Download Chassis ElECtriCal - Central States Bus Sales, Inc.

C h a s s i s E l ec t r i c a l
Charging System
The charging system provides electrical current for the lights, radio, heater blower
and the engine’s electrical systems. It also maintains the batteries in a charged state,
recharging them as necessary to provide cranking power.
The charging system has three main components, or component areas: the alternator, the voltage regulator, and the battery.
The alternator is driven by a belt from the engine crankshaft and produces the
electrical power to operate the systems on the bus. It also recharges the battery.
The voltage regulator acts as a “control valve” for the alternator output. It senses
the current load and maintains a constant voltage in the charging system, independent of the current load, up to its rated output. The Leece Neville™ alternator on the
Blue Bird Vision has a “built in” voltage regulator. It is excited (started) by the ignition
system.
The battery is the reservoir of chemical electrical power. Its primary purpose is to
crank the engine. It also supplies power to the accessories for a short time when the
demand is too high for the alternator alone (i.e., while the bus is at idle). Another key
role of the battery is to act as a filter for the charging system.
The Blue Bird Vision has a 12-volt electrical system. The alternator is a 175-ampere, 12-volt device. Leece Neville model number A0014834LC is standard.
Maintenance
Clean the alternator and all connection points. Dirt buildup restricting air flow
through to the alternator will cause excessive heat and premature failure. Corrosion
at any connecting point will produce resistance to current flow, heat and diminished
power for the starter and accessories.
Ensure that all the components in the charging system are mounted securely.
Check the torque at all mounting bolts — both the bolts that hold the alternator in
the mounting bracket and the bolts that secure the mounting brackets to the engine.
The torque value for mounting bolts at the engine and at the alternator should be 70
– 80 ft lb (95 – 108 Nm)
Blue Bird Vision buses are equipped with an automatic belt tensioner. Ensure
that all the grooves fit properly into the pulleys in the correct path. The drive belt
should be inspected every 11,000 miles (17,700 km), 250 hours of service life, or every 3 months; whichever occurs first.
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Also check:
• Battery voltage
• Alternator output
• Starter current draw
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Troubleshooting
Timely preventive maintenance of the charging system should keep it running
smoothly. However, when a problem occurs, effective troubleshooting procedures
will help locate and correct the problem quickly and economically.
[Warning] Batteries emit an explosive gas. Never smoke while working on
the charging system. Batteries can explode from a spark. Always remove the
negative battery cable at the battery post before removing any other wires in
the charging system. Be careful not to short the system while you are working
on it. Do not wear jewelry.
Before you begin to analyze the charging system, it is necessary that you ensure the
battery is properly tested and charged to at least 75% of their rated capacity. Failure
to confirm the condition of the battery will make the results of any diagnostic testing
unreliable. Refer to the battery manufacturer’s publications on battery maintenance
and testing.
Digital Volt/Ohm Meter
Alternator Performance Test
1. Connect a digital volt/ohmmeter (VOM) to the output terminals of the alternator.
[Caution] Ensure that the test leads are connected properly. Observe the polarity and make secure connections.
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2. Connect an ammeter to the positive terminal of the alternator. Observe that the clamp on the ammeter is located
at least 6 inches (15 cm) from the alternator to lessen the
possibility of faulty readings due to spurious emissions.
3. Verify that the voltage output from the alternator is between 13.6 and 14.2 volts with the engine at operating
RPM (1700 RPM minimum) and not idle.
4. Ensure that all “loads” are in the off position. The reading on the ammeter
should be less than 20 amps.
• If the amp reading is higher than 20 amps, ensure all accessories are
turned off.
• Ensure the battery is charged to at least 75% of their rated capacity.
5. Record the voltage. If the voltage is not within the specified range or the
amperage is not within the specified range, the alternator is defective.
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Ammeter
chassis electrical
6. If the alternator is determined to be defective, repair or replace it in accordance with the instructions below. See Alternator Removal.
7. If the alternator is determined to be functioning properly, proceed as follows:
8. Continue to operate the engine at about 1700 RPM, and with the test equipment set up as illustrated.
9. Turn on vehicle loads (accessories) until the ammeter displays 132 amps,
which is 75% of the rated capac-ity (175 amps). Record the voltage at this
point.
10. Compare the voltage reading with the voltage reading observed in Step 3
above.
11. If the alternator voltage drops more than .5 (1/2) volt, the alternator is defective.
An alternate method of checking the alternator under load is to use a carbon pile
load. Connect the carbon pile across the battery and adjust it until the ammeter
reads 75% of the alternator rated capacity. Record the voltage at this point, shut off
the engine, and compare the readings.
Alternator Cable Tests
To test the positive alternator cable:
1. Clamp the ammeter on the positive cable at least 6
inches (15 cm) from the alternator. See Figure 2.
Digital Volt/Ohm Meter
725
2. Connect the negative lead of the VOM to the positive
post of the alternator.
3. Connect the positive lead of the VOM to the positive
battery post.
4. Start the engine and let it run at about 1700 RPM.
Ammeter
5. Turn on accessories until the ammeter reads 132 amps,
which is 75% of the rated alternator capacity (175 amps).
Use a carbon pile if necessary to achieve the load.
6. Record the voltage reading on the VOM.
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7. If the VOM reads more than -.25 volts, there is a problem
with the positive cable.
• Check and clean all the connections and the condition of all the cables/wires in the circuit.
• Re-test the circuit.
Volt/Ohm Meter
8. If the reading is less than -.25 volts, the cable and connections are good.
9. Connect the lead negative of the VOM to the negative
terminal of the battery.
10. Connect the positive lead of the VOM to the negative
terminal of the alternator.
11. Repeat Steps 4 through 8 for the negative cable.
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Ammeter
Solenoid
Starter
chassis electrical
Bosch Alternator Removal
[Warning] Always disconnect the negative (-) cable from the battery terminal first to avoid arcing, which could ignite explosive battery
gases.
1. Park the bus on a smooth, flat surface.
2. Chock the wheels in both directions.
3. Ensure the engine is not running, the ignition switch is in the “OFF”
position and the key is removed.
4. Disconnect the negative (ground) cable from the battery
post.
5. Lift the automatic belt tensioner to remove the drive belt
from the alternator.
6. Remove the drive belt.
Caterpillar
7. Inspect the drive belt; discard it if any signs of wear are present.
A few minor cracks across the belt are acceptable. Longitudinal cracks are NOT acceptable. Replace the drive belt when any crack is observed to be running lengthwise or with the belt, or when the belt appears frayed.
[Warning] Always disconnect the negative (-) battery cable at the battery
before removing any wiring from the alternator.
8. Remove the negative (-) cable from the alternator.
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Cummins
9. Remove the positive (+) cable from the alternator.
10. Remove the bottom mounting bolts.
11. Support the alternator and remove the top bolts.
Exciter Post
12. Remove the alternator.
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Alternator Reinstallation
Installation of the alternator is accomplished in the reverse order of the removal instructions above.
1. Position the alternator and install the top and bottom bolts. Torque bolts to
33-35 ft. lbs.
2. Install the positive cable on the positive (B+) post. Carefully tighten to avoid
breaking or stripping the stud.
3. Install the negative cable on the negative (B -) post. Carefully tighten to avoid
breaking or stripping the stud.
4. Using a square drive tool, position the automatic tensioner so that the drive
belt can be installed. Inspect the drive belt carefully. Replace the belt if any
signs of wear are present.
5. Install the drive belt. Ensure that the grooves in the belt fit into the proper
places on all the pulleys.
6. Start the engine and test the alternator output.
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chassis electrical
Automatic Belt Tensioner
The automatic tensioner is spring loaded to provide the proper tension for the drive
belt.
The automatic tensioner should travel at least 71º, and the torque to move the
tensioner 25º from the “at rest” position must be 9 – 11 ft lb (12.4 – 15.8 Nm). Inspect the belt tensioner for any unusual noise, excessive looseness and shaking at
the bearings.
Automatic Tensioner Removal
1. Remove the drive belt in accordance with the instruc-tions above.
2. Remove the capscrew (1) from the automatic ten-sioner. See Figure 8.
To install a new automatic tensioner, reverse the removal instructions. Torque the
capscrew (1) to 28 – 42 ft lb (38 – 56 Nm).
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Starter
There are 5 main components or component areas in the starting system: the ignition switch, a neutral safety switch, the starter solenoid, the starter motor and the
batteries.
When the key is turned to the start position, electrical current flows to the starter
solenoid from the batteries. The flow is interrupted if the transmission shift lever is
not in the neutral position or if the neutral sensor switch is defective.
The starter solenoid is an electromagnetic switch mounted on the starter motor.
When electric current energizes coils inside the solenoid, a magnetic field is induced
which pulls a plunger. At one end of this plunger is a shift lever. The lever is connected to the drive pinion and clutch assembly of the starter motor. The plunger also
connects the electrical power from the batteries to the starter motor as it engages
the flywheel ring gear.
The starter motor is a relatively small electric motor, but it can deliver large
amounts of torque for a short time.
When the operator releases the ignition switch it returns to the run position. The
solenoid is disconnected from the batteries and the magnetic field collapses. This
allows the spring in the solenoid to move the plunger in the opposite direction, disengaging the flywheel and removing electrical current from the starter motor.
The Blue Bird Vision has a 12-volt electrical system. The starter motor is Model
35261110, Presto-lite/Leece/Neville M100R series. The Starter motor is capable of
4kw cranking power for peak loads of no more than 30 seconds duration.
Preventative Maintenance
There are two preventative maintenance procedures that can greatly enhance the
efficiency of the starting system. These two steps are also the first two steps taken
when troubleshooting a malfunctioning starting system.
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• An engine that needs a tune up will be difficult to crank; over cranking will
lead to starter motor failure.
• Poor connections due to road dirt, grease, corrosion, loose connectors, or broken insulation at any connecting point rob the starting system of electrical
power and cause it to over-crank.
Troubleshooting
Before beginning to troubleshoot the starting system, ensure the batteries are properly maintained and charged to at least 75% of their rated capacity. A drained battery
will cause any further diagnostic tests to be inaccurate. Common causes of starting
system malfunction include:
1. A battery that is low, poorly charged, or defective places high demands on
the starting system; voltage at the battery should be 12.4 volts or greater to
crank the engine. If the batteries aren’t adequately charging, a problem in
the charging system. Refer to the Alternator section of this Service Manual
for information on the charging system.
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chassis electrical
2. A starter motor can be damaged by heat that is generated by excessive
cranking. The starter should never be engaged for more than 30 seconds. It
must “rest” (cool off) a minimum of 2 minutes between starting attempts.
3. Loose, dirty, or corroded connections in the starting system rob the system
of the power needed to turn the engine. The case of the starter motor is the
ground or “return” connection for the starter motor and solenoid.
4. A loose starter motor will allow vibration that can damage the motor. In addition, the ring gear could be damaged.
5. Improper or excessive use of starting fluid will cause extra stress on the starting system.
6. A defective solenoid will fail to engage the starter motor. A failed pull-up coil
will cause the plunger to fail to pull in. A failed hold-in coil may cause the
starter to fail to stay engaged, or may fail to switch the starter motor on. If
the solinoid is suspect, test the wiring of the solenoid circuit before replacing
the solenoid.
The starting circuit is among those incorporated into the Vision’s Multiplex System.
Therefore, Multiplex diagnostics procedure can help to quickly isolate the root cause
of most starting problems, and thereby minimize downtime. Refer to the Multiplex
chapter for full details on performing Multiplex diagnostics.
1. Refer to the Multiplex Output Table to find out which Port/Pin (B3-07) and
which Output LED (B3-O02) pertain to the Starter Signal Output. The chart
also shows which Ladder Logic Line (#20) describes the logic of the circuit.
2. Use the Diagnostic Switch to cycle the MPX Module to the appropriate Diagnostic Mode (Showing B3 Outputs). Check the LED to see if the Starter Signal
Output (B3-O03) is Active. If the Output LED is Inactive, refer to Ladder Logic
line #20 to systematically verify that each requirement for an Active Output
is true.
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3. Once the Output is Active, if the starter is still not operating, verify a ground
at Pin B3-07 on the MPX Module. If the ground output is present, the problem
exists “downstream” of the Multiplex system, and the starter itself is suspect.
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Volt/Ohm Meter
Ignition/Run Test
Begin by determining whether the problem is with the ignition
switch or the pilot relay, and their associated wiring; or if it is in
the solenoid and/or starting motor. To begin with the ignition
switch:
1. Connect the positive lead of a VOM to the ignition switch
terminal on the solenoid.
2. Connect the negative lead of the VOM to the chassis
ground.
3. While attempting to crank the engine, record the voltage
displayed on the VOM. Observe the following:
• No voltage
• Low voltage
• Normal voltage with slow cranking
• Normal voltage with no cranking at all.
4. Connect a remote start switch to the positive battery post.
5. Connect the other end of the remote start switch to the ignition post of the
solenoid.
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6. Attempt to crank the engine with the remote switch. Record the voltage displayed on the VOM. If there is less than 1 volt difference from the previous
reading, the ignition switch is okay. If there is more than 1 volt difference, the
switch is defective.
7. With the VOM negative lead connected to the chassis ground, move through
the switch system one connection at a time. If your first voltage test has revealed low voltage, the starter motor may be shorted.
8. If the first voltage test indicated normal voltage, but there is slow cranking or
no cranking at all, a problem with the batteries, battery cables, or a damaged
starter motor is indicated.
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Solenoid
Alternator
Starter
chassis electrical
Low Voltage Test
There are various reasons for low voltage but the troubleshooting methods are the same. If the solenoid clicks, it means that either current is
flowing through the solenoid contacts but not through the main contacts; or that the current through the main contacts is insufficient due
to low batteries.
Volt/Ohm Meter
Solenoid
1. Connect the positive lead of the VOM to the starter motor terminal
of the solenoid.
2. Connect the negative lead of the VOM to the chassis ground.
Alternator
Starter
3. While attempting to crank the engine, if there is no voltage displayed on the VOM, the main contacts are not functioning properly.
4. If there is voltage present at the solenoid terminal during Step 3, the problem is in the starter motor or its cabling.
5. If the first voltage check in Step 3 under Ignition/Run Test indicated normal voltage but slow or no cranking, the next step is to check the starter
motor and its connections.
6. If the drive pinion jumps out of mesh with the flywheel ring gear, check
for a broken or loose ground wire at the solenoid.
7. While attempting to crank the engine, place an ammeter on the positive
battery cable. If the power drain is higher than the OEM specifications,
the starter motor is defective. An exception would be if the engine was
not properly tuned or is difficult to turn over; in which case, a new starter
motor would be a temporary fix.
Main Contacts
733
Ammeter
Solenoid
Alternator
Starter
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Volt/Ohm Meter
Slow Cranking
Sluggish cranking can be caused by a small amount of extra resistance in the cranking circuit. This extra resistance can come
from loose or dirty (corroded) connections, or broken wires
and/or cables. First check the positive cables and connections
of the starter motor, then the negative circuit.
1. Connect the positive lead of a VOM to the positive battery
terminal.
Ammeter
Solenoid
Alternator
2. Position an ammeter between the solenoid and the positive terminal of the solenoid.
3. Connect the negative lead of the VOM to the positive terminal of the solenoid.
4. Connect the negative lead of the VOM to the negative
battery post. This is the “unloaded” voltage. Record the
reading; leave the VOM connected.
5. Connect one lead of a carbon pile tester to chassis ground.
6. Connect the other lead from the carbon pile tester to the positive terminal of
the solenoid.
7. Adjust the carbon pile tester until the ammeter on the tester reads 500
amps.
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8. Record the voltage display on the VOM; it should not be less than 0.4-volts
less than the unloaded value.
9. Turn the carbon pile tester to the “OFF” position.
10. Connect the positive lead of the VOM to chassis ground.
11. Connect the negative lead of the VOM to the negative battery post. Record
the reading; leave the VOM connected.
12. Position the ammeter in on the negative battery cable.
13. Turn on the carbon pile tester and adjust it to read 500 amps.
14. Record the voltage on the VOM; it should not drop more than 0.4-volts from
the unloaded reading.
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Starter
Carbon Pile Tester
chassis electrical
15. Turn the carbon pile tester to the OFF position.
16. If the voltage drop was more than 0.4-volts in step 8, the positive cabling is
defective. Look for a broken cable or a loose or corroded connection.
17. If the voltage drop in step 14 is more than 0.4 volts, look for a problem in the
negative cabling; look for broken or defective cables, and loose or corroded
connections.
Final check at solenoid terminals.
Volt/Ohm Meter
1. Disconnect the carbon pile tester.
2. Disconnect the VOM.
3. Remove the ammeter.
4. Connect the positive lead of the VOM to the positive (battery) terminal of the solenoid.
Solenoid
Alternator
5. Set the VOM so that it can read the full battery volt-age; at
least 14 volts.
6. Connect the negative VOM lead to the starter motor terminal of the solenoid.
7. Crank the engine and record the voltage while cranking. There should be no
more than 0.2 volts drop between the solenoid contacts while cranking.
8. The voltage reading in these last three tests (the positive cable check, the
negative cable check and the solenoid test), should not total more than 1.0
volts. If the voltage drop is more than allowable, repeat the cable tests using
a jumper cable. If the tests then indicate an acceptable drop, the cable(s) is
(are) defective.
Starter
735
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Starter Motor Removal
1. Disconnect the negative (ground) cable from the battery. Wrap it with
tape or other suitable insulation to prevent shorts.
2. Disconnect positive cable from the battery. Wrap it with tape or other
suitable insulation to prevent shorts.
3. Identify and tag each wire on the starter motor for reinstallation.
4. Remove all electrical connections from the starter motor. Be sure to
identify and tag all electrical connection locations.
5. Remove 3 capscrews.
6. Remove starter motor from flywheel housing.
Starter Motor Installation
The starter motor is installed in the reverse order of the removal instructions above.
1. Carefully place the starter motor into position on the flywheel housing.
2. Install 3 capscrews (1). Torque to 32 ft lb (43 Nm). See Figure 8.
736
3. Being careful to observe the identification of the electrical wires, connect the wires to the appropriate terminal on the starter motor. See
Figure 7.
[Warning] Always remove the negative (-) cable from the battery terminal
first. Always connect the negative (-) cable to the battery terminal last to avoid
arcing that could ignite explosive battery gases.
4. Install the positive cable on the battery post.
5. Install the negative cable on the battery post.
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chassis electrical
Chassis Harness Routing Diagrams
The following pages illustrate the routings of the main chassis wiring harnesses applicable to most Vision chassis.
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Shunt Battery Side
(Engine harness)
Ammeter Bat Fuse
(Engine Harness)
Torque to 8 ft lb
125A
To Intake Heater
To Alt Power
To PDU Power
200A
To Alt Ground
To PDU Ground
To PDU Ground
See Sheet 3
Shunt Alternator Side
(Engine harness)
Without Ammeter
To PDU Ground
See Sheet 3
To PDU Power
See Sheet 3
Ammeter Alt Fuse
(Engine Harness)
Alternator
Exciter
To
Intake
Heater
To Alt
Power
To Alt
Ground
With Ammeter
Torque to 50 in lb
Torque to 100 in lb
To Intake Heater
To Alt Power
+
Torque to 8 ft. Lbs. (typ)
Ammeter bat fuse
Engine harness
-
To PDU Power
Shunt Bat Side
To PDU Power
To PDU Power
Engine Harness
Ammeter Alt Fuse
To Alt Ground
Alternator Connections
With Ammeter
Breakout of engine harness.
Routing goes back to the PDU panel.
Routes along with Cat engine harness,
along valve cap.
Right
Headlights
Connector
738
Right
Dir Light
Crs Mir Connector
Heat
Connector
To PDU Panel.
See Sheet 3.
Right
Park Light
Connector
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sheet
ABS Harness
Frame Harness
0074133
To PDU Panel
To Engine Ecu
To Transmission Ecu
To Engine Compartment Interface
Abs & Frame Harness
To Frame Component Harness.
See Sheet 2
Viewed From Inside Hood
Right Side Of Bus
chassis electrical
Torque harness connection
to 53 in lb.
To PDU Ground.
See Sheet 3.
To PDU Power.
See Sheet 3
To Main Panel.
See Sheet 3.
Exciter wire
not required
with 320 amp
alternator.
To PDU Panel.
See Sheet 3.
To PDU Panel.
See Sheet 3.
739
To
PDU Ground
Torque To12 ft lb
To PDU
Power
To
Engine
Mount
Starter
Power
Torque To 25 in lb
Starter Ground
Starter Connections
Chassis Harness Routing Sheet 1 of 5
0074133
DIAGRAM, RTG, HARNESS W/AUTOMATIC TRANS
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Chassis Harness Routing Sheet 1 of 5 (continued)
0074133
DIAGRAM, RTG, HARNESS W/AUTOMATIC TRANS
740
L
sheet
PS
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0074133
&MFDUSPOJD
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chassis electrical
741
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Chassis Harness Routing Sheet 2 of 5
0074133
DIAGRAM, RTG, HARNESS W/AUTOMATIC TRANS
Frame Rail
Typical at
Crossmembers
Exhaust Bracket
Typical at
Exhaust Brackets
Exhaust Bracket
Typical at
Exhaust Brackets
Crossmember
Start of
Hydraulic Harness
742
To Abs Connection
on Front Hub
To PDU Panel.
See Sheet 3.
To Abs Connection
on Front Hub
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Air Dryer
Typical at
Wiring Supports
chassis electrical
Left Frame Rail
Left Frame Rail
Harness Routing
To Front For Hydraulic
TO FRONT
OF BUS
Fuel Filter
Modulator Assy
Hydraulic Brakes
DETAIL H
(HYD BRAKE)
Fuel Tank
Fuel Tank Area
Hydraulic Brakes
Left Frame Rail
Left Frame Rail
Air Brakes
743
Harness Routing
To Front For ABS
Air Brakes
Filter Assy
To ABS Modules
0074133
sheet
2
Valve Assy
Fuel Tank
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Chassis Harness Routing Sheet 3 of 5
0074133
DIAGRAM, RTG, HARNESS W/AUTOMATIC TRANS
Power
Ground
Ammeter
On units with Ammeter,
item 24, 26, or 27
attaches to Ammeter Stud.
On units without Ammeter,
item 24, 26, or 27
attaches to Power Stud.
