print preview - c:docume~1u00nlb2locals~1temp

SERVICE MANUAL

SERVICE MANUAL SECTION

3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 SERIES BuiltAfter September 15, 2003 — ELECTRICAL CIRCUIT DIAGRAMS

Truck Model: 3200Start Date: 03/01/2002Truck Model: 4200

Start Date: 10/01/2002Truck Model: 4300








Start Date: 10/01/2002

S082853Copyright© 09/15/2003 International Truck and Engine Corporation

S082853

09/15/2003

S082853Copyright© 09/15/2003 International Truck and Engine Corporation

3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 SERIES Built AfterSeptember 15, 2003 — ELECTRICAL CIRCUIT DIAGRAMS

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Table of Contents

1. INSTRUCTIONS AND CHARTS (CHAPTER 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1. CIRCUIT NUMBER IDENTIFICATION AND LOCATION CHART, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2. CIRCUIT NUMBER IDENTIFICATION AND LOCATION CHART, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.3. CIRCUIT NUMBER IDENTIFICATION AND LOCATION CHART, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31.4. CIRCUIT NUMBER IDENTIFICATION AND LOCATION CHART, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41.5. CIRCUIT NUMBER IDENTIFICATION AND LOCATION CHART, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51.6. NAVPAK/ECM I6 ENGINE CONTROLLER CONNECTOR PIN NUMBER IDENTIFICATION, P.

6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61.7. CIRCUIT DIAGRAM INSTRUCTIONS, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.8. CIRCUIT DIAGRAM INSTRUCTIONS, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81.9. SCHEMATIC SYMBOL CHART, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91.10. RELAY FUNCTIONS, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.11. LAMP BULB CHART, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111.12. INTERNATIONAL V8 AND I6 ECM CONTROLLER CONNECTORS PIN NUMBER

IDENTIFICATION, P.12.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2. 12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (CHAPTER 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132.1. ACCESSORY, P. 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132.2. BATTERY FEEDS, CAB, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142.3. BATTERY, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152.4. 1708 DATA LINK, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162.5. SWITCH DATA LINK, P. 5.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172.6. DRIVETRAIN 1939 DATA LINK (CAB), P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182.7. DRIVETRAIN 1939 DATA LINK (CHASSIS), P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192.8. GROUNDS CHASSIS, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202.9. GROUNDS CHASSIS, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212.10. GROUNDS IP, P. 10.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222.11. GROUNDS IP, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232.12. IGNITION CAB, P. 12.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242.13. IGNITION CAB, P. 13.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252.14. IGNITION FEEDS, CHASSIS, P. 14.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262.15. START, P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

3. CAB ACCESSORIES (CHAPTER 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283.1. CIGAR LIGHTER AND POWER FEEDS, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283.2. CB POWER, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293.3. COMPASS AND TEMPERATURE DISPLAY, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303.4. FRONT DOORS WINDOWS AND LOCKS (POWER), P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313.5. CREW DOORS WINDOWS AND LOCKS (POWER), P. 5.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323.6. HORN, DUAL ELECTRIC, P. 6.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333.7. MIRRORS (HEATED, LIGHTED AND POWER), P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343.8. RADIO (ENTERTAINMENT), SPEAKERS, P. 8.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353.9. WINDSHIELD WIPER AND WASHER PUMP, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363.10. 2–WAY RADIO, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373.11. SWITCH PACK, OPTIONAL GAUGE PACK, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .383.12. LIGHTED AIR SHIELD, P. 12.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .393.13. ROOF AUX. LOAD, P. 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

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3.14. SATELLITE COMMUNICATION QUALCOMM-MCT AND IMCT SYSTEMS, P. 14. . . . . . . . . . . . . .413.15. SELF CONTAINED AIR SEAT, P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423.16. DIGITAL CLOCK PTC, P. 16.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433.17. TRANSMISSION ALLISON LCT COLUMN SHIFTER, P. 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .443.18. HEATED SEATS FOR 7700 MODELS ONLY, P. 18.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

4. 12V CHARGING + CRANKING SYSTEM (CHAPTER 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464.1. I6 EGR ENGINES, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464.2. V8 AVNT ENGINES, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474.3. CATERPILLAR, CUMMINS ISM ENGINES, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .484.4. I6 HEUI ENGINES, P. 4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

5. FANS AND ENGINE ACCESSORIES (CHAPTER 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .505.1. FAN WIRING, P. 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .505.2. ETHER START, P. 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .515.3. SNOW VALVE, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525.4. FAN WIRING, CATERPILLAR AND CUMMINS, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

6. ELECTRONIC ENGINES (CHAPTER 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546.1. ELECTRONIC ENGINE CONTROLS, I6–EGR ENGINES, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546.2. ELECTRONIC ENGINE CONTROLS, I6–EGR ENGINE CRUISE CONTROL AND BODY

BUILDER CONNECTIONS, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .556.3. ELECTRONIC ENGINE CONTROLS, (V8–AVNT) ENGINES, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .566.4. ELECTRONIC ENGINE CONTROLS, V8–AVNT ENGINE CRUISE CONTROL AND BODY

BUILDER CONNECTIONS, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .576.5. CATERPILLAR C10, C11, C12, AND C13 ENGINES, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .586.6. CUMMINS ISM ENGINE, P. 6.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .596.7. I6 HEUI ENGINE, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .606.8. I6 HEUI ENGINE CRUISE CONTROL AND BODY BUILDER CONNECTIONS WITH MANUAL

TRANSMISSION, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

7. GAUGES WITH AND WITHOUT INTEGRAL WARNING LIGHT (CHAPTER 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .627.1. IP/GAUGE LIST, P. 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .627.2. WARNING LIGHT LIST, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .637.3. WARNING LIGHTS CONTROLLED BY ENGINE, TRANSMISSION, ABS CONTROLLER, P.

3.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .647.4. ENGINE OIL PRESSURE AND TEMP, SPEEDOMETER, TACH, VOLTMETER AND WATER

TEMP GAUGE CIRCUITS, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .657.5. IP/GAUGES AND WARNING LIGHTS — GAUGE CLUSTER, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .667.6. AIR PRESSURE INPUT CIRCUIT, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .677.7. AXLE TEMPERATURE, FWD REAR AND REAR AXLES, GAUGE INPUT CIRCUIT, P. 7. . . . . .687.8. FUEL GAUGE INPUT CIRCUIT (SINGLE TANK) DIFFERENTIAL LOCK WARNING LAMPS, P.

8.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .697.9. GAUGES AND WARNING LIGHTS — FUEL FILTER RESTRICTION AND WATER IN FUEL

LIGHTS, P. 9.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .707.10. GAUGES AND WARNING LIGHTS — PARK BRAKE LIGHT AND TRANSMISSION OIL TEMP.

GAUGE, P. 10.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .717.11. GAUGES AND WARNING LIGHTS — AMMETER, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .727.12. ENGINE OIL TEMPERATURE GAUGE WITH CATERPILLAR, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .737.13. FRONT AXLE ENGAGEMENT LAMP, P. 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

8. LIGHTS (CHAPTER 8).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .758.1. BACK UP LIGHTS, P. 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

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8.2. LIGHT SYSTEMS — CLEARANCE, MARKER, PARK, TAIL, TURN AND STOP LAMPS, P.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

8.3. LIGHT SYSTEMS — CLEARANCE, MARKER, PARK, TAIL, TURN AND STOP LAMPS(CONT.), P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

8.4. LIGHT SYSTEMS — TURN SIGNAL AND STOP SWITCHES, P. 4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .788.5. DOME LIGHT, MAP LIGHT, P. 5.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .798.6. DOME LIGHT, MAP LIGHT (CONT.), P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .808.7. FOG LIGHT AND WORK LIGHT, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .818.8. HEADLIGHTS, P. 8.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .828.9. AUX. HEADLIGHTS, AUX. PARK, AUX TURN, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .838.10. PANEL LIGHTS, P. 10.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

9. CHASSIS ACCESSORIES (CHAPTER 9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .859.1. AIR DRYER AND HEATED DRAIN VALVE, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .859.2. ANTILOCK BRAKE SYSTEM (ABS), AIR, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .869.3. ANTILOCK BRAKE SYSTEM (ABS), AIR, TRACTION CONTROL, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . .879.4. ANTILOCK BRAKE SYSTEM (ABS), HYDRAULIC, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .889.5. ANTILOCK BRAKE SYSTEM (ABS), HYDRAULIC (CONT.), P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .899.6. ANTILOCK BRAKE SYSTEM (ABS), HYDRAULIC (CONT.), P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .909.7. TWO SPEED AXLE SWITCH WITH MANUAL TRANSMISSION AND I6 HEUI FUEL HEATER

N/WARN LIGHTS, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .919.8. BRAKE SYSTEM, HYDRAULIC, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .929.9. FUEL TRANSFER PUMP, P. 9.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .939.10. BACK OF CAB BODY BUILDER AND TRAILER STOP, TAIL, MARKER, P. 10. . . . . . . . . . . . . . . .949.11. BODY BUILDER AND TRAILER TURNS, CENTER PIN ABS, CENTER PIN AUX, P. 11. . . . . .959.12. BODY BUILDER AND TRAILER SOCKET BACK OF CAB SOCKETS, P. 12. . . . . . . . . . . . . . . . . . .969.13. BODY BUILDER AND TRAILER SOCKET END OF FRAME (EOF) SOCKET AND BODY

BUILDER, P. 13.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .979.14. AIR SOLENOID 4–WAY PACK, P. 14.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .989.15. REMOTE POWER UNITS, SOLENOID PACKS, REMOTE ENGINE SPEED CONTROLLER, P.

15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .999.16. HYD POWER PARK, P. 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1009.17. AIR SUSPENSION, P. 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1019.18. AUX. TRAILER, ACC CONTROLLED, P. 18.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1029.19. AUX. TRAILER, BTRY CONTROLLED, P. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1039.20. LIFT AXLES (NON-STEERABLE), P. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1049.21. LIFT AXLES (STEERABLE), P. 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1059.22. AIR ACTUATED PARK BRAKE, P. 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1069.23. ANTILOCK BRAKE SYSTEM, WABCO AIR, P. 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1079.24. ANTILOCK BRAKE SYSTEM, WABCO AIR, P. 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1089.25. LIFT AXLES, WITH NON—STEERABLE FOR SS MODELS, P. 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1099.26. FUEL / WATER SEPARATOR WITH 12VDC FUEL PREHEATER, P. 26. . . . . . . . . . . . . . . . . . . . . . . .1109.27. ELECTRONIC TRAILER BRAKE ACCOMMODATION, P. 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1119.28. LECTRASHIFT ACCOMMODATION, P. 28.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1129.29. AUXILIARY 40 AMP CIRCUIT, P. 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1139.30. HOURMETER, CUSTOMER MOUNTED PTO, P. 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1149.31. REMOTE START/ STOP, P. 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1159.32. LIFT AXLE WITH 14RAR, P. 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1169.33. LIFT GATE, P. 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

10. TRANSMISSIONS (CHAPTER 10).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11810.1. ALLISON LCT TRANSMISSION OR ALLISON 1000, 2000, 2400, P. 1. . . . . . . . . . . . . . . . . . . . . . . . .11810.2. ALLISON MD TRANSMISSION, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

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10.3. ALLISON MD TRANSMISSION (WTEC), P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12010.4. ALLISON MD TRANSMISSION (CONT.), P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12110.5. TRANSMISSION, WTEC MD W/AUTO NEUTRAL, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12210.6. EATON AUTOSHIFT TRANSMISSION, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12310.7. EATON AUTOSHIFT TRANSMISSION (CONT.), P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12410.8. EATON LIGHTNING TRANSMISSION, P. 8.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12510.9. ALLISON HD TRANSMISSION, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12610.10. ALLISON HD TRANSMISSION, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12710.11. ALLISON HD TRANSMISSION, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12810.12. ALLISON HD TRANSMISSION WITH AUTO NEUTRAL, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12910.13. ALLISON HD TRANSMISSION WITH AUTO NEUTRAL AND WITH 0013WUA, P. 13. . . . . .13010.14. ALLISON LCT TRANSMISSION (ALLISON 1000, 2000, 2400) WITH I6 HEUI, P. 14. . . . . . . .13110.15. TRANSMISSION RETARDER CONTROL WIRING WITH MD XMSN, HARD WIRED

EFFECTS, P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13210.16. TRANSMISSION RETARDER CONTROL WIRING WITH MD XMSN, HARD WIRED

EFFECTS, P. 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

11. AIR CONDITIONING (CHAPTER 11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13411.1. HVAC SYSTEMS, P. 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13411.2. AIR CONDITIONING (ONLY), P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135

12. CONNECTOR COMPOSITES (CHAPTER 12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13612.1. CONNECTOR COMPOSITES (10M), (71), (72), (345F), P. 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13612.2. CONNECTOR COMPOSITES (420F), (420M), (520), (521), (522), (523), (524), P. 2. . . . . . . . . .13712.3. CONNECTOR COMPOSITES (1002), (1003), (1010), P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13812.4. CONNECTOR COMPOSITE (1011), P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13912.5. CONNECTOR COMPOSITE (1012), P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14012.6. CONNECTOR COMPOSITE (1013), P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14112.7. CONNECTOR COMPOSITE (1014), P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14212.8. CONNECTOR COMPOSITES (1018), (1019M), (1020M), (1021M), (1022M), P. 8. . . . . . . . . . . . .14312.9. CONNECTOR COMPOSITES (1027M, F), (1100), (1101A), (1101), (1102), P. 9. . . . . . . . . . . . . . .14412.10. CONNECTOR COMPOSITES (1104), (1106), (1200), (1210), P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .14512.11. CONNECTOR COMPOSITES (1300), (1301), (1400), (1402), (1410), (1500), (1510), P.

11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14612.12. CONNECTOR COMPOSITES (1553), (1554F), (1555), (1600), (1601), (1650), P. 12. . . . . . . .14712.13. CONNECTOR COMPOSITES (1652), (1657M), (1658), (1659), (1800), P. 13. . . . . . . . . . . . . . . . .14812.14. CONNECTOR COMPOSITES (1804), (1807), (1808), (1809), (1810), (1811), (1812), (1813),

(1814), (1815), P. 14.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14912.15. CONNECTOR COMPOSITES (1820), (1822), (1823), (1824), (1828), (1860), (1861), (1901M),

(1915), P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15012.16. CONNECTOR COMPOSITES (1918), (1935), (1920), (2000), (2002M), (2003M), (2004M),

(2005M), P. 16.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15112.17. CONNECTOR COMPOSITES (2006M), (2007F), (2021F), (2021M), (2022F), (2022M),

(2111M), (2112M), (2113M), (2114M), (2115M), (2116M), (2117M), (2301M), (2302M), (2303M), P.17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152

12.18. CONNECTOR COMPOSITES (2304M), (2305M), (2306M), (2307F), (2308F), (2502F),(2502M), (2503F, M), (2600F, M), P. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153

12.19. CONNECTOR COMPOSITES (2601M, F), (2602M, F), (3000M), (3000F), (3002M), (3003),(3100M), (3200F, M), (3201M), (3202), (3203M), P. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

12.20. CONNECTOR COMPOSITES (3204M, F), (3209), (3210M), (3211M), (4000), P. 20. . . . . . . . .15512.21. CONNECTOR COMPOSITE (4001), P. 21.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15612.22. CONNECTOR COMPOSITE (4002), P. 22.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15712.23. CONNECTOR COMPOSITE (4003), P. 23.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158

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12.24. CONNECTOR COMPOSITES (4004), (4007), (4008), P. 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15912.25. CONNECTOR COMPOSITE (4014), P. 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16012.26. CONNECTOR COMPOSITE (4014/1700), P. 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16112.27. CONNECTOR COMPOSITES (4015), (4017), (4018), (4019), (4020), (4021), (4022), (4023), P.

27.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16212.28. CONNECTOR COMPOSITES (4024), (4030), (4031), (4032), (4033), (4040), (4041), P.

