Download Chassis ElECtriCal - Central States Bus Sales, Inc.
Transcript
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. 723 Also check: • Battery voltage • Alternator output • Starter current draw L 1 service manual 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. 724 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. L 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. L 1 service manual 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. 726 L 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. 727 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. L 1 service manual 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. 728 L 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). 729 L 1 service manual 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. 730 • 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. L 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. 731 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. L 1 service manual 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. 732 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. L 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 L 1 service manual 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. 734 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. L 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 L 1 service manual 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. L chassis electrical Chassis Harness Routing Diagrams The following pages illustrate the routings of the main chassis wiring harnesses applicable to most Vision chassis. 737 L 1 service manual 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 L 1 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 L 1 service manual 5P5SBOT 7FIJDMF)BSOFTT *OUFSGBDF 5P1%6 )BSOFTT 5P5SBOT4IJGUFS)BSOFTT 4FMFDU1VTI#VUUPO 5P"#4)BSOFTT 5P"#4)BSOFTT 5P1%*1)BSOFTT "#4)BSOFTT 'SBNF)BSOFTT .BJO5SBOTNJTTJPO $POOFDUPS &OHJOF 4QFFE4FOTPS 5P&$6#MVF 1 "CT'SBNF )BSOFTT 0VUQVU 4QFFE4FOTPS 5P&$6#MBDL 5P&$6 (SFZ 1545SBOTNJTTJPO Chassis Harness Routing Sheet 1 of 5 (continued) 0074133 DIAGRAM, RTG, HARNESS W/AUTOMATIC TRANS 740 L sheet PS " 0074133 &MFDUSPOJD $POUSPM 6OJU chassis electrical 741 L 1 service manual 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 L 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 L 1 service manual 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 L 1 service manual 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) 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 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 L 1 service manual 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