac- tuation module inoperative Disconnect and reconnect the relay - IGNITION RELAY for diagnosis code 522040-5 or ACC RELAY for 522041-5. If the problem reappears after the above operation, the cause of the problem may be an internal failure of the signal detect and actuation module. Replace the signal detect and actuation module. 522041-5 522097-2 Faulty starter switch signal Check the starter switch-related connectors (18B/15B) of the signal de- tect and actuation module, including disconnection and connection of the connectors. Check the starter switch. 522098-2 522099-2 ---===WSE_1506_00001_0626.djvu===--- 54ES-68 (2) Headlamps, turn-signal lights or wipers would not operate (3) Headlamps cannot be turned off, turn-signal lamps would not operate, and wipers operate spontaneous- ly Diagnosis code Cause Items to be inspected (See the "Electronic control unit circuit diagram" for the location of the sig- nal detect and actuation module connector.) None None Check the connector (18B) and harness of the signal detect and actua- tion module, including disconnection and connection of the connectors. Check the combination switch and connectors, including disconnection and connection of the connectors. In the same way as that for signal detect and actuation module, temporarily replace the combination switch with a known-good one and check if the same failure is detect- ed. 521995-4 Headlamp, LH (high) Check the lamps, related harnesses and connectors. 521995-5 521996-4 Headlamp, RH (high) 521996-5 521997-4 Headlamp, LH (low) 521997-5 521998-4 Headlamp, RH (low) 521998-5 522142-4 Wipers Check the wipers and related harnesses and connectors. 522143-5 522144-3 522007-4 Rear combination lamp, LH (turn) Check the lamps and related harnesses and connectors. 522007-5 522008-4 Rear combination lamp, RH (turn) 522008-5 522009-4 Front & side turn signal, lamps LH 522009-5 522010-4 Front & side turn signal, lamps RH 522010-5 Diagnosis code Cause Items to be inspected (See the "Electronic control unit circuit diagram" for the location of the sig- nal detect and actuation module connector.) 522077-25 (522077-19) Faulty communication to com- bination switch Check the combination switch and connectors, including disconnection and connection of the connectors. In the same way as that for signal detect and actuation module, temporarily replace the combination switch with a known-good one and check if the same failure is detect- ed. Check the connector (18B) and harness of the signal detect and actua- tion module, including disconnection and connection of the connectors. 522078-25 (522078-19) 522077-25 (522077-19) Faulty local interconnect net- work communication Check the harness connection and operation of the unit indicated by the diagnosis code. Check the connector (18B) and harness of the signal detect and actua- tion module, including disconnection and connection of the connectors. 522078-25 (522078-19) 522079-25 (522079-19) 522080-25 (522080-19) 522081-25 (522081-19) TROUBLESHOOTING ---===WSE_1506_00001_0627.djvu===--- 54ES 54ES-69 (4) Headlamps cannot be turned off and wipers would not operate (5) Headlamps cannot be turned on and wipers operate spontaneously Diagnosis code Cause Items to be inspected (See the "Electronic control unit circuit diagram" for the location of the sig- nal detect and actuation module connector.) None None (Internal failure of the signal detect and actuation module is suspected.) Check the connector (10C) and harness of the signal detect and actua- tion module, including disconnection and connection of the connectors. Check the battery, including disconnection and connection of the termi- nals. 522077-25 (522077-19) Faulty communication to com- bination switch If both diagnosis codes 522078-25 (522078-19) and 522114-25 (522114-19) are not generated concurrently, check the combination switch, including disconnection and connection of the connectors. Temporarily replace the combination switch with a known-good one and check if the same failure is detected. 522113-25 (522113-19) Diagnosis code Cause Items to be inspected (See the "Electronic control unit circuit diagram" for the location of the sig- nal detect and actuation module connector.) None None Check the connector (18B) of the signal detect and actuation module, re- lated harnesses and combination switch, including disconnection and connection of the connectors. 522078-25 (522078-19) Faulty communication to com- bination switch If both diagnosis codes 522077-25 (522077-19) and 522113-25 (522113-19) are not generated concurrently, check the combination switch, including disconnection and connection of the connectors. Temporarily replace the combination switch with a known-good one and check if the same failure is detected. 