Documente Academic
Documente Profesional
Documente Cultură
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 alter-
nator, 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, indepen-
dent 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-am-
pere, 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)
723
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 ev-
ery 3 months; whichever occurs first.
Also check:
• Battery voltage
• Alternator output
• Starter current draw
L
1 service manual
Alternator Reinstallation
Installation of the alternator is accomplished in the reverse order of the removal in-
structions 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.
728
L
chassis electrical
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 igni-
tion 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 con-
nected 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, dis-
engaging 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 bro-
ken 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 prop-
erly 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:
L
chassis electrical
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 ad-
dition, the ring gear could be damaged.
5. Improper or excessive use of starting fluid will cause extra stress on the start-
ing 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 Diag-
731
nostic 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.
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:
Solenoid
2. Connect the negative lead of the VOM to the chassis
Alternator
ground.
• No voltage
• Low voltage
• Normal voltage with slow cranking
• Normal voltage with no cranking at all.
5. Connect the other end of the remote start switch to the ignition post of the
solenoid.
6. Attempt to crank the engine with the remote switch. Record the voltage dis-
played 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
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 re-
vealed 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
chassis electrical
Volt/Ohm Meter
Low Voltage Test
There are various reasons for low voltage but the troubleshooting meth-
ods are the same. If the solenoid clicks, it means that either current is
flowing through the solenoid contacts but not through the main con-
tacts; or that the current through the main contacts is insufficient due
Solenoid
to low batteries.
1. Connect the positive lead of the VOM to the starter motor terminal
Alternator
of the solenoid.
4. If there is voltage present at the solenoid terminal during Step 3, the prob-
lem is in the starter motor or its cabling.
5. If the first voltage check in Step 3 under Ignition/Run Test indicated nor-
mal 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.
Ammeter
Solenoid
Alternator
Starter
L
1 service manual
Volt/Ohm Meter
Slow Cranking
Sluggish cranking can be caused by a small amount of extra re-
sistance 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
Ammeter
of the starter motor, then the negative circuit.
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.
11. Connect the negative lead of the VOM to the negative battery post. Record
the reading; leave the VOM connected.
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
chassis electrical
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.
Volt/Ohm Meter
1. Disconnect the carbon pile tester.
Alternator
5. Set the VOM so that it can read the full battery volt-age; at
least 14 volts.
Starter
6. Connect the negative VOM lead to the starter motor ter-
minal 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
735
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.
L
1 service manual
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.
5. Remove 3 capscrews.
1. Carefully place the starter motor into position on the flywheel hous-
ing.
736 [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.
L
chassis electrical
737
L
1 service manual
+ -
Torque to 8 ft. Lbs. (typ)
Ammeter bat fuse
To Intake Heater Engine harness
To Alt Power To PDU Power
Shunt Bat Side
Engine Harness To PDU Power
Ammeter Alt Fuse
To Alt Ground To PDU Power
Alternator Connections
With Ammeter Breakout of engine harness.
Routing goes back to the PDU panel.
Routes along with Cat engine harness, Right
along valve cap. Dir Light
Crs Mir Connector
Heat
Right Connector
Headlights
738 Connector
To PDU Panel.
See Sheet 3.
Right
Park Light
Connector
To Transmission Ecu
To Engine Compartment Interface ABS Harness
Frame Harness
Abs & Frame Harness
To Frame Component Harness.
0074133
See Sheet 2
L
chassis electrical
To PDU Ground.
See Sheet 3.
To PDU Power.
See Sheet 3
To Main Panel.
Exciter wire See Sheet 3.
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 To PDU
Engine Power
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 *OUFSGBDF
7FIJDMF)BSOFTT
5P1%6
)BSOFTT
5P5SBOT4IJGUFS)BSOFTT
4FMFDU
1VTI#VUUPO
5P"#4)BSOFTT
5P"#4)BSOFTT
5P1%*1)BSOFTT
&MFDUSPOJD
$POUSPM
"#4)BSOFTT
6OJU
'SBNF)BSOFTT
PS
"
5P&$6 5P&$6#MBDL
(SFZ
.BJO5SBOTNJTTJPO
$POOFDUPS
5P&$6#MVF
"CT'SBNF
)BSOFTT
1
&OHJOF
sheet
4QFFE4FOTPS
0074133
0VUQVU 1545SBOTNJTTJPO
4QFFE4FOTPS
740
L
chassis electrical
741
L
1 service manual
Typical at
Crossmembers
Exhaust Bracket
Typical at
Exhaust Brackets
Exhaust Bracket
Typical at
Exhaust Brackets
Crossmember
Start of
Hydraulic Harness
742
To PDU Panel.
To Abs Connection See Sheet 3.
on Front Hub
Air Dryer Typical at
Wiring Supports
To Abs Connection
on Front Hub
L
chassis electrical
Harness Routing
To Front For Hydraulic
TO FRONT
OF BUS
Hydraulic Brakes
DETAIL H
(HYD BRAKE)
Fuel Tank
L
1 service manual
Power Ammeter
Ground 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.
ace
erf
24, Int
m ent
26, 24, art
mp ace
27 Co erf ace
26, gin
e Int fac
e erf
E n e 1 ter S Int
27 To i n I n
n/A
B
Eng ine
2
sio nk
Stud Mounting Blocks To Eng mis tali
on Engine Compartment To ra n s
9 Da
T 3
To J19
Side of Firewall To
Components
of Harness
744 24,
26,
27
Electronic
Power Chassis
Power
3sheet
0074133
L
chassis electrical
745
L
1 service manual
Frame Rails
To Batteries E F
To PDU Panel
B A
See Detail
on Sheet 1
C
D
On back of B A
Transmission C
Bell housing D
Route
Battery Cable
Torque bolt to Thru Tie Wrap Pos
21 ft lb.
To Electronic Power Stud (See Sheet 3) Coat connection Neg
To Rem Power Stud (See Sheet 3) With Glyptal sealant. Pos
To Electronic Ground Stud (See Sheet 3)
To Pdu Ground Stud (See Sheet 3) Neg
Using 2 8D Batteries
(Feature 40142-04)
E F
746 A
B
C
D
B A
C
D
Neg
Neg Pos
Pos
Neg
Pos
L
chassis electrical
With
Heavy Duty
Box Only
Battery Tray
From
Positive
Battery With Battery Disconnect Switch
(Feature 40142-01)
DU
oP
w er t
o
ic P DU
SEE DETAIL E
Ele
ctr
on
on
ic G
ro un
dt
oP
747
ctr
Ele
Supplied
with
Switch
(For Delphi)
4
(For 8D Batt)
sheet
L
1 service manual
Frame Rail
A
B
C
D
