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SERVICE MANUAL

SERVICE MANUAL SECTION

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After

ELECTRICAL CIRCUIT DIAGRAMS

Truck Model: 5000iStart Date: 11/04/2002




s082252a, Formerly CTS-5298

11/01/2002

s082252a

Copyright 11/01/2002 International Truck and Engine Corporation

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Table of Contents

1. INSTRUCTIONS AND CHARTS (CHAPTER 1)... ... .... .... ... .... .... ... .... ... .... .... ... .... .... ... .... .... ... .1

1.1. CIRCUIT IDENTIFICATION CHART, P. 1.... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .1

1.2. CIRCUIT IDENTIFICATION CHART, P. 2.... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .2

1.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3.. .. .. .. .. .. ... ... ... ... .. .. .. .. .. .. .. ... ... .. .. .. .. .. .. .. .. ..3

1.4. CIRCUIT DIAGRAM INSTRUCTIONS, P. 4.. .. .. .. .. .. ... ... ... ... .. .. .. .. .. .. .. ... ... .. .. .. .. .. .. .. .. ..4

1.5. SCHEMATIC SYMBOLS, P. 5... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..5

1.6. RELAY PINOUT, FUNCTION DATA & SEALED RELAY, P. 6.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .6

1.7. LAMP BULB CHART, P. 7... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...7

2. 12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (CHAPTER 2).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .8

2.1. START FEED, P. 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.2. ACCESSORY, P. 2 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.3. BATTERY, B 1, P. 3 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.4. BATTERY, B 2, P. 4 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.5. BATTERY, B2 (CONT.), P. 5... ... ... ... ... ... ... ... ... .... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..12

2.6. 3+1 BATTERY SYSTEM (DEEP CYCLE BATTERY B2 BATTERY), P. 6.. .. . . . . .. . . .. . .. . . . . .. .13

2.7. GROUND ADAPTER COMPOSITE, P. 7.... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..14

2.8. GROUND STUD COMPOSITE, P. 8.... ... ... ... ... .... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ...15

2.9. GROUND STUD COMPOSITE, P. 9.... ... ... ... ... .... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ...16

2.10. IGNITION, P. 10... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.11. PANEL LIGHTS ADAPTER COMPOSITE, P. 11... ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. ..18

3. 12 VOLT CHARGING & CRANKING SYSTEM (CHAPTER 3).... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..19

3.1. W/CAT AND CUMMINS ENGINES, P. 1..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..19

3.2. W/OVERCRANK PROTECTION W/CAT AND CUMMINS ENGINES, P. 2.........................203.3. W/I6 HEUI ENGINE, P. 3... ... .... ... ... .... ... ... ... ... ... .... ... .... ... .... ... ... ... ... ... .... ... ... ....21

3.4. W/OVERCRANK PROTECTION W/I6 HEUI, P. 4.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .22

4. ENGINE SYSTEMS (CHAPTER 4)..................................................................................23

4.1. CATERPILLAR C10, C12, C15, AND C16 CRUISE CONTROL, P. 1. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..23

4.2. CATERPILLAR C10, C12, C15 AND C16 ENGINE BRAKE, P. 2.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .24

4.3. CATERPILLAR C10, C12, C15 AND C16 ENGINE CONTROLS, P. 3............................25

4.4. CUMMINS ISM , ISX CRUISE CONTROL, P. 4... ... .. .. .. .. ... .. .. .. .. ... ... .. .. .. .. ... .. ... .. .. ..26

4.5. CUMMINS ISM, ISX ENGINE BRAKE, P. 5.... .. .. .. .. .. .. .. .. ... .. .. .. ... .. .. .. .. .. .. ... .. .. .. ... ..27

4.6. CUMMINS ISM, ISX ENGINE CONTROLS, P. 6.. .. ... ... ... .. .. .. .. ... .. .. .. .. ... .. ... .. .. .. .. ... ..28

4.7. CUMMINS AHD AND ISM ENGINE CONTROLS, P. 7... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..29

4.8. I6 HEUI CRUISE CONTROL, P. 8... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..30

4.9. I6 HEUI ENGINE BRAKE, P. 9...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..314.10. I6 HEUI ENGINE CONTROLS, P. 10... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...32

4.11. I6 HEUI MODULE POWER & GROUND SYSTEM, P. 11........................................ 33

4.12. I6 HEUI ACCELERATOR, BAP, AMBIENT AIR TEMP SENSOR SYSTEM, P. 12. . . . . . .. . .. .34

4.13. I6 HEUI SURGE TANK & EXHAUST BRAKE SOLENOID, P. 13... .. .. .. .. .. .. .. .. .. .. .. .. .. ..35

5. FANS (CHAPTER 5).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

5.1. HORTON AND KYSOR ENGINE FAN WITH CAT C10, C12, C15 AND C16 W/ AND N/ A/C, W/

AND N/ MANUAL FAN OVERRIDE SWITCH, P. 1.. .. ... ... ... ... .. .. .. .. .. ... ... ... .. .. .. .. ... ... .. ..36

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5.2. HORTON AND KYSOR ENGINE FAN WITH CUMMINS ISM, ISX W/ AND N/ A/C, W/ AND N/

MANUAL FAN OVERRIDE SWITCH, P. 2..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...37

5.3. HORTON AND KYSOR ENGINE FAN WITH I6 HEUI ENGINES W/SHUTTER, P. 3..............38

6. GAUGES AND SYSTEMS (CHAPTER 6)...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..39

6.1. 4X2 REAR AXLE OIL TEMPERATURE GAUGE, P. 1.... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. ...39

6.2. 6X4 AXLE FORWARD-REAR AND REAR-REAR TEMPERATURE GAUGE, P. 2................40

6.3. ENGINE OIL PRESSURE GAUGE, P. 3..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..41

6.4. ENGINE OIL TEMPERATURE GAUGE, P. 4... ... .. ... ... .. .. .. .. ... ... ... ... .. ... .. .. .. .. ... ... ... .. .42

6.5. ENGINE WATER TEMPERATURE GAUGE, P. 5.... .. ... ... .. ... ... ... ... ... .. ... ... .. .. .. .. ... .. .. ..43

6.6. FUEL L EVEL G AUGE, P. 6 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

6.7. PYROMETER GAUGE, P. 7... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ... ... ... ... ... ... ..45

6.8. SPEEDOMETER GAUGE TACHOMETER GAUGE, P. 8.........................................46

6.9. TRANSMISSION OIL TEMPERATURE GAUGE, P. 9... .. ... ... ... .. ... ... .. ... ... ... .. ... ... ... .. ...47

6.10. VOLTMETER GAUGE, P. 10.... .... .... ... .... .... .... ... .... .... ... .... .... .... ... .... .... .... ... .... .48

6.11. ETHER START, P. 11... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...49

6.12. MANIFOLD PRESSURE GAUGE, P. 12... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..50

7. WARNING LIGHTS (CHAPTER 7)..................................................................................51

7.1. AIR SUSPENSION RELEASE WARNING LIGHT, P. 1.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .51

7.2. ENGINE OIL PRESSURE WARNING LIGHT, P. 2.... .. .. .. ... ... .. .. .. .. ... ... .. .. .. .. ... ... .. ... ... .52

7.3. ENGINE WATER TEMPERATURE WARNING LIGHT, P. 3..........................................53

7.4. LOW AIR PRESSURE WARNING LIGHT, P. 4.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..54

7.5. LOW FUEL LEVEL WARNING LIGHT, P. 5.... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..55

7.6. POWER DIVIDER LOCK (PDL) WARNING LIGHT AND BUZZER, P. 6. .. .. .. . .. .. .. .. .. .. .. .. .. .56

7.7. DIFFERENTIAL LOCK WARN LIGHT 4X2, P. 7.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .57

7.8. DIFFERENTIAL LOCK WARN LIGHT 6X4, P. 8.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .58

8. CAB ACCESSORIES (CHAPTER 8)...............................................................................59

8.1. CIGAR L IGHTER, P. 1 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

8.2. C LOCK, P. 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .608.3. ELECTRIC WINDOW RIGHT, P. 3... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .61

8.4. ELECTRIC WINDOW RIGHT AND LEFT, P. 4.. .. ... .. ... ... ... .. .. .. .. ... ... .. ... .. .. .. .. ... ... .. .62

8.5. DEFROSTER FAN(S), P. 5... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .63

8.6. ELECTRIC WINDSHIELD WIPERS WITH INTERMITTENT WIPE AND WASH, P. 6............. 64

8.7. HORN, P. 7.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

8.8. MIRROR LIGHTS AND HEATED MIRRORS, P. 8.. .. ... ... ... ... .. .. .. .. .. .. .. ... ... ... .. ... ... .. .. ..66

8.9. RIGHT MOTORIZED MIRROR, P. 9...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ... ... ..67

8.10. DUAL AXIS MOTORIZED MIRRORS, P. 10.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..68

8.11. POWER SOURCE (CB), P. 11...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..69

8.12. RADIO-CB, ACCOMMODATION PACKAGE, P. 12.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .70

8.13. RADIO-CAB, SPEAKERS, P. 13... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..71

8.14. OWNER/OPERATOR SPARE SWITCH, P. 14.. .. .. .. ... ... ... .. ... ... ... .. .. .. .. ... ... ... .. ... ... .. .72

8.15. ELECTRIC LOCK RIGHT AND LEFT, P. 15.... .. ... ... ... .. .. .. .. ... ... ... ... ... .. ... ... ... .. .. ..738.16. INTERVISION DISPLAY, P. 16.... ... .... .... ... .... .... ... .... .... ... .... .... ... .... .... ... .... ... .... .74