522114-25 (522114-19) ---===WSE_1506_00001_0628.djvu===--- 54ES-70 7. Symptoms and inspection procedures when warning lamp (red or amber) illumi- nates (1) When signal detect and actuation module warning lamp (red) illuminates Diagnosis code Symptom Items to be inspected (See the "Electronic control unit circuit diagram" for the location of the sig- nal detect and actuation module connector.) 522040-5 Engine unable to start Check the IGNITION RELAY, including disconnection and connection of the relay. (See Inspection of relays in signal detect and actuation module.) Check service data No. 038 "Starter signal Relays (IGN)". (See FUSO Diagnostics service data (measured values).) 522041-5 Engine unable to start Check the ACC RELAY, including disconnection and connection of the relay. (See Inspection of relays in signal detect and actuation module.) Check service data No. 036 "Starter signal Relays (ACC)". (See FUSO Diagnostics service data (measured values).) 522097-2 Engine unable to start Check the fuse (F13), including disconnection and connection of the fuse. Check the starter switch. Check the starter switch connector, including disconnection and con- nection of the connectors. Check the harness between the starter switch and the signal detect and actuation module. Check the connector (18B) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 064 "Starter Switches (ACC)". (See FUSO Diagnostics service data (measured values).) 522098-2 Engine unable to start Check the fuse (F13), including disconnection and connection of the fuse. Check the starter switch. Check the starter switch connector, including disconnection and con- nection of the connectors. Check the harness between the starter switch and the signal detect and actuation module. Check the connector (18B) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 065 "Starter Switches (ON)". (See FUSO Diagnostics service data (measured values).) 522099-2 Engine unable to start Check the fuse (F13), including disconnection and connection of the fuse. Check the starter switch. Check the starter switch connector, including disconnection and con- nection of the connectors. Check the harness between the starter switch and the signal detect and actuation module. Check the connector (15B) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 066 "Starter Switches (Start)". (See FUSO Diagnostics service data (measured values).) 522112-3 Engine unable to start, or sig- nal detect and actuation mod- ule output function halted Check the battery. Check the alternator. Check the service data No. 087 "Battery Voltage". (See FUSO Diag- nostics service data (measured values).) 522112-4 Engine unable to start, or sig- nal detect and actuation mod- ule output function halted Check the battery. Check the battery cable, including disconnection and connection of the cables. Check the alternator. Check the harness between the battery and alternator. Check the high-current fuse, including disconnection and connection of the fuse. Check the harness between the high-current fuse and the signal detect and actuation module. Check the service data No. 087 "Battery Voltage". (See FUSO Diag- nostics service data (measured values).) 522149-17 (522149-31) Engine unable to start Replace the signal detect and actuation module. 522150-17 (522150-31) Engine unable to start Replace the signal detect and actuation module. TROUBLESHOOTING ---===WSE_1506_00001_0629.djvu===--- 54ES 54ES-71 (2) When signal detect and actuation module warning lamp (amber) illuminates Diagnosis code Symptom Items to be inspected (See the "Electronic control unit circuit diagram" for the location of the sig- nal detect and actuation module connector.) 2372-4 Left stop lamp does not illumi- nate Check the stop lamp bulb. Check the harness between the stop lamp and the signal detect and actuation module. Check the connector (12C) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 007 "Left rear brake light". (See FUSO Di- agnostics service data (measured values).) 2372-5 Left stop lamp does not illumi- nate 2374-4 Right stop lamp does not illu- minate Check the stop lamp bulb. Check the harness between the stop lamp and the signal detect and actuation module. Check the connector (13C) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 006 "Right rear brake light". (See FUSO Di- agnostics service data (measured values).) 2374-5 Right stop lamp does not illu- minate 522003-4 Left parking lamp does not illu- minate Check the parking lamp bulb. Check the harness between the parking lamp and the signal detect and actuation module. Check the connector (15B) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 011 "Left clearance lamps/Left side marker lamps". (See FUSO Diagnostics service data (measured values).) 