On back of B A
Transmission C
Bell housing D
Using 2 8D Batteries
(Feature 40142-04)
748
AB
CD
B A
C
D
Neg
Pos
Neg
Pos
Neg
Pos
L
chassis electrical
With
Heavy Duty
Box Only
Battery Tray
749
5sheet
0074133
L
1 service manual
750
0089022
L
chassis electrical
IGN PWR
F1 HTD FUEL PWR (20A)
F2 INTERLOCK PWR (10A)
F3 AIR DRYER PWR (10A)
F4 SPARE Units with Air Brakes
BRAKE WARN IGN (15A) Units with Hydraulic Brakes
F5 HTD DRAIN PWR (20A)
F6 BODY IGN (15A)
BATT PWR
F7 SPARE Units with Air Brakes
BRK BOOST (40A) Units with Hydraulic Brakes
F8 START REL PWR (5A)
F9 REV SENS+ (10A)
F10 STOP LIGHT PWR (15A)
F11 SPARE Units with Air Brakes
HYD INTLK (30A) Units with Hydraulic Brakes
F12 ABS BATT (30A) Units with Air Brakes
MOD PMP BATT (30A) Units with Hydraulic Brakes
F13 DPWR (3A)
F14 SPARE
ELEC PWR
F15 TRANS BATT (10A)
F16 EECM PWR (40A)
F17 MBC PWR (10A)
F18 SPARE Units with Air Brakes
ABS BATT (25A) Units with Hydraulic Brakes
751
ECM IGN
F19 EJ170 IGN (10A)
F20 TRANS IGN (40A)
F21 ABS IGN (10A)
F22 DASH IGN (10A)
0089022
L
1 service manual
752
L
chassis electrical
753
L
1 service manual
Buffer
Warning Signal
(output to IP)
Ground
Ignition
To ground stud
on HydroMax body
Ignition
Warning Signal to IP
Ground
Brake Light Signal
754
L
chassis electrical
755
CAT C7-07
Micro Relay Heavy Duty Relay Fuse Voltage Stud Shunt Switch Ngr Rocker 3 Wire Twisting
(Non-typical)
2 Wire Twisting 2 Wire Twisting Mini Relay Horn Speaker Light Circuit Breaker
with Shield
L
1 service manual
12V ECM
IGNITION RELAY
30/40A
C9
87A
ELEC PWR (BK)
30 ECM IGN (PK)
87
86 85 RLY GND A (WH)
S26
PDU
PD 12V GROUND
BATTERY STUD
DISCONNECT
SWITCH
(ONLY WITH
OPTION 40142-01)
PD
CURRENT SENSOR DC PD
A B C D
A
756 PD
STARTER PWR (RD)
C14 30 86
TO GRID HEATER STARTER 12
ON ENGINE BLOCK RELAY PD
70A 87 85
C704
STARTER (RD) STARTER (RD)
W
START REL GND (WH)
EX STARTER
TO DCM GND GND B MOTOR
GROUND 2/0 CABLE
ALTERNATOR FROM GND STUD ON FRAME
12V
GROUND BK 1 GA
TO ENGINE BLOCK
L
chassis electrical
5A
F19 EJ170 IGN (OR) CAT C7
SHT. 4
10A
F20 TRANS IGN (OR) TRANS
SHT. 5/6
5A
F21 ABS IGN (OR) ABS
SHT. 8/9
PD 10A
12V ECM F22 DASH IGN (PK) IP
IGNITION BUS SHT. 17
5A HYD BRAKE BOOST
F23 BRAKE WARN IGN (OR)
SHT. 14
AA-111 (OR)
AA MODULE, SHT 10
3A
F13 DPWR (BK) IP
SHT. 17
15A
F10 STOP LGT PWR (RD) AA MODULE,
SHT. 10
30A
F12 MOD PMP BATT (RD) ABS
SHT. 9
PD 40A
12V F7 BRAKE BOOST BATT (RD) ENGINE CAT C7
BATTERY BUS SHT. 4
30A
F11 HYD INTLK PWR (RD) DRIVER'S CNTRL MODULE
SHT. 19
10A DRIVERS CONTROL MOD
F11 INTERLOCK PWR (RD)
SHT. 18
SEN IGN (RD) F9 REV SENS + (RD) SEE DIAGRAM,WRG
FEA 2226
3A
F14 D DIAG PWR (BK) DRIVER'S CNTRL MODULE
SHT 18/19
10A F8 BRAKE SW PWR (RD)
DRIVER'S CNTRL MODULE,
SHT 18/19
757
AMMETER + (RD) CAT C7
SHT 4
AA-114 (RD)
AA MODULE,
AA-113A (PK) SHT 10
AA-113 (PK) AA MODULE,
CAT C7-07
C13
30 86 SHT. 11/10
IGNITION 12
RELAY PD AA-113C (OR) CAT C7
70A 87 85 SHT. 4
20A
F1 HTD FUEL PWR (PK) FRAME COMPOMENTS
SHT 15
IGN REL GND (WH) 20A
F5 HTD DRAIN PWR (BN) FRAME COMPONETS
IGN PWR (RD) SHT. 15
10A
F3 AIR DRYER PWR (BL) FRAME COMPONETS
SHT. 15
PD 15A
12V F6 BODY IGN (OR) BODY INTERFACE
IGNITION BUS SHT. 21
PDU
GROUND
STUD
Sheet 2
0116401C
STARTING AND CHARGING,CAT 2007 C7
L
1 service manual
12V ECM
IGNITION RELAY
30/40A
C9
87A
ELEC PWR (BK)
30 ECM IGN (PK)
87
86 85 RLY GND A (WH)
S26
PDU
PD 12V GROUND
BATTERY STUD
DISCONNECT
SWITCH
(ONLY WITH
OPTION 40142-01)
PD
CURRENT SENSOR DC PD
BATT PWR (RD)
12V 12V
PD BATT IGN PWR (RD)
A B C D
758 PD
STARTER PWR (RD)
C14 30 86
TO GRID HEATER STARTER 12
ON ENGINE BLOCK RELAY PD
70A 87 85
C704
STARTER (RD) STARTER (RD)
W
START REL GND (WH)
EX
TO DCM GND GND B STARTER
MOTOR
ALTERNATOR GROUND 2/0 CABLE
12V FROM GND STUD ON FRAME
GROUND BK 1 GA
TO ENGINE BLOCK
L
chassis electrical
5A
F19 EJ170 IGN (OR) CAT C7
SHT. 4
10A
F20 TRANS IGN (OR) TRANS
SHT. 5/6
5A
F21 ABS IGN (OR) ABS
SHT. 8/9
PD 10A
12V ECM CB22 DASH IGN (PK) IP
IGNITION BUS SHT. 17
7.5 HYD BRAKE BOOST
CB23 BRAKE WARN IGN (OR)
SHT. 14
7.5A
CB13 DPWR (BK) IP
SHT. 17
15A
CB10 STOP LGT PWR (RD) AA MODULE,
SHT. 10
30A
CB12 MOD PMP BATT (RD) ABS
SHT. 9
PD 40A
12V F7 BRAKE BOOST BATT (RD) ENGINE CAT C7
BATTERY BUS SHT. 4
30A
CB11 HYD INTLK PWR (RD) DRIVER'S CNTRL MODULE
SHT. 19
10A
CB11 INTERLOCK PWR (RD) DRIVER'S CNTRL MODULE
SHT. 18
SEN IGN (RD) 10A
CB9 REV SENS + (RD) SEE DIAGRAM,WRG
FEA 2226
7.5A
CB14 D DIAG PWR (BK) DRIVER'S CNTRL MODULE
SHT 18/19
10A
CB8 BRAKE SW PWR (RD) DRIVER'S CNTRL MODULE
759
SHT 18/19
CAT C7-07
AA-114 (RD) AA MODULE,
SHT 10
AA-113A (PK)
AA-113 (PK) AA MODULE,
86 C13 SHT. 10
30
12 IGNITION
PD AA-113C (OR) CAT C7
RELAY
87 85 SHT. 4
70A
20A
CB1 HTD FUEL PWR (PK) FRAME COMPONETS
SHT. 15
IGN REL GND (WH) 20A
CB5 HTD DRAIN PWR (BN) FRAME COMPONETS
IGN PWR (RD) SHT. 15
10A
CB3 AIR DRYER PWR (BL) FRAME COMPONETS
SHT. 15
PD 15A
12V CB6 BODY IGN (OR) BODY INTERFACE
IGNITION BUS SHT. 21
PDU
GROUND
STUD
Sheet 3
0115329C
STARTING AND CHARGING,CAT 2007 C7
W/FEA 40142-11 (Florida circuit breakers)
L
1 service manual
DIMMER/BACKLIGHTING ILLUM J
SHT. 7
DIMMER/BACKLIGHTING GND 3H (WH)
SHT. 7
7 9
TO DRIVER'S CONTROL SEN COM B (TN) SEN COM B 2B 3
MODULE. SHT 18/19 S39 (TN) 1
5B 6
4
8 10
PDU
INTERFACE
CONNECTOR
C701
A
FAN CLUTCH AA-MODULE AA-103 (OR) AA-103 (OR) AA-103 (OR)
SHT. 10 B
VGT SW (BL) C VGT SW (BL)
S1 D
SENS COM B (TN) SENS COM A (TN) E SENS COM B (TN)
THROT PWR (BL) THROT PWR (BL) F THROT PWR (BL)
DRIVERS CTL MOD THROT COM (PK) THROT COM (PK) THROT COM (PK)
SHT. 18/19 G
THROT SIG (BN) THROT SIG (BN) H THROT SIG (BN)
J
COOLING FAN DISABLE AA-MODULE AA-008 (PK) AA-008 (PK) K AA-008 (PK)
SHT. 10
FAST IDLE AB-MODULE L
AB-001B (OR) AB-001B (OR) M AB-001 (OR)
SHT. 11
N
I/P EJ1587 EJ1587+ (YL) EJ1587+ (YL) O EJ1587+ (YL)
SHT. 22/23 EJ1587- (BL) EJ1587- (BL) P EJ1587- (BL)
Q
ENGINE CONTROLS IP AMMETER + (RD) AMMETER + (RD) R AMMETER + (RD)
SHT. 17 AB-009 (BN) AB-009 (BN)
S
THROTTLE INTERLOCK AB-MODULE AB-009 (BN) ENG BRAKE LT (RD) T ENG BRAKE LT (RD)
SHT. 11
U
VGT BRAKE MODELE AA ENG BRAKE LT (RD) V
SHT 10
W
STARTER LOCKOUT AC-MODULE AC-102 (RD) AC-102 (RD) X AC-102 (RD)
SHT. 12
PDU
INTERFACE
CONNECTOR
C704
R
EECM GND (WH) S EECM GND (WH)
START/CHARGE AA-113C (OR) AA-113C (OR) T AA-113C (OR)
SHT. 2/3 EECM PWR (RD) EECM PWR (RD)
U
EECM POWER START/CHARGE EECM PWR (RD) EJ170 IGN (OR) V EJ170 IGN (OR)
SHT. 2/3 BRAKE BOOST BAT (RD) BRAKE BOOST BAT (RD)
X
EJ170 IGN START/CHARGE EJ170 IGN (OR) Y
SHT. 2/3
Z
BRAKE BOOST BAT START/CHARGE BRAKE BOOST BAT (RD)
SHT. 2/3
N.O.
REGENERATION SWITCH
760
N.C.
SHUTTER STAT AIR
SHUTTER COM (OR)
N.C.
STARTER GND (WH)
A B C2 A B
SHUTTER GROUND C815
SOLENOID STUD
ON FAN
STARTER CLUTCH
L
chassis electrical
C800 (EJ1)
CAT C7 ECM CONN
1
COOL LVL PWR (OR) 2 COOL LEVEL + 5V
3
THROT PWR (BL) 4 THROTTLE + 8V
THROT COM (PK) EJ105 (PK) EJ105 (PK) 5 SENSOR/SWITCH COM
S3 REGEN SW (OR)
6 REGENERATION SWITCH