28.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16312.29. CONNECTOR COMPOSITES (4070), (4071), (4087), (4098), (4101), P. 29. . . . . . . . . . . . . . . . . . .16412.30. CONNECTOR COMPOSITE (4103), P. 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16512.31. CONNECTOR COMPOSITES (4105), (4111), (4120), (4301), P. 31. . . . . . . . . . . . . . . . . . . . . . . . . . . .16612.32. CONNECTOR COMPOSITES (4305), (4410), (4410B), (4410C), (4410D), (4410E), (4410H),

(4410M), (4411), P. 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16712.33. CONNECTOR COMPOSITES (4411A), (4411B), (4412), (4415), (4450), (4450A), (4460A),

(4460), P. 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16812.34. CONNECTOR COMPOSITE (4705), P. 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16912.35. CONNECTOR COMPOSITES (4810), (4712F), (4820), (4713F), (4830), (4840), (4850), P.

35.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17012.36. CONNECTOR COMPOSITES (4900), (4910), (4950), (4951), P. 36. . . . . . . . . . . . . . . . . . . . . . . . . . . .17112.37. CONNECTOR COMPOSITES (6007), (6011), P. 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17212.38. CONNECTOR COMPOSITES (6013M), (6014), P. 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17312.39. CONNECTOR COMPOSITES (6015), (6020), (6021), P. 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17412.40. CONNECTOR COMPOSITES (6200), (6316), (6323), (6332), (6333), (6334), (6400), (6401M),

(6401), (6406), (6407), (6407D), (6409), (6500), P. 40.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17512.41. CONNECTOR COMPOSITES (6550), (6703), (6704), (6708), (7103), (7104), (7104A), (7105),

(7106), (7111), P. 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17612.42. CONNECTOR COMPOSITES (7200), (7202), (7203), P. 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17712.43. CONNECTOR COMPOSITES (7204), (7205), (7206), (7211), (7212), (7213), P. 43. . . . . . . . . .17812.44. CONNECTOR COMPOSITES (7214), (7300), (7301), P. 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17912.45. CONNECTOR COMPOSITES (7302), (7304), (7305), (7306), (7500), (7502), (7600), (7601), P.

45.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18012.46. CONNECTOR COMPOSITES (7603), (7604), (7605), (7606), (7607), (7608), (7609), (7610),

(7611), (7612), (7613), (7615), (7700), (7702), (7703), (7703A), P. 46.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .18112.47. CONNECTOR COMPOSITES (7800), (7801M), (7803), (7900), (7901), P. 47. . . . . . . . . . . . . . . . .18212.48. CONNECTOR COMPOSITES (7905), (7906), (8000), (8001), (8102), (8150), (8151), (8200), P.


(8502), (8502A), P. 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18412.50. CONNECTOR COMPOSITES (8503), (8503A), (8505), (8506), (8507), (8508), (8509), (8600),

(8601), (8602), P. 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18512.51. CONNECTOR COMPOSITES (8700), (8701), (8800), (8801), (8802), (8803), (8805), P.


(9255), P. 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18712.53. CONNECTOR COMPOSITES (9260), (9261), (9262), (9263), (9264), (9265), (9303A), P.

53.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18812.54. CONNECTOR COMPOSITES (9405), (9501), (9502), (9503), (9504), (9505), (9506), P.


(9515), P. 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19012.56. CONNECTOR COMPOSITES (9516), (9517), (9518), (9519), P. 56. . . . . . . . . . . . . . . . . . . . . . . . . . . .19112.57. CONNECTOR COMPOSITE (9700), P. 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19212.58. CONNECTOR COMPOSITE (9700), P. 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19312.59. CONNECTOR COMPOSITES (9715), (9715A), (9715B), P. 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194

S082853

vi 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 SERIES Built AfterSeptember 15, 2003 — ELECTRICAL CIRCUIT DIAGRAMS

12.60. CONNECTOR COMPOSITES (9716), (9716A), (9716B), P. 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19512.61. CONNECTOR COMPOSITES (9717A), (9717B), P. 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19612.62. CONNECTOR COMPOSITES (9718), (9719), (9720), (9733), (9734), (9736), (9754), (9762),

(9763), P. 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19712.63. CONNECTOR COMPOSITES (9777), (9778), (9800), P. 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19812.64. CONNECTOR COMPOSITES (9870), (9871), (9811), (9812), (9814), (9815), (9850), (9900),

(9900A), (9913A), (9913B), (9914), P. 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19912.65. CONNECTOR COMPOSITES (4100), (4109), (4112), (6502), (7107), (7208), (7615), P.

65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200

S082853


1

1. INSTRUCTIONS AND CHARTS (CHAPTER 1)1.1. CIRCUIT NUMBER IDENTIFICATION AND LOCATION CHART, P. 1

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK

INTERNATIONAL TRUCK AND ENGINE CORPORATION

PART NO. SHEET

REV

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOTTO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

ELECTRICAL CIRCUIT DIAGRAM

DATE CHANGE

CHAPTER 1

INTERNATIONAL CIRCUIT NUMBER IDENTIFICATIOIN AND LOCATION

U00DLCK

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

09AUG00 01AE08-52365

PREFIX DESIGNATIONS

PREFIX LOCATION

A Cab-instrument Panel Module

B

Cab-Header/Clearance LightsC

Cab-Roof/Rear PanelD

Cab-Left Door/Doors

Cab-Driver Control Module

E

F Cab-Right Door/Doors

H Cab-Sleeper

J Cab-Dash(outside)

K Engine/Radiator

L Transmission

M Chassis/Front End (Cab Dash Panel Forward)

N Chassis/Center Section (Cab Dash Panel to Cab RR Xmbr)

P Chassis/Wheel Base Section

R Chassis/Suspension/Rear Axle/Axles

S Chassis/AF Section/Stop/Tail/Turn Lights

CIRCUIT NUMBER AND IDENTIFICATIONS

CIRCUITNUMBER COLOR DESCRIPTION

1 LTBL ALTERNATOR - FIELD

2 RD ALTERNATOR - CHARGE

3 DKBL 1708 DATA LINK, SWITCH DATA LINK (+)

GY 1708 DATA LINK, SWITCH DATA LINK (-)

4 SERIAL/DATA COMMUNICATION J1922

5 YL DRIVE TRAIN J1939 DATA LINK (+)

GN DRIVE TRAIN J1939 DATA LINK (-)

6 GY LOW VOLTAGE ELECTRONIC FEED (< 9 VOLTS)

7 RD ALTERNATOR - RESISTANCE

8

PRODUCTION RELEASE. A P54304UPEC 16JAN01

Figure 1 Circuit Number Identification and Location Chart

S082853

2 3200, 4200, 4300, 4400, 7300, 7400, 7500, 7600, 8500, 8600 SERIES Built AfterSeptember 15, 2003 — ELECTRICAL CIRCUIT DIAGRAMS

1.2. CIRCUIT NUMBER IDENTIFICATION AND LOCATION CHART, P. 2

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 1

INTERNATIONAL CIRCUIT NUMBERIDENTIFICATION AND LOCATION (CONT.)

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

09AUG00 02AE08-52365

CIRCUIT NUMBER AND IDENTIFICATIONS (CONT.)

CIRCUITNUMBER COLOR DESCRIPTION

9 GY ZERO VOLT REFERENCE (ZVR)

10 WH CHASSIS/ENGINE GROUND

11 WH CAB/SLEEPER GROUND

12 LTBL ACCESSORY FEED

13 PK IGNITION FEED

BK IGNITION FEED (BODY BUILDER CONNECTOR)

14 RD BATTERY FEED

15 RD KEY SWITCH FEED

16

17 PK STARTER CONTROL

18 PK GLOW PLUG/PRE-HEATER

19 GY ENGINE SHUTDOWN

20 LTGN REMOTE POWER MODULE

21 COLD START CONTROLS (ETHER)TN

22

23 TN ENGINE FAN/SHUTTERS

24 GY ENGINE EXHAUST BRAKE

25 TN PYROMETER

26 TN AMMETER

27 TN VOLTMETER

28 TN INSTRUMENTS AND GAUGES

29 TN ENGINE WATER TEMPERATURE

30 ENGINE OIL TEMPERATURETN

31 TN TRANSMISSION OIL TEMPERATURE

32 TN AXLE OIL TEMPERATURE


Figure 2 Circuit Number Identification and Location Chart (Cont.)

S082853


3


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PART NO. SHEET

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DATE CHANGE

CHAPTER 1


U00DLCK

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

15 MAY 00 03AE08-52365


CIRCUITNUMBER

COLOR DESCRIPTION

33 TN ENGINE OIL LEVEL

34 TN COOLANT LEVEL

35 TN ENGINE OIL PRESSURE

36 TN FUEL LEVEL

37 TN FUEL PUMP

38

39 GY AIR DRYER HEATER

40 GY LOW AIR PRESSURE WARNING

41 TN AIR TEMPERATURE

42 GY FRONT AXLE ENGAGED

43 GY POWER DIVIDER LOCK (PDL) WARNING

44 GY PARK BRAKE WARNING

45 LTGN ANTI - THEFT WARNING

46 GY POWER TAKE - OFF WARNING

47 GY SPEEDOMETER

48 GY TACHOMETER

49 GY DIFFERENTIAL LOCK WARNING

50 YL LIGHT SWITCH FEED

51 YL DIMMER SWITCH FEED

52 YL HEADLIGHT HI - BEAM

53 YL HEADLIGHT LO - BEAM

54 BN PARKING/MARKER LIGHTS

55 OR TURN SIGNAL - FEED

56 OR TURN SIGNAL LIGHTS - LEFT

YL TURN SIGNAL LIGHTS - LEFT (BODY BUILDER CONNECTION)

57 OR

LT GN

TURN SIGNAL LIGHTS - RIGHT

TURN SIGNAL LIGHTS - RIGHT (BODY BUILDER CONNECTION)



S082853



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NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 1


U00DLCK

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

15MAY00 04AE08-52365

COLORCIRCUITNUMBER DESCRIPTION


58 BN CLEARANCE/IDENTIFICATION LIGHTS

59 GY SOLENOID

60 OR HAZARD LIGHTS

61 GY AIR SUSPENSION

62 DKBL PANEL LIGHTS

63 DKBL COURTESY/DOME LIGHTS

64 YL FOG/DRIVING LIGHTS

65 OR CAB REAR FLOOD LIGHT

66 YL DAYTIME RUNNING LIGHTS

67

68 BN TAIL LIGHTS

69 BN LICENSE PLATE LIGHT

70 OR STOP LIGHTS

RD STOP LIGHTS (BODY BUILDER CONNECTION)

71 OR BACK - UP LIGHTS

LTBL BACK - UP LIGHTS (BODY BUILDER CONNECTION)

72 OR TRAILER AUXILIARY FEED - BATTERY

73 PWMLTGN

74 LTGN HEATER RECIRC MOTOR

75 LTGN HEATER BLOWER MOTOR

76 LTGN AUXILIARY FAN

77 LTGN AIR CONDITIONER

78 LTGN MIRRORS - HEATED; MOTORIZED

79 GY SEAT BELTS

80 BK SLEEPER BOX RELAY - FEED

81 LTGN POWER DOOR LOCKS



S082853


5



S082853


1.6. NAVPAK/ECM I6 ENGINE CONTROLLER CONNECTOR PIN NUMBERIDENTIFICATION, P. 6

Figure 6 NAVPAK/ECM I6 Engine Controller Connector Pin Number Identification

S082853


7

1.7. CIRCUIT DIAGRAM INSTRUCTIONS, P. 7

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 1

CIRCUIT DIAGRAM INSTRUCTIONS

U00DLCK

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

15MAY00 07AE08-52365

R32-G

B - MULTIPLE CONNECTIONS ARE DISPLAYED ON SCHEMATIC AS SHOWN. REFER TO CONNECTOR COMPOSITE WITH APPLICABLE NUMBER FRO MORE COMPLETE INFORMATION.

SINGLE IN-LINE CONNECTORS DISPLAYEDAS SHOWN WITH OR WITHOUT CONNECTORNUMBER.

R32-GB

WIRE CONNECTION

C - PHANTOM LINES INDICATE PRINTED CIRCUITS OR BUSSED CIRCUITS. THESE CIRCUITS EXIST IN THE INSTRUMENT CLUSTERS AND FUSE/CIRCUIT BREAKER CONNECTORS.

D - MULTPLE CIRCUIT NUMBERS ON A LINE INDICATE ONE WIRE DISTRIBUTING CURRENT TO TWO CIRCUITS.

SUFFIXG IS NOT A SUFFIX BUT INDICATESA GROUND CIRCUIT.

ETHERSWITCH

PRINTED CIRCUIT IN

INSTRUMENT CLUSTER

F - CIRCUIT "11" DENOTES ANY COMMON GROUND, (MORE THAN ONE CIRCUIT). ANY INDIVIDUAL GROUND CIRCUIT IS IDENTIFIED WITH THAT PARTICULAR CIRCUIT NUMBER. (E.G CIRCUIT 97 CRUISE CONTROL, IS IDENTIFIED PER EXAMPLE).

GROUND CIRCUITS ARE DESCRIBED THUS:

A12

11-GB

WIRECONNECTION

A55A16OR

LOCATION IN FUSE/CIRCUITBREAKER CONNECTION

BUSS IN FUSE/CIRCUITBREAKER CONNECTOR

F19

COMMON GROUNDCIRCUIT NUMBER

B

RELAY - SUPPRESSED

12

20A

F1

A - SWITCH AND RELAY POSITIONS AS SHOWN ON CIRCUIT DIAGRAMS INDICATE NORMAL POSITION WITH IGNITION OFF UNLESS OTHERWISE NOTED.

12

R32-GA

BUSSED CONTACT

30 86

87A 87 85

A128

E - SWITCHES, RELAYS AND COMPONENTS INDICATE EXTERNAL WIRE CONNECTIONS AND/OR INTERNAL CONNECTIONS OR CONTACTS.

LOCATION

OFFOFFOFFOFF

A

AA

A IIIIS S SS

B

SGND I A

INDIVIDUAL GROUNDCIRCUIT NUMBER

16BN

A55A/A6016OR

16RD

A6016OR

NOTE: FOR CIRCUIT DESCRIPTION OTHER THAN GROUNDS,NEITHER THE LETTER "G" NOR THE COLOR WHITE SHALL BE USED.

CONTACT

VOLTMETER

A12A

11-GA11-G

KEY SWITCH PIGTAIL

INTERNALCONNECTION

INDICATESCASEGROUND

SUFFIX

FUSE RATING

SWITCH:MANUAL/MECHANICAL

F18

G IS NOT A SUFFIX BUTINDICATES A GROUNDCIRCUIT.

A

20A

AND/OR

PRODUCTION RELEASE. A P54304U

SWITCHMAGNETIC

SUPPRESSED

PEC 16JAN01

LOCATION/CIRCUIT NUMBERWIRE GAUGE/WIRE COLOR

Figure 7 Circuit Diagram Instructions

S082853


1.8. CIRCUIT DIAGRAM INSTRUCTIONS, P. 8

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 1

CIRCUIT DIAGRAM INSTRUCTIONS

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

10AUG00 08AE08-52365

AIR CONDITIONER

WH - WHITE

IND-

NOUN ABBREVIATION

INDICATOR-AWG

ACC

-BLTW/O WITHOUT-

-

G - ABBREVIATIONS: COLOR, NOUN AND ENGINE

-R

COLOR ABBREVIATION

ENGS

RIGHTENGINESTART OR SENDER

BN - BROWN

--

GD - GOLD

-GAW/

GN - GREEN

G

WITH

LT GN - LIGHT GREEN ACCESSORY

PL - PURPLEPK - PINK

GROUND

SIL - SILVER

IGNAUX

VT - VIOLET

IGNITION-

YL - YELLOW

-AUXILIARY

A

LAMERICAN WIRE GAUGE

LEFTBAT LIGHT-BATTERY

-CONNOPTDRL

CONNECTION OR CONNECTOROPTIONALDAYTIME RUNNING LIGHTS

-

AQ - AQUA

--

BL - BLUEBK - BLACK

FWDTHERMO

DK GN - DARK GREEN

FORWARDTHERMOSTAT

GY - GRAY

GAUGE-

LT BL - LIGHT BLUE

GND

ISM - MFG (CUMMINS) 10.8 LITER ELECTRONIC ENGINE CONTROL

N14E PLUS - MFG (CUMMINS) 14 LITER ELECTRONIC ENGINE CONTROL

C-10,C-12 - MFG (CATERPILLAR) 10.3 LITER ELECTRONIC ENGINE CONTROL

V8-AVNT - MFG (INTERNATIONAL) V8 6.0 LITER ELECTRONIC ENGINE CONTROL

I6-HEUI - MFG (INTERNATIONAL) NGD I6 DT466 & DT/HT530 ELECTRONIC ENGINE CONTROL

ENGINE ABBREVIATION

OR - ORANGE

RD - RED

IAC

TN - TAN


Figure 8 Circuit Diagram Instructions (Cont.)

