chassis electrical

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 alternator on the Blue Bird All
American has a “built in” voltage regulator as standard equipment. A remote regula-
tor is available as an option. They are self excited (started) alternators.
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 by providing clean
“electronic power” for the electronic control systems; ECU, ECM, TCM, and gauges.

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 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 should be 70 - 80 ft. lbs. for a L/N
699
and 55 - 59 ft. lbs. for a Bosch.
Blue Bird All American buses are equipped with an automatic belt tensioner. En-
sure that all the grooves fit properly into the pulleys in the correct path. The drive belt
should be inspected per the schedule in the maintenance chart located in the Specs
and Maintenance chapter of this manual.

Also check:
• Battery voltage
• Alternator output
• Starter current draw

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 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
Digital Volt/Ohm Meter
and testing.

Alternator Performance Test

1. Connect a digital volt/ohmmeter (VOM) to the output ter-

minals of the alternator.
Ammeter

[Caution] Ensure that the test leads are connected prop-

erly. Observe the polarity and make secure connections.

2. Connect an ammeter to the positive terminal of the alter-

700 nator. 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 be-

tween 13.8 and 14.2 volts with the engine at operating
RPM (1700 RPM minimum) and not idle.

4. Ensure that all “loads” are in the off position. The reading on the ammeter
should be less than 20 amps.

• If the amp reading is higher than 20 amps, ensure all accessories are
turned off.

• Ensure the battery is charged to at least 75% of their rated capacity.

5. Record the voltage. If the voltage is not within the specified range or the
amperage is not within the specified range, the alternator is defective.

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 chassis Electrical

6. If the alternator is determined to be defective, repair or replace it in accor-

dance with the instructions below. See Alternator Removal.

7. If the alternator is determined to be functioning properly, proceed as fol-

lows:

8. Continue to operate the engine at about 1700 RPM, and with the test equip-
ment set up as illustrated.

9. Turn on vehicle loads (accessories) until the ammeter displays amps, 75% of
the rated capacity of the alternator. 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 defec-
tive.

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
701
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 amps,

which is 75% of the rated alternator capacity, Use a car-
bon pile if necessary to achieve the load.

6. Record the voltage reading on the VOM.

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 SERVICE MANUAL

7. If the VOM reads more than -.25 volts, there is a problem

Volt/Ohm Meter
with the positive cable.

• Check and clean all the connections and the condi-

tion of all the cables/wires in the circuit.

• Re-test the circuit.

8. If the reading is less than -.25 volts, the cable and con-
Ammeter
nections are good.

Solenoid
9. Connect the negative lead of the VOM to the negative
terminal of the battery.

10. Connect the positive lead of the VOM to the negative

Starter
terminal of the alternator.

11. Repeat Steps 4 through 8 for the negative cable.

702

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 chassis Electrical

Alternator Removal
ALT
[Warning] Always disconnect the negative (-) cable from the battery termi-
nal first to avoid arcing, which could ignite explosive battery gases. FAN

1. Park the bus on a smooth, flat surface.

IDL
WP
2. Chock the wheels in both directions.
IDL TEN

3. Ensure the engine is not running, the ignition switch is in the “OFF” position
C/S
and the key is removed.

4. Disconnect the negative (ground) cable from the battery post.

5. Using a square drive tool, position the automatic tensioner so that the drive
belt can be removed.

6. Remove the drive belt.

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 ac-
ceptable. Replace the drive belt when any crack is observed to be running length-
wise 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.
703
8. Remove the negative (-) cable from the alternator.
Exciter Post

9. Remove the positive (+) cable from the alternator.

10. Support the alternator and remove the mounting bolts.

11. Remove the alternator.

Alternator Reinstallation
Installation of the alternator is accomplished in the reverse order of the removal in-
structions above.

1. Position the alternator to the saddle.

2. Install the alternator mounting bolts.

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 SERVICE MANUAL

3. Torque bolts to 70 - 80 ft. lbs. for Leece Neville and 55 - 59 ft. lbs. for Bosch
alternators.

4. Install the positive cable on the B+ post. Carefully tighten to avoid breaking
or stripping the stud.

5. Install the negative cable on the B- post. Carefully tighten to avoid breaking
or stripping the stud.

6. Before installing the drive belt, inspect it closely. Replace the belt if any signs
of wear are present.

7. Using a square drive tool, position the automatic tensioner so that the drive
belt can be installed. Install the belt and ensure that the grooves in the belt
fit properly on all the pulleys.

Automatic Belt Tensioner

The automatic tensioner is spring loaded to provide the proper tension for the drive
belt.
The automatic tensioner should travel freely within its full range of travel. Inspect
the belt tensioner for any unusual noise, excessive loosenenss and shaking at the
bearings.

Automatic Tensioner Removal

1. Remove the drive belt in accordance with the instructions above.

704 2. Remove the bolt from the automatic tensioner.

To install a new automatic tensioner, reverse the removal instructions.

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 chassis Electrical

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 lever. The lever is connected to
the starter drive pinion of the starter motor. The plunger also connects the electri-
cal power from the batteries to the starter motor as the drive pinion 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 drive pinion from the flywheel and removing electrical current from
the starter motor.
The Blue Bird All American has a 12-volt electrical system.

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.

• An engine that needs a tune up will be difficult to crank; over cranking will
705
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.

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 SERVICE MANUAL

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:

1. A battery that is low, poorly charged, or defective places high demands on

the starting system; voltage at the battery should be 12.6 to indicate a fully
charged battery. 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.

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 ad-
dition, the ring gear could be damaged.

5. A defective solenoid will fail to engage the starter drive pinion of the starter
motor. A failed pull-in 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

706 the starter motor on. If the solinoid is suspect, test the wiring of the solenoid
circuit before replacing the solenoid.

[WARNING] DO NOT use starting fluid as an aid to starting the engine. This
could cause an explosion resulting in personal injury or death.

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 chassis Electrical

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.

Solenoid
2. Connect the negative lead of the VOM to the chassis
Alternator
ground.

3. While attempting to crank the engine, record the voltage

Starter
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.

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
707
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 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.

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 SERVICE MANUAL

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.

2. Connect the negative lead of the VOM to the chassis ground.

Starter

3. While attempting to crank the engine, if there is no voltage dis-

played on the VOM, the main contacts are not functioning properly.

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.

7. While attempting to crank the engine, place an ammeter on the positive

Main Contacts
708 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.

Ammeter

Solenoid
Alternator

Starter

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 chassis Electrical

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.

1. Connect the positive lead of a VOM to the positive battery

terminal.
Solenoid
Alternator
2. Position an ammeter between the solenoid and the posi-
tive terminal of the solenoid.

3. Connect the negative lead of the VOM to the positive ter-

Starter
minal of the solenoid.

4. Connect the negative lead of the VOM to the negative

Carbon Pile Tester
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.
709
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.

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 SERVICE MANUAL

14. Record the voltage on the VOM; standard guidelines state it should not drop
more than 0.5-volts from the unloaded reading. Depending on electrical op-
tions installed on the bus voltage drop may be more.

15. Turn the carbon pile tester to the OFF position.

16. If the voltage drop was more than 0.5-volts (depending on options) in step
8, the positive cabling is defective. Look for a broken cable or a loose or cor-
roded 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.

Solenoid
4. Connect the positive lead of the VOM to the positive (bat-
tery) terminal of the solenoid.
Alternator

5. Set the VOM so that it can read the full battery volt-age; at

710 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
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.

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 chassis Electrical

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 hous-
ing.

2. Install 3 capscrews (1). Torque to 32 ft lb (43 Nm). See Figure 8.

3. Being careful to observe the identification of the electrical wires, con-

nect the wires to the appropriate terminal on the starter motor. See
Figure 7.
711
[Warning] Always remove the negative (-) cable from the battery terminal
first. Always connect the negative (-) cable to the battery terminal last to avoid
arcing that could ignite explosive battery gases.

4. Install the positive cable on the battery post.

5. Install the negative cable on the battery post.

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 SERVICE MANUAL

J-1939 Harness Diagnostics

1. Disconnect battery or J-1939 connector from the engine, ABS, transmission

and instrument panel.

2. Measure resistance between pin A and pin B. Reading should be 60 ohms

+/-1% (0.6 ohms).

3. Meassure continuity between shield (pin C) and ground. Reading should be

minimal resistance.

4. Meassure resistance between pin A and ground. Reading should be infinity

(maximum resistance).

5. Meassure resistance between pin B and ground. Reading should be infinity.

6. If all readings are correct, and problem appears to be intermittent:

6.1 Inspect each connector for positive lock connection.

6.2 Inspect for corrosion.

6.3 Inspect for damage to connectors.

7. If resistance between pins A and B is 120 ohms, one of the terminating resis-
torsis missing or bad.

8. If reading between pins A and B is infinity:

712 8.1 One of the connectors is unplugged.

8.2 Both resistors are bad or missing.

8.3 A connector is damaged

DIAG GND
A
DIAG PWR
B
YL
C
GN
D 9-PIN
SH
E DIAGNOSTIC
J1587+B
J1587-B
F TOOL Transmission Chassis ABS
G
H TCM/ECU Ground ECU
J

B A C B A C

C C C C C To
Shield Engine
A A Shield Shield A A A
C C ECM
B B YL (+) B B B
A Pin A Pin A A
C C C GN (-) C C C
120 Ohm B B 120 Ohm
A A A Pin B Pin B A A A
Terminating Terminating
Resistor B B B B B B Resistor

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 chassis Electrical

Chassis Wiring Schematics

The D3 All American electrical diagrams are formatted by electrical system, electri-
cal circuit, or by options/features. They are also divided into two basic groups, body
and chassis electrical systems. There are some over lapping circuits resulting in some
body circuits existing on chassis diagrams and some chassis circuits existing on body
diagrams.
Each circuit is represented on the diagram with its own line running from one
connector to another connector or from a connector to an electrical source or electri-
cal load. When a dot is encountered on a circuit line it indicates a soldered splice with
all the circuits that intersect that point. Each circuit will be identified by a number or
the description of the circuit, the color of the circuit and the gauge of the wire used
in the circuit is also indicated on the diagram. In some cases the circuit will be iden-
tifed as positive (+) or negative (-). Most of the circuits interface the electrical system
through electrical connectors. Each half of the connector will be identified with the
letter “P” or “J” and a number. The two halves of the connector may or may not have
the same number code but each half will be clearly marked on the print. Each pin in
the connector will be indentified with a letter or number, the male and female side
of the connector will be indicated and each circuit flowing through a connector will
have a description. Information concerning the continuation of a circuit that exists
on more than one diagram will also be provided, (example; See Diagram WRG: Power
and Ground).
Some of the diagrams are subdivided by dotted lines that usually run through
the center of a connector. The subdivisions represent the different electrical har-
nesses making up the circuits on a specific diagram. This provides the interaction
between electrical circuits or harnesses and serves as a general locator for the electri-
cal connectors.

The following subdivisions are identified on the drawings:

713
ELEC PANEL – Side (Body) Electrical Panel, located in the access panel below the
driver’s side window. It serves as the main power distribution point for the body
electrical system. The Body Control Module (BCM) is also located in the side body
electrical panel.
PDU – Power Distribution Unit, located in the lower access panel below the driver’s
side window. It serves as the main power distribution point for the chassis electrical
system. Power from the battery is routed through the PDU before being distributed
to the upper electrical panel and throughout the bus.
DCM – Driver Control Module, represents the structural support for the dash, the
steering column, left side of the fire wall, and the structure the driver seat is fastened
to. With respect to electrical diagrams, this subdivision could represent any electri-
cal circuit or device in and around the drivers area, including circuits routed to the
steering column, heaters and etc. These circuits will interface with the PDU, the body
electrical panel, the engine harness and the transmission harness.
ENGINE – This subdivision involves all electrical circuit interfaces between Blue Bird
PDU Access
systems and the engine electrical system, mainly the engine ECU. This does not in-
Electrical Panel Access
clude the engine wiring harness supplied with the engine.

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 SERVICE MANUAL

TRANSMISSION – This subdivision involves all electrical circuit interfaces between

Blue Bird systems and the transmission electrical system.
IP – Instrument Panel, involves all electrical interfaces between the instrument panel
and Blue Bird’s electrical system.
FRAME – This subdivision involves the electrical circuits located on the frame and
circuits not covered by other subdivisions.
BODY - This subdivision involves the electrical circuits located on the body and cir-
cuits not covered by other subdivisions.

For example, on diagram D0001451 - AIR ABS SYSTEM, even though the ABS system
is for the most part a self contain electrical system the circuits between the ABS ECU/
Modulator and the other ABS components are routed through six separate electrical
subdivisions indicated on the drawing. Starting at the top right corner and working
around the print clockwise the PDU provides power to the ABS system. From the
lower right corner across the bottom and up through the center of the diagram the
diagram provides most of the electrical interface between the ABS components and
the rest of the electrical system. Other electrical interfaces on the diagram include
the Transmission, the DCM, Instrument Panel, and Electrical Panel along the left side
of the diagram.
The following pages contain the main wiring schematics applicable to most All
American chassis. These are provided for your convenience when you are limited to
use of the print manual.
The drawings on the CD are in resolution-independent vector format. This allows
you to zoom them at will, without the images becomming jagged as occurs with
bitmap formats. This also means that you may print the drawing to your own office or
desktop printer while maintaining legibility even at significant reductions.