7
EJ1587+ (YL)
8 J1587(+)
EJ1587- (BL) 9 J1587(-)
10
11
ENG BRAKE LT (RD) 12 AUX BRAKE LIGHT
AC-102 (RD) 13 STARTER LOCKOUT
14
15
16
17
SEN COM B (TN) 18 SENSOR COMMON
19
20
AA-008 (PK) 21 COOLING FAN
S7 EJ123 (OR) 22 SET SPEED B
VGT SW (BL) 23 VGT BRAKE SWITCH
24
25
COOL LVL (BL) 26 COOL LEVEL
27
28
29
30
31
32
33
EJ1939- (GN) 34 J1939(-)
35
36
37
38
39
EJ140 (OR) 40 FAST IDLE
41
42
43
44
45
46
S5 47
EJ148 PWR (RD) 48 +12V BATTERY POWER
49
EJ1939+ (YL) 50 J1939(+)
51
EJ152 PWR (RD) 52 +12V BATTERY POWER
EJ153 PWR (RD) 53 +12V BATTERY POWER
54
EJ155 PWR (RD) 55 +12V BATTERY POWER
AB-009 (BN) 56 THROTTLE INTERLOCK
761
57
58
59
60
61
S6 62
EJ163 GND (WH) 63 GND
CAT C7-07
64
EJ165 GND (WH) 65 GND
THROT SIG (BN) 66 THROTTLE POSITION
EJ167 GND (WH) 67 GND
68
EJ169 GND (WH) 69 GND
EJ170 IGN (OR) 70 +12V IGNITION
EJ1939+ (YL)
EJ1939- (GN)
COOL LVL (BL)
EJ149 (BL)
A B C N U C701
C816 Sheet 4
COOLANT EJ1939- (GN)
J1939 DATALINK
LEVEL
SENSOR
EJ1939+ (YL) SHT. 22/23 0113152
2007 CAT C7 ENGINE
L
1 service manual
PDU
INTERFACE
IP TJ1939, SHT 17 C702
IP TJ1939, SHT 17 A TRANS TEMP/164 (BL)
NOT USED B NOT USED
C CHECK TRANS/129 (GN)
NOT USED D NOT USED
NOT USED E NOT USED
AB MODULE, SHT 11 AB-004 (BL) F B2-016/165 (TN)
NOT USED G NOT USED
TJ1939+ (YL) H TJ1939+ (YL)
AB MODULE, SHT 11 AB-107 (RD) J B1-112/141 (TN)
TJ1939- (GN) K TJ1939- (GN)
RESERVED L RESERVED
RESERVED M RESERVED
AB MODULE, SHT 11 AB-003 (RD) N B1-002/105 (OR)
TELEG GNDA (WH) P 169 (GY)
TRANS BATT START/CHARGE, SHT 2/3 TRANS BAT (RD) R TRANS BAT (PK)
TRANS IGN START/CHARGE, SHT 2/3 TRANS IGN (OR) S TRANS IGN/163 (YL)
S14 TELEC GND B (WH) T 109 (GY)
IP TJ1587, SHT 17 TJ1587+ (YL) U NOT USED
IP TJ1587, SHT 17 TJ1587- (BL) V NOT USED
SHIFT INHIBIT IN AB MODULE, SHT 11 AB-005 (GN) W B3-015/101 (BL)
X 124 (WH)
TELEC GND (WH)
762
PS1 4 117 (BL)
ELECTRONIC 5
PS3 6 157 (WH)
GROUND
PS2 7 179 (PK)
SUMP TEMP 8 154 (TN)
SIGNAL RETURN 9 158 (GN)
LSD TCC 10 178 (WH)
PS4 11 177 (GN)
12
13
HSD1 14 111 (OR)
LSD PCS1 15 155 (WH)
HSD2 16 171 (YL)
LSD PCS2 17 136 (OR)
DIGITAL SIGNAL NS 18 138 (OR)
LSD MAIN MOD 19 174 (BL)
DIGITAL SIGNAL C 20 114 (GY)
DIGITAL SIGNAL B 21 153 (YL)
DIGITAL SIGNAL A 22 173 (BL)
DIGITAL SIGNAL P 23 134 (WH)
TRANS ID 24 176 (YL)
L
chassis electrical
763
72
173 (BL) 73 DIGITAL SIGNAL A
174 (BL) 74 LSD MAIN MOD
75
176 (YL) 76 TRANS ID
177 (GN) 77 PS4
CAT C7-07
178 (WH) 78 LSD TCC
179 (PK) 79 PS2
180 (OR) 80 TURBINE SPEED HIGH
140 (GN)
139 (OR)
180 (OR)
159 (TN)
160 (YL)
120 (BL)
L
1 service manual
TO CONNECTOR C6
IP, SHT 21
C6 A B
ENGINE
COMPARTMENT
INTERFACE
IP TJ1939, SHT 17 C702
IP TJ1939, SHT 17 A TRANS TEMP/164 (BL)
B
C CHECK TRANS/129 (GN)
D
E
AB MODULE, SHT 11 AB-004 (BL) F B2-016/165 (TN)
G
J1939+ (YL) H J1939+ (YL)
AB MODULE, SHT 11 AB-107 (RD) J B1-112/141 (TN)
J1939- (GN) K J1939- (GN)
L
M
AB MODULE, SHT 11 AB-003 (RD) N B1-002/105 (OR)
TELEC GNDA (WH) P 169 (GY)
TRANS BATT START/CHARGE, SHT 2/3 TRANS BAT (RD) R TRANS BAT (RD)
TRANS IGN START/CHARGE, SHT 2/3 TRANS IGN (OR) S TRANS IGN (OR)
S14 TELEC GND B (WH) T 109 (GY)
IP TJ1587, SHT 17 TJ1587+ (YL) U TJ1587+ (YL)
IP TJ1587, SHT 17 TJ1587- (BL) V TJ1587- (BL)
SHIFT INHIBIT IN AB MODULE, SHT 11 AB-005 (GN) W B3-015/101 (BL)
X
TELEC GND (WH)
L
chassis electrical
CAT C7-07
73
174 (BL)
74 LSD MAIN MOD
75
176 (YL)
76 TRANS JD
177 (GN)
77 DIGITAL SIGNAL
78
79
180 (OR)
80 TURBINE SPEED HIGH
140 (GN)
139 (OR)
159 (TN)
160 (YL)
C905 B A C902 B A
ENGINE OUTPUT Sheet 6
SPEED SPEED
SENSOR SENSOR
0116649A
ALLISON GEN 4 3000 TRANSMISSION
L
1 service manual
766
L
chassis electrical
ILLUM B (BL)
BODY INTERFACE, SHT 21
ILLUM C (BL)
7 9 7 9 7 9 C12
3 3 3 C
2B 2B 2B AB-106C (BN)
A AB MODULE, SHT 11
1 1 1
6 6 6 D
5B 5B 5B B
4 4 4 F
8 10 8 10 8 10
DIMMER
SWITCH
767
CAT C7-07
Sheet 7
0116651
DIMMER/BACKLIGHTS
L
1 service manual
C504 A B C D E F
RF SENSOR IN (PK)
H E H E
ABS
GROUND
RR SENSOR IN (PK)
TRACTION C514
CONTROL VALVE
TCV RTN
B
TCV IN
A
L
chassis electrical
ABS/ATC LIGHTS
ABS LGT (GN) IP
SHT. 17
C507
AJ1939+ (YL) A AJ1939+
J1939 DATALINK
AJ1939- (GN) B AJ1939- (AIR)
SHT. 23
C505
ATC SLS (RD)
1 X1
ABS GND (WH) 1 ABS/ATC GROUND
2 TRAILER ABS WL (NOT CONNCTED)
ABS IGN (OR) 3 IGNITION (5A FUSED)
TCV RTN 4 TCV RTN
TCV IN 5 TCV IN
6 ATC LAMP/ATC ORS (ATC ONLY)
AJ1939-(GN) 7 J1939-LO
AJ1939+(YL) 8 J1939-HI
ATC SLS (RD) 9 SLS (ATC ONLY)
RR SENSOR IN (PK) 10 RIGHT REAR SENSOR +
RR SENSOR RTN (BK) 11 RIGHT REAR SENSOR -
ABS LGT GND (WH)
12 ABS W/L GND
AJ1587- (BL)
13 J1587-B
AJ1587+ (YL)
14 J1587-A
15 WL INTERLOCK (NOT CONNCTED)
ABS BATT (RD) 16 BATTERY (30A FUSED)
17 RETARDER (NOT CONNECTED)
ABS LGT (GN) 18 ABS WL ABS ECU
X2 BENDIX EC-60
C506
LF MOD HOLD (BL) CAB MOUNT
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)
LR MOD COMMON (GY)
RR MOD EXH (OR)
11
12
13
RIGHT FRONT SENSOR (+)
LEFT REAR MOD COMMON
RIGHT REAR MOD EXHAUST
769
RF SENSOR RTN (BK)
14 RIGHT FRONT SENSOR (-)
LR SENSOR IN (PU)
CAT C7-07
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 -
X3 (NOT CONNECTED)
1 ABS ORS
2 DIFF
3 DIFF_CMN
TRACTION 4 NOT USED
C515 B A CONTROL VALVE 5 RESERVED
6 NOT USED
ATC HARNESS 7 ADDITIONAL MOD EXHAUST
ABS HARNESS SEE CHART 0104429 8 RESERVED
9 ADDITIONAL MOD COMMON
10 ADDITIONAL MOD HOLD
11 ADDITIONAL LEFT SENSOR(+)
12 ADDITIONAL RIGHT SENSOR(+)
13 NOT USED
14 ADDITIONAL LEFT SENSOR(-)
15 ADDITIONAL RIGHT SENSOR(-)
Sheet 8
0116652
ABS - BENDIX
L
1 service manual
ABS ECU
16 WAY
CONNECTOR
C513
I/O DIAG SW & I/P ABS LT (TN) ABS LT (TN)
A
SHT 17 MOD PMP BAT (RD) PMP MTR BAT (RD)
B
C
ABS IGN (OR) ABS IGN (OR)
D
J1939 TJ1939- (GN) TJ1939- (GN)
E
TRANSMISSION TJ1939+ (YL) TJ1939+ (YL)
F
SHT 5/6 AJ1587- (BL) J1587- (BL)
G
AJ1587+ (YL) J1587+ (YL)
H
J
K
ABS BAT (RD) ABS BAT (RD)
L
ABS POWER
M
START/CHARGE
N
SHT 2/3 ABS GND (WH) ABS REF GND (WH)
P
AJ1939- (GN) AJ1939- (GN)
R
AJ1939+ (YL) AJ1939+ (YL) S4
S
S3
I/P
J1587
J1939
SHT 17
RR SENS IN (BN)
LR SENS IN (BN)
LF SENS IN (BN)
L
chassis electrical
MODULATOR PUMP
31 WAY
CONNECTOR
C521
ABS IGN (OR)
1 +12V IGNITION
2
3
4
5
ABS REF GND (WH)
6 GROUND
7
8
9
10
11
12
13
J1939+ (YL)
14 J1939+
J1939- (GN)
15 J1939-
PMP MTR BAT (RD)
16 PUMP MOTOR PWR
ABS BAT (RD)
17 +12 BATTERY PWR
PMP MTR GND (WH)
18 PUMP MOTOR
SOL VLV GND (WH)
19 SOLENOID VALVE
20
ABS LT (TN)
21 ABS LIGHT
RR SENS IN (BN)
22 RR SENSOR INPUT
LR SENS IN (BN)
23 LR SENSOR INPUT
LF SENS IN (BN)
24 LF SENSOR INPUT
RF SENS IN (BN)
25 RF SENSOR INPUT
J1587+ (YL)
26 J1587(-)
RR SENS GND (BK)
27 RR SENSOR GND
LR SENS GND (BK)
28 LR SENSOR GND
LF SENS GND (BK)
29 LF SENSOR GND
RF SENS GND (BK)
30 RF SENSOR GND
J1587- (BL)
31 J1587(+)
771
CAT C7-07
RF SENS GND (BK)
RF SENS IN (BN)
C501 1 2
PUMP MOTOR SOLENOID
GROUND VALVE
GROUND
L
1 service manual
AA-107 (BL)
BODY INTERFACE, SHT 21
START/CHARGE,
SHT 2/3
(RD)
SHT 17 4
3
STOP LGT B (RD) STOP LGT PWR 5
VGT BRAKE
4
