case 325 & 330 articulated dump trucks...

ELECTRICAL

25 & 30 TON ARTICULATED DUMP TRUCKS 1

CASE 325 & 330 ARTICULATED DUMP TRUCKS

Electrical

ELECTRICAL


CNH America LLC © 2004 700 STATE STREET RACINE, WI 53404 U.S.A. Printed in U.S.A.

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Table of Contents Test Equipment ...................................................................................................5 Test Procedures ..................................................................................................8 Legends and Symbols ......................................................................................14 Relay and Fuse Identification and Location ...................................................17 Electrical Legend ..............................................................................................23 Power control and Distribution, Batteries, Alternator, Key Switch ..............26 Headlights, High Beam, Low Beam, Clearance, & Fog Light Circuits ..........30 Hazard and Directional Lights Circuits ...........................................................34 Indicator Lamps, Dash Panel ...........................................................................35 Mirror-Hood-AC, Mirror Alignment Motors & Heating, AC Circuit ................40 TV Monitor and Gauges....................................................................................42 Working Lights and Windshield Wipers..........................................................44 Differential Lock Switch Circuit .......................................................................44 Body Unloading Hoist and Transmission Kick Down Circuits......................46 Parking Brake Circuit........................................................................................46 Ejector Circuit (Optional)..................................................................................46

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Electrical Test Equipment

Electrical Testing The most important aspect of troubleshooting today’s sophisticated electrical and/or electronic systems is the test results. A service technician must have confidence in his testing equipment to get accurate readings.

The days of checking a system with a test light are past. Electronic equipment runs on very low amperage, and a test light can draw enough amperage to burn out a circuit in a control box. Today’s electronics will run on variable voltages. Just because the machine has 24-volt batteries does not mean the system is running on 24 volts. Most machines will have 24, 12, 8 and 5-volt circuits. With different voltages being used, a test light will be useless. The only way to test a circuit is with an electronic voltmeter and an ohmmeter.

The Electronic Voltmeter should be used to do all electrical testing and trouble shooting. Remember that the circuit must be fully connected and operated to get proper test results. You should be looking for voltage drops to determine where the problem is. You must also be aware of how the system functions. If the system shuts down after automatically detecting a fault, you cannot test the circuit for proper system voltage. An Ohmmeter should be used when a voltmeter cannot be used for some reason. The ohmmeter should only be used when checking components or circuits that have a specified resistance. An example would be a solenoid that may have a specified resistance of 7 to 9 ohms; an ohmmeter is the proper tool to be used.

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Listed below is an abbreviated list of electrical tools that can be purchased locally or through the OTC tool catalog.

Piercing Clips may be used to test for voltage in the harness with out

damaging the wires.

An example would be: Piercing Clips Fluke 1TC26 Alligator Clips Fluke 1TC21

Leads 1TC08 Digital Volt/Ohm Meter; An example would be a Fluke 23 Replacement Probes

Fundamentals of Testing an Electrical System Before any testing is done to the electrical system in question, the service technician must fully understand how the entire system (electrical and hydraulic) functions normally. In many instances, the operation of the system may only need to be explained to the operator, or a simple adjustment made to the system for it to function properly. Referencing the appropriate operator’s manual will generally resolve these types of problems. When searching for the cause of an electrical problem, it is desirable to obtain all of the symptoms of the problem from the operator. A few pertinent questions asked of the operator may give you valuable clues as to the cause of the problem. While questioning the operator, a chance remark may well reveal the cause of the problem to an alert service technician. Operate the equipment to see if you can duplicate the problem.

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Utilize the easiest and simplest tests first to try to identify the problem. When it has been determined that a problem does exist with the electrical system, the service technician must understand the fundamentals of electricity. Understanding the properties of voltage, current and resistance is a must. The service technician has to be equipped with the proper testing equipment to resolve the problem. Use of the digital multimeter is strongly recommended. However, just having the equipment is not enough, the service technician must understand and utilize the functions and features of the digital multimeter! Once the problem has been identified, correct repair procedures must be followed to insure that the problem does not reoccur. Use of the Electrical Connector and Terminal Repair Kit, is strongly recommended. The kit is equipped with the necessary tools and connectors for proper repairs as well as information on how to utilize the repair tools in the kit.

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Test Procedures

Visual Inspection Carefully inspect the complete wiring harness for damage. Check for loose or broken wires. Make sure the connector terminals are fully seated and locked in the connector. Insure that the terminals are clean and not damaged. Use of Lectra Clean, is recommended, and Silicone Compound Dielectric Grease, can be used for lubricant and corrosion protection. Testing For “Open” Circuits An “open” circuit is defined as a place in a circuit that is separated and does not permit a path for electrical current to flow. This could be a disconnected connector or a broken wire. Because the circuit is open, the circuit resistance, when measured with a Digital Multimeter, will indicate infinite resistance (OL or Open Lead). Test for continuity through each wire using a digital multimeter. Use wire colors or connector pin identification numbers to identify the wires at each end of the harness. If the harness is long and both ends cannot be reached, connect two pins together at one connector with a jumper wire. Test for continuity through the wires at the other connector. Repeat this process by moving the jumper wire as needed until all wires are checked. Finding an “Open” Circuit Using a digital multimeter set to the ohms (Ω) scale, connect one probe to each end of the broken wire. Move along the length of the harness, flexing the harness by hand, while watching the Multimeter. Any change on the ohmmeter indicates the damaged area has been located. If the damage cannot be located, find the approximate middle of the harness length. Carefully cut the outer jacket of the harness to reach the wire to be tested. Insert a needle or pin through the wire insulation and connect the meter to the needle or pin. Test for continuity between the middle and the end of the wire. If there is continuity, move to another test point farther down the wire and test again. When no continuity is obtained, the break in the circuit will be between the last points tested which will permit the exact location to be determined. If the cable is strapped down, it will be necessary to add a length of wire to one probe of the ohmmeter to lengthen the meter leads.

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“Opens”

A ________________ A B ________________ B C ________________ C D ________________ D E _______ ______ E F ________________ F

G _______ ______ G H ________________ H

I _________________ I J ______ ______ J K _________________ K L _________________ L

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Testing For Short Circuits

A “short” circuit is defined as an unintended, low resistance current path. This means that the current is taking a “shorter” path than was intended in the original circuit. This could be a result of two or more wires rubbing together (copper to copper) or a wire rubbing the system ground (copper to iron). This results in the shorted circuit having resistance much smaller than specifications as shown on the next page. Disconnect the harness at both ends. Use a digital multimeter set to the ohms scale, test for continuity between the wires. To accomplish this, at one of the harness connectors, test for continuity between pins as follows: 1-grd 2-grd 3-grd 4-grd 1-2 2-3 3-4 4-5 1-3 2-4 3-5 4-6 1-4 2-5 3-6 4-7 1-5 2-6 3-7 4-8 etc. etc. etc. etc. By progressively moving through the pin count, no combination of two conductors is missed. Continuity should not be found between any wires or the ground unless shown on the wiring schematic. If continuity IS found, the wires are shorted together. Finding A Short Circuit Connect the Ohm meter probes to the wires in the harness that are shorted to each other. Move along the harness flexing the harness by hand while watching the Digital Multimeter. Any change in the meter indicates that the damaged area has been located. Carefully cut the outer jacket of the harness to repair the shorted wires.