24,
26,
27
Stud Mounting Blocks
on Engine Compartment
Side of Firewall
ace
erf
Int
ent
m
art
mp
ace
Co
ace
erf
e
erf
Int
fac
1
Int
n
E
ter
e
S
n
n
B
o
I
i
T
2
n/A
Eng
ine
sio
nk
To
Eng
tali
mis
s
n
To
Da
ra
9
T
3
To
J19
To
24,
26,
27
e
gin
Components
of Harness
744
24,
26,
27
Chassis
Power
From
Battery
L
Electronic
Ground
Torque Studs
to 11-15 ft lb.
Chassis
Ground
0074133
sheet
3
Electronic
Power
chassis electrical
745
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Frame Rails
Cables
A: Electronic Power To Disconnect Switch
B: Battery To Disconnect Switch
C: Electronic Ground To PDU
D: Battery Ground
E: Disconnect Switch (Electronic Power) To PDU
F: Disconnect Switch (Battery) To Rem Pwr
Fuel Lines
E F
To Batteries
To PDU Panel
B A
See Detail
on Sheet 1
C
D
On back of
Transmission
Bell housing
C
D
To Electronic Power Stud (See Sheet 3)
To Rem Power Stud (See Sheet 3)
To Electronic Ground Stud (See Sheet 3)
To Pdu Ground Stud (See Sheet 3)
B A
Route
Battery Cable
Thru Tie Wrap
Torque bolt to
21 ft lb.
Coat connection
With Glyptal sealant.
Pos
Neg
Pos
Neg
Using 2 8D Batteries
(Feature 40142-04)
E F
746
B
A
C
D
C
D
B A
Neg
Pos
Neg
Pos
Neg
Pos
Using 3 Delco Group 31 Batteries
(Feature 40142-06)
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chassis electrical
4/0 Positive Cable
4 Ga Positive Cable
4/0 Positive Cable
4 Ga Positive Cable
With
Heavy Duty
Box Only
Battery Tray
From
Positive
Battery
With Battery Disconnect Switch
(Feature 40142-01)
SEE DETAIL C & E
DU
oP
er t
w
o
DU
ic P
oP
on
dt
ctr
un
Ele
o
r
ic G
on
ctr
Ele
SEE DETAIL E
747
Supplied
with
Switch
(For Delphi)
Chassis Harness Routing Sheet 4 of 5
Torque 1/2" stud to 100 in lb.
Torque10-32 stud to 14 in lb.
Remove the two 10/32 nuts
supplied with switch.
Install lock washers
supplied with switch
on bottom and
between cables.
0074133
(For 8D Batt)
sheet
4
(For Delphi)
0074133
DIAGRAM, RTG, HARNESS W/AUTOMATIC TRANS
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Frame Rail
Cables
To
PDU Panel
Fuel Lines
A: Electronic Power To PDU
B: Battery To Remote Power
C: Electronic Ground To PDU
D: Battery Ground
To Batteries
B
C
A
D
On back of
Transmission
Bell housing
To Electronic Power Stud (See Sheet 3)
To Rem Power Stud (See Sheet 3)
To Electronic Ground Stud (See Sheet 3)
To Pdu Ground Stud (See Sheet 3)
C
D
Torque bolt to
21 ft lb.
Coat connection
With Glyptal sealant.
Route
Battery Cable
Thru Tie Wrap
B A
See Detail A
Pos
Neg
Pos
Neg
Using 2 8D Batteries
(Feature 40142-04)
748
AB
CD
C
D
B A
Neg
Pos
Neg
Pos
Neg
Pos
Using 3 Delco Group 31 Batteries
(Feature 40142-06)
L
chassis electrical
4/0 Positive Cable
4 Ga Positive Cable
4/0 Positive Cable
4 Ga Positive Cable
With
Heavy Duty
Box Only
Battery Tray
Chassis Harness Routing Sheet 5 of 5
0074133
sheet
5
749
0074133
DIAGRAM, RTG, HARNESS W/AUTOMATIC TRANS
L
1
service manual
Power Distribution Unit Layout
The PDU houses the Main Bus Controller of the Multiplex system
(MPX Module), chassis fuses, relays and interface connections to
some of the main chassis harnesses. The diagram shown here is
representative of standard equipment Visions with air or hydraulic
brakes. Although some differences occur in the cases of specific
equipment options (such as circuit breakers in lieu of fuses, exhaust brake, or manual transmission), the general layout of the
PDU components is the same.
0089022
750
L
chassis electrical
IGN PWR
F1
F2
F3
F4
F5
F6
HTD FUEL PWR (20A)
INTERLOCK PWR (10A)
AIR DRYER PWR (10A)
SPARE
BRAKE WARN IGN (15A)
HTD DRAIN PWR (20A)
BODY IGN (15A)
BATT PWR
F7 SPARE
BRK BOOST (40A)
F8 START REL PWR (5A)
F9 REV SENS+ (10A)
F10 STOP LIGHT PWR (15A)
F11 SPARE
HYD INTLK (30A)
F12 ABS BATT (30A)
MOD PMP BATT (30A)
F13 DPWR (3A)
F14 SPARE
ELEC PWR
F15 TRANS BATT (10A)
F16 EECM PWR (40A)
F17 MBC PWR (10A)
F18 SPARE
ABS BATT (25A)
Units with Air Brakes
Units with Hydraulic Brakes
Units with Air Brakes
Units with Hydraulic Brakes
Units with Air Brakes
Units with Hydraulic Brakes
Units with Air Brakes
Units with Hydraulic Brakes
751
EJ170 IGN (10A)
TRANS IGN (40A)
ABS IGN (10A)
DASH IGN (10A)
0089022
ECM IGN
F19
F20
F21
F22
Units with Air Brakes
Units with Hydraulic Brakes
L
1
752
L
service manual
chassis electrical
Chassis Wiring Schematics
The following pages contain the main wiring schematics applicable to most Blue Bird
Vision chassis. Two sets of schematics are provided in this chapter, one set for Caterpillar-equipped Visions, and another for Cummins-equipped Visions.
The schematics are provided for your convenience when you are limited to use of
the print manual. Additional schematics specific to your bus may be viewed, printed,
or downloaded in Adobe® PDF® format by pointing your web browser to the Customer Access website at:
http://service.blue-bird.com/TechPubs/SchematicsRequest.html
753
L
1
service manual
Hydraulic Brake Booster Harness
This schematic describes the wiring of the Bendix HydroMax brake master cylinder/
booster harness on Blue Bird Visions equipped with hydraulic brakes.
Buffer
Warning Signal
(output to IP)
Ground
Ignition
Warning Signal Input
Brake Light Signal
754
L
Ground
Brake Light Signal
Ignition
To ground stud
on HydroMax body
Warning Signal to IP
Brake Light Signal
chassis electrical
Electrical Diagrams for Caterpillar C7-07 Engines
Description
Index
Starting And Charging, Cat 2007 C7
Starting And Charging (with Florida circuit breakers)
2007 Cat C7 Engine
Allison Gen 4 2000 Transmission
Allison Gen 4 3000 Transmission
Dimmer / Backlights
ABS - Bendix (air)
ABS Hyd-E (hydraulic)
AA Multiplex Module
AB Multiplex Module
AC Multiplex Module
Mirror Heat / Exterior Speaker / Wiper Washer
Hydraulic Brake Boost, Cat
Frame Components
Crossing Arm
Instrument Cluster
Driver’s Control Module, Cat, Air
Driver’s Control Module, Cat, Hydraulic
MBC Module
Body Interface
J1939 Datalink, Hyd-E J1939 Datalink, Air
Sheet
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Drawing Number
0116467F
0116401C
0115329C
0113152A
0116646
0116649A
0116651
0116652
0118822A
0116694C
0116695A
0116696
0116697
0116698
0116699
0116700
0119063
0116702
0116703
0116704
0116705
0118820
0116707
Wire Colors
BL BLUE
BK BLACK
BN BROWN
TN TAN
WH WHITE
YL YELLOW
PK PINK
OR ORANGE
RD RED
GN GREEN
PU PURPLE
GY GRAY
PD
AC
IP
FW
SP
DC
Schematic Legend
PDU PANEL
AIR CLEANER BRACKET
INSTRUMENT PANEL
FIREWALL
SHIFTER PANEL
DCM
Electrical Component Index
2 Wire Twisting
Heavy Duty Relay
Fuse
Voltage Stud
2 Wire Twisting
with Shield
Mini Relay
Shunt
Switch Ngr Rocker
(Non-typical)
Horn
Speaker
CAT C7-07
Micro Relay
755
3 Wire Twisting
Light
Circuit Breaker
Multiplex Wire Indexing (Circuit Number Code)
Zone
Connector
Voltage (0 = Ground, 1 = 12 Volts)
Connector Pin Number
Sheet 1
Example: (Zone A, Connector A, 12 Volts, Pin #11)
0116467F
SCHEMATIC, WRG, 2007 CAT C7, INDEX
L
1
service manual
12V ECM
IGNITION RELAY
30/40A
C9
87A
ELEC PWR (BK)
30
86
ECM IGN (PK)
87
85
RLY GND A (WH)
S26
PD
BATTERY
DISCONNECT
SWITCH
(ONLY WITH
OPTION 40142-01)
12V
PD
ELEC PWR (BK)
12V
-
ELEC
+
DIAG PWR (OR)
-
ELEC PWR A (BK)
+
S25
PDU
GROUND
STUD
DIO PWR (RD)
PD CB1
DC
CURRENT SENSOR
60A
PD
12V
PD
MBC GND A (WH)
MBC GND B (WH)
MBC PWR 2 (RD)
MBC PWR 1 (RD)
12V
BATT PWR (RD)
BATT IGN PWR (RD)
A B C D
A
MAIN BODY &
STARTER FUSE
200A
DC
12V
TO LIFT/AC
COPPER BUS BAR
756
C14
STARTER
RELAY
70A
TO GRID HEATER
ON ENGINE BLOCK
M
TO DCM GND
EX
GND
ALTERNATOR
12V
B
STARTER
MOTOR
C704
W
87
86
12
PD
85
STARTER (RD)
START REL GND (WH)
STARTER (RD)
30
AA-114 (RD)
MAIN BODY 12V
FEED TO SOLENOID
IN BODY ELEC PANEL
GRID HTR
FUSE 125A
GROUND 2/0 CABLE
FROM GND STUD ON FRAME
GROUND BK 1 GA
TO ENGINE BLOCK
L
STARTER PWR (RD)
PD
PDU
GROUND
STUD
chassis electrical
5A
10A
5A
12V ECM
IGNITION BUS
PD
10A
5A
F19
EJ170 IGN (OR)
CAT C7
SHT. 4
F20
TRANS IGN (OR)
TRANS
SHT. 5/6
F21
ABS IGN (OR)
F22
F23
DASH IGN (PK)
BRAKE WARN IGN (OR)
AA-111 (OR)
ABS
SHT. 8/9
IP
SHT. 17
HYD BRAKE BOOST
SHT. 14
AA MODULE, SHT 10
MBC GND A (WH)
MBC GND B (WH)
MBC PWR 2 (RD)
MBC MODULE
SHT. 20
MBC PWR 1 (RD)
40A
10A
12V ELEC
PWR BUS
PD
25A B
3A
15A
30A
12V
BATTERY BUS
PD
40A
30A
10A
SEN IGN (RD)
F15
10A
EECM PWR (RD)
CAT C7
SHT. 4
F17
MBC BATT (RD)
MBC MODULE
SHT. 20
F18
ABS BATT (RD)
ABS
SHT. 9
F13
DPWR (BK)
STOP LGT PWR (RD)
AA MODULE,
SHT. 10
F12
MOD PMP BATT (RD)
ABS
SHT. 9
F7
BRAKE BOOST BATT (RD)
F11
HYD INTLK PWR (RD)
F11
INTERLOCK PWR (RD)
F14
F8
REV SENS + (RD)
D DIAG PWR (BK)
BRAKE SW PWR (RD)
AA-114 (RD)
AA-113A (PK)
30
87
AA-113 (PK)
86
12
PD
85
AA-113C (OR)
20A
20A
IGN REL GND (WH)
IGN PWR (RD)
10A
PDU
GROUND
STUD
12V
IGNITION BUS
PD
15A
IP
SHT. 17
F10
AMMETER + (RD)
C13
IGNITION
RELAY
70A
TRANS
SHT. 5/6
F16
F9
3A
TRANS BATT (RD)
DIAGNOSTIC,
SHT. 22/23
F1
HTD FUEL PWR (PK)
F5
HTD DRAIN PWR (BN)
F3
AIR DRYER PWR (BL)
F6
BODY IGN (OR)
ENGINE CAT C7
SHT. 4
DRIVER'S CNTRL MODULE
SHT. 19
DRIVERS CONTROL MOD
SHT. 18
SEE DIAGRAM,WRG
FEA 2226
DRIVER'S CNTRL MODULE
SHT 18/19
DRIVER'S CNTRL MODULE,
SHT 18/19
CAT C7
SHT 4
AA MODULE,
SHT 10
AA MODULE,
SHT. 11/10
CAT C7
SHT. 4
FRAME COMPOMENTS
SHT 15
FRAME COMPONETS
SHT. 15
FRAME COMPONETS
SHT. 15
BODY INTERFACE
SHT. 21
757
CAT C7-07
DIAG PWR (OR)
10A
Sheet 2
0116401C
STARTING AND CHARGING,CAT 2007 C7
L
1
service manual
ELEC PWR (BK)
12V ECM
IGNITION RELAY
30/40A
C9
87A
30
87
85
86
ECM IGN (PK)
RLY GND A (WH)
S26
12V
PD
BATTERY
DISCONNECT
SWITCH
(ONLY WITH
OPTION 40142-01)
PD
ELEC PWR (BK)
12V
-
+
-
+
ELEC
DIAG PWR (OR)
ELEC PWR A (BK)
S25
PDU
GROUND
STUD
DIO PWR (RD)
PD CB1
DC
CURRENT SENSOR
12V
PD
MBC GND A (WH)
MBC GND B (WH)
MBC PWR 2 (RD)
MBC PWR 1 (RD)
60A
PD
12V
BATT PWR (RD)
BATT IGN PWR (RD)
A B C D
MAIN BODY &
STARTER FUSE
200A
DC
12V
TO LIFT/AC
COPPER BUS BAR
758
GRID HTR
FUSE 125A
C14
STARTER
RELAY
70A
TO GRID HEATER
ON ENGINE BLOCK
M
TO DCM GND
EX
GND
ALTERNATOR
12V
B
STARTER
MOTOR
C704
W
30
87
AA-114 (RD)
86
12
PD
85
STARTER (RD)
START REL GND (WH)
STARTER (RD)
GROUND 2/0 CABLE
FROM GND STUD ON FRAME
GROUND BK 1 GA
TO ENGINE BLOCK
L
STARTER PWR (RD)
PD
MAIN BODY 12V
FEED TO SOLENOID
IN BODY ELEC PANEL
PDU
GROUND
STUD
chassis electrical
5A
10A
5A
12V ECM
IGNITION BUS
PD
10A
7.5
F19
EJ170 IGN (OR)
CAT C7
SHT. 4
F20
TRANS IGN (OR)
TRANS
SHT. 5/6
F21
ABS IGN (OR)
CB22
CB23
ABS
SHT. 8/9
IP
SHT. 17
HYD BRAKE BOOST
SHT. 14
DASH IGN (PK)
BRAKE WARN IGN (OR)
AA MODULE,
SHT. 10
AA-111 (OR)
MBC GND A (WH)
MBC GND B (WH)
MBC MODULE
SHT. 20
MBC PWR 2 (RD)
MBC PWR 1 (RD)
DIAGNOSTICS,
SHT. 22/23
DIAG PWR (OR)
40A
10A
12V ELEC
PWR BUS
PD
25A B
7.5A
15A
30A
12V
BATTERY BUS
PD
40A
30A
10A
10A
SEN IGN (RD)
7.5A
10A
F15
F16
EECM PWR (RD)
CAT C7
SHT. 4
CB17
MBC BATT (RD)
MBC MODULE
SHT. 20
F18
ABS BATT (RD)
ABS
SHT. 9
CB13
CB10
CB12
F7
DPWR (BK)
STOP LGT PWR (RD)
MOD PMP BATT (RD)
BRAKE BOOST BATT (RD)
DRIVER'S CNTRL MODULE
SHT. 19
CB11
INTERLOCK PWR (RD)
DRIVER'S CNTRL MODULE
SHT. 18
REV SENS + (RD)
CB14
D DIAG PWR (BK)
DRIVER'S CNTRL MODULE
SHT 18/19
BRAKE SW PWR (RD)
DRIVER'S CNTRL MODULE
SHT 18/19
CB8
AA-113 (PK)
C13
IGNITION
RELAY
70A
AA-113C (OR)
20A
20A
IGN REL GND (WH)
IGN PWR (RD)
10A
PDU
GROUND
STUD
12V
IGNITION BUS
PD
15A
SEE DIAGRAM,WRG
FEA 2226
CB9
AA-114 (RD)
87
ABS
SHT. 9
ENGINE CAT C7
SHT. 4
HYD INTLK PWR (RD)
AA-113A (PK)
86
12
PD
85
IP
SHT. 17
AA MODULE,
SHT. 10
CB11
AMMETER + (RD)
30
TRANS
SHT. 5/6
TRANS BATT (RD)
CAT C7
SHT 4
AA MODULE,
SHT 10
AA MODULE,
SHT. 10
CAT C7
SHT. 4
CB1
HTD FUEL PWR (PK)
FRAME COMPONETS
SHT. 15
CB5
HTD DRAIN PWR (BN)
FRAME COMPONETS
SHT. 15
CB3
AIR DRYER PWR (BL)
FRAME COMPONETS
SHT. 15
BODY INTERFACE
SHT. 21
CB6
BODY IGN (OR)
759
CAT C7-07
10A
Sheet 3
0115329C
STARTING AND CHARGING,CAT 2007 C7
W/FEA 40142-11 (Florida circuit breakers)
L
1
service manual
DIMMER/BACKLIGHTING
SHT. 7
ILLUM J
DIMMER/BACKLIGHTING
SHT. 7
GND 3H (WH)
TO DRIVER'S CONTROL
MODULE. SHT 18/19
FAN CLUTCH AA-MODULE
SHT. 10
DRIVERS CTL MOD
SHT. 18/19
COOLING FAN DISABLE AA-MODULE
SHT. 10
FAST IDLE AB-MODULE
SHT. 11
I/P EJ1587
SHT. 22/23
ENGINE CONTROLS IP
SHT. 17
THROTTLE INTERLOCK AB-MODULE
SHT. 11
VGT BRAKE MODELE AA
SHT 10
STARTER LOCKOUT AC-MODULE
SHT. 12
START/CHARGE
SHT. 2/3
EECM POWER START/CHARGE
SHT. 2/3
EJ170 IGN START/CHARGE
SHT. 2/3
BRAKE BOOST BAT START/CHARGE
SHT. 2/3
SEN COM B (TN)
SEN COM B
(TN)
S39
AA-103 (OR)
SENS COM B (TN)
THROT PWR (BL)
THROT COM (PK)
THROT SIG (BN)
S1
AA-008 (PK)
AB-001B (OR)
EJ1587+ (YL)
EJ1587- (BL)
AMMETER + (RD)
AB-009 (BN)
ENG BRAKE LT (RD)
AC-102 (RD)
7
9
2B 3
1
5B 6
4
10
8
PDU
INTERFACE
CONNECTOR
C701
A
AA-103 (OR)
AA-103 (OR)
B
VGT SW (BL)
VGT SW (BL)
C
D
SENS COM A (TN)
SENS COM B (TN)
E
THROT PWR (BL)
THROT PWR (BL)
F
THROT COM (PK)
THROT COM (PK)
G
THROT SIG (BN)
THROT SIG (BN)
H
J
AA-008 (PK)
AA-008 (PK)
K
L
AB-001B (OR)
AB-001 (OR)
M
N
EJ1587+ (YL)
EJ1587+ (YL)
O
EJ1587- (BL)
EJ1587- (BL)
P
Q
AMMETER + (RD)
AMMETER + (RD)
R
AB-009 (BN)
AB-009 (BN)
S
ENG BRAKE LT (RD)
ENG BRAKE LT (RD)
T
U
V
W
AC-102 (RD)
AC-102 (RD)
X
PDU
INTERFACE
CONNECTOR
C704
R
EECM GND (WH)
EECM GND (WH)
S
AA-113C (OR)
AA-113C (OR)
T
EECM PWR (RD)
EECM PWR (RD)
U
EJ170 IGN (OR)
EJ170 IGN (OR)
V
BRAKE BOOST BAT (RD)
BRAKE BOOST BAT (RD)
X
Y
Z
AA-113C (OR)
EECM PWR (RD)
EJ170 IGN (OR)
BRAKE BOOST BAT (RD)
N.O.
REGENERATION SWITCH
760
START/CHARGE
SHT. 2/3
S1
SEN IGN (RD)
SHUTTER SW PWR (RD)
SHUTTER GND (WH)
C807
SHUTTER IGN (OR)
A
SHUTTER GND (WH)
B
N.C.
SHUTTER STAT AIR
SHUTTER COM (OR)
S2
STARTER GND (WH)
A B
A B C2
SHUTTER
SOLENOID
L
AA-103 (OR)
FAN CL GND (WH)
SHUTTER PWR (RD)
N.C.
