Diagramas Electricos 5500i_ 5600i_ 5900i_ 9200i_ 9400i and 9900i Chassis Built December 1_ 2005

SERVICE MANUAL

SERVICE MANUAL SECTION

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005to February 28, 2007 ELECTRICAL CIRCUIT DIAGRAMS

Model: 5500iStart Date: 12/01/2005 End Date: 02/28/2007






S08316

11/03/2006

S08316Copyright11/03/2006 International Truck and Engine Corporation

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 andAfter ELECTRICAL CIRCUIT DIAGRAMS

i

Table of Contents

1. INSTRUCTIONS AND CHARTS (CHAPTER 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.1. CIRCUIT IDENTIFICATION CHART, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2. CIRCUIT IDENTIFICATION CHART, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31.4. CIRCUIT DIAGRAM INSTRUCTIONS, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41.5. SCHEMATIC SYMBOLS, P. 5.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51.6. RELAY PINOUT, FUNCTION DATA AND SEALED RELAY, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61.7. LAMP BULB CHART, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2. 12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (CHAPTER 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82.1. START FEED, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82.2. ACCESSORY, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92.3. BATTERY, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.4. BATTERY, B2, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112.5. BATTERY, B2 (CONT.), P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.6. 3+1 BATTERY SYSTEM, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132.7. GROUND ADAPTER COMPOSITE, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142.8. GROUND STUD COMPOSITE, P. 8.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152.9. GROUND STUD COMPOSITE, P. 9.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162.10. IGNITION, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172.11. PANEL LIGHTS ADAPTER COMPOSITE, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3. 12 VOLT CHARGING AND CRANKING SYSTEM (CHAPTER 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193.1. W/CAT AND CUMMINS ENGINES, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193.2. W/OVERCRANK PROTECTION W/CAT AND CUMMINS ENGINES, P. 2. . . . . . . . . . . . . . . . . . . . . . . . .203.3. W/I6 HEUI ENGINE, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213.4. W/OVERCRANK PROTECTION W/I6 HEUI, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223.5. W/CAT AND CUMMINS ENGINES AND W/1GA CHARGING CIRCUIT, P. 5. . . . . . . . . . . . . . . . . . . . . .23

4. ENGINE SYSTEMS (CHAPTER 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244.1. CATERPILLAR C10, C11, C12, C13, C15, AND C16 CRUISE CONTROL, P. 1. . . . . . . . . . . . . . . . . . .244.2. CATERPILLAR C10, C11, C12, C13, C15, AND C16 ENGINE BRAKE, P. 2. . . . . . . . . . . . . . . . . . . . . .254.3. CATERPILLAR C10, C11, C12, C13, C15, AND C16 ENGINE CONTROLS, P. 3. . . . . . . . . . . . . . . . .264.4. CUMMINS ISM, ISX CRUISE CONTROL, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .274.5. CUMMINS ISM, ISX ENGINE BRAKE, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284.6. CUMMINS ISM , ISX ENGINE CONTROLS, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294.7. CUMMINS AHD AND ISM ENGINE CONTROLS, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304.8. I6 HEUI CRUISE CONTROL, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314.9. I6 HEUI ENGINE BRAKE, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .324.10. I6 HEUI ENGINE CONTROLS, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334.11. I6 HEUI MODULE POWER AND GROUND SYSTEM, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344.12. I6 HEUI ACCELERATOR, BAP, AMBIENT AIR TEMP SENSOR SYSTEM, P. 12. . . . . . . . . . . .354.13. I6 HEUI SURGE TANK AND EXHAUST BRAKE SOLENOID, P. 13. . . . . . . . . . . . . . . . . . . . . . . . . . .36

5. FANS (CHAPTER 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375.1. HORTON AND KYSOR ENGINE FAN WITH CAT C10, C11, C12, C13, C15 AND C16 W/ AND

N/ A/C, W/ AND N/ MANUAL FAN OVERRIDE SWITCH, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

S08316

ii 5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 andAfter ELECTRICAL CIRCUIT DIAGRAMS

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

5.3. HORTON AND KYSOR ENGINE FAN WITH I6 HEUI ENGINES W/SHUTTER, P. 3.. . . . . . . . . . . . .39

6. GAUGES AND SYSTEMS (CHAPTER 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406.1. 4X2 REAR AXLE OIL TEMPERATURE GAUGE, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406.2. 6X4 AXLE FORWARD-REAR AND REAR-REAR TEMPERATURE GAUGE, P. 2. . . . . . . . . . . . . . . .416.3. ENGINE OIL PRESSURE GAUGE, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426.4. ENGINE OIL TEMPERATURE GAUGE, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436.5. ENGINE WATER TEMPERATURE GAUGE, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446.6. FUEL LEVEL GAUGE, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .456.7. PYROMETER GAUGE, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466.8. SPEEDOMETER GAUGE TACHOMETER GAUGE, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .476.9. TRANSMISSION OIL TEMPERATURE GAUGE, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .486.10. VOLTMETER GAUGE, P. 10.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .496.11. ETHER START, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .506.12. MANIFOLD PRESSURE GAUGE, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

7. WARNING LIGHTS (CHAPTER 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .527.1. AIR SUSPENSION RELEASE WARNING LIGHT, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .527.2. ENGINE OIL PRESSURE WARNING LIGHT, P. 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .537.3. ENGINE WATER TEMPERATURE WARNING LIGHT, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547.4. LOW AIR PRESSURE WARNING LIGHT, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .557.5. LOW FUEL LEVEL WARNING LIGHT, P. 5.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .567.6. POWER DIVIDER LOCK (PDL) WARNING LIGHT AND BUZZER, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . .577.7. DIFFERENTIAL LOCK WARN LIGHT 4X2, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587.8. DIFFERENTIAL LOCK WARN LIGHT 6X4, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

