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Body

Wiring
Manual

Aeromaster on
Navistar International
Chassis
Aeromaster on Navistar International—Body Wiring Manual 1
Revision B
2 Aeromaster on Navistar International—Body Wiring Manual
Part Number: 03101939
Revision Control
Revision Print Date
Revision B November 2006
Revision A April 2001

Important Notices
©2006, Utilimaster.®

Printed in U.S.A.

Title: Aeromaster on Navistar International Chassis—Body Wiring Manual

Utilimaster Corporation attempts to provide information that is accurate, complete, and useful. All
information contained in this manual is based on the latest product information available at the time of
publication. However, because of the Utilimaster policy of continual product improvement, Utilimaster
reserves the right to amend the information in this document at any time without prior notice. Should
you find inadequacies in the text, please send your comments to the following address:

Utilimaster
Attn: Designer of Technical Publications
65906 State Road 19, P.O. Box 585
Wakarusa, Indiana, 46573-0585 U.S.A.
574-862-4561, FAX 574-862-3961

This material is confidential and the property of Utilimaster. It is shared with your company for the sole
purpose of helping you with the operation of the described equipment.

Utilimaster makes no warranty of any kind with regard to this material, including, but not limited to, the
implied warranties of merchantability and fitness for a particular purpose. Utilimaster shall not be liable
for errors contained herein or for incidental or consequential damages in connection with the furnishing,
performance, or use of this material.

Utilimaster expressly disclaims all responsibility and liability for the installation, use, performance,
maintenance, and support of third-party products. Customers are advised to make their independent
evaluation of such products.

No part of this document may be photocopied, reproduced, or translated to another language without the
prior written consent of Utilimaster.

Utilimaster® is a registered trademark of Utilimaster Corporation. All other trademarks are products of
their respective companies.

Browse the web site www.utilimaster.com for more information about Utilimaster and its products.

Aeromaster on Navistar International—Body Wiring Manual 3


Contents

Introduction ................................................................................................................................ 6
Vehicle Identification ........................................................................................................................... 7
VIN ................................................................................................................................................................ 7
Body Serial Number ..................................................................................................................................... 7
Work Order Numbers ................................................................................................................................... 7
Safety Considerations—Notes, Cautions, and Warnings ..................................................... 8
Chassis ....................................................................................................................................... 9
Battery ................................................................................................................................................ 9
Access .......................................................................................................................................................... 9
Disconnection ............................................................................................................................................... 9
Removal ........................................................................................................................................................ 9
Installation ..................................................................................................................................................... 9
Fuses and Relays ............................................................................................................................. 10
Symbol Codes and Identification ........................................................................................... 11
Codes and Symbols .......................................................................................................................... 11
Circuit Number Identification ............................................................................................................ 12
Harness Layouts .............................................................................................................................. 13
Wiring Diagrams ...................................................................................................................... 14
Accessory Outlet (Cigarette Lighter) ................................................................................................ 14
Back-up Camera .............................................................................................................................. 15
Door Ajar System ............................................................................................................................. 16
Fan, Driver Convenience .................................................................................................................. 17
Grounding System ............................................................................................................................ 18
Heater Only ...................................................................................................................................... 19
Manual (Cable) Controls ............................................................................................................................. 19
Electronic Controls ..................................................................................................................................... 20
Heater and Air Conditioning ............................................................................................................. 21
Manual (Cable) Controls ............................................................................................................................. 21
Electronic Controls ..................................................................................................................................... 22
Heater, Auxiliary ............................................................................................................................... 23
Heater and Air Conditioning, Control Panel Lights ........................................................................... 24

4 Aeromaster on Navistar International—Body Wiring Manual


Light, Cab Dome .............................................................................................................................. 25
Lights, Cargo .................................................................................................................................... 26
Standard ..................................................................................................................................................... 26
Switch on Dash ........................................................................................................................................... 27
Three-Way Switch ...................................................................................................................................... 28
Lights, Forward ................................................................................................................................. 29
Clearance Lights, Standard ........................................................................................................................ 29
Clearance Lights with Relay ....................................................................................................................... 30
Standard ..................................................................................................................................................... 31
Daytime Running Lights ............................................................................................................................. 32
Lights, Rear ...................................................................................................................................... 33
Standard ..................................................................................................................................................... 33
Split Taillights .............................................................................................................................................. 34
Supplemental High Mount Stop Light (SHMSL) ......................................................................................... 35
Lights, Spot, Scene, Flood, or Strobe ............................................................................................... 36
Mirrors, Heated ................................................................................................................................. 37
Power Distribution ............................................................................................................................ 38
Roof Wiring ....................................................................................................................................... 39
Stereo System .................................................................................................................................. 40
Switches ........................................................................................................................................... 41
Vent, Powered .................................................................................................................................. 42
Wiper System ................................................................................................................................... 43
Standard ..................................................................................................................................................... 43
Intermittent Option ...................................................................................................................................... 44
Connectors ............................................................................................................................... 45
Reporting Safety Defects ........................................................................................................ 50
United States Only ............................................................................................................................ 50
Canada Only .................................................................................................................................... 50
More Information ..................................................................................................................... 51
Download Files ................................................................................................................................. 51
Utilimaster Detailed Parts, Service, and Wiring Manuals ................................................................. 51
ACE (Access Control and Entry) System ......................................................................................... 51
Vehicle Access Control System (VACS) ........................................................................................... 51
Contact Utilimaster ........................................................................................................................... 51
Index .......................................................................................................................................... 52

Aeromaster on Navistar International—Body Wiring Manual 5


Introduction
This manual (P/N 03101939) illustrates electrical NOTE: These wiring diagrams
wiring diagrams for Aeromaster® walk-in bodies are a generic sample. Details in
on the Navistar International chassis Model Years these diagrams may differ from
1996 to 2006. Wiring diagrams are dependent those in your vehicle. Because
Model Year and body options. Utilimaster manufactures many
customized vehicle bodies, this
This manual covers only those components manual cannot list and illustrate
manufactured by or installed by Utilimaster® every possible wiring
Corporation. Items such as chassis and drive configuration for every vehicle.
train components or certain interior options are Use this information as a guideline
covered by separate manufacturer-supplied where it applies.
information. Not all options are included in this
manual and some numbers may have changed.
If your vehicle is equipped with a ACE or VACS
system, supplementary information is through
Utilimaster Customer Service by calling 800-
237-7806 (574-862-3219), fax 574-862-7637, or
email CustSvc@Utilimaster.com. See the More
Information Section in this manual for
descriptions and part numbers.
All information, specifications, and Figures
contained in this manual are based on the latest
product information available at the time of
publication. However, because of the Utilimaster
policy of continual product improvement,
Utilimaster reserves the right to amend the
information in this document at any time without
prior notice.

WARNING: Connecting unauthorized devices to the vehicle's wiring can potentially cause vehicle
malfunction, damage, fire, personal injury, and/or voiding of the warranty. Contact Utilimaster
before connecting any devices to the vehicle's wiring other than plugging into a supplied accessory
outlet (cigarette lighter).

6 Aeromaster on Navistar International—Body Wiring Manual


Vehicle Identification
VIN
The 17-digit chassis Vehicle Identification
Number (VIN) is the legal identifier for this
vehicle and is the number recorded in the license
plate registration. The VIN appears on a small
label on the cowl (under the hood) on the driver’s
side. See Figure LA–05. The number is also
recorded on the Federal Certification Label (see
Figure LA–15) and on the International Incomplete
Vehicle Component Information label on the shelf
above the windshield.