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“Short”

1 ________________________ 1

2 ________________________ 2

3 ________________________ 3

4 ________________________ 4

5 ________________________ 5

6 ________________________ 6

7 ________________________ 7

8 ________________________ 8

9 ________________________ 9

10 ______________________ 10

11 ______________________ 11

12 ______________________ 12

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Testing For High Resistance

A “high resistance” circuit is defined as an unintended resistance to current flow. This means that the circuit must overcome more resistance than normally found in the circuit. Corroded connectors or wires, or a wire in the circuit that is nearly pinched in half could cause this condition. This may cause the circuit to work erratically or not at all. If the circuit is tested while disconnected from the load, the circuit may or may not indicate the proper resistance and/or voltage level. A high resistance circuit can generally only be tested when the circuit is under a load (i.e. solenoid activated, control module resetting, etc.). To properly test for a high resistance circuit, the digital multimeter (set to the voltage scale) has to be installed into the completed circuit and operated. If a high resistance circuit is present, the voltage recorded when operating the circuit will be lower than specifications. Finding A High Resistance Circuit

A digital multimeter is used (set to the volts scale) to test for a high resistance circuit. The digital multimeter is placed in the circuit so that it becomes a parallel path for the circuit. The completed circuit voltage (as shown on the multimeter) is then checked between segments of the circuit. The problem area has been located when the voltage changes noticeably on a segment being checked. As an example, refer to the next page, the DVM indicates circuit voltage for three of the segments of .01 volt indicating low resistance. The fourth segment of the circuit indicates .20 volts, indicating higher resistance. The original circuit is using the DVM to indicate the higher circuit resistance in the fourth segment.

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COLOR CODES

The wiring system has been split into ten main functions, associated with ten cable colors. A four-digit number identifies each function. The first digit of the number indicates the basic function and color of the cable. The next three digits indicate the specific wire on the machine.

CODE COLOR FUNCTION 1111 Light Blue Optical and audible signals 2222 White Illumination by headlights 3333 Yellow Parking lights/side position lights 4444 Gray Internal Lighting 5555 Orange Optical signals, engine operation and measuring

instruments 6666 Violet Optical signals 7777 Red Main power not excluded by the ignition switch 8888 Green Switch key operated supply 9999 Pink Electrically operated mechanical components 0000 Brown Ground

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Number 1 Ground (-) (31) Number 2 Battery power (24V+) (30) Number 3 Power when the key switch is in the on or start position (15). Number 4 Power with the key switch in the on position from relay E3 (15/A, off during engine cranking). Number 5 Power when the key switch is in the on or start position from fuse F18 (15).

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Relay numbers and Fuse identification and location

The 25 & 30 ton articulated trucks have one main electrical distribution center, which allows access to relays and fuses. The main electrical distribution center is located in the right front access panel in the cab, all of the fuses and relays for the truck are there. The schematics and pictures on the next pages list the name, location, and function of each relay and fuse. Note that some of the fuses and relays are optional and are not installed on all of the trucks. When replacing relays, it is important to order the same part number for the new relay as the old relay. Failure to do so may result in a short in the circuit, which could result in electrical damage to the wiring harness. There are three different types of relays used on these trucks. They all fit in the same socket. There are two diode blocks, (D1 & D2) that also fit in the same type socket, don’t interchange them.

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Relay and Fuse Locations

INTERCONNECTION CONTROL UNIT

ICU

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INTERCONNECTION CONTROL UNIT

ICU

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White Fuse Block Black Fuse B lock

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FUSE IDENTIFICATION TABLE

Fuse Use Amp. Fuse Use Amp. Fuse Use Amp 1 Position lights-

instr. cluster 7.5 13 Instruments-

CCTV 5 31 LH side wiper 7.5

2 Position lights-warning lights

7.5 14 Warning Lights 3 32 RH side wiper 7.5

3 High beams-Low beam

3 15 Wind shield wiper

7.5 33 Park brake- Body cont.

7.5

4 LH low beam 7.5 16 Hazard Lights 10 34 24/12 converter 10 5 RH low beam 7.5 17 Turn signal

lights 7.5 35 Power socket

12 -volt 7.5

6 LH high beam 7.5 18 Stop light, Reverse light, Fuel Solenoid, Monitor

7.5 36 Hood Raising Pump

10

7 RH high beam 7.5 19 Seat-Low temp. solenoid

7.5 41 Transmission controller

7.5

8 Front Work lamps (75W x 4)

20 20 Speedometer 3 42 Emergency Steering

7.5

9 Rear fog light 5 21 Cigarette lighter Ceiling lamps

10 43 6x6- Jake brake

10

10 Not used 7.5 22 Rotating or Flashing Light

7.5 44 Transmission controller

7.5

11 Horn 10 23 Air conditioner 10 45 Differential lock 7.5 12 Mirror-Hood-

High beam flash 7.5 24 Fan Control 20 46 Not used 7.5

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RELAY IDENTIFICATION TABLE

Type Relay Use Type Relay Use

E1 Not used S E18 K2 relay in rev. N E2 Headlight S E19 Emergency steering N E3 Switched

power S E20 K1 relay

Neutral start N E4 Flasher S E21 Jake brake A S E5 Park brake S E22 Jake brake B N E6 Stop light S E23 Park brake (idle) S E7 Not used S E24 Transfer E8 Not used S E25 Emergency safety

pump X E9 Wiper S E26 Jake brake A retarderS E10 High and low

beam S E27 LH side window wiper

N E11 Work Lights S E28 RH side window wiperN E12 Horn S E29 Hourmeter S E13 Not used S E30 Side window washer S E14A Ejector (opt) S E31 Climate control E14B Not used S E32 Telecamera E15 Not used S E33 Hood lift

S E17 Body hoist and gear shift

Z D1 Emergency steering pump safety pump

buzzer Z D2 Park brake

Light T T1 Heater

8900116885

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ELECTRICAL LEGEND 100 INTERCONNECTION CONTROL UNIT (ICU) 130 RIGHT TURN INDICATOR CIRCUIT

101 BATTERIES 130a RIGHT FRONT TURN INDICATOR LAMP

102 STARTER 130b RIGHT REAR TURN INDICATOR LAMP

103 ALTERNATOR 131 LEFT SIDE TURN INDICATOR LAMP

104A STARTER RELAY 132 RIGHT SIDE TURN INDICATOR LAMP

104B BRAKE PUMP UNLOADING VALVE 133 ENGINE LOW TEMP. SWITCH

105 EMERG. STEERING PUMP (325) 134 ENGINE PRE-START HEATER

106 EMERG. STRG PUMP RELAY (325) 135 ENGINE HEATER TIMER RELAY T1

107 MASTER SWITCH 136 OPERATOR’S SEAT 24 VOLT CONNECTOR

108 ENGINE HEATER LOW TEMP. RELAY 137 EMERG. STEERING PUMP VALVE (30 TON)

109 KEY SWITCH 138 MASTER DISCONNECT RELAY (OPT)

110 HOUR METER RELAY E29 139 MASTER DISC. RELAY SWITCH (OPT)

111 EXTERNAL LIGHT SWITCH 140 FUEL SHUT-OFF SOLENOID (30 TON)

112 FLASHER SWITCH 141 FUEL SHUT-OFF SOLENOID (25 TON)

113 HIGH AND LOW BEAM SWITCH 200 WARNING LAMPS PANEL

114 LEFT CLEARANCE LIGHTS 201 WARNING LAMPS PANEL

114/A FRONT LH CLEARANCE LIGHT 202 WARNING LAMPS PANEL

114/B SIDE LH CLEARANCE LIGHT 203 AIR CLNR RESTRICTION SWITCH N.O.