8. CAB ACCESSORIES (CHAPTER 8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .608.1. CIGAR LIGHTER, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .608.2. CLOCK, P. 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618.3. ELECTRIC WINDOW RIGHT, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .628.4. ELECTRIC WINDOW RIGHT AND LEFT, P. 4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .638.5. DEFROSTER FAN(S), P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .648.6. ELECTRIC WINDSHIELD WIPERS WITH INTERMITTENT WIPE AND WASH, P. 6. . . . . . . . . . . . .658.7. HORN, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668.8. MIRROR LIGHTS AND HEATED MIRRORS, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .678.9. RIGHT MOTORIZED MIRROR, P. 9.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .688.10. DUAL AXIS MOTORIZED MIRRORS, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .698.11. POWER SOURCE (CB), P. 11.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .708.12. RADIO-CB ACCOMMODATION PACKAGE, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .718.13. RADIO-CAB, SPEAKERS, P. 13.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .728.14. OWNER/OPERATOR SPARE SWITCH, P. 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .738.15. ELECTRIC LOCK RIGHT AND LEFT, P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .748.16. INTERVISION DISPLAY, P. 16.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .758.17. EATON VORAD COLLISION AVOIDANCE, P. 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .768.18. EATON VORAD COLLISION AVOIDANCE, P. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .778.19. TEMPERATURE/COMPASS DISPLAY, P. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .788.20. ROAD RELAY IV, P. 20.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .798.21. HEATED SEAT DRIVER, P. 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .808.22. HEATED SEAT PASSENGER, P. 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

9. CHASSIS ACCESSORIES (CHAPTER 9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

S08316


iii

9.1. AIR DRYER, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .829.2. ABS/ATC (BENDIX), P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .839.3. ABS/ATC (BENDIX) (CONT.), P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .849.4. ABS/ATC (BENDIX) (CONT.), P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .859.5. ABS/ATC (WABCO), P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .869.6. ABS/ATC (WABCO) (CONT.), P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .879.7. ABS/ATC (WABCO) (CONT.), P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .889.8. TRAILER CONNECTION BACK OF SLEEPER MOUNTED W/TRACTOR ABS, P. 8. . . . . . . . .899.9. TRAILER CONNECTION W/FOUR WHEEL TRAILER FRAME MOUNTED, P. 9. . . . . . . . . . . . . .909.10. TWO SPEED AXLE WIRING, P. 10.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .919.11. TRUCK BODY CONNECTION, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .929.12. TRAILER CONNECTION N/SLEEPER BACK OF CAB MOUNTED, P. 12. . . . . . . . . . . . . . . . . . . .939.13. TRAILER CONNECTION W/FOUR WHEEL TRAILER FRAME MOUNTED W/5000, P.

13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .949.14. MERITOR G SERIES TRANSMISSION, P. 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .959.15. EATON AUTOSHIFT TRANSMISSION CAB WIRING, P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .969.16. EATON AUTOSHIFT TRANSMISSION TRANSMISSION WIRING, P. 16. . . . . . . . . . . . . . . . . . . . .979.17. EATON LIGHTNING TRANSMISSION TRANSMISSION WIRING, P. 17. . . . . . . . . . . . . . . . . . . . . .989.18. EATON ULTRASHIFT/DM2 TRANSMISSION WIRING, P. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .999.19. EATON ULTRASHIFT/DM2 TRANSMISSION WIRING (CONT.), P. 19. . . . . . . . . . . . . . . . . . . . . . .1009.20. EATON ULTRASHIFT/DM2 AND COBRA SHIFTER, P. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1019.21. ABS6/ATC BENDIX AIR, P. 21.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1029.22. ABS6/ATC BENDIX AIR, P. 22.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1039.23. ABS6/ATC BENDIX AIR, P. 23.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1049.24. ABS6 ADVANCE ECU, W/BENDIX RSP, P. 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1059.25. EATON AUTOSHIFT 3, P. 25.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1069.26. EATON AUTOSHIFT 3, P. 26.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1079.27. EATON AUTOSHIFT 3 W/PUSH BUTTON SHIFTER, P. 27.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1089.28. EATON AUTOSHIFT 3 W/COBRA SHIFTER, P. 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

10. SLEEPER LIGHTING AND ACCESSORIES (CHAPTER 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11010.1. AUXILIARY CIRCULATION FAN (LOW ROOF), P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11010.2. AUXILIARY CIRCULATION FAN (HIGH ROOF), P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11110.3. AUXILIARY CIRCULATION FAN (SKYRISE), P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11210.4. BUNK FLUORESCENT AND READING LIGHTS, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11310.5. BUNK SPEAKERS, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11410.6. LUGGAGE COMPARTMENT LIGHTS, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11510.7. POWER SOURCE, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11610.8. REFRIGERATOR WIRING, P. 8.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11710.9. TV/VCR WIRING, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11810.10. OVERHEAD CABINETS, ACCENT LIGHTS, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11910.11. OPTIONAL SLEEPER MOUNTED RADIO CONTROLS, P. 11.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12010.12. SHORE POWER WIRING (08WET) NOT WITH INVERTER, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .12110.13. SHORE POWER WIRING (08WET) WITH INVERTER (08WES), P. 13. . . . . . . . . . . . . . . . . . . . . . . .122

11. LIGHT SYSTEMS (CHAPTER 11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12311.1. BACK-UP LIGHTS, P. 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12311.2. CAB AND TRAILER LIGHTS SWITCH AND RELAYS WIRING, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .12411.3. CAB CLEARANCE AND IDENTIFICATION LIGHTS, P. 3.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12511.4. WORK LIGHT N/SLEEPER, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12611.5. CAB DOME, READING AND COURTESY LIGHTS N/SKYRISE, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . .12711.6. CAB DOME, READING AND COURTESY LIGHTS W/SKYRISE, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . .12811.7. DAYTIME RUNNING LIGHTS (DRL) USA, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

S08316

iv 5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 andAfter ELECTRICAL CIRCUIT DIAGRAMS

11.8. FOGLIGHTS CAB/FRONT END EFFECTS, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13011.9. HEADLIGHT SWITCH AND DIMMER SWITCH WIRING, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13111.10. HEADLIGHTS, P. 10.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13211.11. PANEL LIGHTS, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13311.12. PARK/TURN/SIDE MARKER LIGHTS WITH DRL, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13411.13. SPOTLIGHT, P. 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13511.14. STOP, TAIL, TURN AND HAZARD SIGNAL LIGHTS WITH FLASHER, P. 14. . . . . . . . . . . . . . . .13611.15. WORK LIGHT W/SLEEPER, P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