Body Serial Number


The 15-digit Utilimaster Body (or Unit) Serial
LA–05
Number is recorded on the Federal Certification
Vehicle Identification Label under the hood
Label. This label is a plastic decal (about 11" long
and 2" high) that contains a variety of
manufacturing information (including the VIN). This label is
found on the driver’s side forward door post. (See Figures
LA–10 and LA–15).

Work Order Numbers


A 7-digit Work Order Number appears below the Unit Serial
Number on the Federal Certification Label. See Figure
LA–15.

LA–10
Federal Certification Label
on Door Post

LA–15
Federal Certification Label
Aeromaster on Navistar International—Body Wiring Manual 7
Safety Considerations—Notes, Cautions, and Warnings
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS.
Each one is there for a specific purpose.
• NOTES give you additional information that will help you to complete the procedure.
• CAUTIONS warn you against making an error that could damage the vehicle.
• WARNINGS remind you to be careful when there is a risk of personal injury.
Below are some basic WARNINGS that you should heed when you work on the
vehicle’s body. They are not all inclusive, however, and common sense must be used when servicing
vehicles.
• Always wear safety glasses and other proper • Avoid contact with hot metal parts, such as
protective equipment (gloves, steel-toed the radiator or exhaust system.
shoes, face shields, knee pads, hearing
• Always remove rings, watches, hanging
protection) as appropriate to the process.
jewelry, and loose clothing before working
• Use safety stands and/or wheel blocks on a vehicle. Tie long hair securely behind
whenever you are underneath the vehicle. your head.
• Put the transmission in Park and set the • Become familiar with all warning labels.
parking brake before working on the vehicle.
• Utilimaster recommends that a licensed
• Be sure that the ignition switch is Off unless automotive air-conditioning specialist
otherwise required by the procedure. work on the vehicle’s air-conditioning
(HVAC) system.
• Operate engines only in well-ventilated
areas. • Avoid breathing A/C refrigerant and
lubricant vapor or mist. Exposure may
• Keep yourself and your clothing away from
irritate eyes, nose, and throat. If
the radiator fan, belts, and any moving parts
accidental system discharge occurs,
when the engine is running.
ventilate work area before resuming
• Keep hands and other objects clear of the service. Additional health and safety
radiator fan blades. The electric fan can information may be obtained from
start at any time even though the ignition refrigerant and lubricant manufacturers.
is Off. Disconnect the fan when working
under the hood.

8 Aeromaster on Navistar International—Body Wiring Manual


Chassis

WARNING: To avoid accidental shock or


damage to the vehicle, disconnect the
battery before servicing an electrical
component. Check your chassis-
supplied operation or service informa-
tion for specific recommendations.

WARNING: Always remove the (black)


Negative cable(s) first and connect it
last.

Figure BA–10
Stepwell Battery Access
Battery
Access
NOTE: The batteries on most
Aeromasters are located under an
access panel in the right-hand
stepwell. See Figure BA–10.
Otherwise see the Chassis Service
Manual.
Disconnection
1. Make sure the ignition switch is Off.
2. Disconnect the Negative (black) battery
cable(s) first. See Figure BA–20.
3. Tuck the battery cable away from the Figure BA–20
Negative (black) Cable Disconnected and Tucked Away
terminal to prevent accidental contact.
4. When servicing the vehicle is finished,
reconnect the cable. Installation
Removal 1. Install the battery in the battery tray—in
the same orientation.
1. Disconnect battery. See the Disconnection
section. 2. Secure the battery hold-downs.
2. Remove the Positive battery cable(s). 3. Connect the battery cables, Negative last.
3. Remove the battery hold-downs. NOTE: Remember to fasten the
access panel.
4. Note the location of the posts and remove
the battery from the vehicle.

Aeromaster on Navistar International—Body Wiring Manual 9


Fuses and Relays
The Navistar International chassis has two banks
of fuses and relays. One is in the cab area just to
the left of the dash panel. See Figure BA–25.
There is also a panel under the hood mounted on
the cowl on the right-hand (passenger’s) side of
the vehicle. See Figure BA–30.

Figure BA–25
Chassis fuses to the left of the dash panel.

Figure BA–30
Chassis fuses under the hood on the right-hand
(passenger’s) side of the vehicle.

10 Aeromaster on Navistar International—Body Wiring Manual


WIRE COLOR CODE: SYMBOL CODE: CONNECTOR CONNECTOR
SYMBOL NUMBER
BK - BLACK
C100 C101
BR - BROWN
A A
DB - DARK BLUE
CAVITY
DG - DARK GREEN CONTINUE TO IDENTIFICATION
ANOTHER SHEET
GY - GRAY
Codes and Symbols

LB - LIGHT BLUE
LG - LIGHT GREEN CONTINUED FROM
ANOTHER SHEET
OR - ORANGE
PK - PINK SPLICE

RD - RED
YL - YELLOW GROUNDED TO BODY
CONNECTOR WITH NO
VT - VIOLET NUMBER ASSIGNED

WT - WHITE

Aeromaster on Navistar International—Body Wiring Manual


Symbol Codes and Identification

CIRCUIT AND CONNECTOR CODE:


CONNECTOR NUMBER
500 BK/WT
C100 DESCRIPTION
STRIPE COLOR (IF APPLICABLE)
COWL CONNECTOR
WIRE COLOR 12020991
CIRCUIT NUMBER PART NUMBER

NOTES:
1) All connectors are shown in the load (wire lead insertion) position.
2) Special customer options may not be covered by these diagrams.
3) Wire colors on some optional equipment may vary from this document.
Wire_Color_Codes_Symbols

11
12
CIRCUIT NUMBER INDENTIFICATION
CIRC CIRC CIRC
No. COLOR DESCRIPTION No. COLOR DESCRIPTION No. COLOR DESCRIPTION

110 PINK W/ BLACK STRIPE IGNITION POWER 258 LIGHT BLUE W/ WHITE STRIPE AUXILIARY SWITCH *925 BLACK RIGHT DOOR OPEN SWITCH 2

120 ORANGE WIPER POWER 280 LIGHT BLUE W/ RED STRIPE ILLUMINATION *926 YELLOW BLKHD DOOR OPEN SWITCH 1

DOOR AJAR SIGNAL *927 BLACK W/ WHITE STRIPE LEFT DOOR SOLENOID 1
130 RED CIGARETTE LIGHTER POWER 350 BLACK W/ PINK STRIPE

380 LIGHT BLUE UPS SECURITY CIR 1 *928 BLACK W/ WHITE STRIPE RIGHT DOOR SOLENOID 1
150 RED BATTERY POWER

381 VIOLET UPS SECURITY CIR 2 *929 BLACK W/ WHITE STRIPE BLKHD DOOR SOLENOID 1
170 RED AUXILIARY BATTERY POWER

UPS SEAT PRESSURE CIR 1 *930 BLACK W/ WHITE STRIPE RIGHT DOOR SOLENOID 2
200 DARK BLUE DOME LIGHT POWER 382 LT BLUE W/ BLK STRIPE
Circuit Number Identification

383 VIOLET W/BLK STRIPE UPS SEAT PRESSURE CIR 2 *931 BLACK W/ WHITE STRIPE LEFT DOOR SOLENOID 2
220 YELLOW CARGO LIGHTS

GROUND *933 BLACK W/ WHITE STRIPE BLKHD DOOR SOLENOID 2


222 YELLOW W/ BLACK STRIPE CARGO LIGHTS (3 WAY SWITCH) 500 BLACK

CARGO LIGHTS (3 WAY SWITCH) 510 BLACK W/ WHT STRIPE WIPER MOTOR GROUND *934 RED COMMUNICATION BUS HIGH
224 YELLOW W/ WHITE STRIPE