SHUTTER STAT WATER
GROUND
STUD
ON
STARTER
C815
FAN
CLUTCH
chassis electrical
TO CURRENT SENSOR
SHT. 2/3
AMMETER + (RD)
C800 (EJ1)
CAT C7 ECM CONN
THROT COM (PK)
S3
THROT PWR (BL)
EJ105 (PK)
REGEN SW (OR)
EJ105 (PK)
EJ1587+ (YL)
EJ1587- (BL)
ENG BRAKE LT (RD)
AC-102 (RD)
SEN COM B (TN)
AA-008 (PK)
EJ123 (OR)
VGT SW (BL)
S7
COOL LVL (BL)
EJ1939- (GN)
EJ140 (OR)
S5
EJ148 PWR (RD)
EJ1939+ (YL)
EJ152 PWR (RD)
EJ153 PWR (RD)
EJ155 PWR (RD)
AB-009 (BN)
S6
EJ163 GND (WH)
EJ165 GND (WH)
THROT SIG (BN)
EJ167 GND (WH)
EJ169 GND (WH)
EJ170 IGN (OR)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
COOL LEVEL + 5V
THROTTLE + 8V
SENSOR/SWITCH COM
REGENERATION SWITCH
J1587(+)
J1587(-)
AUX BRAKE LIGHT
STARTER LOCKOUT
SENSOR COMMON
COOLING FAN
SET SPEED B
VGT BRAKE SWITCH
COOL LEVEL
J1939(-)
FAST IDLE
+12V BATTERY POWER
J1939(+)
+12V BATTERY POWER
+12V BATTERY POWER
+12V BATTERY POWER
THROTTLE INTERLOCK
GND
GND
THROTTLE POSITION
GND
GND
+12V IGNITION
ALT IGN (OR)
BRAKE BOOST BAT (RD)
C816
COOLANT
LEVEL
SENSOR
ALTERNATOR EXCITER START/CHARGE
SHT. 2/3
HYD BRAKE BOOST
SHT. 14
HYD BRAKE BOOST
SHT. 14
EJ149 (BL)
EJ1939+ (YL)
EJ1939- (GN)
COOL LVL PWR (OR)
COOL LVL (BL)
COOL LVL RET (PK)
DCM GND
A B C
761
CAT C7-07
COOL LVL PWR (OR)
N U C701
EJ1939- (GN)
EJ1939+ (YL)
Sheet 4
J1939 DATALINK
SHT. 22/23
0113152
2007 CAT C7 ENGINE
L
1
service manual
PDU
INTERFACE
C702
A TRANS TEMP/164 (BL)
NOT USED
B NOT USED
C CHECK TRANS/129 (GN)
IP TJ1939, SHT 17
IP TJ1939, SHT 17
NOT USED
NOT USED
AB-004 (BL)
AB MODULE, SHT 11
NOT USED
TJ1939+ (YL)
AB-107 (RD)
TJ1939- (GN)
AB MODULE, SHT 11
AB MODULE, SHT 11
TRANS BATT START/CHARGE, SHT 2/3
TRANS IGN START/CHARGE, SHT 2/3
S14
TELEC GND (WH)
IP TJ1587, SHT 17
IP TJ1587, SHT 17
SHIFT INHIBIT IN AB MODULE, SHT 11
762
L
ELECTRONIC
GROUND
RESERVED
RESERVED
AB-003 (RD)
TELEG GNDA (WH)
TRANS BAT (RD)
TRANS IGN (OR)
TELEC GND B (WH)
TJ1587+ (YL)
TJ1587- (BL)
AB-005 (GN)
MAIN TRANSMISSION
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
C906
1
2
3
4
5
PS3 6
PS2 7
SUMP TEMP 8
SIGNAL RETURN
9
LSD TCC 10
PS4 11
12
13
HSD1 14
LSD PCS1 15
HSD2 16
LSD PCS2 17
DIGITAL SIGNAL NS
18
LSD MAIN MOD 19
DIGITAL SIGNAL C
20
DIGITAL SIGNAL B
21
DIGITAL SIGNAL A
22
DIGITAL SIGNAL P
23
TRANS ID
24
LSD SS1
LSD SS2
LSD SS3
PS1
NOT USED
NOT USED
B2-016/165 (TN)
NOT USED
TJ1939+ (YL)
B1-112/141 (TN)
TJ1939- (GN)
RESERVED
RESERVED
B1-002/105 (OR)
169 (GY)
TRANS BAT (PK)
TRANS IGN/163 (YL)
109 (GY)
NOT USED
NOT USED
B3-015/101 (BL)
124 (WH)
152 (GN)
133 (YL)
151 (WH)
117 (BL)
157 (WH)
179 (PK)
154 (TN)
158 (GN)
178 (WH)
177 (GN)
111 (OR)
155 (WH)
171 (YL)
136 (OR)
138 (OR)
174 (BL)
114 (GY)
153 (YL)
173 (BL)
134 (WH)
176 (YL)
chassis electrical
139 (OR)
159 (TN)
140 (GN)
160 (YL)
120 (BL)
180 (OR)
S1
C905 B A
C902 B A
C928 B A
ENGINE
SPEED
SENSOR
OUTPUT
SPEED
SENSOR
TURBINE
SPEED
SENSOR
TRANSMISSION TCM CONNECTOR
AUX FUNCTION RANGE INHIBIT
3 MPH SIGNAL
J1939+
J1939GROUND
BATTERY
HSD1
DIGITAL SIGNAL C
PS1
TURBINE SPEED LOW
RANGE INHIBIT LIGHT
CHECK TRANS
LSD SS2
DIGITAL SIGNAL
LSD PCS2
DIGITAL SIGNAL NS
ENGINE SPEED LOW
OUTPUT SPEED LOW
NEUTRAL SAFETY
LSD SS3
LSD SS1
DIGITAL SIGNAL B
SUMP TEMP
LSD PCS1
PS3
SIGNAL RETURN
ENGINE SPEED HIGH
OUTPUT SPEED HIGH
IGNITION
TRANS TEMP LIGHT
REVERSE SIGNAL
GROUND
BATTERY
HSD2
763
DIGITAL SIGNAL A
LSD MAIN MOD
TRANS ID
PS4
LSD TCC
PS2
TURBINE SPEED HIGH
CAT C7-07
C926
1
2
3
4
B1-002/105 (OR)
5
6
TJ1939+ (YL)
7
TJ1939- (GN)
8
109 (GY)
9
110 (PK)
10
111 (OR)
11
12
13
114 (GY)
14
15
16
117 (BL)
17
18
19
120 (BL)
20
21
22
23
124 (WH)
24
25
26
27
28
CHECK TRANS/129 (GN)
29
30
31
32
133 (YL)
33
134 (WH)
34
35
136 (OR)
36
37
138 (OR)
38
139 (OR)
39
140 (GN)
40
B1-112/141 (TN)
41
42
43
44
45
46
47
48
49
50
151 (WH)
51
152 (GN)
52
153 (YL)
53
154 (TN)
54
155 (WH)
55
56
157 (WH) 57
158 (GN)
58
159 (TN)
59
160 (YL)
60
61
62
TRANS IGN/163 (YL)
63
TRANS TEMP/164 (BL)
64
B2-016/165 (TN)
65
66
67
68
169 (GY)
69
170 (PK)
70
171 (YL)
71
72
173 (BL)
73
174 (BL)
74
75
176 (YL)
76
177 (GN)
77
178 (WH) 78
179 (PK)
79
180 (OR)
80
B3-015/101 (BL)
Sheet 5
0116646
ALLISON GEN 4 2000 TRANSMISSION
L
1
service manual
TO CONNECTOR C6
IP, SHT 21
C6
C932
1
2
ILLUMINATION
3
4
GROUND 5
6
7
J1939+
8
9
10
DIRECTIONAL SIGNAL
11
IGNITION
12
BATTERY POWER
13
14
TRANS BAT (RD)
15
16
SHIFT SELECTOR
IP TJ1939, SHT 17
IP TJ1939, SHT 17
AB MODULE, SHT 11
AB-004 (BL)
AB MODULE, SHT 11
J1939+ (YL)
AB-107 (RD)
J1939- (GN)
AB MODULE, SHT 11
TRANS BATT START/CHARGE, SHT 2/3
TRANS IGN START/CHARGE, SHT 2/3
S14
764
TELEC GND (WH)
IP TJ1587, SHT 17
IP TJ1587, SHT 17
SHIFT INHIBIT IN AB MODULE, SHT 11
ELECTRONIC
GROUND
GND (WH)
SJ1939+ (YL)
134 (YL)
TRANS IGN A (OR)
TRANS BAT A (RD)
SJ1939- (GN)
ENGINE
COMPARTMENT
INTERFACE
C702
A TRANS TEMP/164 (BL)
B
C CHECK TRANS/129 (GN)
D
E
F B2-016/165 (TN)
G
H J1939+ (YL)
B1-112/141 (TN)
J
K J1939- (GN)
AB-003 (RD)
TELEC GNDA (WH)
TRANS BAT (RD)
TRANS IGN (OR)
TELEC GND B (WH)
TJ1587+ (YL)
TJ1587- (BL)
AB-005 (GN)
MAIN TRANSMISSION CONNECTION
HSD1
LSD PCS4
DIGITAL SIGNAL
LSD PCS1
LSD PCS2
HSD2
LSD MAIN MOD
LSD PCS3
LSD SS1
HSD3
LSD TCC
TURBINE SPEED HIGH
TURBINE SPEED LOW
OIL LEVEL
OIL LEVEL SIGNAL
OIL LIFE MONITOR
SUMP TEMP SIGNAL
ANALOG RETURN
TRANS ID
L
ILLUM (BL)
L
M
N
P
R
S
T
U
V
W
X
C906
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
B1-002/105 (OR)
169 (GY)
TRANS BAT (RD)
TRANS IGN (OR)
109 (GY)
TJ1587+ (YL)
TJ1587- (BL)
B3-015/101 (BL)
111 (OR)
155 (WH)
177 (GN)
136 (OR)
152 (GN)
171 (YL)
174 (BL)
133 (YL)
151 (WH)
131 (YL)
137 (WH)
180 (OR)
120 (BL)
116 (BL)
112 (PK)
118 (BK)
154 (TN)
158 (GN)
176 (YL)
A B
chassis electrical
B1-002/105 (OR)
TJ1939+ (YL)
TJ1939- (GN)
109 (GY)
110 (RD)
111 (OR)
112 (PK)
116 (BL)
118 (BK)
120 (BL)
S3
S4
CHECK TRANS/129 (GN)
131 (YL)
TJ1587+ (YL)
133 (YL)
134 (YL)
136 (OR)
137 (WH)
139 (OR)
140 (GN)
B1-112/141 (TN)
151 (WH)
152 (GN)
154 (TN)
155 (WH)
S1
S2
158 (GN)
159 (TN)
160 (YL)
163 (OR)
TRANS TEMP/164 (BL)
B2-016/165 (TN)
169 (GY)
170 (RD)
171 (YL)
TJ1587- (BL)
174 (BL)
176 (YL)
177 (GN)
139 (OR)
159 (TN)
C905
B A
ENGINE
SPEED
SENSOR
TRANSMISSION TCM CONNECTOR
AUX FUNCTION RANGE INHIBIT
3 MPH SIGNAL
J1939+
J1939GROUND
BATTERY POWER
HSD1
OIL LEVEL SIGNAL
OIL LEVEL
OIL LIFE MONITOR
TURBINE SPEED LOW
CHECK TRANS
HSD3
J1587+
LSD PCS3
DIRECTIONAL SIGNAL
LSD PCS1
LSD TCC
ENGINE SPEED LOW
OUTPUT SPEED LOW
NEUTRAL SAFETY
LSD SS1
LSD PCS2
SUMP TEMP SIGNAL
LSD PCS4
ANALOG RETURN
ENGINE SPEED HIGH
OUTPUT SPEED HIGH
IGNITION POWER
TRANS TEMP
REVERSE SIGNAL
765
GROUND
BATTERY POWER
HSD2
J1587LSD MAIN MOD
TRANS JD
DIGITAL SIGNAL
TURBINE SPEED HIGH
140 (GN)
160 (YL)
180 (OR)
C926
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
CAT C7-07
B3-015/101 (BL)
C902
B A
OUTPUT
SPEED
SENSOR
Sheet 6
0116649A
ALLISON GEN 4 3000 TRANSMISSION
L
1
766
L
service manual
chassis electrical
TO ALL OTHER ILLUM
ILLUM B (BL)
ILLUM H (BL)
BODY INTERFACE, SHT 21
INSTRUMENT CLUSTER, SHT 17
ILLUM C (BL)
7
2B
3
9
7
2B
1
6
5B
8
4
3
9
7
2B
1
6
5B
10
8
4
3
C12
C
A
D
B
F
9
1
6
5B
10
8
4
10
AB-106C (BN)
AB MODULE, SHT 11
DIMMER
SWITCH
TYPICAL DASH SWITCH BACKLIGHTING/DIMMER CIRCUITS.
DIMMER POWER AND GROUNDS CONTINUE TO LOOP FROM SWITCH TO SWITCH.
CAT C7-07
767
Sheet 7
0116651
DIMMER/BACKLIGHTS
L
1
service manual
ABS BAT (RD)
ABS IGN (OR)
RIGHT FRONT
MOD VALVE
LEFT FRONT
MOD VALVE
RIGHT FRONT
SENSOR
S
S
H E
H E
C504
LF SENSOR IN (PU)
LF SENSOR RTN (BK)
RF MOD COM (GY)
RF MOD EXH (OR)
RIGHT REAR
MOD VALVE
S
ABS GND (WH)
1 2 3 4
RF MOD HOLD (GN)
LEFT REAR
MOD VALVE
RIGHT REAR
SENSOR
C500
1 2 3 4
S
LEFT REAR
SENSOR
C512
1 2
RF SENSOR IN (PK)
RF SENSOR RTN (BK)
C501
LF MOD EXH (TN)
LF MOD COM (GY)
LF MOD HOLD (BL)
C511 1 2
H E
H E
ABS
GROUND
1 2
C510
1 2 3 4
C502
1 2 3 4
RR MOD EXH (OR)
RR MOD COM (GY)
RR MOD HOLD (GN)
C503
LR MOD EXH (TN)
LR MOD COM (GY)
LR MOD HOLD (BL)
1 2
RR SENSOR IN (PK)
RR SENSOR RTN (BK)
C509
LR SENSOR IN (PU)
LR SENSOR RTN (BK)
768
TRACTION
CONTROL VALVE
C514
B
A
L
TCV RTN
TCV IN
ABS LGT (GN)
LEFT FRONT
SENSOR
ABS IGN (OR)
ABS GND (WH)
ABS BAT (RD)
ATC SLS (RD)
ABS
POWER/START/CHARG
SHT. 2/3
A B C D E F
chassis electrical
ATC SLS (RD)
C513
AJ1587+ (YL)
A
AJ1587- (BL)
B
AJ1587+ (YL)
AJ1587- (BL)
AJ1587+ (YL)
AJ1587- (BL)
ABS LGT (GN)
AJ1939+ (YL)
AJ1939- (GN)
C507
A
B
AJ1939+
AJ1939-
STOP LIGHT SIGNAL
ZONE B PORT 1
SHT. 10
I/P
AJ1587
SHT. 17
ABS/ATC LIGHTS
IP
SHT. 17
J1939 DATALINK
(AIR)
SHT. 23
C505
1
ABS GND (WH)
ABS IGN (OR)
TCV RTN
TCV IN
AJ1939-(GN)
AJ1939+(YL)
ATC SLS (RD)
RR SENSOR IN (PK)
RR SENSOR RTN (BK)
ABS LGT GND (WH)
AJ1587- (BL)
AJ1587+ (YL)
ABS BATT (RD)
ABS LGT (GN)
LF MOD HOLD (BL)
LF MOD EXH (TN)
LF MOD COM (GY)
RF MOD HOLD (GN)
LF SENSOR IN (PU)
RF MOD COM (GY)
RF MOD EXH (OR)
LF SENSOR RTN (BK)
RR MOD COM (GY)
RR MOD HOLD (GN)
RF SENSOR IN (PK)
LR MOD COMMON (GY)
RR MOD EXH (OR)
RF SENSOR RTN (BK)
LR SENSOR IN (PU)
LR MOD HOLD (BL)
LR MOD EXH (TN)
LR SENSOR RTN (BK)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
C506
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
X1
ABS/ATC GROUND
TRAILER ABS WL (NOT CONNCTED)
IGNITION (5A FUSED)
TCV RTN
TCV IN
ATC LAMP/ATC ORS (ATC ONLY)
J1939-LO
J1939-HI
SLS (ATC ONLY)
RIGHT REAR SENSOR +
RIGHT REAR SENSOR ABS W/L GND
J1587-B
J1587-A
WL INTERLOCK (NOT CONNCTED)
BATTERY (30A FUSED)
RETARDER (NOT CONNECTED)
ABS WL
ABS ECU
BENDIX EC-60
X2
CAB MOUNT
LEFT FRONT MOD HOLD
LEFT FRONT MOD EXHAUST
LEFT FRONT MOD COMMON
RIGHT FRONT MOD HOLD
LEFT FRONT SENSOR (+)
RIGHT FRONT MOD COMMON
RIGHT FRONT MOD EXHAUST
LEFT FRONT SENSOR (-)
RIGHT MOD COMMON
RIGHT MOD HOLD
RIGHT FRONT SENSOR (+)
LEFT REAR MOD COMMON
RIGHT REAR MOD EXHAUST
RIGHT FRONT SENSOR (-)
LEFT REAR SENSOR +
LEFT REAR MOD HOLD
LEFT REAR MOD EXHAUST
LEFT REAR SENSOR X3 (NOT CONNECTED)
C515 B
ABS HARNESS
ATC HARNESS
SEE CHART 0104429
A
TRACTION
CONTROL VALVE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
ABS ORS
DIFF
DIFF_CMN
NOT USED
RESERVED
NOT USED
ADDITIONAL MOD EXHAUST
RESERVED
ADDITIONAL MOD COMMON
ADDITIONAL MOD HOLD
ADDITIONAL LEFT SENSOR(+)
ADDITIONAL RIGHT SENSOR(+)
NOT USED
ADDITIONAL LEFT SENSOR(-)
ADDITIONAL RIGHT SENSOR(-)
769
CAT C7-07
ATC SLS (RD)
ABS LGT (GN)
ABS BATT (RD)
ABS GND (WH)
ABS IGN (OR)
Sheet 8
0116652
ABS - BENDIX
L
1
service manual
ABS ECU
16 WAY
CONNECTOR
I/O DIAG SW & I/P
SHT 17
ABS LT (TN)
MOD PMP BAT (RD)
J1939
TRANSMISSION
SHT 5/6
ABS IGN (OR)
TJ1939- (GN)
TJ1939+ (YL)
AJ1587- (BL)
AJ1587+ (YL)
ABS BAT (RD)
ABS POWER
START/CHARGE
SHT 2/3
ABS GND (WH)
AJ1939- (GN)
AJ1939+ (YL)
C513
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
ABS LT (TN)
PMP MTR BAT (RD)
ABS IGN (OR)
TJ1939- (GN)
TJ1939+ (YL)
J1587- (BL)
J1587+ (YL)
ABS BAT (RD)
ABS REF GND (WH)
AJ1939- (GN)
AJ1939+ (YL)
S4
S3
I/P
J1587
J1939
SHT 17
C511
1 2
LEFT FRONT
SPEED SENS
L
C509
1 2
LEFT REAR
SPEED SENS
C503
RR SENS GND (BK)
RR SENS IN (BN)
LR SENS GND (BK)
LR SENS IN (BN)
LF SENS GND (BK)
LF SENS IN (BN)
770
1 2
RIGHT REAR
SPEED SENS
chassis electrical
MODULATOR PUMP
31 WAY
CONNECTOR
C521
ABS IGN (OR)
ABS REF GND (WH)
J1939+ (YL)
J1939- (GN)
PMP MTR BAT (RD)
ABS BAT (RD)
PMP MTR GND (WH)
SOL VLV GND (WH)
ABS LT (TN)
RR SENS IN (BN)
LR SENS IN (BN)
LF SENS IN (BN)
RF SENS IN (BN)
J1587+ (YL)
RR SENS GND (BK)
LR SENS GND (BK)
LF SENS GND (BK)
RF SENS GND (BK)
J1587- (BL)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
+12V IGNITION
GROUND
J1939+
J1939PUMP MOTOR PWR
+12 BATTERY PWR
PUMP MOTOR
SOLENOID VALVE
ABS LIGHT
RR SENSOR INPUT
LR SENSOR INPUT
LF SENSOR INPUT
RF SENSOR INPUT
J1587(-)
RR SENSOR GND
LR SENSOR GND
LF SENSOR GND
RF SENSOR GND
J1587(+)
CAT C7-07
C501
RF SENS GND (BK)
RF SENS IN (BN)
771
1 2
PUMP MOTOR
GROUND
RIGHT FRONT
SPEED SENS
SOLENOID
VALVE
GROUND
Sheet 9
0118822A
ABS Hyd-E
L
1
service manual
BODY INTERFACE,
SHT 21
AA-101A (BN)
DRIVER CONTROL MODULE
SHT 18/19
AA-101B (BN)
CAT, SHT 4
AA-108 (OR)
BODY INTERFACE, SHT 21
AA-107 (BL)
BODY INTERFACE,
SHT 21
STOP LGT B (RD)
STOP LIGHT
RELAY
C7
4
3
5
STOP LGT PWR
(RD)
AA-109A
(RD)
AA-109C (RD)
C701
772
CAT C7
SHT 4
ENG BRK LT (RD)
T
ENG BRK LT (RD)
PARK LGT GND (WH)
1
2 RLY GND C
(WH)
VGT BRAKE
LIGHT RELAY
C15
4
3
5
1
2
-
+
7
2B
3
5B
HEAD LGT GND (WH)
8
9
1
6
4
10
+
HEADLIGHT
SWITCH
C423
CAT C7
SHT 4
L
AA-103 (OR)
RLY GND D
(WH)
AA-004 (BN)
AC-006 (OR)
STOP LGT PWR B (RD)
INSTRUMENT CLUSTER,
SHT 17
STOP LGT A (RD)
STOP LGT PWR A
(RD)
STOP LGT PWR (RD)
START/CHARGE,
SHT 2/3
C709
C715
A B
A B C
LEFT
HEADLIGHT
C706
C718
AA-112 (PU)
AA-114 (RD)
AA-113 (PK)
2
1
2
1
2
2
OUT 5
OUT 3
OUT 6
OUT 4
OUT 7
OUT 8
9
10
11
12
13
14
A B
RIGHT
HEADLIGHT
CAT C7-07
C703
AA-106 (OR)
AA-112 (PU)
8
AA-112 (PU)
7
AA-111(OR)
6
1
AA-110 (RD)
5
IN 8
AA-109 (RD)
2
OUT 4
AA-108 (OR)
AA-107 (BL)
AA-106 (OR)
AA-105 (PK)
AA-004 (BN)
4
1
OUT 2
AA-106 (OR)
3
2
OUT 3
AA-102 (BN)
AA-110 (RD)
AA-106 (OR)
AA-112A (PU)
2
1
AA-102 (BN)
AA-110 (RD)
1
IN 7
AA-110 (RD)
2
OUT 2
AA-102 (BN)
1
OUT 1
AA-103 (OR)
2
OUT 1
AA-102 (BN)
HARNESS CONN C2
PORT #
I/O SEQ
AA-101 (BN)
STARTER RELAY
IGNITION
DROP-OUT
HIGH BEAM HEAD
LGT (RIGHT)
IGNITION
HIGH BEAM HEAD
LGT (LEFT)
STOP LIGHT
RELAY
COOLING FAN
DISABLE
BACK-UP LIGHT
LOW BEAM HEAD
LGT (RIGHT)
PARK BRAKE
PARK/TAIL
LGT SWITCH
FAN CONTROL
POWER
LOW BEAM HEAD
LGT (LEFT)
WIPER MOTOR
INTERMITTANT
chassis electrical
CV-CCM-C
AA-114 (RD)
AA-113 (PK)
AA-111 (OR)
AA-105 (PK)
AA-112B (PU)
AC-006 (OR)
START/CHARGE,
SHT 2/3
INSTRUMENT
CLUSTER, SHT
17
AC-MODULE,
SHT 12
1 2 3 4
773
A B C
Sheet 10
AA MULTIPLEX MODULE
0116694A
L
1
service manual
TRANSMISSION, SHT 5/6
ENGINE, SHT 4
DRIVERS CONTROL MODULE, SHT 18/19
DRIVERS CONTROL MODULE, SHT 18/19
HYDRAULIC BRAKE BOOST, SHT 14
BODY INDTERFACE, SHT 21
INSTRUMENT CLUSTER, SHT 17
BODY INTERFACE, SHT 21
774
DIMMER/BACKLIGHTING, SHT 7
BODY INTERFACE, SHT 21
B A
C B A C713
PARK LIGHTS
WASHER PUMP
SWITCH
THROTTLE
INTERLOCK
RIGHT TURN
LAMPS
3
OUT 3
9
1
OUT 7
10
AB-106 (BN)
AB-107 (RD)
AB-108 (PK)
AB-009 (BN)
AB-110X (GN)
NEUTRAL
SHIFT INHIBIT
SIGNAL
3 MPH SPEED
SIGNAL
LEFT TURN LAMPS
1
IN 4
8
F2
10A
FUSE
AB-001B (OR)
F1
10A
FUSE
AB-003 (RD)
AB-004 (BL)
AB-005 (GN)
AB-107 (RD)
AB-009 (BN)
AB-012 (PK)
AB-111B (RD)
AB-111A (RD)
AB-110B (GN)
AB-110D (GN)
AB-106B (BN)
AB-106C (BN)
AB-102B (YL)
AB-102D (YL)
C703 14
C703
5
C703 16
E D C C709
AB-106A (TN)
C712
LT PK GND (WH)
FT LT PK LGT (BN)
AB-102B (YL)
LT DIR GND (WH)
AB-102A (YL)
INSTRUMENT CLUSTER, SHT 17
1
IN 3
7
AB-110A (GN)
TRANSMISSION, SHT 5/6
1
OUT 6
6
AB-106A (BN)
TRANSMISSION, SHT 5/6
3
OUT 2
5
AB-102A (YL)
TRANSMISSION, SHT 5/6
3
1
IN 2
4
AB-005 (GN)
AB-001 (OR)
ENGINE, SHT 4
AB-001A (OR)
GND C (WH)
FT LT PK LGT (BN)
AB-102 (YL)
AC MODULE, SHT 12
1
IN 1
REVERSE SIGNAL
1
HARNESS CONN C4
1
OUT 5
2
AB-004 (BL)
3
OUT 1
AB-003 (RD)
PORT #
1/0 SEQ.