12. HEATER AND AIR CONDITIONER (CHAPTER 12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13812.1. AIR CONDITIONER CAB, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13812.2. HEATER CAB, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13912.3. HEATER BUNK AUXILIARY BLOWER, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14012.4. HEATER BUNK W/STANDARD TEMPERATURE CONTROL, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . .14112.5. HEATER BUNK W/THERMOSTAT TEMPERATURE CONTROL, P. 5. . . . . . . . . . . . . . . . . . . . . . .14212.6. LOWERED HEATER BOX, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14312.7. AUX HEATER, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14412.8. APU SYSTEM: DISTRIBUTION BOX, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14512.9. APU SYSTEM: DISTRIBUTION BOX, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14612.10. APU SYSTEM, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

13. CONNECTOR COMPOSITES (CHAPTER 13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14813.1. LEFT GAUGE CLUSTER (CONNECTOR 423), P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14813.2. LEFT GAUGE CLUSTER (CONNECTOR 424), P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14913.3. LEFT GAUGE CLUSTER GAUGE INFORMATION, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15013.4. LEFT GAUGE CLUSTER TERMINAL INFORMATION, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15113.5. LEFT GAUGE CLUSTER TERMINAL INFORMATION, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15213.6. RIGHT GAUGE CLUSTER (CONNECTOR 420), P. 6.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15313.7. RIGHT GAUGE CLUSTER GAUGE INFORMATION, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15413.8. RIGHT GAUGE CLUSTER TERMINAL INFORMATION, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15513.9. SPEEDOMETER/TACHOMETER MODULE TERMINAL INFORMATION, P. 9. . . . . . . . . . . . .15613.10. SPEEDOMETER/TACHOMETER MODULE TERMINAL INFORMATION, P. 10.. . . . . . . . . .15713.11. CONNECTOR COMPOSITES (1), (2), (3), P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15813.12. CONNECTOR COMPOSITES (4), (9), (11), (15), (20), (27), P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15913.13. CONNECTOR COMPOSITES (40), (41), (42), (43), (48), (65), P. 13.. . . . . . . . . . . . . . . . . . . . . . . . . . .16013.14. CONNECTOR COMPOSITES (66), (71), (72), (76), (77), (94), P. 14.. . . . . . . . . . . . . . . . . . . . . . . . . . .16113.15. CONNECTOR COMPOSITES (100), (100A), (105), (111), (112), (113), (115), P. 15. . . . . . . . . .16213.16. CONNECTOR COMPOSITES (116), (117), (118), (127A), (128), P. 16. . . . . . . . . . . . . . . . . . . . . . . . .16313.17. CONNECTOR COMPOSITES (137), (141), (142), (143), (144), (145), (146), (147), (148), P.

17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16413.18. CONNECTOR COMPOSITES (149), (150), (151), (152), (161), (162), P. 18. . . . . . . . . . . . . . . . . . .16513.19. CONNECTOR COMPOSITES (165), (166), (167), (170), (171), (180), P. 19. . . . . . . . . . . . . . . . . . .16613.20. CONNECTOR COMPOSITE (190), P. 20.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16713.21. CONNECTOR COMPOSITES (196), (199), (200), (201), (209), (211), (214), (216), P. 21. . . .16813.22. CONNECTOR COMPOSITES (217), (218), (220), (221), P. 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16913.23. CONNECTOR COMPOSITES (227), (228), (229), P. 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17013.24. CONNECTOR COMPOSITES (230), (231), (236), (241), P. 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17113.25. CONNECTOR COMPOSITES (243), (244), (249), (250), (251), P. 25. . . . . . . . . . . . . . . . . . . . . . . . . .17213.26. CONNECTOR COMPOSITES (252), (260), (267), P. 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17313.27. CONNECTOR COMPOSITES (268), (273), (275), (278), (282), (289), P. 27. . . . . . . . . . . . . . . . . . .17413.28. CONNECTOR COMPOSITES (290), (291), (292), (293), (294), (296), P. 28. . . . . . . . . . . . . . . . . . .17513.29. CONNECTOR COMPOSITES (298), (299), (311), (312), (313), (315, 316), P. 29. . . . . . . . . . . . .17613.30. CONNECTOR COMPOSITES (316), (318), (320), (321), (322), (323), P. 30. . . . . . . . . . . . . . . . . . .177

S08316


v

13.31. CONNECTOR COMPOSITES (325), (345), (350), (351), (352), (353), (354), P. 31. . . . . . . . . . .17813.32. CONNECTOR COMPOSITES (355), (360), (363), (379), (393), (396), P. 32. . . . . . . . . . . . . . . . . . .17913.33. CONNECTOR COMPOSITES (400), (402), (403), (404), (406), (409), P. 33. . . . . . . . . . . . . . . . . . .18013.34. CONNECTOR COMPOSITES (417), (420), (421), P. 34.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18113.35. CONNECTOR COMPOSITES (422), (423), (424), (425), (426), P. 35. . . . . . . . . . . . . . . . . . . . . . . . . .18213.36. CONNECTOR COMPOSITES (427), (428), (429), (430), P. 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18313.37. CONNECTOR COMPOSITES (433), (434), (435), P. 37.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18413.38. CONNECTOR COMPOSITES (436), (437), (440), (441), (442), P. 38. . . . . . . . . . . . . . . . . . . . . . . . . .18513.39. CONNECTOR COMPOSITES (453), (454), P. 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18613.40. CONNECTOR COMPOSITES (455), (456), (460), (462), P. 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18713.41. CONNECTOR COMPOSITES (462), (463), P. 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18813.42. CONNECTOR COMPOSITES (463), P. 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18913.43. CONNECTOR COMPOSITES (464), P. 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19013.44. CONNECTOR COMPOSITES (464), (465), (466), (468), (470), (1000), P. 44. . . . . . . . . . . . . . . . .19113.45. CONNECTOR COMPOSITES (474), (480), (481), (482), (483), (489), P. 45. . . . . . . . . . . . . . . . . . .19213.46. CONNECTOR COMPOSITES (491), (492), (494), (495), (497), (498), (499), (501), P. 46. . .19313.47. CONNECTOR COMPOSITES (502), (503), (504), (506), P. 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19413.48. CONNECTOR COMPOSITES (509), (511), (512), (513), (514), (515), P. 48. . . . . . . . . . . . . . . . . . .19513.49. CONNECTOR COMPOSITES (517), (520), (521), (522), (523), (524), (525), (526), P. 49. . .19613.50. CONNECTOR COMPOSITES (528), (529), (530), (531), (550), (560), (562), (574), P. 50. . .19713.51. CONNECTOR COMPOSITES (575), (576), (577), (578), (579), (582), P. 51. . . . . . . . . . . . . . . . . . .19813.52. CONNECTOR COMPOSITES (584), (585), (587), P. 52.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19913.53. CONNECTOR COMPOSITES (592), (592F), (593), (594), (600), P. 53. . . . . . . . . . . . . . . . . . . . . . . . .20013.54. CONNECTOR COMPOSITES (603), (604), (605), (606), (607), (610), (611), P. 54. . . . . . . . . . .20113.55. CONNECTOR COMPOSITES (612), (613), (640), (642), (643), (659), P. 55. . . . . . . . . . . . . . . . . . .20213.56. CONNECTOR COMPOSITES (662), (675), (676), (690), P. 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20313.57. CONNECTOR COMPOSITES (720), (753), (755), (766), (767), (768), P. 57. . . . . . . . . . . . . . . . . . .20413.58. CONNECTOR COMPOSITES (769), (770), (771), (774), (775), (776), (777), (778), (789), P.