TAIL/RUNNING LIGHTS DOME LIGHT GRD *935 BLACK COMMUNICATION BUS LOW
230 BROWN 520 BLACK

530 BLACK HVAC GROUND *936 RED KEYLESS POWER


231 BROWN W/ WHITE STRIPE CLEARANCE LIGHTS ONLY

540 BLACK FRONT LIGHT GROUND *940 YELLOW STARTER RELAY


232 DARK GREEN RIGHT TURN/STOP

700 DARK BLUE W/ WHITE STRIPE BLOWER MOTOR POWER (HVAC) *941 YELLOW ACCESSORY RELAY
233 DARK GREEN FRONT RIGHT TURN

710 DARK GREEN A/C SIGNAL (HVAC) *942 ORANGE W/ BLACK STRIPE RELAY COMMON
234 RED STOP ONLY

FRONT LEFT TURN 720 DARK GREEN A/C SIGNAL (HVAC) *943 PINK IGNITION RELAY
235 YELLOW

BACK UP 721 DARK GREEN W/ WHITE STRIPE A/C SIGNAL TO COMPRESSOR *944 LIGHT BLUE INTERIOR LIGHT RELAY
236 LIGHT GREEN

UNIVERSAL TURN/STOP 731 DARK BLUE HVAC WATER VALVE SIGNAL *945 ORANGE INTERIOR LIGHT RELAY
237 GRAY

LEFT TURN/STOP 820 DARK GREEN WIPER LOW *946 YELLOW INTERIOR LGHT RELAY OUTPUT
238 YELLOW

830 RED WIPER HIGH *947 PINK W/ BLACK STRIPE HORN TRIGGER (GND)
240 LIGHT GREEN W/ BLACK STRIPE LO BEAM (HEADLIGHT)

RIGHT LO BEAM (HEADLIGHT) 840 GRAY WIPER PARK *948 LIGHT GREEN ACC AND IGN RELAY TRIGGER
241 LIGHT GREEN W/ WHITE STRIPE

890 VIOLET WASHER MOTOR *950 BLACK REAR DOOR OPEN SWITCH 2
242 RED W/ BLACK STRIPE HIGH BEAM (HEADLIGHT)

*920 DARK GREEN EXTERIOR DOOR SWITCH *960 YELLOW REAR DOOR OPEN SWITCH 1
243 RED W/ WHITE STRIPE LEFT HIGH BEAM (HEADLIGHT)

AUXILIARY SWITCH *921 DARK GREEN BULKHEAD DOOR SWITCH *961 BALCK W/ WHITE STRIPE REAR DOOR SOLENOID 2
254 DARK GREEN

AUXILIARY SWITCH *922 BLACK LEFT DOOR OPEN SWITCH 2 *962 BALCK W/ WHITE STRIPE REAR DOOR SOLENOID 1
256 DARK GREEN W/ WHITE STRIPE

257 LIGHT BLUE AUXILIARY SWITCH *923 YELLOW W/ BLACK STRIPE LEFT DOOR OPEN SWITCH 1 *970 WHITE HORN OUTPUT

*924 YELLOW RIGHT DOOR OPEN SWITCH 1 *980 DARK GREEN W/ BLACK STRIPE PASSENGER DOOR OVERRIDE
* SPECIFIC TO THE VACS SYSTEM.
NOTE: These wiring diagrams are a generic sample. Details in these diagrams may differ from those in your vehicle. Because Utilimaster manufactures many customized vehicle bodies, this manual cannot list and illustrate every possible wiring configuration for every vehicle.
Use this information as a guideline where it applies.

Aeromaster on Navistar International—Body Wiring Manual


Circit ID - Diagram 58231212ax08 Sheet 8
C510
F19
TO
SCS C112
WIRING CIG GROUNDS
LTR
C331 C720
CLRC
C330 C110 LT
C105
C304 POWER FEED HARNESS
C303 CLRC
LT CLRC
C106 LT
C410 C302 CLRC CLRC
C113 LT LT

C111 C301 CLRC


MAIN HARNESS LT
Harness Layouts

GROUNDS ROOF TO REAR STRUCTURE


C641 CONNECTION (NO CONN. #'S)

CARGO C635
VIEW-AA C100 LIGHT

(UNDER DASH) CLRC


LT
C636

C642

CARGO C637
LIGHT C632
C621

C631
C638
C620

CLRC DOME
LT LIGHT BACKUP
ALARM

C634
C633

Aeromaster on Navistar International—Body Wiring Manual


C611
C610

CLRC
LT
CLRC
LT
CLRC
LT

CLRC
LT C415
C413

C202 C414
C412
C203
VIEW-AA
C411
C207

C208
C206

C209
C101
C710

C714 C210

C204
C712 C200
C205

C711

C713
C715

Connector Locating Diagram 58231015a07 SHEET 7

13
Wiring Diagrams
Accessory Outlet (Cigarette Lighter)

ACCESSORY

Accessory Outlet - Diagram 58231212ax32 Sheet 32


OUTLET
ACCESSORY OUTLET (CIGARETTE LIGHTER)

WARNING: Connecting
unauthorized devices to the
vehicle's wiring can potentially
500 BK 16

cause vehicle malfunction,


damage, fire, personal injury, and/
or voiding of the warranty.
Contact Utilimaster before
connecting any devices to the
GROUND

vehicle's wiring other than


plugging into a supplied
accessory outlet (cigarette
130 RD 16

lighter).
BATTERY HOT

14 Aeromaster on Navistar International—Body Wiring Manual


Back-up Camera

KIT SUPPLIED
CABLE

58231292A19a19
MONITOR

CAMERA
IN-LINE 3 AMP FUSE PROVIDED
WITH MONITOR

RD

DB
BK
RD
110 PK/BK

500 BK

236 LG
110 PK/BK

500 BK

236 LG

NOTE: These wiring diagrams


are a generic sample. Details in
110 PK/BK

these diagrams may differ from


those in your vehicle. Because
Utilimaster manufactures many
customized vehicle bodies, this
manual cannot list and illustrate
every possible wiring
GROUND SYSTEM
CAMERA POWER

CHASSIS REAR
LAMP FEED

configuration for every vehicle.


BACK UP

Use this information as a


guideline where it applies.