C15
3
5
- +
7 9
AA-004 (BN)
PARK LGT GND (WH) 2B 3
1
5B 6 AC-006 (OR)
HEAD LGT GND (WH)
4
8 10
- +
HEADLIGHT
SWITCH
C423
CAT C7 AA-103 (OR)
SHT 4
L
HARNESS CONN C2
I/O SEQ
PORT #
AA-101 (BN)
1
WIPER MOTOR
2
OUT 1
INTERMITTANT
POWER
4
IN 7
LGT SWITCH
AA-105 (PK)
2
PARK BRAKE
OUT 3
LGT (RIGHT)
AA-107 (BL)
2
BACK-UP LIGHT
CV-CCM-C
OUT 4
DISABLE
RELAY
OUT 5
C715
C709
C703
AA-102 (BN) AA-102 (BN) AA-102 (BN)
AA-110 (RD) AA-110 (RD) AA-110 (RD) HIGH BEAM HEAD
A B
1
10
LGT (LEFT)
OUT 3
LEFT
AA-110 (RD) AA-106 (OR)
A B C
HEADLIGHT
AA-112A (PU)
1 2 3 4
AA-111(OR)
2
11
IGNITION
OUT 6
12
LGT (RIGHT)
OUT 4
C718
C706
AA-106 (OR) AA-106 (OR)
AA-112 (PU) AA-113 (PK) IGNITION
2
A B
13
OUT 7
RIGHT
A B C
HEADLIGHT
AA-114 (RD)
2
14
STARTER RELAY
OUT 8
chassis electrical
AA-112B (PU)
AA-113 (PK)
AA-105 (PK)
AC-006 (OR)
AA-111 (OR)
AA-114 (RD)
Sheet 10
0116694A
AA MULTIPLEX MODULE
17
SHT 12
SHT 2/3
AC-MODULE,
CLUSTER, SHT
INSTRUMENT
START/CHARGE,
L
773
CAT C7-07
1 service manual
CV-CCM-C
REVERSE SIGNAL
WASHER PUMP
SHIFT INHIBIT
3 MPH SPEED
PARK LIGHTS
RIGHT TURN
LAMPS
INTERLOCK
THROTTLE
HIGH IDLE
NEUTRAL
SWITCH
SIGNAL
SIGNAL
PORT # 3 1 1 1 3 1 1 1 3 1
1/0 SEQ. OUT 1 OUT 5 IN 1 IN 2 OUT 2 OUT 6 IN 3 IN 4 OUT 3 OUT 7
HARNESS CONN C4 1 2 3 4 5 6 7 8 9 10
AB-005 (GN)
AB-001 (OR)
AB-106 (BN)
AB-009 (BN)
AB-003 (RD)
AB-107 (RD)
AB-110X (GN)
AB-108 (PK)
AB-004 (BL)
AB-102X (YL)
AB-001A (OR)
AC MODULE, SHT 12 F2 F1
10A 10A
AB-001B (OR) FUSE FUSE
ENGINE, SHT 4
AB-003 (RD)
TRANSMISSION, SHT 5/6
AB-004 (BL)
TRANSMISSION, SHT 5/6
AB-005 (GN)
TRANSMISSION, SHT 5/6
AB-107 (RD)
TRANSMISSION, SHT 5/6
AB-009 (BN)
ENGINE, SHT 4
AB-012 (PK)
DRIVERS CONTROL MODULE, SHT 18/19
AB-111B (RD)
DRIVERS CONTROL MODULE, SHT 18/19
AB-111A (RD)
HYDRAULIC BRAKE BOOST, SHT 14
AB-110B (GN)
BODY INDTERFACE, SHT 21
AB-110D (GN)
INSTRUMENT CLUSTER, SHT 17
AB-106B (BN)
BODY INTERFACE, SHT 21
AB-102B (YL)
BODY INTERFACE, SHT 21
AB-102D (YL)
INSTRUMENT CLUSTER, SHT 17
AB-110A (GN)
AB-106A (BN)
AB-102A (YL)
LT DIR GND (WH)
FT LT PK LGT (BN)
FT LT PK LGT (BN)
LT PK GND (WH)
AB-102A (YL)
AB-102B (YL)
GND C (WH)
AB-102 (YL)
L
chassis electrical
PARKING BRAKE
WIPER WASHER
SERVICE BRAKE
LAMP SWITCH
LIFT ENABLE
INTERLOCK
ACC HOT
SWITCH
BRAKE
PUMP
HORN
1 1 3 1 3 3 3 3
CNETA CNETB VIN GND
IN 5 IN 6 OUT 4 OUT 8 OUT 5 OUT 8 OUT 6 OUT 7
11 12 13 14 15 16 17 18 19 20 21 22
AB-015 (WH)
AB-116 (GN)
AB-111 (RD)
AB-021 (RD)
AB-122 (TN)
AB-012 (PK)
AB-114X (BK)
C703 9
GND A (WH)
HORN GND (WH)
GND (WH)
AB-114 (BK)
GND B (WH)
GND C (WH)
A B 725
775
CAT C7-07
HORN
S2
S1
FT RT PK LGT (BN)
RT PK GND (WH)
AB-110A (GN)
AB-110B (GN)
GND B (WH)
AB-110 (GN)
Sheet 11
GND B (WH) DIR/PARK DIRECTIONAL
LIGHT LIGHT 0116695A
AB MULTIPLEX MODULE
L
1 service manual
STARTER LOCKOUT
IGNITION SWITCH
START SWITCH
ACCESSORY
HIGH IDLE
SIGNAL
SWITCH
SWITCH
PORT# 2 2 2 2 2
I/O SEQ IN 1 IN 2 IN 3 IN 4 IN 5
HARNESS CONN C1 1 2 3 4 5
AC-001 (GN)
AC-102 (RD)
AC-005 (PU)
AA-004 (PK)
AC-003 (YL)
AC HI IDLE (GN)
BODY INTERFACE, SHT 21
AC-102 (RD)
CAT, SHT 4
AC-003 (YL)
DRIVER CONTROL MODULE, SHT 18/19
AC-004 (PK)
DRIVER CONTROL MODULE, SHT 18/19
AC-005 (PU)
DRIVER CONTROL MODULE, SHT 18/19
AC-006 (OR)
AC MODULE, SHT 12
AC-007 (OR)
DRIVER CONTROL MODULE, SHT 18/19
AC-008A (YL)
DRIVER CONTROL MODULE, SHT 18/19
AC-009A (GN)
DRIVER CONTROL MODULE, SHT 18/19
AC-010 (GY)
DRIVER CONTROL MODULE, SHT 18/19
AB-001A (OR)
AB MODULE, SHT 11
1
6
5B
4 HIGH IDLE SW
8 10 C425
ILLUM F (BL)
DIMMER/BACKLIGHTS, SHT 7
7 9
3 AC-008B (YL)
GND (WH) 2B
1
6 AC-009B (GN)
GND (WH)
5B
4 HAZARD SW
8 10 C424
ILLUM E (BL)
DIMMER/BACKLIGHTS, SHT 7
7 9
3 AC-015 (GN)
GND (WH) 2B
1
6
ABS LT GND (WH)
5B ABS LT (TN)
4
8 10
C422
ABS DIAGNOSTIC SWITCH
L
chassis electrical
CV-CCM-C
HEADLAMP SWITCH
EXTERIOR DOOR
I/O DIAGNOSTIC
HORN BUTTON
INTERMITTANT
WIPER SWITCH
VANDAL LOCK
RIGHT TURN
HIGH BEAM
SCC ALARM
INTERLOCK
LEFT TURN
FEEDBACK
SWITCH
SWITCH
SWITCH
SWITCH
SIGNAL
2 2 2 3 3 3 3 3 3 3 3
N/A N/A
IN 6 IN 7 IN 8 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8
6 7 8 9 10 11 12 13 14 15 16 17 18
AC-009 (GN)
AC-014 (GN)
AC-015 (GN)
AC-010 (GY)
AC-006 (OR)
AC-007 (OR)
AC-013 (OR)
AC-016 (TN)
AC-112 (BK)
AC-008 (YL)
AC-011 (BL)
AC-016 (TN)
BODY INTERFACE, SHT 21
AC-014 (GN)
BODY INTERFACE, SHT 21
AC-013 (OR)
DRIVERS CONTROL MODULE, SHT 18/19
AC-112 (BK)
DRIVERS CONTROL MODULE, SHT 18/19
AC-011 (BL)
BODY INTERFACE, SHT 21
ABS LT (TN)
INSTRUMENT CLUSTER, SHT 17
777
CAT C7-07
Sheet 12
0116696
AC MULTIPLEX MODULE
L
1 service manual
CRS MR HT LT(PU)
S6
CRS MR HT(PU)
778
C700
C711
G
TO OUT SPKR +(YL) OUT SPKR +
J B
HEATER STEPWELL OUT SPKR -(PU) OUT SPKR -
HARNESS K A
N
L
M
WASH MTR PWR(YL) WASH MTR PWR
WASHER MOTOR GROUND A
WASH MTR GND(WH) WASH MTR GND(WH) WASH MTR GND
FRAME COMPONETS B
SHT. 15
C708
2302J(GY)
A
M
1213X(WH)
B
HEATER PUMP
C726 MOTOR
L
chassis electrical
C714
CRS MR GND (WH)
A
CRS MR HT LT (PU)
B
C
C719
CRS MR GND (WH)
A
CRS MR HT RT (PU)
B
C
779
CAT C7-07
OUT SPKR +
EXTERIOR
OUT SPKR - SPEAKER
Sheet 13
0116697
MIRROR HEAT/EXTERIOR SPEAKER/WIPER WASHER
L
1 service manual
780
L
chassis electrical
C703
BRAKE WARNING IGNITION
START/CHARGE BRAKE WARN IGN (OR) BRAKE WARN IGN (OR) 18 BRAKE WARN IGN (OR)
SHT. 2/3
C729
BRAKE WARN IGN (OR) A
C703 BRAKE WARN LGT (TN) TO
S25 B HYDRAULIC BRAKE
BRAKE WARN GND (WH) 15 BRAKE WARN GND (WH) BRAKE WARN GND (WH) C BOOST HARNESS
AB-111A (RD) D
GROUND PDU
GROUND
STUD
C703
BRAKE WARNING LIGHT
IP BRAKE WARN LGT (TN) BRAKE WARN LGT (TN) 13 BRAKE WARN LGT (TN)
SHT. 17
781
CAT C7-07
Sheet 14
0116698
HYDRAULIC BRAKE BOOST,CAT
L
1 service manual
GROUND PDU
GROUND
STUD
C710 A B C
C730
LT (YL) A LT (YL)
FUEL TANK GND (WH)
FUEL TANK SIG (BK)
A B C A B
WATER IN HEATED
FUEL FUEL FUEL
SENDER SENSOR FILTER
L
chassis electrical
S4 GND
GND A
GROUND
C703 6 7 8 10 12
FUEL TANK GND (WH)
CONNECTS TO
ENGINE HARNESS
C705 A B C D E F 1 2 C736
HTD DRAIN GND (WH)
HTD DRAIN PWR (PU)
C726
A
B
HTD FUEL PWR (PK)
HTD FUEL GND (WH) 783
HTR DRAIN PWR C (PU) S2
CAT C7-07
HTD DRAIN GND C (WH)
HTR DRAIN PWR B (PU) S1
HTD DRAIN GND B (WH)
HTD DRAIN GND A (WH)
HTD DRAIN PWR A (PU)
Sheet 15
0116699
FRAME COMPONENTS
L
1 service manual
C700
784
L
chassis electrical
C730
C723
CAT C7-07
C722
CRS ARM LGT(YL)
A
CROSSING ARM
LIGHT
Sheet 16
0116700
CROSSING ARM
L
1 service manual
INSTRUMENT CLUSTER
C302
PROGRAM 1 (RD)
13
PROGRAM 2 (RD)
14
D PWR (BK)
1
D IGN (RD)
3
D RETURN (YL)
4
DESC (OR)
5
"A" CONNECTOR C302 DUP (GN)
6
22 WAY CONNECTOR D DOWN (BL)
7
GREEN AB-110D (GN)
21
DCHASS GND (WH)
2
J1939+ (YL)
15
J1939- (GN)
16
J1587+A (YL)
17
J1587-A (BL)
18
C300
FUEL TANK SIG (BK)
3
AB-102D (YL)
25
AA-105 (PK)
23
AA-112B (PU)
28
F AIR IN (GN)
13
"B" CONNECTOR C300 F AIR +5V (OR)
20
30 WAY CONNECTOR R AIR IN (GN)
GREEN 14
R AIR +5V (OR)
21
ILLUM H (BL)
9
24
WIF SENSOR (YL)
10
AMMETER+ (RD)
6
C301
ABS HYD 1 (TN)
3
BRAKE WARN LGT (TN)