S082853


9

1.9. SCHEMATIC SYMBOL CHART, P. 9

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 1

SCHEMATIC SYMBOL CHART

U00DLCK

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

19MAY00 09AE08-52365

RESISTOR

SOLENOID - GENERAL USAGE

SWITCH CONTACT, NORMALLY CLOSED

SPLICE

CIGAR LIGHTER

SWITCH-MANUAL/MECHANICAL

SYMBOL

SPEAKER - SOUND SYSTEM

LIGHT - SINGLE FILMENT

SENDER - OIL, WATER, FUEL, TEMPERATURE

DESCRIPTION

GROUND

MALE TERMINAL

LIGHT EMITTING DIODE

SWITCH CONTACT, NORMALLY OPEN

JUNCTION POINT

MOTOR - ELECTRIC

SWITCH-PRESSURE

RELAY-SUPPRESSED

30 86

87A 87 85

HORN

DESCRIPTION

MAGNETIC SWITCH

LIGHT - DOUBLE FILAMENT

MALE/FEMALE IN-LINE CONNECTIONSYMBOL

FEMALE TERMINAL

FUSE


Figure 9 Schematic Symbol Chart

S082853


1.10. RELAY FUNCTIONS, P. 10

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 1

RELAY FUNCTIONS AND WIRING GUIDE

U00DLCK

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

21JUN00 10AE08-52365

30 86

87A 87 85

4

ENERGIZING COIL

85

NORMALLYCLOSED

CONTACT

FUSEBLOCK SOCKETCONNECTOR SOCKETCABLE INSERTIN END

5

NORMALLY CLOSED CONTACT

2

ENERGIZING COIL

3086

87A8785

A

RELAY FUNCTIONS

D

RELAY SCHEMATIC

86

MICRO RELAY FUNCTION AND WIRING GUIDE

85

87A

TYPICAL RELAY (INSERTION END)

30 AE

1

86

3

NORMALLYOPENCONTACT

30

87A

2

ENERGIZING COIL

ENERGIZING COIL

3

C

NORMALLY OPEN CONTACT

14

COMMON CONTACT

B

MINIATURE RELAY FUNCTION AND WIRING GUIDE

TYPICAL RELAY (INSERTION END)

86

87

FUSEBLOCK SOCKETCONNECTOR SOCKETRELAY INSERTION END

RELAY SCHEMATIC

30

87A

B

85

87C

D

E

5

COMMONCONTACT

87


CNA 23AUG02 MINI RELAY #2 WAS #5. B 56507K

Figure 10 Relay Functions

S082853


11

1.11. LAMP BULB CHART, P. 11

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 1

LAMP BULB CHART

U00DLCK

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

20JUN00 11AE08-52365

BULB APPLICATION BULB TRADE NUMBERCANDLEPOWER OR WATTS


BACK-UP LIGHTS 32 CANDLEPOWER GE1156

CLEARANCE & INDENTIFICATION 3 CANDLEPOWER GE193

COURTESY LIGHT 3 CANDLEPOWER GE168

DOME LIGHTS 12 CANDLEPOWER GE561

FOG LIGHTS 55 CANDLEPOWER VH550

HEAD LIGHTS:

LOW BEAMS 65 WATTS GE9007

HIGH BEAMS GE900765 WATTS

INSTRUMENT CLUSTER:

GAUGE BACK LIGHT 082S270538-3

GAUGE WARNING LED (RED) 082S272109-3

RANGE INHIBIT LED (YELLOW) 082S272109-4

COLD AMBIENT PROTECTION LED (YELLOW) 082S272109-4

FUEL FILTER LED (YELLOW) 082S272109-4

WARN ENGINE LED (YELLOW) 082S272109-4

STOP ENGINE LED (RED) 082S272109-3

BRAKE PRESSURE LED (RED) 082S272109-3

BRAKE FLUID LED (RED) 082S272109-3

WAIT TO START LED (YELLOW) 082S272109-4

CHECK TRANSMISSION LED (YELLOW) 082S272109-4

TRAILER ABS LED (YELLOW) 082S272109-4

WASHER FLUID LED (YELLOW) 082S272109-4

LEFT TURN SIGNAL LED (GREEN) 082S272109-2

TRACTION CONTROL LED (GREEN) 082S272109-2

WATER IN FUEL LED(YELLOW) 082S272109-4

PARK FLUID LED LIGHT (RED) 082S272109-3

CHECK ELECTRICAL SYSTEMS LED (YELLOW) 082S272109-4

PARK BRAKE LED (RED) 082S272109-3

CRUISE CTRL ACTIVE LED (GREEN) 082S272109-2

ANTILOCK BRAKING SYSTEM LED (YELLOW) 082S272109-4

RIGHT TURN LED (GREEN) 082S272109-2

COOLANT LEVEL LED (RED) 082S272109-3

SEAT BELT LED (RED) 082S272109-3

HIGH BEAM ICON LED (BLUE) 082S272109-5

CHECK AIR CONDITIONER LED (YELLOW) 082S272109-4

RETARD OVER HEAT LED (RED) 082S272109-3

PTO/THROTTLE LED (RED) 082S272109-3

MAP LIGHT 3 CANDLEPOWER 1816

SIDE MARKER 2458

STOP & TURN/TAIL & LICENSE PLATE 32/3 CANDLEPOWER 1157

TURN SIGNAL/MARKER (FENDER) 3157

TURN SIGNAL & MARKER LIGHT 2356

WORK (TRAILER HOOK-UP) LIGHT 4411

REVISED DRWG SHEET. B P54634FPEC 18JUN01

Figure 11 Lamp Bulb Chart

S082853


1.12. INTERNATIONAL V8 AND I6 ECM CONTROLLER CONNECTORS PIN NUMBERIDENTIFICATION, P.12

CHAPTER 1

INTERNATIONAL V8 & I6 ECM CONTROLLER CONNECTORS PIN NUMBER IDENTIFICATION

U00DLCK

P54304U

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

16JAN01 12AE08-52365

CNA 25FEB03PIN 6 OF CONN X4 INOUTCHANGED TO INPUT

58928SB

CONNECTOR X3 REFERENCE (6020)

ECMPIN #

TERM DESCRIPTION

1 FPM FUEL PUMP MONITIOR

2 FLI FUEL LEVEL INDICATOR

3 KL.15 IGNITION FEED

4 ECL ENGINE COOLANT LEVEL

5 MPR MAIN POWER RELAY

6 KL.31 GROUND

7 KL.31 GROUND

8 DDS DRIVELINE DISENAGE SWITCH

9 FPC FUEL PUMP CONTROL

10 TCSS TORQUE CURVE SELECT SWITCH

11 TACH TACHOMETER CONTROL

12 CAN1+ DRIVETRAIN J1939 DATALINK +

13 CAN1- DRIVETRAIN J1939 DATALINK -

14 RAS RESUME/ACCELERATE

15 CAN1-SHLD DRIVETRAIN 1939 DATALINK SHLD

16 NOT POPULATED

17 VSS_CAL VEHICLE SPEED SENSORCALIBRATION

18 VRE VEHICLE RETARDER ENABLE

19 RPRE REMOTE PRESET PTO ENABLE

20 RVAR REMOTE VARIABLE PTO ENABLE

21 SCS SET/COAST

22 ESHTR ELECTRONIC SHUTTER RELAY

23 ECI ENGINE CRANK INHIBIT

24 BAP BAROMETRIC AIR PRESSURE

KL.87

NOT POPULATED

8

NOT POPULATED

GSC

ECMPIN #

ELECTRIC FAN CONTROLEFAN

6

J1708 DATALINK -ATA-

IDLE VALIDATION SWITCH

4

NOT POPULATED

VEHICLE SPEED SENSOR+

KL.87

NOT POPULATED

9

KL.31B

DESCRIPTION

LOW SIDE OUTPUT 4

7

NOT POPULATED

NOT POPULATED

J1708 DATALINK +

12

19

10

BATTERY POWER

17

GENSET SPEED CONTROL

TERM

15

LSI_SPARE2

22

13

SENSOR REFERENCE VOLTAGEVBREF

20

11

BATTERY POWER

APS18

VSS-

SENSOR REFERENCE GROUND

1

16

23

CONNECTOR X4 REFERENCE (6021)

14

NOT POPULATED

21

IVS

NOT POPULATED

VSS+

2

NOT POPULATED

24

LSO_SPARE4

LOW SPEED INPUT 2

5

ATA+

NOT POPULATED

3

ACCELERATION POSITION SENSOR

VEHICLE SPEED SENSOR-

Figure 12 International V8 and I6 ECM Controller Connectors Pin Number Identification

S082853


13

2. 12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (CHAPTER 2)2.1. ACCESSORY, P. 1

A78L18LTGN

A12B

10LT

BL

5AE1 F1

F5

A

5AA4 B4

F36

10AG1 H1

F1

DIAGCONN(1650)

B

A1218LTBL

C

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 2

ACCESSORY

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

09AUG00 01AE08-52366

CNA 12SEP02 DVD/A12M WAS CONNECTEDTO F21.

56507ZC

A14AA6RD

A14AAA6RDA14AS

10RD

CAB FUSEBLOCK(1011)

A11-

GAF

16W

H

OFFOFFOFFOFF

A

AAA

IIIIS S SSKEY

SWITCH (1100)

B

SGND I A

A14BB6RD

5AA3 B3

F35

OPTIONALSPLICE

A14A

T10

RD

TO IGNITION RELAY

CB RADIO

POWER MIRRORS

ELECT SYSTEMCONTROLLER(1600)

RADIO

SEE CH02_12

BODY BUILDERS CONN

2

(CH 3, PG 8)

(CH 3, PG 7)

(CH 3, PG 2)

100 AMEGAFUSE

(CH 9, PG 10)

3086

87A8785

J4 G4

J3G3

ACCESSORY RELAY

(CAB FUSE BLOCK) (1012)

F2

E25A

F6

A15

18R

D

A9818VT

SWITCH PACK(CH 3, PG 11)

TRAILER AUX/ROOF AUX(CH 3, PG 12)TO IGN RELAY

SEE CH02_12

A13D

D18

PK

A12AB18LTBL

DIODE ASSY(1106M)

A

A13DH18PK

B

D

A12M16LTBL

A12C10LTBL

A12E10LTBL

A12D10LTBL

A12P18LTBL

A12N18LTBL

A12S16LTBL

A8618LTGN

D2

C2

B2

A2

H2

G2

A86F16LTGN

CAB FUSEBLOCK(1013)

CAB FUSEBLOCK(1011)

Figure 13 Accessory

S082853


2.2. BATTERY FEEDS, CAB, P. 2

A14A

A6R

DA1

4AAB

6RD

A14FJ10RD

30A

A3 B3

CAB FUSE BLOCK(1011)

F15

ROOF MOUNTED ASSY

100A

AUX PWR

A14AB10RD

5A

E2 F2F6

MEGAFUSESTUD

A14A

A6R

D

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 2

BATTERY FEEDS, CAB

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

21JUN00 02AE08-52366

CNA 23AUG02 DVD/ADDED F38 TO FUSEBLOCK 1014.

56507ZD

20A

A2 B2F14

10A

G2 H2F38

KEY SW & DIAG

HVAC CONTROL

A1410RD

10A

C4 D4F12

TBD

INSTR CLUSTER

C2 D2


F42

PWR WIN/LOCK (DRIVER)

A14EG10RD

30A

A4 B4F13

IGNITION RELAY (1012) D4 SEE CH02_12

PWR WIN/LOCK(PASS)

A14AV10RD

5A

C2 D2F10

ACCESSORY RELAY (1012) G4

A14AS10RD

A14FR10RD

PWR WIN/LOCK (TRAVEL CREW)

E2 F2F40

D4

G4

G4

G4

CH 3_04

CH 3_04

CH 03_01

CH 11_01

CH 2_01, 12, 15

SEE CH 2_01

CH 7_05

DOME LT/RADIO MEMORY CH 3_08 CH 8_05

15A

G2 H2F2

A14AT10RD

OR

CAB FUSEBLOCK(1012)

30A

A1 B1F43

TBD

LIGHTED AIR SHIELD

OPTIONAL IGN RELAY (1013) G4 SEE CH 2_13

SEE CH 3_05

SEE CH 3_12

BLOCK1&2

OR

BLOCK1&2

BLOCK3&4

A2 B2F44

AIR SEAT/QUALCOM SEE CH 3_15

A14FM10RD

CAB FUSEBLOCK(1013)

Figure 14 Battery Feeds, Cab

S082853


15

2.3. BATTERY, P. 3

J14T

12R

D

J14AW12RD

J14D

12R

D

J94HC14GY

J94H14GY

5A

F2-C3 F2-D35A

F2-E3 F2-F3

25A

F2-G4 F2-H4

J14R10RD

30A

F2-C4 F2-D4

J14S12RD

J14MM8RD

30AF2-A2F2-B2

15AF2-E2 F2-F2

J56T12OR

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 2

12V POWER DISTRIBUTION -BATTERY (CONT)

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

30JUN00 03AE08-52366

CNA 25SEP02 DVD/ADDED LCT SHIFT RELAY, REMOVED J92UA.