AB-102X (YL)
HIGH IDLE
CV-CCM-C
DIRECTIONAL
LIGHT
L
DIR/PARK
LIGHT
AB-102A (YL)
FT LT PK LGT (TN)
GND C (WH)
S3
AB-110A (GN)
FT RT PK LGT (TN)
AB-116 (GN)
CNETB
VIN
GND
17
18
19
20
WIPER WASHER
PUMP
AB-015 (WH)
CNETA
3
OUT 6
21
3
OUT 7
22
AB-122 (TN)
3
OUT 8
16
LIFT ENABLE
ACC HOT
3
OUT 5
15
AB-021 (RD)
BRAKE
INTERLOCK
1
OUT 8
14
F3
10A
FUSE
AB-122 (TN)
DRIVER CONTROL MODULE, SHT 18/19
AB-021 (RD)
BODY INTERFACE, SHT 21
AB-116 (GN)
BODY INTERFACE, SHT 21
AB-015A (WH)
DRIVER CONTROL MODULE, SHT 18/19
AB-015B (WH)
INSTRUMENT CLUSTER, SHT 17
AB-108 (PK)
C703
DRIVER CONTROL MODULE, SHT 18/19
9
A B
GND (WH)
AB-114 (BK)
HORN GND (WH)
GND A (WH)
725
CAT C7-07
775
HORN
S2
C706 C D E
C717
A B C
AB-110A (GN)
RT DIR GND (WH)
AB-110B (GN)
FT RT PK LGT (BN)
RT PK GND (WH)
S1
AB-110 (GN)
FT RT PK LGT (BN)
GND B (WH)
GND C (WH)
GND B (WH)
AB-111 (RD)
11
3
OUT 4
13
HORN
1
IN 6
12
AB-114X (BK)
PARKING BRAKE
SWITCH
1
IN 5
AB-012 (PK)
SERVICE BRAKE
LAMP SWITCH
chassis electrical
A B C716
Sheet 11
GND B (WH)
DIR/PARK
LIGHT
DIRECTIONAL
LIGHT
0116695A
AB MULTIPLEX MODULE
L
BODY INTERFACE, SHT 21
CAT, SHT 4
DRIVER CONTROL MODULE, SHT 18/19
DRIVER CONTROL MODULE, SHT 18/19
DRIVER CONTROL MODULE, SHT 18/19
AC MODULE, SHT 12
DRIVER CONTROL MODULE, SHT 18/19
DRIVER CONTROL MODULE, SHT 18/19
DRIVER CONTROL MODULE, SHT 18/19
DRIVER CONTROL MODULE, SHT 18/19
AB MODULE, SHT 11
776
AC HI IDLE (GN)
AC-102 (RD)
AC-003 (YL)
AC-004 (PK)
AC-005 (PU)
AC-006 (OR)
AC-007 (OR)
AC-008A (YL)
AC-009A (GN)
AC-010 (GY)
AB-001A (OR)
7
HIGH IDLE GND (WH)
2B
3
9
AC-001A (GN)
1
6
5B
8
DIMMER/BACKLIGHTS, SHT 7
HIGH IDLE SW
10 C425
ILLUM F (BL)
7
GND (WH)
2B
3
9
1
6
GND (WH)
5B
8
DIMMER/BACKLIGHTS, SHT 7
4
4
AC-009B (GN)
HAZARD SW
10 C424
ILLUM E (BL)
7
GND (WH)
2B
3
9
AC-015 (GN)
1
6
ABS LT GND (WH)
5B
8
4
ABS LT (TN)
10
C422
ABS DIAGNOSTIC SWITCH
L
AC-008B (YL)
START SWITCH
IGNITION SWITCH
ACCESSORY
SWITCH
2
IN 5
1
2
3
4
5
AC-005 (PU)
2
IN 4
AA-004 (PK)
2
IN 3
AC-003 (YL)
2
IN 2
AC-102 (RD)
HARNESS CONN C1
2
IN 1
AC-001 (GN)
PORT#
I/O SEQ
STARTER LOCKOUT
SIGNAL
service manual
HIGH IDLE
SWITCH
1
chassis electrical
VANDAL LOCK
6
7
8
9
10
11
12
13
14
15
16
N/A
N/A
17
18
AC-016 (TN)
3
IN 8
AC-015 (GN)
3
IN 7
AC-014 (GN)
3
IN 6
AC-013 (OR)
3
IN 5
AC-112 (BK)
3
IN 4
AC-011 (BL)
3
IN 3
AC-010 (GY)
3
IN 2
AC-009 (GN)
3
IN 1
AC-008 (YL)
2
IN 8
AC-007 (OR)
2
IN 7
AC-006 (OR)
2
IN 6
AC-016 (TN)
AC-014 (GN)
AC-013 (OR)
AC-112 (BK)
AC-011 (BL)
ABS LT (TN)
BODY INTERFACE, SHT 21
BODY INTERFACE, SHT 21
DRIVERS CONTROL MODULE, SHT 18/19
DRIVERS CONTROL MODULE, SHT 18/19
BODY INTERFACE, SHT 21
INSTRUMENT CLUSTER, SHT 17
777
CAT C7-07
I/O DIAGNOSTIC
SWITCH
SCC ALARM
INTERLOCK
FEEDBACK
INTERMITTANT
WIPER SWITCH
EXTERIOR DOOR
SWITCH
HORN BUTTON
RIGHT TURN
SIGNAL
LEFT TURN
SWITCH
HIGH BEAM
SWITCH
HEADLAMP SWITCH
CV-CCM-C
Sheet 12
0116696
AC MULTIPLEX MODULE
L
service manual
CRS MR HT LT(PU)
1
CRS MR HT(PU)
S6
778
C700
TO
HEATER STEPWELL
HARNESS
WASHER MOTOR GROUND
FRAME COMPONETS
SHT. 15
WASH MTR GND(WH)
G
J
K
N
L
M
C711
OUT SPKR +(YL)
OUT SPKR -(PU)
WASH MTR PWR(YL)
WASH MTR GND(WH)
B
A
A
B
WASH MTR PWR
WASH MTR GND
C708
2302J(GY)
1213X(WH)
A
M
B
C726
L
OUT SPKR +
OUT SPKR -
HEATER PUMP
MOTOR
chassis electrical
C714
CRS MR GND (WH)
CRS MR HT LT (PU)
CRS MR HT LT (PU)
C709
F
A
B
C
LEFT CROSS
MIRROR HEAT
CRS MR HT LT (PU)
C719
CRS MR GND (WH)
CRS MR HT RT (PU)
C706
F
LEFT CROSS
MIRROR HEAT
CRS MR HT RT(PU)
779
OUT SPKR +
OUT SPKR -
WASH MTR PWR
WASH MTR GND
EXTERIOR
SPEAKER
CAT C7-07
CRS MR HT RT(PU)
A
B
C
WASHER
BOTTLE
Sheet 13
0116697
MIRROR HEAT/EXTERIOR SPEAKER/WIPER WASHER
L
1
780
L
service manual
chassis electrical
BRAKE WARNING IGNITION
START/CHARGE
SHT. 2/3
C703
BRAKE WARN IGN (OR)
BRAKE WARN IGN (OR)
18
BRAKE WARN IGN (OR)
C729
S25
ENGINE C7
SHT. 4
15
BRAKE WARN GND (WH)
A
B
C
D
TO
HYDRAULIC BRAKE
BOOST HARNESS
C703
BRAKE WARN LGT (TN)
BRAKE WARN LGT (TN)
13
BRAKE WARN LGT (TN)
C703
AB-111A (RD)
DCM GND (WH)
BRAKE BOOST BAT (RD)
AB-111A (RD)
17
SERVICE BRAKE LAMP SW - 111A (RD)
DCM GND (WH)
BRAKE BOOST BAT (RD)
C818
A
B
HYD
BRAKE
BOOST
781
CAT C7-07
SERVICE BRAKE
AB MODULE,
SHT. 11
BRAKE WARN GND (WH)
BRAKE WARN IGN (OR)
BRAKE WARN LGT (TN)
BRAKE WARN GND (WH)
AB-111A (RD)
PDU
GROUND
STUD
GROUND
BRAKE WARNING LIGHT
IP
SHT. 17
C703
Sheet 14
0116698
HYDRAULIC BRAKE BOOST,CAT
L
1
service manual
AIR DRYER POWER
START/CHARGE
SHT. 2/3
AIR DRYER PWR
HEATED DRAIN POWER
START/CHARGE
SHT. 2/3
HTD DRAIN PWR (BN)
HEATED FUEL POWER
START/CHARGE
SHT. 2/3
HTD FUEL PWR (PK)
FUEL TANK SIGNAL
IP
SHT. 17
FUEL TANK SIG
FUEL TANK GND (WH)
PDU
GROUND
STUD
C703
11
FUEL TANK GND (WH)
FUEL TANK SIG (BK)
WIF SENSOR (YL)
782
WIF SENSOR (YL)
(BK)
S25
GROUND
WATER IN FUEL
SENSOR LT
SHT. 17
(BL)
12V DC (RD)
SEN GND (BK)
C710 A B C
C730
A
LT (YL)
FUEL
SENDER
HTD FUEL PWR A
HTD FUEL GND A
FUEL TANK GND (WH)
FUEL TANK SIG (BK)
LT (YL)
A B C
A B
WATER IN
FUEL
SENSOR
HEATED
FUEL
FILTER
NOTE: DASHED LINES INDICATE THAT THERE IS AN ADDITIONAL
HARNESS INSTALLED FOR THE WATER IN FUEL OPTION.
L
chassis electrical
S4
GND A
GND
GROUND
WASH MTR GND (WH)
WASH MTR GN (WH)
S5
WASHER MOTOR GROUND
MIRROR HEAT
SHT. 13
AIR DRYER GND (WH)
HTD DRAIN GND (WH)
HTD FUEL GND (WH)
FUEL TANK GND (WH)
FUEL TANK SIG (BK)
HTD FUEL PWR (PK)
HTD DRAIN PWR (BN)
AIR DRYER PWR (BL)
C703 6 7 8 10 12
CONNECTS TO
ENGINE HARNESS
C734 A B
HEATER
DRAIN
VALVE
C733 A B
HEATER
DRAIN
VALVE
CAT C7-07
S2
S1
WIF 2 (WH)
WIF RTN (YL)
HTR DRAIN PWR C (PU)
HTD DRAIN GND C (WH)
HTR DRAIN PWR B (PU)
HTD DRAIN GND B (WH)
C736
783
AIR DRYER PWR (BL)
AIR DRYER GND (WH)
HTD FUEL PWR (PK)
HTD FUEL GND (WH)
1 2
HTD DRAIN PWR A (PU)
HTD DRAIN GND A (WH)
C726
A
B
HTD DRAIN PWR (PU)
HTD DRAIN GND (WH)
C705 A B C D E F
C727 B A
C728 A B
C735 A B
HEATED
DRAIN
VALVE
AIR
DRYER
CUMMINS
FUEL FILTER
AT FRAME RAIL
Sheet 15
0116699
FRAME COMPONENTS
L
1
service manual
C700
A
TO
HEATER/STEPWELL
HARNESS
C
D
E
F
CRS ARM CTL(BL)
CRS ARM CTL(BL)
S2
CRS ARM HEAT(PU)
CRS ARM PWR(BK)
CRS ARM LGT(YL)
CRS ARM GND(WH)
CRS ARM CTL A(BL)
P
CRS ARM MG PWR(OR)
784
L
CRS ARM CTL B(BL)
chassis electrical
C730
CRS ARM MG PWR(OR)
CRS ARM GND B(WH)
CRS ARM CTL B(BL)
A
B
C
CROSSING ARM
MAGNET
CRS ARM GND B(WH)
D
CRS ARM GND(WH)
CRS ARM GND A(WH)
S1
C723
CRS ARM CTL A(BL)
CRS ARM HEAT(PU)
A
B
C
785
CROSSING ARM
D
CAT C7-07
CRS ARM PWR(BK)
CRS ARM GND A(WH)
C722
CRS ARM LGT(YL)
A
CROSSING ARM
LIGHT
Sheet 16
0116700
CROSSING ARM
L
"A" CONNECTOR C302
22 WAY CONNECTOR
GREEN
"B" CONNECTOR C300
30 WAY CONNECTOR
GREEN
"C" CONNECTOR C301
30 WAY CONNECTOR
BLUE
C300
3
25
23
28
13
20
14
21
9
24
10
6
C301
3
5
23
8
10
12
1
13
20
14
21
22
24
25
26
PROGRAM 1 (RD)
PROGRAM 2 (RD)
D PWR (BK)
D IGN (RD)
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
AB-110D (GN)
DCHASS GND (WH)
J1939+ (YL)
J1939- (GN)
J1587+A (YL)
J1587-A (BL)
FUEL TANK SIG (BK)
AB-102D (YL)
AA-105 (PK)
AA-112B (PU)
F AIR IN (GN)
F AIR +5V (OR)
R AIR IN (GN)
R AIR +5V (OR)
ILLUM H (BL)
WIF SENSOR (YL)
AMMETER+ (RD)
ABS HYD 1 (TN)
BRAKE WARN LGT (TN)
HYD INTLK AML (YL)
STOP LGT A (RD)
ABS AIR 1 (TN)
HIGH IDLE (OR)
FAA IN (GN)
FAA +5V (OR)
RAA IN (GN)
RAA +5V (OR)
AB-015B (WH)
CC ON/OFF (GY)
CC SET (BN)
CC RESUME (GN)
F AIR GND (WH)
F AIR +5V (OR)
F AIR IN (GN)
786
C302
13
14
1
3
4
5
6
7
21
2
15
16
17
18
C304
A B C
FRONT AIR
TRANSDUCER
L
C305
A B C
REAR AIR
TRANSDUCER
FAA GND (WH)
FAA +5V ((OR)
FAA IN (GN)
INSTRUMENT CLUSTER
service manual
R AIR GND (WH)
R AIR +5V (OR)
R AIR IN (GN)
1
C306
A B C
FRONT APPLIED
AIR TRANSDUCER
chassis electrical
PROGRAM 1 (RD)
PROGRAM 2 (RD)
C303
B
A
DASH PROGRAM PORT
D PWR (BK)
D IGN (RD)
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
AB-110D (GN)
J1939+ (YL)
J1939- (GN)
J1587+A (YL)
J1587-A (BL)
FUEL TANK SIG (BK)
AB-102D (YL)
AA-105 (PK)
AA-112B (PU)
ILLUM H (BL)
WIF SENSOR (YL)
AMMETER+ (RD)
ABS LT (TN)
ABS HYD (TN)
BRAKE WARN LGT (TN)
HYD INTLK AML (YL)
STOP LGT A (RD)
ABS AIR (TN)
HIGH IDLE (OR)
ABS LT (TN)
J1939 DIAGNOSTIC INTERFACE, SHT 22/23
J1939 DIAGNOSTIC INTERFACE, SHT 22/23
J1587 DIAGNOSTIC INTERFACE, SHT 22/23
J1587 DIAGNOSTIC INTERFACE, SHT 22/23
FUEL TANK SIGNAL, FRAME COMPONETS, SHT 15
L/TURN SIGNAL, AB MODULE, SHT 11
PARK BRAKE SIGNAL, AA MODULE, SHT 10
HIGH BEAM INPUT, AA MODULE, SHT 10
PANEL DIMMER, SHT 7
WATER IN FUEL, SHT 15
CURRENT SENSOR, SHT 2/3
HYD ABS DIAG LIGHT; AC MODULE , SHT 12
HYD ABS LIGHT, SHT 9
BRAKE WARNING LIGHT, SHT 14
DRIVERS CONTROL MODULE, SHT 18/19
STOPLIGHT, AB MODULE, SHT 10
AIR ABS LIGHT, SHT 8
HIGH IDLE INPUT, AB MODULE, SHT 11
AIR ABS DIAG LIGHT; AC MODULE, SHT 12
SHIFT INHIBIT SIGNAL, AB MODULE, SHT 11
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
787
RAA GND (WH)
RAA +5V (OR)
RAA IN (GN)
CAT C7-07
AB-015B (WH)
CC ON/OFF (GY)
CC SET (BN)
CC RESUME (GN)
DASH POWER, SHT 2/3
DASH POWER, SHT 2/3
DRIVERS CONTROL MODULE, SHT 18/19
DRIVERS CONTROL MODULE, SHT 18/19
DRIVERS CONTROL MODULE, SHT 18/19
DRIVERS CONTROL MODULE, SHT 18/19
R/TURN SIGNAL, AB MODULE, SHT 11
C307
A B C
REAR APPLIED
AIR TRANSDUCER
Sheet 17
0119063
INSTRUMENT CLUSTER
L
1
service manual
AC MODULE, HORN BUTTON, SHT 12
AC MODULE, HIGH BEAM SWITCH, SHT 12
CAT 7, SHT 4
AC MODULE, LEFT TURN SWITCH, SHT 12
AC MODULE, RIGHT TURN SWITCH, SHT 12
AB MODULE, PARK BRAKE SWITCH, SHT 11
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
AB MODULE, SERVICE BRAKE, SHT 11
START/CHARGE SHT 2/3
AC MODULE, ACCESSORY SWTICH, SHT 12
AC MODULE, IGNITION SWITCH, SHT 12
AC MODULE, START SWITCH, SHT 12
AC MODULE, INTERLOCK FEEDBACK, SHT 12
INTERLOCK POWER, SH 2/3
BRAKE INTERLOCK POWER, SHT 2/3
CAT 7, SHT 4
CAT 7, SHT 4
CAT 7, SHT 4
AA-101B
AA MODULE,WIPER MOTOR INTERMITTANT,SHT 10
WIPER + (BK)
WIPER INT (GN)
BODY INTERFACE, SHT 18/19
BODY INTERFACE, SHT 18/19
788
WINDSHIELD
WIPER
MOTOR
HIGH 2
LOW 1
PARK 4
12V 3
GND 5
C200
2112 (RD)
2111 (DK GN)
2115 (YL)
1124SS (BK)
1216DD (WH)
WIPER
WASHER
PUMP
A
B
C
D
E
F
M
AC MODULE, WIPER WASHER PUM, SHT 13
AC MODULE, INTERMITTANT WIPER SWITCH, SHT 12
AB MODULE, WASHER PUMP SWITCH, SHT 11
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
START CHARGE SHT 2/3
L
WIPER
PARK
RELAY
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK 2 (BL)
WIPER +A (BK)
WIPER GND (WH)
AB-122 (TN)
86
85
30
87
87A
chassis electrical
COLUMN GND (WH)
AC-010 (GY)
TURN SIG GND (WH)
AC-007 (OR)
SEN COM B (TN)
WIPER+B (BK)
AC-008A (YL)
AC-009A (GN)
PARK BK GND (WH)
AB-012 (PK)
CC ON/OFF (GY)
CC RESUME (GN)
CC SET (BN)
AB-111B (RD)
BRAKE SW PWR (RD)
IGN SW GND (WH)
AC-003 (YL)
AC-004 (PK)
AC-005 (PU)
INTLK FB GND (WH)
AC-013 (OR)
AB-015A (WH)
INTLK PWR (RD)
THROT SIG (BN)
THROT COM (PK)
THROT PWR (BL)
DCM
C5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
HORN SIG
TURN SIG GND
HIGH BEAM
SENS COMA
WIPER+A
LH DIR
RH DIR
PARK BK GND
PARK BRAKE SIG
EJ159
EJ144
EJ135
STOP LGT SIG
STOP LGT PWR
IGN SW GND
ACC
IGN
START SW
BVA PRESSURE SW
BVA PRESSURE SW
BVA GND
BVA POWER
THROT SIG
THROT COM
THROT PWR
HORN AND HAZARD
HORN SIG #2
COLUMN GND
1
2
HORN SIG #1
HORN SIGNAL
3
AIR BRAKE PARK SWITCH
A
B
D
C
PARK BRAKE GROUND
PARK BRAKE SIGNAL
STOP LIGHT SWITCH #2
A
B
D
C
STOP LIGHT
STOP LIGHT POWER
TO BVA
PRESSURE SWITCH
BVA SOLENOID
BVA GROUND
BVA POWER
B
A
THROTTLE
A
B
C
THROTTLE
SENSOR
PEDAL
STOP LIGHT SWITCH #1
A
B
C
D
START SWITCH
TURN SIGNAL
1
2
3
4
5
6
7
8
9
10
11
12
13
14
C16
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
D DIAG PWR (BK)
HIGH BEAM INDICATOR