714 For more information see; About the TechReference CD; Electrical Schematics
located in the Introduction section of Volume 1. Also see additional wiring schemat-
ics for your bus at the Customer Access web site:

http://service.blue-bird.com

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Index of Schematics

DAYTIME RUNNING LIGHTS.................................Sheet 1 Schematic Legend Wire Colors

BACK-UP LIGHT ALARM.......................................Sheet 2 PD Power Distribution Unit (PANEL) BL BLUE
HORN.................................................................Sheet 3 AC AIR CLEANER BRACKET BK BLACK
J1587 DATALINK.................................................Sheet 4 IP INSTRUMENT PANEL BN BROWN
J1939 DATALINK.................................................Sheet 5 FW FIREWALL TN TAN
CUMMINS ENGINE....................................Sheet 6, 1 of 3 SP SHIFTER PANEL WH WHITE
CUMMINS ENGINE....................................Sheet 6, 2 of 3 DC Driver Control Module (DCM) YL YELLOW
CUMMINS ENGINE....................................Sheet 6, 3 of 3 PK PINK
2000 TRANSMISSION...............................Sheet 7, 1 of 2 OR ORANGE
2000 TRANSMISSION...............................Sheet 7, 2 of 2 RD RED
3000 TRANSMISSION...............................Sheet 8, 1 of 2 GN GREEN
3000 TRANSMISSION...............................Sheet 8, 2 of 2 PU PURPLE
HYDRAULIC ABS BRAKES.....................................Sheet 9 GY GRAY
AIR ABS BRAKES.................................................Sheet 10
LUGGAGE & AIR DRYER........................................Sheet 11
AMMETER...........................................................Sheet 12
WIPERS & WASHER PUMP...................................Sheet 13
POWER....................................................Sheet 14, 1 of 6
POWER....................................................Sheet 14, 2 of 6
POWER....................................................Sheet 14, 3 of 6
POWER....................................................Sheet 14, 4 of 6
POWER....................................................Sheet 14, 5 of 6
POWER....................................................Sheet 14, 6 of 6
CHASSIS GROUND...............................................Sheet 15

715

Micro Relay Heavy Duty Relay Fuse Circuit Breaker Voltage Stud Switch Ngr Rocker
(Non-typical)

Twisted Wires Mini Relay Horn Speaker Light Shunt

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 SERVICE MANUAL

DCM IP

P230
CLUSTER
P270 P270
PK BRK SIG D RD 18 GA 18 PK BRK CLU RD 20 GA
10 WH 18 GA 10 22 PARK BRK
SIGNAL

PARK BRAKE
PROX
SWITCH

P275 P275
37 BN 18 GA

PK BRK EP RD 18 GA
F
GND PK BRK WH 18 GA

P70
SPLICE PACK:
GND

CONNECTS TO CONNECTS
ENGINE HARNESS TO IP

P210 P7
DRL ENG RUN GY 18 GA 6

716 P17
A W
P6

P6
P17
ELEC PANEL R16
PARK LIGHT
RELAY
PK BRK RD 18 GA

3 4
5 DRL ENABLE 1 PU 18 GA
DRL ENG RUN GY 18 GA 1 2

R19
PARK BRAKE
RELAY
SPLICE PACK:
PARK BRAKE GND 4 PK BRK DRL SIG RD 18 GA
GND PK BRK WH 18 GA 3
RELAY P70 5 ADJ PED PK BRK RD 18 GA
CB 43
IGN B A IGN PK BRK PK 18 GA 1 2 PK BRK RD 18 GA
5A

ADJ PED PK BRK RD 18 GA

SEE DIAGRAM WRG:
40099-01, ADJ PEDAL
IGN ADJ PEDAL PK 18 GA

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 chassis Electrical

ENGINE PDU
P1
CUMMINS ECM

STARTER LOCKOUT
ECM RETURN

32 2 DRL RELAY
P3E
4
DRL BATT BK 16 GA 3
5 1317 GY 18 GA
ENG RUN RD 18 GA 1 2
ECM RET WH 18 GA
ENG RUN RD 18 GA

ECM RET A WH 18 GA

FUSE P1
DRL BATT BK 16 GA D6 5A D7 BATT

ECM RET A WH 18 GA 7

PDU POWER CONNECTS TO

INTERFACE ENGINE HARNESS

P15 J3
ENG RUN RD 18 GA ENG RUN RD 18 GA
15
ECM RET WH 18 GA ECM RET WH 18 GA
19
1317 GY 18 GA 1317 GY 18 GA
14

SEE DIAGRAM WRG: ECM RET B WH 18 GA

40179: CUMMINS ENG

717
BCM
R8
DRL CONTROL
RELAY
P710
4 DRL ENABLE PU 18 GA
3 16 DRL ENABLE
5 PK TAIL BATT BN 18 GA
1 2 GND PK LGT WH 18 GA SEE DIAGRAM WRG:
PK TAIL SIG BN 18 GA STD EQP, HEAD / PARK LIGHT
PK TAIL 3 BN 18 GA

DRL BATT BK 14 GA SEE DIAGRAM WRG:

STD EQP, HEAD / PARK LIGHT

Sheet 1
D0000810A
DAYTIME RUNNING LIGHTS

L
 SERVICE MANUAL

PDU

BACK-UP
CONNECTS TO PDU POWER
RELAY P3A
FRAME HARNESS INTERFACE
SEE DIAGRAM WRG: FUSE P1
D9 4
BATT 10A
D8 1165E BK 16 GA 3
5 J2 P5
POWER 1 2 18113 GN 18 GA 18113 LT GN 18 GA
IGN 1133K PK 16 GA T
1322 LT BL 16 GA F 1322 LT BL 16 GA

40179 CUMMINS ENG 1133 PK 16 GA

IP
ELEC PANEL

CONNECTS TO CONNECTS
FRAME HARNESS TO IP
P200 P1
P6 P6
1322 LT BL 14 GA 1322 LT BL 14 GA B/U LGT LT BL 14 GA
U 10

W/O 02226-00
W/O 02234-00

P5
3
P5

BODY
718
P238
1322A LT BL 16 GA B
1322 LT BL 16 GA

LH B/U
1216D WH 18 GA A LH BACK UP GND
5
1216FF WH 14 GA

TO AUX-3 GND
P264-B
P243
1322 LT BL 16 GA 1322 LT BL 16 GA
B RH B/U
8 1216J WH 18 GA A RH BACK UP GND
4
1216EE WH 14 GA

TO AUX-3 GND
P264-A

L
 chassis Electrical

FRAME TRANSMISSION
C926

CONNECTS TO VEHICLE/FRAME TRANSMISSION

TRANS INTERFACE TCM CONNECTOR

P12 C3
18113 LT GN 18 GA 165 (TN) 18 GA REVERSE
B 65
1322 LT BL 16 GA
P21 SIGNAL
BACK UP ALARM
14 B/U ALARM DK BL 14 GA
A BACK UP ALARM
B 1212AL
B/U LGT LT BL 14 GA

1212AL WH 14 GA

T1

CHASSIS GROUND

719

Sheet 2
D0001436A
BACK-UP LIGHT ALARM

L
 SERVICE MANUAL

IP ENGINE

HORN GND
HORN
B A HORN

1212WW WH 16 GA
HORN BN 16 GA
14

1231X WH 12 GA
T4

STARTER
GND
PDU POWER CONNECTS TO
CONNECTS TO
INTERFACE ENGINE HARNESS
ENGINE HARNESS CONNECTS TO IP
P15 J3
P210 P7

HORN BN 16 GA HORN BN 16 GA
HORN SIG BN 18 GA HORN SIG BN 18 GA 8
HORN SIG BN 16 GA
13 5

720

P270
2
P270

DCM
2 YL 18 GA

HORN BUTTON

COLUMN GROUND

L
 chassis Electrical

PDU

HORN RELAY
P2F

BATT HORN A RD 16 GA
4
BATT HORN RD 16 GA 3
5 HORN BN 16 GA
BATT HORN A RD 16 GA 1 2

FUSE P6
BATT HORN RD 16 GA 3A BATT
20A 3B

HORN BN 16 GA
HORN SIG BN 16 GA

721

Sheet 3
D0001439A
HORN

L
 SERVICE MANUAL

P260

DIAGONISTIC CONNECTOR

F G

IP
16142H YL 18 GA
16151H LT BL 18 GA

CONNECTS TO
ENGINE HARNESS CONNECTS TO IP

P210 P7
11 16142F YL 18 GA
15 J1587 (+) YL 18 GA
16151F LT BL 18 GA 14 J1587 (-) LT BL 18 GA
12

CONNECTS TO
FRAME HARNESS CONNECTS TO IP

722 16142G YL 18 GA
P200 P1
16142G YL 18 GA
23
16151G LT BL 18 GA 16151G LT BL 18 GA
24
16142H YL 18 GA
16151H LT BL 18 GA

L
 chassis Electrical

P1

CUMMINS ECM

39 29

ENGINE FRAME

AIR BRAKE

P4

J1587 (-) LT BL 18 GA
J1587 (+) YL 18 GA 5 1

16151G LT BL 18 GA
16142G YL 18 GA
WITH AIR BRAKE

723
16151H LT BL 18 GA
16142H YL 18 GA

WITH HYDRAULIC BRAKE

HYD BRAKE ABS MODULE

31 26
P24

Sheet 4
D0001440
J1587 DATALINK

L
 SERVICE MANUAL

IP

P235

P260 CLUSTER

DIAGONISTIC CONNECTOR 3 4
C D

D-1939(+) YL 20 GA
D-1939(-) GN 20 GA
D1-1939(-) GN 20 GA
D1-1939(+) YL 20 GA

P250

3000 TRANS SHIFTER

6 5 11 7 16 14 15 8 12 13 3 10 9 4 2 1

CONNECTS
CONNECTS ENG
WITH 3000 TRANSMISSION TO IP
HARNESS
P210 P7

1939 (+) SHIFT YL 20 GA 27 J1939 (+) JOIN YL 20 GA 14 B-1939(+) YL 20 GA B2-1939(+) YL 20 GA

CAN 29
1939 (-) SHIFT GN 20 GA J1939 (-) JOIN GN 20 GA B-1939(-) GN 20 GA B2-1939(-) GN 20 GA
DRIVER 30
42 15
TERM RESISTOR GN 18 GA

WITH 2000 TRANSMISSION

TERMINATION

724 RESISTOR
J1939(+) CAP YL 20 GA
J1939(-) CAP GN 20 GA

P290

2000 TRANS CAP

A
B

L
 chassis Electrical

TRANSMISSION ENGINE FRAME

C926

P1
TRANSMISSION TCM
CONNECTOR CUMMINS ECM

1 21
48 68
T-1939(+) YL 20 GA
T-1939(-) GN 20 GA

P4

AIR BRAKE
CONNECTS ENG
6 2
HARNESS
C910
E-1939(+) YL 20 GA
E-1939(-) GN 20 GA

1 2
P16

CONNECTS TRANS
HARNESS

B1-1939 (+) YL 20 GA
B1-1939 (-) GN 20 GA
T-1939(+) YL 20 GA
T-1939(-) GN 20 GA

WITH AIR BRAKE

CONNECTS TO CONNECTS TO
FRAME HARNESS ENGINE HARNESS
P14 P23 P14 J14
3 B1-1939(+) YL 20 GA 1 B-1939(+) YL 20 GA B-1939(+) YL 20 GA 5 B2-1939(+) YL 20 GA 120
1 2
B1-1939(-) GN 20 GA B-1939(-) GN 20 GA B-1939(-) GN 20 GA B2-1939(-) GN 20 GA
2 1
4 2 4

J1939 HARNESS
TERMINATING
RECEPTACLE
725
B1-1939 (+) YL 20 GA
B1-1939 (-) GN 20 GA

WITH HYDRAULIC BRAKE

14 15

P24

HYD BRAKE ABS MODULE

Sheet 5
D0001441A
J1939 DATALINK

L
 SERVICE MANUAL

IP
SEE DIAGRAM WRG: SEE DIAGRAM WRG:
ALTERNATOR J1587 DATA LINK J1939 DATA LINK
TO
TO FIELD SHEET 2
F- +
A/C-

J1587 (+)

J1939 (+)
J1939 (-)
J1587 (-)
REFERENCE: ALT
GND CABLE
REFERENCE: ALT P210
HOT CABLE 7 10 11 12 14 15 29 30
P7

WITH LEECE-

SHUTTER SIG TN 18 GA
SEN RET B BK 18 GA
THROT SIG 2 TN 18 GA
SEN PWR B GN 18 GA

J1587(-) LT BL 18 GA
J1587(+) YL 18 GA

B2-1939(+) YL 20 GA
B2-1939(-) GN 20 GA
NEVILLE ALT

P52

VOLTAGE REGULATOR
1133C 1133C PK 16 GA
A
VR GND B VR GND WH 18 GA
FIELD C FIELD GN 18 GA
D VR BATT RD 16 GA
VR BATT

P5
FAN CLUTCH
BK FAN BL 18 GA
A
BK FAN CL GND WH 18 GA
B

P8
SHUTTER SOLENOID

SHUTTER IGNITION 1133A PK 18 GA

A
SHUTTER SIG SHUTTER SIG TN 18 GA
B

1114 PU 12 GA

726
FAN BL 18 GA
1111M BK 12 GA
1114B PU 12 GA
TO SHEET 2:
1111K BK 12 GA
PDU VR BATT RD 16 GA
1133 PK 16 GA
1133B PK 16 GA
13
B1-1939(+) YL 20 GA
3
B1-1939(-) GN 20 GA
4