56507ZC

K14H4RD

60A

A2

J26D18TN

A14AA6RD

20A W/BODY BUILDER25A W/AUX TRLR SOCKET

F2-A3F2-B3

J14V

6RD

J1916GY

30A W/AIR ABS25A W/HYD ABS

F2-E4 F2-F4

20AF2-G3 F2-H3

40A

A6

J17D10PK

J4410RD

J44J18GY

MEGAFUSE

J57T12OR

40A

A1

15A

F2-G2 F2-H2

J90*16BK

J9012GY

PTC BODY BUILDER FEED CH03_01

STARTER RELAY CH02_15,CH04_01,02

POWER PARK MOTOR CH09_16

CAB FEED CH02_01,02,12,15

HYDRAMAX MOTOR RELAY CH09_08

FROM START SOLENOID

TAIL MARKER RELAY FEED CH09_10

STOP RELAY FEED CH09_10

TRAILER ABS RELAY CH09_11

TRLR RIGHT TURN RELAY CH09_11

TRLR LEFT TURN RELAY CH09_11

BODY ACCESSORY RELAY CH09_10TRLR AUX CTR PIN RELAY CH09_11

REAR REMOTE POWER MODULE CH09_15

FUEL HEATER & WIF MODULE CH07_09,CH09_07

FORWARD REMOTE POWER MODULE CH09_15

PAM MODULE CH07_11

EATON AUTOSHIFT CH10_06

AIR ABS RELAY CH09_02

HYD ABS MOD RELAY CH09_06

HYD ABS ECU RELAY CH09_04

J14W16RD

J14X16RD

J14BB14RD J72

12OR

J14J

12R

DJ1

4J12

RD

J94A12GY

J14M10RD

*FUSEABLE LINK

IGN

REL

AY R

9 C

H02

_14

SYSTEMCONTROLLER

*12BL

*12BL

J14H

4RD 12RD

12RD*14GY

40A

A5

J92FB16TN LCT SHIFT RELAY CHO3_17

10A

F2-C4 F2-D4

Figure 15 Battery

S082853


2.4. 1708 DATA LINK, P. 4

10

9

W/V8-AVNT ENGINES

10

G2

1

10

W/ALLISON WTEC TRANSMISSION

W/EATON AUTOSHIFTTRANSMISSION

15

11

20

ECM2CONN(6021)

C3

DASH/CENTERCHASSIS(9700)

21

(W/HYD ABS BRAKES)

11

C2

10

11

G3

AIR ABSECU #1(4024)

FDIAGNOSTICCONN(1650)

W/AIR ABS BRAKES

B2

AUTOSHIFTSELECTOR(7905M)

9

17

ECU "S"CONN BLACK(7204F)

20

ECM 2CONN(6021)

G

10ENGINE(4103)

16

DASH(4705F2)

J1708 SPLICE(4820)

C4

CHAPTER 2

1708 DATA LINK

U00DAG9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

19JUN00 04AE08-52366

CNA 12SEP03 ADDED I6-HEUI ENGINES. 58774TE

9PASS THRUAT DASH(4014)

(4820)J1708 SPLICE

21

G

10

FDIAGNOSTICCONN(1650)

N/EATON AUTOSHIFTTRANSMISSION

W/I6-EGR ENGINES

2

3

IDM2(6011)

2

3

IDM2(6011)

15

TCM BULKHEAD(7214)

14

W/ALLISON HD WTECTRANSMISSION

SEE CH09_04

SEE CH09_04

16

ECM CONN(6007)

17

10 11

W/I6-HEUI ENGINES

Figure 16 1708 Data Link

S082853


17

2.5. SWITCH DATA LINK, P. 5

T3BB

(+)

18D

KBL

SWITCHPACK(1101)

D E

E3X(

-)18

GY

A3Z(-)18GY

A3J(

+)18

DKB

L

D3A

A(-)

18G

Y

DOOR PODSIGNAL(3202)

D C

E3W

(+)

18D

KBL

DOOR PODPASSENGER(3204)

A B

ELECT SYSTEM CONTROLLER

(1600)

30 29

A3Y(+)18DKBL

D3Y

(+)

18D

KBL

A3K(

-)18

GY

T3AA

(-)18

GY

RIGHT CREWDOOR POD(3208)

B A

E3X(

-)18

GY

T3AA

(-)

18G

Y


C D

D3B

(+)

18D

KBL

D3B

B(+)

18D

KBL

A3P(

-)18

GY

T3BB

(+)

18D

KBL

A3W

(+)

18D

KBL

D3C

C(-)

18G

Y

CREW DOOR

(2600)

E BD

3Z(-)

18G

Y

A3N

(+)

18D

KBL

DOOR POD SIGNAL

(3209)C D

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 2

SWITCH DATA LINK

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

25AUG00 05AE08-52366

E3W

(+)

18D

KBL

DOOR PODDRIVER

(3200)

B A

A3E(

+)20

DKB

L

A3X(

-)18

GY


C D

A3F(

-)20

GY

LEFT CREW DOOR POD

(3208)B A


Figure 17 Switch Data Link

S082853


2.6. DRIVETRAIN 1939 DATA LINK (CAB), P. 6

CHAPTER 2

DRIVETRAIN 1939 DATA LINK (CAB)

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

09AUG00 06AE08-52366

CNA 12SEP03 REVISED 1510 PIN OUTS. 58774TC

ELECT SYSTEM CONTROLLER

(1600)

34 35

120A

C

TERMINATINGRESISTOR

(1657M)

J1939SHIFTER

(1652)

A B CLUSTER

(1500)4 5

OPTIONALGAUGES

(1659)

A B

TODRIVETRAINJ1939SEE CH02_07

DIAGNOSTICCONNECTOR

(1650)

C D

OPTIONALGAUGE PACK

(1510)

11 10

AUTO HVAC

(1658)

A B

DASH PASS THRU(4014)

11

12

W/ EATONAUTOSHIFT

SE

E C

H07

_05

SE

E C

H07

_05

SE

E C

H10

_07

SE

E C

H10

_07

Figure 18 Drivetrain 1939 Data Link (Cab)

S082853


19

2.7. DRIVETRAIN 1939 DATA LINK (CHASSIS), P. 7

L5B18418GN

L5B18318YL

(+)20YL

W/WTEC

FROM DASH PASS THRU (4014)

(-)18GN

(+)18YL

(-)18GN

WITHOUT WTECWITHOUT LCT

PAM MODULE(4087)

7

9

8

(-)20GN

(-)20GNSEE CH02_06

(+)20YL

AIR ABSECU #1

(4024)

D3

D2

C3

W/ AIR ABS BRAKES

(-)18GN

(-)20GN

W/AMMETER or PYROMETER

A

C120 ohms

(+)18YL

(+)18YL

ECU "S" CONN BLACK

(7204F)

12

13

29

(+)20YL

(+)20YL

(-)20GN

120 ohms

CHAPTER 2

DRIVETRAIN 1939 DATA LINK (CHASSIS)

U00TRH2

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

22JUN00 07AE08-52366

CNA 12SEP03 ADDED I6-HEUI; REVISED LCTCONN 7305F PINOUTS.

58774TG

ENGINE/ DASH

(4103)

9

7

8(-)18GN

(+)18YL

CAN(-)

CAN(+)

ECM2

(6020)

12

15

13

ECU "J1" CONN(7305F)

31

29

32

W/LCTSEE Chapter 10, Sheet 1

NOTE: NOT ALL MODULES NEED BE PRESENT. J1939 BACKBONE BY-PASSES MISSING Y-SPLICES.

W/V8-AVNT ORI6-EGR ENGINES

N/AMMETER ORPYROMETER

A

C

37

38

D

E

TCMBULKHEAD(7214)

ENGINE/XMSN(7800)

W/ ALLISON HD XMSN

SEE CH07_11

SEE CH07_11

J5R(+)20YL

J5R(-)20GN

L5B1

8418

GN

L5B1

8418

GN

L5B

183

18YL

L5B1

8318

YL

(-)

18G

N(-

)18

GN

(+)

18YL

(+)

18YL

ECM

(6007)

19

18

20

I6-HEUI ENGINES

Figure 19 Drivetrain 1939 Data Link (Chassis)

S082853


2.8. GROUNDS CHASSIS, P. 8

J94-GHD18WH

J94-GHF18WH

J94-GHE18WH

J94-GHA14WH

J94-GHB14WH

J94-GHC14WH

STARTER GND(4036) J94-GA

12WH

J5M(D)20WH

PRIMARY IGN RELAY GND CH02_14

J94-GAB18WH

HYD MOD PUMP RELAY GND CH09_06

J11-GD18WH

ABS WARN LIGHT RELAY GND CH09_06

J11-GL4WH

J5M(S)20 SHLD

WIPER MOTOR GND CH03_09

J94-GAA18WH

ABS EVENT RELAY GND CH09_06

J11-GPM14WH

REAR REMOTE SOLENOID POWER MODGND CH09_15

AIR ABS GND CH09_02

J94-GH10WH

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 2

GROUNDS, CHASSIS

U00JXP9

52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

26MAY00 08AE08-52366

J82-G16WH

J1939 GND CH09_15

J94-GAD18WH

AIR ABS GND CH09_02

AIR ABS GND CH09_02

HYD ABS GND CH09_04

J11-GJ10WH

SYSTEM CONTROLLER SHD GND CH09_15

ABS ECU POWER RELAY GND CH09_02

HYD ABS GND CH09_04

GND(4005)(4006)

J11-G12WH

FWD REMOTE POWER MOD CH09_15

J11-GQR14WH

FWD CHASSIS GND CH03_6, CH08_02

HYD ABS MOD GND CH09_04

J11-GA14WH

J94-GAC18WH

REAR CHASSIS GNDCH07_08; CH08_01,02; CH09_01,09

J11-GPN16WH

J11-GQS14WH

(FWD ONLY)

(FWD AND REAR)FWD REMOTE POWER MOD CH09_15


Figure 20 Grounds Chassis

S082853


21

2.9. GROUNDS CHASSIS, P. 9

J11-GAM12WH

J61-G18WH

J11-GPN16WH

J11-GPM16WH

J90-GM12WH

POWER PARK GND

J11-GBR18WH

TRAILER RIGHT TURN RELAY CH9_11

TRAILER LEFT TURN RELAY CH9_11

J11-GL4WH

J19-GA16WH

J11-GM8WH

POWER PARK GND

TRAILER AUX CENTER PIN RELAY CH9_11

EATON AUTOSHIFT GND

J11-GH8WH

FUEL HEATER RELAY CH9_07

J56-GH18WH

GND(4005)(4006)

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 2

GROUNDS, CHASSIS

U00JXP9

52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

26MAY00 09AE08-52366

J90-G16WH

J19-G18WH

J11-GW18WH

CRANK INHIBIT W/AUTO NEUTRAL CH10_05

BODY BUILDER GND CH9_10

WORK LIGHT GND CH08_05

J57-GH18WH

ACCESSORY BODY BUILDER RELAY CH9_10

J44-GA16WH

J17-GR118PK

J11-GBG12WH

FUEL FILTER WARNING LIGHT GND CH07_09

J11-GBB12WH

TRAILER SOCKET GND CH9_11

STARTER GND(4036)

J65-G18WH

FLOW SWITCH GND CH09_8

J72-G18WH

TRAILER ABS CENTER PIN RELAY CH9_11

J44-G10WH

PAM MODULE CH7_11

FORWARD REMOTE POWER MODULE CH9_15

AIR SUSPENSION SOLENOID CH9_17

HYDRAMAX MOTOR CH9_08


Figure 21 Grounds Chassis (Cont.)

S082853


2.10. GROUNDS IP, P. 10

A98-G18WH

A84-G14WH

RADIO GND CH3_08

A86-GA14WH

A73-G12WH

A28-G18WH

A74-G18WH

AUX PWR GND CH3_01

A11-GAB20WH

PWM GND CH11_01

A11-GAD16WH

A63-GA20WH

SWITCH PAK GND CH3_11

CIGAR LTR GND CH3_01

FB2 IGN RELAY GND CH2_12

HVAC CONTROL GND CH11_01

A11-GDB18WH

MARKER LTR GND CH8_04

DOME LT GND CH8_04

A11-GAH14WH

A11-GAA18WH

A86-G18WH

A11-GF16WH

CLUSTER GND CH7_05

A11-GA10WH

CAB GNDSTUD(1851)(1852)(1859)

WASHER GND CH3_09

A11-G10WH

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 2

GROUNDS, IP

U00JXP9

52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

9AUG00 10AE08-52366

A

DIAGNOSTICCONNECTOR(1650)

1

SYSTEM CONTROLLER(1600)

B


16JAN01

B 56507KRMVD CLUSTER GND CH7_05

A P54304UPRODUCTION RELEASE.PEC

22AUG02CNA

Figure 22 Grounds IP

S082853


23

2.11. GROUNDS IP, P. 11

A28-GC18TN

A62-GC18WH

A23-GA18WH

A21-G16WH

GND STUD(1858)(1862)(1552F)

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 2

GROUNDS, IP

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

9AUG00 11AE08-52366

A18818DKBL

PREMIUM TRIM GNDCH3_03

A81-GA12WH

A11-GDX16WH

A62-GD18WH

A81-G12WH

TRANSMISSION GNDCH10_03

A41-G18WH

A11-GBA18WH

A81-GB12WH

COURTESY LIGHT DRV CH8_04

TRANSMISSION GNDCH10_03

A11-GDW18WH

D

E

BUSS

BAR

F

G

J

H

A

K

B

C

GROUND(1003)

A81-GC12WH

COURTESY LIGHT PASS CH8_04A11-GDV18WH

A11-GAL12WH

POWER WINDOW / LOCK DRV CH3_04

OPT IGN RELAY GND CH2_13

POWER WINDOW / LOCK PASSTRAVEL CREW CH3_05

POWER WINDOW / LOCK PASS CH3_04

SNOW VALVESWITCH(1901)

A62-GF16WH

A18618DKBL

POWER WINDOW / LOCK DRVTRAVEL CREW CH3_05

A11-GH8WH

IP AIR HORN SWCH3_06

A11-GDY12WH

SEE CH03_07

10

ETHER START SWITCH (1010)

SEECH05_02

5B

SEE CH05_03

SHIFTER GND CH10_01

AUTO NEUTRAL LIGHT

MIRROR SWITCH

SEE CH10_05

PRODUCTION RELEASE. A P54304U PEC 16JAN01

Figure 23 Grounds IP

S082853


2.12. IGNITION CAB, P. 12

Figure 24 Ignition Cab

S082853


25

2.13. IGNITION CAB, P. 13

A13DB18PK

A11-GBA18WH

SNOW VALVE SWITCHCONNECTOR

C2

CHAPTER 2

12 VOLT POWER DISTRIBUTION -IGNITION CAB (CONT)

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

09AUG00 13AE08-52366

CNA 12SEP03 F30 WAS 10A 58774TF

7.5A

A1 B1F33

A14FJ10RD

10A

G2 H2F28

5A

E1 F1F29

10A

A2 B2F34

BATT FEED

A13FA10PK


J3

G4

J4

G3

SEE CH02_11

CH2_02


3086

87A

8785

CAB FUSE BLOCKIGNITION(1013)

5A

E2 F2F30

2 WAY RADIOSEE CH03_10

SATELLITE COMMUNICATIONQUAL COMM-IMCT SYSTEM

SEE CH03_14

SEE CH03_13

LIFT AXLES

SEE CH09_25

A13F16PK

5A

C1 D1F31

ETHER START

OPTIONAL WARNINGLIGHTS

SEE CH07_08

SEE CH05_02

5A

G1 H1F36

5A

F2

E2

CAB FUSE BLOCK(1011)F6

OFFOFFOFFOFF

A

AA

AI

II

I

S S SS

B

SGND I A

B2

A2

A13D

D18

PK

A12A

B18

LTBL

D

D2

C2

A15

18R

D

DIODE ASSY(1106M)

A12

18LT

BL

A

A13

DH

18PK

H2

G2

A

C

B

A86P16LTGN

A21C16TN

A59H18BKA59J18BK

A13E16PK

A13F

B10

PK

A13DB18PK

TO ACC RELAYCH2_01

A11-GAM16WH

KEY SWITCH(1100)

SEE CH05_03

A13DA18PK

A49C18GY

A49E18GY

CH09_31REMOTE STOP RELAY

Figure 25 Ignition Cab (Cont.)