114/C REAR LH CLEARANCE LIGHT 204 PARK BRAKE PRESSURE N.C.

115 RIGHT CLEARANCE LIGHTS 205 TRANS. DIFF-LOCK INDIC. SWITCH N.O.

115/A FRONT RH CLEARANCE LIGHT 206 REAR AXLE DIFF-LOCK SWITCH N.O.

115/B SIDE RH CLEARANCE LIGHT 207 ACCUM. LOW BRAKE PRESSURE

115/C REAR RH CLEARANCE LIGHT 208 BRAKE OIL FILTER SWITCH N.O.

116 LH LOW BEAM 209 LAMP TEST SWITCH

117 RH LOW BEAM 210 ROTATING BEACON SWITCH

118 LH HIGH BEAM 211 ROTATING BEACON LAMP

119 RH HIGH BEAM 212 HEATED MIRROR SWITCH (OPT)

120 REAR FOG LIGHT SWITCH 213 LH HEATED MIRROR (OPT)

121 REAR FOG LIGHT LAMP 214 RH HEATED MIRROR (OPT)

122 BACK-UP LIGHT LAMP 215 MIRROR MOTOR SWITCH (OPT)

123 BACK-UP ALARM HORN 216 LH MIRROR MOTOR (OPT)

124 BRAKE LIGHT SWITCH 217 RH MIRROR MOTOR (OPT)

125 BRAKE LIGHTS 218 HOOD RAISING RELAY E33

126 HAZARD LIGHT SWITCH 219 HOOD OPENING BUTTON CHASSIS

127 TURN SIGNAL SWITCH 220 CLIMATE CONTROL

128 FLASHER MODULE 221 AIR CONDITION PRESSURE SWITCH N.O.

129 LEFT TURN INDICATOR CIRCUIT 222 BODY RAISED SWITCH N.C. - HELD OPEN

129a LEFT FRONT TURN INDUCATOR LAMP 223 AIR CONDITIONING COMPRESSOR

129b LEFT REAR TURN INDICATOR LAMP 224 CIGARETTE LIGHTER (24V)

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ELECTRICAL LEGEND 225 LH CEILING LIGHT SWITCH 410 EMERGENCY STEERING PRES. SWITCH

226 RH CEILING LIGHT SWITCH 411 CAB WARNING BUZZER

301 SPEEDOMETER 412 24/12V CONVERTER

302 TACHOMETER 413 SOCKET 12V

303 ENGINE WATER TEMP. GAUGE 414 SOCKET 12V

304 FUEL LEVEL GAUGE 416 BODY RAISING CONTROL SWITCH

305 FUEL LEVEL SENDER 417 EJECTOR SWITCH (IF EQUIPPED)

306 ENGINE OIL PRESSURE GAUGE 418 BODY RAISING/LOWERING SOLENOID

307 TRANS. OIL TEMPERATURE GAUGE 419 EJECTOR SOLENOID (IF EQUIPPED)

308 TRANSMISSION TEMPERATURE SENSOR 420 BODY RAISED LIMIT SWITCH (OPT.)

309 ~ 421 BODY LOWERING TIMER (OPT)

310 TV MONITOR, REAR VIEW DEVICE 422 PARK BRAKE SWITCH

311 WINDSHIELD WIPER/WASHER SWITCH 423 PARK BRAKE SOLENOID VALVE

312 WINDSHIELD WIPER MOTOR 424 RADIO

313 WINDSHIELD WASHER PUMP 425 LEFT RADIO SPEAKER

314 SIDE WINDOWS WIPER SWITCH 426 RIGHT RADIO SPEAKER

315 LH SIDE WINDOW WIPER MOTOR 427 CB RADIO (OPT)

316 RH SIDE WINDOW WIPER MOTOR 428 ZF TRANS. DIF-LOCK INTERFACE

317 SIDE WINDOWS WASHER SWITCH 429 JAKE BRAKE/RETARDER INTERFACE (330)

318 SIDE WINDOWS WASHER PUMP 500 ZF TRANSMISSION CONTROLLER EST37

319 HORN SWITCH 501 DIAGNOSTIC CONNECTOR

320 HORN 502 TRANSMISSION SHIFTER CONNECTOR

321 HOURMETER 503 CAN. DATA BUS CONNECTOR

322 ENGINE TEMPERATURE LIGHT SWITCH 504 ZF TRANSMISSION DISPLAY

322 ENGINE TEMP GAUGE SENDING UNIT 505 31 PIN EST 37 CONNECTOR

323 ENGINE OIL PRESSURE LIGHT SWITCH 506 7 PIN EST 37 CONNECTOR

324 ENGINE OIL PRESSURE INDI. SENDER 507 22 PIN EST 37 CONNECTOR

325 FRONT WORK LIGHT SWITCH 508 ENGINE SPEED SENSOR (TRANSMISSION)

326 FRONT WORK LIGHTS 509 TURBINE SPEED SENSOR (TRANSMISSION)

327 TACHOMETER SENDER 510 GEAR TRAIN SENSOR (TRANSMISSION)

328 TACHOMETER SIGNAL FILTER (330) 511 TRANSMISSION RETARDER TEMP. SENSOR

400 JAKE BRAKE/RETARDER SWITCH (330) 512 TRANS. FILTER RESTRICTION SWITCH

401 RETARDER SWITCH (330 OPT) 513 TRANSMISSION CONTROL VALVE CONNECT

402 DIFFERENTIAL LOCK SWITCH 514 TRANSMISSION OUT-PUT SPEED SENSOR

403 TRANSMISSION KICK DOWN SWITCH 515 TRANSMISSION DIFF-LOCK SOLENOID

404 INTERMED. AXLE DIFF-LOCK SOLENOID 516 RETARDER SOLENOID VALVE

406 JAKE BRAKE ENGINE SENSOR 517 ENGINE LOAD SENSOR

408 JAKE BRAKE "A" SOLENOID (330) 518 CONVERTER LOCK UP CLUTCH SOLENOID

409 JAKE BRAKE "B" SOLENOID (330)

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POWER CONTROL AND DISTRIBUTION

General (Batteries, Master Switch, Key Switch, Starter & Emergency Steering Pump) The starting circuits consist of two 12-volt batteries 101 connected in series. The negative post of one battery is grounded to the engine block. Power from the positive post of the other battery is routed through the Battery master switch 107 and on to the starter relay 104A. Power is also supplied to the alternator 103, starter motor 102, emergency steering Pump Relay 106 (E8) and the key switch 109. Alternator: 103 The positive post of the alternator (B+), is connected to the battery master switch 107. The negative post (B-), is connected to the chassis. The alternator exciter post (D+), is fed back through the Alternator charge warning light and the Hour Meter Relay E29. Key Switch 109 (Off Position) The key switch 109 has three-positions, off, on and start. Power is supplied to the ignition switch from the batteries through the battery cut off switch 107. In the off position no power is supplied through the ignition switch. Key Switch 109 (On Position) When the key switch 109 is turned to the first position clockwise, power flows from terminal 15/A of the key switch to the E3 relay coil, which turns it on. The E3 relay then supplies power by wire 15/A to fuses F12, F15, F24, F31 and F32, and to terminal 8 of the headlight switch 111. Power from terminal 15 of the key switch flows by wire 15 to fuses F13, F14, F17, F18, F19, F22 and F23, and to terminal 4 of the headlight switch 111. Key Switch 109 (Start Position) When the key switch 109 is turned to the start position and the shift lever is in the neutral position, 24 volt power is sent through the key switch to K1 relay E20, the gearbox-in-neutral relay. Power continues on to activate the brake pump unloading solenoid valve 104, and to energize the starter relay 104, which cranks the engine. The circuits previously discussed from terminal 15 of the key switch 109, also remain active in the start position.

