diag connectors guide

MULTIBRAND DIAGNOSIS FOR

INDUSTRIAL VEHICLE

Connector's guide

Version C07-T1

DIAGNOSIS KIT

EDITION: JANUARY 2007 © Copyright COJALI S.L. This document has been written by Cojali S.L. Passing, copying, using or communicating the contents of this document is not allowed without the written consent by Cojali S.L. Cojali S.L. withholds the right to make all modifications it deems convenient for improvement of the product at any time and without previous notice of such. The information, messages and data contained in this manual or in the tool are only indicative, and do not bind the manufacturer in any way.

Connector’s guide

Version C07-T1 - 1 -

CONTENTS I. DAF ..................................................................................................................................2

I.1 LF................................................................................................................................2 I.2 CF65, CF75, CF85......................................................................................................3 I.3 XF95............................................................................................................................4 I.3 XF105..........................................................................................................................5

II. ERF..................................................................................................................................6 III. IVECO.............................................................................................................................7

III.1 EUROCARGO...........................................................................................................7 III.2 EUROSTAR ..............................................................................................................9 III.3 EUROTECH ............................................................................................................11 III.4 EUROTRAKKER.....................................................................................................13 III.5 STRALIS .................................................................................................................15

IV. MAN .............................................................................................................................16 IV.1 Models E/F/L/M 2000, F/M/U 90 .............................................................................16 IV.2 TG Series................................................................................................................17

V. MERCEDES-BENZ .......................................................................................................19 V.1 Models before 1996 .................................................................................................19 V.2 ACTROS..................................................................................................................20 V.3 ATEGO, AXOR ........................................................................................................21 V.4 ACTROS MPII .........................................................................................................22 V.5 ATEGO OBD, AXOR OBD.......................................................................................23

VI. RENAULT ....................................................................................................................24 VI.1 Models before 2006 ................................................................................................24 VI.2 Models DXi .............................................................................................................29 VI.3 Models DXi EURO4 ................................................................................................30

VII. SCANIA.......................................................................................................................31 VIII. VOLVO.......................................................................................................................32

VIII.1 Models before 1998 ..............................................................................................32 VIII.2 Models after 1998 .................................................................................................33 VIII.3 VOLVO V2 EURO4...............................................................................................34

IX. TRAILER......................................................................................................................35 IX.1 WABCO Trailer ECAS ............................................................................................35 IX.2 WABCO Vario C (Trailer ABS)................................................................................36 IX.3 WABCO VCS (Trailer ABS) ....................................................................................37 IX.4 WABCO VCSII (Trailer ABS) ..................................................................................38 IX.5 WABCO Trailer EBS...............................................................................................39 IX.6 HALDEX MODAL (Trailer ABS) ..............................................................................40 IX.7 HALDEX MODULAR (Trailer ABS) .........................................................................42 IX.8 KNORR KB3-TA (Trailer ABS)................................................................................43 IX.9 KNORR TEBS (TRAILER EBS) ..............................................................................44 IX.10 BOSCH / KNORR ABS A18..................................................................................47 IX.11 EB+ (Trailer EBS) .................................................................................................48

Connector’s guide


I. DAF In the following chapters we will study the different brake systems used by vehicles DAF, the location of the connector in every vehicle and the reference of JALTEST diagnosis connector. I.1 LF

LOCATION CONNECTOR

Diagnosis with multipins SYSTEM Diagnosis with connectors

JDC 100.2 + JTP 100-3

BRAKES Pin 1: Red Cable Pin

Pin 2: Black Cable Pin Pin 3: Yellow Cable Pin

SUSPENSION Pin 1: Red Cable Pin


ENGINE CONTROL

Pin 1: Red Cable Pin Pin 2: Black Cable Pin Pin 5: Yellow Cable Pin

GEARBOX Pin 1: Red Cable Pin


RETARDER

JDC 100.2 + MULTIPLEXOR + JDC 209M

Pin 1: Red Cable Pin Pin 2: Black Cable Pin

Pin 11: Yellow Cable Pin

Connector’s guide


I.2 CF65, CF75, CF85

LOCATION CONNECTOR


JDC 100.2 + JTP 100-3





ENGINE CONTROL




RETARDER




Connector’s guide


I.3 XF95

LOCATION CONNECTOR


JDC 100.2 + JTP 100-3





ENGINE CONTROL




RETARDER




Connector’s guide


I.3 XF105

LOCATION CONNECTOR

Diagnosis with multipins

SYSTEM Diagnosis with connectors JDC 100.2 + JTP 100-3







RETARDER

--



Connector’s guide


II. ERF The following chart shows the different systems of ERF vehicles, the connector location and its look and the reference of the necessary JALTEST cable for the diagnosis.