S082853


2.14. IGNITION FEEDS, CHASSIS, P. 14

Figure 26 Ignition Feeds, Chassis

S082853


27

2.15. START, P. 15

A104EB18DKBL

14G

Y

J17E10PK

J17

18PK

A15

18R

D

CHAPTER 2

12VOLT POWER DISTRIBUTION - START

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

10AUG00 15AE08-52366

CNA 12SEP03 ADDED A17 FOR HD WTEC. 58774TF

OFFOFFOFFOFF

A

AA

AI

II

I

S S SS

KEYSWITCH(1100)

B

SGND I A

5A

F2

E2

FUSE BLOCK #2 (1011)

F6

D2

C2

B2

A2

H2

G2

A14AAA6RD

100AMEGAFUSE

A14BB6RD

A14AA6RD

8 PASS THRUAT DASH(4014)

J17D

10PK

J17S18PK

TO START SOLENOID POS

TO ENGINE ECM

TO START SOLENOID

A14AS10RDA14AS10RD

K14H4RD

A

B

W/AUTO NEUTRAL

CH04_01,02

CH4_1,2

CH4_1,2

NOTE:

SHOWN NOT WITH WTEC AUTONEUTRALALSO SEE CH10_5

N/AUTO NEUTRAL

8687

30 87A

85

(4003)STARTERRELAYS

R12-1

R12-2

R12-3

R12-4

R12-5

A1718PK SEE CH10_05

SEE CH10_13

TO REMOTE STOP RELAYCH9_31

D

A1718PK SEE CH10_09

W/HD WTEC

A17

18PK

Figure 27 Start

S082853


3. CAB ACCESSORIES (CHAPTER 3)3.1. CIGAR LIGHTER AND POWER FEEDS, P. 1

A86-GA14WH

AA86-GA14WH

B

CIG LTRPWR SOURCE (1860)

B

60AMP POWER FEED

TO POINT ATHIS SHEET

B

A86N14LTGN

CIG LTR PWR (1854)

A

AUXILIARY POWER (10)

A86M14LTGN

A


15A

H3G3

F3


B

CIG LTRPWR SOURCE (1860)

A86-GB14WH

A86N14LTGN

A

PTC BODY BUILDER DCM BATT FEED (1820)

A

TWO POSTPWR SOURCE (1861)

(STANDARD EQUIPMENT)

BA86-GA14WH

NEGSTUD(1851)

(OPTIONAL WIRING 1)

60A

A2MAXIFUSE BLOCK (4000)

A

J14MM8RD

A86-GA14WH

A86M14LTGN

A8414LTGN

(OPTIONAL WIRING 2)

POINT A

CIG LTR

P148RD

BODY BUILDER FEED STUD (1870)

A86-GA14WH

B

A86M14LTGN

A84-G14WH

(OPTIONAL WIRING 3)

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

CIGAR LIGHTER & POWER FEEDS

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

26JUN00 01AE08-52367

A


20A

B2A2

F14

A

TWO POSTPWR SOURCE (1861)

CIG LTR GND (1853)

A86-GB14WH

A86M14LTGN

A86M14LTGN

A86

-GA

14W

H

CIGAR LIGHTER

A11-GA10WH


20A

B2A2

F14

B

(CH 2, PG 2)

(CH 2, PG 2)

(CH 2, PG 2)

(CH 2, PG 2)






20A

B2A2

F14

F14 WAS F2 B 56507K23AUG02CNA

Figure 28 Cigar Lighter and Power Feeds

S082853


29

3.2. CB POWER, P. 2

C11

-GF

16W

H

B

C8

6F1

6LT

GN

ROOF/IPCONN(2000)

12 11

CAB FUSEBLOCK(1011)

A11-G10WH

A11-GF16WH

D11

-GF

16W

H

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

CB POWER

U00EDL2

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

25AUG00 02AE08-52367

10A

H1

G1

F1

C86

-GF

16W

H

A

NEGATIVESTUD(1851)

D86

F1

6LT

GN

CONSOLE/ROOF

(2502)A B

CB RADIOPOWER(2303)

(CH

2, P

G 1

)


A86

F16

LTG

N

56507KBCHGD F20 TO F1, 1012 TO 101123AUG02CNA

Figure 29 CB Power

S082853


3.3. COMPASS AND TEMPERATURE DISPLAY, P. 3

J41

A18

GY

J41

18G

Y

H

35 PASS THRU(4014)

A62F18DKBL

B

E

A41-G18WH

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

COMPASS ANDTEMPERATURE DISPLAY

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

25AUG00 03AE08-52367

H

GROUND (1003)

ADOME/READING LIGHTCOMPASS/TEMP UNIT(2117)

34

4 103

C4

118

GY

C41

B18

GY

C4

1-G

18W

H

5A

B1

A1

F23

A4118GY

2

G

C4

1A18

GY

A41

B18

GY

C6

2F18

DK

BL

G

PANEL LIGHT BUSS BAR (1002)

ATEMPSENDER(8601)

COMPASS/TEMPMODULE

GR

OU

ND

12V

IGN

DIM

ME

R

TEM

P +

TEM

P -

A41A18GY

1

CONSOLE/IPPREMIUM(2503)

D

CBAUX FWD/DASH(4305)

M41

18G

Y

M41

A18

GY

SEE CH08_08


CAB FUSEBLOCK(1012)

RMVD 1200, F23 WAS F10 B 56507K23AUG02CNA

Figure 30 Compass and Temperature Display

S082853


31

3.4. FRONT DOORS WINDOWS AND LOCKS (POWER), P. 4

A81B12LTGN

A3N(+)18DKBL

A3E(+)20DKBL

A3W(+)18DKBL

A3Y(+)18DKBL

A3X(-)18GY

A3F(-)20GY

A3P(-)18GY

A81-G12WH

A81-GB12WH

A11-GH10WH

A81A12LTGN

E

F

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

FRONT DOORSWINDOWS AND LOCKS (POWER)

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

25AUG00 04AE08-52367

WINDOW MOTOR

(3100)

B A

C

D

F


C

WINDOW MOTOR

(3100)

A B

29 SYSTEMCONTROLLER (1600)

30A

B3 A3

F15

A

DOOR/IP (3200)

A

DOOR/IP (3204)

B

30A

B4 A4

F16

B

NEGATIVE STUD (1858)

30

DOORLOCK

(3203)

B A

DOORLOCK

(3203)

A B

E

D

WINDOW

DATA +

ADDRESS 1

DO

OR

PO

DDATA -

LOCK

LOCK

WINDOW

ADDRESS 2

POWER

GND

B

F

E

C

D

B

D

C

A

A

G

DOORPOD SIGNAL

(3202)

DOORPOD LOAD

(3201)

WINDOW

DATA +

ADDRESS 1

DO

OR

PO

D DATA -

LOCK

LOCK

WINDOW

ADDRESS 2

POWER

GND

B

F

E

C

D

B

D

C

A

A

G

DOORPOD SIGNAL

(3202)

DOORPOD LOAD

(3201)ite_drawn:

NOTE: THE DOTTED LINESARE AN OPTION FOR TRAVEL CREW DOOR PODS

A81-GA12WH

E3X(-)18GY

E3W(+)18DKBL

E81-GA12WH

E81B12LTGN

E3X(-)18GY

E3W(+)18DKBL

E81-GA12WH

E81B12LTGN

E83E14LTGN

E83A14LTGN

E81A14LTGN

E81

E14

LT

GN

E83E14LTGN

E83A14LTGN

E81A14LTGN

E81

E14

LT

GN


PA

SS

EN

GE

R

DR

IVE

R

SEE CH03_05

SEE CH03_05

A3Z(-)18GY

SEE CH03_05

SEE CH03_05 A81-GC12WH

B 56507KF15 WAS F27, F16 WAS F34,

1011 WAS 1013

23AUG02CNA

Figure 31 Front Doors Windows and Locks (Power)

S082853


3.5. CREW DOORS WINDOWS AND LOCKS (POWER), P. 5

T3BB(+)18DKBL

E

D3B(+)18DKBL

A

LEFT CREWDOOR POD (2601)

D

A81C12LTGN

F

DOORLOCK

(3211)

B A

D

A3Y

(+)

18D

KB

L

D81-GD12WH

D81C12LTGN

A

ROOF / IPCREW DOOR(2600)

B

A81

-GB

12W

H

D81

-GB

12W

H

30A

B1 A1

F43

D3AA(-)18GY

E

E

A3Z

(-)

18G

Y

D81-GG18WH

B

D81D12LTGN

D3CC(-)18GY

F

WINDOW MOTOR

(3002)

A B

C

D81-GE18WH

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

CREW DOORSWINDOWS AND LOCKS (POWER)

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

25AUG00 05AE08-52367

D3BB(+)18DKBL

B

C

DOORLOCK

(3211)

A B

C

A

RIGHT CREWDOOR POD (2602)


D81-GF12WH

D

WINDOW MOTOR

(3002)

B A

D3Y

+)18

DK

BL

F

A81D12LTGN

D81

-GC

12W

H

30A

H1 G1

F37

D3

Z(-

)18

GY

T81E12LTGN

WINDOW

DATA +

ADDRESS 1

DO

OR

PO

D

DATA -

LOCK

LOCK

WINDOW

ADDRESS 2

POWER

GND

B

F

E

C

D

B

D

C

A

A

G

DOORPOD SIGNAL

(3209)

DOORPOD LOAD

(3210)

WINDOW

DATA +

ADDRESS 1

DO

OR

PO

D

DATA -

LOCK

LOCK

WINDOW

ADDRESS 2

POWER

GND

B

F

E

C

D

B

D

C

A

A

G

DOORPOD SIGNAL

(3209)

DOORPOD LOAD(3210)

ite_drawn:

T8A18WH

T8A18WH

T81E12LTGN

T83F12LTGN

T83C12LTGN

T81C12LTGN

T8

1F12

LTG

N

T83F12LTGN

T83C12LTGN

T81C12LTGN

T81

F1

2LT

GN

T81-GD12WH

T3BB(+)18DKBL

T3AA(-)18GY

T8B18WH


SE

E C

H03

_04

SE

E C

H03

_04

SE

E C

H03

_04

A81

-GC

12W

HS

EE

CH

03_

04

LEF

T C

RE

W

T8B18WH

T3AA(-)18GY

T81-GD12WH

RIG

HT

CR

EW

F37 WAS F28, F43 WAS F35 B 56507K

1014 WAS 1013

22AUG02CNA

Figure 32 Crew Doors Windows and Locks (Power)

S082853


33

3.6. HORN, DUAL ELECTRIC, P. 6

M11-GC12WH

5

AIR

HO

RN

A9M18GY

AIR

HO

RN

A4CAB/DCM (1800)

A85B

20G

Y

20

M85

E16

GY

B9V

18G

Y

ESYSTEMCONTROLLERBROWN FRONT(4007)

A9V

18G

YC

ITY

HO

RN


ZER

O V

OLT

REF

20

D

10

M11

-G12

WH

A9H

20G

Y

A85K18GY

A62R

18D

KBL

FGROUNDADAPTER(1003)

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

HORN, DUAL ELECTRIC

U00EDL2

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

19JUN00 06AE08-52367

A85C

20G

YB

J11-G12WH

B10

3

A62-

GF

18W

H

A

RIGHT SIDEELECT HORN (8312)

J11-GJ10WH

13

ELEC

HO

RN

SW

(4006)GND 2

B85B

18G

Y

CACLOCKSPRING(1809)

M85-GD16WH

W/INSTRUMENT PANEL HORN SWITCH

EPANEL LIGHT BUSS BAR (1002)

B

B85C

18G

Y18

1310 FWD CHASSIS/DASH(4301)

M11-GD12WH

A85L18GY

A85C

20G

Y

B11

A

LEFT SIDEELECT HORN (8311)

2B

HORNSWITCH(1018)

M85-GE16WH

8

20

B9R

18G

Y

M85L16GY

M85-GA16WH

M85-GC16WH

B

A

(8301)

M85J16GY

M85K16GY

J85A

A16

GY

SEE CH08_08

GROUNDADAPTER #1(8800)

GROUNDADAPTER #2(8801)

RADIATORA

RADIATOR GND (8600)


Figure 33 Horn, Dual Electric

S082853


3.7. MIRRORS (HEATED, LIGHTED AND POWER), P. 7

A62

D18

DK

BL

E

HSYSTEM CONTROLLER (1601)

H

A78

P16

LTG

N

10A

H2

G2

(1012)

F18

A78-GD16WH

F

DOOR/IPMIRROR(3000)

A

DOOR/IPMIRROR

(3003)

ANT GND

AXISD

E

LIGHT

C

HEATER

AXIS

B

G

L/R

A

F

U/D

DRIVERPOWERMIRROR

K

J

10A

B1

A1

F13

CAB FUSE BLOCK (1011)

A78-GB16WH

D

A58

S16

BN

A78

H1

6LT

GN

ANT GND

AXISD

E

LIGHT

C

HEATER

AXIS

B

G

L/R

A

F

U/D

PASSENGER Power Mirror

20BL

CAB FUSEBLOCK

20OR

A1

A2

A3

A4

B1

B2

B3

B4

MIRRORSWITCH

D

G

CAB FUSEBLOCK

J

20BL

BB

A78D18LTGN

K

G

F

E

A78L18LTGN

A78E18LTGN

20WH

A

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

MIRRORS (HEATED, LIGHTED & POWER)

U00JXP9

52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

25AUG00 07AE08-52367

H

A78

M16

LTG

N

A58U18BN

CA78F18LTGN

5A

B4

A4

(1013)F36

C

A78

14LT

GN

G

A58T18BN

A78J16LTGN

20OR

20YL

20BN

18RD

18DKGN

18BK

18OR

18BN

18YL

18RD

18LTGN

18BK

18BK

20YL

A1

1-G

DY

12W

H

SEE CH02_11

SE

E C

H08

_10


23AUG02 56507KREV FUSE BLOCK/DEL A. GNDCNA B

Figure 34 Mirrors (Heated, Lighted and Power)

S082853


35

3.8. RADIO (ENTERTAINMENT), SPEAKERS, P. 8

A86-

G20

WH

A6218DKBL

4

ROOFCONN(2000)

8 6

PREMIUMROOFCONN(2503)

GND STUD(1851)

1


LEFT CONSOLE SPEAKER

(2305)

A B+ -

C86

K18

LTG

N

CLUSTER CONN (1500)

7

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

RADIO (ENTERTAINMENT), SPEAKERS

U00JXP9

52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

25AUG00 08AE08-52367

CNA 16SEP02 DVD/ADDED PREMIUM RADIOWIRING.

56507ZD

5

RIGHTCONSOLESPEAKER

(2304)

A B+ -

W/PREMIUMCAB TRIMONLY

13

LEFT REAR SPEAKER

(2302)

A B

+ -

NOTE: REAR SPEAKER WIRING IS THE SAME FOR STD, EXTENDED AND TRAVEL CREW CAB.

9

A86J20LTGN

C86

H18

LTG

N

RIGHT REAR SPEAKER

(2301)

A B

+ -

10A

D4

C4F12

10A

H1

G1F23

D86

B18

LTG

N

D86

D18

LTG

N

C86

L18

LTG

N

C86

J18

LTG

N

D86

C18

LTG

N

D86

E18

LTG

N

1


A86D20LTGN

A86L20LTGN

A86K20LTGN

A86H20LTGN

A62E20DKBL

A86C20LTGN

A86B20LTGN

A86A

18LT

GN

LEFT CONSOLE

RIGHT CONSOLE

RADIO POWER

RIGHT FRONT +

LEFT FRONT +

LEFT REAR -

RADIO MEMORY

PANEL LIGHT

RIGHT REAR -

RIGHT REAR +

LEFT REAR +

GROUNDC

B

O

I

K

M

J

L

D

F

G

EA8

618

LTG

N

A86E20LTGN

5

3

7

10

4

11

12

1

7

6

8

2

GROUND

LEFT REAR +

RIGHT REAR +

RIGHT REAR -

LEFT REAR -

PANEL LIGHT

RADIO MEMORY

LEFT FRONT +

RIGHT FRONT +

RADIO POWER

RIGHT CONSOLE -

LEFT CONSOLE -

A11-

GA

10W

H

RADIOCONN(1301)

RADIOCONN(1300)

PREMIUM RADIO

AM-FM CASSETTE BASE RADIO

W/PREMIUMRADIO ONLY

Figure 35 Radio (Entertainment), Speakers

S082853


3.9. WINDSHIELD WIPER AND WASHER PUMP, P. 9

J87B18GY

J87KA18GY

J87C18GY

N87DB18GY

J87KB18GY

N87DB18GY

J87CA18GY

N87EA18GY

J82L16GY

J82H16GY

J82RH18GY

J82P16GY

J82RP18GY

J82H

L16

GY

J82F

A18

GY

J82F

B18

GY

J82HLP16GY

N87HA18GY

(1810)

22

(4006)

GND 2

A9H20GY

5

B87A18GY

A87A20GY

WIPER 0

20GN

3

30

PASS THRUAT DASH(4014)

C1

24A82B20GY

A3

12

8

GND

LO

HI

WV50V2.2uF x2A

B+

4.4uH x3

PRK

C/B

WIPER MOTOR(4015)

A

B

C

D

E

2

1

WASHER PUMP (4021)

SYSTEM CONTROLLERBLUE(4008)

A82A20GY

B8218GY

7

WASHER20YL

DCMCONNECTOR(1800)

WIPER 1

20RD

WASHER FLUIDLEVEL SENSOR (4022)

12

B1

WIPER 1

28

WIPER HIGHWINDING

A8220GY

6A11-GAA18GY

23

SYSTEMCONTROLLER

J82-G16WH

B9S18GY

A87C18GY

F

11

WIPER 0C9

WIPER 2

B82A18GY

B82B18GY

B9U18GY A5

A11

-G10

WH

WASHER PUMP

WIPER 2

20OR

20WH A4

12


TURN SIGNALSWITCH

(1600)

(1852)

NEGATIVE STUD

J11-

GJ

10W

H

A9V (250)18GY

A87B18GY

CHAPTER 3

WINDSHIELD WIPER AND WASHER PUMP

U00JXP9

52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

10AUG00 09AE08-52367

CNA 12SEP03 4021 WAS 9747. 4022 WAS 9748.