HIGH BEAM SIGNAL
LEFT TURN SIGNAL
RIGHT TURN SIGNAL
GROUND
STEERING COLUMN SWITCH
DCM
A
B
C
D
E
F
G
H
J
K
L
M
COM
ON
RESUME/COAST
SET SET +/ ACCEL
WIPER/INST
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK (BL)
AC-112 (BK)
AB-108 (PK)
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
D DIAG PWR (BK)
1
2
3
4
5
6
7
8
9
10
11
12
789
CAT C7-07
BAT
START
IGN 1
IGN 2
ACC 1
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK 1 (BL)
AC-112 (BK)
AB-108 (PK)
STOP LIGHT POWER
STOP LIGHT
+12V SUPPLY
HIGH SPEED WIPER
LOW SPEED WIPER
PARK CONTROL WIPER
INTERMITTENT WIPER
WASHER MOTOR
RETURN
ESC
UP
DOWN
COM
Sheet 18
0116702
DRIVER’S CONTROL MODULE,CAT,AIR
L
1
service manual
AC MODULE, HORN BUTTON, SHT 12
AC MODULE, HIGH BEAM SWITCH, SHT 12
CAT 7, SHT 4
AC MODULE, LEFT TURN SWITCH, SHT 12
AC MODULE, RIGHT TURN SWITCH, SHT 12
AB MODULE, PARK BRAKE SWITCH, SHT 11
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
AB MODULE, SERVICE BRAKE, SHT 11
START/CHARGE SHT 2/3
AC MODULE, ACCESSORY SWTICH, SHT 12
AC MODULE, IGNITION SWITCH, SHT 12
AC MODULE, START SWITCH, SHT 12
HYDRAULIC INTERLOCK ALARM, SHT 17
AC MODULE, INTERLOCK FEEDBACK, SHT 12
HYDRAULIC INTERLOCK POWER, SH 2/3
AB MODULE, BRAKE INTERLOCK, SHT 11
CAT 7, SHT 4
CAT 7, SHT 4
CAT 7, SHT 4
AA-101B
AA MODULE,WIPER MOTOR INTERMITTANT,SHT 10
WIPER + (BK)
WIPER INT (GN)
BODY INTERFACE, SHT 18/19
BODY INTERFACE, SHT 18/19
790
WINDSHIELD
WIPER
MOTOR
HIGH
LOW
PARK
12V
GND
2
1
4
3
5
WIPER
WASHER
PUMP
AC MODULE, WIPER WASHER PUM, SHT 11
AC MODULE, INTERMITTANT WIPER SWITCH, SHT 12
AB MODULE, WASHER PUMP SWITCH, SHT 11
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
START CHARGE SHT 2/3
L
C200
A
B
C
D
E
F
2112 (RD)
2111 (DK GN)
2115 (YL)
1124SS (BK)
1216DD (WH)
M
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK 2 (BL)
WIPER +A (BK)
WIPER GND (WH)
AB-122 (TN)
WIPER
PARK
RELAY
86 30
85
87
87A
chassis electrical
THROT SIG (BN)
THROT COM (PK)
THROT PWR (BL)
DCM
C5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
HORN SIG
TURN SIG GND
HIGH BEAM
SENS COMA
WIPER+A
LH DIR
RH DIR
PARK BK GND
HYD PARK BRAKE SIG
EJ159
EJ144
EJ135
STOP LGT SIG
STOP LGT PWR
IGN SW GND
ACC
IGN
START
ALARM OUT
LOCKED OUT
HYD INTLK PWR
HYD INTLK GND
HYD INTLK ACT INPUT
THROT SIG
THROT COM
THROT PWR
BAT
START
IGN 1
IGN 2
ACC 1
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
D DIAG PWR (BK)
HYDRAULIC STOP LIGHT SWITCH
STOP LIGHT SIGNAL
B
A
STOP LIGHT POWER
MICO HYD BRAKE INTERLOCK MODULE
DIRECT ALARM OUTPUT
23
LOCKED OUTPUT
15
12V BATT
1
GROUND
17
ACTIVATION INPUT
8
A
B
C
THROTTLE
SENSOR
PEDAL
STEERING COLUMN SWITCH
DCM
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK 1 (BL)
AC-112 (BK)
AB-108 (PK)
HYDRAULIC PARK BRAKE SWITCH
A
CHASSIS GROUND
PARK BRAKE SIG
B
TURN SIGNAL
COM
1
ON
2
RESUME/COAST
3
SET 4
SET +/ACCEL
5
6
7
8
9
HIGH BEAM INDICATOR
10
HIGH BEAM SIGNAL
11
LEFT TURN SIGNAL
12
RIGHT TURN SIGNAL
13
GROUND
14
START SWITCH
C16
A
B
C
D
E
F
G
H
J
K
L
M
HORN AND HAZARD
COLUMN GND
1
2
HORN SIG #1
HORN SIGNAL
3
HORN SIG #2
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK (BL)
AC-112 (BK)
AB-108 (PK)
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
D DIAG PWR (BK)
WIPER/INST
+12V SUPPLY
1
HIGH SPEED WIPER
2
LOW SPEED WIPER
3
PARK CONTROL WIPER
4
INTERMITTENT WIPER
5
WASHER MOTOR
6
7
RETURN
8
ESC
9
UP
10
DOWN
11
COM
12
791
CAT C7-07
COLUMN GND (WH)
AC-010 (GY)
TURN SIG GND (WH)
AC-007 (OR)
SEN COM B (TN)
WIPER+B (BK)
AC-008A (YL)
AC-009A (GN)
PARK BK GND (WH)
AB-012 (PK)
CC ON/OFF (GY)
CC RESUME (GN)
CC SET (BN)
AB-111B (RD)
BRAKE SW PWR (RD)
IGN SW GND (WH)
AC-003 (YL)
AC-004 (PK)
AC-005 (PU)
HYD INTLK ALM (YL)
AC-013 (OR)
HYD INTLK PWR (RD)
HYD INTLK GND (WH)
AB-015A (WH)
Sheet 19
0116703
DRIVER’S CONTROL MODULE,CAT,HYD
L
1
792
L
service manual
chassis electrical
MBC POWER START/CHARGE,
SHT 2/3
MBC PWR 2 (RD)
MBC POWER START/CHARGE,
SHT 2/3
MBC GND A (WH)
MBC POWER START/CHARGE,
SHT 2/3
MBC PWR 1 (RD)
MBC POWER START/CHARGE,
SHT 2/3
MBC BATT (RD)
MBC POWER START/CHARGE,
SHT 2/3
MBC GND B (WH)
C3 1 2 3
CONN. E
C8
9 CONN. D
10
CV-CCM-C
MBC/DIO
MODULE
Sheet 20
0116704
MBC MODULE
SCC OPTION 30195-13,19
AC MODULE SHT 12
AB MODULE, SHT 11
AA MODULE, SHT 10
AB MODULE, SHT 11
AB MODULE, SHT 11
AC MODULE, SHT 12
DIMMER/BACKLIGHTS, SHT 7
AB MODULE, SHT 11
BODY IGN (OR)
AB-116 (RD)
BODY IGN (OR)
AB-116 (RD)
AC-014 (RD)
AC-014 (RD)
AB-106B (BN)
AA-107 (BL)
AB-110 (GN)
AB-102B (YL)
AB-106B (BN)
AA-107 (BL)
AB-110 (GN)
AB-102B (YL)
AC-011 (PK)
ILLUM B (BL)
AB-021 (RD)
AC-011 (PK)
ILLUM B (BL)
AB-021 (RD)
AA MODULE, SHT 10
AB MODULE, SHT 12
SEE REVERSE MOTION SENSOR DIAGRAM
STOP LGT B (RD)
AC-016 (TN)
REV SENS SIG (GN)
DRIVERS CONTROL MODULE, SHT 18/19
AA MODULE, SHT 10
DRIVERS CONTROL MODULE, SHT 18/19
AC MODULE, SHT 12
WIPER INT (GN)
AA-101 (BN)
WIPER + (BK)
AC HIGH IDLE (GN)
STOP LGT B (RD)
AC-016 (TN)
REV SENS SIG (GN)
BCHASS GND (WH)
WIPER INT (GN)
AA-101 (BN)
WIPER + (BK)
AC HIGH IDLE (GN)
C11
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
+12V IGNITION
ACCESSORY HOT
SCC ALARM
PARK/TAIL LIGHTS
BACK-UP LIGHTS
RIGHT TURN LAMPS
LEFT TURN LAMPS
793
TO BODY
DOOR SWITCH SIGNAL
PANEL DIMMER
LIFT ENABLE
STOP LIGHTS
VANDAL LOCK
REVERSE SENSOR
GROUND
2109A (GN)
2109 (GN)
1124PP (BK)
12V BATT.
AC HIGH IDLE
25A
INTERMITTANT
WIPER
RELY
CAT C7-07
START/CHARGE, SHT 2/3
AA MODULE, SHT 11
86 30
85
87
87A
Sheet 21
0116705
BODY INTERFACE
L
1
service manual
J1587
ENGINE
SHT 4
EJ1587 + (YL)
EJ1587 - (BL)
J1587
TRANS
SHT 5/6
TJ1587 + (YL)
TJ1587 - (BL)
J1587
ABS
SHT 8/9
AJ1587 + (YL)
AJ1587 - (BL)
ENGINE
SHT. 4
TRANS ECU
SHT. 5/6
S15
S16
EJ1939+ (YL)
EJ1939- (GN)
TJ1939+ (YL)
TJ1939- (GN)
S34
S35
J1939+A (YL)
J1939-A (GN)
TJ1939+ (YL)
TJ1939- (GN)
794
J1939
TRANS ECU
SHT. 5/6
L
TJ1939+ (YL)
TJ1939- (GN)
S
R
chassis electrical
J1587+A (YL)
J1587-A (BL)
DIAG PWR (RD)
J1587
INSTRUMENT
CLUSTER
SHT. 17
DIAGNOSTIC
POWER
SHT 2/3
DIAG GND (WH)
J1587+ (YL)
J1587- (GN)
S8
J1587+ B
J1587- B
S9
J1939+A (YL)
J1939-A (GN)
S33
S32
A
B
C
D
E
F
G
H
J
9-PIN
DIAGNOSTIC
TOOL
J1939+ (YL)
J1939- (GN)
J1939
DIAGNOSTIC
INTERFACE
SHT. 17
795
CAT C7-07
DIAG GND
DIAG PWR
DJ1939+ (YL)
DJ1939- (GN)
Sheet 22
0118820
J1939 DATALINK,HYD-E
L
1
J1587
ENGINE
SHT 4
EJ1587 + (YL)
EJ1587 - (BL)
J1587
TRANS
SHT 5/6
TJ1587 + (YL)
TJ1587 - (BL)
J1587
ABS
SHT 8/9
AJ1587 + (YL)
AJ1587 - (BL)
ENGINE
SHT. 4
796
TRANS ECU
SHT. 5/6
ABS ECU
BENDIX
SHT. 8
L
service manual
S15
S16
EJ1939+ (YL)
EJ1939- (GN)
TJ1939+ (YL)
TJ1939- (GN)
S36
J1939+B (YL)
J1939-B (GN)
S37
AJ1939+ (YL)
AJ1939- (GN)
S34
S35
J1939+A (YL)
J1939-A (GN)
chassis electrical
J1587+A (YL)
J1587-A (BL)
DIAG PWR (RD)
J1587
INSTRUMENT
CLUSTER
SHT. 17
DIAGNOSTIC
POWER
SHT 2/3
DIAG GND (WH)
J1587+ (YL)
J1587- (GN)
S8
J1587+ B
J1587- B
S9
J1939+A (YL)
J1939-A (GN)
A
B
C
D
E
F
G
H
J
9-PIN
DIAGNOSTIC
TOOL
J1939+ (YL)
J1939- (GN)
S33
S32
J1939
DIAGNOSTIC
INTERFACE
SHT. 17
797
CAT C7-07
DIAG GND
DIAG PWR
DJ1939+ (YL)
DJ1939- (GN)
Sheet 23
0116707
J1939 DATALINK,AIR
L
1
798
L
service manual
chassis electrical
Electrical Diagrams for Cummins ISB-07 Engines
Description
Index
Starting And Charging, Cummins
Starting And Charging (with Florida circuit breakers)
Cummins ISB07 Engine
Allison Gen 4 2000 Transmission
Allison Gen 4 3000 Transmission
Dimmer / Backlights
ABS - Bendix (air)
ABS - Wabco (hydraulic)
AA Multiplex Module
AB Multiplex Module
AC Multiplex Module
Mirror Heat / Exterior Speaker / Wiper Washer
Hydraulic Brake Boost
Frame Components
Crossing Arm
Instrument Cluster
Driver’s Control Module - Air
Driver’s Control Module - Hydraulic
MBC Module
Body Interface
J1939 Datalink, Hydraulic
J1939 Datalink, Air
Sheet
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Drawing Number
0117178C
0117347A
0117348A
0112291C
0112276
0112292A
0112293
0112294
0117179A
0112296C
0112297B
0112298
0112299
0112300
0112301A
0112302
0117181
0112304A
0112305A
0112306A
0112307
0117183
0112310
Wire Colors
BL BLUE
BK BLACK
BN BROWN
TN TAN
WH WHITE
YL YELLOW
PK PINK
OR ORANGE
RD RED
GN GREEN
PU PURPLE
GY GRAY
PD
AC
IP
FW
SP
DC
Schematic Legend
PDU PANEL
AIR CLEANER BRACKET
INSTRUMENT PANEL
FIREWALL
SHIFTER PANEL
DCM
Electrical Component Index
Fuse
Voltage Stud
2 Wire Twisting
with Shield
Mini Relay
Shunt
Switch Ngr Rocker
(Non-typical)
Horn
Speaker
CUM ISB-07
Heavy Duty Relay
799
3 Wire Twisting
Light
Circuit Breaker
Multiplex Wire Indexing (Circuit Number Code)
Zone
Connector
Voltage (0 = Ground, 1 = 12 Volts)
Connector Pin Number
Sheet 1
Example: (Zone A, Connector A, 12 Volts, Pin #11)
0117178C
SCHEMATIC, WRG, CUM ISB07, INDEX
L
1
service manual
ELEC PWR (BK)
12V ECM IGNITION
RELAY 30/40A
C9
87A
30
87
85 RLY GND A (WH)
86
S26
BATTERY
DISCONNECT
SWITCH
(ONLY WITH
OPTION 40142-01)
PD
12V
PDU
GROUND
STUD
PD
ELEC PWR (BK)
12V
-
ELEC
+
DIAG PWR (OR)
ELEC PWR A (BK)
S25
PDU
GROUND
STUD
CURRENT
SENSOR
-
+
DIO PWR (RD)
PD CB1
DC
12V
MBC GND A (WH)
MBC GND B (WH)
MBC PWR 2 (RD)
MBC PWR 1 (RD)
60A
PD
BATT PWR (RD)
12V
PD
BATT IGN PWR (RD)
A B C D
SEN IGN (RD)
DC
STARTER PWR (RD)
PD
MAIN BODY 12V
FEED TO SOLENOID
IN BODY ELEC PANEL
GND
PDU GND
STUD
C14
STARTER
RELAY
70A
STARTER
MOTOR
STARTER (RD)
C704
W
STARTER (RD)
AA-113C (PK)
C704
T
AA-113C (PK)
M
B
SHUTTER SW PWR (RD)
ALTERNATOR
12V
L
STARTER GND
EX
GND
30
87
86
12
PD
85
START REL GND (WH)
800
AMMETER SIG (RD)
SEN GND (WH)
COPPER BUSBAR
FRAME
GND
GND
MAIN BODY &
STARTER FUSE
200A
ENGINE GND STUD
(HOT SIDE)
chassis electrical
5A
10A
ECM IGN (PK)
5A
12V ECM
IGNITION BUS
PD
10A
5A
F19
5A ENG IGN (OR)
F20
TRANS IGN (OR)
F21
ABS IGN (OR)
F22
DASH IGN (PK)
F23
BRAKE WARN IGN (OR)
AA-111 (OR)
CUMMINS ISB07
SHT. 4
TRANS
SHT. 5/6
ABS
SHT. 8/9
IP
SHT. 17
HYD BRAKE BOOST
SHT. 14
AA MODULE,
SHT 10
MBC GND A (WH)
MBC GND B (WH)
MBC PWR 2 (RD)
MBC MODULE
SHT. 20
MBC PWR 1 (RH)
30A
10A
12V ELEC
PWR BUS
PD
25A
3A
15A
BATT PWR (RD)
30A
12V
BATTERY BUS
PD
40A
30A
10A
10A
3A
10A
F15
TRANS BATT (RD)
F16
EECM PWR (RD)
F17
MBC PWR (RD)
F18
ABS BATT (RD)
F13
DPWR (BK)
F10
STOP LGT PWR (RD)
F12
PMP MTR BATT (RD)
F7
BRAKE BOOST BATT (RD)
F11
HYD INTLK PWR (RD)
F11
INTERLOCK PWR (RD)
F9
REV SENS + (RD)
F14
D DIAG PWR (BK)
F8
BRAKE SW PWR (RD)
AA-114 (RD)
AA-113 (PK)
AA-113A (PK)
30
87
86
12
PD
85
C13
IGNITION
RELAY
70A
IGN REL GND (WH)
20A
20A
S26
IGN PWR (RD)
10A
12V
IGNITION BUS
PDU
GROUND
STUD
F1
HTD FUEL PWR (PK)
F5
HTD DRAIN PWR (BN)
F3
AIR DRYER PWR (BL)
PD
10A
15A
F4
FAN PWR (RD)
F6
BODY IGN (OR)
AMMETER SIG (RD)
DCM GND
DIAGNOSTIC, SHT 22/23
TRANS
SHT.5/6
CUMMINS ISB07
SHT. 4
MBC MODULE
SHT. 20
ABS
SHT. 9
IP
SHT. 17
AA MODULE
SHT. 10
ABS
SHT. 9
HYD BRAKE BOOST
SHT. 14
DRIVER'S CNTRL MODULE
SHT. 18
DRIVERS CONTROL MOD
SHT. 19
SEE DIAGRAM,WRG
FEA 2226
DRIVER'S CNTRL MODULE,
SHT 18/19
DRIVER'S CNTRL MODULE,
SHT 18/19
AA MODULE, SHT 10
801
AA MODULE, SHT 10
FRAME COMPONETS
SHT. 15
FRAME COMPONETS
SHT. 15
FRAME COMPONETS
SHT. 15
CUMMINS ISB07
SHT. 4
BODY INTERFACE
SHT. 21
CUM ISB-07
DIAG PWR (OR)
10A
CUMMINS ISB07 SHT. 4
HYD BRAKE BOOST
SHT. 14
SHUTTER GND
SHUTTER SW PWR (RD)
CUMMINS ISB07
SHT. 4
Sheet 2
0117347A
STARTING AND CHARGING,CUMMINS
L
1
service manual
ELEC PWR (BK)
12V ECM IGNITION
RELAY 30/40A
C9
87A
30
86
87
85 RLY GND A (WH)
S26
BATTERY
DISCONNECT
SWITCH
(ONLY WITH
OPTION 40142-01)
PD
12V
PD
ELEC PWR (BK)
12V
-
ELEC
+
DIAG PWR (OR)
ELEC PWR A (BK)
S25
PDU
GROUND
STUD
CURRENT
SENSOR
-
+
DIO PWR (RD)
PD CB1
DC
12V