Aeromaster on Navistar International—Body Wiring Manual 15


16
Door Ajar System

DOOR AJAR

MAGNETIC DOOR
SWITCH AJAR
(NORMALLY CLOSED) LIGHT

350 BK 16 350 BK/PK 18 350 BK/PK 18 350 BK/PK 18 CHASSIS OEM


SUPPLIED 12V
POWER

500 BK 18
Door Ajar - Diagram 58231008ax Sheet 27

Aeromaster on Navistar International—Body Wiring Manual


Fan, Driver Convenience

Dash Fan - Diagram 58231008ax Sheet 34


DASH
M

FAN
RD

OR
256 DG/WT 16

254 DG 16

WIRE COLORS USED ON THIS OPTION MAY DIFFER


BASED ON NUMBER OF OPTIONS ON THE VEHICLE
256 DG/WT 14

254 DG 14
DASH FAN

280 LB/RD 18

110 PK/BK 14
500 BK 18
256 DG/WT 14

280 LB/RD 18
110 PK/BK 14

WARNING: Connecting
254 DG 14

500 BK 18

unauthorized devices to the


POWER DISTRIBUTION
GROUND

ILLUMINATION POWER

vehicle's wiring can potentially


cause vehicle malfunction,
damage, fire, personal injury, and/
or voiding of the warranty.
Contact Utilimaster before
1
8

connecting any devices to the


(AUX. SW #2)
SWITCH ON
DASH FAN
ON/OFF/ON

vehicle's wiring other than


DASH

plugging into a supplied


accessory outlet (cigarette
lighter).
6
7

Aeromaster on Navistar International—Body Wiring Manual 17


GROUNDING SYSTEM

18
500 BK
INTERMITTENT WIPER
MODULE

530 BK
HVAC SYSTEM

500 BK
PANEL LAMPS
500 BK COWL
DRL-DOMESTICS
Grounding System

500 BK 500 BK C410 C411 C412 ROOF CENTRAL


FORWARD LAMPS
14 14 14 GROUND

500 BK 500 BK 500 BK 12 500 BK


WASHER PUMP AUXILIARY SWITCHS

500 BK 500 BK
AUXILIARY HEATER CIGARETTE LIGHTER
(SCS ONLY)

500 BK 500 BK
WIPER SYSTEM CLEARANCE LIGHT RELAY

SPL GROUND SYSTEM NAVISTAR


500 BK
REAR LAMP SYSTEM

500 BK 500 BK 500 BK


FORWARD LAMP SYSTEM CLEARANCE AND I.D. LIGHT

500 BK
BACK UP CAMERA SYSTEM

COWL

Grounding System 58231015a10 SHEET 10


and 58231292a11 SHEET 11

Aeromaster on Navistar International—Body Wiring Manual


Heater Only
Manual (Cable) Controls

HEATER ONLY SYSTEM


BLOWER
MOTOR
RELAY
ILLUMINATION

85 86

87
30
87a

Aeromaster on Navistar International—Body Wiring Manual


LB 16
LB 16

BK 16
BK 16
BK 16
OR/WT 12

POWER 700 DB/WT 12 DB/WT 12 DB/WT 12


DISTRIBUTION
OR 16

DB 16

POWER 280 LB/RD 18 LB 16


DISTRIBUTION
530 BK 12 BK 12 BK 12
GROUND

OR 16

YL 16 DB 16

BN 16

DB/WT 14
BK 12

C B L M H
OR/WT 12

BLOWER
M
MOTOR
RESISTOR BLOWER
BLOWER MOTOR
SWITCH

Heat Only Sys - Diagram 58231008a Sheet 13

19
20
HEAT ONLY ELECTRONIC CONTROLS
Heater Only

TEMPERATURE
PANEL LAMPS CONTROL

CONTROLLER
Electronic Controls

20 1

GY

YL
VT

RD
PK
LG
DB

WT
OR
DG

YL/BK

BR/BK
DB/BK
YL/WT

DG/BK
DB/WT

DG/WT
LB

BK
BK
RD/BK

RD/WT
REC BK
M
DB/WT

DEFROST
M 530 BK
GROUNDING
MODE SWITCH
1 OFF 700 DB/WT POWER
2 PANEL DISTRIBUTION
3 FLOOR/PANEL
4 FLOOR
5 FLOOR/DEFROST
6 DEFROST
7 A/C
VENT
731 DB

8 A/C MAX
700 DB/WT

M LB
280 LB/RD POWER
DISTRIBUTION

DB

FLOOR
M B

FAN SWITCH
1 LOW
2 MED LOW
3 MED HIGH
4 HIGH
M
L H

85 86

87 DB YL
30
87a OR/RD
731 DB

500 BK
700 DB/WT

GROUNDING

DB/WT
SYSTEM POWER
RELAY
YL/RD

BR

85 86 M
2 1 4
87
OR 30 3
87a WATER VALVE
BLOWER
MOTOR
BLOWER MOTOR RESISTOR
M
BLOWER HI
RELAY

BK BK Heat Elect Conrols - Diagram 58231212a Sheet 17

Aeromaster on Navistar International—Body Wiring Manual


Heater and Air Conditioning
Manual (Cable) Controls

Aeromaster on Navistar International—Body Wiring Manual 21


22
HVAC ELECTRONIC CONTROLS

PANEL TEMPERATURE
LAMPS
Electronic Controls

CONTROL

CONTROLLER COMPRESSOR CLUTCH

20 1
GY
SWITCH A
OPENS @ 460 PSI

VT

DB
CLOSES @ 22 PSI

DG

LG
GR NORM CLOSED

LB

BK

YL/WT
YL

YL/BK
RD
PK
OR

BR/BK
DG/WT
Heater and Air Conditioning

WT

DG/BK
DB/WT
DB/BK
BK
RD/BK

RD/WT

BK
M
DB/WT
REC
1
6

C333
C333
1
6
C334

C334

M C331 C330 C331 C330


(GROUND)
MODE SWITCH 4 4 4 4 530 BK
DEFROST 1 OFF C331 C330 C331 C330 (POWER
2 PANEL 1 1 DISTRIBUTION)
1 1 700 DB/WT
3 FLOOR/PANEL
4 FLOOR
5 FLOOR/DEFROST
6 DEFROST
7 A/C
731 DB

8 A/C MAX
700 DB/WT

M LB
C331 C330 C331 C330 (POWER
3 3 3 3 280 LB/RD DISTRIBUTION)
VENT
DB
C331 C330 C331 C330 (POWER
5 5 5 5 715 OR/WT DISTRIBUTION)
S
T

C100
C100

M B

FLOOR A/C CLUTCH


S
T

DB
C101

C101

85 86

M 87
L H 30
FAN SWITCH
1 LOW 87a
85 86 2 MED LOW
3 MED HIGH
87 DB YL 4 HIGH
30
87a OR/RD
731 DB

500 BK 18
700 DB/WT

(GROUND)
DB/WT
SYSTEM POWER
RELAY
YL/RD
8
7
5

C332
C332
C332

BR
DE-ICING SWITCH
OPEN 29°F
CLOSED 35°F

85 86 M
2 1 4
87
OR 30 3
87a WATER VALVE
BLOWER
MOTOR
BLOWER MOTOR RESISTOR
M
BLOWER HI
RELAY

BK BK
HVAC Elect Controls - Diagram 58231212aXX (Sheet 18)

Aeromaster on Navistar International—Body Wiring Manual


AUXILIARY HEATER (DRIVER’S FOOT AREA)

ON/OFF/ON

7 258 LB/WT
Heater, Auxiliary

1 150 RD

2 257 LB
6 3
280 LB/RD

500 BK
AUX. HEATER
SWITCH ON
DASH
(AUX. SW #3)

SECONDARY SWITCH

500 BK
GROUND

280 LB/RD

Aeromaster on Navistar International—Body Wiring Manual


ILLUMINATION POWER

150 RD
BATTERY POWER

ON/OFF/ON

7 256 DG/WT 256 RD


8

1 110 PK/BK 500 BK 14 AUXILIARY


GROUND HEATER
2 254 DG 254 YL
6 3
280 LB/RD

LOCATED AT
500 BK DRIVERS FOOT
AUX. HEATER
SWITCH ON AREA OF CAB
DASH
(AUX. SW #2)

PRIMARY SWITCH
AUXILIARY SWITCH #2 (C302) IS THE PRIMARY SWITCH FOR THIS OPTION,
BUT IF THIS SWITCH IS ALREADY IN USE, THEN AUXILIARY SWITCH #3 (C303)
500 BK
IS THE SECONDARY SWITCH.
GROUND