4830 WAS 8802.

58928SE

LOW WASHERFLUID LIGHT DIGITAL

ZERO VOLT REFERENCE

B11-GAA18WH

5 AMPF1-D2 F1-C2

MINIFUSE BLOCK(4001)

ZERO VOLT REF SPLICE (4830)

3086

87A

8785

WIPER PWRRELAY(4003)

R1-1

R1-2

R1-3

R1-5

R1-4

3086

87A

8785

WIPERHI-LOWRELAY(4003)

R2-1

R2-2

R2-3

R2-5

R2-4

J82F16GY

J82B16GY

29

20


D3

D2

D6

CENTERCHASSIS(9700)

J87BB18GY

NOTE: ALL DASH LINES REFER TO RH-MRD MODELS.

Figure 36 Windshield Wiper and Washer Pump

S082853


37

3.10. 2–WAY RADIO, P. 10

A13

FA

18P

KA

86P

16LT

GN

A11

-GA

P16

WH

A14

HC

16

RD

J14

-GD

16W

H

J14H

C16R

D

N14

-GD

10W

H

N14H

C10R

DN

14H

C10

RD

N14

HB

10R

D

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

2-WAY RADIO

U00DLCK

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

19JUN00 10AE08-52367

2-WAYRADIOCONN

(6334)

A B

PASS THRU(4014) 21 28

20A

B

A

5A

F2

E2

F30

A

A

N14-G

D1

0WH

(9265) 2-WAY RADIONEGATIVE CONN(9263)

2-WAY RADIOPOSITIVE CONN

(9264)

2-W

AY

RA

DIO

BTR

YP

OS

ITIV

E

2-W

AY

RA

DIO

BT

RY

NE

GA

TIV

E

BATTERY

2-W

AY

RA

DIO

CO

NN

EC

TIO

NS

EE

CH

02_1

3

CAB FUSEBLOCK(1013)

A13FA WAS A13DF, F30 WAS C 56507K22AUG02

F38, 1013 WAS 1014

CNA

Figure 37 2–Way Radio

S082853


3.11. SWITCH PACK, OPTIONAL GAUGE PACK, P. 11

A5C(-)20LTGN

A5C(+)20YL

A14FF18RD

A62S18DKBL

A12FC18LTBL

A11-GJ18WH

A12P18LTBL

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

SWITCH PACK, OPTIONAL GAUGE PACK

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

09AUG00 11AE08-52367

F

GROUND

SWITCH D/L +

POWER

BACKLIGHT

C

E

SWITCH D/L -

F

D

ADDRESS SEL

B

SWITCH D/L +

A

POWER

B

A

BACKLIGHT

C

E

SWITCH D/L -

D

ADDRESS SEL

GROUND

(1101)

(1101A)

SWITCH PACK

NEG STUD(1851)

5 A

F1

E1


F5

A11-GDB18WH

A11

-GA

10W

H

A62C18DKBL

A62

18D

KB

L

A

DRIVETRAINJ1939(1659)

B

1

CLUSTER (1500)

A3E(+)20DKBL

A3F(-)20GY


NOTE:FOR MULTIPLE SWITCH PACKS,CONNECT 1101 OF NEXT SWITCHPACK TO 1101A OF PREVIOUSSWITCH PACK. CONNECT OPTIONALGAUGE PACK TO LAST SWITCH PACK.

A3J(+)18DKBL

A3K(-)18GY

F

GROUND

SWITCH D/L +

POWER

BACKLIGHT

C

E

SWITCH D/L -

F

D

ADDRESS SEL

B

SWITCH D/L +

A

POWER

B

A

BACKLIGHT

C

E

SWITCH D/L -

D

ADDRESS SEL

GROUND

(1101)

(1101A)

SWITCH PACK

TO

PR

EV

IOU

SS

WIT

CH

PA

CK

TO

NE

XT

SW

ITC

HP

AC

K O

R O

PT

ION

AL

G

AU

GE

PA

CK

A12FC WAS A13FC;F39 WAS C 56507K23AUG02CNA

5 A

F1

E1


F39

7

8

1

5

2

6

3

4

9

10

11

13

12

14

BATTERY

ACCESSORY

GROUND

BACKLIGHT

DRIVE TRAIN J1939 (+)

DRIVE TRAIN J1939 (-)

OPTIONAL GUAGEPACK(1510)

F12;F5 WAS F19.

Figure 38 Switch Pack, Optional Gauge Pack

S082853


39

3.12. LIGHTED AIR SHIELD, P. 12

A58AE20BN

WH

18W

H

BK

18B

K

A11

-GH

F18

WH

A58

AD

18B

N

A58

AC

18B

N

A58AB18BN

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

LIGHTED AIR SHIELD

U00DLCK

P54304U

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

16JAN01 12AE08-52367

10A

F2 E2

3086

87A

87

85

A


BATTERY FEED

D4

F4

F3

D3

BIP/AUX ROOFCONNECTION (2022)

6SYSTEMCONTROL

(1600)

CONTROL = (HEADLIGHTS AND /OR PARK LIGHTS) & ACC

SEE CH02_02

GROUNDADAPTERBUSS BAR(1003)

F40

MULTIPLE CHANGES A P54634FPEC 18JUN01

CNA 23AUG02 F40 WAS F39. B 56507K

Figure 39 Lighted Air Shield

S082853


3.13. ROOF AUX. LOAD, P. 13

D5

8-G

W1

4W

H

D5

8W

14B

N

A11-GAM18WH

A1

1-G

HE

14

WH

A12

U1

4LT

BL

A12

Z1

4LT

BL

A14FR10RD

A12V14LTBL

A12Y14LTBL

A12X14LTBL

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

ROOF AUX LOAD

U00DLCK

P54304U

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

16JAN01 13AE08-52367

20A

A4

B4

30 86

87A 87 855A

B3

A3

J

2B

3

7

8

9

CAB FUSEBLOCK(1013)

AUX ROOF LOADSWITCH CONNECTOR

(1915)

PANEL LIGHTADAPTERBUSS BAR

(1002)

SEE CH08_08

BA

A12

-GB

14

WH

A12-GA18WH

JIP/AUX ROOFCONNECTION

(2021)

GROUND ADAPTERBUSS BAR(1003)

CAB FUSEBLOCK(1014)

AUX ROOF LOADCAB FUSEBLOCK #4

(1014)

SEE CH02_13

BATT FEEDSEE CH02_02

CAB FUSEBLOCK(1013)

G4 J4

J3 G3

A3 WAS G1; B3 WAS H1 B

F35

F45

A62U18DKBLA62U18DKBL

CNA 23AUG02

1013 WAS 1012.

56507K

Figure 40 Roof Aux. Load

S082853


41

3.14. SATELLITE COMMUNICATION QUALCOMM-MCT AND IMCT SYSTEMS, P. 14

D14

AF

16R

D

D1

3F16

PK

D62

B16

DK

BL

D3A

B(+

)18

DK

BL

D3AB(-)18GY

D11-GG16WH 14

QA

16R

D

62Q

A16

LTG

N

13Q

A16

DK

BL

11-G

QB

16W

H1

1-G

Q1

6WH

11-

GQ

C16

WH

14Q

B16

OR

14Q

C16R

D

D11-GG16WH

D62B16DKBL

D13F16PK

D14AF16RD

A11-GG16WH

A3AB(-)18GY

A3AB(+)16DKBL

A62

B16

DK

BL

A13F16PK

A14AF16RD

A13E16PK

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 3

SATELLITE COMMUNICATIONQUALCOMM-MCT & IMCT SYSTEMS

U00DLCK

P54304U

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

16JAN01 14AE08-52367

10A

B2 A2

10A

G2H2

MSGLIGHT

CE F DB A

A DC B

C BAFE D

F

AEC F

C

D

D

D

B

CAB FUSEBLOCK(1014)

OPT WARN LIGHTCONNECTOR(1555M)

NEG STUD(1865)

J1708 PUBLIC (+)(1660)

J1708 PUBLIC (-)(1661)

QUALCOMM POWER(1902F)

MCT SYSTEMQUALCOMM POWER CONN(2700M)

MCT SYSTEMQUALCOMMPOWER-CONN(2701F)

COMMUNICATIONCONNECTOR UNIT(XXXX)

B A C D

MCTSATELLITE COMMUNICATIONQUALCOMM SYSTEM

B DC E F A

IMCT SYSTEMQUALCOMM PWR CONN

(2702M)

IMCT SYSTEMQUALCOMM

POWER CONN(2703M)

IMCT SATELLITEANTENNA CONNECTION

CONNECTOR

9 TERMINALDISPLAY/KEYBOARD

CONNECTOR

PANIC BUTTON(NOT USED)

TTRACS(NOT USED)

A

B

OR

AN

GE

BLU

E

A

BLA

CK

CABLE

YE

LLO

W

YE

LLO

W

YE

LLO

W

WH

ITE

WH

ITE

GR

EE

N

GR

EE

N

BR

OW

N

BR

OW

NR

ED

RE

D

BLA

CK

BLA

CK

BLA

CK

IMCTSATELLITE COMMUNICATIONQUALCOMM SYSTEM

F28

F38

CNA 23AUG02 F28 WAS F36;F38 WAS F37. A 56507K

Figure 41 Satellite Communication Qualcomm-MCT and IMCT Systems

S082853


3.15. SELF CONTAINED AIR SEAT, P. 15

A14J

14R

D

WH14WH

RD

14R

D

AIR SEAT(1918)

A B

DASH GROUNDSTUD

FROM BATT FEEDFUSE F38

CHAPTER 3

SELF CONTAINED AIR SEAT

U00ARW2

P54634F

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

31MAY01 15AE08-52367

CNA 12SEP03 CHANGED FORMAT 58774TB

Figure 42 Self Contained Air Seat

S082853


43

3.16. DIGITAL CLOCK PTC, P. 16

GEOMETRY WASREMOVED

CHAPTER 3

DIGITAL CLOCK PTC

U00DLCK

P54634F

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

05MAY01 16AE08-52367

CNA 12SEP03 CHANGED FORMAT 58774T

Figure 43 Digital Clock PTC

S082853


3.17. TRANSMISSION ALLISON LCT COLUMN SHIFTER, P. 17

J92F

BA16

TNJ9

2FN

16TN

J92RD16TN

K13M

318

PK

K13#10418PK

K13#10218PK

K13M

418

PKJ9

2NB

16TN

J92F

B16

TN

10A

F1-H

2

F1-

G2

10A

F2-D

4F2

-C4

3086

87A8785

19

SYSTEMCONTROLLER(4004)

MICRORELAY(4002)

(4001)

GXMSN(4705)

2

4

ECU "J1"GRAY(7305)

ENSBU SWVEHICLE(7301)

BA

TT

IGN

CHAPTER 3

XMSN ALLISON LCT COLUMN SHIFTER

U00DLCK

55043Z

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

02JAN02 17AE08-52367

CNA 12SEP03 CHANGED FORMAT 58774TD

Figure 44 Transmission Allison LCT Column Shifter

S082853


45

3.18. HEATED SEATS FOR 7700 MODELS ONLY, P. 18

Figure 45 Heated Seats for 7700 Models Only

S082853


4. 12V CHARGING + CRANKING SYSTEM (CHAPTER 4)4.1. I6 EGR ENGINES, P. 1

Figure 46 I6 EGR Engines

S082853


47

4.2. V8 AVNT ENGINES, P. 2

J17D10PK

K17

L18

PK

K17L18PK

K17K18PK

A

ECMNEGATIVE (9260)

100A

MEGA-FUSE

A1718PK

BATTERIES

1/0RD

N14

BA

10R

D

NOTE:FOR CIRCUIT K18 FUSELINK IS 10RSFOR CIRCUIT K14H FUSELINKS ARE 2-12BLFOR CIRCUIT K2 FUSELINKS ARE 2-12BL

AECM POSITIVEFEED (9261)

GR

BALTERNATOR

1/0RD

N9

7-G

10W

H

1/0BK

N14

AY

10R

D

FUSIBLE LINKS

J17S18PK

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 4

CHARGING AND CRANKING (V8-AVNT) ENGINES

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

10AUG00 02AE08-52368

1/0RD

N97

AA

10R

D

K24RD

1/0BK

MAXIFUSE BLOCK (4000)

KEYSWITCH S

ENGINEBLOCKGND

CECM POWER/STARTER SOLENOID(4105)

TO ECM2 CLEANPOWER/GROUND CONN

(A-12V,B-GND)(6323F)

SEE CH06_03

1/0BK

K17

C10

PK

8

PASS THRU AT DASH (4014)

GND(4005)

J17

E10

PK

K2-

G4

WH

K11

-GL

4W

H

40A

AB

ENGINEECMFEED FUSE(9254)

23ECM2(6020)

4/0BK

N1

4-G

10W

H

17

ENGINE/DASHCONN(4103)

FRAMEGND

CRANK MOTORSOLENOID

CRANKING MOTOR

M

B S

G

4/0RD

2/0B

KK10-GC1BK

K14H4RD

J14H4RD

GLOW PLUG RELAY (4057)

K18

6PK

J17E10PK

SEE CH10_05

W/AUTO NEUTRAL

8687

3087A

85

STARTERISO & POWERRELAY(4003)

R12-1

R12-2

R12-3

R12-4

R12-5J1718PK

B

A

23AUG02 DEL MAXI FUSE BLOCK 4004 D 56507KCNA

14GY

FUSIBLELINK

11JAN02JKP REV CRANKING MOTOR. C 55043Z

Figure 47 V8 AVNT Engines

S082853


4.3. CATERPILLAR, CUMMINS ISM ENGINES, P. 3

FUSIBLE LINK14GY

J17J18PK

K17G14PK

K17F14PK

J17G14PK

J17F14PK

J17D10PK

A17-GH18WH

B17H18PK

B17J18PK

A17J18PK

A1718PK

J17

18PK

J17J18PK

J17S

18PK

K17S

16PK

K17J16PK

4RD

K11-

GL

4WH

K10-GC1BK

K2-G

4WH

2BK

4BK

K24RD

1BK

1RD

GR

B

CR

AN

K M

OT

OR

SO

LEN

OID

CRANKING MOTOR THERMAL

OVERCRANK(6316)

B S

M

G

16 15

18

8

CLUTCHSWITCH

B

AD7

D8

100 AMPS

17

18

DASH/ENG (4103)

MEGA FUSE

STARTERISO & PWR RELAY (4003)

R12-5

R12-2

R12-4

R12-1

PASSTHRU(4014)

DCM(1800)

NEGSTUD(1863)

DASH/ ENG (4103)

FRAME GND

CAB GND(4005)

ENGINEBLOCKGND(6303)

BATTERIES

ALTERNATOR

FUSIBLELINKS

KEY SWITCH"S" TERMINALCH02_15

NOT W/ THERMALOVERCRANK

3086

87A

8785

A

B

NOTES:

FOR 4 GAUGE CHARGE CIRCUITS K2-FL & K2A-FL FUSELINKS ARE 2 - 12BLFOR 1 GAUGE CHARGE CIRCUITS K2D-FL, K2E-FL & K2F-FL FUSELINKS ARE 3 - 10RSFOR 1 GAUGE CHARGE CIRCUITS K2B-G & K2B