8.17. EATON VORAD COLLISION AVOIDANCE, P. 17.. .. .. .. .. ... ... .. .. .. ... .. .. .. .. ... .. .. .. ... ...75

8.18. EATON VORAD COLLISION AVOIDANCE, P. 18.. .. .. .. .. ... ... .. .. .. ... .. .. .. .. ... .. .. .. ... ...76

8.19. TEMPERATURE/COMPASS DISPLAY, P. 19.... .. .. .. ... .. .. .. .. ... ... .. .. .. .. .. ... ... ... .. ... ... ...77

8.20. ROAD RELAY IV, P. 20... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .78

8.21. HEATED SEAT DRIVER, P. 21... ... ... ... ... .... ... ... ... .... ... ... ... ... ... ... ... ... ... .... ... ... .79

8.22. HEATED SEAT PASSENGER, P. 22... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...80

9. CHASSIS ACCESSORIES (CHAPTER 9)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .81

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9.1. AIR D RYER, P. 1 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

9.2. ABS/ATC (BENDIX), P. 2...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...82

9.3. ABS/ATC (BENDIX) (CONT.), P. 3... ... .... .... ... .... .... ... .... .... ... .... .... .... ... .... .... ... .... ..83

9.4. ABS/ATC (BENDIX) (CONT.), P. 4... ... .... .... ... .... .... ... .... .... ... .... .... .... ... .... .... ... .... ..84

9.5. ABS/ATC (WABCO), P. 5... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ... ... ... ... ... ... ... ... ... ..85

9.6. ABS/ATC (WABCO) (CONT.), P. 6..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..86

9.7. ABS/ATC (WABCO) (CONT.), P. 7..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..87

9.8. TRAILER CONNECTION BACK OF SLEEPER MOUNTED W/TRACTOR ABS, P. 8. . . . . . .. .88

9.9. TRAILER CONNECTION W/FOUR WHEEL TRAILER FRAME MOUNTED, P. 9..............89

9.10. TWO SPEED AXLE WIRING, P. 10...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..90

9.11. TRUCK BODY CONNECTION, P. 11...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...91

9.12. TRAILER CONNECTION N/SLEEPER BACK OF CAB MOUNTED, P. 12.. .. . .. .. .. .. . .. .. ..92

9.13. TRAILER CONNECTION W/FOUR WHEEL TRAILER FRAME MOUNTED W/5000, P.

13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..93

9.14. MERITOR G SERIES TRANSMISSION, P. 14.... .. ... ... ... .. ... ... ... ... .. ... ... ... ... ... .. ... ... ..94

9.15. EATON AUTOSHIFT TRANSMISSION CAB WIRING, P. 15.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..95

9.16. EATON AUTOSHIFT TRANSMISSION TRANSMISSION WIRING, P. 16.. .. . . . . .. .. . . . . .. . ..96

9.17. EATON LIGHTNING TRANSMISSION TRANSMISSION WIRING, P. 17.. . .. .. .. .. . .. . .. . .. . .97

10. SLEEPER LIGHTING AND ACCESSORIES (CHAPTER 10)... ... .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. ... ..98

10.1. AUXILIARY CIRCULATION FAN (LOW ROOF), P. 1................................................98

10.2. AUXILIARY CIRCULATION FAN (HIGH ROOF), P. 2...............................................99

10.3. AUXILIARY CIRCULATION FAN (SKYRISE), P. 3.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. ..100

10.4. BUNK FLUORESCENT AND READING LIGHTS, P. 4.. .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. .. .101

10.5. BUNK SPEAKERS, P. 5.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

10.6. LUGGAGE COMPARTMENT LIGHTS, P. 6.. .. ... .. .. .. .. .. .. ... ... .. .. .. .. ... .. .. .. ... ... ... .. .. ..103

10.7. POWER SOURCE, P. 7.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

10.8. REFRIGERATOR WIRING, P. 8..... .... ... ... ... ... .... .... ... .... ... .... ... .... .... ... .... ... ... ... .105

10.9. TV/VCR WIRING, P. 9... ... ... ... ... ... ... ... .... ... ... ... ... ... ... .... ... ... ... ... ... ... .... ... ... ... .106

10.10. OVERHEAD CABINETS, ACCENT LIGHTS, P. 10.... .. .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..107

10.11. OPTIONAL SLEEPER MOUNTED RADIO CONTROLS, P. 11.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..10810.12. SHORE POWER WIRING WITHOUT DC/AC INVERTER, P. 12... .. . .. .. .. .. .. .. .. .. .. .. .. .. ..109

10.13. SHORE POWER WIRING WITH DC/AC INVERTER, P. 13.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..110

11. LIGHT SYSTEMS (CHAPTER 11)................................................................................111

11.1. BACK-UP LIGHTS, P. 1...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..111

11.2. CAB AND TRAILER LIGHTS SWITCH AND RELAYS WIRING, P. 2............................112

11.3. CAB CLEARANCE AND IDENTIFICATION LIGHTS, P. 3... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..113

11.4. WORK LIGHT N/SLEEPER, P. 4... ... .... ... .... ... .... ... .... ... ... ... ... .... ... .... ... .... ... .... ..114

11.5. CAB DOME, READING AND COURTESY LIGHTS N/SKYRISE, P. 5...........................115

11.6. CAB DOME, READING AND COURTESY LIGHTS W/SKYRISE, P. 6.......................... 116

11.7. DAYTIME RUNNING LIGHTS (DRL) USA, P. 7... .. .. .. .. .. ... ... .. .. .. .. ... .. ... .. .. .. .. ... ... .117

11.8. FOGLIGHTS CAB/FRONT END EFFECTS, P. 8... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. ..118

11.9. HEADLIGHT SWITCH AND DIMMER SWITCH WIRING, P. 9... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .11911.10. HEADLIGHTS, P. 10... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .120

11.11. PANEL LIGHTS, P. 11...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..121

11.12. PARK/TURN/SIDE MARKER LIGHTS WITH DRL, P. 12.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .122

11.13. SPOTLIGHT, P. 13... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

11.14. STOP, TAIL, TURN AND HAZARD SIGNAL LIGHTS WITH FLASHER, P. 14................124

11.15. WORK LIGHT W/SLEEPER, P. 15... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...125

12. HEATER AND AIR CONDITIONER (CHAPTER 12)...........................................................126

12.1. AIR CONDITIONER CAB, P. 1... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..126

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12.2. HEATER CAB, P. 2... ... ... ... ... .... .... .... ... .... .... ... .... .... ... .... .... ... .... .... ... .... ....127

12.3. HEATER BUNK AUXILIARY BLOWER, P. 3.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..128

12.4. HEATER BUNK W/STANDARD TEMPERATURE CONTROL, P. 4.. .. .. .. . .. . .. . .. .. . .. .. .. .129

12.5. HEATER BUNK W/THERMOSTAT TEMPERATURE CONTROL, P. 5. .. .. .. .. .. .. .. .. .. .. ..130

12.6. LOWERED HEATER BOX, P. 6... ... ... .... ... ... .... ... ... .... ... ... .... ... ... ... ... ... ... ... .... ...131

13. CONNECTOR COMPOSITES (CHAPTER 13)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..132

13.1. LEFT GAUGE CLUSTER (CONNECTOR 423).....................................................132

13.2. LEFT GAUGE CLUSTER (CONNECTOR 424).....................................................133

13.3. LEFT GAUGE CLUSTER GAUGE INFORMATION.. ... ... .. ... ... ... ... .. ... ... ... .. .. .. .. .. ..134

13.4. LEFT GAUGE CLUSTER TERMINAL INFORMATION.........................................135

13.5. LEFT GAUGE CLUSTER TERMINAL INFORMATION.........................................136

13.6. RIGHT GAUGE CLUSTER (CONNECTOR 420)...................................................137

13.7. RIGHT GAUGE CLUSTER GAUGE INFORMATION... .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. ..138

13.8. RIGHT GAUGE CLUSTER TERMINAL INFORMATION.......................................139

13.9. SPEEDOMETER/TACHOMETER MODULE TERMINAL INFORMATION.. . .. . . .. . . . .. . . .. .140

13.10. SPEEDOMETER/TACHOMETER MODULE TERMINAL INFORMATION..................141

13.11. CONNECTOR COMPOSITES (1), (2), (3)..........................................................14213.12. CONNECTOR COMPOSITES (4), (9), (11), (15), (20), (27).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..143

13.13. CONNECTOR COMPOSITES (40), (41), (42), (43), (48), (65).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .144

13.14. CONNECTOR COMPOSITES (66), (71), (72), (76), (77), (94).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .145

13.15. CONNECTOR COMPOSITES (100), (100A), (105), (111), (112), (113), (115).................146

13.16. CONNECTOR COMPOSITES (116), (117), (118), (127A), (128)................................ 147

13.17. CONNECTOR COMPOSITES (137), (141), (142), (143), (144), (145), (146), (147), (148). . .148

13.18. CONNECTOR COMPOSITES (149), (150), (151), (152), (161), (162).. . .. .. .. . .. . .. . .. .. . .. .. .149


13.20. CONNECTOR COMPOSITE (190)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...151

13.21. CONNECTOR COMPOSITES (196), (199), (200), (201), (209), (211), (214), (216).. . . . . . . . . .152

13.22. CONNECTOR COMPOSITES (217), (218), (220), (221).........................................153

13.23. CONNECTOR COMPOSITES (227), (228), (229).... .. .. .. ... .. .. .. ... .. .. .. .. .. .. .. ... .. .. .. ... .154

13.24. CONNECTOR COMPOSITES (230), (231), (236), (241).........................................15513.25. CONNECTOR COMPOSITES (243), (244), (249), (250), (251)..................................156




13.29. CONNECTOR COMPOSITES (298), (299), (311), (312), (313), (315, 316).. .. . . . .. . .. . . . .. . ..160


13.31. CONNECTOR COMPOSITES (325), (345), (350), (351), (352), (353), (354).................. 162




13.35. CONNECTOR COMPOSITES (422), (423), (424), (425), (426)..................................166


13.37. CONNECTOR COMPOSITES (433), (434), (435).... .. .. .. ... .. .. .. ... .. .. .. .. .. .. .. ... .. .. .. ... .16813.38. CONNECTOR COMPOSITES (436), (437), (440), (441), (442)..................................169