LOCATION CONNECTOR

--


SYSTEM Diagnosis with connectors JDI 201.2 + JTP 100-3

BRAKES --

Pin 1: Red Cable Pin Pin 2: Black Cable Pin Pin 8: Black Cable Pin


Connector’s guide


III. IVECO

In the following chapters we will study the different brake systems used by vehicles IVECO, the location of the connector in every vehicle and the reference of JALTEST diagnosis connector. III.1 EUROCARGO

EUROCARGO (Vehicles before 1998) LOCATION CONNECTOR


JDC 100-A.2 + JDC 200-A.2 + JTP 100-1

BRAKES JDC 100-A.2 + JDC 200-A.2 + JDC 202.2

Pin 1: Green Cable Pin Pin 2: --

Pin 3: Yellow Cable Pin • Diagnosis with connectors

In case you select the connection option to JalTest with connectors, you will then connect this one to the JDC 100A.2. There are two cables in this connector: one of them must be connected to JDC 200A.2, and the other one to connector JDC202.2.

• Diagnosis with multipins

The connection to JALTEST with multipins is carried out like this:

First of all, the connector JDC 100-A is coupled. Two cables appear from this connector: in one of them it can be read the text POWER, this one will be coupled to the connector JDC 200-A, and the other one will be coupled to the multipin connector JTP 100-1.

Connector’s guide


EUROCARGO (Vehicles after 1998) LOCATION CONNECTOR



BRAKES

Pin 3: Green Cable Pin Pin 4: Yellow Cable Pin Pin 29: Black Cable Pin Pin 30: Red Cable Pin

SUSPENSION


ENGINE CONTROL



Connector’s guide


III.2 EUROSTAR

EUROSTAR (Vehicles before 1998) LOCATION CONNECTOR


JDC 100-A.2 + JDC 200-A.2 + JTP 100-1




For the JalTest diagnosis with connectors: link the unit to JDC 100A.2. Two additional cables emerge from this connector: one of them goes to JDC200A.2. and from this one to the vehicle lighter, the other one shall be connected to JDC 202.2.



First, connect JDC 100A.2. Two cables emerge from this connector: One of them is to be connected to JDC 200A.2 and from this one to the vehicle lighter; the other is connected to JTP 100-1. Introduce the multipins in the diagnosis connector according to the below diagram:

Connector’s guide


EUROSTAR (Vehicles after 1998) LOCATION CONNECTOR

Diagnosis with multipinsSYSTEM Diagnosis with connectors

JDC 100.2 + JTP 100-4

BRAKES


SUSPENSION


ENGINE CONTROL


GEARBOX


RETARDER

JDC 100.2 +

MULTIPLEXOR +

JDC 206M


Connector’s guide


III.3 EUROTECH

EUROTECH ( Vehicles before 1998) LOCATION CONNECTOR


JDC 100-A.2 + JDC 200-A.2 + JTP 100-1







First you must connect JDC 100-A. There are two cables in this connector: one is connected to the JDC 200A.2 and from this one to the vehicle lighter, the other one is connected to multipins JTP 100-1. The multipins are then inserted to the vehicle diagnosis connector according to the following diagram.

Connector’s guide


EUROTECH ( Vehicles after 1998) LOCATION CONNECTOR



BRAKES


SUSPENSION


ENGINE CONTROL


GEARBOX


RETARDER



Connector’s guide


III.4 EUROTRAKKER

EUROTRAKKER ( Vehicles before 1998) LOCATION CONNECTOR


JDC 100-A.2 + JDC 200-A.2 + JTP 100-1




• Diagnosis with connectors




First, connect JDC 100A.2. There are two cables that emerge from this connector, one goes to JDC 200A.2 and from this one to the vehicle lighter, the other one goes to JTP 100-1. The multipins are plugged to the diagnosis connector following the below diagram.