CHAPTER 4

CHARGING AND CRANKINGCAT ENGINES, CUMMINS ISM

U00DLCK

55043Z

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

01-04-02 03AE08-52368

CNA 12SEP03 CHANGED FORMAT 58774TC

Figure 48 Caterpillar, Cummins ISM Engines

S082853


49

4.4. I6 HEUI ENGINES, P. 4

CHAPTER 4

CHARGING AND CRANKINGI6-HEUI ENGINES

U00DLCK

58774T

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

12SEP03 04AE08-52368

CNA 12SEP03 RELEASE FOR PRODUCTION. 58774T-

SEE CH10_05

N/THERMALOVERCRANKPROTECTION

100A

MEGAFUSE

A1718PK

BATTERIES

K10-GC1BK

J17E10PK

K17M

18PK

NOTE:FOR CIRCUIT K14H FUSELINKS ARE 2-12BLWITH 4 GAUGE CHARGE CIRCUITS K2-G & K2 FUSELINKS ARE 2-12BLWITH 2 GAUGE CHARGE CIRCUITS K2-GA & K2A FUSELINK ARE 2-10RSWITH 1 GAUGE CHARGE CIRCUITS K2-GB & K2B FUSELINK ARE 3-12RS

J1718PK

GR

B

ALTERNATOR

2/0B

KW/THERMALOVERCRANKPROTECTION

FUSIBLELINKS

K17L18PK

FUSIBLELINKS

J17S18PK

1/0RD

K2*4RD

J17D10PK

FRAMEGND

14GY

1/0BK

MAXIFUSEBLOCK (4000)

J14H4RD

KEYSWITCH S (1100) B

ENGINEBLOCKGND

K14H4RD

C ECM POWERSTARTER(4101)

W/AUTO NEUTRAL

K17K18PK

K17C

10PK

2/0RD

8

PASS THRU AT DASH (4014)

DASH PANELGND(4005)

J17E

10PK

K2-G

*4W

H

K11

-GL

4WH

SEE NOTE

SEE NOTE

CRANKINGMOTORSOLENOID

CRANKING MOTOR

THERMALOVERCRANK(6316)

A

B

B S

M

G

2/0B

K

46ECM(6007)

8687

3087A

85

STARTERISO & POWERRELAY(4003)

R12-1

R12-2

R12-3

R12-4

R12-5

FUSIBLELINK

17

ENGINE/DASH(4103)

FRAMEGND

Figure 49 I6 HEUI Engines

S082853


5. FANS AND ENGINE ACCESSORIES (CHAPTER 5)5.1. FAN WIRING, P. 1

K97B18VT

K23A18TN

K23A18TN

K97DF18VT

14

ENGINE/DASH (4103)

K23-G16WH

MINI FUSE BLOCKS (4001)

CHAPTER 5

FAN WIRING

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

10AUG00 01AE08-52369

CNA 12SEP03 ADDED HEUI TO I6 DESG; ADDED CONN 6401

58774TE

14

ENGINE/DASH (4103)

ELECTRIC FANRELAY CONTROL

14ECM 2 (6021)

K2318TN

B

14

ECM2(6021)

V8-AVNT WITH FAN CLUTCH

A FAN AIR SOLENOID (4111)

B

I6 EGR/HEUI WITH FAN SOLENOID

FANCLUTCH

A ELECTRICFAN(6406)

MINI FUSE BLOCKS (4001)

J23A18TN

FAN SOLENOID

15

J2318TN

ENGINE BLOCKGROUND

(6412)

K23B16TN

K23A16TN

W/BODYBUILDERCONNECTIONS

8687

30 87A

85

M1-A3

M1-B3

M1-C4

M1-A4

FAN RELAY (4002)

(J23Z)

ASINGLE BOX

ENGINE HARNESS (6401)

FOR V8

FOR I6 HEUI

K23A16TN

N/BODY BUILDER

J23FS18TNSEE CH02_14

J23Z18TNSEE CH02_14

AENGINE CONTROLLER

K97B18VT

I6 HEUI ENGINEHARNESS CONN (6401)

Figure 50 Fan Wiring

S082853


51

5.2. ETHER START, P. 2

K10

-GU

14W

H

K10

-GA

18W

H

CAB FUSEBLOCK(1013)

J21F18TN

A21B16TN

ETHERBOTTLECONTROLVALVE

A

B

J21

E1

8TN

K21B16TN

19FWD CHASSIS/DASH(4301)

K10

-G1

8WH

A21

E16

TN


29PASS THRU(4014)

K21-G16WH

A

THERMAL SWITCH(6650)

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 5

ETHER START

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

21JUN00 02AE08-52369

12ENGINE/DASH(4103)

BETHER START(8400)

M21

D1

8TN

GROUND BUS BAR (1003)

K10

-GB

14W

H

9 7

3 2B5B

16

4

10 8

ETHER START SWITCH(1010)

A21-G16WH

M21

C1

8TN

22

SPLICE BLOCK (6704)

F

PANEL LIGHTBUSS BAR(1002)

SEE CH08_08

G

SEE CH02_11

B1 A1

10A

F33

F33 WAS F30 C 56507K25AUG02CNA


FOR USE WITHCAT ENGINES

11JAN02 ADDED CAT ENGINE. B 55043ZJKP

A21C16TN SEE CH02_13

Figure 51 Ether Start

S082853


5.3. SNOW VALVE, P. 3

J23K

18T

N

NC READSWITCH

CURRENTPROTECT

MOTOR

DUAL FUNCTION REED SWITCH(NO & NC)

SNOW VALVE (4120)

ABCDE

J23H

18T

N

A

31PASS THRU AT DASH (4014)

J23J

18T

N

H

OPTIONAL WARNINGLIGHT CONNECTOR(1555)

GROUND BUSS BAR (1003)

J23

F1

8TN

26 24

A23

F1

8TN

25

J23L

18T

N

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 5

SNOW VALVE

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

21JUN00 03AE08-52369

27

A23

M1

8TN

A23

H1

8TN

A23

J18

TN

A23

K18

TN

A23

L18

TN

A62P18LTBL

A23-GA18WH

A13DA18PK

SEE CH02_13

IGN RELAY

9 7

32B5B

16

4

10

8

SNOW VALVE SWITCH

(1901)

4

6

3

1

79

8

5B

2B

SNOW VALVE WARNING LIGHT IN CLUSTER

SNOW VALVE MODULE

C

PANEL LIGHT BUSS BAR (1002)

SEE CH08_08

D

SEE CH02_11

PRODUCTION RELEASE. A P54304U16JAN01PEC

10A

B2

A2

CAB FUSE BLOCK SNOW VALVE

(1013)

F34

CNA 25AUG02 ADDED F34 LABEL B 56507K

Figure 52 Snow Valve

S082853


53

5.4. FAN WIRING, CATERPILLAR AND CUMMINS, P. 4

K23N16TN

K23N16TN

K10-GU14WH

K23-G16WH

A B

38

11

ENG BLOCKGROUND(6340)

FANSOLENOID

FAN AIRSOLENOID(6409)

ENGINECONTROLLER

(6014)

ENGINECONTROLLER

(6013)

W/CATERPILLAR

W/CUMMINS ISM

CHAPTER 5

FAN WIRING, CAT AND CUMMINS

U00DLCK

56507Z

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

04OCT02 04AE08-52369

CNA 12SEP03 CHANGED FORMAT 58774TA

Figure 53 Fan Wiring, Caterpillar and Cummins

S082853


6. ELECTRONIC ENGINES (CHAPTER 6)6.1. ELECTRONIC ENGINE CONTROLS, I6–EGR ENGINES, P. 1

K97S16VT

K97E16VT

INTAKE AIR TEMP SENSORS(6703)(LOCATED ON AIR INTAKE)

A

B

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 6

ELECTRONIC ENGINE CONTROLS (I6-EGR) ENGINES

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

10AUG00 01AE08-52370

CNA 25FEB03 CHANGED TO MATCH I6-EGRENGINE CHANGES.

56126SD

10

K97K18VT

J97

TA

10V

T

8687

30

87A

85MICRO RELAY (4002)

M1-G4

M1-J4M1-H3 M1-J3

M1-G3

N97-G10WH

K97J18VT

BAPSENSOR(1808)

13

2

J97T

C10

VT

K97-GV16WH

5A

A2

B2 CAB FUSE

BLOCK(1012)

F24

N97AA10RD

18

10A

F2-B4 F2-A4

7

B97

Q18

VT

K97-GA12WH

20A F1-G4

F1-H4

MINI-FUSE BLOCKSENGINE ECM(4001)

12

EC

M2

(602

1)

J97QA18VT

5

A

ECMNEGATIVE(9260) BATTERIES

A99U18VT

A99V18VT

J97L

D16

VT

B99V18VT

9

(6704) GND

J97UA16VT

K97C18VT

4

2

K97LA16VT

8687

30

87A

85

POWER RELAY(4003)

R8-1

R8-5R8-3 R8-4

R8-2

1


A97P18VT

K97M16VT

J97J

18V

T

4

J97JA18VT

A

ECM POSITIVEFEED (9261)

K9718VT

K97Y12VT

1

ENGINE/DASH(4103)

B97

AH

18V

T

5A

F1-E1F1-F1

MINI FUSE BLOCK(4001)

K97

AZ

16V

T

B

K34

-G1

8W

H

LOWCOOLANTSENSOR(6400M)

A B

6

6

7

J97P18VT

K9

7LC

16V

T

B97

AE

18V

T

24

K97-GW16WH

A97Y18VT

B99U18VT

18

A99

E18

VT

N14AY10RD

J13S14PK

19

C5

3

2B97AF18VT

K97F16VT

1

IDM

2 (6

011)

J97LC

16V

T

C10

DCMCONN(1800)

12

N14BA10RD

C4

K97-G10WH

B5

K99T18VT

A

CLEAN POWER & GROUND (6323)

J99V18VT

J97Y18VT

8

K97T10VT

B97Y18VT

2

12

B97AD18VT

A

J97

LB18

VT

1

AB

CD

EF

APS/IVS(1804)

6

B99E18VT

K97H16VT

C2

A97Q18VT

24

A13AH10PK

5

K97X10VT

J97

HA

14V

T

K97UA18VT

3

N14-G10WH

K97Z16VT

J97HB14VT

J97X

A10

VT

FROM PRIMARYIGNITION FEEDRELAY

MINI-FUSEBLOCK(4001)

J97H

14V

T

C6

K99S18VT

K34A18TN

B4

4

5

EC

M2

(602

0)

J99U18VT

B

POWER/STARTERSOLENOID (4105)

40A

AB

ENGINE ECMFEED FUSE(9254)

4

J13CW10PK

E2

21

B97P18VT

J97L

A18

VT

K97R18VT

K97D18VT

5IDM

2(6

011)

FROM PRIMARYIGNITIONRELAY (R9-4)(4003) CH 02_14

4

K97-GB16WH

Figure 54 Electronic Engine Controls, I6–EGR Engines

S082853


55

6.2. ELECTRONIC ENGINE CONTROLS, I6–EGR ENGINE CRUISE CONTROL ANDBODY BUILDER CONNECTIONS, P. 2

99E16VT

B9S18GY

B9VG18GY

B9V

H1

8GY

B9VF18GY

A9H

20G

Y

A9V

18G

YB

9V18

GY

B9R

18G

Y

B9V

B18

GY

J17J18PK

A17

J18

PK

B17

J18

PK

K17

E18

PK

J13CW10PK

J13S14PK

K97AR18VT

A13AH10PK

K97CB18VT

K46A18GY

J23FS18TN

K23A16TN

K97DF18VT

K97DF18VT

B70

C18R

D

A96

A20

VT

B96

A18

VT

K97CC18VT

A17

H16

PK

B17

H18

PK

K47

18G

Y

K47B18GY

K46B18GY

11

EC

M2

(602

0)

FROM PRIMARYIGNITION

RELAY(4003)

SET/COAST SWITCH - SCS

1210

OH

M

6190

OH

M

2370

OH

M

RE

SU

ME

SE

T

CR

UIS

E O

N

CR

UIS

E O

FF

AIR

HO

RN

CIT

Y H

OR

N

STEERING WHEEL SWITCHES

ABCD

D8

20

17

TACHOMETER CHANNEL A - TACA

W/HYDBRAKES

VEHICLE SPD SENSOR CHAN A - VSSCALA

10

10

F

XMSN/DASH(4705)

21

RESUME/ACCEL SWITCH - RAS

IGNITION FEED FROMIGNITION RELAY

3

W/AIR FAN DRIVE

19

CLOCKSPRING(1809)

ABCD

F1-E1

18


14

ENGINE/DASH(4103)

E2

33


A4

14

REMOTE PTO VARIABLE - RVAR

10A

F1-G1F1-H1


C2

CAB FUSEBLOCK(1012)

17

REMOTE PTO PRESET - RPRE

5A

A2B2

F24

D7 DCM

CONN(1800)

9

C11

N/AIR FAN DRIVE

TRANS SPEEDSENSOR(7601)

AB

(CH 2, PG 14)

BA

STOP LIGHT (1814)

6.8V

150

B96

18V

T

B70CA18OR

B70CB18OR

7

TURNSIGNAL

SWITCH(1810)

B70C18OR

B12

A96

20V

T

B9

A70

C20R

D

K47

A18

GY

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 6

ELECTRONIC ENGINE CONTROLS - I6-EGR ENGINECRUISE CONTROL & BODY BUILDER CONNECTIONSWITH MANUAL TRANSMISSION

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

10AUG00 02AE08-52370

CNA 25FEB03 CHANGED TO MATCH I6-EGRENGINE CHANGES.

56126SD

NOTE:

ONLY ONE STOP LIGHT SWITCH USEDW/AIR BRAKES & W/TRACTOR

BODYBUILDER

BODYBUILDER

DC

STOP LIGHT#2W/AIR BRAKES(1824)

6.8

V

150 D

CSTOP LIGHT#1W/AIR BRAKES(1823)

6.8V

150

120

0

12

00

ABCD

CLUTCHSWITCH(1807)

ACCELERATORPEDAL

8

ECM 2(6020)

ECM 2(6021)

Figure 55 Electronic Engine Controls, I6–EGR Engine Cruise Control and Body Builder Connections

S082853


6.3. ELECTRONIC ENGINE CONTROLS, (V8–AVNT) ENGINES, P. 3

K97

AZ

18V

T

J97LC

16V

T

J97LD

16V

T

K97

LC16

VT

5A

A2

B2 CAB FUSE

BLOCK(1012)

F24

B97

AE

18V

T

B97AD18VT

J13CW10PK

C4

5A

F1-E1F1-F1


1

B97Y18VT


12

J97Y18VT

J97

HA

18V

T

N97AA10RD

C10

DCMCONN(1800)

12

EC

M2

(602

1)

K97J18VT

K97C18VT

A97Q18VT

N97-G10WH

2

2

3

4

K99S18VT

6

19

A97Y18VT

BAPSENSOR(1808)

13

2

18

A99U18VT

LOWCOOLANTSENSOR(6400M)

A B

J97L

B18

VT

FROM PRIMARYIGNITION RELAY (R9-4)(4003)

B97P18VT

A

ECM2 CLEANPOWER & GROUND (6323)

24 B4

J97HB18VT

J97QA18VT

B5

B97AF18VT

K97Z16VT

1

ENGINE/DASH(4103)

K97M16VT

J97P18VT

K97T10VT

C2

3

A97P18VT

J13S14PK

A

ECMNEGATIVE(9260)

K97-GV16WH

K34

-G16

WH

BATTERIES

K97X10VT

5

J97

TC

10V

T

1

IDM

2 (6

011)

A

J99V18VT

J99U18VT

K99T18VT

K34A18TN

7

6

3

8

B99E18VT

1


A99V18VT

K97-GW16WH

J97L

A18

VT

10A F1-G4

F1-H4

MINI-FUSE BLOCKSENGINE ECM(4001)

8687

30

87A

85

V8 IDM POWER RELAY(4003)

R8-1

R8-5R8-3 R8-4

R8-2

5

5

EC

M2

(602

0)

4

J97X

A10

VT

40A

AB

ENGINE ECMFEED FUSE(9254)

J97J

18V

T

K97F16VT

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 6

ELECTRONIC ENGINE CONTROLS (V8-AVNT) ENGINES

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

10AUG00 03AE08-52370

9

18

6

C6

N14-G10WH

K97-GA12WH

8687

30

87A

85ECM ISO &POWER RELAY(4003)

R11-1

R11-5R11-3 R11-4

R11-2

A99W18VT

K97UA18VT

A


K97LA16PL

K97D18VT

AB

CD

EF

APS/IVS(1804)

B99W18VT

24

B6

N14AY10RD

21

A13AH10PK

J97UA18VT

A99

E18

VT

K97H16PL

J97

TA

10V

T

B99V18VT

ENGINEBLOCKGND

K97-G10WH

2

E2

K97Y12VT

C5B99U18VT

B

ECM POWER/STARTERSOLENOID (4105)

7

4

K9718VT

N14BA10RD

B

J97JA18VT

WAS F13,A2 WAS A1.