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Number 1 GROUND Number 2 BATTERY POWER (+) Number 3 POWER WITH KEY IN RUN/START POSITION (15) Number 4 POWER WITH KEY IN RUN POSITION FROM RELAY E3 (15/A) Number 5 POWER WITH KEY IN ON/ START POSITION FROM FUSE 18

100 FUSE AND RELAY BOARD 101 BATTERIES 109 KEY SWITCH 102 STARTER 133 LOW TEMP. BUTTON 103 ALTERNATOR 134 LOW TEMP. HEATER 105 EMERGENCY STEERING PUMP 107 MASTER SWITCH

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POWER CONTROL AND DISTRIBUTION

Brake Pump Unloading Solenoid Valve: 104B The brake pump unloading solenoid valve 104B is energized every time the key switch is in the start position and the transmission shift lever 502 is in neutral, to release the brake pump back-pressure for easier starting. Cold temperature Start Relay: T1 The cold engine temperature start relay T1 is supplied with power from fuse F19, with the key switch in the on or start position. The low temperature start push button 133 is supplied power through the normally closed contacts of the hourmeter relay E29, from fuse F19, with the key switch 109 in the on or start position, and the alternator 103 not charging. When the low temperature start push button 133, is pressed, power is sent to energize the engine heater relay T1. The power going through the relay supplies the power to the low temperature start relay 108. When this relay is energized, battery power is able to flow to the heater.

Neutral start relay: E20 The neutral start relay E20 (Page 46 & 47), is activated by a signal that is sent from the transmission shift selection lever 502. This relay is active only when the shift selection lever is in the neutral position. Engine run/stop solenoid: 140 or 141 On the 8.3-liter engine, there are 3 wires plugged into the engine stop solenoid, (141). Pink wire 9903 is powered whenever the key switch is in the run or start position, from fuse F18. This is the holding coil wire. Green wire 8888 is powered only when the key switch is in the start position, green wire 8888* is powered through the neutral start relay number E20, (page 49). This is the pull-in coil wire. The other wire is a ground wire, connected to the chassis. On the M11 engine, solenoid 140, there is the pink wire 9903, powered whenever the key switch is in the run or start position, from fuse F18. It must be powered for the engine to run.

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100 FUSE AND RELAY BOARD 101 BATTERIES 109 KEY SWITCH 102 STARTER 133 LOW TEMP. BUTTON 103 ALTERNATOR 134 LOW TEMP. HEATER 105 EMERGENCY STEERING PUMP 107 MASTER SWITCH

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Lighting

The headlight switch 111 is a THREE-position toggle switch. The following table illustrates the THREE positions. Off Position (A) Power is fed into the headlight switch 111 from three sources: The first power supply comes directly from the battery101, through the Battery Switch 107 to terminal 2 of the headlight switch 111, yellow wire 3333. The second power source comes directly from the key switch 109 when it is in run or start position to terminal 4, green wire 8887. The third source comes from relay number E3 when the key switch is in the run position to terminal 8, white wire 2235. When the headlight switch is in the off position, power stops at all three points. Second Position (B) When the headlight switch 111 is pressed to the number two position, power flows from terminal number 2, through the switch and out terminal number 3 of the headlight light switch, yellow wire 3380, powering fuses F1 and F2, and on to the 4 clearance lights 114 & 115 on the front and rear of the main frame. Third Position (C) When the headlight light switch 111 is pressed to the number 3 position, power flows from terminal 4, powered from the key switch in the run or start position, out terminal 3 of the light switch, yellow wire 3380. This powers fuses F1 and F2 flowing on to the 4 clearance lights 114 & 115 on the front and rear of the main frame. Power from terminal number 8, coming from the key switch in the run position flows out terminal number 6, to fuses F3 and F9. Power from fuse F3 energizes relay E2 and on to terminal 3 of the headlight low/high beam switch 113. With the E2 relay energized, battery power is able to flow to relay E10 contacts. With relay E10 not energized (low beam position), this power flows through relay E10 NC contacts to fuses F4 and F5, powering the low beam headlights. With the low beam/high beam switch 113, in the high beam, closed position, relay E10 will be energized, sending power from relay E2, out to fuses F6, F7 and F10, turning on the headlight high beams. At the same time that the headlights are on, power from fuse F9 is sent to terminal 2 of the fog lamp switch 120, when the switch is turned on, this power flows out terminal 3 to the rear red fog light 121.

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111 LIGHT SWITCH 119 R-H HIGH BEAM 112 HIGH BEAM FLASHER SWITCH 120 REAR FOG LIGHT SWITCH 113 HIGH AND LOW BEAM SWITCH 121 REAR FOG LIGHT LAMP 114 A/B/C LEFT SIDE AND MARKER LIGHTS 122 REVERSE LIGHT LAMP 115 A/B/C RIGHT SIDE AND MARKER LIGHTS 123 REVERSE ALARM HORN 116 L-H LOW BEAM 124 BRAKE LIGHT SWITCH 117 R-H LOW BEAM 125 BRAKE LIGHTS 118 L H HIGH BEAM Number 1 GROUND Number 2 BATTERY POWER (+) Number 3 POWER WITH KEY IN RUN/START POSITION (15) Number 4 POWER WITH KEY IN RUN POSITION FROM RELAY E3 (15/A) Number 5 POWER WITH KEY IN ON/ START POSITION FROM FUSE 18

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Lighting

HIGH BEAM FLASH RELAY: E4 The E4 relay is powered from fuse F12, any time the key switch is in the run position. When the High Beam Flasher Control 112 is squeezed, a ground path is made to energize relay E4, which sends battery power out to fuses F6, F7 and F10, turning on the high beam headlights as long as the control is squeezed. BACK UP LIGHT 122 AND REVERSE ALARM 123 Relay E18 is powered from fuse F18 when the key switch is in the run or start position. When the Transmission Selector Lever 502, is shifted to reverse, relay E18 is energized, sending this power to the back up light 122 and the reverse alarm 123. Additional lighting for backing up can be had in the US by replacing the Red Fog light lens with a clear lens and switching it on when backing. BRAKE LIGHTS 125 The brake light switch 124, and the brake light relay E6, are supplied with power when the key switch is in the run or start position through fuse F18. When brake light switch 124 closes by brake pressure, power flows to the brake light relay E6. When this relay is energized, it sends power to the brake lights 125. The brake light pressure switch is located on the treadle valve of the 25 ton truck, and on the manifold on the back of the cab on the 30 ton truck.