Connector’s guide


EUROTRAKKER ( Vehicles after 1998) LOCATION CONNECTOR



BRAKES


SUSPENSION


ENGINE CONTROL


GEARBOX


RETARDER



Connector’s guide


III.5 STRALIS

STRALIS ( Vehicles after 1998) LOCATION CONNECTOR



ABS/EBS &

ECAS

Pin 4: Yellow Cable Pin Pin 29: Black Cable Pin Pin 30: Red Cable Pin

ENGINE CONTROL


GEARBOX Pin 18: Yellow Cable Pin Pin 29: Black Cable Pin Pin 30: Red Cable Pin

RETARDER



Connector’s guide


IV. MAN In the following sections we will see the different systems of MAN vehicles, the connector location in each vehicle and its look and the reference of the necessary JALTEST cable for the diagnosis. IV.1 Models E/F/L/M 2000, F/M/U 90

LOCATION CONNECTOR

SYSTEM Diagnosis with multipins Diagnosis with multipins

BRAKES

Pin A: Black Cable Pin Pin D: Red Cable Pin

Pin E: Yellow Cable Pin Pin F: Green Cable Pin

SUSPENSION


Pin G: Yellow Cable Pin Pin H: Green Cable Pin

ENGINE CONTROL


Pin a: Yellow Cable Pin Pin Z: Green Cable Pin

RETARDER

JDC 100.2 + JTP 100-4


Pin U: yellow Cable Pin

Connector’s guide


IV.2 TG Series

Models before 2005 LOCATION CONNECTOR


SYSTEM Diagnosis with connectors JDC 100A.2 + JTP 100-3 + JDC 200 A.2

BRAKES

SUSPENSION

ENGINE MANAGEMENT

RETARDER

GEARBOX

CENTRAL COMPUTER

JDC 207.2 Pin 4: Yellow Cable Pin

Connector’s guide




First of all, the connector JDC 100-A.2 (auxiliary cable) is coupled to the JALTEST, then the multipins JTP 100-3 are connected to the JDC 100-A.2.

Finally, the connector JDC 100-A.2 (auxiliary cable) is coupled with the JDC 200-A.2.

Models after 2005 LOCATION CONNECTOR


JDC 100.2 + JTP100-1 BRAKES

SUSPENSION

ENGINE

MANAGEMENT

RETARDER

GEARBOX

CENTRAL COMPUTER

--

Pin 16: Red Cable Pin

Pin 4: Black Cable Pin


Connector’s guide


V. MERCEDES-BENZ In the following sections you will see the different systems of MERCEDES-BENZ vehicles, the location of the connector in each vehicle and its look and the reference of the necessary JALTEST cable to make the diagnosis. V.1 Models before 1996

LOCATION CONNECTOR

SYSTEM Diagnosis with connectors Diagnosis with multipins *BRAKES

*SUSPENSION

INJECTION

GEAR BOX

INSTRUMENTATION

SPEED LIMITTER

ENGINE CONTROL

JDC 100.2 +

MULTIPLEXOR +

JDC 203M

--

NOTE: *There are more posibilities to diagnose connecting directly to ECU. To connect directly to these control units, it must use the inter-adapter of 25, 35 or 54 pins. See ABS/ASR C example in user´s manual.These inter-adapters are not included on JalTest diagnosis kit; otherwise it can be sent to a customer by order.