58.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20513.59. CONNECTOR COMPOSITES (791), (823), (851), (854), (884), (885), (887), P. 59. . . . . . . . . . .20613.60. CONNECTOR COMPOSITES (904), (905), (906), P. 60.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20713.61. CONNECTOR COMPOSITES (907), (909), (912), (913), (914), (915), (916), (918), P. 61. . .20813.62. CONNECTOR COMPOSITES (922), (923), (925), P. 62.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20913.63. CONNECTOR COMPOSITES (926), (930), (935), (936), (937), P. 63. . . . . . . . . . . . . . . . . . . . . . . . . .21013.64. CONNECTOR COMPOSITES (938), (939), (940), (941), (942), P. 64. . . . . . . . . . . . . . . . . . . . . . . . . .21113.65. CONNECTOR COMPOSITES (955), (956), (962), (963), (992), (993), (994), P. 65. . . . . . . . . . .21213.66. CONNECTOR COMPOSITES (995999), (1000), (1033), (1034), P. 66. . . . . . . . . . . . . . . . . . . . . . . .21313.67. CONNECTOR COMPOSITES (1039), (1040), (1041), (1042), (1043), (1044), P. 67. . . . . . . . . .21413.68. CONNECTOR COMPOSITES (1045), (1046), (1047), (1048), P. 68. . . . . . . . . . . . . . . . . . . . . . . . . . . .21513.69. CONNECTOR COMPOSITES (1049), (1050), (1051), P. 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21613.70. CONNECTOR COMPOSITES (1053), (1054), (1056), (1057), P. 70. . . . . . . . . . . . . . . . . . . . . . . . . . . .21713.71. CONNECTOR COMPOSITES (1058), (1059), (1060), (1084), (1085), (1086), (1088), (1090F),

P. 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21813.72. CONNECTOR COMPOSITES (1090M), (1091), (1093), (1094), (1095), P. 72. . . . . . . . . . . . . . . . .21913.73. CONNECTOR COMPOSITES (1097), (1098), (1099), (1108), P. 73. . . . . . . . . . . . . . . . . . . . . . . . . . . .22013.74. CONNECTOR COMPOSITES (1110), (1112), (1113), (1125), (1126), P. 74. . . . . . . . . . . . . . . . . . . .22113.75. CONNECTOR COMPOSITES (1127), (1128), (1130), (1135), P. 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . .22213.76. CONNECTOR COMPOSITES (1137), (1138), (1139), (1140), (1141), P. 76. . . . . . . . . . . . . . . . . . . .22313.77. CONNECTOR COMPOSITES (1155), (1156), (1157), (1158), (1159), (1170), P. 77. . . . . . . . . . .22413.78. CONNECTOR COMPOSITES (1171), (1188), (1189), AND JUNCTION POINTS J7 AND J4, P.

78.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22513.79. CONNECTOR COMPOSITES (1190), (1193), (1194), (1195), (1223), (1224), (1225), P.

79.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226

S08316

vi 5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 andAfter ELECTRICAL CIRCUIT DIAGRAMS

13.80. CONNECTOR COMPOSITES (1227), (1229), (1239A, B, C), (1239), (1240), P. 80. . . . . . . . . .22713.81. CONNECTOR COMPOSITES (1241), (1243), (1244), (1258), (1260), (1261), P. 81. . . . . . . . . .22813.82. CONNECTOR COMPOSITES (1262), (1263), (1264), (1265), (1279), P. 82. . . . . . . . . . . . . . . . . . .22913.83. LEFT BLANK INTENTIONALLY, P. 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23013.84. CONNECTOR COMPOSITE (1285), P. 84.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23113.85. CONNECTOR COMPOSITES (1286), (1287), (1288), (1289), (1290), P. 85. . . . . . . . . . . . . . . . . . .23213.86. CONNECTOR COMPOSITES (1304), (1305), (1306), (1307), (1308), (1309M), P. 86. . . . . . . .23313.87. CONNECTOR COMPOSITES (1310), (1311), (1312), (1313), (1315), (1316OL), (1316PL), P.

87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23413.88. CONNECTOR COMPOSITES (1321), (1322), (1323), (1324), (1327), (1328), P. 88. . . . . . . . . .23513.89. CONNECTOR COMPOSITES (1331), (1332), P. 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23613.90. CONNECTOR COMPOSITES (1348), (1349), P. 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23713.91. CONNECTOR COMPOSITES (1360), (1361), (5710L), P. 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238

14. POWER DISTRIBUTION LAYOUT (CHAPTER 14). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23914.1. POWER DISTRIBUTION CENTER, FUSE AND CIRCUIT BREAKER LOCATION, P. 1. . . . . .23914.2. FUSE AND CIRCUIT BREAKER LOCATION (CONT.), P. 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24014.3. RELAY LOCATION, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24114.4. PRO SLEEPER FUSE INDEX, P. 4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242

S08316


1

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

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.

ELECTRICAL CIRCUIT DIAGRAM

CHANGE

SHEET

DRAWN

PART NO.