13.39. CONNECTOR COMPOSITES (453), (454).... ... .. ... ... ... .. ... .. .. .. .. ... .. .. .. .. ... ... .. ... ... .170


13.41. CONNECTOR COMPOSITES (462), (463).... ... .. ... ... ... .. ... .. .. .. .. ... .. .. .. .. ... ... .. ... ... .172

13.42. CONNECTOR COMPOSITES (463)..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..173

13.43. CONNECTOR COMPOSITES (464)..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..174

13.44. CONNECTOR COMPOSITES (464), (465), (466), (468), (470), (1000).. .. .. .. .. .. .. . .. .. .. .. ..175


13.46. CONNECTOR COMPOSITES (491), (492), (494), (495), (497), (498), (499), (501).. . . . . . . . . .177

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v

13.47. CONNECTOR COMPOSITES (502), (503), (504), (506)... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..178

13.48. CONNECTOR COMPOSITES (509), (511), (512), (513), (514), (515)..........................179

13.49. CONNECTOR COMPOSITES (517), (520), (521), (522), (523), (524), (525), (526)........... 180

13.50. CONNECTOR COMPOSITES (528), (529), (530), (531), (560), (562), (574).. . . . . . . . . . . . . . . . .181


13.52. CONNECTOR COMPOSITES (584), (585), (587)... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..183

13.53. CONNECTOR COMPOSITES (592), (592F), (593), (594), (600).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..184



13.56. CONNECTOR COMPOSITES (662), (675), (676), (690)... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..187


13.58. CONNECTOR COMPOSITES (769), (770), (771), (774), (775), (776), (777), (778), (789). . .189



13.61. CONNECTOR COMPOSITES (907), (909), (912), (913), (914), (915), (916), (918)........... 192


13.63. CONNECTOR COMPOSITES (926), (930), (935), (936), (937).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..194

13.64. CONNECTOR COMPOSITES (938), (939), (940), (941), (942).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..19513.65. CONNECTOR COMPOSITES (955), (956), (962), (963), (992), (993), (994).. . . . . . . . . . . . . . . . .196

13.66. CONNECTOR COMPOSITES (995999), (1000), (1033), (1034).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .197

13.67. CONNECTOR COMPOSITES (1039), (1040), (1041), (1042), (1043), (1044). .. . .. . .. . .. . .. . .198

13.68. CONNECTOR COMPOSITES (1045), (1046), (1047), (1048)...................................199

13.69. CONNECTOR COMPOSITES (1049), (1050), (1051).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. ..200


13.71. CONNECTOR COMPOSITES (1058), (1059), (1060), (1084), (1085), (1086), (1088),

(1090F). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202

13.72. CONNECTOR COMPOSITES (1090M), (1091), (1093), (1094), (1095)........................203

13.73. CONNECTOR COMPOSITES (1097), (1098), (1099), (1108).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..204

13.74. CONNECTOR COMPOSITES (1110), (1112), (1113), (1125), (1126)...........................205

13.75. CONNECTOR COMPOSITES (1127), (1128), (1130), (1135).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..206

13.76. CONNECTOR COMPOSITES (1137), (1138), (1139), (1140), (1141)...........................20713.77. CONNECTOR COMPOSITES (1155), (1156), (1157), (1158), (1159), (1170).. . .. . .. . .. .. . .. . .208

13.78. CONNECTOR COMPOSITES (1171), (1188), (1189), AND JUNCTION POINTS J7 AND

J4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209

13.79. CONNECTOR COMPOSITES (1190), (1193), (1194), (1195), (1223), (1224), (1225).. . . . . . . .210

13.80. CONNECTOR COMPOSITES (1227), (1229), (1239A, B, C), (1239), (1240) . . . . .. . .. .. . .. .. .211

13.81. CONNECTOR COMPOSITES (1241), (1243), (1244), (1258), (1260), (1261). .. . .. . .. . .. . .. . .212

13.82. CONNECTOR COMPOSITES (1262), (1263), (1264), (1265), (1279)..........................213

13.83. LEFT BLANK INTENTIONALLY....................................................................214

13.84. CONNECTOR COMPOSITE (1285)... ... .... .... ... ... ... ... .... .... .... ... ... ... ... .... .... .... ...215




13.88. CONNECTOR COMPOSITES (1322), (1323), (1324), (1327), (1328)..........................21913.89. CONNECTOR COMPOSITES (1331), (1332)......................................................220

14. FUSES, CIRCUIT BREAKERS, RELAYS (CHAPTER 14)... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .221

14.1. POWER DISTRIBUTION CENTER, FUSE AND CIRCUIT BREAKER LOCATION, P. 1. . . . . .221

14.2. FUSE AND CIRCUIT BREAKER LOCATION (CONT.), P. 2.......................................222

14.3. RELAY LOCATION, P. 3..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..223

14.4. PRO SLEEPER FUSE INDEX, P. 4... ... ... ... ... ... ... ... ... .... ... ... ... ... ... ... .... ... ... ... ... ..224

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1

1. INSTRUCTIONS AND CHARTS (CHAPTER 1)

1.1. CIRCUIT IDENTIFICATION CHART, P. 1

CHANGE

RELEASE NO.

NAME

ELECTRICAL CIRCUIT DIAGRAM

DATE

DATE REV

NAVISTAR INTERNATIONALTRANSPORTATION CORP.

SHEET

THIS PRINT IS PROVIDED ONA RESTRICTEDBASISAND

IS NOT TOBE USEDIN ANYWAY DETRIMENTAL TO THE

INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

DRAWN

PART NO.

CHK REFERENCE

P52600M

NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR

29JUL98 1

INSTRUCTIONS AND CHARTS FOR ALL MODELSRROEPKE

AE08-52011

CHAPTER 1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

CIRCUIT

NUMBERDESCRIPTION - COLOR

GENERATOR - CHARGE - RED

GROUND - WHITE

BATTERYFEED - RED

STARTER CONTROL - PINK

ENGINE SHUT-OFF - GRAY

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

ETHER START - TAN

ENGINE COOLING - TAN

ENGINE BRAKE GRAY

VOLTMETER - TAN

INSTRUMENT FEED - TAN

ENGINE WATER TEMPERATURE - TAN

ENGINE OILTEMPERATURE - TAN

TRANSMISSION OIL TEMPERATURE - TAN

AXLE OIL TEMPERATURE - TAN

WATER LEVEL - TAN

ENGINE OILPRESSURE - TAN

FUEL LEVEL - TAN

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

LOW AIR PRESSURE WARNING - GRAY

POWER DIVIDER LOCK (PDL) - GRAY

SPEEDOMETER - GRAY

TACHOMETER - GRAY

HEADLIGHT - HIGH BEAM - YELLOW

TURN SIGNAL - ORANGE

CLEARANCE AND IDENTIFICATION LIGHTS - BROWN58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

PANEL LIGHTS - DARK BLUE

COURTESYAND DOME LIGHTS - DARK BLUE

AUXILIARYLIGHTS - YELLOW

5TH WHEEL/WORK LIGHT - ORANGE

DAYTIME RUNNING LIGHTS - YELLOW

TAILLIGHTS - BROWN

STOP LIGHTS - ORANGE

BACK-UP LIGHTS - ORANGE

CIRCUIT

NUMBERDESCRIPTION - COLOR

IGNITION FEED - PINK

KEY SWITCH FEED - RED

AIR DRYER - GRAY

LIGHT SWITCH FEED - YELLOW

DIMMER SWITCH - YELLOW

HEADLIGHT - LOW BEAM - YELLOW

TURN SIGNAL LIGHTS - LEFT - ORANGE

TURN SIGNAL LIGHTS - RIGHT - ORANGE

TRAILER AUXILIARY - ORANGE

PYROMETER - TAN

DIFFERENTIALLOCK - GRAY

PARKING/MARKER LIGHTS - BROWN

HAZZARD LIGHTS - ORANGE

ALTERNATOR - RESISTANCE - RED

ACCESSORY FEED - LIGHT BLUE

FRONT AXLE - GRAY

FUEL PUMP - TANGENERATOR - FIELD - LIGHT BLUE

GLOW PLUG/PRE-HEATER - PINK

AMMETER - TAN

ENGINE OILLEVEL - TAN

PARK BRAKE WARNING - GRAY

ANTI-THEFT WARNING - LIGHT GREEN

POWER TAKE-OFF WARNING - GRAY

AIR SUSPENSION - GRAY

LICENSE PLATE LIGHT - BROWN

Figure 1 Circuit Identification Chart, page 1

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2 5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After


1.2. CIRCUIT IDENTIFICATION CHART, P. 2

INTERNATIONAL TRUCK AND ENGINE CORPORATION

NAME

DATE

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE

INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.