56507KCNA 22AUG02

J97H

18V

T

K97K18VT

4

12

10A

F2-B4 F2-A410

MINI-FUSEBLOCK(4001)

B4 WAS D4,A4 WAS C4,F24 C

B97

Q18

VT

B97

AH

18V

T

Figure 56 Electronic Engine Controls, (V8–AVNT) Engines

S082853


57

6.4. ELECTRONIC ENGINE CONTROLS, V8–AVNT ENGINE CRUISE CONTROL ANDBODY BUILDER CONNECTIONS, P. 4

K97DF18VT

K97AR18VT

K46A18GY

K47B18GY

K97CB18VT

K97CC18VT

K46B18GY

B9S

18G

Y

B9VH18GY

B70C18OR

B70CA18OR

B70CB18OR

B9VG18GY

C2

CAB FUSEBLOCK(1012)

W/HYDBRAKES

B9

10

ECM2(6021)

B9V

18G

Y

K47

18G

Y

33


18


A96

20VT

F

XMSN/DASH(4705)

L17E

18PK

J17J18PK

B70C

18R

D

5A

E2F2F24

IGNITION FEED FROMINGITION RELAY

A17J

18PK

B9R

18G

Y

17

B96

18VT

A17H

18PK

A4A9

H20

GY

C11

8

ECM2(6020)

A13AH10PK

A2

K47A

18G

Y

DRAWN

RELEASE NO.

NAME

DATE

REFERENCECHK


PART NO. SHEET

REV



DATE CHANGE

CHAPTER 6

ELECTRONIC ENGINE CONTROLS - V8-AVNTENGINE CRUISE CONTROL & BODY BUILDER CONNECTIONS

U00JXP9

P52778H

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

10AUG00 04AE08-52370

CNA 9SEO02 DVD/RMVD ENG/TRANS CONN(7800).

56507ZD

10

A96A

20VT

D8

D7 DCM

CONN(1800)

1210

OH

M

6190

OH

M

2370

OH

M RES

UM

E

SET

CR

UIS

E O

N

CR

UIS

E O

FF

AIR

HO

RN

CIT

Y H

OR

N


ABCD

9

3

CLOCKSPRING(1809)

ABCD

B9VF18GY

A9V

18G

Y

A70C

20R

DB1

2


AB

BA

STOP LIGHT (1814)

6.8V

150

7

TURN SIGNALSWITCH(1810)

NOTE:


21

ECM

2 (6

020)

20

19

17

11

14

SET PTO SPEED - SCS

VARIABLE PTO ENABLE - RVAR

PRESET PTO ENABLE - RPRE

VEHICLE SPD SENSOR CAL CNTRL - VSS_CAL

RESUME PTO SPEED - RAS

TACHOMETER CONTROL - TACH

BODYBUILDER

TO FUEL FILTER(6708) SEE CH07_09

DC


6.8V

150

DC


6.8V

150

1200

1200

ABCD

CLUTCHSWITCH(1807)

B17J

18PK

B17H

18PK

B96A

18VT

B9VB

18G

Y

Figure 57 Electronic Engine Controls, V8–AVNT Engine Cruise Control and Body Builder Connections

S082853


6.5. CATERPILLAR C10, C11, C12, AND C13 ENGINES, P. 5

B99V

18VT

B97Y

18VT

B97P

18VT

J97U

18VT

K97

U18

VT

A5AG(+)18YL

A5AL(+)18YL

A5AC

(+)

20YL

A5AR(+)20YL

A5AE(+)18YL

A5AN(+)20YL

A5B(

+)18

YL

A5AH(-)18LTGN

A5AM(-)18LTGN

A5AD

(-)20

LTG

N

A5AF(-)18LTGN

A5AS(-)20LTGN

A5AP(-)20LTGNA5

B(-)

18LT

GN

A97P

18VT

A97Y

18VT

A99V

18VT

J3B

(-)

18G

Y

J3B

(+)

18D

KBL

J5C(

+) W

/BEN

DIX

20YL

J5E(

+) W

/WAB

CO

20YL

J5C

(-) W

/BEN

DIX

20G

N

J5E(

-) W

/WAB

CO

20G

N

J99V

18VT

J97Y

18VT

J97P

18VT

J77B16GN

K10-GU14WH

K77-G16WH

K77B

16LT

GN

K3B

(-)18

GY

K3A(

+)18

DKB

L

K5S

18YL

K5T

18LT

GN

K97Y

18VT

K99V

18VT

K97P

18VT

K34

D16

TN

K5U18YL

K5V

20YL

K5AE18LTGN

K5W

20LT

GN

K47A

16G

Y

K47

16G

Y

K34-

GA

16W

H

K97Y

A18

VT

K34

C16

TN

K34B

16TN

K97AM10VT

K97A

S14

VTK9

7AT

14VT

K97

-GD

14W

H

K97-GA10WH

K97-

GE

14W

H

N14

AY10

RD

N14-G10WH

N14BA10RD

N97-G10WHN97AA10RD

535034333298542 49 52 54 65 66 67

ECM (6013)

A B C D

A

B

A

A

30AAB

CLEAN PWR& GND(6323)

ECM POSFEED(9261)

ECM NEGFEED(9260)

BATTERIES

LOW COOLANT (6407)

A

B

D

E

ENGINE/TRANSMISSION (7800)

4 6 10 11 8 7 5DASH(4103)

B

A

20

ENGINE GND (6340)

FREON COMP (6200)

GSYS CONTROL BLUE (4008)

5 2 12 11 1PASS THRU (4014)

B4C5 C4

4

5

DCM(1800)

35

34

D

C

A

C

DIAGNOSTIC(1650)

SYS CONTROLLER(1600)

CLUSTER(1500)

J1939PUBLIC(1652)

J1708 & 5VREF SPLICE (4820)

70

19

5 AMPF1-F1F1-E1

MINI FUSE (4001)

IGN FEEDCH02_14

CBA(1805)

ACCEL. PEDALSENSOR

CHAPTER 6

CAT C10, C11, C12 & C13 ENGINES

U00DLCK

55043Z

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

16DEC01 05AE08-52370

CNA 12SEP03 CHANGED FORMAT 58774TC

Figure 58 Caterpillar C10, C11, C12, and C13 Engines

S082853


59

6.6. CUMMINS ISM ENGINE, P. 6

A5A

C(+

)20

YL

A5AG(+)18YL

A5AL(+)18YL

A5AE(+)18YL

A5AR(+)20YL

A5AN(+)20YL

A5B

(+)

18Y

L

A5A

D(-

)20

LTG

N

A5AM(-)18LTGN

A5AH(-)18LTGN

A5AP(-)20LTGN

A5A

S(-

)20

LTG

N

A5AF(-)18LTGN

A5B

(-)

18LT

GN

A99

E18

VT

A99

E18

VT

B99

W18

VT

A99

W18

VT

B99

U18

VT

A99

U18

VT

B99

V18

VT

A99

V18

VT

B97

Y18

VT

A97

Y18

VT

B97P

18V

TA

97P

18V

T

J5C

(-) W

/ BE

ND

IX20

GN

J5E

(-)

W/ W

AB

CO

20G

NJ5

C(+

) W

/ BE

ND

IX20

YL

J5E

(+)

W/ W

AB

CO

20Y

LJ9

7P18

VT

J97Y

18V

T

J99V

18V

T

J99U

18V

T

J99W

18V

T

J97Q

18V

T

J3B

(+)

18D

KB

L

J3B

(-)

18G

Y

J97U

18V

T

J77B16GN

N14

AY

10R

DN

14B

A10

RD

N97

AA

10R

DK

97A

M12

VT

K97

U2

12V

T

K97

U1

18V

T

K10

-GV

12W

H

K10

-GU

14W

HK

77-G

16W

H

K77

B16

LTG

N

K97

U18

VT

K3B

(-)

18G

Y

K3A

(+)

18D

KB

L

K97

Q18

VT

K99

W18

VT

K99

U18

VT

K99

V18

VT

K97

Y18

VT

K97

P18

VT

K5S

18Y

L

K5T

18LT

GN

K5W

20LT

GN

K5AE18LTGN

K5V

20Y

L

K5U18YL

K47A16GY

K4716GY

K34E16TN

K34-GB16WH

32 28 27 36 46 47 22 23 9 1 11 34 10 20 39

B

A

LOWCOOLANT

(6407D)

ECM (6014)

A

B

D

E

ENGINE/TRANS(7800)

8 7 4 6 5 2 1 3 10 11 19 20

B AFREONCOMP(6200)

ENGINEGND

(6340)

1 2 4

A

A

ECMPWR(6015)

CLEANPWR(6323)

ECMPOSFEED(9261)

30AB

A

BATTERIES

G SYS CONTROLBLUE(4008)

DASH(4103)

5A

F1-F1 F1-E1

MINI FUSE (4001)

IGN FEEDCH02_14

J1708 & 5VREF SPLICE(4820)

12 11 5 2 1 4 3 7PASSTHRU(4014)

C6

F

B6B5C4B4C5

EDABC

DCM(1800)

(1804)

ACCEL PEDAL SENSOR/IVS

C

AJ1939PUBLIC

(1652)

5

4CLUSTER(1500)

35SYS

CONTRL(1600) 34

D

CDIAGNOSTIC(1650)

CHAPTER 6

CUMMINS ISM ENGINE

U00DLCK

56507Z

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

04OCT02 06AE08-52370

CNA 16SEP03 ADDED N/2004 ISM ENGINESNOTE.

58689ZB

N/2004 ISM ENGINES

Figure 59 Cummins ISM Engine

S082853


6.7. I6 HEUI ENGINE, P. 7

1


BATTERIES

5

40A

ABENGINE ECMFEED FUSE(9254)

INTAKE AIR TEMP SENSORS(6703)(LOCATED ON AIR INTAKE)

A

B

8687

30

87A

85

POWER RELAY(4003)

R11-1

R11-5R11-3 R11-4

R11-2

27

CHAPTER 6

ELECTRONIC ENGINE CONTROLS (I6-HEUI) ENGINES

U00JLH3

58774T

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

12SEP03 07AE08-52370

CNA 12SEP03 RELEASE FOR PRODUCTION. 58774T-

25

LOWCOOLANTSENSOR(6400)

A B

E2

5

A


C5

2 B4

47

EC

M (

6007

)

42

FROM PRIMARYIGNITIONRELAY (R9-4)(4003) CH 02_14

B

5A

F1-E1F1-F1MINI FUSE BLOCK(4001)

41

11

29

6

BAPSENSOR(1808)

13

2

C2

A

CLEAN POWER & GROUND (6323)

5A

A2

B2

CAB FUSEBLOCK(1012)

F24

A

12

F1-E2

3

3

A

ECMNEGATIVE(9260)

C6

19

AB

CD

EF

APS/IVS(1804)

2

24

4

(6704) GND

C10

DCM/CABCONN(1800)

10

C4

4

8

B5


7

ENGINE/DASH(4103)

22

21

ECM POWER/STARTER(4105)

23

1

2

ENGINE/DASH(4103)

18

ECM POWER/STARTER(4105)

B

8687

30

87A

85EXHAUST BRAKERELAY(4002)

M1-A4

M1-C4M1-B3 M1-C3

M1-A3

FROM SECONDARYIGNITION RELAY(4003)

5A

F1-B2F1-A2

MINIFUSEBLOCK(4001)

MULTIFED TERMINAL/BUSS BAR

16

ENGINE/DASH(4103)

18

ENGINE/DASH(4103)

15

EXHAUSTBRAKESOLENOID(6502)

EXHAUSTBRAKESOLENOID(6500)

AB

ENGINEBLOCKGND

Figure 60 I6 HEUI Engine

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61

6.8. I6 HEUI ENGINE CRUISE CONTROL AND BODY BUILDER CONNECTIONS WITHMANUAL TRANSMISSION, P. 8

CHAPTER 6

ELECTRONIC ENGINE CONTROLS - I6-HEUI ENGINECRUISE CONTROL & BODY BUILDER CONNECTIONSWITH MANUAL TRANSMISSION

U00DLV1

58774T

42/43/44/85/8600 & 73/74/7500 CIRC DIAGRAMS

12SEP03 08AE08-52370

CNA 12SEP03 RELEASE FOR PRODUCTION 58774T-

K46B18GY


AB

C2CAB FUSEBLOCK(1012)

13

B9VH

18G

Y

B96

18VT

W/HYDBRAKES

TACHOMETER CHANNEL A - TACA

B9

B9S18GY

B9V

18G

Y

L47D

18G

Y

A96

20VT

33


18


F1-E1

F

XMSN/DASH(4705)

REMOTE ACCELERATOR POS SENSOR - RPS

L17D

18PK

J17J18PK

CENG/TRANS CONN (7800)

7 K97WA18VT

99E16VT

B70

C18

RD

HYD PRESSURE GOVERNOR SENSOR - HPS

K23A16TN

B70C18OR

7

5AA2

B2F2

TO CAB FUSE BLOCK(1011) A2

BA

STOP LIGHT (1814)

6.8V

150

K97HM18VT

A17J

18PK

30 K99F18VT

B9R

18G

Y

NOTE:


17

K97EA18VT

B70CB18OR

14

ENGINE/DASH(4103)

DC


6.8V

150

J13CW10PK

RESUME/ACCEL SWITCH - RAS

1200

1200

ABCD

CLUTCHSWITCH(1807)

(CH 2, PG 14)BODYBUILDER

A17H

18PK

TURNSIGNAL

SWITCH(1810)

B

K97DF18VT

B9VG18GY

A4

W/AIR FAN DRIVE

6

B17

J18

PK

ACCELERATORPEDAL

B9VB

18G

Y

DC


6.8V

150

A9H

20G

Y

C11

FROM PRIMARYIGNITION

RELAY(4003)

K97DF18VT

K46A18GY

A13AH10PK

J13S14PK

E2

10

B17

H18

PK

B9VF18GY

A96A

20VT

D8

REMOTE ACCEL POS. SENSOR RTN - RPS_RTN

D7

DCM CONN(1800)

REMOTE VOLTAGE REF. GND - VCREF GND

32

EC

M (6

007)

31

1210

OHM

6190

OHM

2370

OHM

RES

UM

E

SET

CRU

ISE

ON

CRUI

SE O

FF

AIR

HO

RN

CIT

Y HO

RN


ABCD

B70CA18OR

10A

F1-G1F1-H1


3

CLOCKSPRING(1809)

ABCD

A

BODYBUILDER

N/AIR FAN DRIVE

B96A

18VT

A9V

18G

Y

A70C

20R

D

J23FS18TN

L47E

18G

Y

B12

36

37

49

54

55

58

59

9

39

40

26

4

5REMOTE VOLTAGE REFERENCE - VCREF

HYD PRESSURE GOVERNOR ENABLE - HGE

SET/COAST SWITCH - SCS

REMOTE PTO PRESET - RPRE

HYD PRESSURE GOVERNOR LAMP - HMI

OIL WATER LAMP - OWL

ENGINE WARNING LAMP - WARN

VEHICLE SPD SENSOR CHAN A - VSSCALA

REMOTE PTO VARIABLE - RVAR

TRANSFER CASE SWITCH - XCS

K97DD18VT

K97HE18VT

K97CC18VTK97CB18VTK97HG18VTK97WL18VTK97EW18VTK47B18GYK97AR18VTK97XC18VT

K47A

18G

YK4

718

GY

K17E

18PK

Figure 61 I6 HEUI Engine Cruise Control and Body Builder Connections with Manual Transmission

S082853

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