STARTER
BAT 1114A PU 10 GA
S
1231X WH 12 GA
T-1939(-) GN 20 GA
T-1939(+) YL 20 GA

GND REFERENCE: GROUND TO 14

FRAME RAIL STARTER

GROUND

C1 P10
1536 TN 18 GA A 1536 TN 18 GA
1208D WH 18 GA 1208D WH 18 GA
B
1536 TN 18 GA
2 GA BK 2 GA BK 2 GA BK 1 2
125A
INTAKE
J1939 (+)
J1939 (-)

INTAKE HEATER HEATER

SOLENOID K1
INTAKE HEATER ASSEMBLY
P16
SEE DIAGRAM WRG:
PDU ISOLATED J1939 DATA LINK

HOT STUD

L
 chassis Electrical

ENGINE

COOLANT LVL SNR PWR

ECM RETURN (SENDOR)

COOLANT LVL SNR
P32

COOLANT LEVEL

A B C

SEN PWR A GN 18 GA
COOL LVL PK 18 GA
SEN RET A BK 18 GA
P1

CUMMINS ISB07 ECM

THROT S1G2 TN 18GA THROTTLE POSITION SIGNAL #2

25
20

18
24

J1587(+) YL 18 GA 35
39 DATA LINK + (1587)
1702 LT BL 18 GA
SEE DIAGRAM WRG: 5 VGT BRAKE SWITCH
40076-01,02 BRAKES 17

15
VGT BRK SIG RD 18 GA 16
55 BRAKE LIGHT

J1587(-) LT BL 18 GA
29 DATA LINK - (1587)
53
27
28
19
30

COOL LVL PK 18 GA 33
60 COOLANT LEVEL SENSOR
32
SEN PWR GN 18 GA
26 ECM SENSOR SUPPLY (5VDC)
12 SEN RET BK 18 GA
22 ECM RETURN (SENSOR)
11
41

23
727
52
45
1536 TN 18 GA
54 AIR INTAKE HEATER OUTPUT
1208D WH 18 GA 44 AIR INTAKE HEATER RETURN
E-1939(+) YL 20 GA 1 DATA LINK + (1939)
1 E-1939(-) GN 20 GA
21 DATA LINK - (1939)
2 2
FILTER 1 RD 18 GA PARTICULATE FILTER TEMP SNR 1
49
FILTER 2 OR 18 GA 40
FILTER 3 YL 18 GA PARTICULATE FILTER TEMP SNR 2
9 PARTICULATE FILTER TEMP SNR 3
DELTA PSI BL 18 GA 34
TEMP RET BK 18 GA CSF DELTA PRESSURE SENSOR SIG
38 ECM RETURN (TEMPERATURE)
SEN PWR C GN 18 GA
SEN RET C BK 18 GA

EMISSIONS PARTICULATE
B-1939(+) YL 20 GA

FILTER
B-1939(-) GN 20 GA

ENGINE BLOCK TO SENSORS PROVIDED

GROUND ON PARTICULATE FILTER
P6

C1 EXHAUST FILTER HARNESS

ENG GND 2 WH 12 GA

1 2 3 6 7 5 4 8
ENG GND 1 WH 12 GA

1111M BK 12 GA
1111K BK 12 GA

C2
1 2
8
TEMP RET BK 18 GA 4
SEN PWR C GN 18 GA
J1939 (+)

5
J1939 (-)

SEN RET C BK 18 GA
7
DELTA PSI BL 18 GA 6
FILTER 3 YL 18 GA
1 2 3 4 3
FILTER 2 OR 18 GA 2
FILTER 1 RD 18 GA 1
P14
+12V BATT
+12V BATT
GROUND
GROUND

SEE DIAGRAM WRG:

J1939 DATA LINK P2 Sheet 6, 1 of 3
ENGINE
POWER
D0001447A
CONNECTOR
CUMMINS ENGINE

L
 SERVICE MANUAL

DCM

CRUISE
SWITCH
P270 P270
A

31 GY 18 GA THROT 5V 2 PK 18 GA
THROTTLE SENSOR 31
29 YL 18 GA 29 THROT POS 2 TN 18 GA
R CUMMINS 30 GN 18 GA THROT RET 2 BK 18 GA
30
26 WH 18 GA THROT POS 1 TN 18 GA
THROTTLE SENSOR 26
28 RD 18 GA THROT 5V 1 PK 18 GA
28
OFF C CUMMINS 27 BK 18 GA THROT RET 1 BK 18 GA
27
11 BL 18 GA CRUISE SIG GY 18 GA
ACC 11
ON 12 OR 18 GA CRUISE RESUME OR 18 GA
13 RD 18 GA 12
ST S CRUISE SET BN 18 GA
13
B 3 GN 18 GA ECM GND CRUISE WH 18 GA
3
SEE DIAGRAM WRG: 19 BK 18 GA START KEY PU 16 GA
19
POWER: SHEET 1

ELEC PANEL SWITCH

P225 GROUND
1206RR WH 18 GA 7
REGENERATION B
REGEN SW OR 18 GA
A
SWITCH
P110 P111
START ENG YL 16 GA
A

W/O VANDAL LOCK

728 SEE DIAGRAM WRG:

1922-02: DAYTIME
ECM RET A WH 18 GA
PDU

RUNNING LIGHTS
COOLING FAN
RELAY P2A
4
IGN FAN PWR RD 16 GA FAN BL 16 GA
3 5
FAN CL(+) OR 18 GA 1 2 ECM RET B WH 18 GA
7
SEE DIAGRAM WRG:
POWER BATT 1182 14 GA FUSIBLE LINK 1 1182A BK 10 GA. 1114B PU 12 GA
1114 PU 12 GA
IGN START YL 16 GA 75A
1001 YL 16 GA. 86 85 18114A GN 18 GA
2 1
STARTER
K1

40432 18114A GN 18 GA.

TRANSMISSION
FUSE P6
ELEC BATT 4B 30A 4A 1111L BK 12 GA 4
1111M BK 12 GA
IGN B9 5A B8 11136P PK 16 GA
FUSE P1 1111K BK 12 GA
BACK UP LIGHTS / 1133 PK 16 GA
ALARM
FUSE P1
BATT A7
SEE DIAGRAM WRG: 10A A6
POWER

L
 chassis Electrical

ENGINE
P1

IP CUMMINS ISB07 ECM

SHUTTER SIG

1444A TN 18 GA 25
20 REGENERATION SWITCH

P230 18
24
14 CLUSTER

1514 WH 18 GA
35 THROTTLE POS SIG #1
39
5

17
P210 P7
15
1504 GY 18 GA CRUISE CONTROL ON/OFF
16
SHUTTER SIG TN 20 GA SHUTTER SIG TN 18 GA
7 55
THROT 5V 2 PK 18 GA SEN PWR B GN 18 GA FROM
12
THROT POS 2 TN 18 GA THROT SIG 2 TN 18 GA SHEET 1
11
THROT RET 2 BK 18 GA SEN RET B BK 18 GA
10 29
THROT POS 1 TN 18 GA 1514 WH 18 GA
4 1526 PK 18 GA 53
THROT 5V 1 PK 18 GA 9 1526 PK 18 GA 27
1527 OR 18 GA +5V THROTTLE POWER
THROT RET 1 BK 18 GA 1527 OR 18GA
3 28 THROTTLE POSITION RET
CRUISE SIG GY 18 GA 16 1504 GY 18 GA 1528 OR 18 GA
19 CRUISE CONTROL RESUME
CRUISE RESUME OR 18 GA 1528 OR 18 GA 1529 BN 18 GA
17 30 CRUISE CONTROL SET
CRUISE SET BN 18 GA 18 1529 BN 18 GA
1206NN WH 18 GA SW RET TN 18 GA
24 33
REGEN SW OR 18 GA 1444A TN 18 GA
23 60
START ENG YL 18 GA 1001 YL 16 GA ECM RET WH 18 GA
2 32 ECM RETURN
1133B PK 16 GA
21 26

22
SW RET TN 18 GA 41 SWITCH RETURN

23
FAN CL(+) OR 18 GA
52 FAN CLUTCH OUTPUT
11136P PK 18 GA
45 IGNITION KEY SWITCH
54

44
1
SEE DIAGRAM WRG: ENG RUN RD 18 GA 21
1922-02, DAYTIME 2 STARTER LOCKOUT
RUNNING LIGHTS 49

729
40
9
34

38

J3 P15
1133B PK 16 GA
1114 PU 12 GA 1114 PU 12 GA 1114 PU 12 GA
1
FAN BL 16 GA
6 FAN BL 18 GA FAN BL 18 GA
1111M BK 12 GA
2 1111M BK 12 GA 1111M BK 12 GA
1114B PU 12 GA
3 1114B PU 12 GA 1114B PU 12 GA TO SHEET 1
11136P PK 16 GA 11136P PK 18 GA
1111K BK 12 GA
7 1111K BK 12 GA 1111K BK 12 GA
1133 PK 16 GA
4 1133 PK 16 GA 1133 PK 16 GA
1001 YL 16 GA
9
1001 YL 16 GA.
FAN CL(+) OR 18 GA
16 FAN CL(+) OR 18 GA
ECM RET WH 18 GA
17 ECM RET WH 18 GA
VR BATT RD 16 GA
19 VR BATT RD 16 GA VR BATT RD 16 GA
13
Sheet 6, 2 of 3
D0001447A
CUMMINS ENGINE

L
 SERVICE MANUAL

IP

12
FILTER PWR PK 14 GA 1168L PK 12 GA
HEATED FUEL
FILTER P13

FILTER PWR A
FILTER GND WH 14 GA
FILTER GND B

WATER IN FUEL
SENSOR LIGHTS
P11
13
SENSOR GND WH 16 GA 1206PP WH 14 GA
SENSOR GND A
B SENSOR PWR PK 16 GA
SENSOR PWR
C WIF SENSOR YL 18 GA
WIF SENSOR

CONNECTS TO
CONNECTS TO IP
FRAME HARNESS

P1

SEE DIAGRAM WRG: WIF SENSOR YL 18 GA

18
1206P WH 14 GA 1206P WH 14 GA
730
3000 TRANSMISSION 22

CLUSTER
P230 P200 P1
T3
ENGINE FUEL 1403B PU 20 GA 1403B PU 18 GA
18 20 FUEL LEVL TANK
GAUGE

T2
GND FUEL LEVEL WH 16 GA
GND FUEL LEVL TANK

L
 chassis Electrical

FRAME PDU

PDU POWER CONNECTS TO

INTERFACE FRAME HARNESS

P5 J2

FUSE P1
1168L PK 12 GA 1168L PK 12 GA C2 25A C3 IGN
G

PDU POWER CONNECTS TO

INTERFACE FRAME HARNESS

P8 J1
SEE DIAGRAM WRG:
1206PP WH 14 GA 1206P WH 14 GA 2 1206 WH 16 GA
B HYD BRAKES
1206D WH 16 GA AMMETER

1206EE WH 10 GA
2

ELEC GND
STUD
1212AD WH 10 GA

731
T1

CHASSIS GND

Sheet 6, 3 of 3
D0001447A
CUMMINS ENGINE

L
 SERVICE MANUAL

IP
P240
TRANS 2K SHIFTER
SPLICE PACK:
ILLUM 2K SHIFTER LT BL 18 GA
ILLUMINATION A P75 ILLUMINATION
GROUND GND 2K SHIFTER WH 18 GA P70 GND
B
P200 P1
ELEC IGN SHIFT PK 14 GA
NOT USED ON 2000 4
P290 ELEC BATT SHIFT BK 14 GA
TRANSMISSION 2
EOL J1939 (+) CAP YL 20 GA SEE DIAGRAM
A
RES J1939 (-) CAP GN 20 GA WRG J1939
B

PDU/FRAME PDU/FRAME
PDU INTERFACE INTERFACE

FUSE P1 J2 P5
ELEC BATT A3 10A A2 15
11136A BK 16 GA ELEC BATT BK 14 GA
P
ELEC GND 18123 TN 16 GA 18123 TN 16 GA
A
FUSE P1 12143B WH 14 GA 12143 WH 16 GA
K
IGN B3 10A B2 11146E PK 16 GA ELEC IGN PK 14 GA
N
18114 LT GN 18 GA
W 16
101 LT BL 18 GA
H AIR BRAKES ONLY
BRAKE 101 LT BL 18 GA
SEE DIAGRAM WRG: RELAY P2B SEE DIAGRAM WRG:
1231AE WH 18 GA BACK UP LIGHT /
POWER, 4
1231AB WH 16 GA 3 ALARM
SHEET 2 5
BRK SIG RD 18 GA 1 2

BRAKES SHIFT ENABLE BK 18 GA AIR BRAKE

ABS MODULE

18154 LT GN 18 GA
SEE DIAGRAM WRG: P4 10
40179 ENGINE 18114A GN 16 GA

AIR BRAKES
NEUTRAL ONLY
RELAY P3D
POWER, GND GND IGN DO WH 18 GA
SHEET 2 4
1231AK WH 16 GA 3 5
18123 TN 16 GA 1 2 1231BC WH 16 GA
1231AK WH 16 GA