DATE REFERENCEREVCHK

P 526 00M 2 9J UL98 02

INSTRUCTIONS AND CHARTS FOR A LL MODELSRROEPKEGSC2 ADDED CIR 73 DESC

AE08-52011

CHAPTER 1

A P53583SJPM 10DEC01

ADDED SEAT BELTS. B 55093FJ KP 4MAR 02

73

74

75

76

77

78

79

80

81

82

83

84

85

86

CIRCUITNUMBER

DESCRIPTION - COLOR

HEATER BLOWER MOTOR - LIGHT GREEN

87

88

89

90

91

92

93

94

95

96

97

98

99

CIRCUITNUMBER

DESCRIPTION - COLOR

AIR CONDITIONER - LIGHT GREEN

MIRRORS - HEATED * MOTORIZED - LIGHT GREEN

POWER WINDOW - LIGHT GREEN

CIGAR LIGHTER - LIGHT GREEN

HORN - ELECTRIC - GRAY

RADIO - ENTERTAINMENT - LIGHT GREEN

WINDSHIELD WASHER - GRAY

CLOCK/HOURMETER - LIGHT GREEN

DATA LINK AND DIAGNOSTICS - BLACK

AXLE SHIFT CONTROL - TAN

THROTTLE POSITION SENSOR - VIOLET

CRUISE CONTROL AND ELECTRONIC ENGINE - VIOLET

AUXILIARY FAN - LIGHT GREEN

POWER DOOR LOCKS - LIGHT GREEN

WINDSHIELD WIPERS - GRAY

TRANSMISSION (ELECTRONIC) - TAN

ANTILOCK BRAKES - GRAY

EXHAUST EMISSION - TAN

SNOW PLOW LIGHTS - YELLOW

* NOTE:

NOT ALL CIRCUITS MAY BE USED.

COLORS ABOVE ARE NEW STD COLORSFOR MAJOR HARNESSES.

INTERCOMMUNICATIONS - VIOLET

HYDRAULIC BRAKE PUMP - GRAY

COLLISION AVOIDANCE SYSTEM - LIGHT BLUE

NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR

SEAT BELTS - LIGHT GREEN

Figure 2 Circuit Identification Chart, page 2

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3

1.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3

P52600M 3


29JUL98

INSTRUCTIONS

AE08-52011

CHAPTER 1

A - SWITCH AND RELAY POSITIONS AS

SHOWN ON CIRCUIT DIAGRAMS

INDICATE NORMAL POSITION WITH

IGNITION OFF UNLESS OTHERWISE

NOTED.

B - MULTIPLE CONNECTORS ARE

DISPLAYED ON SCHEMATIC AS

SHOWN. REFER TO CONNECTOR

COMPOSITE WITH APPLICABLE

NUMBER FOR MORE COMPLETE

INFORMATION.

12 AND/OR 12

SINGLE IN-LINE CONNECTORS

DISPLAYED AS SHOWN WITHOUT

CONNECTOR NUMBER.

C - PHANTOM LINES INDICATE PRINTED CIRCUITS OR BUSSED

CIRCUITS. THESE CIRCUITS EXIST IN THE INSTRUMENT CLUSTERS

AND FUSE/CIRCUIT BREAKER CONNECTORS.

VOLTMETER

PRINTED

CIRCUIT

IN

INSTRUMENT

CLUSTER

13

16PK

A

B

F1

20A

BUSS IN FUSE

CIRCUIT BREAKER

CONNECTOR

INDICATES

BASIC FEED

WIRE CIRCUIT

IDENTIFICATION

FUSE RATING

LOCATION IN

FUSE/CIRCUIT

BREAKER

CONNECTOR

D - MULTIPLE CIRCUIT NUMBERS ON A LINE INDICATE ONE WIRE

DISTRIBUTING CURRENT TO TWO CIRCUITS.

FLASHER

55A/60

16OR

55

16OR

60

16OR

55A

16OR

30

A

87

87

86

85A

87

RELAY-SUPPRESSED

SWITCH-MANUAL MAGNETIC SWITCH

INDICATES

CASE GROUND

WIRE GAUGE &

COLOR

CIRCUIT

NUMBER

E - SWITCHES , RELAYS & COMPONENTS INDICATE EXTERNAL WIRE

CONNECTIONS AND/OR INTERNAL CONNECTIONS OR CONTACTS.

UP

DOWN

83-E

83-C

83-H83-F

83-GB

SWITCH

WINDOW

WIRE

CONNECTION

INTERNAL

CONTACT 20A

F19

75A

F18

78

BUSSED

CONTACTWIRE

CONNECTIONINTERNAL

CONTACT

ETHER

SWITCH

16RD

16BN

PIG-TAIL

IGN (24)

16LTGN

16LTGN

16WH

16LTGN16LTGN16LTGN 14LTGN

14LTBL

12B

Figure 3 Circuit Diagram Instructions, page 3

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1.4. CIRCUIT DIAGRAM INSTRUCTIONS, P. 4

P52600M 4


29JUL98

INSTRUCTIONS

AE08-52011

CHAPTER 1

F - JUNCTIONS ARE USED TO IDENTIFY MULTIPLE CONNECTIONS

WITH A COMMON FEED OR GROUND. THE JUNCTION MAY BE A STUD OR

A CONNECTOR WITH ALL CIRCUITS CONNECTED INTERNALLY BY BUS BAR.

STUD

OR

ADAPTER

J6

GROUND JUNCTION

THIS VEHICLE USES BUSSED CONNECTORS

AND ARE REFERRED TO AS ADAPTERS -

GROUND, FEED, IGNITION, ACCESSORY OR BATTERY.

A B C D E F G H J K

BUS ADAPTER

G - CIRCUIT 11 DENOTES ANY COMMON GROUND, (MORE THAN ONE CIRCUIT).

ANY DEDICATE GROUND CIRCUIT IS IDENTIFIED WITH THAT PARTICULAR

SYSTEM CIRCUIT NUMBER. (E.G CIRCUIT 97 CRUISE CONTROL, IS

IDENTIFIED PER EXAMPLE).

GROUND CIRCUITS ARE DESCRIBED THUS:

11-G

11-GA

11-GB

97-G

97-GA

97-GB

SUFFIX

G IS NOT A SUFFIX BUT

INDICATES A GROUND CIRCUIT

COMMON GROUND

CIRCUIT NUMBER

H - ABBREVIATIONS: COLOR,NOUN AND ENGINE

COLOR ABBREVIATION NOUN ABBREVIATION

NOTE: FOR CIRCUIT DESCRIPTION OTHER THAN

GROUNDS, NEITHER THE LETTER G OR

THE COLOR WHITE WILL BE USED.

SUFFIX

G IS NOT A SUFFIXBUT

INDICATES A GROUND CIRCUIT

DEDICATED GROUND

CIRCUIT NUMBER

AQ - AQUA

BK - BLACK

BL - BLUE

BN - BROWN

DK GN - DARK GREEN

GD - GOLD

GY - GRAY

GN - GREEN

LT BL - LIGHT BLUE

LT GN - LIGHT GREEN

OR - ORANGE

PK - PINK

PL - PURPLE

RD - RED

SIL - SILVER

TN - TAN

VT - VIOLET

WH - WHITE

YL - YELLOW

A

ACC

AC - AIR CONDITIONER

AUX - AUXILIARY

AWG - AMERICAN WIRE GAUGE

B

BAT

CONN - CONNECTION OR CONNECTOR

DRL- DAYTIME RUNNING LIGHTS

ENG - ENGINE

FWD - FORWARD

GA - GAUGE

G

GND

I

IGN

IND - INDICATOR

L- LEFT

LT - LIGHT

N/ - NOT WITH

OPT - OPTIONAL

R - RIGHT

S - START OR SENDER

THERMO - THERMOSTAT

W/ - WITH

ACCESSORY

BATTERY

GROUND

IGNITION

FL - FUSIBLE LINK

W/O - WITHOUT

Figure 4 Circuit Diagram Instructions, page 4

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5

1.5. SCHEMATIC SYMBOLS, P. 5

RROEPKE

529JUL98

INSTRUCTIONS AND CHARTS FOR ALL MODELS

P52600M

SCHEMATIC SYMBOL CHART

AE08-52011

CHAPTER 1

SYMBOL DESCRIPTION

MALE/FEMALE I N-LINE CONNECTION

MALE TERMINAL

FEMALE TERMINAL

GROUND

LIGHT-SINGLE FILAMENT

LIGHT-DOUBLE FILAMENT

FUSE / CIRCUIT BREAKER

DIODE

JUNCTION POINT

SPLICE

SWITCH-PUSH BUTTON

SWITCH-MANUAL/MECHANICAL

SWITCH-PRESSURE

SWITCH-WITH LIGHT

RELAY-SUPPRESSED

ACCELERATOR POSITION SENSOR

SYMBOL DESCRIPTION

RESISTOR

SWITCH CONTACT, NORMALLY OPEN

SWITCH CONTACT, NORMALLY CLOSED

30

87

A 87

86

85

SENDER-OIL,WATER,FUEL,TEMPERATURE

ALARM-ELECTRONIC

SOLENOID-GENERALUSAGE

MOTOR-ELECTRIC

CIGAR LIGHTER

HORN

SPEAKER-SOUND SYSTEM

FLASHER-TURN SIGNAL,HAZARD

MAGNETIC SWITCH

FUSIBLE LINK

LIGHT EMITTING DIODE (LED)

BB

A

CIRCUIT BREAKER

TYPE 1 TYPE 2OR 3

A

BB

A

CIRCUIT BREAKER

A

Figure 5 Schematic Symbols

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1.6. RELAY PINOUT, FUNCTION DATA & SEALED RELAY, P. 6

RROEPKE

RELAY PINOUT AND FUNCTION DATA

SEALED MINIATURE RELAY DATA

29JUL98 6

INSTRUCTIONS AND CHARTS FOR ALL MODELS

P52600M AE08-52011

CHAPTER 1

85

TYPICAL RELAY(INSERTION END)

87A

85

87

30

A 87

86

NORMALLY OPEN

CONTACT

RELAY SCHEMATIC

RELAY INSERTION END

FUSEBLOCK SOCKET

CONNECTOR SOCKET

C/4

A/2

E/1

B/5

D/3

CABLE INSERTION END

FUSEBLOCK SOCKET

CONNECTOR SOCKET

C

A

E

B

D

COMMON

CONTACT

ENERGIZING COIL

ENERGIZING COIL

NORMALLY CLOSED

CONTACT

30

86

87

87

30

85

86

87A

1 5

3 4 2

FUSEBLOCK SOCKET

CONNECTOR SOCKET

RELAY INSERTION END

WHEN 12V IS APPLIED TO THE

RELAYCOIL,THE SWITCH WIPER IS

PULLED FROM THE NORMALLY CLOSED

POSITION TO THE NORMALLYOPEN

POSITION.