280 LB/RD
ILLUMINATION POWER
110 PK/BK
IGNITION POWER

Aux Heater - Diagram 58231212ax40 Sheet 40

23
280 LB/RD 18 C304 C304

24
8 7

PANEL LAMPS (AUX. SW #4)

280 LB/RD 18 C303 C303


8 7

(AUX. SW #3)

280 LB/RD 18 C302 C302


8 7

(AUX. SW #2)

500 BK 18
280 LB/RD 18 280 LB/RD 18 C301 C301
POWER DIST.
ILLUMINATION 8 7
Heater and Air Conditioning, Control Panel Lights

MASTER LIGHT SWITCH

GROUND

C330 C331 C331 C330 530 BK 18


GROUND
3 3 4 4

HVAC PANEL
ILLUMINATION

280 LB/RD 18 500 BK 18


GROUND

WIPER SWITCH Panel Lamps 58231015a22 SHEET 22

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LEGEND ILLUMINATION
Light, Cab Dome

LIGHT
DOME

Cab Dome Light - Diagram 58231212ax36 Sheet 36


200 DB
CAB DOME LIGHT DASH MOUNTED SWITCH

200 DB

NOTE: These wiring diagrams


are a generic sample. Details in
these diagrams may differ from
280 LB/RD

280 LB/RD

those in your vehicle. Because


200 DB
150 RD

150 RD
500 BK

500 BK

Utilimaster manufactures many


customized vehicle bodies, this
manual cannot list and illustrate
C301

C301

C301

C301

every possible wiring


configuration for every vehicle.
BATTERY POWER
ILLUMINATION POWER
GROUND
2

3
8

Use this information as a


DOME LIGHT
SWITCH IN

guideline where it applies.


ON/OFF

DASH
7

Aeromaster on Navistar International—Body Wiring Manual 25


26
Standard
Lights, Cargo

CARGO LIGHTS STANDARD WIRING

JUMPER WIRE

222 YL/BK 18

ON/OFF
224 YL/WT 14

150 RD 14 8 7
REAR
220 YL 14 220 YL 14 220 YL/BK 16 220 YL/BK 16 2 CARGO LIGHT
SWITCH
220 YL 16 220 YL 16 3

CARGO
LIGHT
POWER 150 RD 18
DISTRIBUTION

Cargo Lights Std - Diagram 58231008a Sheet 30

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Lights, Cargo
Switch on Dash

CARGO LIGHTS SWITCHED ON DASH

ON/OFF 222 YL/BK 18

224 YL/WT 14
7 8
150 RD 14 CARGO
CARGO LIGHT
SWITCHED AT LIGHT
2 220 YL 14 220 YL 14 220 YL 16
DASH
3

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280 LB/RD 18

500 BK 18

500 BK 18
GROUND

POWER DISTRIBUTION 280 LB/RD 18


ILLUMINATION
150 RD 14
POWER DISTRIBUTION Cargo Lights Switched at Dash - Diagram 58231008a Sheet 31

27
28
Lights, Cargo
Three-Way Switch

CARGO LIGHTS 3-WAY SWITCH

ON/ON

7
8
1

CARGO 2
LIGHT
3
6

REAR CARGO
LIGHT SWITCH

222 YL/BK 18 222 YL/BK 18 222 YL 16


ON/ON

7 224 YL/WT 14 224 YL/WT 14 224 YL/BK 16


8
150 RD 14

220 YL 14 220 YL 14 220 YL/BK 16

6
280 LB/RD 18

500 BK 18

CARGO LIGHT
SWITCH ON
DASH

GROUND 500 BK 18

POWER DISTRIBUTION 280 LB/RD 18


ILLUMINATION
150 RD 14
POWER DISTRIBUTION
Cargo Lights 3-Way Switch - Diagram 58231008ax Sheet 32

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Lights, Forward

CLEARANCE AND I.D. LIGHTS


Clearance Lights, Standard

REAR CLEARANCE
FRONT CLEARANCE LIGHT
LIGHT

230 BR
500 BK

230 BR

500 BK
REAR I.D.
FRONT I.D.
LIGHTS
LIGHTS

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FRONT CLEARANCE REAR CLEARANCE
LIGHT LIGHT
230 BR

500 BK
500 BK

230 BR

TO
NAVISTAR 230 BR
REAR LAMP
FEED CONNECTION

230 BR 230 BR 230 BR

500 BK 500 BK 500 BK


GROUND SYSTEM

58231292A16

29
30
CLEARANCE LIGHTS

231 BR/WT 14
Lights, Forward

ROOF WIRING

231 BR/WT 14
Clearance Lights with Relay

87
500 BK 18 231 BR/WT 18 231 BR/WT 18 CLEARANCE
86 87a 85 LIGHT
SIGNAL

30

170 RD 14 POWER
DISTRIBUTION

GROUND

Clearance Lights 58231015a21 SHEET 21

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FORWARD LAMP WIRING (DOMESTIC & CANADA)

230 BR 18
LEFT
235 GY 18 SIDEMARKER
Standard

LED
INCAN
230 BR 18 230 BR 18

500 BK 16 500 BK 18 LEFT


Lights, Forward

TURN SIGNAL
235 GY 18 235 GY 18

240 LG/BK 18

242 RD/BK 16 240 LG/BK 18

500 BK 16 LEFT
HEADLAMP
242 RD/BK 16

235 YL 18

242 RD/BK 16

NAVISTAR COWL 240 LG/BK 18


CONNECTOR
233 DG 18

230 BR 18

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242 RD/BK 16

500 BK 16 RIGHT
HEADLAMP
242 RD/BK 16 240 LG/BK 16

240 LG/BK 18

233 GY 18 233 GY 18

500 BK 16 500 BK 18 RIGHT


TURN SIGNAL
230 BR 18 230 BR 18

233 GY 18
LED
INCAN

GROUNDING RIGHT
230 BR 18 SIDEMARKER
500 BK 16

NOTE: All chassis for Canada have


Daytime Running Lights
(DRL) as part of the chassis
wiring (and not part of
Utilimaster body wiring) 58231015a16x2

31
32
Lights, Forward

IGN PWR C100 C101 DG


S S FORWARD LIGHT WIRING (W/DRL-DOMESTIC)
DRL
BATT PWR C100 C101 RD MODULE
D D (16511938)
Daytime Running Lights

GROUND BK 230 BR 18 C715


A LEFT
235 GY 18 C715 SIDE MARKER
B

C204 C205 230 BR 18 230 BR 18 C713

OR
WT
B B A
C204 C205 500 BK 16 500 BK 18 C713 LEFT
E E B TURN SIGNAL
C204 C205 235 GY 18 235 GY 18 C713
A A C
C204 C205 240 LG/BK 18
C C

A
B
C204 C205 242 RD/BK 16 240 LG/BK 18 C711

C210
C210
D D B
500 BK 16 C711 LEFT
A HEADLIGHT
242 RD/BK 16 C711
C
C200 235 YL 18

C200 242 RD/BK 16

HEADLIGHT C200 240 LG/BK 18


FEED CONNECTION

C200 233 DG 18

C200 230 BR 18

242 RD/BK 16 C710


C
500 BK 16 C710 RIGHT
A HEADLIGHT
C202 C203 242 RD/BK 16 240 LG/BK 16 C710
D D B
C202 C203 240 LG/BK 18
C C
C202 C203 233 GY 18 233 GY 18 C712
A A C
C202 C203 500 BK 16 500 BK 18 C712 RIGHT
E E B TURN SIGNAL
C202 C203 230 BR 18 230 BR 18 C712
B B A