732 SEE DIAGRAM WRG:

POWER, GND 1231BM WH 16 GA

SHEET 2

3
1231AJ WH 12 GA

1212AL WH 14 GA
FILTER GND WH 14 GA
1212E WH 14 GA
J1 P8 1231Q WH 12 GA
2
F GND PDU WH 12 GA GND FUEL LEVEL WH 16 GA
1212AF WH 14 GA
1212AC WH 14 GA
1208C WH 12 GA
1208D WH 12 GA
1212AD WH 10 GA

T1

CHASSIS
GROUND

L
 chassis Electrical

TRANSMISSION
FRAME
TRANSMISSION TCM CONNECTOR
TRANS IP/OP VEHICLE/FRAME C926
INTERFACE 101 (BL) 18 GA
P12 C3 1 INPUT 6
2
ELEC BATT TRANS BK 16 GA TRANS BATT (PK) 18 GA (SHIFT INHIBIT)
A 3
18123 TN 16 GA 141 (TN) 18 GA 4
D
12143 WH 16 GA TELEC GND (WH) 18 GA 5
H
ELEC IGN TRANS PK 16 GA TRANS IGN/163 (YL) 18 GA 6
K
18154 LT GN 18 GA 121 (GN) 18 GA 7
F 8
18114 LT GN 18 GA 124 (WH) 18 GA 109 (GY) 18 GA
C 9 GROUND
FOR FUTURE USE CHECK TRANS/129 (GN) 18 GA 110 (PK) 18 GA
J 10 BATTERY
101 LT BL 18 GA G 101 (BL) 18 GA 1 11
18113 LT GN 18 GA 165 (TN) 18 GA 12
B
13
14
15
16
17
18
19
121 (GN) 18 GA 20
21 ABS SIGNAL
22
C18 23
124 (WH) 18 GA
125B (TN) 18 GA 3 24 RANGE INH INDICATOR
FOR FUTURE USE 125 (TN) 18 GA
A 25 VEHICLE SPEED
B 26
27
CHECK TRANS/129 (GN) 18 GA 28
29 CHECK TRANS
30
2 31
32
33
34
35
36
37
ENGINE 38
39
40
141 (TN) 18 GA 41 NEUTRAL SAFETY

733
42
43
44
45
46
C4 47
T-1939(+) (YL) 20 GA 48 J1939 (+)
125A (TN) 18 GA 49
FOR FUTURE USE A 50
B 51
52
53
54
55
56
57
58
59
60
61
62
TRANS IGN/163 (YL) 18 GA 63 IGNITION POWER
64
SEE DIAGRAM WRG 165 (TN) 18 GA 65 REVERSE SIGNAL
66
BACK UP ALARM 67
T-1939(-) (GN) 20 GA
ENGINE,SHEET3 68 J1939 (-)
169 (GY) 18 GA 69 GROUND
AIR DRYER 170 (PK) 18 GA
AIR BRAKES 70 BATTERY POWER
71
ENGINE,SHEET3 72
AIR BRAKES 73
T-1939(+) (YL) 20 GA
T-1939(-) (GN) 20 GA

LUGGAGE CMPT LGT 74

HYD BRAKES 75
76
HYD BRAKES
77
78
79
80

C910 A B
J1939 (+)
J1939 (-)

Sheet 7, 1 of 2
SEE DIAGRAM WRG D0001448A
J1939
2000 TRANSMISSION

L
 SERVICE MANUAL

734
C906

MAIN TRANSMISSION
CONNECTOR
152 (GN) 18 GA
LSD SS1 1
133 (YL) 18 GA
LSD SS2 2 151 (WH) 18 GA
LSD SS3 3
117 (BL) 18 GA
PS1 4
5
157 (WH) 18 GA
PS3 6 179 (PK) 18 GA
PS2 7
SUMP TEMP 8 154 (TN) 18 GA
SIGNAL RETURN 158 (GN) 18 GA
9 178 (WH) 18 GA
LSD TCC 10
177 (GN) 18 GA
PS4 11
12
13
111 (OR) 18 GA
HSD1 14
LSD PCS1 15 155 (WH) 18 GA
HSD2 171 (YL) 18 GA
16
136 (OR) 18 GA
LSD PCS2 17
DIGITAL SIGNAL NS 138 (OR) 18 GA
18
LSD MAIN MOD 174 (BL) 18 GA
19
DIGITAL SIGNAL C 114 (GY) 18 GA
20
DIGITAL SIGNAL B 153 (YL) 18 GA
21
173 (BL) 18 GA
DIGITAL SIGNAL A 22
23 134 (YL) 18 GA
DIGITAL SIGNAL P 176 (YL) 18 GA
TRANS ID 24

L
 chassis Electrical

C926
1
2
3
4
TRANSMISSION 5
6
7
8
9
111 (OR) 18 GA 10
11 HSD1
12
114 (GY) 18 GA 13
14 DIGITAL SIGNAL C
15
117 (BL) 18 GA 16
17 PS1
18
120 (BL) 18 GA 19
20 TURBINE SPEED LOW
21
22
23
24
25
26
27
28
29
30
31
32
133 (YL) 18 GA
33 LSD PCS3
134 (YL) 18 GA 34 DIGITAL SIGNAL P
35
136 (OR) 18 GA 36 LSD PCS1
37
138 (OR) 18 GA 38 DIGITAL SIGNAL NS
139 (OR) 18 GA ENGINE SPEED LOW
39
140 (GN) 18 GA 40 OUTPUT SPEED LOW
41
42
43
44
45
46
47
48
49
50
151 (WH) 18 GA 51 LSD SS1
152 (GN) 18 GA 52 LSD PCS2
153 (YL) 18 GA 53 DIGITAL SIGNAL B
154 (TN) 18 GA SUMP TEMP SIGNAL
54
155 (WH) 18 GA 55 LSD PCS4

735
56
157 (WH) 18 GA PS3
57
158 (GN) 18 GA ANALOG RETURN
58
159 (TN) 18 GA ENGINE SPEED HIGH
59
160 (YL) 18 GA 60 OUTPUT SPEED HIGH
61
62
63
64
65
66
67
68
69
70
171 (YL) 18 GA HSD2
71
72
173 (BL) 18 GA 73 DIGITAL SIGNAL A
174 (BL) 18 GA 74 LSD MAIN MOD
75
176 (YL) 18 GA 76 TRANS ID
177 (GN) 18 GA 77 PS4
178 (WH) 18 GA LSD TCC
78
179 (PK) 18 GA PS2
79
180 (OR) 18 GA TURBINE SPEED HI
80
140 (GN) 18 GA

180 (OR) 18 GA
160 (YL) 18 GA
159 (TN) 18 GA
139 (OR) 18 GA

120 (BL) 18 GA

B A B A B A

C905 C902 C928 Sheet 7, 2 of 2

ENGINE OUTPUT TURBINE D0001448A
SPEED SPEED SPEED
SENSOR SENSOR SENSOR 2000 TRANSMISSION

L
 SERVICE MANUAL

IP
P250
TRANS 3K SHIFTER SPLICE PACK:
ILLUMINATION ILLUM 3K SHIFTER LT BL 18 GA P75 ILLUMINATION P200 P1
3
GND SHIFTER 5 GND 3K SHIFTER WH 18 GA ELEC IGN SHIFT PK 14 GA
TRANS IGN A 12 ELEC IGN SHIFT PK 18 GA 4
ELEC BATT SHIFT BK 14 GA
TRANS BATT A 13 ELEC BATT SHIFT BK 18 GA 2
DIR SIGNAL 11 134 DIR SIG YL 18 GA 27 134 YL 18 GA
1206P WH 14GA 1206P WH 14 GA
J1939 JUMPER 16 TERMINATING RESISTOR GN 18 GA 13 22
7
J1939 DATALINK(+) 8 1939(+) SHIFT YL 20 GA SEE DIAGRAM WRG:
J1939 DATALINK(-) 15 1939(-) SHIFT GN 20 GA J1939

PDU
PDU/FRAME PDU/FRAME
INTERFACE INTERFACE
FUSE P1 J2 P5
ELEC BATT A3 A2 11136A BK 16 GA ELEC BATT BK 14 GA 15
10A P
ELEC GND 18123 TN 16 GA 18123 TN 16 GA
A
FUSE P1 12143B WH 14 GA 12143 WH 16 GA
K
IGN B3 10A B2 11146E PK 16 GA ELEC IGN PK 14 GA
N
18114 LT GN 18 GA 16
W
101 LT BL 18 GA AIR BRAKES ONLY
H
101 LT BL 18 GA
BRAKE
RELAY P2B

SEE DIAGRAM WRG: 1231AE WH 18 GA SEE DIAGRAM WRG:

POWER, SHEET 2 4 BACK UP LIGHT /
1231AB WH 16 GA 3
5
ALARM
BRK SIG RD 18 GA 1 2

BRAKES
SHIFT ENABLE BK 18 GA

AIR BRAKES
ONLY
SEE DIAGRAM WRG: 18114A GN 16 GA AIR BRAKE
40179 ENGINE ABS MODULE
18154 LT GN 18 GA
P4 10
NEUTRAL
RELAY P3D
GND GND IGN DO WH 18 GA
POWER SHEET 2
4
1231AK WH 16 GA 3
5
18123 TN 16 GA 1 2 1231BC WH 16 GA
1231AK WH 16 GA

736
GND 1231BM WH 16 GA
POWER SHEET 2

3
1231AJ WH 12 GA

1212AL WH 14 GA
FILTER GND WH 14 GA
1212E WH 14 GA
J1 P8 1231Q WH 12 GA
GND PDU WH 12 GA 2 GND FUEL LEVEL WH 16 GA
F
1212AF WH 14 GA
1212AC WH 14 GA
1208C WH 12 GA
1208D WH 12 GA
1212AD WH 10 GA

T1

CHASSIS
GROUND

L
 chassis Electrical

FRAME

1206EE WH 10 GA
ELEC GND
STUD
TRANSMISSION
TRANSMISSION TCM CONNECTOR
TRANS IP/OP VEHICLE/FRAME
INTERFACE
P12 C3 C926
101 (BL) 18 GA
1 INPUT 6
ELEC BATT TRANS BK 16 GA TRANS BATT (PK) 18 GA 2
A (SHIFT INHIBIT)
18123 TN 16 GA 141 (TN) 18 GA 3
D 4
12143 WH 16 GA TELEC GND (WH) 18 GA
H 5
ELEC IGN TRANS PK 16 GA TRANS IGN/163 (YL) 18 GA 6
K
18154 LT GN 18 GA 121 (GN) 18 GA 7
F
134 YL 18 GA 134 (YL) 18 GA 8
E 109 (GY) 18 GA
101 LT BL 18 GA 101 (BL) 18 GA 9 GROUND
G 110 (PK) 18 GA 10 BATTERY
FOR FUTURE USE CHECK TRANS/129 (GN) 18 GA
J 1 11
18114 LT GN 18 GA 145 (OR) 18 GA
18113 LT GN 18 GA C 12
165 (TN) 18 GA 13
B
14
15
16
17
18
19
121 (GN) 18 GA 20
21 ABS SIGNAL
22
23
24
25
26
27
CHECK TRANS/129 (GN) 18 GA 28
29 CHECK TRANS
30
2 31
32
134 (YL) 18 GA 33
34 DIRECTIONAL SIGNAL
35
36
37
38
39
40
141 (TN) 18 GA
41 NEUTRAL SAFETY

145 (OR) 18 GA
42
43
44
737
45 RANGE INDICATOR
46
T-1939(+) (YL) 20 GA 47
48 J1939 (+)
49
50
51
52
53
54
55
56
57
58
59
60
61
62
TRANS IGN/163 (YL) 18 GA IGNITION POWER
63
64
SEE DIAGRAM WRG 165 (TN) 18 GA 65 REVERSE SIGNAL
66
BACK UP ALARM T-1939(-) (GN) 20 GA 67
ENGINE,SHEET3 68 J1939 (-)
169 (GY) 18 GA GROUND
AIR DRYER 69
170 (PK) 18 GA 70
AIR BRAKES BATTERY POWER
71
ENGINE,SHEET3 72
AIR BRAKES 73
T-1939(+) (YL) 20 GA
T-1939(-) (GN) 20 GA

LUGGAGE CMPT LGT 74

HYD BRAKES 75
76
HYD BRAKES
77
78
79
80

C910 1 2
J1939 (+)
J1939 (-)

Sheet 8, 1 of 2
SEE DIAGRAM WRG D0001449A
J1939
3000 TRANSMISSION

L
 SERVICE MANUAL

738
C906

MAIN TRANSMISSION
CONNECTOR

1 111 (OR) 18 GA
HSD1 155 (WH) 18 GA
LCD PCS4 2
177 (GN) 18 GA
DIGITAL SIGNAL 3
4
136 (OR) 18 GA
LSD PCS1 152 (GN) 18 GA
LSD PCS2 5
HSD2 171 (YL) 18 GA
6
7
LSD MAIN MCD 8 174 (BL) 18 GA
LSD PCS3 133 (YL) 18 GA
9
LSD SS1 10 151 (WH) 18 GA
HSD3 11
131 (YL) 18 GA
LSD TCC 12
137 (WH) 18 GA
180 (OR) 18 GA
TURBINE SPEED HIGH 13
120 (BL) 18 GA
TURBINE SPEED LOW 14
116 (BL) 18 GA
OIL LEVEL 15
OIL LEVEL SIGNAL 16 112 (PK) 18 GA
OIL LIFE MONITOR 17
118 (YL) 18 GA
SUMP TEMP 18 154 (TN) 18 GA
ANALOG RETURN 19 158 (GN) 18 GA
TRANS ID 20
176 (YL) 18 GA