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111 LIGHT SWITCH 118 L-H HIGH BEAM 112 HIGH BEAM FLASHER SWITCH 119 R-H HIGH BEAM 113 HIGH AND LOW BEAM SWITCH 120 REAR FOG LIGHT SWITCH 114 A/B/C LEFT SIDE AND MARKER LIGHTS 121 REAR FOG LIGHT LAMP 115 A/B/C RIGHT SIDE AND MARKER LIGHTS 122 & 123 REVERSE LIGHT/HORN 116 L-H LOW BEAM 124 BRAKE LIGHT SWITCH 117 R-H LOW BEAM 125 BRAKE LIGHTS

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LIGHT CIRCUIT

CONTROL OF TURN SIGNAL AND HAZARD LIGHTS Off position Fuse F17 sends power to the hazard light switch 126 terminal 8, whenever the key switch is in the on or start position. With the hazard switch in the off position, this power is sent to terminal 2 of the flasher module 128. Since terminal 1 of the flasher module is connected to terminal 2A of the turn signal directional control switch 127, and terminal 5 of the hazard light switch, it is ready for which ever choice the operator makes. The flasher module will not send power out terminal numbers 4 or 12, no lights will be turned on. HAZARD LIGHTS On position Battery power from fuse F16 enters the hazard light switch 126, at terminal 2, with the switch in the on position, this power is sent to terminal 2 of the flasher module 128, which is mounted behind the dash panel. Also, with the switch in the on position, terminal 1 of the flasher module is connected to terminals 8 and 13 of the flasher module 128, through the hazard light switch terminals 1, 3 and 5. Therefore the flasher module will send power out terminals 4, and 12, to flash the left and right, front and rear directional lights. Turn signals The turn signal control 127 connects terminal number 1 of the flasher module 128 to either terminal 8 or 13, depending on whether a right or left turn. At this time the flasher module will send power out terminal 4, or terminal 12, to flash the appropriate lights, left or right, front and rear.

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INDICATOR LAMPS


126 HAZARD SWITCH 130 RIGHT TURN INDICATOR LAMPS 127 TURN SIGNAL SWITCH 131 LEFT SIDE TURN INDICATOR LAMPS 128 FLASHER MODULE 132 RIGHT SIDE TURN INDICATOR LAMPS 129 LEFT TURN INDICATOR LAMPS

ELECTRICAL


The indicator lights are shown in three blocks of ten lights apiece. Blocks number 200, 201 & 202. Not all lights are used in each of the blocks. Block 200 Number 1 Engine cold start heating indicator light: Powered from the heater relay T1 when the heat coils are on. It has a constant path to ground. Number 2 Engine air filter restriction indicator light: Powered from fuse F14 when the key switch is in the run or start position. It receives a path to ground through the vacuum operated switch 203, when the air filter needs to be serviced. This light is also connected to the lamp test button 209, pressing the test button will complete a ground path and illuminate the light. Number 3 Alternator indicator light: Powered from fuse F14 when the key switch is in the run or start position. It receives a path to ground through the D+ terminal of the alternator, number 103. Number 4 High beam indicator light: Powered from fuse F6 when the headlights are on high beam. It has a constant path to ground. Number 5 Clearance lights indicator light: Powered from fuse F2 when the clearance lights are on. It has a constant path to ground. The clearance lights can be turned on without the key switch being on. Number 6 & Number 7 Direction indicators & Hazard lights indicator light: Only one lamp, Number 6 is used to indicate both Directional and Hazard lights on condition. The lamp is powered from terminal 6 of the flasher module 128. It has a constant path to ground.

ELECTRICAL


200 WARNING LAMPS 203 AIR CLEANER RESTRICTION. SWITCH

Number 1 GROUND Number 4 POWER WITH KEY IN RUN POSITION FROM RELAY E3 (15/A) Number 2 BATTERY POWER (+) Number 5 POWER WITH KEY IN ON OR START POSITION FROM FUSE 18 Number 3 POWER WITH KEY IN RUN OR START POSITION (15)

ELECTRICAL


INDICATOR LAMPS Number 8 Park brake indicator light: Powered from fuse F14 when the key switch is in the run or start position. It receives a ground from the park brake switch 422, when the switch is in the on position. This light is also hooked to the lamp test button 209, pressing the test button will complete a ground path and illuminate this light. Numbers 9 and 10 Front and Rear brake pressure indicator lights: Powered from fuse F14 when the key switch is in the run or start position. Brake system low pressure light receives a ground from the accumulator pressure switch 207, when the brake system pressure is low. This light is also hooked to the lamp test button 209, pressing the test button will complete a ground path and illuminate the light. Number 11 Low engine oil pressure indicator light: Powered from fuse F14 when the key switch is in the run or start position. It receives a ground from the engine oil pressure switch 323 when engine oil pressure is low. Number 12 Differential lock indicator light: Powered from fuse F14 when the key switch is in the run or start position. It receives a ground from the differential lock switch 205 when the differential lock is in the on position. This light is also hooked to the lamp test button 209, pressing the test button will complete a ground path and illuminate this light. Number 13 Body raised indicator light: Powered from fuse F14 when the key switch is in the run or start position. It receives a ground from the body-raised switch 222, when the body is in the raised position. This light is also hooked to the lamp test button 209, pressing the test button will complete a ground path and illuminate this light. LAMP TEST BUTTON: 209 When this button is pressed, a ground path is made to the following indicator lights turning them on: Air cleaner restriction, high beams, clearance lights, brake pressure, park brake, differential lock and body up.

ELECTRICAL


201 WARNING LAMPS 209 DASH LAMP TEST BUTTON 202 WARNING LAMPS 222 BODY RAISED SWITCH 206 REAR DIFF LOCK SWITCH 207 ACCUMULATOR BRAKE PRESSURE SWITCH 208 BRAKE OIL FILTER SWITCH

Number 1 GROUND Number 4 POWER WITH KEY IN RUN POSITION FROM RELAY E3 (15/A) Number 2 BATTERY POWER (+) Number 5 POWER WITH KEY IN ON OR START POSITION FROM FUSE 18 Number 3 POWER WITH KEY IN RUN OR START POSITION (15)

ELECTRICAL


Rotating light: Fuse F22 sends power to the rotating light switch 210 when the key switch is in the run or start position. When the switch is turned on, the power travels to the rotating light 211. This light has a constant ground. Mirrors: With the key switch in the run position, power from fuse F12 flows to the mirror heat switch 212, and to the mirror control switch 215. With the heat switch turned on, power flows to heat the mirrors, 213 and 214. When the remote control mirror adjustment switch 215 is moved, power will flow to the mirror motors 216 or 217. Hood raise or lower: With the key switch in the run position, power from fuse F12 travels to the hood relay, number E33. When the hood opening/closing button number 218 is pressed a ground path is made to energize relay number E33. This allows power from fuse number F36 to flow to hood pump motor number 219. Cigarette lighter: 224 The cigarette lighter receives battery power from fuse F21 all the time. Internal lighting: 225 and 226 The inside lights receive battery power from fuse F21 all the time. When the switch is closed it sends power to internal lights 225 or 226. Air-condition: With the key switch in the run or start position, power from fuse F24 is sent to the climate control switch 220, when this switch is closed, power will flow to the climate control relay, E31. When the air-conditioner switch number 220 is turned on, a ground path is made to energize relay E31, sending power from fuse F23 to the air-conditioner clutch, 223.