233 GY 18 C714
B
RIGHT
230 BR 18 C714 SIDE MARKER
A
500 BK 16
GROUNDING

Forward Light Wiring (DRL Domestic) - Diagram 58231008a Sheet 18

Aeromaster on Navistar International—Body Wiring Manual


Standard
REAR LAMP SYSTEM
TRAILER WIRING
(INSIDE LICENSE
PLATE LIGHT COVER)
Lights, Rear

230 BR LEFT

238 YL
500 BK
230 BR
234 RD

232 DG
REAR
500 BK SIDEMARKER
LAMP
232 DG

238 YL 238 YL

500 BK 500 BK LEFT


TURN/TAIL
LAMP
230 BR 230 BR

234 RD 234 RD

500 BK LEFT
STOP/TAIL
LAMP
230 BR

500 BK
LEFT
BACK-UP
236 LG 236 LG 236 LG LAMP

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230 BR 18
238 YL 238 YL LICENSE
PLATE
LAMP
234 RD 234 RD

REAR LAMP 236 LG 236 LG


FEED
CONNECTION 236 LG 236 LG 236 LG
230 BR 230 BR RIGHT
BACK-UP
500 BK LAMP
232 DG 232 DG

230 BR

500 BK RIGHT
STOP/TAIL
LAMP
234 RD 234 RD 234 RD

GROUND SYSTEM 500 BK


230 BR 230 BR 230 BR

500 BK 500 BK 500 BK RIGHT


TURN/TAIL
LAMP
232 DG 232 DG 232 DG

500 BK
RIGHT
SIDEMARKER
230 BR LAMP

58231292a15

33
34
Lights, Rear
Split Taillights

230 BR 18 C622
REAR LAMP WIRING-SPLIT TAILLIGHTS A LICENSE
PLATE
LAMP

238 GY 18 C633 C634 238 GY 18 234 RD 18 C637


E E C
* LICENSE PLATE WIRING CONNECTORS 620 & 621 500 BK 18 LEFT
500 BK 18 C633 C634 500 BK 18 C637
ARE UTILIZED WHEN REAR LIGHTING IS LOCATED STOP/TAIL
OUTSIDE THE KICKPLATE AREA(I.E. KIDNEYS B B B LAMP
OR SIDEMETAL) 230 BR 18 C633 C634 230 BR 18 230 BR 18 C637
C C A
BACK-UP
ALARM 236 LG 18 C633 C634 236 LG 18
(OPTIONAL) A A 500 BK 18 C642
234 RD 18 C633 C634 234 RD 18 B
LEFT
D D 238 GY 18 C642 TURN/TAIL
A LAMP
230 BR 18 C642
C

500 BK 18
500 BK 18 C638
238 YL 18 C112 C113 C1 C1 C611 C610 238 YL 18 B LEFT
14 14 N N E E BACK-UP
236 LG 18 C638 LAMP
236 LG 16 C112 C113 C1 C1 C611 C610 236 LG 16 C
15 15 O O A A
POWER C1 C1 C611 C610 230 BR 16 230 BR 18 C621 * LICENSE
DISTRIBUTION L L C C A PLATE
(SHEET 9) LAMP
(OPTIONAL)
C112 C1 C1 C1 C611 C610 234 RD 16
7 7 P P D D
C112 C1 C1 C1 C611 C610 232 DG 18 230 BR 18 C620 * LICENSE
1 1 M M B B
A PLATE
LAMP
(OPTIONAL)

234 RD 16
232 DG 18
236 LG 18 C636
RIGHT
C BACK-UP
500 BK 18 C636 LAMP
B

F
A

D
G
232 GY 18

C105
C105
C105
C105
C641
234 RD 18 C631 C632 234 RD 18
A RIGHT
D D 500 BK 18 C641 TURN/TAIL
236 LG 18 C631 C632 236 LG 18 LAMP
B
A A 230 BR 18 C641
230 BR 18 C631 C632 230 BR 18
C
C C
500 BK 16 500 BK 18 C631 C632 500 BK 18 230 BR 18 C635
B B A
232 DG 18 C631 C632 232 GY 18 500 BK 18 RIGHT
C635 STOP/TAIL
E E B LAMP
56 71 70 57 234 RD 18
GROUND C635
YL LB RD LG
TO FRAME C
RAIL
NAVISTAR
IP LICENSE
HARNESS PLATE
230 BR 18 C623 LAMP
A

Aeromaster on Navistar International—Body Wiring Manual


Rear Lamp Wiring Split Taillights 5823
Lights, Rear

Supplemental High Mount Stop Light (SHMSL)

234 RD 16 234 RD 16 234 RD 16 234 RD 16


C413 C412 C411 C410 C113 C112 C105 70 RD
SHMSL 13 13 13 13 7 7 A 1
LAMP NAVISTAR
(OPTIONAL) IP HARNESS

CLEARANCE LIGHTS C100

Aeromaster on Navistar International—Body Wiring Manual


Supplemental High Mount Stop Light (SHMSL)

CHMSL 58231015a25 SHEET 25

35
36
SPOTLIGHT/STROBE LIGHTS

where it applies.
ON/OFF

Because Utilimaster
C3 258 LB/WT 14 C410 C411 258 LB/WT 14 C412
7 8 those in your vehicle.
NOTE: These wiring

1 12 12 12
diagrams are a generic

C3 150 RD 14
sample. Details in these

information as a guideline
diagrams may differ from

for every vehicle. Use this


2

vehicle bodies, this manual


C3 257 LB 14 C410 C411 257 LB 14 C412
3 11 11 11

possible wiring configuration


6 3

cannot list and illustrate every


C3 280 LB/RD 18
manufactures many customized
8
C3 500 BK 18
7 LIGHTING
SPOTLIGHT/STROBE
SWITCH ON
DASH
(AUX. SW #3)
SECONDARY SWITCH

500 BK 18
GROUND
Lights, Spot, Scene, Flood, or Strobe

280 LB/RD 18
POWER DISTRIBUTION

150 RD 14
POWER DISTRIBUTION

ON/OFF

C302 256 DG/WT 14 C410 C411 256 DG/WT 14 C412


7 8 1 8 8 8
C302 110 PK/BK 14
2
2 254 DG 14 C410 C411 254 DG 14 C412 C413 254 DG 16
C302
3 9 9 9 9/11
6 3
C302 280 LB/RD 18
8
C302 500 BK 18
SPOTLIGHT/STROBE 7 * WIRE COLORS USED ON THIS OPTION MAY DIFFER
SWITCH ON BASED ON NUMBER OF OPTIONS ON THE UNIT
DASH
(AUX. SW #2)
PRIMARY SWITCH AUXILIARY SWITCH #2 (C302) IS THE PRIMARY SWITCH FOR THIS OPTION,
BUT IF THIS SWITCH IS ALREADY IN USE, THEN AUXILIARY SWITCH #3 (C303)
IS THE SECONDARY SWITCH.
500 BK 18
GROUND