85

NOTE:

30

87A

THE RELAY IS PRINTED WITH

THE NUMBERS 85,86,87,87A AND 30.

THE CONNECTOR BODY IS PRINTED

WITH 85,86,87,87A AND 30.

ENERGIZINGCOIL

30

87A ENERGIZING

COIL

86

FUNCTION

COMMONCONTACT

A

86

85

86

87A87

CABLE INSERTION END

87

87

87

NORMALLY OPEN

COIL

SEALED MINIATURE RELAY DATA

86

TYPICAL RELAY (INSERTION END)

30

85

30

RELAY SCHEMATIC

85

NORMALLY CLOSED

COIL

FUSEBLOCK SOCKET

CONNECTOR SOCKET

87

DATA RELAY AND FUNCTION DATA

Figure 6 Relay Pinout, Function Data & Sealed Relay

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7

1.7. LAMP BULB CHART, P. 7


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.


RROEPKE

LAMP BULB CHART

29JUL98 07

INSTRUCTIONS AND CHARTS FOR A LL MODELS

P52600M AE08-52011

CHAPTER 1

A 55093FADDED & EDITED SLPR ITEMSJKP 4MAR02

BULB APPLICATION WATTS OR CANDLEPOWER TRADE NUMBER

2 CANDLEPOWER.......................... 57AIR RESTRICTION GAUGE..............................

BACK-UP LIGHTS.....................................

CIGAR LIGHTER......................................

CLOCK - ANALOG.....................................

COURTESY LIGHT.....................................

DOME LIGHT.........................................

FOG LIGHT..........................................

HEADLIGHTS

HIGH/LOW BEAMS..............................

HIGH BEAM INDICATOR...............................

INSTRUMENT CLUSTER

ILLUMINATION LIGHT.............................

WARNING LIGHT.................................

READING LIGHT......................................

SIDE TURN SIGNAL - 9200/9400/9900..................

32 CANDLEPOWER.........................

1 CANDLEPOWER..........................

2 WATTS............................

21 CANDLEPOWER.........................

21 CANDLEPOWER.........................

100 WATTS..............................

32/3 CANDLEPOWER.......................

65/35 WATTS............................

3 CANDLEPOWER..........................

0.5 CANDLEPOWER........................

1 CANDLEPOWER..........................

0.5 CANDLEPOWER........................

15 CANDLEPOWER.........................

1156

1455

VDO-600 802

1142

1142

4921-1

3157

6053

168

37

161

37

1003

3157

SLEEPER

DOME LIGHT......................................... 15 WATTS............................... F15T8-CW

FRONT TURN SIGNAL

9200/9400/9900 INCANDESCENT

SPEEDOMETER....................................... 161

9200/9400/9900.....................................

HEATER AND AIR CONDITIONER CONTROLS................

SPOTLIGHT..........................................

STOP-TAIL-TURN SIGNAL..............................

1 CANDLEPOWER..........................

30 WATTS...............................

32/3 CANDLEPOWER.......................

4405

1157

LUGGAGE COMPARTMENT LIGHT..........................

READING LIGHT......................................

12 CANDLEPOWER.........................

12 CANDLEPOWER.........................

211-2

912

EXTERIOR MIRROR LIGHT.............................. 2 CANDLEPOWER.......................... 1895

HIGH/LOW B EAM............................... 65/35 WATTS............................ H5054

HALOGEN (OPTIONAL)

CLEARANCE/IDENTIFICATION LIGHTS - SMALL............

CLEARANCE/IDENTIFICATION LIGHTS - LARGE............

2 CANDLEPOWER..........................

4 CANDLEPOWER..........................

194

904

TACHOMETER......................................... 1 CANDLEPOWER.......................... 161

TURN SIGNAL INDICATOR............................. 0.5 CANDLEPOWER........................ 37

WORK LIGHT......................................... 35 WATTS............................... 4411

32/3 CANDLEPOWER.......................

OVERHEAD CABINET LIGHT.............................

TV/VCR & MICROWAVE CABINET LIGHT...................

12 CANDLEPOWER.........................

12 CANDLEPOWER......................... 211-2

211-2

Figure 7 Lamp Bulb Chart

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2. 12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (CHAPTER 2)

2.1. START FEED, P. 1

CHANGE

RELEASE NO.

NAME


DATE

DATE REV


SHEET




DRAWN

PART NO.

CHK REFERENCE

CHAPTER 212V POWER DISTRIBUTION - START FEED

CHAPTER 2

12FEB99 AE08-52502 1

5000/9100/9200/9400/9900U00EDL2

P50317A

B1 BAT

STUD

IS

GND

OFF

I

S

OFF

I

A

S

AI

OFF

S

AI

OFF

S

B

A

KEY

SWITCH

(40)

14FB

8RD

14C

10RD

15

12RD

F7-A

25A

PUSH

BUTTON

START

SWITCH

(41)

17A

14PK

17

14PK

17

14PK

START

FEED

ADAPTER

(509)

17B

14PK

STARTMAGNETICSWITCH

(CH3

,PG1-5

)

17B

16PK

(2)

W/PUSH

BUTTON

START

W/KEY

SWITCH

START

17

14PK

44

18GY

44A

16GY

FROM DRL

PARK BRAKE

SWITCH

(CH 11,PG 7)

Figure 8 Start Feed

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9

2.2. ACCESSORY, P. 2

CHANGE

RELEASE NO.

NAME


DATE

DATE REV


SHEET




DRAWN

PART NO.

CHK REFERENCE

12FEB99

12V POWER DISTRIBUTION - ACCESSORY

CHAPTER 2CHAPTER 2CHAPTER 2

AE08-52502 2

5000/9100/9200/9400/9900U00EDL2

P50317A

(426)

B1 BAT

STUD

IS

GND

OFF

I

S

OFF

I

A

S

AI

OFF

S

AI

OFF

S

B

A

KEY SWITCH

(40)

14FB

8RD

14C

10RD

F7-A

25A

86

16LT GN

F5-B

15A12M

12LT BL

12

12LTB

L

A1

ACCESSORY

ADAPTER

(499)

12AC

12LT BL

12-GH

16WH

TO 4C

CONTROL RELAY

12AD

10LTBL

A3

ACCESSORY

ADAPTER

(501)

12P

12LTBL

FOGLIGHTSFUSE

12W

12LTBL

RIGHTELECTRICWINDOW

RELAY

ACCESSORY

ADAPTER

RELAY

(145)

86

16LT GNTO RADIO

(CH 8,PG 13)

*

(CH11

,PG8)

(CH8

,PG3)

30

87

A 85

86

87

12A

12LTB

L

ELECTRICWIPERINTERMITTENT

REL

AY

(CH8,PG6)

12F

12LTBL

12F12LT BL

86E16LT GN

86E16LT GN

(428)

TO CB RADIO

(CH 8,PG 12)

* FUSE AND RELAY

LOCATIONS VARY -

CHECK INSIDE POWER

DISTRIBUTION CENTERFOR ACTUAL LOCATION.

14BJ

10RD

F6-C

30A

ONWER/OPERATORSPARESWITCH

W/FUSE

(CH8

,PG14)

12S

12LTBL

15

12RD

14AJ

10RD

D

E

(CH 12,PG 1)

Figure 9 Accessory

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2.3. BATTERY, B1, P. 3

CHANGE

RELEASE NO.

NAME


DATE

DATE REV


SHEET




DRAWN

PART NO.

CHK REFERENCE

12FEB99

12V POWER DISTRIBUTION - BATTERY

AE08-52502 3

5000/9100/9200/9400/9900U00EDL2

P50317A

CHAPTER 2

B1 BAT

STUD

14FB

8RD

14C

10RD

15

12RD

14R

10RD

14S

12RD

55

12OR

70E

10OR

85

16GY

57H

12OR

14F

10RD

14L

10RD

14AM

10RD

88B

16LT GN

F7-A 25A

F2-C 30A

F2-D 20A

F7-D 30A

F5-C 15A

F7-C 15A

14AN

10RD

B2 BAT

STUD

14AD

16RD

14BD

14RD

TO KEY SWITCH

TO IGNITION RELAY

TO STOP LIGHT RELAY

TO HORN RELAY

TO RADIO BATTERY

FEED

TO RIGHT TURN RELAY

TO ABS RELAY

TO AIR DRYER FUSE

TO RIGHT ELECTRIC WINDOW FUSE

TO FLASHER

14V

10RD

14A

2RD

FROM STARTER

MAGNETIC

SWITCH

(CH 3,PG 1-5)

FUSE LOCATIONS VARY -

CHECK INSIDE POWER

DISTRIBUTION CENTER

FOR ACTUAL LOCATION.

*

(CH 2,PG 2)

(CH 11,PG 14)

(CH 11,PG 14)

(CH 11,PG 14)

(CH 2,PG 10)

(CH 8,PG 7)

(CH 8,PG 13)

(CH 9,PG 2)

(CH 8,PG 3)

((CH 9, PG 1)

06BK B

M

S

(CH 3,PG 1-5)

B1 BAT

STUD

B2 BAT

STUD

14AL

10RDTO ELECTRIC WIPER

INTERMITTENT RELAY

82K

16GY

(CH 8,PG 6)

14J

16RD

14G

18RDTO SPEEDOMETER/

TACHOMETER MODULE(CH 6,PG 3,5,6,8,10

CH 7,PG 2-5

CH 9,PG 10)

TO LEFT TURN RELAY56H

12OR

F7-B 15A

(CH 11,PG 14)

14BC

14RDTO CATERPILLAR RUN RELAY FUSE

(CH 4,PG 3)

F4-D 15A

STARTER

MAGNETIC

SWITCH

CRANKING

MOTOR

SOLENOID

BATTERIES

COPPER

BUS BAR

N/3+1 BAT

(CH 8,PG 2)

TO A3 ACC ADAPTER RELAY14AJ

10RD

TO DRL MODULE (USA)(CH 11,PG 7)

14A

02RD

150A

MEGA FUSE

FROM

ALTERNATOR

14

02RD

2

04RD

FUSIBLE LINKS

14A

02RD

BA

TYPE I ONLY

14CP

10RD

(CH 9,PG 8,9)

94AH

10GYTO TRAILER ABS RELAY

F10-A 30A

66A

14YL

39A

16GY

F9-A 15A

F9-C 15A

14BL

14RD

B1 BAT

ADAPTER

(497)

14W

6RD

14K

8RD

Figure 10 Battery, B1

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11

2.4. BATTERY, B2, P. 4


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.