DATE REFERENCEREVCHK

P52600M

NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR

29JUL98 01

INSTRUCTIONS AND CHARTS FOR ALL MODELSRROEPKE

AE08-52011

CHAPTER 1

ADDED DESC AT 38 & 41. A 55093FJKP 4MAR02

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

CIRCUITNUMBER

DESCRIPTION - COLOR

GENERATOR - CHARGE - RED

GROUND - WHITE

BATTERY FEED - 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 OIL TEMPERATURE - TAN

TRANSMISSION OIL TEMPERATURE - TAN

AXLE OIL TEMPERATURE - TAN

WATER LEVEL - TAN

ENGINE OIL PRESSURE - 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

COURTESY AND DOME LIGHTS - DARK BLUE

AUXILIARY LIGHTS - YELLOW

5TH WHEEL/WORK LIGHT - ORANGE

DAYTIME RUNNING LIGHTS - YELLOW

TAIL LIGHTS - BROWN

STOP LIGHTS - ORANGE

BACK-UP LIGHTS - ORANGE

CIRCUITNUMBER

DESCRIPTION - 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

DIFFERENTIAL LOCK - 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 OIL LEVEL - TAN

PARK BRAKE WARNING - GRAY

ANTI-THEFT WARNING - LIGHT GREEN

POWER TAKE-OFF WARNING - GRAY

AIR SUSPENSION - GRAY

LICENSE PLATE LIGHT - BROWN

OUTSIDE AIR TEMP/COMPASS - TAN

HEATED SEAT - LIGHT GREEN

Figure 1 Circuit Identification Chart, page 1

S08316

2 5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 andAfter ELECTRICAL CIRCUIT DIAGRAMS

1.2. CIRCUIT IDENTIFICATION CHART, P. 2


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


P52600M 29JUL98 02

INSTRUCTIONS AND CHARTS FOR ALL MODELSRROEPKEGSC2 ADDED CIR 73 DESC

AE08-52011

CHAPTER 1

A P53583SJPM 10DEC01

ADDED SEAT BELTS. B 55093FJKP 4MAR02

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 COLORS FOR 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

S08316


3

1.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3

Figure 3 Circuit Diagram Instructions, page 3

S08316


1.4. CIRCUIT DIAGRAM INSTRUCTIONS, P. 4

Figure 4 Circuit Diagram Instructions, page 4

S08316


5

1.5. SCHEMATIC SYMBOLS, P. 5

Figure 5 Schematic Symbols

S08316


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

Figure 6 Relay Pinout, Function Data and Sealed Relay

S08316


7

1.7. LAMP BULB CHART, P. 7


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


RROEPKE

LAMP BULB CHART

29JUL98 07

INSTRUCTIONS AND CHARTS FOR ALL MODELS

P52600M AE08-52011

CHAPTER 1

A 55093FADDED & EDITED SLPR ITEMS JKP 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 BEAM............................... 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

S08316


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

Figure 8 Start Feed

S08316


9

2.2. ACCESSORY, P. 2

Figure 9 Accessory

S08316


2.3. BATTERY, P. 3

Figure 10 Battery, B1

S08316


11

2.4. BATTERY, B2, P. 4


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


12V POWER DISTRIBUTION - BATTERY

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 10ATO A/C CONTROL RELAY

14Z10RD

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 20ATO 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)

14M10RD XXX

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

14A

H10R

D

8414LT GN TO CAB CIGAR LIGHTER

EXTRA FUSES PROVIDEDFOR OWNER/OPERATORCONNECTION

**

**

**

(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 CENTERFOR ACTUAL LOCATION.

*

(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

14W6RD

Figure 11 Battery, B2

S08316


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


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


12FEB99

12V POWER DISTRIBUTION - BATTERY

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.

JKP 4MAR02

FUSE LOCATIONS VARY -CHECK INSIDE POWERDISTRIBUTION CENTERFOR ACTUAL LOCATION.

*

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 20A14AP14RD

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.)

S08316


13

2.6. 3+1 BATTERY SYSTEM, P. 6

Figure 13 3+1 Battery System

S08316


2.7. GROUND ADAPTER COMPOSITE, P. 7


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


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 AN INTERNALLY BUSSED CONNECTOR USED TO CONNECT & DISTRIBUTE GROUND 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 2 CH 11,PG 11)

(CH 6,PG 7)

(LEFTDASH

PANEL)

(RIGHTDASH

PANEL)

11-G

A6W

H

TO ENGGND

(CH 3,PG 1-4)

GNDSTUD

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

G1

G4

G3

G2

11-GAD18WH

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

S08316


15

2.8. GROUND STUD COMPOSITE, P. 8

Figure 15 Ground Stud Composite

S08316


2.9. GROUND STUD COMPOSITE, P. 9

Figure 16 Ground Stud Composite

S08316


17

2.10. IGNITION, P. 10

Figure 17 Ignition

S08316


2.11. PANEL LIGHTS ADAPTER COMPOSITE, P. 11


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


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-GD18WH

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-G

P12W

H

62-G

W18W

H

11-G

S16W

H

(CH 11,PG 11)

62B18DK BL

SPEEDO/TACH MODULE62C

18DK BL LEFT SIDE CLUSTER

WIPER SWITCH(CH 8,PG 6)

(CH 11,PG 11)

62D18DK BL

62AG16DK BL

RIGHT SIDE CLUSTER(CH 11,PG 11)

62T16DK BL CIGAR LIGHTER LIGHT

(CH 11,PG 11)

62

W16

DK

BL

62W

16D

K B

L

62A

16D

K B

L62

A1

6D

K B

L

62

16D

K B

L

(CH 11,PG 11)

HEADLIGHT SWITCH62AP

16DK 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

16D

K B

L

62AQ16DK BL CLOCK

(CH 8,PG 3)

62AL16DK BL

(CH 11,PG 11)

(CH 11,PG 8)

RIGHT WINDOW SWITCH

FOG LIGHT SWITCH62AN16DK BL

62M

16

DK

BL

(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)

62A

E16D

K B

L

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

S08316


19

3. 12 VOLT CHARGING AND CRANKING SYSTEM (CHAPTER 3)3.1. W/CAT AND CUMMINS ENGINES, P. 1


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


26JUL01

CHARGING AND CRANKING (12V)W/CAT AND CUMMINS ENGINES

AE08-54038 01

5000/9200/9400/9900U00CJB5

54719V

CHAPTER 3

S

M

B

+

17

C 0

8PK

B

M

S

- -

BATTERIES

STARTERMAGNETICSWITCH

CRANKINGMOTORSOLENOID

2/O BK

11-GS02BK

FRAMEGROUND

ENGINEGROUND

11-GA06WH

CABJ4 GROUND

2-G04WH

4/0 BK

+- -

4/0 BK

(2) 12GA, BLFUSIBLE LINKS

06B

K

06B

K

4/0 BK

06B

K

06B

K

+- -

+- -

06B

K

06B

K 01B

K

FRAMEGROUND

4/0

BK

17B

16

PK

(2)