5
HYD INTLK AML (YL)
23
STOP LGT A (RD)
8
ABS AIR 1 (TN)
10
12
HIGH IDLE (OR)
"C" CONNECTOR C301 1
FAA IN (GN)
30 WAY CONNECTOR 13
BLUE FAA +5V (OR)
20
RAA IN (GN)
14
RAA +5V (OR)
21
AB-015B (WH)
22
CC ON/OFF (GY)
24
786
CC SET (BN)
25
CC RESUME (GN)
26
R AIR GND (WH)
F AIR GND (WH)
FAA IN (GN)
L
chassis electrical
C303
PROGRAM 1 (RD)
B
PROGRAM 2 (RD) DASH PROGRAM PORT
A
D PWR (BK)
DASH POWER, SHT 2/3
D IGN (RD)
DASH POWER, SHT 2/3
D RETURN (YL)
DRIVERS CONTROL MODULE, SHT 18/19
DESC (OR)
DRIVERS CONTROL MODULE, SHT 18/19
DUP (GN)
DRIVERS CONTROL MODULE, SHT 18/19
D DOWN (BL)
DRIVERS CONTROL MODULE, SHT 18/19
AB-110D (GN)
R/TURN SIGNAL, AB MODULE, SHT 11
J1939+ (YL)
J1939 DIAGNOSTIC INTERFACE, SHT 22/23
J1939- (GN)
J1939 DIAGNOSTIC INTERFACE, SHT 22/23
J1587+A (YL)
J1587 DIAGNOSTIC INTERFACE, SHT 22/23
J1587-A (BL)
J1587 DIAGNOSTIC INTERFACE, SHT 22/23
ILLUM H (BL)
PANEL DIMMER, SHT 7
AB-015B (WH)
SHIFT INHIBIT SIGNAL, AB MODULE, SHT 11
CC ON/OFF (GY)
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
787
CC SET (BN)
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
CC RESUME (GN)
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
CAT C7-07
RAA GND (WH)
RAA +5V (OR)
RAA IN (GN)
C307 A B C
REAR APPLIED
Sheet 17
AIR TRANSDUCER 0119063
INSTRUMENT CLUSTER
L
1 service manual
CAT 7, SHT 4
CAT 7, SHT 4
CAT 7, SHT 4
AA-101B
AA MODULE,WIPER MOTOR INTERMITTANT,SHT 10
WIPER + (BK) 86 30
BODY INTERFACE, SHT 18/19 WIPER
WIPER INT (GN) PARK
BODY INTERFACE, SHT 18/19 87
RELAY 85 87A
C200
2112 (RD) WIPER HI (RD)
WINDSHIELD HIGH 2 A
WIPER LOW 1 2111 (DK GN) WIPER LOW A (GN)
B
2115 (YL) WIPER PARK 2 (BL)
788
MOTOR PARK 4 C
1124SS (BK) WIPER +A (BK)
12V 3 D
1216DD (WH) WIPER GND (WH)
GND 5 E
AB-122 (TN)
F
WIPER
WASHER M
PUMP
L
chassis electrical
CAT C7-07
9
10 HIGH BEAM INDICATOR
11 HIGH BEAM SIGNAL
12 LEFT TURN SIGNAL
13 RIGHT TURN SIGNAL
14 GROUND
Sheet 18
0116702
DRIVER’S CONTROL MODULE,CAT,AIR
L
1 service manual
CAT 7, SHT 4
CAT 7, SHT 4
CAT 7, SHT 4
AA-101B
AA MODULE,WIPER MOTOR INTERMITTANT,SHT 10
86 30
WIPER + (BK) WIPER
BODY INTERFACE, SHT 18/19 PARK
WIPER INT (GN) 87
BODY INTERFACE, SHT 18/19 RELAY 85 87A
C200
2112 (RD) WIPER HI (RD)
WINDSHIELD HIGH 2 A
WIPER LOW 1 2111 (DK GN) WIPER LOW A (GN)
B
MOTOR 2115 (YL) WIPER PARK 2 (BL)
PARK 4 C
790
1124SS (BK) WIPER +A (BK)
12V 3 D
1216DD (WH) WIPER GND (WH)
GND 5 E
AB-122 (TN)
F
WIPER
WASHER M
PUMP
L
chassis electrical
CAT C7-07
DCM STEERING COLUMN SWITCH
C16 WIPER/INST
A 1 +12V SUPPLY
WIPER HI (RD) WIPER HI (RD)
B 2 HIGH SPEED WIPER
WIPER LOW A (GN) WIPER LOW A (GN)
C 3 LOW SPEED WIPER
WIPER PARK 1 (BL) WIPER PARK (BL)
D 4 PARK CONTROL WIPER
AC-112 (BK) AC-112 (BK)
E 5 INTERMITTENT WIPER
AB-108 (PK) AB-108 (PK)
F 6 WASHER MOTOR
G 7
D RETURN (YL) D RETURN (YL)
H 8 RETURN
DESC (OR) DESC (OR)
J 9 ESC
DUP (GN) DUP (GN)
K 10 UP
D DOWN (BL) D DOWN (BL)
L 11 DOWN
D DIAG PWR (BK) D DIAG PWR (BK)
M 12 COM
Sheet 19
0116703
DRIVER’S CONTROL MODULE,CAT,HYD
L
1 service manual
792
L
chassis electrical
C8
MBC POWER START/CHARGE, MBC GND B (WH) 9 CONN. D CV-CCM-C
SHT 2/3 10 MBC/DIO
MODULE
Sheet 20
0116704
MBC MODULE
C11
START/CHARGE, SHT 2/3 BODY IGN (OR) BODY IGN (OR) A +12V IGNITION
AA MODULE, SHT 11 AB-116 (RD) AB-116 (RD) B ACCESSORY HOT
C
SCC OPTION 30195-13,19 AC-014 (RD) AC-014 (RD) D SCC ALARM
AC MODULE SHT 12
E
F
AB MODULE, SHT 11 AB-106B (BN) AB-106B (BN) G PARK/TAIL LIGHTS
793
AA MODULE, SHT 10 AA-107 (BL) AA-107 (BL) H BACK-UP LIGHTS
AB MODULE, SHT 11 AB-110 (GN) AB-110 (GN) J RIGHT TURN LAMPS
AB MODULE, SHT 11 AB-102B (YL) AB-102B (YL) K LEFT TURN LAMPS
L
AC MODULE, SHT 12 AC-011 (PK) AC-011 (PK) M DOOR SWITCH SIGNAL TO BODY
DIMMER/BACKLIGHTS, SHT 7 ILLUM B (BL) ILLUM B (BL) N PANEL DIMMER
AB-021 (RD) AB-021 (RD)
CAT C7-07
AB MODULE, SHT 11 P LIFT ENABLE
R
AA MODULE, SHT 10 STOP LGT B (RD) STOP LGT B (RD) S STOP LIGHTS
AB MODULE, SHT 12 AC-016 (TN) AC-016 (TN) T VANDAL LOCK
SEE REVERSE MOTION SENSOR DIAGRAM REV SENS SIG (GN) REV SENS SIG (GN) U REVERSE SENSOR
BCHASS GND (WH) V GROUND
DRIVERS CONTROL MODULE, SHT 18/19 WIPER INT (GN) WIPER INT (GN) W 2109A (GN)
AA MODULE, SHT 10 AA-101 (BN) AA-101 (BN) X 2109 (GN)
DRIVERS CONTROL MODULE, SHT 18/19 WIPER + (BK) WIPER + (BK) Y 1124PP (BK)
12V BATT.
AC MODULE, SHT 12 AC HIGH IDLE (GN) AC HIGH IDLE (GN) Z AC HIGH IDLE 25A
INTERMITTANT 86 30
WIPER
RELY 87
85 87A
Sheet 21
0116705
BODY INTERFACE
L
1 service manual
EJ1939+ (YL)
ENGINE EJ1939- (GN)
SHT. 4
TJ1939+ (YL)
S
TJ1939- (GN)
R
L
chassis electrical
J1587
J1587+A (YL) INSTRUMENT
J1587-A (BL) CLUSTER
SHT. 17
DIAGNOSTIC
DIAG PWR (RD) POWER
SHT 2/3
DIAG GND
A
DIAG PWR
B
DJ1939+ (YL)
C
DJ1939- (GN)
D 9-PIN
E DIAGNOSTIC
J1587+ (YL) S8 J1587+ B
S9 F TOOL
J1587- (GN) J1587- B
G
H
J
J1939
J1939+A (YL) S33 J1939+ (YL) DIAGNOSTIC
J1939-A (GN) S32 J1939- (GN) INTERFACE
SHT. 17
795
CAT C7-07
Sheet 22
0118820
J1939 DATALINK,HYD-E
L
1 service manual
EJ1939+ (YL)
ENGINE
SHT. 4 EJ1939- (GN)
L
chassis electrical
J1587
J1587+A (YL)
INSTRUMENT
J1587-A (BL) CLUSTER
SHT. 17
DIAGNOSTIC
DIAG PWR (RD) POWER
SHT 2/3
DIAG GND
A
DIAG PWR
B
DJ1939+ (YL)
C
DJ1939- (GN)
D 9-PIN
E DIAGNOSTIC
J1587+ (YL) S8 J1587+ B
F TOOL
J1587- (GN) S9 J1587- B
G
H
J
J1939
J1939+A (YL) S33 J1939+ (YL)
DIAGNOSTIC
J1939-A (GN) J1939- (GN) INTERFACE
S32
797
SHT. 17
CAT C7-07
Sheet 23
0116707
J1939 DATALINK,AIR
L
1 service manual
798
L
chassis electrical
799
CUM ISB-07
Heavy Duty Relay Fuse Voltage Stud Shunt Switch Ngr Rocker 3 Wire Twisting
(Non-typical)
L
1 service manual
CURRENT
SENSOR DC PD
GND
PD
SEN GND (WH)
SEN IGN (RD)
EX
GND B
STARTER GND
ALTERNATOR
12V
C704
AA-113C (PK) AA-113C (PK)
T
L
chassis electrical
5A
F19 5A ENG IGN (OR) CUMMINS ISB07
SHT. 4
10A
F20 TRANS IGN (OR) TRANS
ECM IGN (PK) SHT. 5/6
5A
F21 ABS IGN (OR) ABS
SHT. 8/9
PD 10A
12V ECM F22 DASH IGN (PK) IP
IGNITION BUS SHT. 17
5A
F23 BRAKE WARN IGN (OR) HYD BRAKE BOOST
SHT. 14
AA-111 (OR) AA MODULE,
SHT 10
MBC GND A (WH)
3A
F13 DPWR (BK) IP
SHT. 17
15A
F10 STOP LGT PWR (RD) AA MODULE
BATT PWR (RD) SHT. 10
30A
F12 PMP MTR BATT (RD) ABS
SHT. 9
PD 40A
12V F7 BRAKE BOOST BATT (RD) HYD BRAKE BOOST
BATTERY BUS SHT. 14
30A
F11 HYD INTLK PWR (RD) DRIVER'S CNTRL MODULE
SHT. 18
10A DRIVERS CONTROL MOD
F11 INTERLOCK PWR (RD)
SHT. 19
10A
F9 REV SENS + (RD) SEE DIAGRAM,WRG
FEA 2226
3A
F14 D DIAG PWR (BK) DRIVER'S CNTRL MODULE,
SHT 18/19
10A
F8 BRAKE SW PWR (RD) DRIVER'S CNTRL MODULE,
SHT 18/19
AA-114 (RD)
AA MODULE, SHT 10 801
AA-113A (PK) AA-113 (PK) AA MODULE, SHT 10
C13
CUM ISB-07
30 86 20A
12 IGNITION F1 HTD FUEL PWR (PK) FRAME COMPONETS
PD RELAY SHT. 15
87 85 70A 20A
F5 HTD DRAIN PWR (BN) FRAME COMPONETS
SHT. 15
S26 10A
IGN REL GND (WH) F3 AIR DRYER PWR (BL) FRAME COMPONETS
SHT. 15
IGN PWR (RD) PD
12V
IGNITION BUS
10A CUMMINS ISB07
F4 FAN PWR (RD)
SHT. 4
PDU 15A BODY INTERFACE
F6 BODY IGN (OR)
GROUND SHT. 21
STUD