280 LB/RD 18
POWER DISTRIBUTION

110 PK/BK 14
POWER DISTRIBUTION

Aeromaster on Navistar International—Body Wiring Manual


Spotlight Strobes 58231015a32 SHEET 32
HEATED MIRRORS

ON/OFF

C303 258 LB/WT 14 C410


7 8 1 12
C303 150 RD 14
Mirrors, Heated

2
2 257 LB 14 C410
C303
3 11
6 3 500 BK 16 500 BK 16
C303 280 LB/RD 18 LEFT RIGHT
8 HEATED HEATED
MIRROR 254 DG 16 254 DG 16 MIRROR
C303 500 BK 18
HEATED MIRRORS 7
SWITCH ON
DASH
(AUX. SW #3)
SECONDARY SWITCH

500 BK 18
GROUND

POWER DISTRIBUTION
280 LB/RD 18

150 RD 14

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POWER DISTRIBUTION

ON/OFF

C302 256 DG/WT 14 C410


7 8 1 8
C302 110 PK/BK 14
2
2 254 DG 14 C410 C411 254 DG 16
C302
3 9 9/12
6 3
C302 280 LB/RD 18
8
C302 500 BK 18 500 BK 16
GROUND
HEATED MIRRORS 7
SWITCH ON
DASH
(AUX. SW #2)
PRIMARY SWITCH
AUXILIARY SWITCH #2 (C302) IS THE PRIMARY SWITCH FOR THIS
OPTION, BUT IF THIS SWITCH IS ALREADY IN USE, THEN AUXILIARY
SWITCH #3 (C303) IS THE SECONDARY SWITCH.
500 BK 18
GROUND

280 LB/RD 18
POWER DISTRIBUTION

POWER DISTRIBUTION
110 PK/BK 14
Heated Mirrors 58231015a30 SHEET 3

37
38
POWER DISTRIBUTION

120 OR 120 OR INTERMITTENT


POWER
WIPER SYSTEM
FEED CONNECTOR
Power Distribution

IGNITION 110 PK/BK 110 PK/BK BACK UP


SWITCH IGNITION CAMERA SYSTEM
POWER POST

POWER 700 DB/WT 700 DB/WT


HEAT/VENT
FEED CONNECTOR CABLE CONTROL
STYSTEM

150 RD 150 RD
FUSE BLOCK DOME LIGHT

150 RD
CARGO LIGHTS

HEAT/VENT
280 LB/RD 280 LB/RD CABLE CONTROL
POWER
FEED CONNECTOR STYSTEM

280 LB/RD INTERMITTENT


WIPER SYSTEM

280 LB/RD
DOME LIGHT

280 LB/RD
CARGO LIGHTS

Aeromaster on Navistar International—Body Wiring Manual


58231292a10
TYPICAL ROOF WIRING

ON/ON

7 8
REAR
1
CARGO
SWITCH 2
Roof Wiring

(STANDARD UNIT)
3

DOOR
AJAR
DASH
SWITCH
FAN
(OPTIONAL)
(OPTIONAL)

CARGO
LIGHT
M

CHMSL
LAMP
(OPTIONAL)
CAB
LIGHT

CLEARANCE/I.D. LAMPS
CARGO
LIGHT

Aeromaster on Navistar International—Body Wiring Manual


CLEARANCE/I.D. LAMPS

222 YL 16
C415 231 BR/WT 16
A
C413 255 OR 16
8
222 YL 16
220 YL/WT 16
350 BK/PK 18
234 RD 18
231 BR/WT 16

224 YL/BK 16

C413 257 RD 16
9
C413 224 YL/BK 16
TO
"A" PILLAR 1
HARNESS

222 YL 16

C413 220 YL/BK 16


2
C413 350 BK 16
7
C413 234 RD 16
13
C413 231 BR/WT 16
6

INDICATES OPTION WIRING

Roof Wiring 58231015a20 SHEET 20

39
STEREO SYSTEM WIRING

40
150 RD 16 C410 C411 150 RD 16 C412 C413 YL
POWER 10 10 10 10
DISTRIBUTION 180 PK 16 C410 C411 180 PK/BK 18 C412 C413 RD
15 15 15 15

BK
Stereo System

BK BK

WT GY

SONY
STEREO
LEFT EXR-14 RIGHT
SPKR SPKR

C413 RD
10
C413 PK/BK
15
BK

BK/WT BK/WT

DB DG

STEREO
SONY
EXR-10,XR-2100,XR-2390
LEFT & FLEET SPEC CRC-2500 RIGHT
SPKR SPKR

Stereo 58231015a23 SHEET 23

Aeromaster on Navistar International—Body Wiring Manual


SWITCHES

C301 222 YL/BK 18 C410 C411 222 YL/BK 18 C412


6 1 1 1
ON/ON
C301 224 YL/WT 14 C410 C411 224 YL/WT 14 C412
1 3 3 3
Switches

8 7
C301 150 RD 14
1 2
MASTER LIGHT
SWITCH C301 220 YL 14 C410 C411 220 YL 14 C412
2 3 2 2 2
(BATTERY
POWER) C301 500 BK 18
3 6
7
C301 280 LB/RD 18
8

ON/ON C302 256 DG/WT 14 C410 C411 256 DG/WT 14 C412


1 8 8 8
8 7 C302 110 PK/BK 14
2
AUXILiARY 1
SWITCH 2 C302 254 DG 14 C410 C411 254 DG 14 C412
(IGNITION 3 9 9 9
2
POWER)
C302 500 BK 18
3 6 7
C302 280 LB/RD 18
8

C100
K
ON/OFF/ON C303 258 LB/WT 14 C410 C411 258 LB/WT 14 C412
1 12 12 12

Aeromaster on Navistar International—Body Wiring Manual


8 7 C303 150 RD 14
AUXILIARY 2
1
SWITCH 3 C303 257 LB 14 C410 C411 257 LB 14 C412
(BATTERY 3 11 11 11
POWER) 2
C303 500 BK 18 C100
3 6 7 H
C303 280 LB/RD 18
8

WIRE COLOR TO LOAD FUNCTION MAY VARY, BASED


ON OPTIONS CHOSEN AND NUMBER OF SWITCHED
ON/OFF C304 253 DB/WT 14 C100 OPTIONS CHOSEN.
1 U REFER TO SHEETS 28 THRU 32 FOR STANDARD
8 7 C304 110 PK/BK 14 OPTION WIRING.
AUXILIARY 2 SPECIAL REQUESTED OPTIONS MAYBE WIRED DIFFERENTLY
SWITCH 4 C304 255 DB 14 C100 THAN SHOWN ON THIS OR OTHER SHEETS.
(IGNITION 3 V
POWER) 2
C304 500 BK 18
3 7
C304 280 LB/RD 18 500 BK 18
PANEL LAMPS GROUND
8

SWITCHS SHOWN ARE FOR VISUAL FUNCTIONAL


REASONS ONLY. THEY ARE NOT NECESSARILY
MATCHED TO THE CONNECTOR # SHOWN.