ELECTRICAL


210 ROTATING LAMP SWITCH 221 A-C SWITCH 211 ROTATING LAMP 215 MIRROR MOTOR SWITCH 223 A-C COMPRESSOR 212 HEATED MIRROR SWITCH 216 L-H MIRROR MOTOR 213 L-H HEATED MIRROR 217 R-H MIRROR MOTOR 214 R-H HEATED MIRROR 220 CLIMATE CONTROL

Number 1 ground Number 4 power with key in run position from relay E3 (15/A) Number 2 battery power (+) Number 5 power with key in on or start position from fuse 18 Number 3 power with key in run or start position (15)

ELECTRICAL


TV monitor: 310 With the key switch in the run or start position, power from fuse F13 is sent to the TV relay E32, sending power to the TV monitor, 310, whenever the shift selector lever is in the reverse position, to power the monitor. Speedometer: 301 The speedometer receives power from fuse F20 all the time and power from fuse F13 whenever the key switch is in the run or start position. It also receives a speed signal from pin 36 of the ZF transmission controller. Tachometer: 302 The tachometer receives power from fuse F13 whenever the key switch is in the run or start position. It also receives a signal from the engine RPM Sender, 327. Module 328 is a noise suppression device. Engine coolant temperature gauge and warning light 303 The engine coolant temperature gauge receives power from fuse F13 when the key switch is in the run or start position. It also receives a signal from the engine coolant temperature-sending unit, number 322. The engine coolant warning light receives power from fuse F13 and a ground from the sending unit 322. Fuel level gauge: 304 The fuel level gauge receives power from fuse F13 when the key switch is in the run or start position, and a signal from the fuel level-sending unit 305. Engine oil pressure gauge: 306 The engine oil pressure gauge receives power from fuse F13 when the key switch is in the run or start position, and a signal from the engine oil pressure-sending unit 324. Engine oil pressure light: The engine oil pressure light receives power from fuse F13 when the key switch is in the run or start position, and a signal from the engine oil pressure switch 323. Transmission oil temperature gauge: 307 The transmission oil temperature gauge receives power from fuse F13 when the key switch is in the run or start position, and a signal from the transmission oil temperature-sending unit 308. Hour meter: 321 The hour meter receives power from the hour meter relay E29, which is turned on by power from the D+ terminal of the alternator 103.

ELECTRICAL


224.CIGARETTE LIGHTER 24 VOLT 313.WINDSHIELD WASHER PUMP 225.L-H ADJ. CEILING LIGHT 314.SIDE WINDOWS WIPER BUTTON 225.L-H CEILING LIGHT SWITCH 315.L-H SIDE WINDOW WIPER MOTOR 226.R-H ADJ. CEILING LIGHT 316.R-H SIDE WINDOW WIPER MOTOR 226.R-H CEILING LIGHT SWITCH 317.SIDE WINDOWS WASHER SWITCH 301.SPEEDOMETER 318.SIDE WINDOWS WIPER WASHER PUMP 302.TACHOMETER 319.HORN SWITCH 303.ENGINE WATER TEMP.GAUGE 320.HORN 304.FUEL LEVEL GAUGE 321.HOURMETER 305.FUEL LEVEL SENDER 322.ENGINE TEMP LIGHT SWITCH 306.ENGINE OIL PRESSURE GAUGE 322.ENGINE TEMP. GAUGE SENDER 307.TRAN. OIL TEMP. GAUGE 323.ENGINE OIL PRESSURE LIGHT SWITCH 311.WINDSHIELD WASHER SWITCH 324.ENGINE OIL PRESSURE INDICATOR SENDER 311.WINDSHIELD WIPER SWITCH 327.TACHOMETER SENDER 312.WINDSHIELD WIPER

Number 1.GROUND Number 2.BATTERY POWER (+) Number 3.POWER WITH KEY IN RUN OR START POSITION (15) Number 4.POWER WITH KEY IN RUN POSITION FROM RELAY E3 (15/A) Number 5 POWER WITH KEY IN ON OR START POSITION FROM FUSE 18

ELECTRICAL


Work Lights switch: 325 With the external light switch 111 in the Headlight on position, power from fuse F1 enters the Work light switch 325 at terminal 2. With the switch in the on position this power energizes the work light relay E11, sending power from fuse F8 to the work lights 326, located on the top front of the cab. Windshield wiper / washer switch: 311 The windshield wiper switch receives power from fuse F15 when the key switch is in the run position. When switch 311 is closed, power flows to the windshield wiper motor 312. When the windshield washer switch 311 is pressed, power flows to the windshield washer pump, 313, and to the windshield wiper through the timed relay E9. Side window wiper switch: 314 The switch receives power from fuse F31 when the key switch is in the run or start position. When the switch is closed, power flows to energize relay E27, sending power from fuse F31 to the left hand wiper motor 315, and also relay E28 which sends power from fuse F32 to the right hand wiper motor, 316. Side window washer switch: 317 The switch receives power from fuse F32 when the key switch is in the run or start position. When the switch is closed, power flows to energize relay E27, sending power from fuse F31 to the left hand wiper motor 315, and relay E28, sending power from fuse F32 to the right hand wiper motor 316. In addition, power from fuse F32 is sent to the window washer pump 318, which sends washer fluid to both side windows. The switch also energizes relay E30 to keep the side window wipers from parking until the switch is released. Horn: 320 Battery power from fuse F11 is sent to the horn switch 319, and to the horn relay E12. When the horn switch 319 is pressed, power from fuse F11 energizes relay E12, sending power from fuse F11 to blow the horn.

ELECTRICAL


224.CIGARETTE LIGHTER 313.WINDSHIELD WASHER PUMP 225.L-H ADJ. CEILING LIGHT 314.SIDE WINDOW WIPER BUTTON 225.L-H CEILING LIGHT SWITCH 315.L-H SIDE WINDOW WIPER 226.R-H ADJ. CEILING LIGHT 316.R-H SIDE WINDOW WIPER 226.R-H CEILING LIGHT SWITCH 317.SIDE WINDOW WASHER BUTTON 301.SPEEDOMETER 318.SIDE WINDOW WIPER WASHER PUMP 302.TACHOMETER 319.HORN SWITCH 303.ENGINE COOLANT TEMP.GAUGE 320.HORN 304 .FUEL LEVEL GAUGE 321.HOURMETER 305.FUEL LEVEL SENDER 322.ENGINE TEMP LIGHT SWITCH 306.ENGINE OIL GAUGE 322.ENGINE TEMP. GAUGE SENDER 307.TRAN. OIL TEMP. GAUGE 323.ENGINE OIL PRESSURE SWITCH 311.WINDSHIELD WASHER SWITCH 324.ENGINE OIL PRESSURE SENDER 311.WINDSHIELD WIPER SWITCH 327.TACHOMETER SENDER 312.WINDSHIELD WIPER