L
 chassis Electrical

C926

1
2
TRANSMISSION 3
4
5
6
7
8
9
111 (OR) 18 GA 10
112 (PK) 18 GA
11 HSD1
12 OIL LEVEL SIGNAL
13
14
116 (BL) 18 GA 15
16 OIL LEVEL
17
118 (YL) 18 GA
18 OIL LIFE MONITOR
120 (BL) 18 GA 19
20 TURBINE SPEED LOW
21
22
23
24
25
26
27
28
29
131 (YL) 18 GA 30
31 HSD3
133 (YL) 18 GA 32
33 LSD PCS3
34
35
136 (OR) 18 GA LSD PCS1
36
137 (WH) 18 GA
37 LSD TCC
139 (OR) 18 GA 38
39 ENGINE SPEED LOW
140 (GN) 18 GA
40 OUTPUT SPEED LOW
41
42
43
44
45
46
47
48
49
50
151 (WH) 18 GA
51 LSD SS1
152 (GN) 18 GA
52 LSD PCS2
53
154 (TN) 18 GA SUMP TEMP SIGNAL
54
155 (WH) 18 GA
55 LSD PCS4

739
56
57
158 (GN) 18 GA ANALOG RETURN
58
159 (TN) 18 GA
59 ENGINE SPEED HIGH
160 (YL) 18 GA
60 OUTPUT SPEED HIGH
61
62
63
64
65
66
67
68
69
70
171 (YL) 18 GA
71 HSD2
72
73
174 (BL) 18 GA LSD MAIN MOD
74
176 (YL) 18 GA 75
76 TRANS ID
177 (GN) 18 GA PS4
77
78
79
180 (OR) 18 GA
80 TURBINE SPEED HI
140 (GN) 18 GA
139 (OR) 18 GA

160 (YL) 18 GA
159 (TN) 18 GA

B A B A

C905 C902
Sheet 8, 2 of 2
ENGINE OUTPUT
D0001449A
SPEED SPEED
SENSOR SENSOR 3000 TRANSMISSION

L
 SERVICE MANUAL

ELEC PANEL ENGINE

SEE DIAGRAM WRG:
STD EQUIP, SEE DIAGRAM WRG:
BRAKE LIGHT 40050-03 VGT BRAKE

VGT BRK SIG

VGT BRAKE
P17 P17 P108
M U R 6
P17 P17 P108 P1
55 5
P230 P235 CUMMINS ECM
IP
CLUSTER
CLUSTER

1702 LT BL 18 GA
1316K RD 16 GA
1316B RD 16 GA
BRAKE WARN

BATT BRK SIG BK 14 GA

VGT BRK SIG RD 18 GA

BRAKE SIGNAL

1702 LT BL 18 GA
CONNECTS TO CONNECTS TO IP
9 ENG HARNESS
P210 P7
14
VGT BRK SIG RD 6 GA
22
1702 LT BL 18 GA 1702 LT BL 18 GA
31
SHIFT ENBL GND 1 WH 16 GA SHIFT ENABLE BK 18 GA
33
W/O 31047-01
BRK WARN RD 20 GA

FRAME
1316D RD 20 GA

P70 CONNECTS TO
CONNECTS TO IP
SPLICE PACK: FRAME HARNESS
GND P200
BRK WARN RD 20 GA BRK WARN SIG RD 16 GA
8
1316K RD 16 GA 9 BRK LGT RD 16 GA
3

3
BATT BRK SIG BK 14 GA
BRAKE SIG D RD 16 GA

P270
14 15
P270

DCM
15 RD 16 GA
14 BK 18 GA

740 STOP LIGHT DIFF PRESS

SW CONN
SWITCH
8 WH 18 GA

P25 P25
FLOW SW
MONITOR MODULE CONN BRAKE MONITOR
8 WH 18 GA
CONNECTOR
8 WH 18 GA 4 3 OR 14 GA BRK WARN IGN PK 16 GA
A A
4 TN 18 GA 4 TN 18 GA BRK WARN SIG RD 16 GA
C B
5 WH 18 GA 5 WH 18 GA BRK WARN GND WH 16 GA
D 0.5A 6 RD 18 GA C
3 OR 14 GA BRK WARN LGT TN 16 GA
E 3 D
F
6 RD 18 GA
G
6 RD 18 GA
H 2
13
9 YL 18 GA

8 WH 18 GA

3 OR 14 GA
6 RD 18 GA

SEE DIAGRAM WRG:

GROUND, SHEET 1

P26 P26
HYD BRAKE BOOST
2 RD 12 GA BRK BOOST BAT RD 12 GA
B
1 BK 12 GA DCM GND WH 12 GA
A
FRAME T11
GROUND

RELAY
87A
TRANSMISSION
30 7 RD 12 GA
87
0.5A C926
86 85
MICRO 1 RANGE AUX 101 LT BL 18 GA
0.5A 1
FUNCTION
MOTOR
GROUND
MOTOR PWR
RING TERMINAL

L
 chassis Electrical

PDU

BRAKE RELAY

P2B
PDU POWER CONNECTS TO
INTERFACE ENGINE HARNESS 1231AE WH 18 GA SEE DIAGRAM WRG:
4 POWER, SHEET 2
P15 J3 3 1231AB WH 16 GA
101 LT BL 18 GA 5
SHIFT ENABLE BK 18 GA SHIFT ENABLE BK 18 GA 2 1
11

PDU POWER CONNECTS TO

INTERFACE FRAME HARNESS
P5 J2

101 LT BL 18 GA 101 LT BL 18 GA
H A8 25A A9 ELEC BATT
1119A BK 12 GA 1119A BK 12 GA FUSE P1
B
1102B BK 12 GA 1102B BK 12 GA FUSE P6 2A 30A 2B BATT
E
1163 PK 16 GA 1163 PK 16 GA FUSE P1 B4 5A B5 ELEC IGN
M ELEC
1206 WH 16 GA 1206 WH 16 GA 2 1206EE WH 10 GA
S GND
BRK WARN IGN PK 16 GA BRK WARN IGN PK 16 GA FUSE P1 C4 5A C5 IGN
W
BRK VGT LGT RD 18 GA BRK SIG RD 18 GA
X

P8 J1 FUSE P6
BRK BOOST BATT B BK 12 GA 8 BRK BOOST BATT BK 10 GA 1A 40A 1B BATT
G
C BRK BOOST BATT A BK 12 GA

1163 PK 16 GA
1 ABS IGNITION
2
3
4
1206 WH 16 GA 5
6
BRK BOOST BAT A RD 12 GA

ABS REF GROUND

BRK BOOST BAT B RD 12 GA

7
TERMINATING 120 P14 8
RESISTOR B2-1939(+) YL 20 GA P24
2 9
B2-1939(-) GN 20 GA
101 LT BL 18 GA

1 10
ABS

SEE DIAGRAM J1939 (+)

P23
B-1939(+) YL 20 GA 5 B1-1939(+) YL 20 GA
11
12
13
ECU/MODULATOR
741
1 14 J1939 DATALINK (+)
WRG: J1939 J1939 (-) B-1939(-) GN 20 GA B1-1939(-) GN 20 GA
2 15 J1939 DATALINK (-)
4 1102B BK 12 GA
16 PMP MTR BATT
1119A BK 12 GA 17 ABS BATT
1208C WH 12 GA
18 PMP MTR GROUND
1208D WH 12 GA 19 ABS GROUND
20
21
RR SENS IN BN 18 GA
22 RIGHT REAR SPEED SENSOR IN
LR SENS IN BN 18 GA LEFT REAR SPEED SENSOR IN
23
LF SENS IN BN 18 GA 24 LEFT FRONT SPEED SENSOR IN
RF SENS IN BN 18 GA
25 RIGHT FRONT SPEED SENSOR IN
16151H LT BL 18 GA 26 J1587 DATALINK (-)
RR SENS GND BK 18 GA
27 RIGHT REAR SENSOR GROUND
LR SENS GND BK 18 GA 28 LEFT REAR SENSOR GROUND
LF SENS GND BK 18 GA LEFT FRONT SENSOR GROUND
29
RF SENS GND BK 18 GA
2 30 RIGHT FRONT SENSOR GROUND
16142H YL 18 GA
31 J1587 DATALINK (+)
1212AD WH 10 GA

16151H LT BL 18 GA
16142H YL 18 GA

RF SENS GND BK 18 GA

RR SENS GND BK 18 GA
LR SENS GND BK 18 GA
LF SENS GND BK 18 GA
RF SENS IN BN 18 GA

RR SENS IN BN 18 GA
LF SENS IN BN 18 GA

LR SENS IN BN 18 GA

17

T1

P12
G CHASSIS 24 23
C3 GROUND 1 2 1 2 1 2 1 2
J1587 (+)
J1587 (-)

RF SENSOR
RF SENSOR

LR SENSOR
LR SENSOR
LF SENSOR

RR SENSOR
RR SENSOR
LF SENSOR

Sheet 9
GND

GND

GND

GND

P1
SEE WRG DIAGRAM
J1587 P7 P10 P17 P16
D0001450A
RIGHT FRONT LEFT FRONT LEFT REAR RIGHT REAR
SPD SENSOR SPD SENSOR SPD SENSOR SPD SENSOR HYDRAULIC ABS BRAKES

L
 SERVICE MANUAL

ELEC PANEL ENGINE

SEE DIAGRAM WRG:
STD EQUIP, SEE DIAGRAM WRG:
BRAKE LIGHT 40050-03 VGT BRAKE

VGT BRK SIG

VGT BRAKE
P17 P17 P108
M U R 6
P108 P1
P17 P17 55 5

P235
IP CUMMINS ECM

1702 LT BL 18 GA
1316K RD 16 GA

CLUSTER
1316B RD 16 GA
BATT BRK SIG BK 14 GA

VGT BRK SIG RD 18 GA

BRAKE SIGNAL

1702 LT BL 18 GA
CONNECTS ENG CONNECTS TO IP
HARNESS
P210 P7

VGT BRK SIG RD 16 GA

14 22
1702 LT BL 18 GA 1702 LT BL 18 GA
31
SHIFT ENBL GND 1 WH 16 GA SHIFT ENABLE BK 18 GA
33

W/O 31047-01
1316D RD 20 GA

FRAME
P70
SPLICE PACK:
GND
CONNECTS TO
FRAME HARNESS CONNECTS TO IP
3

P200 P1

1316K RD 16 GA 1316K RD 18 GA
9

P2
BATT BRK SIG BK 14 GA
BRAKE SIG D RD 16 GA

HEATED DRAIN VALVE

1
1181C 1181C PK 14 GA
B
1212AF 1212AF WH 14 GA
A
2

P270
1212AD WH 10 GA

14 15
P270

DCM 15 RD 16 GA
14 BK 18 GA

742 STOP LIGHT SWITCH

CHASSIS
T1

GROUND
TRANSMISSION
VEHICLE FRAME TRANS I/P O/P
INTRFACE
C926 C3 P12
121 GN 18 GA 18154 LT GN 18 GA
ABS SIGNAL 21 F
101 LT BL 18 GA 101 LT BL 18 GA
RANGE AUX. 1 G
FUNCTION
1715 DK GN 16 GA

1718 LT GN 16 GA

1703 OR 16 GA

1706 OR 16 GA
1707 BN 16 GA
1719 PU 16 GA

1705 GY 16 GA
1716 TN 16 GA

1708 TN 16 GA
1717 BK 16 GA

1704 BK 16 GA
1714 PK 16 GA

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1716
1715
1714
BLOCKED

1719
1718
1717
BLOCKED

1705
1704
1703
BLOCKED

1708
1707
1706
BLOCKED

P15 P18 P3 P6
RIGHT REAR LEFT REAR RIGHT FRONT LEFT FRONT M/22
MOD VALVE MOD VALVE M/22 MODULATOR MODULATOR

L
 chassis Electrical

PDU

BRAKE RELAY
P2B
PDU POWER CONNECTS TO
INTERFACE ENGINE HARNESS 1231AE WH 18 GA
4
SEE DIAGRAM WRG:
P15 J3 3 1231AB WH 16 GA
101 LT BL 18 GA 5 POWER, SHEET 2
SHIFT ENABLE BK 18 GA SHIFT ENABLE BK 18 GA 2 1
11

PDU POWER CONNECTS TO

INTERFACE FRAME HARNESS
P5 J2

101 LT BL 18 GA 101 LT BL 18 GA
H FUSE P1 B4 B5 IGN
1163 PK 12 GA 1163 PK 12 GA 30A
B
1181 PK 12 GA 1181 PK 12 GA FUSE P1 C8 30A C9 IGN
D
1316AA RD 18 GA BRK SIG RD 18 GA
X