Connector’s guide


V.2 ACTROS

LOCATION CONNECTOR



BRAKES

SUSPENSION

ENGINE CONTROL

GEAR BOX

CENTRAL COMPUTER

RETARDER

INSTRUMENTATION

TACHOGRAPH

CONFORT SYSTEMS

JDC 203.2 Pin 1: Black Cable Pin Pin 2: Red Cable Pin


Connector’s guide


V.3 ATEGO, AXOR

LOCATION CONNECTOR


JDC 100.2 + JTP 100-4

BRAKES

SUSPENSION

ENGINE CONTROL

GEAR BOX

CENTRAL COMPUTER

RETARDER

INSTRUMENTATION

TACHOGRAPH

CONFORT SYSTEMS

JDC 203.2 Pin 1: Black Cable Pin Pin 2: Red Cable Pin


Connector’s guide


V.4 ACTROS MPII

LOCATION CONNECTOR


JDC 100.2 + JTP 100-1

BRAKES

SUSPENSION

ENGINE CONTROL

GEAR BOX

CENTRAL COMPUTER

RETARDER

INSTRUMENTATION

TACHOGRAPH

CONFORT SYSTEMS

JDC 208.2

Pin 4: Black Cable Pin Pin 7: Yellow Cable Pin Pin 15: Green Cable Pin Pin 16: Red Cable Pin

Connector’s guide


V.5 ATEGO OBD, AXOR OBD

LOCATION CONNECTOR


JDC 100.2 + JTP 100-1

BRAKES

SUSPENSION

ENGINE CONTROL

GEAR BOX

CENTRAL COMPUTER

RETARDER

INSTRUMENTATION

TACHOGRAPH

CONFORT SYSTEMS

JDC 208.2

Pin 4: Pin Cable Negro Pin 7: Pin Cable Amarillo Pin 15: Pin Cable Verde Pin 16: Pin Cable Rojo

Connector’s guide


VI. RENAULT VI.1 Models before 2006 In the following chart it is shown the look of the Renault vehicles diagnosis connector, as well as the reference of the JALTEST connector necessary to make the diagnosis. On the other hand, in the graphical schemes of this chapter it is indicated where the diagnosis connector and the control unit are placed in the different types of vehicle.

LOCATION CONNECTOR

SEE LOCATION IN ACCORDANCE WITH MODEL



BRAKES SUSPENSION

ENGINE MANAGEMENT

INSTRUMENTATION

JDC 205.2


Pin 11: Yellow Cable Pin Pin 12: Green Cable Pin

RETARDER VOITH


EDC V-MAC EDC ITC

JDC 100.2 +

MULTIPLEXOR +

JDC 205M Pin 2: Red Cable Pin


Connector’s guide


The drawings show the location of the connector and the ECU:

• FR1 / ILIADE

• TRACER

• PR 100.2 / PR 112 / PR 180.2 / PR 118

• PR 112 / PR 118 / R 312

Connector’s guide


• SHORT BUS

• AGORA

• S ... A / S ... B / M ... C / M ... D

• AE

Connector’s guide


• C 4x2 / CLM / C 6x4 / CBH

• R / G MANAGER / G MAXTER

• TRM 700.100

• KERAX 4x2/4x4/6x4/6x6/8x4

Connector’s guide


• MAGNUM OLD CABINE

• MAGNUM NEW CABINE

• PREMIUM

Connector’s guide


VI.2 Models DXi

Models DXi LOCATION CONNECTOR



JDI 201.2 + JTP 100-5 BRAKES

SUSPENSION

ENGINE MANAGEMENT

GEARBOX

INSTRUMENTATION

CENTRAL COMPUTER

AIR CONDITIONING

RETARDER

(...)

JDC 100.2 +

MULTIPLEXOR +

JDC 205M

Pin 2: Red Cable Pin Pin 5: Black Cable Pin Pin 8: Yellow Cable Pin Pin 9: Green Cable Pin

Connector’s guide


VI.3 Models DXi EURO4

Models DXi EURO4 LOCATION OBD CONNECTOR



SYSTEM JDI 201.2 + JTP 100-5

BRAKES

SUSPENSION

ENGINE MANAGEMENT

GEARBOX

INSTRUMENTATION

CENTRAL COMPUTER

AIR CONDITIONING

RETARDER

(...)



Connector’s guide


VII. SCANIA The following chart shows the different systems of SCANIA vehicles, the connector location and its look and the reference of the necessary JALTEST cable for the diagnosis.