17B

14P

K

CRANKING MOTOR

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

11-GU12WH

B

G

B1BATTERY

STUD

STARTFEED

ADAPTER(509)

1402RD

204RD

1402RD

204RD

2-G

04W

H

14A

02R

D14A

02R

D

150AMEGAFUSE

ALTERNATOR

11-G12WH

TO ECMPOWERCONN

W/CAT(CH 4,PG 2)

14B

12

RD

14

A1

2R

D

TO ECMPOWERCONN

(CH 4,PG 2,7)

15A

15A

14

D1

2R

D

14

C12

RD

11-G12WH

FROM ECMGROUNDW/ISX,ISM(CH 4,PG 7)

Figure 19 W/Cat and Cummins Engines

S08316


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


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


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



TO ALTERNATOR(CH 3,PG 1)

17

D1

8P

K

17

D1

8P

K

FL

12B

L

FL

12B

L

17-G18WH

17-G

18W

H11-G

U1

2W

H

CRANKINGMOTOR

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

(275) 17D 18PK

17B

16

PK

(2)

17B

14P

K

STARTFEED

ADAPTER(509)

ENGINEGROUND

B1BATTERY

STUD

14

A02R

D14A

02R

D

150AMEGAFUSE

1402RD

204RD

1402RD

204RD

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

S08316


21

3.3. W/I6 HEUI ENGINE, P. 3


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


54719V

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

26JUL01 03

5000/9200/9400/9900U00CJB5

AE08-54038

CHAPTER 3

06B

K

204R

D

B

01

BK

STARTFEED

ADAPTER(509)

+

CRANKING MOTOR

B

B1BATTERY

STUD

4/0 BK

06B

K

FRAMEGROUND

BATTERIES

24RD

-

+

17

B16P

K

14-F

L02R

D

S

M

06B

K

06B

K

14A

02R

D

150AMEGAFUSE

17

C08P

K

-


G

4/0 BK

06B

K

2

06

BK

-

ALTERNATOR

+1

7B

14P

K

11-G

L

4/0 BK

06B

K

MAINGROUND

-


11-GA06WH

+

14

A02R

D

40A14B

10RD

11-G10WH

TO MODULEPOWER

14A10RD

(CH 4,PG 11)

Figure 21 W/I6 HEUI Engine

S08316


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


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


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

18

PK

B1BATTERY

STUD

B

150AMEGAFUSE

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

TO ALTERNATOR

2

16

PK

S 17

D

STARTFEED

ADAPTER(509)

02R

D

14

02R

D

04RD

STARTERMAGNETICSWITCH(4 TERM)

14

A

275

18

PK

14P

K

18PK

17

C14A

17B

11-G

U

02R

D

2

S

18

WH

04RD

17

D

CRANKING

17B

MOTORSOLENOID

MOTOR 17D

14W

H

18WH

B

17-G

M

8PK

STARTER MOTORGROUND

Figure 22 W/Overcrank Protection W/I6 HEUI

S08316


23

3.5. W/CAT AND CUMMINS ENGINES AND W/1GA CHARGING CIRCUIT, P. 5

NAME




DATE

REFERENCE

RELEASE NO.

CHANGE

SHEET


DRAWN

PART NO.

DATE


REVCHK

20OCT05

CHARGING AND CRANKING (12V)W/CAT AND CUMMINS ENGINESAND W/1GA CHARGING CIRCUIT

AE08-54038 05

5000/9200/9400/9900U00DLK8

59843F

CHAPTER 3

S

M

B

+

17

C 0

8PK

B

M

S

- -

BATTERIES



2/O BK

11-GS02BK

FRAMEGROUND

ENGINEGROUND

11-GA06WH

CABJ4 GROUND

2-G01WH

4/0 BK

+- -

4/0 BK

(3) 10GA, RUSTFUSIBLE LINKS

06B

K

06B

K

4/0 BK

06B

K

06B

K

+- -

+- -

06B

K

06B

K 01B

K

FRAMEGROUND

4/0

BK

17B

16

PK

(2)

17B

14P

K

CRANKING MOTOR

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

11-GU12WH

B

G

B1BATTERY

STUD

STARTFEED

ADAPTER(509)

1402RD

201RD

1402RD

201RD

2-G

01W

H

14A

02R

D14A

02R

D

150AMEGAFUSE

ALTERNATOR

11-G12WH

TO ECMPOWERCONN

W/CAT(CH 4,PG 2)

14B

12

RD

14

A1

2R

D

TO ECMPOWERCONN

(CH 4,PG 2,7)

15A

15A

14

D1

2R

D

14

C12

RD

11-G12WH

FROM ECMGROUNDW/ISX,ISM(CH 4,PG 7)

(2) 10GA, RUSTFUSIBLE LINKS

Figure 23 W/Cat and Cummins Engines and W/1GA Charging Circuit

S08316


4. ENGINE SYSTEMS (CHAPTER 4)4.1. CATERPILLAR C10, C11, C12, C13, C15, AND C16 CRUISE CONTROL, P. 1

Figure 24 Caterpillar C10, C11, C12, C13, C15, and C16 Cruise Control

S08316


25

4.2. CATERPILLAR C10, C11, C12, C13, C15, AND C16 ENGINE BRAKE, P. 2

Figure 25 Caterpillar C10, C11, C12, C13, C15, and C16 Engine Brake

S08316


4.3. CATERPILLAR C10, C11, C12, C13, C15, AND C16 ENGINE CONTROLS, P. 3

Figure 26 Caterpillar C10, C11, C12, C13, C15, and C16 Engine Controls

S08316


27

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


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


CUMMINS ISM, ISX - CRUISE CONTROL

27JUL01 AE08-54039 04

5000/9200/9400/9900U00CJB5

54719V

CHAPTER 4

97-GB18VT

97-GC18VT

97-GH18VT

ECMCONN

(1086)