10 SEE DIAGRAM WRG: P1

J1587 J1587 (-) 24 P4
J1587 (+) 23
ABS ECU/MODULATOR
P14
16151G LT BL 18 GA
120 4 1 J1587-
B2-1939(-) GN 20 GA B1-1939(-) GN 20 GA
1 2 J1939-
B2-1939(+) YL 20 GA 1711 LT GN 18 GA
2 3 LEFT FRONT SENSOR +
1702 YL 18 GA RIGHT FRONT SENSOR +
4
TERMINATING RESISTOR 16142G YL 18 GA J1587 +
5
B1-1939(+) YL 20 GA J1939+
6
5 1709 DK GN 18 GA LEFT FRONT SENSOR-
7
1722 RD 18 GA 8 RIGHT FRONT SENSOR -
7 1163A PK 16 GA 9 IGNITION (5A FUSED)
18154 LT GN 18 GA 10 RETARDER DISABLE
11 TRAILER ABS W/L
12 ABS W/L
13 ATC LAMP/ATC ORS

743
1163B PK 12 GA
14 BATTERY (30A FUSED)
1231Q WH 12 GA GROUND
15
P9
ABS ECU
CONN (X2)
1721 TN 18 GA 1 LEFT REAR SENSOR +
1720 YL 18 GA 2 LEFT REAR SENSOR -
1713 DK BL 18 GA 3 RIGHT REAR SENSOR +
1712 YL 18 GA
4 RIGHT REAR SENSOR -
1316Z RD 18 GA
5 STOP LAMP SIGNAL (ATC ONLY)
1706 OR 16 GA 6 ABS ORS (PREMIUM ONLY)
7 LEFT FRONT MOD HOLD
1708 TN 16 GA
8 LEFT FRONT MOD EXHAUST
1703 OR 16 GA 9
1705 GY 16 GA RIGHT FRONT MOD HOLD
10 RIGHT FRONT MOD EXHASUT
1717 BK 16 GA 11 LEFT REAR MOD HOLD
1719 PU 16 GA 12 LEFT REAR MOD EXHAUST
1707 BN 16 GA 13 LEFT FRONT MOD COMMON
1704 BK 16 GA
14 RIGHT FRONT MOD COMMON
1718 LT GN 16 GA 15 LEFT REAR MOD COMMON
1715 DK GN 16 GA 16 RIGHT REAR MOD COMMON
1714 PK 16 GA RIGHT REAR MOD HOLD
17
1716 TN 16 GA 18 RIGHT REAR MOD EXHAUST
B-1939(-) GN 20 GA
B-1939(+) YL 20 GA

1709 DK GN 18 GA
1713 DK BL 18 GA

1711 LT GN 18 GA
1722 RD 18 GA
1721 TN 18 GA
1712 YL 18 GA

1720 YL 18 GA

1702 YL 18 GA

1 2 P23 1 2 1 2 1 2
1 2
RR SENSOR
RR SENSOR

LR SENSOR

J1939 (+)
J1939 (-)

RF SENSOR
RF SENSOR

LF SENSOR
LF SENSOR
LR SENSOR

GND
GND

GND
GND

Sheet 10
P16 P17 P7 P10
SEE DIAGRAM D0001451A
LEFT REAR WRG: J1939 LEFT FRT
RIGHT REAR RIGHT FRT
SPD SENSOR SPD SENSOR SPD SENSOR SPD SENSOR AIR ABS BRAKES

L
 SERVICE MANUAL

FRAME

LUGGAGE COMPARTMENT
LIGHTS

P20
1
1181B PK 14 GA
A
1212AC WH 14 GA
B

AIR DRYER

P19
1181D PK 14 GA
A
1212E WH 14 GA
B

744

T1
1212AD WH 10 GA

FRAME GROUND

L
 chassis Electrical

PDU

PDU POWER CONNECTS TO

INTERFACE FRAME HARNESS

P5 J2 FUSE P1
1181 PK 12 GA 1181 PK 12 GA C8 C9 IGN
D 30A

745

Sheet 11
D0001453A
LUGGAGE AND AIR DRYER

L
 SERVICE MANUAL

IP FRAME

P230 P200 P1
CLUSTER
1440A BK 20 GA 1440A BK 16 GA
AMMETER 7 13

746

L
 chassis Electrical

FRAME PDU
P5 J2

1440A BK 16 GA 1440A BK 16 GA
J

SEE DIAGRAM WRG: IGN

POWER & GND
1206EE WH 10 GA

ELEC GND
1181C PK 16 GA

1206D WH 16 GA
1440A BK 16 GA

A B C D P7

ISOLATED HOTSTUD
4/0 RD

CURRENT SENSOR

TO BATTERY DISCT
SWITCH OPTION

BATTERY DISCT
SWITCH OPTION
747
4 GA
4/0

+ -

Sheet 12
D0001473A
AMMETER

L
 SERVICE MANUAL

SPLICE PACK: GND WIPER B/C WH 16 GA

P70
GND
2114 YL 14 GA R31
WIPER LH PK B/C YL 18 GA LH WIPER LOW
WIPER LH PK IGN PK 14 GA 4
3 2110 DK GN 14 GA
WIPER LH LOW IGN PK 14 GA 5
GND LH LOW RELAY WH 18 GA 1 2
WIPER LH SIG TN 18 GA

WIPER RH PK B/C YL 18 GA R32

2115 YL 14 GA RH WIPER LOW
WIPER RH PK IGN PK 14 GA 4 3 2111 DK GN 14 GA
WIPER RH LOW IGN PK 14 GA 5
GND RH LOW RELAY WH 18 GA 1 2 WIPER RH SIG TN 18 GA
GND LH LOW RELAY WH 18 GA

R34
RH WIPER HI
WIPER RH LOW IGN PK 14 GA 4
3 1124FF BK 14 GA
2112 RD 14 GA 5
GND LH HI RELAY WH 18 GA 1 2 WIPER HI SIG TN 18 GA
GND RH HI RELAY WH 18 GA WIPER HI SIG LH TN 18 GA
R33
LH WIPER HI
WIPER LH LOW IGN PK 14 GA 4 3 1124EE BK 14 GA
2113 RD 14 GA 5
GND LH HI RELAY WH 18 GA 1 2 WIPER HI SIG LH TN 18 GA
GND RH LOW RELAY WH 18 GA
WIPER RH PK IGN PK 14 GA
WIPER LH PK IGN PK 14 GA

2111 DK GN 14 GA

2110 DK GN 14 GA

R35
2113 RD 14 GA
2112 RD 14 GA

WASHER PUMP
2115 YL 14 GA

2114 YL 14 GA

4
WASH PUMP BN 16 GA 3 IGN WASH PUMP BN 16 GA
5
GND RH HI RELAY WH 18 GA 2 1 WASH PUMP SIG RE BN 16 GA
SPLICE PACK: GND WASH PUMP RE WH 18 GA
P70
GND
P2
8 3 9 4 5 6 1 2
P2
P340 LH WIPER
2110 DK GN 14 GA 1
1 L
2113 RD 14 GA 2
2 H MOTOR SHOWN
WIPER LH PK IGN PK 14 GA 3 M
3 P

748
2114 YL 14 GA IN PARK POSITION
4 S
GND WIPER LH WH 14 GA 4
5 X
5

P440 RH WIPER
2111 DK GN 14 GA 1
1 L
2112 RD 14 GA 2
2 H
WIPER RH PK IGN PK 14 GA 3 M MOTOR SHOWN
3 P
2115 YL 14 GA 4 IN PARK POSITION
S
GND WIPER RH WH 14 GA 4
5 X
1 5
SPLICE GND
T1
CHASSIS GND

WIPER SWITCH LOGIC

A B C HI PUMP
1 2 3 4 5 6
OFF - - - - - 12V DCM
INT1 12V - - - - 12V
INT2 12V 12V - - - 12V
INT3 - 12V - - - 12V
INT4 - 12V 12V - - 12V
INT5 - - 12V - - 12V
LOW 12V - 12V - - 12V
HIGH 12V - 12V 12V - 12V
WASH - - - - 12V 12V
P270 P270
20 OR 18 GA
20
21 WH 18 GA
22 YL 18 GA 21
24 BL 18 GA 22
24
25 TN 18 GA
25
6 BK 18 GA
6

L
 chassis Electrical

ELEC PANEL
BCM
P700
WIPER LH SIG TN 18 GA
10 LH WIPER LOW (OUT)
WIPER LH PK B/C YL 14 GA
WIPER RH PK B/C YL 14 GA 11 WIPER PRK LT (IN)
WIPER RH SIG YL 14 GA 12 WIPER PRK RT (IN)
14 RH WIPER LOW (OUT)
WIPER 1 B/C WIPER SW 1 (IN)
WIPER 2 B/C 15
16 WIPER SW 2 (IN)
WIPER 3 B/C
GND BCM WH 14 GA 19 WIPER SW 3 (IN)
IGN WIPER/STROBE PK 14 GA 21 GROUND
22 +12 VOLT IGN
CB 41
WIPER/STROBE
IGN WIPER/STROBE PK 14 GA A 20A B IGN
WIPER SW PWR BK 16 GA CB 40
WIPER RH IGN
1124FF BK 14 GA A 20A B
WIPER HI SIG TN 18 GA

WIPER 1 B/C TN 18 GA CB 39
WIPER 1 TN 18 GA WIPER LH
1124EE BK 14 GA A 20A B IGN
WIPER 3 B/C TN 18 GA
WIPER 3 TN 18 GA
C C
D6 WASH PUMP SIG 2 BN 16 GA D7
WASH PUMP SIG BN 16 GA
A WASH PUMP SIG 3 BN 16 GA A
WIPER 2 B/C TN 18 GA
WASH PUMP BN 16 GA WIPER 2 TN 18 GA C
D8
CB 38
A WIPER WASH PUMP
IGN WASH PUMP BN 16 GA A 5A B IGN
WASH PUMP SIG RE BN 16 GA

P6 P17
J K L MN E J
P6 P17
WIPER 1 TN 18 GA
WIPER 2 TN 18 GA
WIPER 3 TN 18 GA
WIPER HI SIG TN 18 GA
WASH PUMP SIG BN 16 GA
WIPER SW PWR BK 16 GA

WASH PUMP BN 16 GA

IP
ENGINE
749
P4
P210 P7 WATER PUMP
WASH PUMP BN 16 GA WASH PUMP
20 GND WASH WH 16 GA 2
1 GND WASH
14

STARTER GND

WIPER 1 TN 18 GA
WIPER 2 TN 18 GA
WIPER 3 TN 18 GA
Sheet 13
WIPER HI SIG TN 18 GA
WASH PUMP SIG BN 16 GA D0000807A
WIPER SW PWR BK16 GA
WIPERS & WASHER PUMP

L
 SERVICE MANUAL

P5 J2
IP FRAME
V BATT CLU BK 18 GA
P235

CLUSTER
BATTERY P8 J1
DIAG
PWR
1 P260 BATT IGN SW BK 14 GA
H
B DIAGNOSTIC
ELEC BATT DIAG BK 18 GA
1185 BK 20 GA

P200 P1

ELEC BATT DIAG

BK 18 GA
BATT CLU BK 18 GA
6
6 BATT IGN SW BK 14 GA
3
BATT IGN SW BK 14 GA

750
P270
16
P270

SEE DIAGRAM WRG:

DCM IGN POWER: SHEET 2
16 RD 18 GA

40179: CUMMINS ENG

ACC POWER: SHEET 3

17 YL 18 GA A

19 BK 18 GA R

18 BN 18 GA C OFF

ACC
ON
S ST
B

IGN SWITCH

L
 chassis Electrical

SEE DIAGRAM WRG:

PDU
40432 A2 10A A3
TRANSMISSION 11136A BK 16 GA
BATT CLU BK 18 GA A4 A5 BATTERY DISCT
10A
40179 VR BATT RD 16 GA A6 10A A7 ELEC SWITCH OPTION
CUMMINS ENG 1119A BK 12 GA A8 25A A9
40076 - 02 1111 BK 10 GA BATT
RD 4 GA 4/0 RD
HYD ABS BRAKES 1111F BK 14 GA

BATTERY 1165D BK 16 GA D2 15A D3

SHEET 2 BATT IGN SW BK 14 GA D4 D5 1165 BK 10 GA
10A
01922 - 02 DR L DRL BATT BK 16 GA D6 5A D7

4 GA.
4/0
BACK UP LIGHT /
1165E BK 16 GA D8 10A D9
ALARM
FUSE P1

+ -

ELEC BATT BK 10 GA
SEE DIAGRAM WRG: FUSE P6

BRK BOOST BATT BK 10 GA 1A 1B 1182D BK 10 GA

40076-02 40A 6
HYD BRAKES 1102B BK 12 GA 2A 30A
2B 1182E BK 12 GA
BATT HORN RD 16 GA 3A 3B 1182F BK 12 GA
20A
HORN

40179 1111L BK 12 GA 4A 30A 4B ELEC BATT A BK 12 GA

CUMMINS ENG 5A 5B ELEC BATT B BK 12 GA
-
6A 6B
- 5
1 1182A BK 10 GA
SEE DIAGRAM WRG:
40179 CUMMINS
ENGINE- SHEET 2 751
1182 14 GA. FUSIBLE LINK

1165 BK 10 GA 1111F BK 14 GA
1183A BK 10 GA IGNITION
MEGA FUSE 1183B BK 10 GA SHEET 2
200A

A B C D P7
1182C BK 10 GA CURRENT SENSOR
F1
1 GA
SEE DIAGRAM WRG:
ALTERNATOR HOT CABLE 4/0 RD
40179
CUMMINS ENG INTAKE HEATER CABLE 2 GA BK
ISOLATED
HOT STUD 2/0
LOAD