LOCATION CONNECTOR


JDC 100.2 + JTP 100-3

BRAKES

SUSPENSION

ENGINE CONTROL

COORDINATOR

RETARDER

JDC 204.2

Pin 1: Red Cable Pin Pin 2: Black Cable Pin Pin 8: Yellow Cable Pin Pin 10: Green Cable Pin

Connector’s guide


VIII. VOLVO In the following chart we can see the different systems of VOLVO vehicles, the location of the connector and its look and the reference of the necessary JALTEST cable to make the diagnosis. VIII.1 Models before 1998

Models before 1998 LOCATION CONNECTOR

SYSTEM Diagnosis with connectors

JDC 201.2

BRAKES JDC 201.2 BLACK BLOCK

INJECTION JDC 201.2 YELLOW BLOCK

Connector’s guide


VIII.2 Models after 1998

Models after 1998 LOCATION CONNECTOR

SYSTEM Diagnosis with connectors BRAKES

SUSPENSION

ENGINE MANAGEMENT

GEARBOX

INSTRUMENTATION

CENTRAL COMPUTER

AIR CONDITIONING

RETARDER

(...)

JDC 201.2 *

If there is not JDC 201.2 connector, it must connect using JDI 201.2 and JDC 201 connectors together

Connector’s guide


VIII.3 VOLVO V2 EURO4

VOLVO V2 EURO4 LOCATION OBD CONNECTOR

Diagnosis with multipins SYSTEM

JDI 201.2 + JTP 100-5

BRAKES

SUSPENSION

ENGINE MANAGEMENT

GEARBOX

INSTRUMENTATION

CENTRAL COMPUTER

AIR CONDITIONING

RETARDER

(...)



Connector’s guide


IX. TRAILER IX.1 WABCO Trailer ECAS The diagnosis of the ECAS Trailer system is carried out through the following connector placed in the chassis of the towed vehicle.

Diagnosis connector Trailer ECAS

For such connector the JDC 103.2 cable of the JalTest Diagnosis KIT must be used.

When the user selects the option Trailer ECAS and the ECU are recognized by JalTest, the communication is established and the user enters into the main menu Trailer ECAS. If the ECU is not recognized, JalTest displays a message advising of this situation.

Connector’s guide


IX.2 WABCO Vario C (Trailer ABS) The diagnosis of the Vario C-Trailer ABS system is carried out by means of the following connector placed at the chassis of the towed vehicle.

Diagnosis connector for Vario C (Trailer ABS) For such connector the JDC 103.2 cable of the JalTest Diagnosis KIT must be used. If there is no specific diagnosis connector in the towed vehicle, we must proceed as follows, using the cable JalTest JDC 100.2 and the connector with phaston terminals JTP 100-6. • Open the ECU. • Disconnect the supplying connector (white block) and extract the Pin 1 (female phaston

with red colour cable). • Connect the removed phaston in the male phaston of the cable JTP 100-6. • Introduce the removed female phaston with red cable from JTP 100-6 in the gap of the

supply connector (PIN 1 white block) and reconnect. • Introduce in the diagnosis block the following connectors:

o Green cable: PIN 6. o Yellow cable: PIN 9. o Black cable: PIN 10.

Connector’s guide


IX.3 WABCO VCS (Trailer ABS) The diagnosis of the VCS-Trailer ABS system is carried out by means of the following connector placed at the chassis of the towed vehicle.

Diagnosis connector for VCS (Trailer ABS) For such connector the JDC 103.2 cable of the JalTest Diagnosis KIT must be used.

In the case of not existing connector in ECU's output labelled as "DIAGN" it will be necessary t use diagnosis connector Wabco 449 612 030 0.

Connector’s guide


IX.4 WABCO VCSII (Trailer ABS) The diagnosis of the VCSII-Trailer ABS system is carried out by means of the following connector placed at the chassis of the towed vehicle.

Diagnosis connector for VCS II (Trailer ABS) For such connector the JDC 103.2 cable of the JalTest Diagnosis KIT must be used.

In the case of not existing connector in ECU's output labelled as "DIAGN" it will be necessary to use diagnosis connector Wabco 449 615 030 0.

Connector’s guide


IX.5 WABCO Trailer EBS The diagnosis of the Trailer EBS system is carried out by means of the following connector placed at the chassis of the towed vehicle.

Diagnosis connector for Trailer EBS For such connector the JDC 103.2 cable of the JalTest Diagnosis KIT must be used. In case there is no connector, in the outlet of the ECU labelled "DIAGN" will be necessary to connect the diagnosis cable Wabco 449 672 030 0.