ELECTRICAL


Park Brake Release Switch: 422 Power from fuse F33 when the key switch is in the run or start position sends power to the park brake relay E5. When the park brake switch 422 is closed, a ground path is made energizing relay E5, sending power from fuse F33 to the two park brake solenoids 423. This action turns the park brake off by hydraulic pressure to the caliper pistons. Unloading the body control switch: 416 Power is available at fuse F33 whenever the key switch is in the run or start position. The power is sent to the unloading control switch 416 by wire 8840. Pulling back on this switch will send power to the unloading solenoid 418 to raise the body. Pushing forward on the switch will lower the body. Number 421 is a jumper connector in place of an optional timer, for lowering the body without holding the switch in the lower position. Possible Future Ejector control switch option: 417 Power is available at fuse F33 when the key switch is in the run or start position. The power is sent to the ejector control switch 417. Moving this switch will send power to the ejector solenoid 419 to extend or retract the ejector cylinder 12 Volt supply: 412 The 24V/12V converter 412 is supplied 24 volts from fuse F34 and sends 12 volts through fuse F35 to the 12 volt supply socket.

ELECTRICAL


ELECTRICAL


Transmission Electronic Control Unit (T.E.C.U.)

Body Hoist Relay: E17 When the truck body raises to dump the load, Body Raised Switch number 222, closes, this provides the ground for relay E17. The relay receives its powered from fuse F41 when the key switch is in the run or start position. When the relay is energized, the normally open contacts close, this condition sends power from fuse F41 through pin 5 of connector 507 to pin 66 of the T.E.C.U. The purpose is to keep the transmission from shifting higher than second gear with the body raised. Reverse Alarm Relay: E18 Power from fuse F41 is sent to the reverse relay E18 when the key switch is in the run or start position. A ground is supplied through pin 3 of connector 507 and Pin 7 of the T.E.C.U. connector when the shift selector handle is in reverse. Energizing this relay sends power to the reverse alarm, back up light and TV Monitor. Neutral Start Relay: E20 To energize the neutral start relay, power from fuse F41 is sent to the shift assembly on wire 900, through pin 1 of connector 507. When the shift assembly is in neutral, power goes out pin 2 of connector number 507 to the neutral start relay E20. Park Brake Relay: E23 When the park brake pressure is low (brake on condition), the park brake pressure switch 204, closes, this provides the ground for Park Brake Indicator light and Park Brake Relay E23. The relay receives its power from fuse F41. When Relay E23 closes, it provides a path from Fuse F41 through wire 444 through pin 17 of connector 507 to the T.E.C.M. pin number 44. Power on wire 444 puts the transmission in neutral. Kick Down Switch: 403 The kick down switch button 403 is powered from fuse F41 when the key switch is in the run or start position. When this button is pressed, power flows through pin 7 of connector number 507 to the T.E.C.U pin 29. As long as the button is pressed by the accelerator petal, the transmission will not Up-Shift. It is important to have the throttle linkage adjusted properly for full High Idle before pressing the button.

ELECTRICAL


ELECTRICAL


Differential Switch: 402 The differential switch number 402 is powered from fuse F45, with the switch in the off position, no power exits the switch. With the switch in the second position, power exits the switch to power the Intermediate Axle differential lock solenoid 404, and locks the differential between the two rear axles. With the switch in the third position, power exits the switch to power the Intermediate Axle differential lock solenoid and also sends power to relay E24. When the relay E24 is energized, there is a signal to the transmission to lock the differential between the front axle and the rear driveline. The transmission controller EST 37 number 500 also receives a signal by wire number 430 through pin 8 of connector 507, and on to power pin 30 of the T.E.C.U.

ELECTRICAL


ELECTRICAL


Front Differential lock Solenoid: 515 The front differential lock solenoid 515 receives power and ground connections from the T.E.C.U. pins 8 and 11

ELECTRICAL


RELAY IDENTIFICATION TABLE Type Relay Use Page Type Relay Use Page

E1 Not used S E18 K2 relay in rev. 32,48N E2 Headlight 30 S E19 Emergency

steering 49

N E3 Switched power 15,26 30

S E20 K1 relay Neutral start

26,28 48

N E4 Flasher 32 S E21 Jake brake A 49 S E5 Park brake 46 S E22 Jake brake B 49 N E6 Stop light 32 S E23 Park brake (idle) 48 S E7 Not used S E24 Transfer 50 E8 Emergency

Steering Pump 26 S E25 Emergency safety

pump warning 49

X E9 Wiper-Washer Timer

44 S E26 Jake brake A retarder

49

S E10 High and low beam

30 S E27 LH side window wiper

44

N E11 Work Lights 44 S E28 RH side window wiper

44

N E12 Horn 44 S E29 Hourmeter 26,28 42

S E13 Not used (Option)

47 S E30 Side window washer & wiper

44

S E14A Ejector (opt) 47 S E31 Climate control 40 E14B Not used S E32 Telecamera 42 E15 Not used S E33 Hood lift 40