Sheet 14, 1 of 6
BATTERY & ELEC BATT
D0001438A
POWER

L
 SERVICE MANUAL

DCM IP ENGINE

P270 P270 P210 P7 P15 J3

1102 PK 18 GA.
18 1 12
18 BN 18 GA

IGN CHAS PK 18 GA
IGN PK 18 GA

FRAME
SW

16
TO IGN

P200 P1 P8 J1

11136G PK 14 GA
BATT

IGN BODY PK 18 GA

12 A

SEE DIAGRAM WRG:

11136G PK 20 GA

POWER: SHEET 1

EP
SEE DIAGRAM C
WRG POWER
SHEET 3 P17 P17

P230 10
CLUSTER

752 ELEC PWR

IGNITION

SEE DIAGRAM WRG:

1181C PK 14 GA P5 J2
40076 BRAKES 1
1181B PK 14 GA 1181 PK 12 GA
00165-03:LUGGAGE CMPT & D
1181D PK 14 GA
40081-01: AIR DRYER

L
 chassis Electrical

PDU
SEE DIAGRAM WRG:
1183B BK 10 GA BATT
1183A BK 10 GA SHEET 1
1111F BK 14 GA ELEC BATT: SHEET 1
OPTIONAL IGNITION
1102 PK 18 GA 1181C PK 16 GA
K2 SEE DIAGRAM WRG:
1183A BK 10 GA 1181B PK 10 GA STANDARD AMMETER
1183B BK 10 GA 1181A PK 10 GA

86 85 1231AH WH 18 GA
P14-2
P14-1
IGN DO PK 16 GA
75A

IGN DO
ECM IGN PK 16 GA P3C
4 IGN DO PK 16 GA
IGN PK 16 GA
3
5
11136G PK 14 GA SEE DIAGRAM WRG:
1 2 GND IGN DO WH 18 GA
START YL 16 GA 40432 TRANSMISSION

ELEC IGNITION SEE DIAGRAM WRG:

RELAY P2E 40076-01,02
4 BRAKES
1111F BK 14 GA
11146 PK 14 GA
3
5
1102 PK 18 GA 1 2 1231AE WH 18 GA
1102A PK 18 GA 1231AH WH 18 GA

IGNITION 753
RELAY P3B

SEE DIAGRAM WRG: 4

BATTERY 1165D BK 16 GA 3 SEE DIAGRAM WRG:
5 1133K PK 16 GA
SHEET 1 BACKUP LIGHT/ALARM
1102A PK 18 GA 1 2 1231BM WH 16 GA
40432: 2000/3000
1231AB WH 16 GA
IGN PK 16 GA TRANSMISSION

NOTE:
SEE DIAGRAM WRG: 16 GA: HYD BRAKES
12 GA: AIR BRAKES
40432:3000 11146E PK 16 GA B2 10A B3 11146 PK 14 GA
TRANSMISSION 1163 PK 12 GA B4 B5 NOTE:
5A
11136G PK 14 GA B6 B7 5A: HYD BRAKES
10A
11136P PK 16 GA B8 B9 ECM IGN PK 16 GA 30A: AIR BRAKES
5A
40179: 1168L PK 12 GA C2 C3 1181A PK 10 GA
25A
CUMMINS ENG BRK WARN IGN PK 16 GA C4 C5
5A
FAN PWR RD 16 GA C6 C7 1181B PK 10 GA
10A
1181 PK 12 GA 1181 PK 12 GA C8 30A C9

40076-02:HYD
ABS BRAKES;
40076-01:AIR Sheet 14, 2 of 6
ABS BRAKES FUSE P1
D0001438A
40076-02:HYD IGNITION POWER
ABS BRAKES

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 SERVICE MANUAL

IP ELEC PANEL

P17 P17 CB37

EXIT/SCC MONITOR
SEE MONITOR IGN PK 18 GA B 5A A 1168DD PK 18 GA
SHEET 2 C
CB36
STARTER LOCKOUT
VANDAL LCK IGN PK 18 GA B 5A A 2408 OR 16 GA
2408J OR 16 GA
ENG DR RLY IGN OR 18 GA

1106E LT BL 18 GA

754
P6 P6
1106 YL 14 GA 1106C YL 18 GA
H
80
ACC YL 14 GA

P270
17
P270
17 YL 18 GA

DCM

TO IGN SW

SEE DIAGRAM WRG:

BATT
POWER: SHEET 1

L
 chassis Electrical

30195-10,11,13,19: EXIT/SCC MONITOR

00217-03,04; 00218-02: VANDAL LOCK

31048-09: ENGINE DOOR STARTER LOCKOUT
NOISE SUP-A BK 8 GA
SPLICE PACK: NOISE SUP-B BK 8 GA SEE
GND NOISE SUP-C1 BK 8 GA OR NOISE SUP-C2 BK 8 GA SHEET 4
P70 NOISE SUP-D BK 8 GA

P75

ILLUMINATION
NOISE
P208
1341F LT BL 18 GA
1265G WH 18 GA

SUPPRESSION
SOLENOID BATT-A BK 8 GA
P813 BATT-B BK 10 GA SEE
BATT-C BK 8 GA SHEET 4
NOISE SUPPRESS BATT-D BK 8 GA BATT-E BK 10 GA
SWITCH A B SEE
BATT-F BK 10 GA SHEET 6
82
7 9
3 1346 OR 18 GA
1106E LT BL 18 GA 2B
1 1106K LT BL 18 GA 1206Z WH 18 GA SPLICE PACK:
P70
6 1 2 GND
5B
4 BUS BAR

8 10
ACC-A BK 8 GA
ACC-B BK 10 GA
ACC-C BK 10 GA SEE
ACC-D BK 8 GA SHEET 5
ACC-E BK 10 GA
ACC-F BK 8 GA ACC-G BK 10 GA
84
ACC-H BK 10 GA SEE
SHEET 6 755
A B
P209 ACC SOLENOID
RD 2 GA
1106C YL 18 GA DCM PWR
1206N WH 18 GA
1 2 P70 SPLICE PACK: STUD
GND

PDU
MEGA FUSE
200A
BATT 2/0

ISOLATED
HOT STUD

30328-07: BREAKER,ADDITIONAL,20 AMP IGNITION

30328-25: CIRCUIT BREAKER,10 AMP,ADDITIONAL

Sheet 14, 3 of 6
POWER: PART 1 D0001438A
POWER

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 SERVICE MANUAL

CB 1
ELEC PANEL
PWR PORT
SEE DIAGRAM WRG:
B 20A A 1125 BK 14 GA
STD, EQP, POWER PORT
CB 2
PARK LIGHTS
B 15A A PK TAIL BATT 2 BK 18 GA STD, EQP, HEAD/PARK LGTS
PK TAIL BATT BN 18 GA STD, EQP, HEAD/PARK LGTS
CB 3
HEADLIGHTS HI
B 20A A BATT HI BEAM RD 14 GA
STD, EQP, HEAD/PARK LGTS
CB 4
BCM FEED 1 BATT HDLGT BK 18 GA STD, EQP, HEAD/PARK LGTS
SEE BATT-A BK 8 GA B 30A A BATT HDLGT BC BK 18 GA STD, EQP, HEAD/PARK LGTS
SHEET 3
CB 5
BREAK LIGHTS
B 15A A BATT BRK BK 14 GA STD, EQP, PARK BRK/BRK LGTS
BATT BRK SIG BK 14 GA
STD, EQP, PARK BRK/BRK LGTS
CB 6
RADIO/PA
B 6A A BATT RADIO BK 16 GA
30269-06; 38115-27: RADIO
CB 7
W/L EMERG OVERRIDE
B 30A A 1126T BK 18 GA
30222-04,05:
1126R BK 14 GA W/L EMERGENCY OVERRIDE

CB 8
EXIT/SCC MONITOR
B 6A A 1441A PK 18 GA 30195-10,11,13,19:DORAN MONITOR
CB 9
SPARE
B A

CB 10
WEBASTO HTR
B 30A A AUX HTR BATT BK 10 GA 01345-02,09: WEBASTO HEATER
CB 11
ADJ PEDAL
SEE BATT-B BK 10 GA B 15A A BATT ADJ PED BK 16 GA 40099-01: ADJUSTABLE PEDAL
SHEET 3
CB 12
VIDEO RECORDER
B 6A A 1106M BK 16 GA 30755-01: VIDEO RECORDER

CB 13
BACK UP LGT

756 W/EMERG EXIT

B 10A A 1122 BK 14 GA
02234-00: BACK-UP LGHTS
CB 14
LED DRIVER ALERT
B 6A A 1123B BK 16 GA
30298-02: LED MOTORIST ALERT

CB 15
BRK INTLK
B 6A A BRK INTLK PWR RD 16 GA 40051-02: AIR BRAKE INTLK
(AIR)
FUSE 15
BRK INTLK
B 30A A BRK INTLK PWR RD 16 GA 40051-01: HYD BRAKE INTLK
(HYD)
CB 16
BACK UP ALARM
B 10A A 1146 BK 14 GA
02226-00: BACK UP ALARM
1179E BK 16 GA 02226-00: BACK UP ALARM
CB 17
TIRE CHAINS
SEE BATT-C BK 8 GA B 10A A TIRE CHAIN PWR BK 14 GA
40390-08: AUTOMATIC TIRE CHAINS
SHEET 3 CB 18
FUEL PUMP
B 10A A FUEL PMP PWR RD 14 GA
40233-12: FUEL PUMP SWITCH
CB 19
STOP/CROSS ARM
B 20A A 1128 BK 16 GA 30286-02: ELEC CROSS ARM
CB 20 AIR ST ARM PWR RD 14 GA 30297-07: AIR STOP ARM
LIFT CNTRL PWR ST ARM BC RD 14 GA 30297-08: ELEC STOP ARM
B 5A A LIFT ENBL BATT BK 16 GA 31047-01: LIFT ENABLE RELAY
CB 21
SPARE
B - A

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 chassis Electrical

CB 71
HTR/DEFROSTER SEE DIAGRAM WRG:
B 30A A 1125V BK 10 GA
STANDARD HEATER
CB 2
HTR BOOST PUMP
B 15A A 1125R BK 14 GA 30058-02,03; 01345-02,09:
CB 73 HEATER PUMP
PASSENGER HTR 1
B 15A A HTR 1-1 PWR BK 14 GA 30060-08,09,12,13,18,19,22,
SEE CB 74 23: LH FRONT U/S HEATERS
SHEET 3 PASSENGER HTR 1
NOISE SUP A BK 8 GA B 15A A HTR 1-2 PWR BK 14 GA 30060-12,13,18,19,22, 23:
LH FRONT U/S HEATERS
CB 75
PASSENGER HTR 2
B 15A A HTR 2-1 PWR BK 14 GA 30060-14,15,24,25:
RH FRONT U/S HEATERS
CB 76
PASSENGER HTR 2
B 15A A HTR 2-2 PWR BK 14 GA 30060-24,25:
CB 77 RH FRONT U/S HEATERS
PASSENGER HTR 3
B 15A A HTR 3-1 PWR BK 14 GA 30060-10,11,20,21,22,23:
LH REAR U/S HEATERS
CB 78
PASSENGER HTR 3
B 15A A HTR 3-2 PWR BK 14 GA 30060-20,21,22,23:
LH REAR U/S HEATERS
CB 79
PASSENGER HTR 4
B 15A A HTR 4-1 PWR BK 14 GA 30060-16,17,26,27:
RH REAR U/S HEATERS
CB 80
PASSENGER HTR 4
B 15A A HTR 4-2 PWR BK 14 GA 30060-26,27:
RH REAR U/S HEATERS
SEE CB 81
SHEET 3 DRIVER'S FAN RH
NOISE SUP B BK 8 GA B 10A A 1132 BK 16 GA
30026-01: FAN AUX, RH
CB 82
DRIVER'S FAN LH
B 10A A 1131 BK 16 GA 30026-02: FAN AUX, LH
CB 83
DRIVER'S FAN CENTER
B 10A A 1130 BK 16 GA 30026-03: FAN AUX. CENTER
CB 84
FRONT PWR VENT
B 15A A 1134 BK 16 GA 00551-00; 30029-03:
EXHAUST FAN 2 SPD
CB 85
REAR PWR VENT
B 15A A 1134A BK 16 GA 00551-00; 30029-03:
CB 86 EXHAUST FAN 2 SPD (QTY. 2)
WEBASTO HTR
B 6A A
CB 87
CONVENTION HTR
1168L PK 18 GA
01345-02,09: WEBASTO HEATER
757
B 5A A 1125TT BK 18 GA
1125VV BK 18 GA 30059-12,13,14,15,16,17:
SEE CB 88 CONVECTION HEATER
SHEET 3 A/C CONTROL 1
B 6A A 19 RD 14 GA 30006-03,04,06,07,09,12,13,
NOISE SUP C BK 8 GA 14,18,20,21; 30007-02,03,05,
CB 89 06,09,12,13: A/C
A/C CONTROL 2
B 6A A 20 RD 14 GA 30006-03,04,06,07,09,12,13,
14,18,20,21; 30007-02,03,05,
CB 90 06,09,12,13: A/C
DRIVER'S U/S HTR
B 10A A 1125GG BK 14 GA 30060-01: DRIVER'S U/S HTR
CB 91
RADIO/PA
B 6A A IGN RADIO PK 16 GA 30269-06 W/O 30057-03;
38115-27 W/O 30057-03: RADIO
CB 92
WALL HTR 1
B 20A A WL HTR 1 PWR BK 18 GA 30060-05,06,29: WALL HEATER
WL HTR 1 PWR A BK 14 GA 30060-05,06,29: WALL HEATER
CB 93
WALL HTR 2
B 20A A WL HTR 2 PWR BK 18 GA 30060-06,29: WALL HEATER
CB 94 WL HTR 2 PWR A BK 14 GA 30060-06,29: WALL HEATER
SPARE
B - A
SEE CB 95
SHEET 3 SPARE
NOISE SUP D BK 8 GA B - A
CB 96
SPARE POWER: PART 2
B - A Sheet 14, 4 of 6
CB 97
SPARE D0001438A
B - A
CB 98 POWER
SPARE
B - A