AMMETER SIG (RD)
CUMMINS ISB07 SHT. 4
Sheet 2
0117347A
STARTING AND CHARGING,CUMMINS
L
1 service manual
CURRENT
SENSOR DC PD
12V 12V BATT PWR (RD)
- +
PD
BATT IGN PWR (RD)
A B C D
MAIN BODY &
STARTER FUSE
200A
FRAME COPPER BUSBAR STARTER PWR (RD)
AMMETER SIG (RD)
GND
PD
SEN GND (WH)
SEN IGN (RD)
802
STARTER 30
12
PDU GND RELAY PD
70A 87 85
STUD
STARTER
MOTOR
START REL GND (WH)
C704
STARTER (RD) STARTER (RD)
W
EX
GND B
STARTER GND
ALTERNATOR
12V
(HOT SIDE)
C704
AA-113C (PK) AA-113C (PK)
T
L
chassis electrical
5A CUMMINS ISB07
F19 5A ENG IGN (OR)
SHT. 4
10A TRANS
F20 TRANS IGN (OR)
ECM IGN (PK) SHT. 5/6
5A ABS
F21 ABS IGN (OR)
PD SHT. 8/9
12V ECM 10A
CB22 DASH IGN (PK) IP
IGNITION BUS SHT. 19
7.5A
CB23 BRAKE WARN IGN (OR) HYD BRAKE BOOST
SHT. 16
AA-111 (OR) AA MODULE, SHT 10
7.5A
CB13 DPWR (BK) IP
SHT. 17
15A
CB10 STOP LGT PWR (RD) AA MODULE, SHT 10
BATT PWR (RD)
30A
CB12 PMP MTR BATT (RD) ABS
SHT. 9
PD 40A
12V F7 BRAKE BOOST BATT (RD) HYD BRAKE BOOST
BATTERY BUS SHT. 14
30A
CB11 HYD INTLK PWR (RD) DRIVER'S CNTRL MODULE
SHT. 18
10A DRIVERS CONTROL MOD
CB11 INTLK PWR (RD)
SHT. 19
10A
CB9 REV SENS + (RD) SEE DIAGRAM,WRG
FEA 2226
3A
CB14 D DIAG PWR (BK) DRIVER'S CNTRL MODULE,
SHT 18/19
10A
CB8 BRAKE SW PWR (RD) DRIVER'S CNTRL MODULE,
SHT 18/19
803
AA-114 (PK) AA MODULE, SHT 10
CUM ISB-07
12 IGNITION
PD RELAY SHT. 15
87 85 20A
70A CB5 HTD DRAIN PWR (BN) FRAME COMPONETS
SHT. 15
S26 10A
IGN REL GND (WH) CB3 AIR DRYER PWR (BL) FRAME COMPONETS
SHT. 15
IGN PWR (RD) PD
12V
IGNITION BUS
10A CUMMINS ISB07
CB4 FAN PWR (RD)
SHT. 4
PDU 15A BODY INTERFACE
CB6 BODY IGN (OR)
GROUND SHT. 21
STUD
Sheet 3
0117348A
STARTING AND CHARGING, CUMMINS W/FEA 40142-11
(Florida circuit breakers)
L
1 service manual
7 9
2B 3 VGT SW (BL)
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 FAN PWR (RD) 3
5
1 2
804
J1939 DATALINK SHT. 22/23
INSTRUMENT PANEL SHT. 17
INSTRUMENT PANEL SHT. 17
START/CHARGE SHT. 2/3
250A FUSE
START/CHARGE SHT. 2/3 2 GA (RD)
INTAKE AIR
HEATER SOLENOID
2 1
INTAKE AIR
HEATER
85 86
C807 B A
NC NC
SHUTTER AIR TEMP WATER TEMP
SOLENOID SHUTTER SWITCH SWITCH
L
chassis electrical
C808
ENG GND 1 (WH) 1
ENG GND 2 (WH) 2 ENGINE
POWER
ENGINE BLOCK EECM PWR 1 (RD) 3 CONNECTOR
GROUND S5 EECM PWR 2 (RD) 4
C704 ENGINE CONTROL MODULE (ECM)
EECM PWR (RD) U C800 (ENGINE J1 - 60 PIN CONNECTOR)
5A ENG IGN (OR) V 5A ENG IGN1 (OR) 5A ENG IGN2 (OR) 45 KEYSWITCH
S10
C701
WAIT START (GN) 1 WAIT START (GN) 53 WAIT TO START LAMP
AC-102 (RD) 23 AC-102 (RD) 2 STARTER LOCKOUT
AB-009 (BN) 18 AB-009 (BN) 17 THROTTLE INTERLOCK
VGT BRK SIG 24 VGT BRK SIG (RD) 55 VGT BRAKE LGT
AB-001A 12 HI IDLE (OR) 18 REMOTE PTO ON/OFF SW
C821
1 DPF TEMP 1 (RD) 49 DPF TEMPERATURE SENSOR 1 (INLET)
2 DPF TEMP 2 (OR) 40 DPF TEMPERATURE SENSOR 2 (MID)
3 DPF TEMP 3 (YL) 9 DPF TEMPERATURE SENSOR (OUTLET)
TO DPF 6 PRES SENSOR SIG (BL) 34 CST DELTA PRESSURE SENSOR SIG
4 ECM RET TL-D2 (TN)
7 ECM RET SENS-B2 (TN)
5 SENSOR PWR-C3 (GN)
C816
COOLANT A
LEVEL B COOL LVL (PK) 60 COOLANT LEVEL SENSOR
PROBE C ECM RET TL-D1 (WH) S8 ECM RET TL-D (TN) 38 ECM RETURN (SENSOR)
C815
A FAN CL +A (OR)
FAN
CONTROLLER
C FAN CL GND (WH)
C701
FAN CL +A (OR) 25
ECM FAN +(BL) 26 ECM FAN + (BL) 52 FAN CLUTCH OUTPUT
ECM RET GEN (WH) 27 ECM RET GEN-E (WH) 32 ECM RETURN
EJ1939+ (YL) 30 J1939+ (YL) 1 J1939 DIAGNOSTIC +
805
EJ1939- (GN) 31 J1939- (GN) 21 J1939 DIAGNOSTIC -
EJ1587+ (YL) 14 EJ1587+ (YL) 39 J1587 DIAGNOSTIC +
EJ1587- (BL) 15 EJ1587- (BL) 29 J1587 DIAGNOSTIC -
AMMETER SIG (RD) 17
CUM ISB-07
AMMETER SIG (RD)
C802
A
1536 (TN) B IAH OUT (TN) 54 INTAKE AIR HEATER OUTPUT
1208D (WH) C ECM RET GEN-F (WH) 44 ECM RETURN
WIF2 WH 16 GA
WIF RTN YL 16 GA
C823 1 2 C822 1 2
WATER IN FUEL RETURN
WATER IN FUEL
Sheet 4
0112291C
CUMMINS ISB07 ENGINE
L
1 service manual
PDU
INTERFACE
IP TJ1939, SHT 17 C702
IP TJ1939, SHT 17 A TRANS TEMP/164 (BL)
NOT USED B NOT USED
C CHECK TRANS/129 (GN)
NOT USED D NOT USED
NOT USED E NOT USED
AB MODULE, SHT 11 AB-004 (BL) F B2-016/165 (TN)
NOT USED G NOT USED
TJ1939+ (YL) H TJ1939+ (YL)
AB MODULE, SHT 11 AB-107 (RD) J B1-112/141 (TN)
TJ1939- (GN) K TJ1939- (GN)
RESERVED L RESERVED
RESERVED M RESERVED
AB MODULE, SHT 11 AB-003 (RD) N B1-002/105 (OR)
TELEG GNDA (WH) P 169 (GY)
TRANS BATT START/CHARGE, SHT 2/3 TRANS BAT (RD) R TRANS BAT (PK)
TRANS IGN START/CHARGE, SHT 2/3 TRANS IGN (OR) S TRANS IGN/163 (YL)
S14 TELEC GND B (WH) T 109 (GY)
IP TJ1587, SHT 17 TJ1587+ (YL) U NOT USED
IP TJ1587, SHT 17 TJ1587- (BL) V NOT USED
SHIFT INHIBIT IN AB MODULE, SHT 11 AB-005 (GN) W B3-015/101 (BL)
X 124 (WH)
TELEC GND (WH)
ELECTRONIC 5
PS3 6 157 (WH)
GROUND
PS2 7 179 (PK)
SUMP TEMP 8 154 (TN)
SIGNAL RETURN 9 158 (GN)
LSD TCC 10 178 (WH)
PS4 11 177 (GN)
12
13
HSD1 14 111 (OR)
LSD PCS1 15 155 (WH)
HSD2 16 171 (YL)
LSD PCS2 17 136 (OR)
DIGITAL SIGNAL NS 18 138 (OR)
LSD MAIN MOD 19 174 (BL)
DIGITAL SIGNAL C 20 114 (GY )
DIGITAL SIGNAL B 21 153 (YL)
DIGITAL SIGNAL A 22 173 (BL)
DIGITAL SIGNAL P 23 134 (WH)
TRANS ID 24 176 (YL)
L
chassis electrical
807
67
68
169 (GY)
69 GROUND
170 (PK)
70 BATTERY
171 (YL)
71 HSD2
72
CUM ISB-07
173 (BL)
73 DIGITAL SIGNAL A
174 (BL)
74 LSD MAIN MOD
75
176 (YL)
76 TRANS ID
177 (GN)
77 PS4
178 (WH)
78 LSD TCC
179 (PK)
79 PS2
180 (OR)
80 TURBINE SPEED HIGH
140 (GN)
139 (OR)
180 (OR)
159 (TN)
160 (YL)
120 (BL)
L
1 service manual
TO CONNECTOR C6
IP, SHT 17
C6 A B
ENGINE
COMPARTMENT
INTERFACE
IP TJ1939, SHT 17 C702
IP TJ1939, SHT 17 A TRANS TEMP/164 (BL)
B
C CHECK TRANS/129 (GN)
D
E
AB MODULE, SHT 11 AB-004 (BL) F B2-016/165 (TN)
G
J1939+ (YL) H J1939+ (YL)
AB MODULE, SHT 11 AB-107 (RD) J B1-112/141 (TN)
J1939- (GN) K J1939- (GN)
L
M
AB MODULE, SHT 11 AB-003 (RD) N B1-002/105 (OR)
TELEC GNDA (WH) P 169 (GY)
TRANS BATT START/CHARGE, SHT 2/3 TRANS BAT (RD) R TRANS BAT (RD)
TRANS IGN START/CHARGE, SHT 2/3 TRANS IGN (OR) S TRANS IGN (OR)
S14 TELEC GND B (WH) T 109 (GY)
IP TJ1587, SHT 17 TJ1587+ (YL) U TJ1587+ (YL)
IP TJ1587, SHT 17 TJ1587- (BL) V TJ1587- (BL)
SHIFT INHIBIT IN AB MODULE, SHT 11 AB-005 (GN) W B3-015/101 (BL)
X
TELEC GND (WH)
L
chassis electrical
169 (GY)
170 (RD)
67
68
69 GROUND
809
70 BATTERY POWER
171 (YL) 71 HSD2
TJ1587- (BL)
CUM ISB-07
72 J1587-
73
174 (BL) 74 LSD MAIN MOD
75
176 (YL) 76 TRANS JD
177 (GN) 77 DIGITAL SIGNAL
78
79
180 (OR) 80 TURBINE SPEED HIGH
140 (GN)
139 (OR)
159 (TN)
160 (YL)
C905 B A C902 B A
ENGINE OUTPUT Sheet 6
SPEED SPEED
SENSOR SENSOR
0112292A
ALLISON GEN 4 3000 TRANSMISSION
L
1 service manual
810
L
chassis electrical
ILLUM J (BL)
TO ALL OTHER ILLUM
ILLUM B (BL)
BODY INTERFACE, SHT 21
ILLUM H (BL)
INSTRUMENT CLUSTER, SHT 17
ILLUM C (BL)
S12
7 9 7 9 7 9 C12
3 3 3 C
2B 2B 2B AB-106C (BN)
A AB MODULE, SHT 11
1 1 1
6 6 6 D AB-106D (BN)
5B 5B 5B B
4 4 4 F
8 10 8 10 8 10
DIMMER
SWITCH
TYPICAL DASH SWITCH BACKLIGHTING/DIMMER CIRCUITS.
DIMMER POWER AND GROUNDS CONTINUE TO LOOP FROM SWITCH TO SWITCH.