MBC GND A (WH)
MBC GND B (WH)
MBC PWR 2 (RD)
MBC PWR 1 (RD)
60A
PD
BATT PWR (RD)
12V
PD
BATT IGN PWR (RD)
A B C D
802
STARTER PWR (RD)
PD
MAIN BODY 12V
FEED TO SOLENOID
IN BODY ELEC PANEL
C14
STARTER
RELAY
70A
GND
PDU GND
STUD
STARTER
MOTOR
STARTER (RD)
C704
W
STARTER (RD)
AA-113C (PK)
C704
T
AA-113C (PK)
M
B
SHUTTER SW PWR (RD)
ALTERNATOR
12V
L
STARTER GND
EX
GND
ENGINE GND STUD
(HOT SIDE)
30
87
86
12
PD
85
START REL GND (WH)
DC
GND
COPPER BUSBAR
AMMETER SIG (RD)
SEN GND (WH)
SEN IGN (RD)
FRAME
GND
MAIN BODY &
STARTER FUSE
200A
PDU
GROUND
STUD
chassis electrical
5A
10A
ECM IGN (PK)
5A
12V ECM
IGNITION BUS
PD
10A
7.5A
F19
5A ENG IGN (OR)
F20
TRANS IGN (OR)
F21
ABS IGN (OR)
CB22
DASH IGN (PK)
CB23
BRAKE WARN IGN (OR)
AA-111 (OR)
CUMMINS ISB07
SHT. 4
TRANS
SHT. 5/6
ABS
SHT. 8/9
IP
SHT. 19
HYD BRAKE BOOST
SHT. 16
AA MODULE, SHT 10
MBC GND A (WH)
MBC GND B (WH)
MBC MODULE
SHT. 20
MBC PWR 2 (RD)
MBC PWR 1 (RD)
10A
30A
10A
12V ELEC
PWR BUS
PD
25A
7.5A
15A
BATT PWR (RD)
30A
12V
BATTERY BUS
PD
40A
30A
10A
10A
3A
10A
F15
TRANS BATT (RD)
F16
EECM PWR (RD)
CB17
MBC BATT (RD)
F18
ABS BATT (RD)
CB13
87
86
12
PD
85
20A
C13
IGNITION
RELAY
70A
IGN REL GND (WH)
IGN PWR (RD)
20A
10A
S26
12V
IGNITION BUS
PDU
GROUND
STUD
15A
ABS
SHT. 9
IP
SHT. 17
STOP LGT PWR (RD)
AA MODULE, SHT 10
CB12
PMP MTR BATT (RD)
ABS
SHT. 9
HYD BRAKE BOOST
SHT. 14
F7
BRAKE BOOST BATT (RD)
CB11
HYD INTLK PWR (RD)
CB11
INTLK PWR (RD)
CB9
REV SENS + (RD)
CB14
D DIAG PWR (BK)
CB8
BRAKE SW PWR (RD)
DRIVER'S CNTRL MODULE
SHT. 18
DRIVERS CONTROL MOD
SHT. 19
SEE DIAGRAM,WRG
FEA 2226
DRIVER'S CNTRL MODULE,
SHT 18/19
DRIVER'S CNTRL MODULE,
SHT 18/19
AA-114 (PK)
AA MODULE, SHT 10
AA-113 (PK)
AA MODULE, SHT 10
CB1
HTD FUEL PWR (PK)
CB5
HTD DRAIN PWR (BN)
CB3
AIR DRYER PWR (BL)
FRAME COMPONETS
SHT. 15
FRAME COMPONETS
SHT. 15
FRAME COMPONETS
SHT. 15
CB4
FAN PWR (RD)
CB6
BODY IGN (OR)
PD
10A
TRANS
SHT. 5/6
CUMMINS ISB07
SHT. 4
MBC MODULE
SHT. 20
CB10
AA-113A (PK)
30
DPWR (BK)
DIAGNOSTICS, SHT 22/23
AMMETER SIG (RD)
DCM GND
SHUTTER GND
SHUTTER SW PWR (RD)
CUMMINS ISB07
SHT. 4
BODY INTERFACE
SHT. 21
CUMMINS ISB07
SHT. 4
HYD BRAKE BOOST
SHT. 14
803
CUM ISB-07
DIAG PWR (OR)
CUMMINS ISB07
SHT. 4
Sheet 3
0117348A
STARTING AND CHARGING, CUMMINS W/FEA 40142-11
(Florida circuit breakers)
L
1
service manual
EECM POWER START CHARGE SHT. 2/3
ENGINE IGN START CHARGE SHT. 2/3
INSTRUMENT PANEL SHT. 19
MODULE AB SHT. 11
MODULE AC SHT. 12
MODULE AC SHT. 12
MODULE AC SHT. 12
DRIVER'S CONTROL MODULE
SHT. 18/19
DIMMER/BACKLIGHTS SHT. 7
DIMMER/BACKLIGHTS SHT. 7
GND 3H
ILLUM K
GND 3H
ILLUM K
9
7
VGT SW (BL)
2B 3
1
5B 6
4
8
10
VGT BRAKE
SWITCH
C426
VGT RET SW (WH)
910ΩRESISTOR
.5W 5%
C10
FAN RELAY
4
START CHARGE SHT. 2/3
804
FAN PWR (RD)
3
1
5
2
J1939 DATALINK SHT. 22/23
J1939 DATALINK SHT. 22/23
INSTRUMENT PANEL SHT. 17
INSTRUMENT PANEL SHT. 17
START/CHARGE SHT. 2/3
INSTRUMENT PANEL SHT. 17
250A FUSE
START/CHARGE SHT. 2/3
2 GA (RD)
INTAKE AIR
HEATER SOLENOID
2
1
85
86
INTAKE AIR
HEATER
START/CHARGE SHT. 2/3
START/CHARGE SHT. 2/3
SHUTTER SW PWR (RD)
SHUTTER GND (WH)
SHUTTER PWR (OR)
SHUTTER COM (OR)
C807 B A
SHUTTER
SOLENOID
L
NC
AIR TEMP
SHUTTER SWITCH
NC
WATER TEMP
SWITCH
chassis electrical
ENGINE BLOCK
GROUND
S5
EECM PWR (RD)
5A ENG IGN (OR)
C704
U
V
WAIT START (GN)
AC-102 (RD)
AB-009 (BN)
VGT BRK SIG
AB-001A
C701
1
23
18
24
12
THROT PWR 1 (BL)
THROT SIG 1 (BN)
THROT RET 1 (PK)
THROT RET SENS (PK)
THROT SIG 2 (BN)
SENSOR PWR (BL)
VGT SW (BL)
ENG GND 1 (WH)
ENG GND 2 (WH)
EECM PWR 1 (RD)
EECM PWR 2 (RD)
C808
1
2
3
4
ENGINE
POWER
CONNECTOR
5A ENG IGN1 (OR)
6
8
7
5
13
20
5A ENG IGN2 (OR)
S10
ECM RET SENS-B1 (PK)
SENSOR PWR-C1 (BL)
SENSOR PWR-C2 (GN)
SENSOR PWR-C3 (GN)
S9
S6
ENGINE CONTROL MODULE (ECM)
(ENGINE J1 - 60 PIN CONNECTOR)
C800
45 KEYSWITCH
WAIT START (GN)
AC-102 (RD)
AB-009 (BN)
VGT BRK SIG (RD)
HI IDLE (OR)
53
2
17
55
18
WAIT TO START LAMP
STARTER LOCKOUT
THROTTLE INTERLOCK
VGT BRAKE LGT
REMOTE PTO ON/OFF SW
THROT PWR 1 (BL)
THROT SIG 1 (BN)
THROT RET 1 (PK)
ECM RET SENS-B (TN)
THROT SIG 2 (BN)
SENSOR PWR-C (BL)
27
35
28
22
25
26
APS 1 SOURCE
APS 1 SENSOR
APS 1 RET
ECM RET (SENSOR)
APS 2 SENSOR
SENSOR SUPPLY +5V
VGT SW (BL)
5
VGT BRAKE SWITCH
REGEN SIG (OR)
20
DIAGNOSTIC/REGEN SW
ECM RET SW-A (TN)
41
ECM RETURN
49
40
9
34
DPF TEMPERATURE SENSOR 1 (INLET)
DPF TEMPERATURE SENSOR 2 (MID)
DPF TEMPERATURE SENSOR (OUTLET)
CST DELTA PRESSURE SENSOR SIG
COOL LVL (PK)
ECM RET TL-D (TN)
60
38
COOLANT LEVEL SENSOR
ECM RETURN (SENSOR)
ECM FAN + (BL)
ECM RET GEN-E (WH)
J1939+ (YL)
J1939- (GN)
EJ1587+ (YL)
EJ1587- (BL)
52
32
1
21
39
29
FAN CLUTCH OUTPUT
ECM RETURN
J1939 DIAGNOSTIC +
J1939 DIAGNOSTIC J1587 DIAGNOSTIC +
J1587 DIAGNOSTIC -
IAH OUT (TN)
ECM RET GEN-F (WH)
54
44
INTAKE AIR HEATER OUTPUT
ECM RETURN
3
REGENERATION SWITCH
4
S7
C821
1
2
3
6
4
7
5
TO DPF
C816
A
B
C
COOLANT
LEVEL
PROBE
C815
A
FAN
CONTROLLER
S8
FAN CL +A (OR)
FAN CL GND (WH)
C
FAN CL +A (OR)
ECM FAN +(BL)
ECM RET GEN (WH)
EJ1939+ (YL)
EJ1939- (GN)
EJ1587+ (YL)
EJ1587- (BL)
AMMETER SIG (RD)
ECM RET TL-D1 (WH)
DPF TEMP 1 (RD)
DPF TEMP 2 (OR)
DPF TEMP 3 (YL)
PRES SENSOR SIG (BL)
ECM RET TL-D2 (TN)
ECM RET SENS-B2 (TN)
SENSOR PWR-C3 (GN)
C701
25
26
27
30
31
14
15
17
AMMETER SIG (RD)
C802
A
B
C
WIF2 WH 16 GA
WIF RTN YL 16 GA
WIF ENGINE
INTERFACE
C822 1 2
WATER IN FUEL
WATER IN FUEL RETURN
C823 1 2
WATER IN FUEL
WATER IN FUEL RETURN
1536 (TN)
1208D (WH)
805
CUM ISB-07
ECM RET SW (TN)
ECM RET SW-A1 (TN)
ECM RET SW-A2 (TN)
WIF FRAME HARNESS
INTERFACE
Sheet 4
0112291C
CUMMINS ISB07 ENGINE
L
1
service manual
PDU
INTERFACE
C702
A TRANS TEMP/164 (BL)
IP TJ1939, SHT 17
IP TJ1939, SHT 17
NOT USED
NOT USED
NOT USED
AB-004 (BL)
AB MODULE, SHT 11
NOT USED
TJ1939+ (YL)
AB-107 (RD)
TJ1939- (GN)
AB MODULE, SHT 11
AB MODULE, SHT 11
TRANS BATT START/CHARGE, SHT 2/3
TRANS IGN START/CHARGE, SHT 2/3
S14
806
TELEC GND (WH)
IP TJ1587, SHT 17
IP TJ1587, SHT 17
SHIFT INHIBIT IN AB MODULE, SHT 11
ELECTRONIC
GROUND
RESERVED
RESERVED
AB-003 (RD)
TELEG GNDA (WH)
TRANS BAT (RD)
TRANS IGN (OR)
TELEC GND B (WH)
TJ1587+ (YL)
TJ1587- (BL)
AB-005 (GN)
MAIN TRANSMISSION
LSD SS1
LSD SS2
LSD SS3
PS1
PS3
PS2
SUMP TEMP
SIGNAL RETURN
LSD TCC
PS4
HSD1
LSD PCS1
HSD2
LSD PCS2
DIGITAL SIGNAL NS
LSD MAIN MOD
DIGITAL SIGNAL C
DIGITAL SIGNAL B
DIGITAL SIGNAL A
DIGITAL SIGNAL P
TRANS ID
L
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
C906
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
NOT USED
CHECK TRANS/129 (GN)
NOT USED
NOT USED
B2-016/165 (TN)
NOT USED
TJ1939+ (YL)
B1-112/141 (TN)
TJ1939- (GN)
RESERVED
RESERVED
B1-002/105 (OR)
169 (GY)
TRANS BAT (PK)
TRANS IGN/163 (YL)
109 (GY)
NOT USED
NOT USED
B3-015/101 (BL)
124 (WH)
152 (GN)
133 (YL)
151 (WH)
117 (BL)
157 (WH)
179 (PK)
154 (TN)
158 (GN)
178 (WH)
177 (GN)
111 (OR)
155 (WH)
171 (YL)
136 (OR)
138 (OR)
174 (BL)
114 (GY )
153 (YL)
173 (BL)
134 (WH)
176 (YL)
chassis electrical
B1-002/105 (OR)
TJ1939+ (YL)
TJ1939- (GN)
109 (GY)
110 (PK)
111 (OR)
114 (GY)
117 (BL)
120 (BL)
124 (WH)
CHECK TRANS/129 (GN)
133 (YL)
134 (WH)
136 (OR)
138 (OR)
139 (OR)
140 (GN)
B1-112/141 (TN)
151 (WH)
152 (GN)
153 (YL)
154 (TN)
155 (WH)
S1
157 (WH)
158 (GN)
159 (TN)
160 (YL)
TRANS IGN/163 (YL)
TRANS TEMP/164 (BL)
B2-016/165 (TN)
169 (GY)
170 (PK)
171 (YL)
173 (BL)
174 (BL)
C905 B A
ENGINE
SPEED
SENSOR
C902 B A
OUTPUT
SPEED
SENSOR
TRANSMISSION TCM CONNECTOR
AUX FUNCTION RANGE INHIBIT
3 MPH SIGNAL
J1939+
J1939GROUND
BATTERY
HSD1
DIGITAL SIGNAL C
PS1
TURBINE SPEED LOW
RANGE INHIBIT LIGHT
CHECK TRANS
LSD SS2
DIGITAL SIGNAL
LSD PCS2
DIGITAL SIGNAL NS
ENGINE SPEED LOW
OUTPUT SPEED LOW
NEUTRAL SAFETY
LSD SS3
LSD SS1
DIGITAL SIGNAL B
SUMP TEMP
LSD PCS1
PS3
SIGNAL RETURN
ENGINE SPEED HIGH
OUTPUT SPEED HIGH
IGNITION
TRANS TEMP LIGHT
REVERSE SIGNAL
807
GROUND
BATTERY
HSD2
DIGITAL SIGNAL A
LSD MAIN MOD
TRANS ID
PS4
LSD TCC
PS2
TURBINE SPEED HIGH
120 (BL)
180 (OR)
140 (GN)
160 (YL)
139 (OR)
159 (TN)
176 (YL)
177 (GN)
178 (WH)
179 (PK)
180 (OR)
C926
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
CUM ISB-07
B3-015/101 (BL)
C928 B A
TURBINE
SPEED
SENSOR
Sheet 5
0112276
ALLISON GEN 4 2000 TRANSMISSION
L
1
service manual
TO CONNECTOR C6
IP, SHT 17
C6 A B
C932
1
2
ILLUMINATION
3
4
GROUND 5
6
7
J1939+ 8
9
10
DIRECTIONAL SIGNAL
11
IGNITION
12
BATTERY POWER 13
14
TRANS BAT (RD)
15
16
SHIFT SELECTOR
AB MODULE, SHT 11
J1939+ (YL)
AB-107 (RD)
J1939- (GN)
AB MODULE, SHT 11
AB MODULE, SHT 11
TRANS BATT START/CHARGE, SHT 2/3
TRANS IGN START/CHARGE, SHT 2/3
S14
TELEC GND (WH)
808
ELECTRONIC
GROUND
L
GND (WH)
SJ1939+ (YL)
134 (YL)
TRANS IGN A (OR)
TRANS BAT A (RD)
SJ1939- (GN)
ENGINE
COMPARTMENT
INTERFACE
C702
A TRANS TEMP/164 (BL)
B
C CHECK TRANS/129 (GN)
D
E
AB-004 (BL)
F B2-016/165 (TN)
IP TJ1939, SHT 17
IP TJ1939, SHT 17
IP TJ1587, SHT 17
IP TJ1587, SHT 17
SHIFT INHIBIT IN AB MODULE, SHT 11
ILLUM (BL)
AB-003 (RD)
TELEC GNDA (WH)
TRANS BAT (RD)
TRANS IGN (OR)
TELEC GND B (WH)
TJ1587+ (YL)
TJ1587- (BL)
AB-005 (GN)
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
MAIN TRANSMISSION CONNECTION
C906
HSD1 1
LSD PCS4 2
DIGITAL SIGNAL
3
LSD PCS1 4
LSD PCS2 5
HSD2 6
7
LSD MAIN MOD 8
LSD PCS3 9
LSD SS1 10
HSD3 11
LSD TCC 12
TURBINE SPEED HIGH 13
TURBINE SPEED LOW 14
OIL LEVEL 15
OIL LEVEL SIGNAL
16
OIL LIFE MONITOR
17
SUMP TEMP SIGNAL 18
ANALOG RETURN 19
TRANS ID 20
J1939+ (YL)
B1-112/141 (TN)
J1939- (GN)
B1-002/105 (OR)
169 (GY)
TRANS BAT (RD)
TRANS IGN (OR)
109 (GY)
TJ1587+ (YL)
TJ1587- (BL)
B3-015/101 (BL)
111 (OR)
155 (WH)
177 (GN)
136 (OR)
152 (GN)
171 (YL)
174 (BL)
133 (YL)
151 (WH)
131 (YL)
137 (WH)
180 (OR)
120 (BL)
116 (BL)
112 (PK)
118 (BK)
154 (TN)
158 (GN)
176 (YL)
chassis electrical
S3
S4
S1
139 (OR)
159 (TN)
140 (GN)
160 (YL)
S2
C905 B A
C902 B A
ENGINE
SPEED
SENSOR
OUTPUT
SPEED
SENSOR
TRANSMISSION TCM CONNECTOR
AUX FUNCTION RANGE INHIBIT
3 MPH SIGNAL
J1939+
J1939GROUND
BATTERY POWER
HSD1
OIL LEVEL SIGNAL
OIL LEVEL
OIL LIFE MONITOR
TURBINE SPEED LOW
CHECK TRANS
HSD3
J1587+
LSD PCS3
DIRECTIONAL SIGNAL
LSD PCS1
LSD TCC
ENGINE SPEED LOW
OUTPUT SPEED LOW
NEUTRAL SAFETY
LSD SS1
LSD PCS2
SUMP TEMP SIGNAL
LSD PCS4
ANALOG RETURN
ENGINE SPEED HIGH
OUTPUT SPEED HIGH
IGNITION POWER
TRANS TEMP
REVERSE SIGNAL
809
GROUND
BATTERY POWER
HSD2
J1587-
CUM ISB-07
C926
1
2
3
4
B1-002/105 (OR)
5
6
TJ1939+ (YL)
7
TJ1939- (GN)
8
109 (GY)
9
110 (RD)
10
111 (OR)
11
112 (PK)
12
13
14
15
116 (BL)
16
17
118 (BK)
18
19
120 (BL)
20
21
22
23
24
25
26
27
28
CHECK TRANS/129 (GN)
29
30
131 (YL)
31
TJ1587+ (YL)
32
133 (YL)
33
134 (YL)
34
35
136 (OR)
36
137 (WH) 37
38
139 (OR)
39
140 (GN)
40
B1-112/141 (TN)
41
42
43
44
45
46
47
48
49
50
151 (WH) 51
152 (GN)
52
53
154 (TN)
54
155 (WH) 55
56
57
158 (GN)
58
159 (TN)
59
160 (YL)
60
61
62
163 (OR)
63
TRANS TEMP/164 (BL)
64
B2-016/165 (TN)
65
66
67
68
169 (GY)
69
170 (RD)
70
171 (YL)
71
TJ1587- (BL)
72
73
174 (BL)
74
75
176 (YL)
76
177 (GN)
77
78
79
180 (OR)
80
B3-015/101 (BL)
LSD MAIN MOD
TRANS JD
DIGITAL SIGNAL
TURBINE SPEED HIGH
Sheet 6
0112292A
ALLISON GEN 4 3000 TRANSMISSION
L
1
810
L
service manual
chassis electrical
ILLUM J (BL)
ILLUM B (BL)
ILLUM H (BL)
TO ALL OTHER ILLUM
BODY INTERFACE, SHT 21
INSTRUMENT CLUSTER, SHT 17
ILLUM C (BL)
S12
7
2B
3
9
7
2B
1
6
5B
8
4
3
9
7
2B
1
6
5B
10
8
4
3
C12
9
C
A
D
B
F
1
6
5B
10
8
4
10
AB-106C (BN)
AB MODULE, SHT 11
AB-106D (BN)
DIMMER
SWITCH
TYPICAL DASH SWITCH BACKLIGHTING/DIMMER CIRCUITS.
DIMMER POWER AND GROUNDS CONTINUE TO LOOP FROM SWITCH TO SWITCH.