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 SERVICE MANUAL

ELEC PANEL

CB 38 SEE DIAGRAM:
WIPER WASH PUMP
B 5A A IGN WASH PUMP BN 16 GA WIPERS AND WASH PUMP
CB 39
WIPER LH
B 20A A 1124EE BK 14 GA WIPERS AND WASH PUMP
CB 40
WIPER RH
SEE ACC-A BK 8 GA B 20A A 1124FF BK 14 GA WIPERS AND WASH PUMP
SHEET 3
CB 41
BODY CNTRL
WIPER/STROBE WIPER SW PWR BK 16 GA WIPERS AND WASH PUMP
B 20A A IGN B/C WIPER/STROBE PK 14 GA WIPERS AND WASH PUMP
CB 42
BODY MODULE IGN
B 5A A IGN BC PK 18 GA B/C PIN 11 OF BCM P710

CB 43
PARK BRK RELAY IGN PK BRK PK 18 GA STD, EQP, PARK BRK/BRK LGTS
B 5A A IGN ADJ PED PK 18 GA
40099-01: ADJUSTABLE PEDAL
CB 44
CROSS ARM MAGNET
B 5A A 1168W PK 16 GA 30286-04: CROSSING ARM
CB 45
AIR SEAT
B 10A A 1127V RD 14 GA 02810-00: AIR SEAT
CB 46
HTD/REMOTE MIR IGN MIR BK 18 GA 30481-01: REMOTE MIRROR
SEE ACC-B BK 10 GA B 15A A IGN HEAT MIR PK 16 GA 30482-06: HEATED MIRROR
SHEET 3
CB 47
STEPWELL LGT
IGN CONT
B 10A A STEP LIGHT IGN PK 16 GA 31166-01: STEPWELL LGT
CB 48
DRIVER'S DOME LGT
B 5A A 1124R BK 16 GA 30155-01,02: DRIVER'S DOME LGT
758 CB 49
DORAN LGT MONITOR
B 6A A 1141 PK 18 GA 30195-12: DORAN LIGHT MONITOR

CB 50
BRK INTLK DR
RELAY
B 5A A IGN ENT DR PK 18 GA 40051-03,04; 04569-00:
CB 51 ENT DR/KNEEL INTLK
EXIT PILOT LGT
B 5A A 1106H YL 18 GA 30318-01: EMERGENCY EXIT PILOT
CB 52
LIFT PILOT LGT
B 6A A 1330 TN 16 GA
30319-07: RED PILOT LIGHT LIFT DOOR
1125BB BK 16 GA 30319-03,05,06: FLASH PILOT LGT LIFT DOOR
CB 53
WATER REG VALVE
SEE ACC-C BK 10 GA B 5A A 1125WW PK 18 GA STANDARD HEATER
SHEET 3 CB 54
DESTINATION SIGN
B 20A A 1142 BK 14 GA 31138-04,05,07; 31139-01:
CB 55 1147 BK 14 GA DESTINATION SIGN
STEP DE-ICE
B 20A A 1135 BK 16 GA 01350-02:
CB 56 2305W RD 18 GA ENTRANCE STEP HEATER
HI IDLE
B 5A A IGN HI IDLE PK 18 GA STD,EQP,HI IDLE

L
 chassis Electrical

CB 57
AIR DUMP SOL VAL
B 5A A 1168FF PK 16 GA 00222-03: AIR PWR DRYERS
CB 58
VIDEO RECORDER
B 6A A 1168V PK 16 GA 30755-01: VIDEO RECORDER
CB 59
KNEELING
B 15A A KNL IGN PK 14 GA 04569-00: KNEELING
CB 60
FRT LANDING LGT
B 15A A 1167K PK 14 GA 30178-04:
FRONT DOOR LANDING LIGHT
CB 61
2 WAY RADIO
SEE ACC-D BK 8 GA B 15A A 1125W BK 14 GA 30281-01: 2 WAY RADIO
SHEET 3
W/30328-07
CB 62
ADD. 20A CB
B 20A A ADD IGN BK 10 GA

CB 62 P209-C
ADD. 10A CB
B 10A A ADD IGN BK 10 GA

CB 63 W/30328-25 P209-C
STROBE LIGHT
B 10A A 1125LL BK 14 GA 30246-03,04: STROBE LIGHT

CB 64
LCK STORAGE COMPT BUZZ
B 5A A 1168GG PK 16 GA 30906-04:
CB 65 LH OVERHEAD STORAGE LOCKING
LH/RH FLOOD
B 25A A FRT ENT LGT PWR PK 14 GA 30178-02:
CB 66 LH AND RH FRONT LANDING LIGHTS
RADIO/PA
B 6A A ACC RADIO BK 16 GA 30269-06 W/30057-03;
CB 67 38115-27 W/30057-03: RADIO
SPARE
SEE
SHEET 3
ACC-E BK 10 GA B -
CB 68
SPARE
A
759
B - A
CB 69
SPARE
B - A
CB 70
SPARE
B - A

30328-07: BREAKER,ADDITIONAL,20 AMP IGNITION

30328-25: CIRCUIT BREAKER,10 AMP,ADDITIONAL

POWER: PART 3

Sheet 14, 5 of 6
D0001438A
POWER

L
 SERVICE MANUAL

ELEC PANEL
SPLICE PACK

SSACC IGN W/L CONTROL PK 16 GA (W/O 30325-02)

TO SSACC
SEE BATT W/L CONTROL BK 16 GA (W/ 30325-02)
ACC-G BK 10 GA TO SSBATT
SHEET 3 A
-
- IGN W/L SEL START PK 14 GA (W/O 30325-02)
TO SSACC
- BATT W/L SEL START BK 14 GA (W/ 30325-02)
TO SSBATT
-
IGN BRK INT PK 14 GA (W/O 31045-02)
- TO SSACC
SEE BATT BRK INT BK 14 GA (W/ 31045-02)
ACC-H BK 10 GA TO SSBATT
SHEET 3 G
-
-
IGN DR PK 16 GA (W/O 30325-08)
- TO SSACC
BATT DR BK 16 GA (W/ 30325-08)
- TO SSBATT

-
IGN CLR/MRK LGT PK 14 GA (W/O 30325-03)
TO SSACC
BATT CLR/MRK LGT BK 14 GA (W/ 30325-03)
TO SSBATT
IGN DOME LGT PK 14 GA (W/O 30325-04)
TO SSACC
BATT DOME LGT BK 14 GA (W/ 30325-04)
TO SSBATT

SPLICE PACK
IGN LIFT DR LGT PK 14 GA (W/O 31045-02)
TO SSACC
SSBATT
BATT LIFT DR LGT BK 14 GA (W/ 31045-02)
SEE TO SSBATT
BATT-E BK 10 GA
760
SHEET 3 A
-
-
-
-
-
SEE
BATT-F BK 10 GA
SHEET 3 G
- IGN DOME LGT 2 PK 14 GA (W/O 30325-04)
TO SSACC
- BATT DOME LGT 2 BK 14 GA (W/ 30325-04)
TO SSBATT
-
- IGN DOME LGT 3 PK 14 GA (W/O 30325-04)
TO SSACC
-
BATT DOME LGT 3 BK 14 GA (W/ 30325-04)
TO SSBATT

TO SSACC IGN EMER EXT PK 14 GA (W/O 06689-02,03)

TO SSBATT BATT EMER EXT BK 14 GA (W/ 06689-02,03)

L
 chassis Electrical

SEE DIAGRAM WRG:

CB 22
W/L CONTROL
B A
30A 1126 BK 18 GA 30218-01,02,03,04: W/L MASTER
1128D BK 16 GA
30316-01: W/L SYSTEM

CB 23
W/L SELECTABLE START
B A 1126KK BK 14 GA
20A 30225-04: W/L SELECTABLE START

CB 24
BRK INTLK RELAY
B A LIFT BATT BK 18 GA
5A 31047-01: LIFT ENABLE
BATT BRK INTLK BK 18 GA 40051-01,02: BRK INTLK

CB 25
ENTRANCE DOOR (AIR/ELEC)
1168Z PK 18 GA 30978-04,07 W/ 30210-18: AIR PWR ENT DOOR
B 6A A 1168F PK 18 GA 30978-07 W/ 30210-17: AIR PWR ENT DOOR
(AIR) PWR DR OPEN RD 16 GA
20A 30978-06: ELECTRIC DOOR
(ELEC) PWR DR CLOSE RD 16 GA 30978-06: ELECTRIC DOOR
CB 26
CLR/MARKER LGT
B 15A A 1124 BK 14 GA
30101-02: CLR/MARKER LIGHTS

CB 27
DOME LGT 1
B 10A A 1124B BK 14 GA
30158-02,03: DOME LIGHTS

CB 28
SPARE
B - A

CB 29
LIFT DR LGT
1121 BK 14 GA
B 10A A
31044-01,02 W/ 31051-02,03: LIFT DR LGTS

CB 30
SPARE
B - A 761
CB 31
SPARE
B - A

CB 32
DOME LGT 2
B 10A A 1124M BK 14 GA
30158-02,03: DOME LIGHTS

CB 33
DOME LGT 3
B 5A A 1124N BK 14 GA
30157-03,04: DOME LIGHTS

CB 34
EMERGENCY EXIT BUZZERS
B 5A A 1124NN BK 18 GA 06689-02,03: DOME LIGHTS W/ EMER EXIT
1124LL BK 16 GA 31201-03,04 W/O 06689-02,03: EMER EXIT BUZZER
1124MM BK 18 GA 31201-03,04: EMER EXIT BUZZER
CB 35
SPARE
B - A

POWER: PART 4
30325-02: POWER,BAT CONTROL,WARNING LIGHTS Sheet 14, 6 of 6
30325-03: POWER,BAT CONTROL,CLER/CSTR/ID LGTS
30325-04: POWER,BAT CONTROL,DOME LIGHTS D0001438A
30325-08: POWER,BAT CONTROL,ENTRANCE DOOR POWER
31045-02: POWER,BAT CONTROL,W/C LIFT

L
 SERVICE MANUAL

4 GA BK

4/0
+ -

PDU
ELEC GROUND STUD
SEE DIAGRAM WRG:
12143B WH 14 GA 4 GA BK J1 P8
40432
TRANSMISSION 1206PP WH 14 GA
B
GND PDU WH 12 GA
F

1206P WH 14 GA
1206EE WH 10 GA

1231AJ WH 12 GA
1206D WH 16 GA
AMMETER
1206 WH 16 GA
40076 - 02
2
HYD BRAKES
3
40432
1231BC WH 16 GA
TRANSMISSION
1231BM WH 16 GA
IGNITION

762 IP
2/0 BLACK

P230 DCM GROUND STUD

CLUSTER 40179 ENGINE
1206S WH 20 GA
ELEC GND 2
P200 P1
13 1206P WH 14 GA
22
P260

DIAG
1206T WH 18 GA
ELEC GND A

L
 chassis Electrical

FRAME
BRK WARN GND WH 16 GA 13
SEE DIAGRAM WRG :
40076 - 02 HYD BRAKES 1206PP WH 14 GA

1206P WH 14 GA
SENSOR GND

4/0
ALT 4/0

FRAME
GROUND

SEE DIAGRAM WRG:

1231Q WH 12 GA
40076 - 01
AIR BRAKES
1212AF WH 14 GA

4/0
SENSOR GND WH 16 GA
40179
ENGINE FILTER GND WH 14 GA

1212AL WH 14 GA T1
BACK UP LIGHTS / ALARM

1212E WH 14 GA 1212AD WH 10 GA
00165-03 LUGGAGE
1212AC WH 14 GA 2
LIGHTS & AIR DRYER
CHASSIS
1208C WH 12 GA
40076 - 01
1208D WH 12 GA
GROUND
763
HYD BRAKES

FRAME
T2
GROUND
GND FUEL LEVEL WH 18 GA

1206P WH 14 GA

ENGINE
SEE DIAGRAM WRG:

14 1231X WH 12 GA
40179 VR GND WH 18 GA
ENGINE STARTER
FAN CL GND WH 18 GA
GROUND
HORN 1212WW WH 16 GA

WIPER & GND WASH WH 16 GA

WASH PUMP Sheet 15

D0001442A
CHASSIS GROUND & ELEC GROUND CHASSIS GROUND