811
CUM ISB-07
Sheet 7
0112293
DIMMER/BACKLIGHTS
L
1 service manual
RF SENSOR IN (PK)
RF MOD COM (GY)
H E H E
ABS
GROUND
RR SENSOR IN (PK)
TRACTION C514
CONTROL VALVE
TCV RTN
B
TCV IN
A
L
chassis electrical
ABS/ATC LIGHTS
ABS AIR (GN) IP
SHT. 17
ABS GND (WH)
ABS IGN (OR)
C507
ATC SLS (RD)
C504 A B C D E F
C505
ATC SLS (RD)
1 X1
ABS GND (WH) 1 ABS/ATC GROUND
2 TRAILER ABS WL (NOT CONNCTED)
ABS IGN (OR) 3 IGNITION (5A FUSED)
TCV RTN 4 TCV RTN
TCV IN 5 TCV IN
6 ATC LAMP/ATC ORS (ATC ONLY)
AJ1939-(GN) 7 J1939-LO
AJ1939+(YL) 8 J1939-HI
ATC SLS (RD) 9 SLS (ATC ONLY)
RR SENSOR IN (PK) 10 RIGHT REAR SENSOR +
RR SENSOR RTN (BK) 11 RIGHT REAR SENSOR -
ABS LGT GND (WH) 12 ABS W/L GND
AJ1587- (BL) 13 J1587-B
AJ1587+ (YL) 14 J1587-A
15 WL INTERLOCK (NOT CONNCTED)
ABS BATT (RD) 16 BATTERY (30A FUSED)
17 RETARDER (NOT CONNECTED)
ABS LGT (GN) 18 ABS WL ABS ECU
X2 BENDIX EC-60
C506
LF MOD HOLD (BL) CAB MOUNT
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)
813
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 (-)
CUM ISB-07
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 -
X3 (NOT CONNECTED)
1 ABS ORS
2 DIFF
3 DIFF_CMN
TRACTION 4 NOT USED
C515 B A CONTROL VALVE 5 RESERVED
6 NOT USED
ATC HARNESS 7 ADDITIONAL MOD EXHAUST
ABS HARNESS SEE CHART 0104429 8 RESERVED
9 ADDITIONAL MOD COMMON
10 ADDITIONAL MOD HOLD
11 ADDITIONAL LEFT SENSOR(+)
12 ADDITIONAL RIGHT SENSOR(+)
13 NOT USED
14 ADDITIONAL LEFT SENSOR(-)
15 ADDITIONAL RIGHT SENSOR(-)
Sheet 8
0112294
ABS - BENDIX
L
1 service manual
ABS ECU
16 WAY
CONNECTOR
C513
I/O DIAG SW & I/P ABS LT (TN) ABS LT (TN)
A
SHT 17 MOD PMP BAT (RD) PMP MTR BAT (RD)
B
C
ABS IGN (OR) ABS IGN (OR)
D
J1939 TJ1539- (GN) TJ1939- (GN)
E
TRANSMISSION TJ1939+ (YL) TJ1939+ (YL)
F
SHT 5/6 AJ1587- (BL) J1587- (BL)
G
AJ1587+ (YL) J1587+ (YL)
H
J
K
ABS BAT (RD) ABS BAT (RD)
L
ABS POWER
M
START/CHARGE
N
SHT 2/3 ABS GND (WH) ABS REF GND (WH)
P
AJ1939- (GN) AJ1939- (GN)
R
AJ1939+ (YL) AJ1939+ (YL) S4
S
S3
I/P
J1587
J1939
SHT 17
814
LR SENS GND (BK)
LF SENS GND (BK)
LR SENS IN (BN)
LF SENS IN (BN)
C511 1 2 C509 1 2
L
chassis electrical
MODULATOR PUMP
31 WAY
CONNECTOR
C521
ABS IGN (OR)
1 +12V IGNITION
2
3
4
5
ABS REF GND (WH)
6 GROUND
7
8
9
10
11
12
13
J1939+ (YL)
14 J1939+
J1939- (GN)
15 J1939-
PMP MTR BAT (RD)
16 PUMP MOTOR PWR
ABS BAT (RD)
17 +12 BATTERY PWR
PMP MTR GND (WH)
18 PUMP MOTOR
SOL VLV GND (WH)
19 SOLENOID VALVE
20
ABS LT (TN)
21 ABS LT
RR SENS IN (BN)
22 RR SENSOR INPUT
LR SENS IN (BN)
23 LR SENSOR INPUT
LF SENS IN (BN)
24 LF SENSOR INPUT
RF SENS IN (BN)
25 RF SENSOR INPUT
J1587- (BL)
26 J1587(-)
RR SENS GND (BK)
27 RR SENSOR GND
LR SENS GND (BK)
28 LR SENSOR GND
LF SENS GND (BK)
29 LF SENSOR GND
RF SENS GND (BK)
30 RF SENSOR GND
J1587+ (YL)
815
31 J1587(+)
CUM ISB-07
RR SENS GND (BK)
RF SENS IN (BN)
C503 1 2 C501 1 2
L
1 service manual
AA-107 (BL)
BODY INTERFACE, SHT 21
816
C7
- +
7 9
AA-004 (BN)
PARK LGT GND (WH) 2B 3
1
5B 6 AC-006 (OR)
HEAD LGT GND (WH)
4
8 10
- +
HEADLIGHT
SWITCH
C423
L
HARNESS CONN C2
I/O SEQ
PORT #
AA-101 (BN)
1
WIPER MOTOR
2
OUT 1
INTERMITTANT
2
1
OUT 1
LGT (LEFT)
3
2
OUT 2
4
IN 7
LGT SWITCH
AA-105 (PK)
2
PARK BRAKE
OUT 3
LGT (RIGHT)
AA-107 (BL)
2
BACK-UP LIGHT
OUT 4
CV-MBC-2424
1
IN 8
8
RELAY
OUT 5
C715
C709
C703
AA-102 (BN) AA-102 (BN) AA-102 (BN)
AA-110 (RD) AA-110 (RD) AA-110 (RD) HIGH BEAM HEAD
A B
1
10
LGT (LEFT)
OUT 3
LEFT
AA-110 (RD) AA-106 (OR)
A B C
HEADLIGHT
AA-112A (PU)
1 2 3 4
AA-111(OR)
2
11
IGNITION
OUT 6
12
LGT (RIGHT)
OUT 4
C718
C706
AA-106 (OR) AA-106 (OR)
AA-112 (PU) AA-113 (PK) IGNITION
2
A B
13
OUT 7
RIGHT
A B C
HEADLIGHT
AA-114 (RD)
2
14
STARTER RELAY
OUT 8
chassis electrical
AA-112B (PU)
AA-113 (PK)
AA-105 (PK)
AC-006 (OR)
AA-111 (OR)
AA-114 (RD)
Sheet 10
0112296C
17
SHT 12
AA MULTIPLEX MODULE
SHT 2/3
AC-MODULE,
CLUSTER, SHT
INSTRUMENT
START/CHARGE,
L
817
CUM ISB-07
1 service manual
CV-MBC-2424
REVERSE SIGNAL
WASHER PUMP
SHIFT INHIBIT
3 MPH SPEED
PARK LIGHTS
INTERLOCK
THROTTLE
HIGH IDLE
NEUTRAL
SWITCH
SIGNAL
SIGNAL
PORT # 3 1 1 1 3 1 1 1 3
1/0 SEQ. OUT 1 OUT 5 IN 1 IN 2 OUT 2 OUT 6 IN 3 IN 4 OUT 3
HARNESS CONN C4 1 2 3 4 5 6 7 8 9
AB-005 (GN)
AB-001 (OR)
AB-106 (BN)
AB-009 (BN)
AB-003 (RD)
AB-107 (RD)
AB-108 (PK)
AB-004 (BL)
AB-102X (YL)
AB-001A (OR)
AC MODULE, SHT 12 F2
10A
AB-001B (OR) FUSE
ENGINE, SHT 4
AB-003 (RD)
TRANSMISSION, SHT 5/6
AB-004 (BL)
TRANSMISSION, SHT 5/6
AB-005 (GN)
TRANSMISSION, SHT 5/6
AB-107 (RD)
TRANSMISSION, SHT 5/6
AB-009 (BN)
ENGINE, SHT 4
AB-012 (PK)
DRIVERS CONTROL MODULE, SHT 18/19
AB-111B (RD)
DRIVERS CONTROL MODULE, SHT 18/19
AB-111A (RD)
HYDRAULIC BRAKE BOOST, SHT 14
AB-110B (GN)
BODY INTERFACE, SHT 21
AB-110D (GN)
INSTRUMENT CLUSTER, SHT 17
AB-106B (BN)
BODY INTERFACE, SHT 21
AB-106C (BN)
DIMMER/BACKLIGHTING, SHT 7
AB-102D (YL)
INSTRUMENT CLUSTER, SHT 17
AB-106A (BN)
AB-102A (YL)
LT DIR GND (WH)
FT LT PK LGT (BN)
FT LT PK LGT (BN)
LT PK GND (WH)
AB-102A (YL)
AB-102B (YL)
GND C (WH)
AB-102 (YL)
C703 14 C703 5
AB-102A (YL)
FT LT PK LGT (TN) S3
DIRECTIONAL DIR/PARK GND C (WH)
LIGHT LIGHT
L
chassis electrical
PARKING BRAKE
WIPER WASHER
SERVICE BRAKE
LAMP SWITCH
LIFT ENABLE
RIGHT TURN
LAMPS
INTERLOCK
ACC HOT
SWITCH
BRAKE
PUMP
HORN
1 1 1 3 1 3 3 3 3
CNETA CNETB VIN GND
OUT 7 IN 5 IN 6 OUT 4 OUT 8 OUT 5 OUT 8 OUT 6 OUT 7
10 11 12 13 14 15 16 17 18 19 20 21 22
AB-015 (WH)
AB-116 (GN)
AB-111 (RD)
AB-021 (RD)
AB-122 (TN)
AB-110X (GN)
AB-012 (PK)
AB-114X (BK)
C703 9
GND A (WH)
HORN GND (WH)
GND (WH)
AB-114 (BK)
GND B (WH)
GND C (WH)
A B 725
819
CUM ISB-07
HORN
S2
S1
AB-110A (GN)
FT RT PK LGT (BN)
RT PK GND (WH)
AB-110A (GN)
AB-110B (GN)
GND B (WH)
AB-110 (GN)
C703 16
AB-110A (GN)
FT RT PK LGT (TN)
Sheet 11
GND B (WH) DIR/PARK DIRECTIONAL
LIGHT LIGHT 0112297B
AB MULTIPLEX MODULE
L
1 service manual
HEADLAMP SWITCH
STARTER LOCKOUT
IGNITION SWITCH
START SWITCH
ACCESSORY
HIGH BEAM
HIGH IDLE
SIGNAL
SWITCH
SWITCH
SWITCH
PORT# 2 2 2 2 2 2 2
I/O SEQ IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7
HARNESS CONN C1 1 2 3 4 5 6 7
AC-001 (GN)
AC-102 (RD)
AC-006 (OR)
AC-007 (OR)
AC-005 (PU)
AA-004 (PK)
AC-003 (YL)
AC HI IDLE (GN)
BODY INTERFACE, SHT 21
AC-102 (RD)
ENGINE SHT 4
AC-003 (YL)
DRIVER CONTROL MODULE, SHT 18/19
AC-004 (PK)
DRIVER CONTROL MODULE, SHT 18/19
AC-005 (PU)
DRIVER CONTROL MODULE, SHT 18/19
AC-006 (OR)
AC MODULE, SHT 12
AC-007 (OR)
DRIVER CONTROL MODULE, SHT 18/19
AC-008A (YL)
DRIVER CONTROL MODULE, SHT 18/19
AC-009A (GN)
DRIVER CONTROL MODULE, SHT 18/19
AC-010 (GY)
DRIVER CONTROL MODULE, SHT 18/19
ILLUM D
DIMMER/BACKLIGHTS SHT 8
7 9
3 AC-001A (GN)
HIGH IDLE GND (WH) 2B
820 1
6
5B
4 HIGH IDLE SW
8 10 C425
ILLUM F (BL)
DIMMER/BACKLIGHTS, SHT 8
7 9
3 AC-008B (YL)
GND 2B
1
6 AC-009B (GN)
GND
5B
4 HAZARD SW
8 10 C424
ILLUM E (BL)
DIMMER/BACKLIGHTS, SHT 8
7 9
3 AC-015 (GN)
GND 2B
1
ABS LT GND 6
5B ABS LT (TN)
4
8 10 I/O DIAGNOSTIC SW
C422
L
chassis electrical
CV-MBC-2424
EXTERIOR DOOR
I/O DIAGNOSTIC
HORN BUTTON
INTERMITTANT
WIPER SWITCH
VANDAL LOCK
RIGHT TURN