CUM ISB-07
811
Sheet 7
0112293
DIMMER/BACKLIGHTS
L
service manual
ABS BAT (RD)
ABS IGN (OR)
LEFT FRONT
SENSOR
LF SENSOR IN (PU)
LF SENSOR RTN (BK)
ABS GND (WH)
S
H E
RF MOD COM (GY)
RF MOD EXH (OR)
RIGHT REAR
MOD VALVE
H E
H E
1 2
C510
1 2 3 4
C502
1 2 3 4
RR MOD EXH (OR)
RR MOD COM (GY)
RR MOD HOLD (GN)
C503
LR MOD EXH (TN)
LR MOD COM (GY)
LR MOD HOLD (BL)
1 2
RR SENSOR IN (PK)
RR SENSOR RTN (BK)
C509
TRACTION
CONTROL VALVE
C514
B
A
L
1 2 3 4
RF MOD HOLD (GN)
LEFT REAR
MOD VALVE
RIGHT REAR
SENSOR
C500
1 2 3 4
ABS
GROUND
LR SENSOR IN (PU)
LR SENSOR RTN (BK)
812
LEFT REAR
SENSOR
C512
1 2
RF SENSOR IN (PK)
RF SENSOR RTN (BK)
C501
S
H E
LF MOD EXH (TN)
LF MOD COM (GY)
LF MOD HOLD (BL)
C511 1 2
RIGHT FRONT
MOD VALVE
LEFT FRONT
MOD VALVE
RIGHT FRONT
SENSOR
S
ABS
POWER/START/CHARG
SHT. 2/3
S
1
TCV RTN
TCV IN
chassis electrical
STOP LIGHT SIGNAL
AA MODULE
SHT. 10
I/P
AJ1587
SHT. 17
ATC SLS (RD)
AJ1587+ (YL)
AJ1587- (BL)
C513
AJ1587+ (YL)
A
AJ1587- (BL)
B
AJ1587+ (YL)
AJ1587- (BL)
ABS/ATC LIGHTS
IP
SHT. 17
AJ1939+ (YL)
AJ1939- (GN)
C507
A
B
AJ1939+
AJ1939-
J1939 DATALINK
(AIR)
SHT. 23
A B C D E F
ABS LGT (GN)
ABS BATT (RD)
ABS GND (WH)
ABS IGN (OR)
C505
X1
ABS/ATC GROUND
TRAILER ABS WL (NOT CONNCTED)
ABS IGN (OR)
IGNITION (5A FUSED)
TCV RTN
TCV RTN
TCV IN
TCV IN
ATC LAMP/ATC ORS (ATC ONLY)
AJ1939-(GN)
J1939-LO
AJ1939+(YL)
J1939-HI
ATC SLS (RD)
SLS (ATC ONLY)
RR SENSOR IN (PK)
RIGHT REAR SENSOR +
RR SENSOR RTN (BK)
RIGHT REAR SENSOR ABS LGT GND (WH)
ABS W/L GND
AJ1587- (BL)
J1587-B
AJ1587+ (YL)
J1587-A
WL INTERLOCK (NOT CONNCTED)
ABS BATT (RD)
BATTERY (30A FUSED)
RETARDER (NOT CONNECTED)
ABS LGT (GN)
ABS WL
ABS ECU
BENDIX EC-60
X2
C506
CAB MOUNT
LF MOD HOLD (BL)
1 LEFT FRONT MOD HOLD
LF MOD EXH (TN)
2 LEFT FRONT MOD EXHAUST
LF MOD COM (GY)
3 LEFT FRONT MOD COMMON
RF MOD HOLD (GN)
4 RIGHT FRONT MOD HOLD
LF SENSOR IN (PU)
5 LEFT FRONT SENSOR (+)
RF MOD COM (GY)
6 RIGHT FRONT MOD COMMON
RF MOD EXH (OR)
7 RIGHT FRONT MOD EXHAUST
LF SENSOR RTN (BK)
8 LEFT FRONT SENSOR (-)
RR MOD COM (GY)
9 RIGHT MOD COMMON
RR MOD HOLD (GN)
10 RIGHT MOD HOLD
RF SENSOR IN (PK)
11 RIGHT FRONT SENSOR (+)
LR MOD COMMON (GY)
12 LEFT REAR MOD COMMON
RR MOD EXH (OR)
13 RIGHT REAR MOD EXHAUST
RF SENSOR RTN (BK)
14 RIGHT FRONT SENSOR (-)
LR SENSOR IN (PU)
15 LEFT REAR SENSOR +
LR MOD HOLD (BL)
16 LEFT REAR MOD HOLD
LR MOD EXH (TN)
17 LEFT REAR MOD EXHAUST
LR SENSOR RTN (BK)
18 LEFT REAR SENSOR -
1
ABS GND (WH)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
X3 (NOT CONNECTED)
C515 B A
ABS HARNESS
ATC HARNESS
SEE CHART 0104429
TRACTION
CONTROL VALVE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
ABS ORS
DIFF
DIFF_CMN
NOT USED
RESERVED
NOT USED
ADDITIONAL MOD EXHAUST
RESERVED
ADDITIONAL MOD COMMON
ADDITIONAL MOD HOLD
ADDITIONAL LEFT SENSOR(+)
ADDITIONAL RIGHT SENSOR(+)
NOT USED
ADDITIONAL LEFT SENSOR(-)
ADDITIONAL RIGHT SENSOR(-)
813
CUM ISB-07
ATC SLS (RD)
C504
ABS AIR (GN)
ABS IGN (OR)
ABS GND (WH)
ABS BAT (RD)
ATC SLS (RD)
ABS AIR (GN)
Sheet 8
0112294
ABS - BENDIX
L
1
service manual
ABS ECU
16 WAY
CONNECTOR
I/O DIAG SW & I/P
SHT 17
ABS LT (TN)
MOD PMP BAT (RD)
ABS IGN (OR)
J1939
TRANSMISSION
SHT 5/6
TJ1539- (GN)
TJ1939+ (YL)
AJ1587- (BL)
AJ1587+ (YL)
C513
ABS LT (TN)
A
PMP MTR BAT (RD)
B
C
ABS IGN (OR)
D
TJ1939- (GN)
E
TJ1939+ (YL)
F
J1587- (BL)
G
J1587+ (YL)
H
J
ABS BAT (RD)
ABS POWER
START/CHARGE
SHT 2/3
K
ABS BAT (RD)
L
M
ABS GND (WH)
AJ1939- (GN)
AJ1939+ (YL)
N
ABS REF GND (WH)
P
AJ1939- (GN)
R
S4
AJ1939+ (YL)
S
S3
I/P
J1587
J1939
SHT 17
C511
1 2
LEFT FRONT
SPEED SENS
L
C509
LR SENS GND (BK)
LR SENS IN (BN)
LF SENS GND (BK)
LF SENS IN (BN)
814
1 2
LEFT REAR
SPEED SENS
chassis electrical
MODULATOR PUMP
31 WAY
CONNECTOR
C521
ABS IGN (OR)
1
+12V IGNITION
2
3
4
ABS REF GND (WH)
5
6
GROUND
7
8
9
10
11
12
J1939- (GN)
PMP MTR BAT (RD)
ABS BAT (RD)
PMP MTR GND (WH)
SOL VLV GND (WH)
ABS LT (TN)
RR SENS IN (BN)
LR SENS IN (BN)
LF SENS IN (BN)
RF SENS IN (BN)
J1587- (BL)
RR SENS GND (BK)
LR SENS GND (BK)
LF SENS GND (BK)
RF SENS GND (BK)
C503
1 2
RIGHT REAR
SPEED SENS
C501
RF SENS GND (BK)
RF SENS IN (BN)
RR SENS GND (BK)
RR SENS IN (BN)
J1587+ (YL)
PUMP MOTOR
GROUND
13
14
J1939+
15
J1939-
16
PUMP MOTOR PWR
17
+12 BATTERY PWR
18
PUMP MOTOR
19
SOLENOID VALVE
20
21
ABS LT
22
RR SENSOR INPUT
23
LR SENSOR INPUT
24
LF SENSOR INPUT
25
RF SENSOR INPUT
26
J1587(-)
27
RR SENSOR GND
28
LR SENSOR GND
29
LF SENSOR GND
30
RF SENSOR GND
31
J1587(+)
SOLENOID
VALVE
GROUND
1 2
RIGHT FRONT
SPEED SENS
815
CUM ISB-07
J1939+ (YL)
Sheet 9
0117179A
ABS - WABCO
L
1
service manual
BODY INTERFACE,
SHT 21
AA-101A (BN)
DRIVERS CONTROL MODULE
SHT 22/23
AA-101B (BN)
BODY INTERFACE, SHT 21
START/CHARGE,
SHT 2/3
AA-107 (BL)
STOP LGT PWR (RD)
INSTRUMENT CLUSTER
SHT 17
STOP LGT A (RD)
BODY INTERFACE,
SHT 21
STOP LGT B (RD)
4
AA-109A (RD)
S31
ENGINE
SHT. 4
3
5
1
2
VGT BRK SIG (RD)
STOP LIGHT
RELAY
C7
816
PARK LGT GND (WH)
-
+
7
2B
3
5B
HEAD LGT GND (WH)
8
9
1
6 AC-006 (OR)
4
10
+
HEADLIGHT
SWITCH
C423
L
AA-004 (BN)
C709
C715
A B
A B C
LEFT
HEADLIGHT
C706
C718
AA-114 (RD)
AA-113 (PK)
2
1
2
1
2
2
OUT 5
OUT 3
OUT 6
OUT 4
OUT 7
OUT 8
9
10
11
12
13
14
A B
RIGHT
HEADLIGHT
CUM ISB-07
C703
AA-106 (OR)
AA-112 (PU)
8
AA-112 (PU)
7
AA-112 (PU)
6
1
AA-111(OR)
5
IN 8
AA-110 (RD)
2
OUT 4
AA-109 (RD)
AA-107 (BL)
AA-106 (OR)
AA-105 (PK)
4
1
OUT 2
AA-106 (OR)
3
2
OUT 3
AA-110 (RD)
2
1
AA-102 (BN)
AA-110 (RD)
AA-106 (OR)
AA-112A (PU)
1
IN 7
AA-102 (BN)
AA-110 (RD)
2
OUT 2
AA-102 (BN)
1
OUT 1
AA-004 (BN)
2
OUT 1
AA-102 (BN)
HARNESS CONN C2
PORT #
I/O SEQ
AA-101 (BN)
STARTER RELAY
IGNITION
DROP-OUT
HIGH BEAM HEAD
LGT (RIGHT)
IGNITION
HIGH BEAM HEAD
LGT (LEFT)
STOP LIGHT
RELAY
BACK-UP LIGHT
LOW BEAM HEAD
LGT (RIGHT)
PARK BRAKE
PARK/TAIL
LGT SWITCH
LOW BEAM HEAD
LGT (LEFT)
WIPER MOTOR
INTERMITTANT
chassis electrical
CV-MBC-2424
AA-114 (RD)
AA-113 (PK)
AA-111 (OR)
AA-105 (PK)
AA-112B (PU)
AC-006 (OR)
START/CHARGE,
SHT 2/3
INSTRUMENT
CLUSTER, SHT
17
AC-MODULE,
SHT 12
1 2 3 4
817
A B C
Sheet 10
AA MULTIPLEX MODULE
0112296C
L
1
service manual
ENGINE, SHT 4
DRIVERS CONTROL MODULE, SHT 18/19
DRIVERS CONTROL MODULE, SHT 18/19
HYDRAULIC BRAKE BOOST, SHT 14
BODY INTERFACE, SHT 21
INSTRUMENT CLUSTER, SHT 17
BODY INTERFACE, SHT 21
818
DIMMER/BACKLIGHTING, SHT 7
BODY INTERFACE, SHT 21
LT DIR GND (WH)
AB-102A (YL)
INSTRUMENT CLUSTER, SHT 17
B A
AB-004 (BL)
AB-005 (GN)
AB-107 (RD)
AB-009 (BN)
AB-012 (PK)
AB-111B (RD)
AB-111A (RD)
AB-110B (GN)
AB-110D (GN)
AB-106B (BN)
AB-106C (BN)
AB-102B (YL)
AB-102D (YL)
C B A C713
C703 14
DIRECTIONAL
LIGHT
L
DIR/PARK
LIGHT
C703
5
E D C C709
AB-102A (YL)
FT LT PK LGT (TN)
GND C (WH)
S3
THROTTLE
INTERLOCK
3
OUT 3
9
AB-009 (BN)
WASHER PUMP
SWITCH
AB-107 (RD)
AB-003 (RD)
AB-108 (PK)
8
5
NEUTRAL
PARK LIGHTS
7
AB-106 (BN)
REVERSE SIGNAL
3 MPH SPEED
SIGNAL
LEFT TURN LAMPS
1
IN 4
AB-106A (TN)
C712
1
IN 3
AB-106A (BN)
TRANSMISSION, SHT 5/6
1
OUT 6
6
AB-102A (YL)
TRANSMISSION, SHT 5/6
SHIFT INHIBIT
SIGNAL
AB-001 (OR)
TRANSMISSION, SHT 5/6
3
3
OUT 2
1
IN 2
4
F2
10A
FUSE
AB-001B (OR)
GND C (WH)
FT LT PK LGT (BN)
AB-102 (YL)
ENGINE, SHT 4
TRANSMISSION, SHT 5/6
AB-001A (OR)
LT PK GND (WH)
FT LT PK LGT (BN)
AB-102B (YL)
AC MODULE, SHT 12
1
IN 1
AB-005 (GN)
1
HARNESS CONN C4
1
OUT 5
2
AB-004 (BL)
3
OUT 1
AB-003 (RD)
PORT #
1/0 SEQ.
AB-102X (YL)
HIGH IDLE
CV-MBC-2424
LIFT ENABLE
WIPER WASHER
PUMP
3
OUT 8
CNETA
CNETB
VIN
GND
3
OUT 6
3
OUT 7
14
15
16
17
18
19
20
21
22
AB-021 (RD)
AB-114X (BK)
F1
10A
FUSE
F3
10A
FUSE
AB-122 (TN)
ACC HOT
3
OUT 5
AB-116 (GN)
BRAKE
INTERLOCK
1
OUT 8
AB-015 (WH)
AB-111 (RD)
11
3
OUT 4
13
HORN
PARKING BRAKE
SWITCH
1
IN 6
12
AB-012 (PK)
SERVICE BRAKE
LAMP SWITCH
1
IN 5
RIGHT TURN
LAMPS
1
OUT 7
10
AB-110X (GN)
chassis electrical
AB-122 (TN)
DRIVER CONTROL MODULE, SHT 18/19
AB-021 (RD)
BODY INTERFACE, SHT 21
AB-116 (GN)
BODY INTERFACE, SHT 21
AB-015A (WH)
DRIVER CONTROL MODULE, SHT 18/19
AB-015B (WH)
INSTRUMENT CLUSTER, SHT 17
AB-108 (PK)
C703
DRIVER CONTROL MODULE, SHT 18/19
9
A B
GND (WH)
AB-114 (BK)
HORN GND (WH)
GND C (WH)
GND B (WH)
GND A (WH)
725
CUM ISB-07
819
HORN
S2
C703 16
C706 C D E
AB-110A (GN)
FT RT PK LGT (TN)
C717
A B C
AB-110A (GN)
RT DIR GND (WH)
AB-110B (GN)
FT RT PK LGT (BN)
RT PK GND (WH)
AB-110 (GN)
FT RT PK LGT (BN)
GND B (WH)
AB-110A (GN)
S1
A B C716
Sheet 11
GND B (WH)
DIR/PARK
LIGHT
DIRECTIONAL
LIGHT
0112297B
AB MULTIPLEX MODULE
L
ENGINE SHT 4
DRIVER CONTROL MODULE, SHT 18/19
DRIVER CONTROL MODULE, SHT 18/19
DRIVER CONTROL MODULE, SHT 18/19
AC MODULE, SHT 12
DRIVER CONTROL MODULE, SHT 18/19
DRIVER CONTROL MODULE, SHT 18/19
DRIVER CONTROL MODULE, SHT 18/19
DRIVER CONTROL MODULE, SHT 18/19
DIMMER/BACKLIGHTS SHT 8
4
5
6
7
AC-001 (GN)
AC-102 (RD)
AC-004 (PK)
AC-005 (PU)
AC-006 (OR)
AC-007 (OR)
AC-008A (YL)
AC-009A (GN)
AC-010 (GY)
ILLUM D
820
9
AC-001A (GN)
1
6
5B
8
DIMMER/BACKLIGHTS, SHT 8
7
2B
HIGH IDLE SW
10 C425
3
9
1
6
GND
5B
8
DIMMER/BACKLIGHTS, SHT 8
4
ILLUM F (BL)
GND
4
AC-008B (YL)
AC-009B (GN)
HAZARD SW
10 C424
ILLUM E (BL)
9
7
GND
2B
3
1
6
ABS LT GND
5B
8
L
3
4
HIGH BEAM
SWITCH
3
AC-015 (GN)
ABS LT (TN)
10 I/O DIAGNOSTIC SW
C422
AC-007 (OR)
2
AC-003 (YL)
2B
HEADLAMP SWITCH
1
AC-006 (OR)
2
IN 7
AC-102 (RD)
7
START SWITCH
2
IN 6
AC-005 (PU)
2
IN 5
AC HI IDLE (GN)
HIGH IDLE GND (WH)
IGNITION SWITCH
2
IN 4
AA-004 (PK)
2
IN 3
HARNESS CONN C1
BODY INTERFACE, SHT 21
ACCESSORY
SWITCH
2
IN 2
AC-003 (YL)
2
IN 1
PORT#
I/O SEQ
STARTER LOCKOUT
SIGNAL
service manual
HIGH IDLE
SWITCH
1
chassis electrical
VANDAL LOCK
8
9
10
11
12
13
14
15
16
N/A
N/A
17
18
AC-016 (TN)
3
IN 8
AC-015 (GN)
3
IN 7
AC-014 (GN)
3
IN 6
AC-013 (OR)
3
IN 5
AC-112 (BK)
3
IN 4
AC-011 (BL)
3
IN 3
AC-010 (GY)
3
IN 2
AC-009 (GN)
3
IN 1
AC-008 (YL)
2
IN 8
AC-016 (TN)
AC-014 (GN)
AC-013 (OR)
AC-112 (BK)
AC-011 (BL)
ABS LT (TN)
BODY INTERFACE, SHT 21
BODY INTERFACE, SHT 21
DRIVERS CONTROL MODULE, SHT 18/19
DRIVERS CONTROL MODULE, SHT 18/19
BODY INTERFACE, SHT 21
I/P, SHT 17
821
CUM ISB-07
I/O DIAGNOSTIC
SWITCH
SCC ALARM
INTERLOCK
FEEDBACK
INTERMITTANT
WIPER SWITCH
EXTERIOR DOOR
SWITCH
HORN BUTTON
RIGHT TURN
SIGNAL
LEFT TURN
SWITCH
CV-MBC-2424
Sheet 12
0112298
AC MULTIPLEX MODULE
L
1
service manual
C714
CRS MR GND (WH)
CRS MR HT LT (PU)
C709
F
C700
TO
HEATER STEPWELL
HARNESS
WASHER MOTOR GROUND
FRAME COMPONETS
SHT. 15
G
J
K
N
L
M
WASH MTR GND(WH)
C719
CRS MR GND (WH)
CRS MR HT RT (PU)
CRS MR HT RT(PU)
C706
F
WASH MTR PWR(YL)
WASH MTR GND(WH)
B
A
A
B
0112299
L
WASH MTR PWR
WASH MTR GND
OUT SPKR +
OUT SPKR -
WASH MTR PWR
WASH MTR GND
A
M
B
C726
MIRROR HEAT/EXTERIOR SPEAKER/WIPER WASHER
OUT SPKR +
OUT SPKR -
C708
1213X(WH)
Sheet 13
LEFT CROSS
MIRROR HEAT
CRS MR HT RT(PU)
C711
OUT SPKR +(YL)
OUT SPKR -(PU)
2302J(GY)
822
A
B
C
CRS MR HT(PU)
S6
LEFT CROSS
MIRROR HEAT
CRS MR HT LT (PU)
CRS MR HT LT(PU)
CRS MR HT LT (PU)
A
B
C
HEATER PUMP
MOTOR
EXTERIOR
SPEAKER
WASHER
BOTTLE
chassis electrical
C703
BRAKE WARNING IGNITION
START/CHARGE
SHT. 2/3
BRAKE WARN IGN (OR)
18
BRAKE WARN IGN (OR)
C729
S25
GROUND
BRAKE WARNING LIGHT
IP
SHT. 17
C703
BRAKE WARN GND (WH)
15
BRAKE WARN GND (WH)
BRAKE WARN IGN (OR)
BRAKE WARN LGT (TN)
BRAKE WARN GND (WH)
AB-111 (RD)
PDU
GROUND
STUD
A
B
C
D
C703
BRAKE WARN LGT (TN)
13
BRAKE WARN LGT (TN)
C703
SERVICE BRAKE
AB MODULE,
SHT. 11
AB-111 (RD)
17
AB-111 (RD)
C818
DCM GND (WH)
BRAKE BOOST BAT (RD)
DCM GND (WH)
BRAKE BOOST BAT (RD)
A
B
HYD
BRAKE
BOOST
823
CUM ISB-07
BRAKE BOOSTER +12V
START/CHARGE
SHT. 2/3
TO
HYDRAULIC BRAKE
BOOST HARNESS
Sheet 14
0112300
HYDRAULIC BRAKE BOOST, CUMMINS
L
service manual
AIR DRYER POWER
START/CHARGE
SHT. 2/3
AIR DRYER PWR
(BL)
HEATED DRAIN POWER
START/CHARGE
SHT. 2/3
HTD DRAIN PWR
(BN)
HEATED FUEL POWER
START/CHARGE
SHT. 2/3
HTD FUEL PWR
S4
GND
GROUND
GND A
1
(PK)
WASH MTR GND (WH)
FUEL TANK SIG
S5
(BK)
S25
C703
WIF SENSOR (YL)
C703
WIF 2 (WH)
CUMMINS ISB07 ENGINE
SHT 4
WIF RTN (YL)
CUMMINS ISB07 ENGINE
SHT 4
AIR DRYER GND (WH)
WATER IN FUEL
SENSOR LT
SHT. 17
FUEL TANK GND
FUEL TANK SIG
HTD FUEL PWR
HTD DRAIN PWR
AIR DRYER PWR
(WH)
(BK)
(PK)
(BN)
(BL)
6 7 8 10 12
HTD DRAIN GND (WH)
GROUND
11
A
B
HTD FUEL PWR (PK)
HTD FUEL GND (WH)
HTR DRAIN PWR C (PU)
HTD DRAIN GND C (WH)
A B C
C736
1 2
S2
HTR DRAIN PWR B (PU) S1
HTD DRAIN GND B (WH)
LT (YL)
C710
C726
12V DC (RD)
SEN GND (BK)
HTD DRAIN PWR (PU)
HTD DRAIN GND (WH)
FUEL TANK GND (WH)
FUEL TANK SIG (BK)
WIF SENSOR (YL)
C705 A B C D E F
824
WASHER MOTOR GROUND
MIRROR HEAT
SHT. 13
FUEL TANK GND (WH)
PDU
GROUND
STUD
HTD FUEL GND (WH)
FUEL TANK SIGNAL
IP
SHT. 17
A B C
WATER IN
FUEL
SENSOR
FUEL
SENDER
A B
HEATED
FUEL
FILTER
NOTE: DASHED LINES INDICATE THAT THERE IS AN ADDITIONAL
HARNESS INSTALLED FOR THE WATER IN FUEL OPTION.