Connector’s guide


IX.6 HALDEX MODAL (Trailer ABS)

The diagnosis of the ABS MODAL system is carried out through the following connector placed in the lower part of the ECU.

Diagnosis connector ABS MODAL For such connector the JDC 100.2 cable and the JTP 100-4, connector with male Ø 1.5 cylinder terminals of the JalTest diagnosis Kit must be used. The connector has 6 male Ø 1,5 cylinder pins with cables of different colours. The pins must be connected according to the following scheme:

1: Black cable Pin. 2: Red cable Pin. 3: Orange cable Pin. 4: Blue cable Pin.

The pins with green and white cables remain free.

Connector’s guide


It is possible connect directly to the ECU using JDC 101.2 diagnosis cable. In this case it is necessary to open the ECU and connect in the diagnostic block according with the photograph:

Connector’s guide


IX.7 HALDEX MODULAR (Trailer ABS) The diagnosis of the ABS MODULAR system is carried out by means of the following connector placed at the chassis of the towed vehicle:

Diagnosis connector HALDEX MODULAR (Trailer ABS) For such connector the JDC 102 cable of the JalTest Diagnosis KIT must be used. Generally this connector is placed in the side of the vehicle:

The multipin cable JTP 100-3 must be connected as follows: 1: Red cable Pin. 2: Orange cable Pin. 3: Blue cable Pin. 4: Black cable Pin.

Connector’s guide


IX.8 KNORR KB3-TA (Trailer ABS) The diagnosis of the KB3-TA is carried out through the following connector placed in the chassis of the towed vehicle.

Diagnosis connector KB3-TA The JDC 100A.2 connector has two versions: • If the output of this connector has 9 pins, connect following this instructions: Use JTP 100-4 multipins with JDC 100A.2 cable and JDC 200A.2 lighter supply cable. JTP 100-4 multipins has to be connected in this way: Pin 3 – Yellow Pin 7 – Black • If the output of this connector has 15 pins, connect following this instructions: Use JDC 105.2 cable with JDC 100A.2 cable and JDC 200A.2 lighter power supply cable. In the case of not being able to locate the connector previously shown, the following connection with cable Knorr-Bremse EK3050 will be necessary to make the previous description.

Connector’s guide


IX.9 KNORR TEBS (TRAILER EBS) The diagnosis of the TEBS system is carried out through the following connector placed in the chassis of the towed vehicle.

Diagnosis connector TEBS For such connector the JDC 105.2 cable of the JalTest Diagnosis KIT must be used. When the user selects the option TEBS (Trailer EBS), communication is established and the user enters Trailer EBS main menu.

Connector’s guide


It must use multipins in the diagnosis connector following these instructions:

CONNECTOR MULTIPIN JTP 100-3

Pin 3 - Black Cable Pin 4 - Yellow Cable Pin 5 - Red Cable

If there is not diagnosis connector, there is two kind of connection: Option 1: To connect with the Knorr-Bremse cable reference EK3101.

Option 2: Diagnosis by CAN line using ISO 7628 cable: JA1 110.2: Electronic device for the connection in Knorr-Bremse TEBS systems through CAN lines. It has a green led that shows if the polarity and voltage are the correct in the diagnosis connector of the vehicle.

Connector’s guide


The connection diagram is shown below: • 9 pins connector: JalTest + JA1 110.2 + JDC 100.2 + JDC 110. • 15 pins connector: JalTest + JA1 110.2 + JDC 100.3 + JDC 110.2.

Connector’s guide


IX.10 BOSCH / KNORR ABS A18 The diagnosis of the ABS A18 system is carried out by means of the following connector located at the chassis of the towed vehicle.

Diagnosis connector TEBS For such connector the JDC 105.2 cable of the JalTest Diagnosis KIT must be used.

Connector’s guide


IX.11 EB+ (Trailer EBS) Diagnosis on EB+ system is done through the below connector situated in the ECU (upper left part). The connector can be identified either by the text on the lower part "DIAG" or by the tap colour: green.

EB+ Diagnosis connector

For such connector the JDC 108.2 cable of the JalTest Diagnosis KIT must be used. When the user selects the option EB+, communication is established and the user enters EB+ main menu.

diag connectors guide

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