12FEB99 AE08-52502 04

5000/9100/9200/9400/9900U00EDL2

P50317A

CHAPTER 2

P52739ESEB//ADDED 14BW A

RMVD 14N, ADDED 14AX. 55093FBJKP 4MAR02

14BW6RD

14X10RD

7510LT GN

F1-A 30A

77T14LT GN

F1-B 10A

TO A/C CONTROL RELAY14Z

10RD

14H6RD

14B10RD

6810BN

5018YL

14D10RD

50A18YL

5114YL

F3-C 30A

F3-D 10A

F8-A 10A

F8-B 25A

TO CAB & TRAILER TAIL RELAY

TO HEADLIGHT SWITCH

TO HEADLIGHT SWITCH

58D12BN

14E10RD

F3-A 20A

TO TRAILER MARKER RELAY

7012OR

F3-B 20A

TO HEADLIGHT RELAY

TO STOP LIGHT SWITCH

(CH 12,PG 2)

(CH 12,PG 1)

(CH 11,PG 2)

(CH 11,PG 2)

(CH 11,PG 9)

(CH 11,PG 9)

(CH 11,PG 9)

(CH 11,PG 14)

14M

10RDXXX

XXX

14T10RD

65A14OR

6318DK BL

F6-A 20A

F6-B 10A

F2-A 15A

F2-B 10A

14AX18RD

B2BATTERYADAPTER

(498)

TO OWNER/OPERATOR OPTION

TO OWNER/OPERATOR OPTION

TO WORK LIGHT

TO REFRIGERATOR FUSE

TO DOME & COURTESY LIGHTS

14AH

10RD

84

14LT GNTO CAB CIGAR LIGHTER

EXTRA FUSES PROVIDEDFOR OWNER/OPERATOR

CONNECTION

**

**

**

(CH 11,PG 15)

(CH 8,PG 1)

(CH 11,PG 5)

(CH 10,PG 8)

86K14LT GN

(CH 8,PG 11)

14AA14RD TO POWER SOURCE

F5-D 20A

63P16DK BL

14Y14RD

F1-D 15ATO SPOTLIGHT & READINGLIGHTS (CH 11,PG 5,13)

B2BATTERY

STUD

14AR10RD

F10-A 30A *14AS10RD TO OWNER/OPERATOR SPARE

SWITCH W/FUSE (CH 8,PG 14)

FUSE LOCATIONS VARY -CHECK INSIDE POWERDISTRIBUTION CENTER


*

(CH 12,PG 2)

TO HEATER CONTROL RELAY75A14LT GN

F1-C20A

BA

BA

TO HIGH SPEED RELAY

TYPE 1 ONLY

TYPE 1 ONLY

97DL14VT (CH 4,PG 3,6,10,14)

TO DATA LINK

14W

6RD

Figure 11 Battery, B2

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2.5. BATTERY, B2 (CONT.), P. 5


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.


12FEB99


AE08-52502 05

5000/9100/9200/9400/9900U00EDL2

P50317A

CHAPTER 2

55093FAADDED O/H CABINET LTS TO

F10-D & AUX CIR FAN PG WAS 1, F8-D WAS CH 10, PG 3,5.

J KP 4MAR 02

FUSE LOCATIONS VARY -CHECK INSIDE POWERDISTRIBUTION CENTER


*

TO SLEEPER POWER SOURCE

F10-C 20A14AW10RD

14AK6RD

*14AY12RD

(CH 10,PG 7)

TO AUX BUNK BLOWER RELAY

F10-B 15A*

(CH 12,PG 3)

F10-A 30A14AU10RD

75AW10LT GN TO SLEEPER BLOWER RELAYS

(CH 12,PG 3)

*

F8-D 20A

14AP14RD

63AA14DK BL TO SLEEPER LIGHTS/LUGGAGE

COMPARTMENT LIGHTS(CH 10,PG 4,6)

B2BATTERY

STUD

14AV10RD

14AX10RD TO AUX CIRCULATION FAN

*

(CH 10,PG 1-3)

F10-D 30A

75AX14LT GN

TO TV/VCR WIRING(CH 10,PG 9)

TO OVERHEAD CABINET LIGHTS(CH 10,PG 10)

Figure 12 Battery, B2 (cont.)

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13

2.6. 3+1 BATTERY SYSTEM (DEEP CYCLE BATTERY B2 BATTERY), P. 6

12V POWER DISTRIBUTION - 3 + 1 BATTERY SYSTEM

CHANGE

RELEASE NO.

NAME


DATE

DATE REV


SHEET




DRAWN

PART NO.

CHK REFERENCE

12FEB99 AE08-52502 6

5000/9100/9200/9400/9900U00EDL2

P50317A

CHAPTER 2

ALTERNATOR

BG

7V

ISOLATED

BATTERY

MAGNETIC

SWITCH

R

7

16RD

7

16RD

11H

14WH

+ + + +

1ST 2ND 3RD

1/0BK

DEEP CYCLE

BATTERY

----

POWER

DISTRIBUTION

CENTER

GND STUD

14-F

L

10RUST

14A

6RD

14AB

6RD

B1

B2

GND

STUD

14A

2RD

11-G

G

10WH

11-G

8WH

4/0BK

TO

CRANKING

MOTOR

SOLENOID

(CH 3,PG 1-5)

7

16RD

1/0RD

14A

6RD

FROM

MEGA

FUSE

(CH 3,PG 1-5)

(RIGHT

DASH

PANEL)

Figure 13 3+1 Battery System (Deep Cycle Battery B2 Battery)

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2.7. GROUND ADAPTER COMPOSITE, P. 7


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.


U00EDL2

12V POWER DISTRIBUTION - GROUND ADAPTER COMPOSITE

07AE08-52502P50317A

CHAPTER 2

12FEB99

5000/9100/9200/9400/9900REVISED 11-GBC &

11-GBD. ADDED 38-G & 38-GB.

A 55093FJKP 4MAR02

*NOTE - A GROUND ADAPTER AS REFERRED TO IN THIS MANUAL IS ANINTERNALLY BUSSED CONNECTOR USED TO CONNECT & DISTRIBUTEGROUND CIRCUITS TO VARIOUS POINTS IN THE VEHICLE.

11-GA12WH

11-GC10WH

11-GX18WH

RIGHT MOTORIZED MIRROR

GROUNDADAPTER

(453)

GROUNDADAPTER

(456)

11-GE12WH

11-GAW14WH

13-GAD18WH

94-G16WH

11-GAC14WH

AIR DRYER RELAY

ABS RELAYS

FOG LIGHT RELAY & SWITCH

GROUNDADAPTER

(455)

11-GY10WH

11-GBC12WH

11-GAV18WH

AUXILIARY BUNK BLOWER RELAY& SLEEPER OPTIONS

CLOCK

GROUNDADAPTER

(454)

11-GB8WH

11-GD8WH

11-GI10WH

11-G8WH

GNDSTUD

25-G18WH PYROMETER CONTROL MODULE

(CH 8,PG 9)

(CH 9,PG 1)

(CH 9,PG 2,5)

(CH 11,PG 8)

(CH 12,PG 3 ; CH 10,PG 6-10)

(CH 8,PG 2CH 11,PG 11)

(CH 6,PG 7)

(LEFTDASH

PANEL)

(RIGHTDASH

PANEL)

11-GA

6WH

TOENGGND

(CH 3,PG 1-4)

GNDSTUD

RIGHT WINDOW SWITCH & RELAY(CH 8,PG 3)

G1

G4

G3

G2

11-GAD

18WH

SLEEPER OPTIONS(CH 10,PG 1-4)

11-GBD12WH

ABS TRAILER RELAY13-GCP

14WH

11-GAE18WH

(CH 8,PG 8)

RIGHT POWER MIRROR

(CH 9,PG 8)11-GZ18WH LEFT POWER MIRROR

(CH 8,PG 8)

11-GT18WH

62-GL18WH

62-GN18WH

62-GK18WH

62-GJ18WH

11-GR14WH

62-GQ18WH

62-GR18WH

DATA LINK 6-WAY(CH 4,PG 3,6,10,14)

CRUISE ON/OFF SWITCH(CH 4,PG 1,4,8)

CRUISE SET/RESUME SWITCH(CH 4,PG 1,4,8)

ENG BRAKE ON/OFF(CH 4,PG 2,5,9)

ENG BRAKE SELECT

INC/DEC IDLE DIAG(CH 4,PG 10,14)

DIAG ON/OFF(CH 4,PG 14)

(CH 4,PG 2,5,9)

CUMMINS & DET.

CUMMINS ONLY

DEIS. ONLY

38-G18WH DRIVER HEATED SEAT

(CH 8,PG 21)

38-GB18WH PASSENGER HEATED SEAT

(CH 8,PG 22)

Figure 14 Ground Adapter Composite

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15

2.8. GROUND STUD COMPOSITE, P. 8

CHANGE

RELEASE NO.