SCC ALARM
INTERLOCK
LEFT TURN
FEEDBACK
SWITCH
SWITCH
SWITCH
SIGNAL
2 3 3 3 3 3 3 3 3
N/A N/A
IN 8 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8
8 9 10 11 12 13 14 15 16 17 18
AC-009 (GN)
AC-014 (GN)
AC-015 (GN)
AC-010 (GY)
AC-013 (OR)
AC-016 (TN)
AC-112 (BK)
AC-008 (YL)
AC-011 (BL)
AC-016 (TN)
BODY INTERFACE, SHT 21
AC-014 (GN)
BODY INTERFACE, SHT 21
AC-013 (OR)
DRIVERS CONTROL MODULE, SHT 18/19
AC-112 (BK)
DRIVERS CONTROL MODULE, SHT 18/19
AC-011 (BL)
BODY INTERFACE, SHT 21
ABS LT (TN)
I/P, SHT 17
821
CUM ISB-07
Sheet 12
0112298
AC MULTIPLEX MODULE
L
1 service manual
C714
CRS MR GND (WH)
A
CRS MR HT LT (PU)
B
C
CRS MR HT LT(PU)
C719
CRS MR GND (WH)
A
CRS MR HT RT (PU)
B
C
CRS MR HT(PU)
C700
C711
G
TO OUT SPKR +(YL) OUT SPKR + OUT SPKR +
J B EXTERIOR
HEATER STEPWELL OUT SPKR -(PU) OUT SPKR - OUT SPKR -
HARNESS K A SPEAKER
N
L
M
WASH MTR PWR(YL) WASH MTR PWR WASH MTR PWR
WASHER MOTOR GROUND A WASHER
WASH MTR GND(WH) WASH MTR GND(WH) WASH MTR GND WASH MTR GND BOTTLE
FRAME COMPONETS B
SHT. 15
C708
2302J(GY)
A
M
1213X(WH)
B
HEATER PUMP
C726 MOTOR
822
Sheet 13
0112299
MIRROR HEAT/EXTERIOR SPEAKER/WIPER WASHER
L
chassis electrical
C703
BRAKE WARNING IGNITION
START/CHARGE BRAKE WARN IGN (OR) BRAKE WARN IGN (OR)
18
SHT. 2/3
C729
BRAKE WARN IGN (OR)
A TO
C703 BRAKE WARN LGT (TN)
S25 B HYDRAULIC BRAKE
BRAKE WARN GND (WH) BRAKE WARN GND (WH) BRAKE WARN GND (WH) BOOST HARNESS
15 C
AB-111 (RD)
D
GROUND PDU
GROUND
STUD
C703
BRAKE WARNING LIGHT
IP BRAKE WARN LGT (TN) BRAKE WARN LGT (TN)
13
SHT. 17
C703
SERVICE BRAKE
AB MODULE, AB-111 (RD) AB-111 (RD)
17
SHT. 11
C818
BRAKE BOOSTER +12V DCM GND (WH) DCM GND (WH) HYD
A BRAKE
START/CHARGE BRAKE BOOST BAT (RD) BRAKE BOOST BAT (RD) B BOOST
SHT. 2/3
823
CUM ISB-07
Sheet 14
0112300
HYDRAULIC BRAKE BOOST, CUMMINS
L
1 service manual
GROUND
GND A
HEATED FUEL POWER
START/CHARGE HTD FUEL PWR (PK)
SHT. 2/3
WASHER MOTOR GROUND
WASH MTR GND (WH) MIRROR HEAT
FUEL TANK SIGNAL S5 SHT. 13
FUEL TANK SIG (BK)
IP
SHT. 17
S25 FUEL TANK GND (WH)
(WH)
(BN)
(BK)
(BL)
(PK)
C705 A B C D E F C736 1 2
FUEL TANK GND (WH)
FUEL TANK SIG (BK)
C730 A
HTD DRAIN GND A (WH)
HTD DRAIN PWR A (PU)
FUEL TANK GND (WH)
Sheet 15
0112301A
FRAME COMPONENTS
L
chassis electrical
C730
C723
C722
CRS ARM LGT(YL)
A
CROSSING ARM
LIGHT
825
CUM ISB-07
Sheet 16
0112302
CROSSING ARM
L
1 service manual
INSTRUMENT CLUSTER
PROGRAM 1 (RD)
13
PROGRAM 2 (RD)
14
D PWR (BK)
1
D IGN (RD)
3
D RETURN (YL)
4
DESC (OR)
5
"A" CONNECTOR C302 DUP (GN)
6
22 WAY CONNECTOR D DOWN (BL)
GREEN 7
AB-110D (GN)
21
DCHASS GND (WH)
2
J1939+ (YL)
15
J1939- (GN)
16
J1587+A (YL)
17
J1587-A (BL)
18
RAA IN (GN)
FAA IN (GN)
C306 A B C C307 A B C
L
chassis electrical
C303
PROGRAM 1 (RD)
B
PROGRAM 2 (RD) DASH PROGRAM PORT
A
D PWR (BK)
DASH POWER, SHT 2/3
D IGN (RD)
DASH POWER, SHT 2/3
D RETURN (YL)
DRIVERS CONTROL MODULE, SHT 18/19
DESC (OR)
DRIVERS CONTROL MODULE, SHT 18/19
DUP (GN)
DRIVERS CONTROL MODULE, SHT 18/19
D DOWN (BL)
DRIVERS CONTROL MODULE, SHT 18/19
AB-110D (GN)
R/TURN SIGNAL, AB MODULE, SHT 11
J1939+ (YL)
J1939 DIAGNOSTIC INTERFACE, SHT 22/23
J1939- (GN)
J1939 DIAGNOSTIC INTERFACE, SHT 22/23
J1587+A (YL)
J1587 DIAGNOSTIC INTERFACE, SHT 22/23
J1587-A (BL)
J1587 DIAGNOSTIC INTERFACE, SHT 22/23
ILLUM H (BL)
PANEL DIMMER, SHT 7
WIF SENSOR (YL)
WATER IN FUEL, SHT 15
AMMETER SIG (RD)
CURRENT SENSOR, SHT 4
ABS LGT (TN)
DIAGNOSTIC SW. AC MODULE, SHT 12
ABS HYD (TN)
HYD ABS LIGHT, SHT 9
BRAKE WARN LGT (TN)
BRAKE WARNING LIGHT, SHT 14
HYD INTLK AML (YL)
DRIVERS CONTROL MODULE, SHT 18/19
STOP LGT A (RD)
STOPLIGHT, AB MODULE, SHT 10
ABS AIR (TN)
S42 AIR ABS LIGHT, SHT 8
WAIT START (GN)
WAIT TO START LIGHT, SHT 4
HIGH IDLE (OR)
HIGH IDLE INPUT, AB MODULE, SHT 11
ABS LT (TN)
DIAGNOSTIC SW, AC MODULE, SHT 12
AB-015B (WH)
CC ON/OFF (GY)
SHIFT INHIBIT SIGNAL, AB MODULE, SHT 11
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT18/19
827
CC SET (BN)
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
CC RESUME (GN)
CUM ISB-07
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
F AIR GND (WH) OR A5 GND (WH)
F AIR +5V ((OR) OR A5 +5V (OR)
F AIR IN (GN) OR A5 IN (GN)
C304 A B C C305 A B C
L
1 service manual
AA-101B
AA MODULE,WIPER MOTOR INTERMITTANT,SHT 11
WIPER + (BK) 86 30
BODY INTERFACE, SHT 21 WIPER
WIPER INT (GN) PARK
BODY INTERFACE, SHT 21 87
RELAY 85 87A
C200
2112 (RD) WIPER HI (RD)
HIGH 2 A
2111 (DK GN) WIPER LOW A (GN)
WINDSHIELD LOW 1 B
828
2115 (YL) WIPER PARK 2 (BL)
WIPER PARK 4 C
MOTOR 1124SS (BK) WIPER +A (BK)
12V 3 D
1216DD (WH) WIPER GND (WH)
GND 5 E
AB-122 (TN)
F
WIPER
WASHER M
PUMP
L
chassis electrical
CUM ISB-07
8
9
10 HIGH BEAM INDICATOR
11 HIGH BEAM SIGNAL
12 LEFT TURN SIGNAL
13 RIGHT TURN SIGNAL
14 GROUND
Sheet 18
0112304A
DRIVER’S CONTROL MODULE, AIR
L
1 service manual
AA-101B
AA MODULE,WIPER MOTOR INTERMITTANT,SHT 11
86 30
WIPER
PARK
87
RELAY 85 87A
WIPER + (BK)
BODY INTERFACE, SHT 21
WIPER INT (GN)
C200
2112 (RD) WIPER HI (RD)
WINDSHIELD HIGH 2 A
2111 (DK GN) WIPER LOW A (GN)
WIPER LOW 1 B
MOTOR 2115 (YL) WIPER PARK 2 (BL)
PARK 4 C
1124SS (BK) WIPER +A (BK)
12V 3 D
1216DD (WH) WIPER GND (WH)
GND 5 E
AB-122 (TN)
F
WIPER
WASHER M
PUMP
L
chassis electrical
TURN SIGNAL/ICC
1 COM
2 ON
START SWITCH 3 RESUME/COAST
4 SET -
BAT
START
5
6
SET +/ACCEL
831
IGN 1 7
IGN 2 8
CUM ISB-07
ACC 1 9
10 HIGH BEAM INDICATOR
11 HIGH BEAM SIGNAL
12 LEFT TURN SIGNAL
13 RIGHT TURN SIGNAL
14 GROUND
Sheet 19
0112305A
DRIVER’S CONTROL MODULE, HYD
L
1 service manual
C8
MBC POWER START/CHARGE, MBC GND B (WH) 9 CONN. D CV-MBC-2424
SHT 2/3 10
MBC/DIO
MODULE
Sheet 20
0112306A
MBC MODULE
C11
BODY IGN (OR) BODY IGN (OR)
START/CHARGE, SHT 2/3 A +12V IGNITION
AB-116 (RD) AB-116 (RD)
AB MODULE, SHT 11 B ACCESSORY HOT
C
AC-014 (RD) AC-014 (RD)
SCC OPTION 30195-13,19 ONLY D SCC ALARM
E
F
Sheet 21
0112307
BODY INTERFACE
L
chassis electrical
DIAG GND A
DIAG PWR B
J1587 AJ1587 + (YL) DJ1939+ (YL)
AJ1587 - (BL) C
ABS DJ1939- (GN)
SHT 8/9 D 9-PIN
E DIAGNOSTIC
J1587+ (YL) S8 J1587+ B F
J1587- (GN) S9 J1587- B TOOL
G
H
J
S3 C513 J1939
ABS AJ1939+ (YL) J1939+ (YL) AJ1939+ (YL) S34 J1939+A (YL) S33 J1939+ (YL)
F S32 INSTRUMENT
ECU AJ1939- (GN) J1939- (GN) E AJ1939- (GN) S35 J1939-A (GN) J1939- (GN) CLUSTER
SHT 9 S4 SHT. 17
C513
TJ1939+ (YL) S
TJ1939- (GN) R
Sheet 22
0117183
J1939 DATALINK, HYD
J1587
J1587+A (YL)
INSTRUMENT
J1587-A (BL) CLUSTER
J1587 EJ1587 + (YL)
SHT. 17
ENGINE EJ1587 - (BL)
SHT 4 DIAGNOSTIC
DIAG PWR (RD) POWER
SHT 2/3
833
TJ1587 + (YL) S15 DIAG GND (WH)
J1587
TRANS TJ1587 - (BL) S16
SHT 5/6
CUM ISB-07
AJ1587 + (YL) DIAG GND
J1587 A
AJ1587 - (BL) DIAG PWR
ABS B
SHT 8/9 DJ1939+ (YL)
C
DJ1939- (GN)
D 9-PIN
E DIAGNOSTIC
J1587+ (YL) S8 J1587+ B
F TOOL
J1587- (GN) S9 J1587- B
G
H
J
EJ1939+ (YL)
ENGINE
EJ1939- (GN)
SHT. 4
J1939
TJ1939+ (YL) S36 J1939+B (YL) S34 J1939+A (YL) J1939+A (YL) S33 J1939+ (YL)
TRANS ECU DIAGNOSTIC
TJ1939- (GN) J1939-B (GN) J1939-A (GN) J1939-A (GN) J1939- (GN) INTERFACE
SHT. 5/6 S37 S32
S35 SHT. 17