R

97A

H18V

T

15

KJ I

97A

E18V

T

CRUISEON/OFFSWITCH(435)

97

AA

18

VT

97A

B18V

T

97A

E1

8V

T

97A

A1

8V

T

97A

B18V

T

16 24 25 36 27

97A

J16V

T

97A

K1

6V

T

97-G

B18

VT

VEHICLESPEED

SENSOR(1099)

CRUISESET/

RESUMESWITCH(436)

DASHCONN

(190)

7

831

2

62J16DK BL

62K

16D

K B

L

62-G

J18W

H

62

-GK

18W

H11-G

T18W

H62A

V16D

K B

L

97A

H18V

T

CLUTCHSWITCH

W/PEDALRELEASED

(294)

18B

K18B

K

(294)

(294)

PANELLTS FEEDADAPTER

(504)

G4 GROUNDADAPTER

(456)

(CH 4,PG 6)

TOSPLICE

B

A

2 5

3 4 68

7

4

5

6

111

-GX

18W

H

A B

Figure 27 Cummins ISM, ISX Cruise Control

S08316


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


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


CUMMINS ISM, ISX - ENGINE BRAKE

U00CJB5

27JUL01

CHAPTER 4

54719V AE08-54039 05

5000/9200/9400/9900

ENGINEBRAKE

ON/OFFSWITCH(434)

TOSPLICE

24-G

18G

Y

2 5

1 3 4 68

7

G4 GROUNDADAPTER

(456)

62-G

L18W

H

62-GN18WH

62N16DK BL

62A

V1

6D

K B

L62L

16D

K B

L

(190)

87

MQ

24A

E18G

Y24A

E18G

Y


(504)

ENGINEBRAKE

SELECTOR2-1-3

SWITCH(433)

(CH 4,PG 6)

24AD18GY

24A

P18G

Y24A

P18G

Y

ECMCONN

(1086)

11-GT18WH

5 2

4 6 18

7

3

FRT & REARSOLENOID

98S

HD

20

98G

N(-

)20

GN

98G

N(-

)20G

N

J1939 TERMRESISTOR

(1098)

98Y

L(+

)20

YL

BC A

47

98Y

L(+

)20

YL

46

98GN(-)20GN

98G

N(-

)20G

N

J1939BACKBONE

(1097)

98SHD20

98YL(+)20YL

98S

HD

20

98Y

L(+

)20Y

L

37

98S

HD

20

C AB

24A

F18G

Y

L

24A

F18G

Y

18

REARSOLENOID

11-G

X18W

H

98SHD14BK

ENGINEBLOCK

GROUND

Figure 28 Cummins ISM, ISX Engine Brake

S08316


29

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


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


CUMMINS ISM, ISX - ENGINE CONTROLS

27JUL01 AE08-54039 06

5000/9200/9400/9900U00CJB5

54719V

CHAPTER 4

97-G

F

(423)

98

C(-

)

(141)

B

F5-D20A

97

-GA

18V

T

C

14W

H


(504)

DASHCONN

(190)

98(+

)

G4GND

ADAPTER(456)

TO SPEEDO/TACH MODULE

DATA LINKPOSITIVE

(514)

4

B

B2BATTERY

STUD

FROMTHROTTLEPOSITION

SENSOR

18V

T

W/PEDAL

11-G

T18W

H

97-GC

97-G

E

1

11-GT

97A

T

14B

K

62-G

R18W

H

98

B(-

)

97A

P

47/4

8(-

)

V

C

(CH 4,PG 4)

47/4

8(+

)

97A

L

DATALINK

(137)

18

GY

10

18

BK

18VT

18

GY

RELEASED

98

A(+

)

U

(CH 2,PG 10)

14W

6R

D

20 34

FROM FUSEF4-A

(141)

5

97A

L

7

(423)

18V

T

98(+

)

97-GB

A

BRAKE SWITCH

97A

P

(CH 4,PG 4)

97DL

E

14A

A14R

D

(CH 6,PG 3,5,8 CH 7,PG 2,3)

18V

T

5

28D

18T

N

(CH 4,PG 7)

18VT

18V

T

A

11-G

R

62R

16D

KB

L

18V

T

WARNENG

(CH 4,PG 5)

18V

T

97-G

A18V

T

99-GA 1

6B

K

DA

TA

LIN

K (

-)

2

98

B(-

)

18V

T

2

97-GH

FROMCRUISE

CONTROL

FE

ED

12V

A

LEFTGAUGE

CLUSTER

24-G

ECMCONN

(1086)

14VT

S

18GY

8

G

DA

TA

LIN

K (

+)

18V

T

18V

T

14B

K

43

H

13V

16P

K

44

T

STOPENG

DATALINKNEG

(515)

6

B

DIAGNOSTICON/OFFSWITCH(241)

FROMENGINEBRAKE

GR

OU

ND

18VT

97-G

A

18VT

62AV16DKBL

18V

T

C

G4GND ADAPTER

(456)

16B

K

18V

T

FROMCLUTCHSWITCH

97A

T

3

F

97A

M

18WH

18

BK

97

AM

11-GX18WH

11-GX18WH

FROMA/C

PRESSURESWITCH

(CH 5,PG 2)

97-G

AB

18V

T

16TN23-GB

10 11

Figure 29 Cummins ISM, ISX Engine Controls

S08316


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

Figure 30 Cummins AHD and ISM Engine Controls

S08316


31

4.8. I6 HEUI CRUISE CONTROL, P. 8


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


30JUL01 08

5000/9200/9400/9900U00CJB5

54719V

I6 HEUI - CRUISE CONTROL

AE08-54039

CHAPTER 4

4

F10-C5A

8

62-G

K18W

H

J

97D

J18V

T

3

G4 GNDADAPTER

(456)

47

16

VT

2

6

R

97A

D18V

T

CRUISEON/OFFSWITCH(435)

32

62-G

J18W

H

1

2

97C

F18V

T

K

CRUISESET/

RESUMESWITCH(436)

97DS16VT

40

97A

E18V

T

62K

16D

K B

L

CECCONN

(379)

97C

F18V

T

7

6

5

VEHICLESPEED

SENSOR(303)

13AA16PK

62

AV

16D

K B

L

24

I1-IGN ADAPTER

97D

K18V

T

DASHCONN

(190)