Sheet 15
0112301A
FRAME COMPONENTS
L
C734 A B
HEATER
DRAIN
VALVE
C733 A B
HEATER
DRAIN
VALVE
C727
B A
HEATED
DRAIN
VALVE
C728
A B
AIR
DRYER
WIF 2 (WH)
WIF RTN (YL)
AIR DRYER PWR (BL)
AIR DRYER GND (WH)
HTD DRAIN PWR A (PU)
HTD DRAIN GND A (WH)
HTD FUEL PWR A
HTD FUEL GND A
LT (YL)
FUEL TANK GND (WH)
FUEL TANK SIG (BK)
C730 A
C735
A B
RACOR
SENSOR
chassis electrical
C730
CRS ARM MG PWR(OR)
CRS ARM GND B(WH)
CRS ARM CTL B(BL)
S2
CRS ARM CTL B(BL)
MAGNET
CRS ARM GND(WH)
S1
C723
CRS ARM PWR(BK)
CRS ARM GND A(WH)
CRS ARM CTL A(BL)
CRS ARM HEAT(PU)
A
B
C
D
CROSSING ARM
C722
CRS ARM LGT(YL)
A
CROSSING ARM
LIGHT
825
CUM ISB-07
HARNESS
CRS ARM MG PWR(OR)
CRS ARM CTL(BL)
CRS ARM HEAT(PU)
CRS ARM PWR(BK)
CRS ARM LGT(YL)
CRS ARM GND(WH)
CRS ARM GND A(WH)
HEATER/STEPWELL
A
C
D
E
F
P
CRS ARM CTL A(BL)
TO
CROSSING ARM
CRS ARM GND B(WH)
C700
A
B
C
D
Sheet 16
0112302
CROSSING ARM
L
1
service manual
INSTRUMENT CLUSTER
"B" CONNECTOR C300
30 WAY CONNECTOR
GREEN
3
25
23
28
13
20
14
28
9
24
10
6
"C" CONNECTOR C301
30 WAY CONNECTOR
BLUE
FUEL TANK SIG (BK)
AB-102D (YL)
AA-105 (PK)
AA-112B (PU)
F AIR IN (GN) OR A5 IN (GN)
F AIR +5V (OR) OR A5 +5V (OR)
R AIR IN (GN)
R AIR +5V (OR)
ILLUM H (BL)
WIF SENSOR (YL)
AMMETER+ (RD)
ABS HYD (TN)
BRAKE WARN LGT (TN)
HYD INTLK AML (YL)
STOP LGT A (RD)
ABS AIR 1 (TN)
WAIT START (GN)
HIGH IDLE (OR)
FAA +5V (OR)
FAA IN (GN)
RAA +5V (OR)
RAA IN (GN)
AB-015B (WH)
CC ON/OFF (GY)
CC SET (BN)
CC RESUME (GN)
FAA GND (WH)
FAA +5V (OR)
FAA IN (GN)
826
3
5
23
8
10
12
1
20
13
21
14
22
24
25
26
PROGRAM 1 (RD)
PROGRAM 2 (RD)
D PWR (BK)
D IGN (RD)
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
AB-110D (GN)
DCHASS GND (WH)
J1939+ (YL)
J1939- (GN)
J1587+A (YL)
J1587-A (BL)
C306 A B C
FRONT AIR
TRANSDUCER
L
RAA GND (WH)
RAA +5V (OR)
RAA IN (GN)
"A" CONNECTOR C302
22 WAY CONNECTOR
GREEN
13
14
1
3
4
5
6
7
21
2
15
16
17
18
C307 A B C
REAR AIR
TRANSDUCER
chassis electrical
PROGRAM 1 (RD)
PROGRAM 2 (RD)
D PWR (BK)
D IGN (RD)
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
AB-110D (GN)
FUEL TANK SIG (BK)
AB-102D (YL)
AA-105 (PK)
AA-112B (PU)
ILLUM H (BL)
WIF SENSOR (YL)
AMMETER SIG (RD)
S42
ABS LGT (TN)
ABS HYD (TN)
BRAKE WARN LGT (TN)
HYD INTLK AML (YL)
STOP LGT A (RD)
ABS AIR (TN)
WAIT START (GN)
HIGH IDLE (OR)
ABS LT (TN)
C304 A B C
FRONT APPLIED
AIR TRANSDUCER
DASH POWER, SHT 2/3
DASH POWER, SHT 2/3
DRIVERS CONTROL MODULE, SHT 18/19
DRIVERS CONTROL MODULE, SHT 18/19
DRIVERS CONTROL MODULE, SHT 18/19
DRIVERS CONTROL MODULE, SHT 18/19
R/TURN SIGNAL, AB MODULE, SHT 11
J1939 DIAGNOSTIC INTERFACE, SHT 22/23
J1939 DIAGNOSTIC INTERFACE, SHT 22/23
J1587 DIAGNOSTIC INTERFACE, SHT 22/23
J1587 DIAGNOSTIC INTERFACE, SHT 22/23
FUEL TANK SIGNAL, FRAME COMPONETS, SHT 15
L/TURN SIGNAL, AB MODULE, SHT 11
PARK BRAKE SIGNAL, AA MODULE, SHT 10
HIGH BEAM INPUT, AA MODULE, SHT 10
PANEL DIMMER, SHT 7
WATER IN FUEL, SHT 15
CURRENT SENSOR, SHT 4
DIAGNOSTIC SW. AC MODULE, SHT 12
HYD ABS LIGHT, SHT 9
BRAKE WARNING LIGHT, SHT 14
DRIVERS CONTROL MODULE, SHT 18/19
STOPLIGHT, AB MODULE, SHT 10
AIR ABS LIGHT, SHT 8
WAIT TO START LIGHT, SHT 4
HIGH IDLE INPUT, AB MODULE, SHT 11
DIAGNOSTIC SW, AC MODULE, SHT 12
SHIFT INHIBIT SIGNAL, AB MODULE, SHT 11
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT18/19
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
827
R AIR GND (WH)
R AIR +5V (OR)
R AIR IN (GN)
F AIR GND (WH) OR A5 GND (WH)
F AIR +5V ((OR) OR A5 +5V (OR)
F AIR IN (GN) OR A5 IN (GN)
AB-015B (WH)
CC ON/OFF (GY)
CC SET (BN)
CC RESUME (GN)
DASH PROGRAM PORT
CUM ISB-07
J1939+ (YL)
J1939- (GN)
J1587+A (YL)
J1587-A (BL)
C303
B
A
C305 A B C
REAR APPLIED
AIR TRANSDUCER
Sheet 17
0117181
INSTRUMENT CLUSTER
L
1
service manual
AC MODULE, HORN BUTTON, SHT 12
AC MODULE, HIGH BEAM SWITCH, SHT 12
AC MODULE, LEFT TURN SWITCH, SHT 12
AC MODULE, RIGHT TURN SWITCH, SHT 12
AB MODULE, PARK BRAKE SWITCH, SHT 11
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
AB MODULE, SERVICE BRAKE, SHT 11
START/CHARGE SHT 2/3
AC MODULE, ACCESSORY SWTICH, SHT 12
AC MODULE, IGNITION SWITCH, SHT 12
AC MODULE, START SWITCH, SHT 12
AC MODULE, INTERLOCK FEEDBACK, SHT 12
INTERLOCK POWER, SH 2/3
BRAKE INTERLOCK POWER, SHT 2/3
THROTTLE CUMMINS ISB ENGINE, SHT 4
THROTTLE CUMMINS ISB ENGINE, SHT 4
THROTTLE CUMMINS ISB ENGINE, SHT 4
THROTTLE CUMMINS ISB ENGINE, SHT 4
THROTTLE CUMMINS ISB ENGINE, SHT 4
THROTTLE CUMMINS ISB ENGINE, SHT 4
AA-101B
AA MODULE,WIPER MOTOR INTERMITTANT,SHT 11
WIPER + (BK)
WIPER INT (GN)
BODY INTERFACE, SHT 21
BODY INTERFACE, SHT 21
828
WINDSHIELD
WIPER
MOTOR
HIGH 2
LOW 1
PARK 4
12V 3
GND 5
2112 (RD)
2111 (DK GN)
2115 (YL)
1124SS (BK)
1216DD (WH)
WIPER
WASHER
PUMP
AC MODULE, WIPER WASHER PUMP, SHT 13
AC MODULE, INTERMITTANT WIPER SWITCH, SHT 12
AB MODULE, WASHER PUMP SWITCH, SHT 11
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
START CHARGE SHT 2/3
L
C200
A
B
C
D
E
F
M
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK 2 (BL)
WIPER +A (BK)
WIPER GND (WH)
AB-122 (TN)
WIPER
PARK
RELAY
86
85
30
87
87A
chassis electrical
COLUMN GND (WH)
AC-010 (GY)
TURN SIG GND (WH)
AC-007 (OR)
CC GND (WH)
WIPER+B (BK)
AC-008A (YL)
AC-009A (GN)
PARK BK GND (WH)
AB-012 (PK)
CC ON/OFF (GY)
CC RESUME (GN)
CC SET (BN)
AB-111B (RD)
BRAKE SW PWR (RD)
IGN SW GND (WH)
AC-003 (YL)
AC-004 (PK)
AC-005 (PU)
INTLK FB GND (WH)
AC-013 (OR)
AB-015A (WH)
INTLK PWR (RD)
THROT SIG 1 (BN)
THROT RET 1 (PK)
THROT PWR 1 (BL)
SENSOR PWR (GY)
THROT SIG 2 (TN)
ECM RET SENS (TN)
DCM
C5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
HORN SIG #2
HORN SIG
TURN SIG GND
HIGH BEAM
CC GND
WIPER+A
LH DIR
RH DIR
PARK BK GND
PARK BRAKE SIG
EJ159
EJ144
EJ135
STOP LGT SIG
STOP LGT PWR
IGN SW GND
ACC
IGN
START SW
BVA PRESSURE SW
BVA PRESSURE SW
BVA GND
BVA POWER
THROT SIG 1
THROT RET 1
THROT PWR 1
SENSOR PWR
THROT SIG 2
ECM RET SENS
HORN SIG #1
HORN AND HAZARD
1
2
3
HORN SIGNAL
HORN SIGNAL
AIR BRAKE PARK SWITCH
A
B
D
C
PARK BRAKE GROUND
PARK BRAKE SIGNAL
STOP LIGHT SWITCH #2
A
B
D
C
STOP LIGHT
STOP LIGHT POWER
TO BVA PRESSURE SWITCH
BVA SOLENOID
B
A
BVA GROUND
BVA POWER
THROTTLE
A
B
C
D
E
F
THROTTLE
SENSOR 1
THROTTLE
SENSOR 2
STOP LIGHT SWITCH #1
A
B
C
D
START SWITCH
TURN SIGNAL/CC
1
2
3
4
5
6
7
8
9
10
11
12
13
14
DCM
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
D DIAG PWR (BK)
HIGH BEAM INDICATOR
HIGH BEAM SIGNAL
LEFT TURN SIGNAL
RIGHT TURN SIGNAL
GROUND
STEERING COLUMN SWITCH
C16
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK 1 (BL)
AC-112 (BK)
AB-108 (PK)
COM
ON
RESUME/COAST
SET SET +/ACCEL
WIPER/INST
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK (BL)
AC-112 (BK)
AB-108 (PK)
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
D DIAG PWR (BK)
1
2
3
4
5
6
7
8
9
10
11
12
+12V SUPPLY
HIGH SPEED WIPER
LOW SPEED WIPER
PARK CONTROL WIPER
INTERMITTENT WIPER
WASHER MOTOR
829
CUM ISB-07
BAT
START
IGN 1
IGN 2
ACC 1
A
B
C
D
E
F
G
H
J
K
L
M
STOP LIGHT POWER
STOP LIGHT
RETURN
ESC
UP
DOWN
COM
Sheet 18
0112304A
DRIVER’S CONTROL MODULE, AIR
L
1
service manual
AC MODULE, HORN BUTTON, SHT 12
AC MODULE, HIGH BEAM SWITCH, SHT 12
AC MODULE, LEFT TURN SWITCH, SHT 12
AC MODULE, RIGHT TURN SWITCH, SHT 12
AB MODULE, PARK BRAKE SWITCH, SHT 11
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
AB MODULE, SERVICE BRAKE, SHT 11
START/CHARGE SHT 2/3
AC MODULE, ACCESSORY SWTICH, SHT 12
AC MODULE, IGNITION SWITCH, SHT 12
AC MODULE, START SWITCH, SHT 12
HYDRAULIC INTERLOCK ALARM, SHT 17
AC MODULE, INTERLOCK FEEDBACK, SHT 12
HYDRAULIC INTERLOCK POWER, SH 2/3
AB MODULE, BRAKE INTERLOCK, SHT 11
THROTTLE CUMMINS ISB ENGINE, SHT 4
THROTTLE CUMMINS ISB ENGINE, SHT 4
THROTTLE CUMMINS ISB ENGINE, SHT 4
THROTTLE CUMMINS ISB ENGINE, SHT 4
THROTTLE CUMMINS ISB ENGINE, SHT 4
THROTTLE CUMMINS ISB ENGINE, SHT 4
AA-101B
AA MODULE,WIPER MOTOR INTERMITTANT,SHT 11
WIPER
PARK
RELAY
WIPER + (BK)
WIPER INT (GN)
BODY INTERFACE, SHT 21
BODY INTERFACE, SHT 21
830
C200
WINDSHIELD
WIPER
MOTOR
HIGH 2
LOW 1
PARK 4
12V 3
GND 5
2112 (RD)
2111 (DK GN)
2115 (YL)
1124SS (BK)
1216DD (WH)
WIPER
WASHER
PUMP
AC MODULE, WIPER WASHER PUM, SHT 13
AC MODULE, INTERMITTANT WIPER SWITCH, SHT 12
AB MODULE, WASHER PUMP SWITCH, SHT 11
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17
START CHARGE SHT 2/3
L
A
B
C
D
E
F
M
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK 2 (BL)
WIPER +A (BK)
WIPER GND (WH)
AB-122 (TN)
86
85
30
87
87A
chassis electrical
COLUMN GND (WH)
AC-010 (GY)
TURN SIG GND (WH)
AC-007 (OR)
CC GND (WH)
WIPER+B (BK)
AC-008A (YL)
AC-009A (GN)
PARK BK GND (WH)
AB-012 (PK)
CC ON/OFF (GY)
CC RESUME (GN)
CC SET (BN)
AB-111B (RD)
BRAKE SW PWR (RD)
IGN SW GND (WH)
AC-003 (YL)
AC-004 (PK)
AC-005 (PU)
HYD INTLK ALM (YL)
AC-013 (OR)
HYD INTLK PWR (RD)
HYD INTLK GND (WH)
AB-015A (WH)
THROT SIG 1 (BN)
THROT RET 1 (PK)
THROT PWR 1 (BL)
SENSOR PWR (GY)
THROT SIG 2 (TN)
ECM RET SENS (TN)
DCM
C5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
HORN SIG #2
HORN SIG
TURN SIG GND
HIGH BEAM
CC GND
WIPER+A
LH DIR
RH DIR
PARK BK GND
HYD PARK BRAKE SIG
EJ159
EJ144
EJ135
STOP LGT SIG
STOP LGT PWR
IGN SW GND
ACC
IGN
START
ALARM OUT
LOCKED OUT
HYD INTLK PWR
HYD INTLK GND
HYD INTLK ACT INPUT
THROT SIG 1
THROT RET 1
THROT PWR 1
THROT PWR
THROT SIG 2
ECM RET SENS
HORN SIG #1
HORN AND HAZARD
1
2
3
HORN SIGNAL
HORN SIGNAL
HYDRAULIC PARK BRAKE SWITCH
B
A
CHASSIS GROUND
PARK BRAKE SIG
HYDRAULIC PARK LIGHT SWITCH
D
C
STOP LIGHT SIGNAL
STOP LIGHT POWER
MICO HYD BRAKE INTERLOCK MODULE
23
15
1
17
8
DIRECT ALARM OUTPUT
LOCKED OUTPUT
12V BATT
GROUND
ACTIVATION INPUT
A
B
C
D
E
F
THROTTLE
SENSOR 1
THROTTLE
SENSOR 2
TURN SIGNAL/ICC
START SWITCH
BAT
START
IGN 1
IGN 2
ACC 1
C16
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK 1 (BL)
AC-112 (BK)
AB-108 (PK)
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
D DIAG PWR (BK)
HIGH BEAM INDICATOR
HIGH BEAM SIGNAL
LEFT TURN SIGNAL
RIGHT TURN SIGNAL
GROUND
STEERING COLUMN SWITCH
DCM
A
B
C
D
E
F
G
H
J
K
L
M
COM
ON
RESUME/COAST
SET SET +/ACCEL
WIPER/INST
WIPER HI (RD)
WIPER LOW A (GN)
WIPER PARK (BL)
AC-112 (BK)
AB-108 (PK)
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
D DIAG PWR (BK)
1
2
3
4
5
6
7
8
9
10
11
12
+12V SUPPLY
HIGH SPEED WIPER
LOW SPEED WIPER
PARK CONTROL WIPER
INTERMITTENT WIPER
WASHER MOTOR
831
CUM ISB-07
1
2
3
4
5
6
7
8
9
10
11
12
13
14
RETURN
ESC
UP
DOWN
COM
Sheet 19
0112305A
DRIVER’S CONTROL MODULE, HYD
L
1
service manual
MBC POWER START/CHARGE,
SHT 2/3
MBC PWR 2 (RD)
MBC POWER START/CHARGE,
SHT 2/3
MBC GND A (WH)
MBC POWER START/CHARGE,
SHT 2/3
MBC PWR 1 (RD)
MBC POWER START/CHARGE,
SHT 2/3
MBC BATT (RD)
MBC POWER START/CHARGE,
SHT 2/3
MBC GND B (WH)
C3 1 2 3
CONN. E
C8
9
10
CV-MBC-2424
MBC/DIO
MODULE
CONN. D
Sheet 20
0112306A
MBC MODULE
C11
START/CHARGE, SHT 2/3
AB MODULE, SHT 11
SCC OPTION 30195-13,19 ONLY
832
AB MODULE, SHT 11
AA MODULE, SHT 10
AB MODULE, SHT 11
AB MODULE, SHT 11
AC MODULE, SHT 12
DIMMER/BACKLIGHTS, SHT 7
AB MODULE, SHT 11
AA MODULE, SHT 10
AC MODULE, SHT 12
SEE REVERSE MOTION SENSOR DIAGRAM
DRIVERS CONTROL MODULE, SHT 18/19
AA MODULE, SHT 10
DRIVERS CONTROL MODULE, SHT 18/19
AC MODULE, SHT 12
Sheet 21
0112307
BODY INTERFACE
L
BODY IGN (OR)
AB-116 (RD)
BODY IGN (OR)
AB-116 (RD)
AC-014 (RD)
AC-014 (RD)
AB-106B (BN)
AA-107 (BL)
AB-110B (GN)
AB-102B (YL)
AB-106B (BN)
AA-107 (BL)
AB-110B (GN)
AB-102B (YL)
AC-011 (PK)
ILLUM B (BL)
AB-021 (RD)
AC-011 (PK)
ILLUM B (BL)
AB-021 (RD)
STOP LGT B (RD)
AC-016 (TN)
REV SENS SIG (GN)
WIPER INT (GN)
AA-101 (BN)
WIPER + (BK)
AC HIGH IDLE (GN)
STOP LGT B (RD)
AC-016 (TN)
REV SENS SIG (GN)
BCHASS GND (WH)
WIPER INT (GN)
AA-101 (BN)
WIPER + (BK)
AC HIGH IDLE (GN)
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
+12V IGNITION
ACCESSORY HOT
SCC ALARM
PARK/TAIL LIGHTS
BACK-UP LIGHTS
RIGHT TURN LAMPS
LEFT TURN LAMPS
DOOR SWITCH SIGNAL
PANEL DIMMER
LIFT ENABLE
STOP LIGHTS
VANDAL LOCK
REVERSE SENSOR
GROUND
WIPER INTERMITTANT
WIPER MOTOR LOW SPEED
WIPER + 12V
AC HIGH IDLE
TO BODY
chassis electrical
J1587
INSTRUMENT
CLUSTER
SHT. 17
J1587+A (YL)
J1587-A (BL)
J1587
ENGINE
SHT 4
EJ1587 + (YL)
EJ1587 - (BL)
J1587
TRANS
SHT 5/6
TJ1587 + (YL)
TJ1587 - (BL)
J1587
ABS
SHT 8/9
AJ1587 + (YL)
AJ1587 - (BL)
S15
DIAG GND (WH)
S16
DIAG GND
DIAG PWR
DJ1939+ (YL)
DJ1939- (GN)
J1587+ (YL)
J1587- (GN)
J1939
ENGINE
SHT. 4
EJ1939+ (YL)
EJ1939- (GN)
ABS
ECU
SHT 9
AJ1939+ (YL)
AJ1939- (GN)
J1939
TRANS ECU
SHT. 5/6
DIAGNOSTIC
POWER
SHT 2/3
DIAG PWR (RD)
S3
J1939+ (YL)
J1939- (GN)
C513
F
E
TJ1939+ (YL)
TJ1939- (GN)
C513
S
R
S4
AJ1939+ (YL)
AJ1939- (GN)
S34
S8
J1939+A (YL)
J1939-A (GN)
S35
J1587+ B
J1587- B
S9
S33
A
B
C
D
E
F
G
H
J
9-PIN
DIAGNOSTIC
TOOL
J1939
INSTRUMENT
CLUSTER
SHT. 17
J1939+ (YL)
J1939- (GN)
S32
TJ1939+ (YL)
TJ1939- (GN)
Sheet 22
0117183
J1939 DATALINK, HYD
EJ1587 + (YL)
EJ1587 - (BL)
J1587
TRANS
SHT 5/6
TJ1587 + (YL)
TJ1587 - (BL) S16
J1587
ABS
SHT 8/9
AJ1587 + (YL)
AJ1587 - (BL)
S15
DIAG GND (WH)
DIAG GND
DIAG PWR
DJ1939+ (YL)
DJ1939- (GN)
J1587+ (YL)
J1587- (GN)
ENGINE
SHT. 4
TRANS ECU
SHT. 5/6
ABS ECU
BENDIX
SHT. 8
DIAGNOSTIC
POWER
SHT 2/3
DIAG PWR (RD)
J1587+ B
J1587- B
S8
S9
EJ1939+ (YL)
EJ1939- (GN)
TJ1939+ (YL)
TJ1939- (GN)
S36
S37
AJ1939+ (YL)
AJ1939- (GN)
S34 J1939+A (YL)
J1939-A (GN)
J1939+B (YL)
J1939-B (GN)
S35
J1939+A (YL)
J1939-A (GN)
A
B
C
D
E
F
G
H
J
9-PIN
DIAGNOSTIC
TOOL
J1939
DIAGNOSTIC
INTERFACE
SHT. 17
J1939+ (YL)
J1939- (GN)
S33
833
CUM ISB-07
J1587
ENGINE
SHT 4
J1587
INSTRUMENT
CLUSTER
SHT. 17
J1587+A (YL)
J1587-A (BL)
S32
Sheet 23
0112310
J1939 DATALINK, AIR
L