522003-5 Left parking lamp does not illu- minate 522004-4 Right parking lamp does not il- luminate Check the parking lamp bulb. Check the harness between the parking lamp and the signal detect and actuation module. Check the connector (15B) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 010 "Right clearance lamps/Right side marker lamps". (See FUSO Diagnostics service data (measured val- ues).) 522004-5 Right parking lamp does not il- luminate 522005-4 Left tail lamp does not illumi- nate Check the tail lamp bulb. Check the harness between the tail lamp and the signal detect and ac- tuation module. Check the connector (13C) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 009 "Left taillamp". (See FUSO Diagnostics service data (measured values).) 522005-5 Left tail lamp does not illumi- nate 522006-4 Right tail lamp does not illumi- nate Che ck the tail lamp bulb. Check the harness between the tail lamp and the signal detect and ac- tuation module. Check the connector (12C) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 008 "Right taillamp". (See FUSO Diagnos- tics service data (measured values).) 522006-5 Right tail lamp does not illumi- nate 522020-4 License plate lamp does not il- luminate Check the license plate lamp bulb. Check the harness between the license plate lamp and the signal de- tect and actuation module. Check the connector (13C) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 013 "Left license plate lamp". (See FUSO Diagnostics service data (measured values).) 522020-5 License plate lamp does not il- luminate 522038-5 Blower does not operate Check the A/C BLOWER RELAY, including disconnection and connec- tion of the relay. (See Inspection of relays in signal detect and actua- tion module.) Check the service data No. 041 "Blower motor Relays". (See FUSO Di- agnostics service data (measured values).) 522039-5 Option ACC power unable to use Check the ACC RELAY, including disconnection and connection of the relay. (See Inspection of relays in signal detect and actuation module.) Check the service data No. 037 "Relay 'Power supply for optional bod- ies' (ACC)". (See FUSO Diagnostics service data (measured values).) 522042-5 Option IGN power unable to use Alternator does not operate (24 V models) Check the IGN RELAY, including disconnection and connection of the relay. (See Inspection of relays in signal detect and actuation module.) Check the service data No. 039 "Relay 'Power supply for optional bod- ies' (IGN)". (See FUSO Diagnostics service data (measured values).) ---===WSE_1506_00001_0630.djvu===--- 54ES-72 522043-5 Air conditioner does not oper- ate Check the A/C COMP COND RELAY, including disconnection and con- nection of the relay. (See Inspection of relays in signal detect and actu- ation module.) Check the service data No. 040 "Refrigerant compressor Relays". (See FUSO Diagnostics service data (measured values).) 522067-25 (522067-19) Headlamps illuminate sponta- neously Check the fuse (F09), including disconnection and connection of the fuse. Check the combination switch. Check the combination switch connector, including disconnection and connection of the connectors. Check the harness between the combination switch and the signal de- tect and actuation module. Check the connector (18B) of the signal detect and actuation module, including disconnection and connection of the connector. Check the service data No. 002 "Right turn signal". (See FUSO Diag- nostics service data (measured values).) 522077-25 (522077-19) Headlamps illuminate sponta- neously Diagnosis code Symptom Items to be inspected (See the "Electronic control unit circuit diagram" for the location of the sig- nal detect and actuation module connector.) TROUBLESHOOTING ---===WSE_1506_00001_0631.djvu===--- 54ES 54ES-73 E: Ignition relay H: Engine relay J: ACC relay (normally open 4-pin) Replace the relay if any abnormal conditions are found during checking for conductivity or operation. A: A/C blower relay B: Horn relay C: 12 V ACC relay (option) D: 12 V IGN relay (option) F: Fuel pump relay G: A/C compressor (normally open 4-pin) Replace the relay if any abnormal conditions are found during checking for conductivity or operation. C: 24 V ACC relay (option) D: Inspection of 24 V IGN relay (normally open 4-pin) Replace the relay if any abnormal conditions are found during checking for conductivity or operation. INSPECTION OF RELAYS IN SIGNAL DETECT AND ACTUATION MODULE ---===WSE_1506_00001_0632.djvu===--- (EURO 5 b+. EURO VI) AdBlue ® : Registered trademark of the Verband der Automobilindustrie e.V. (VDA) BlueTec ® : A brand of Daimler AG DUONIC ® : Registered trademark of Daimler AG ---===WSE_1506_00001_0633.djvu===--- Pub.No.Pub.No.00ELT0080, FEBRUARY 2015