S E17 Body hoist and gear shift

48 N E34 Battery Relay Option

27

Z D1 Emergency steering pump safety pump

buzzer

49 S E35 Battery Relay Light (Option)

39

Z D2 Park brake Light

38 T T1 Engine Cold Start Heater

28

ELECTRICAL


ELECTRICAL LEGEND INDEX No. Description Page Numbers

100 INTERCONNECTION CONTROL UNIT (ICU) 16-27-29

101 BATTERIES 26-27-29 30

102 STARTER 26-27-29

103 ALTERNATOR 26-27-28-29-36-42

104A STARTER RELAY 16-26

104B BRAKE PUMP UNLOADING VALVE 28

105 EMERG. STEERING PUMP (325) 27-29

106 EMERG. STRG PUMP RELAY (325) 26

107 MASTER SWITCH 26-27-29-30

108 ENGINE HEATER LOW TEMP. RELAY 28

109 KEY SWITCH 26-27-28-29-30

110 HOUR METER RELAY E29 26-28-42

111 EXTERNAL LIGHT SWITCH 26-30-31-33-44

112 FLASHER SWITCH 31-32-33

113 HIGH AND LOW BEAM SWITCH 30-31-33

114 LEFT CLEARANCE LIGHTS 30-31-33

114/A FRONT LH CLEARANCE LIGHT 30

114/B SIDE LH CLEARANCE LIGHT 30

114/C REAR LH CLEARANCE LIGHT 30

115 RIGHT CLEARANCE LIGHTS 30-31-33

115/A FRONT RH CLEARANCE LIGHT 30

115/B SIDE RH CLEARANCE LIGHT 30

115/C REAR RH CLEARANCE LIGHT 30

116 LH LOW BEAM 30-31-33

117 RH LOW BEAM 30-31-33

118 LH HIGH BEAM 30-31-33

119 RH HIGH BEAM 30-31-33

120 REAR FOG LIGHT SWITCH 30-31-33

121 REAR FOG LIGHT LAMP 30-31-33

122 BACK-UP LIGHT LAMP 31-32-33

123 BACK-UP ALARM HORN 31-32-33

124 BRAKE LIGHT SWITCH 31-32-33

125 BRAKE LIGHTS 31-32-33

126 HAZARD LIGHT SWITCH 34-35

127 TURN SIGNAL SWITCH 34-35

128 FLASHER MODULE 34-35

129 LEFT TURN INDICATOR CIRCUIT 34-35

129a LEFT FRONT TURN INDUCATOR LAMP 34-35

129b LEFT REAR TURN INDICATOR LAMP 34-35

130 RIGHT TURN INDICATOR CIRCUIT 34-35

ELECTRICAL


130a RIGHT FRONT TURN INDICATOR LAMP 34-35

130b RIGHT REAR TURN INDICATOR LAMP 34-35

131 LEFT SIDE TURN INDICATOR LAMP 34-35

132 RIGHT SIDE TURN INDICATOR LAMP 34-35

133 ENGINE LOW TEMP. SWITCH 27-28-29

134 ENGINE PRE-START HEATER 27-29

135 ENGINE HEATER TIMER RELAY T1 28

136 OPERATOR’S SEAT 24 VOLT CONNECTOR

27

137 EMERG. STEERING PUMP VALVE (30 TON) 27

138 MASTER DISCONNECT RELAY (OPT) 27

139 MASTER DISC. RELAY SWITCH (OPT) 27

140 FUEL SHUT-OFF SOLENOID (30 TON) 28

141 FUEL SHUT-OFF SOLENOID (25 TON) 28

200 WARNING LAMPS PANEL 36-37



203 AIR CLNR RESTRICTION SWITCH N.O. 36-37

204 PARK BRAKE PRESSURE N.C. 48

205 TRANS. DIFF-LOCK INDIC. SWITCH N.O. 38

206 REAR AXLE DIFF-LOCK SWITCH N.O. 39

207 ACCUM. LOW BRAKE PRESSURE 38-39

208 BRAKE OIL FILTER SWITCH N.O. 39

209 LAMP TEST SWITCH 36-38-39

210 ROTATING BEACON SWITCH 40-41

211 ROTATING BEACON LAMP 40-41

212 HEATED MIRROR SWITCH (OPT) 40-41

213 LH HEATED MIRROR (OPT) 40-41

214 RH HEATED MIRROR (OPT) 40-41

215 MIRROR MOTOR SWITCH (OPT) 40-41

216 LH MIRROR MOTOR (OPT) 40-41

217 RH MIRROR MOTOR (OPT) 40-41

218 HOOD RAISING RELAY E33 40

219 HOOD OPENING BUTTON CHASSIS 40

220 CLIMATE CONTROL 40-41

221 AIR CONDITION PRESSURE SWITCH N.O. 40-41

222 BODY RAISED SWITCH N.C. - HELD OPEN 38-39-48

223 AIR CONDITIONING COMPRESSOR 40-41

224 CIGARETTE LIGHTER (24V) 40-41

225 LH CEILING LIGHT SWITCH 40-41

226 RH CEILING LIGHT SWITCH 40-41

301 SPEEDOMETER 42-43

ELECTRICAL


302 TACHOMETER 42-43

303 ENGINE WATER TEMP. GAUGE 42-43

304 FUEL LEVEL GAUGE 42-43

305 FUEL LEVEL SENDER 42-43

306 ENGINE OIL PRESSURE GAUGE 42-43

307 TRANS. OIL TEMPERATURE GAUGE 42-43

308 TRANSMISSION TEMPERATURE SENSOR 42

309 ~ -

310 TV MONITOR, REAR VIEW DEVICE 42

311 WINDSHIELD WIPER/WASHER SWITCH 44-45

312 WINDSHIELD WIPER MOTOR 44-45

313 WINDSHIELD WASHER PUMP 44-45

314 SIDE WINDOWS WIPER SWITCH 44-45

315 LH SIDE WINDOW WIPER MOTOR 44-45

316 RH SIDE WINDOW WIPER MOTOR 44-45

317 SIDE WINDOWS WASHER SWITCH 44-45

318 SIDE WINDOWS WASHER PUMP 44-45

319 HORN SWITCH 44-45

320 HORN 44-45

321 HOURMETER 42-43

322 ENGINE TEMPERATURE LIGHT SWITCH 42-43

322 ENGINE TEMP GAUGE SENDING UNIT 42-43

323 ENGINE OIL PRESSURE LIGHT SWITCH 38-42-43

324 ENGINE OIL PRESSURE INDI. SENDER 42-43

325 FRONT WORK LIGHT SWITCH 44

326 FRONT WORK LIGHTS 44

327 TACHOMETER SENDER 42-43

328 TACHOMETER SIGNAL FILTER (330) 42-43

400 JAKE BRAKE/RETARDER SWITCH (330) 49

401 RETARDER SWITCH (330 OPT) 49

402 DIFFERENTIAL LOCK SWITCH 50

403 TRANSMISSION KICK DOWN SWITCH 48

404 INTERMED. AXLE DIFF-LOCK SOLENOID 50

406 JAKE BRAKE ENGINE SENSOR 49

408 JAKE BRAKE "A" SOLENOID (330) 49

409 JAKE BRAKE "B" SOLENOID (330) 49

410 EMERGENCY STEERING PRES. SWITCH 49

411 CAB WARNING BUZZER 49

412 24/12V CONVERTER 46

413 SOCKET 12V 46

414 SOCKET 12V 46

416 BODY RAISING CONTROL SWITCH 46

ELECTRICAL


417 EJECTOR SWITCH (IF EQUIPPED) 46

418 BODY RAISING/LOWERING SOLENOID 46

419 EJECTOR SOLENOID (IF EQUIPPED) 46

420 BODY RAISED LIMIT SWITCH (OPT.) 46

421 BODY LOWERING TIMER (OPT) 46

422 PARK BRAKE SWITCH 38-46

423 PARK BRAKE SOLENOID VALVE 46

424 RADIO 47

425 LEFT RADIO SPEAKER 47

426 RIGHT RADIO SPEAKER 47

427 CB RADIO (OPT) 47

428 ZF TRANS. DIF-LOCK INTERFACE -

429 JAKE BRAKE/RETARDER INTERFACE (330)

-

500 ZF TRANSMISSION CONTROLLER EST37 50

501 DIAGNOSTIC CONNECTOR 59

502 TRANSMISSION SHIFTER CONNECTOR 28-32-59

503 CAN. DATA BUS CONNECTOR 59

504 ZF TRANSMISSION DISPLAY 59

505 31 PIN EST 37 CONNECTOR 59

506 7 PIN EST 37 CONNECTOR 59

507 22 PIN EST 37 CONNECTOR 48-50-59

508 ENGINE SPEED SENSOR (TRANSMISSION)

59

509 TURBINE SPEED SENSOR (TRANSMISSION)

59

510 GEAR TRAIN SENSOR (TRANSMISSION) 59

511 TRANSMISSION RETARDER TEMP. SENSOR

59

512 TRANS. FILTER RESTRICTION SWITCH 59

513 TRANSMISSION CONTROL VALVE CONNECT

59

514 TRANSMISSION OUT-PUT SPEED SENSOR 59

515 TRANSMISSION DIFF-LOCK SOLENOID 52-59

516 RETARDER SOLENOID VALVE 59

517 ENGINE LOAD SENSOR 59

518 CONVERTER LOCK UP CLUTCH SOLENOID

59

ELECTRICAL


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