NAME


DATE

DATE REV


SHEET




DRAWN

PART NO.

CHK REFERENCE

GROUND STUD COMPOSITE

12FEB99 AE08-52502 8

5000/9100/9200/9400/9900U00EDL2

P50317A

CHAPTER 2

RIGHT TURN RELAY57-G

18WH

11-GB

8WH

11-G

8WH

(CH 11,PG 14)

75-G

10WHHEATER CONN #1

(CH 12,PG 2)

GND

STUD

(RIGHT

DASH

PANEL)

11-G

A6WH

TO

ENG

GND

(CH 3,PG 1-5)

11-GG

10WH

FUSE BLOCK

ASSY GND

56-G

18WHLEFT TURN RELAY

(CH 11,PG 14)

70-G

18WHSTOP LIGHT RELAY

(CH 11,PG 14)

58-G

18WHTRAILER TAIL RELAY

(CH 11,PG 2)

(CH 11,PG 2)

TRAILER MARKER RELAY

77-G

18WH AIR CONDITIONING RELAY(CH 12,PG 1)

13-GT

18WHHEATER CONTROL RELAY

58-GA

18WH

(CH 12,PG 2)

(CH 11,PG 9)

50-GB

18WH HEADLIGHT RELAY

75-GC

18WHMED SPEED RELAY

(CH 12,PG 2)

75-GB

18WHHIGH SPEED RELAY

(CH 12,PG 2)

13-GA

18WHIGNITION RELAY

(CH 2,PG 20)

57-GA

16WHRIGHT SIDE TURN LIGHT

(CH 11,PG 12)

11-GAB

16WHDOME,READING,CLEARANCE & ID LIGHTS

(CH 11,PG 3-6)

38-G

18WHAIR SUSPENSION RELEASE SWITCH

(CH 7,PG 1)

43-G

18WHPDL SWITCH

(CH 7,PG 6)

11-GC

10WHG4 GND ADAPTER

(CH 2,PG 7)

(CH 2,PG 7)

G1 GND ADAPTER11-GA

12WH

(CH 12,PG 2)

HVAC CONTROL75-GL

18WH

(CH 12,PG 2)

AIR DIST75-GM

18WH

(CH 12,PG 2)

RECIRC75-GK

18WH

(CH 9,PG 14)

MERITOR G XMSN14WH

Figure 15 Ground Stud Composite

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2.9. GROUND STUD COMPOSITE, P. 9

CHANGE

RELEASE NO.

NAME


DATE

DATE REV


SHEET




DRAWN

PART NO.

CHK REFERENCE

12FEB99

GROUND STUD COMPOSITE

AE08-52502 9

5000/9100/9200/9400/9900U00EDL2

P50317A

CHAPTER 2

GND

STUD(LEFT

DASH

PANEL)

11-GD

8WH

52-GE

12WHHEADLIGHTS

(CH 11,PG 9)

RIGHT SIDE CLUSTER(CH 6,PG 1,2,9)

11-GJ

18WH

11-GF

10WH

77-GS

18WHA/C CONTROL RELAY

(CH 12,PG 1)

82-GB

16WHWASH/WIPE INTERMITTENT SWITCH

(CH 8,PG 6)

82-GC

16WH WIPER MOTOR(CH 8,PG 6)

11-GM

18WHLEFT SIDE CLUSTER

(CH 6,PG 4)

11-GL

18WHSPEEDO/TACH MODULE

(CH 6,PG 3,5,6,8,10

CH 7,PG 2-5

CH 9,PG 10)

11-GQ

16WH

62-GC

18WHLEFT GAUGE CLUSTER PANEL LIGHTS

(CH 11,PG 11)

62-GD

18WHSPEEDO/TACH MODULE PANEL LIGHTS

(CH 11,PG 11,14)

62-GB

18WHRIGHT GAUGE CLUSTER PANEL LIGHTS

(CH 11,PG 11)

11-GY

10WH

TO AUX POWER

11-GN

10WH(CH 9,PG 9 ; CH 12,PG 4,5)

TO GROUND TERMINAL (B-PILLAR)

(CH 2,PG 7)

TO G2 GROUND ADAPTER

86-GK

14WH(CH 8,PG 11)

11-GI

10WH

G3 GND ADAPTER(CH 2,PG 7)

CIGAR LIGHTER(CH 8,PG 1)

LOW AIR SWITCH 1(CH 7,PG 4)

LOW AIR SWITCH 2(CH 7,PG 4)

LT SIDE TURN LGT(CH 11,PG 12)

11-GE

12WH

84-G

16WH

11-GK

16WH

40-GA

16WH

40-GB

16WH

56-GA

16WH

11-GS

16WH

11-GP

12WH

62-GW

18WH

62-GAR

16WH

66-G

14WH

62-GAS

18WH

CAB/TRAILER LGT SWITCH

PANEL LGT SWITCH

CAB/TRAILER LGT SWITCH

L4 PANEL GND ADAPTER(CH 2,PG 11)

(CH 2,PG 11 ; CH 11,PG 11)

(CH 11,PG 2)

(CH 11,PG 2)

PANEL LGT SWITCH(CH 2,PG 11; CH 11,PG 11)

DRL PARK BRAKE

SWITCH

44-GB

16WH

DRL MODULE

(CH 11,PG 7)

(CH 11,PG 7)

66-GA

14WH

Figure 16 Ground Stud Composite

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17

2.10. IGNITION, P. 10


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.


12FEB99

12V POWER DISTRIBUTION - IGNITION

AE08-52502 10

5000/9100/9200/9400/9900U00EDL2

P50317A

CHAPTER 2

2 SPEED AXLE SW WAS GOING B 55093F

TO CH 11, PG 10. ADDED 13EF & 13EG AT (495).

J KP 4MAR 02

B1 BATSTUD

I1IGNITIONADAPTER

(494)

IS

GND

OFF

I

S

OFF

I

AS

AIOFF

S

AI

OFF

S

B

A

14C10RD

15

12RD

F7-A25A

13

12PK

F4-C10A

13H12PK

F4-A10A

13B12PK

13V

16PK

TOBACK-UPLIGHTS

30

87 A

87

86

85

13A12PK

13AH

14PK

13Z

12PK

13AB

14PK

13W

14PK

13L

12PK

AIRDRYERRELA

Y

2SPEEDAXLESWITCH

PYROMETERFUSE

ABSIGNITIONRELAY

ETHERSTARTFUSE

EC

M

28C

18TN

28D

18TN

28A

18TN

28B

18TN

LEFTGAUGECLUSTER

LEFTGAUGECLUSTER

SPEEDO/TACHCLUSTER

RIGHTGAUGECLUSTER

IGNITIONRELAY

(462-R1)

14R10RD

14S12RD

F2-C30A

(CH4,PG3,6,14

CH6,PG4

CH7,PG2

CH11,PG4,15)

(CH6,PG1,2,9

CH7.PG1,4-8

CH9,PG2,5

CH11,PG7)

(CH4,PG3,6,10,14)

(CH6,PG3,5,6,8,10

CH7,PG2-5

CH9,PG10)

(CH6,PG11)

(CH9,PG2,6)

(CH6,PG7)

(CH4,PG3,7,10,15)

(CH9,PG10)

(CH9,PG1)

(CH 11,PG 1)

13F

12PK

(CH7,PG6)

PDLB

UZZER

13X

18PK

13U

12PK

(CH12,PG

2)

HVACCONTROLF

EE

D

14K

8RD

KEYSWITCH

(40)(CH 12,PG 2)

13-GA

18WH

IGN-DRLFE

ED

(CH

11,PG7)

TOHIGH SPEED

RELAY(462-R2)

13BN

12PK

13J

12PK

71

18OR

TO MOTORIZEDAND HEATED

MIRRORS

(CH 8,PG 8)

13P12PK1

3BL

14PK

93

14TN

I2IGNITIONADAPTER

(495)

AUXBUNKBLOWERRELAY

(CH12,PG3)

13AT

18PK

AUXBUNKBLOWERRELAY

(CH12,PG3)

13AT

18PK

ABSTRAILERRELAY

(CH9,PG8)

13CP

14PK

14FB

8RD

13Y

14PK

MERITORGXMSNFUSE

(CH9,PG14)

13BM

16PK

ENGINEFAN

(CH5,PG1)

DRIVERHEATEDSEAT

(CH8,PG21)

13EF

18PK

PASSENGERHEATEDSEAT

(CH8,PG22)

13EG

18PK

Figure 17 Ignition

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2.11. PANEL LIGHTS ADAPTER COMPOSITE, P. 11


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.