39

5

35

7

8

I

97D

K18V

T

97

CR

18

VT

11-G

T18W

H

47A

16V

T


(504)97

CR

18

VT

97D

J18V

T

4

62J16DK BL

1

31

3

97-G

B1

8V

T

11-G

X18W

H

Figure 31 I6 HEUI Cruise Control

S08316


4.9. I6 HEUI ENGINE BRAKE, P. 9


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


CHAPTER 4

AE08-5403930JUL01 09

5000/9200/9400/9900

54719V

U00CJB5

I6 HEUI - ENGINE BRAKE

62N16DK BL

1 64

G1 GNDADAPTER

(453)

62-GN18WH

3

62A

X16

DK

BL

5

L2 PNLLGT ADAPTER

(504)

8

72ENG BRAKEON/OFF(434)

4

ENG BRAKESELECT(433)

5

6

2

1 3

7

8

62

L16D

K B

L

24-G

A18W

H

86

85

8787A 87

ENG BRAKERELAY(286)

30

TO ABSCONTROLMODULE

(CH 9,PG 2)

A

24A

R16G

Y

24A

18G

Y24A

N18G

Y

24AT18GY

24AS16GY

I1 IGNADAPTER

(494)

24AF16GY

B C D E F

24AD18GY

24AE16GY

62-G

L18W

H11

-GA

X18W

H

G4 GNDADAPTER

(456)

24

16

GY

L

RESISTOR PRINTEDCIRCUIT BOARD

CONNECTOR(390)

24A

M16G

Y

TO CEC CONN(379)

(CH 4,PG 10)

(PRINTEDCIRCUITBOARD)

(190)

Figure 32 I6 HEUI Engine Brake

S08316


33

4.10. I6 HEUI ENGINE CONTROLS, P. 10


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


30JUL01 10

5000/9200/9400/9900U00CJB5

54719V

I6 HEUI - ENGINE CONTROLS

AE08-54039

CHAPTER 4

SERV/CHECK

ENG

2

I1 IGNADAPTER

62-G

R18W

H

U

47/4

8(+

)18 G

Y

97C

K14P

L

97N

M18

VT

97A

F18V

T

97M

18V

T

FE

ED

12V

17

10

F10-D5A

4

DATA LINKPOSITIVE

(514)

1 21

C

P

98A

(+)

14B

K

F

11-G

X14W

H

DATALINKNEG

(515)

11-G

W14W

H

42

7

44

14B10RD

11-G

T18W

H

98-G18VT

6

3

14BB14RD

5

B

GR

OU

ND

16

97A

A18V

T

5

97C

L14P

L

C

B

BRAKESW

(141)

B1 BATADAPTER

(497)

G

98

(+)

14B

K

45

DIAGNOSTICON/OFFSWITCH(241)

F11-A5A

(423)

97DL14VT

47/4

8(-

)18G

Y

B1 BATADAPTER

(497)

(141)

CECMODULERELAY(396)

25

11-G

Z14W

H

86

98A

(+)

18B

K

34

97DT16VT

1

S

11-G

10W

H

41

97T

18V

T

DATALINK

(137)D

AT

A L

INK

(+

)

30

SPEEDO-TACH

MODULE(421)

T

28

A18T

N

2

98

C(-

)14B

K

(423)

CECCONN

(379)


(504)

43

97AL16VT

62A

V1

6D

K B

LF10-B

10A

55

A

97A

L14P

L

C

12

DA

TA

LIN

K (

-)

97N

18V

T

H

3

85

22

14

DLF

14R

D

87A

54

WARNENG

97A

H16V

T

97T

18V

T

B

A

98

C(-

)18B

K

A

POWER CONN(490)

97A

F18V

T

23

28D

18T

N1

3V

16P

K

13

B

PANELLTS GNDADAPTER

(506)

97C

T16V

T

98

B(-

)14B

K

97N

M18

VT

11

E

97A

A18V

T

LEFTGAUGE

CLUSTER

6

A

STOPENG

11-G

R1

4W

H

DASHCONN

(190)

87

GND ADAPTER(453)

98

18B

K8

O

11-G

Y14W

H

97CT16VT

28A

18T

N

TO FUSEF4-A

(CH 2,PG 10)

(CH 4,PG 19)

97C

M10P

L

* FUSE LOCATIONS VARY CHECK INSIDE POWER DISTRIBUTION CENTER FOR ACTUAL LOCATIONS

15

24

18G

Y

(CH 6,PG 3,5,8CH 7,PG 2,3)

TO ENGBRAKE(CH 4, PG 17)

98

18B

K

98

18B

K

Figure 33 I6 HEUI Engine Controls

S08316


4.11. I6 HEUI MODULE POWER AND GROUND SYSTEM, P. 11


NAME

DATE




RELEASE NO.


CHANGE

SHEET

DRAWN

PART NO.


30JUL01 11

5000/9200/9400/9900U00CJB5

54719V

I6 HEUI - MODULE POWER & GROUND SYSTEM

AE08-54039

CHAPTER 4

NEG BAT

25

97DS16VT

DC/DC(-)

11-GY14WH

1

14B10RD

97CK14PL

POWER CONN(490)

14BB14RD

11-G

10W

H

B

F10-C *5A

97CR16VT

LOW PWR GND

DC/DC(+)

F

V IGN

A

B1 BATTERYADAPTER

(497)

POS BAT

97AL14PL

HSO GND

97DT16VT

DC/DC(-)

21

V

V IGN-HSO

97CT16VT

A

86

2

14B

10R

D

* FUSE LOCATIONS VARYCHECK INSIDE POWERDISTRIBUTION CENTER FOR ACTUAL LOCATIONS

30

97CT16VT

DC/DC(+)

41

MPR

11-G10WH

11-GZ14WH

87

MODULE POWERRELAY(396)

13AA16PK

97AH16VT

11-G

10W

H

97CR16VT

85

23

(190)

11-GX14WH

42

CEC MODULE CONN(379)

11-GW14WH

24

I1 IGNADAPTER

(494)

97CL14PL

97CM10PL

87

22

F10-B *10A

TO BATTERY(CH 3,PG 6)

14B

10R

D

Figure 34 I6 HEUI Module Power and Ground System

S08316


35

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


NAME

DATE

Documents

Diagramas Electricos 5500i_ 5600i_ 5900i_ 9200i_ 9400i and 9900i Chassis Built December 1_ 2005