CHAPTER 2

12FEB99

12V POWER DISTRIBUTION - PANEL LIGHTS ADAPTER

COMPOSITE

P50317A

U00EDL2 5000/9100/9200/9400/9900

AE08-52502 11A 55093FADDED CIR 62X & 86-GKJKP 4MAR02

11-GF10WH

GNDSTUD

62-GC18WH

62-GB18WH

62-GD

18WH

L4PANEL

LTS GNDADAPTER

(506)

LEFT SIDE CLUSTER

RIGHT SIDE CLUSTER

SPEEDO/TACH MODULE

(CH 11,PG 11)

(CH 11,PG 11)

(CH 11,PG 11)

PANELLIGHT

SWITCH(425)

AC

B

D

F

L1PANEL

LTS FEEDADAPTER

(503)

(LEFTDASH

PANEL)

11-GD8WH

62-GAS18WH

62-GAR16WH

HEADLIGHT SWITCH

TRAILER LIGHTS SWITCH(CH 11,PG 9)

(CH 11,PG 2)

11-GK16WH

11-GT18WH CRUISE/DIAGNOSTIC/ENG

BRAKE SWITCHES

62-GAY18WH ETHER START SWITCH

(CH 6,PG 11)

11-GP

12WH

62-GW

18WH

11-GS

16WH

(CH 11,PG 11)

62B18DK BL

SPEEDO/TACH MODULE

62C18DK BL LEFT SIDE CLUSTER

WIPER SWITCH(CH 8,PG 6)

(CH 11,PG 11)

62D18DK BL

62AG

16DK BL

RIGHT SIDE CLUSTER(CH 11,PG 11)

62T16DK BL CIGAR LIGHTER LIGHT

(CH 11,PG 11)

62W

16DKBL

62W

16DKBL

62A

16DKBL

62

A

16DK

BL

62

16D

KBL

(CH 11,PG 11)

HEADLIGHT SWITCH

62AP16DK BL DOME LIGHT SWITCH

TRAILER LIGHTS SWITCH(CH 11,PG 2)

(CH 11,PG 9)

62AS16DK BL

62AR16DK BL

HEATER CONTROL PANEL LIGHT(CH 11,PG 11)

62P16DK BL

62S

16DKBL

62AQ16DK BL CLOCK

(CH 8,PG 3)

62AL16DK BL

(CH 11,PG 11)

(CH 11,PG 8)

RIGHT WINDOW SWITCH

FOG LIGHT SWITCH62AN

16DK BL

62M

16DKBL

(CH 4,PG 1,2,4-6,8-10,12-14)

62AV16DK BL

ETHER START SWITCH(CH 8,PG 9)

62AY16DK BL

62AW16DK BL

CRUISE/DIAGNOSTIC/ENGBRAKE SWITCHES

RT MOTO MIRRORS SW

L2PANEL

LTS FEEDADAPTER

(504)

62AE

16DKBL

62AB16DK BL GAUGE PANEL LIGHT

(CH 11,PG 11)

62-GAB18WH GAUGE PANEL LIGHT

(CH 11,PG 11)

62-GH18WH SPARE SWITCH N/FUSE

(CH 8,PG 14)

11-GAL18WH SPARE SWITCH W/FUSE

(CH 8,PG 14)

62H16DK BL SPARE SWITCH N/FUSE

(CH 8,PG 14)

62U16DK BL SPARE SWITCH W/FUSE

(CH 8,PG 14)

(CH 4,PG 1,2,4-6,8-10,12-14)

62BP16DK BL

BUNK CONTROL PNL SWITCH(CH 10,PG 3,8,9)

62M16DK BL

ENGINE FAN OVERRIDE SWITCH(CH 5,PG 3,4)

(CH 6,PG 11)

REFRIGERATOR SWITCH(CH 10,PG 6)

62X16DK BL

REFRIGERATOR SWITCH(CH 10,PG 6)

86-GK18WH

Figure 18 Panel Lights Adapter Composite

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19

3. 12 VOLT CHARGING & CRANKING SYSTEM (CHAPTER 3)

3.1. W/CAT AND CUMMINS ENGINES, P. 1


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.


26JUL01

CHARGING AND CRANKING (12V)

W/CAT AND CUMMINS ENGINES

AE08-54038 01

5000/9200/9400/9900U00CJB5

54719V

CHAPTER 3

S

M

B

+

17C

08PK

B

M

S

- -

BATTERIES

STARTERMAGNETICSWITCH

CRANKING

MOTORSOLENOID

2/O BK

11-GS02BK

FRAMEGROUND

ENGINEGROUND

11-GA06WH

CABJ4 GROUND

2-G04WH

4/0 BK

+- -

4/0 BK

(2) 12GA, BLFUSIBLE LINKS

06

BK

06BK

4/0 BK

06

BK

06BK

+- -

+- -

06

BK

06BK 0

1BK

FRAMEGROUND

4/ 0

BK

17B

16PK

(2)

17B

14PK

CRANKING MOTOR

FROM SENSORGROUND SPLICE

(CH 3,PG 2CH 5,PG 2CH 6,PG 4,9CH 12,PG 1)

11-GU12WH

B

G

B1BATTERY

STUD

STARTFEED

ADAPTER(509)

1402RD

204RD

1402RD

204RD

2-G

04WH

14A

02RD

14A

02RD

150AMEGAFUSE

ALTERNATOR

11-G12WH

TO ECMPOWERCONN

W/CAT(CH 4,PG 2)

14B

12RD

14A

12RD

TO ECMPOWERCONN

(CH 4,PG 2,7)

15A

15A

14D

12RD

14C

12RD

11-G

12WH

FROM ECMGROUND

W/ISX,ISM(CH 4,PG 7)

Figure 19 W/Cat and Cummins Engines

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3.2. W/OVERCRANK PROTECTION W/CAT AND CUMMINS ENGINES, P. 2


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.


26JUL01

12V CRANKING SYSTEM W/OVERCRANK PROTECTIONW/CAT AND CUMMINS

AE08-54038 02

5000/9200/9400/9900U00CJB5

54719V

CHAPTER 3

S

M

B

17C

8PK

B

M

S


CRANKINGMOTORSOLENOID

TO ALTERNATOR(CH 3,PG 1)

17D

18PK

17D

18PK

FL 12BL

FL

12BL

17-G18WH

17-G

18WH

11-GU

12WH

CRANKINGMOTOR

FOR REMAINDER OFCRANK MOTOR SOLENOIDAND CRANK MOTOR WIRINGSEE CHARGING & CRANKINGSECTION.

(275)17D18PK

17B

16PK

(2)

17B

14PK

STARTFEED

ADAPTER(509)

ENGINEGROUND

B1BATTERY

STUD

14A

02RD

14A

02RD

150AMEGAFUSE

1402RD

204RD

1402RD

204RD

Figure 20 W/Overcrank Protection W/Cat and Cummins Engines

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21

3.3. W/I6 HEUI ENGINE, P. 3


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.


54719V

CHARGING AND CRANKING (12V)W/I6 HEUI ENGINE

26JUL01 03

5000/9200/9400/9900U00CJB5

AE08-54038

CHAPTER 3

06BK

2

04RD

B

01BK

STARTFEED

ADAPTER(509)

+

CRANKING MOTOR

B

B1BATTERY

STUD

4/0 BK

06BK

FRAMEGROUND

BATTERIES

24RD

-

+

17B

16PK

14-FL

02RD

S

M

06BK

06BK

14A

02RD

150AMEGAFUSE

17C

08PK

-


G

4/0 BK

06BK

2

06BK

-

ALTERNATOR

+

17B

14PK

11-GL

4/0 BK

06BK

MAINGROUND

-

CRANKINGMOTORSOLENOID

11-GA06WH

+

14A

02RD

40A14B

10RD

11-G10WH

TO MODULEPOWER

14A10RD

(CH 4,PG 11)

Figure 21 W/I6 HEUI Engine

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3.4. W/OVERCRANK PROTECTION W/I6 HEUI, P. 4


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.


CHAPTER 3

26JUL01 04

5000/9200/9400/9900U00CJB5

54719V

12V CRANKING SYSTEM W/OVERCRANK PROTECTIONW/I6 HEUI

AE08-54038

(CH 3,PG 3)

2

CRANKING

17-G

M

18PK

B1BATTERY

STUD

B

150AMEGA

FUSE

FOR REMAINDER OFCRANK MOTOR SOLENOIDAND CRANK MOTOR WIRINGSEE CHARGING & CRANKINGSECTION.

TO ALTERNATOR

2

16PK

S17D

STARTFEED

ADAPTER(509)

02

RD

14

02

RD

04RD

STARTERMAGNETICSWITCH(4 TERM)

14A

275

18PK

14PK

18PK

17C

14A

17B

11-GU

02

RD

2

S

18WH

04RD

17D

CRANKING

17B

MOTORSOLENOID

MOTOR 17D

14WH

18WH

B

17-G

M

8PK

STARTER MOTORGROUND

Figure 22 W/Overcrank Protection W/I6 HEUI

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23

4. ENGINE SYSTEMS (CHAPTER 4)

4.1. CATERPILLAR C10, C12, C15, AND C16 CRUISE CONTROL, P. 1


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PARTNO.


26JUL01

CAT C10, C12, C15 & C16 - CRUISE CONTROL

AE08-54039 01

5000/9200/9400/9900U00CJB5

54719V

CHAPTER 4

99

16

VT

ECM (400)

97-GC

18VT

97AE18VT

CRUISESET/

RESUME(436)

97-GB

18VT

97AL

18VT

97AB

18VT

97AA

18VT

97AH

18VT

97AE

18VT

99

18VT 9

9A(8V)

18VT

97-GF18VT

CRUISEON/OFF(435)

(404)

99A(8V)18VT

9918VT

THROTTLEPOSITION

SENSOR

(PEDAL INRELEASED

POSITION)

CLUTCHSWITCH(PEDAL INRELEASED

POSITION)

BK

WH

RD

BRAKESWITCH(141) 18

BK

VEHICLE

SPEEDSENSOR(1099)

18BK

BA

66

97AE

16VT

J

59

97AH

16VT

R

22

97AL

16VT

F

45

97AB

16VT

I

35

97AA

16VT

K

44

99-GA

18VT

7

8

31

2

5

V

97-GA

16VT

97-GA

18VT

(294)

97-GH18VT

62-GK

18WH

62

K

16DKBL

62-GJ

18WH

11-GT

18WH

62AV

16DKBL

62J

16DKBL

PANELLTS FEEDADAPTER

(504)

G4 GROUNDADAPTER

(456)

32334

99A(8V)

16VT

97AK

16

VT

97AJ

16VT

97-G

16VT

FROM

ENGINEBRAKEON/OFFSWITCH

(CH 4,PG 2)

24-G18GY

(190)

25

346

8

7

4

5

6

1

11-GX

18WH

Figure 23 Caterpillar C10, C12, C15 and C16 Cruise Control

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4.2. CATERPILLAR C10, C12, C15 AND C16 ENGINE BRAKE, P. 2


NAME

DATE


circuitos_9200[1]

Documents