280 LB/RD 18 TYPICAL SWITCH USAGES:


ON/OFF — LIGHTING, HTD MIRRORS, POWER VENTS
ON/ON — 3-WAY CARGO LIGHT SWITCHING ONLY
POWER 150 RD 14 ON/OFF/ON — AUX. HEATERS, DASH FANS, (2 SPEED LOADS)
DISTRIBUTION
110 PK/BK 14
Switches 58231015a11 SHEET 1

41
POWER VENT

42
ON/OFF

C303 258 LB/WT 14 C410 C411 258 LB/WT 14 C412


7 8 1 12 12 12
C303 150 RD 14
Vent, Powered

2
2 257 LB 14 C410 C411 257 LB 14 C412
C303
3 11 11 11
6 3
C303 280 LB/RD 18
8
C303 500 BK 18 POWER
POWER VENT 7 VENT
SWITCH ON
DASH
(AUX. SW #3) M
SECONDARY SWITCH

500 BK 18
GROUND

280 LB/RD 18
POWER DISTRIBUTION

150 RD 14
POWER DISTRIBUTION

ON/OFF

C302 256 DG/WT 14 C410 C411 256 DG/WT 14 C412


7 8 1 8 8 8
C302 110 PK/BK 14
2
2 254 DG 14 C410 C411 254 DG 14 C412 C413 254 DG 16
C302
3 9 9 9 9/11
6 3
C302 280 LB/RD 18
8
C302 500 BK 18
POWER VENT 7
SWITCH ON * WIRE COLORS USED ON THIS OPTION MAY DIFFER
DASH BASED ON NUMBER OF OPTIONS ON THE UNIT.
(AUX. SW #2)
PRIMARY SWITCH
AUXILIARY SWITCH #2 (C302) IS THE PRIMARY SWITCH FOR THIS OPTION,
BUT IF THIS SWITCH IS ALREADY IN USE, THEN AUXILIARY SWITCH #3 (C303)
500 BK 18
GROUND IS THE SECONDARY SWITCH.
280 LB/RD 18
POWER DISTRIBUTION
110 PK/BK 14
POWER DISTRIBUTION

Aeromaster on Navistar International—Body Wiring Manual


Power Vent 58231015a29 SHEET 29
Standard

WIPER SYSTEM (STANDARD)


WIP

MOT
Wiper System

WT
C 120 OR 16 C C
C1 120 OR 16 C C 120 OR 16
A 4 4
4 A A
C DG L
WT B
C 890 VT 18 C C
C1 890 VT 18 C C 890 VT 18 C RD H
B 2 2
2 B B A M
C BK B
C

WT C YL P
C 820 DG 16 C C
C1 820 DG 16 C C 820 DG 16 D G
D 5 5
5 F F

75228-07
WT
C 830 RD 16 C C 830 RD 16 C C 830 RD 16 C BR

WIPER SWITCH
E 3 3 E E A

WT C 840 GY 16 C C 840 GY 16 C C 840 GY 16


F 6 6 G G

Aeromaster on Navistar International—Body Wiring Manual


890 VT 18 C
A

M
500 BK 18 C
GROUND B

WIPER POWER WASHER


PUMP

120 OR 16 - WIPER POWER

510 BK/WT 16 - GROUND

820 DG 16 - LOW SPEED

830 RD 16 - HIGH SPEED

840 GY 16 - PARK

890 VT 18 - WASHER PUMP

Wiper System (Standard) 58231015a12

43
44
Wiper System
Intermittent Option

500 BK 16
GROUND

WIPER PWR

WIPER
RD 120 OR 16 120 OR 16 120 OR 16
MOTOR

DG L

BR 890 VT 18 890 VT 18 890 VT 18 H


RD
M
BK B

YL P
YL 820 DG 16 820 DG 16 820 DG 16 G

WIPER SWITCH
WT 830 RD 16 830 RD 16 830 RD 16 BR

COLE HERSEE INTERMITTENT


DB 840 GY 16 840 GY 16 840 GY 16

890 VT 18

120 OR 16 - WIPER POWER

510 BK/WT 16 - GROUND

820 DG 16 - LOW SPEED


M
830 RD 16 - HIGH SPEED 500 BK 18
GROUND
840 GY 16 - PARK

890 VT 18 - WASHER PUMP WASHER


PUMP

58231015a13x2

Aeromaster on Navistar International—Body Wiring Manual


890 VT 120 OR
170 RD
170 RD 120 OR
710 DG 234 RD 234 RD 890 VT
700 DB/WT 110 PK/BK 710 DG
110 PK/BK 232 DG 238 YL
255 DB 236 LG
A R 236 LG R A 230 BR
238 YL
830 RD 700 DB/WT
C B Q P P Q B C
238 YL
D O O D
V S S V 830 RD
N E
HGF E
E N
U T T U 820 DG A B C D
F M M F
Connectors

G H K L L K H G
253 DB/WT 232 DG 236 LG
I J J I 234 RD
232 DG 230 BR 280 LB/RD
820 DG 230 BR 180 PK
840 GY
C105
258 LB/WT 510 BK/WT POWER FEED CONN.
840 GY
12066195
257 LB 510 BK/WT
C101
C100 COWL CONNECTOR
COWL CONNECTOR 12020005
12020991

150 RD
150 RD
890 VT 150 RD
890 VT 110 PK/BK
830 RD 200 DB 830 RD
130 RD (NOT USED) 500 BK 280 LB/RD
840 GY 3 2 1
120 OR 3 2 1 120 OR
840 GY 120 OR
C D 1 2 3 6 5 4
6 5 4 700 DB/WT
700 DB/WT B E 180 PK 4 5 6 231 BR/WT 9 8 7

Aeromaster on Navistar International—Body Wiring Manual


A F 9 8 7 520 BK
234 RD
7 8 9 350 BK/PK 12 11 10
820 DG 520 BK
230 BR
180 PK 15 14 13
820 DG
510 BK/WT 510 BK/WT 236 LG 232 DG
C106 (NOT USED)
POWER FEED CONN. C111 238 YL 130 RD
12064754 C110 POWER FEED #1 CAP
POWER FEED #1 PLUG 770028-1 C112
770021-1
POWER FEED #2(PLUG)
770023-1

150 RD
110 PK/BK 170 RD

280 LB/RD 500 BK 230 BR


233 DG 230 BR
1 2 3

4 5 6 700 DB/WT 500 BK


235 YL 233 DG 233 GY
240 LG/BK 500 BK
231 BR/WT 7 8 9 B
B B
234 RD 10 11 12 350 BK/PK E A A
A E E
710 DG 18 13 14 15 230 BR C D D C
(NOT USED) D C
236 LG 242 RD/BK
230 BR 240 LG/BK
232 DG 240 LG/BK
130 RD 242 RD/BK 242 RD/BK
238 YL
C113 C200 C203
FORWARD LAMP DIST C202
POWER FEED #2(CAP) RT HEADLAMP FEED RT HEADLAMP DIST
770030-1 12034342 12034342
12065158

Connector Loading Diagrams (1 of 5) 58231015a02 SHEET 2

45
NOTE: All connectors are shown in the load (wire lead insertion) position.
230 BR 230 BR
500 BK

46
235 GY 830 RD 820 DG
500 BK
235 YL 500 BK
B
B B
A A B
E A E A

C D D C
(continued)

D C
890 VT
Connectors

242 RD/BK 120 OR


240 LG/BK 840 GY
242 RD/BK 240 LG/BK
C207
C206
C204 WIPER MOTOR
C205 WASHER PUMP
LT HEADLAMP FEED 12015798
LT HEADLAMP DIST 480115-1
12065158 12034342

500 BK 500 BK
280 LB/RD
242 RD/BK 240 LG/BK 280 LB/RD
510 BK/WT 710 DG 8 7
8 7
224 YL/WT 256 DG/WT

150 RD 110 PK/BK 1 4


1 4
A A A B 220 YL 222 YL/BK 254 DG

6 3 6
3
C208 C209
WIPER MOTOR A/C JUMPER C210
12015791 12015791 DRL (DAYTIME RUNNING)
12015792 C301 C302
AUXILIARY SW(BATTERY) AUXILIARY SW(IGNITION)
999-16716.001 999-16716.001

500 BK 500 BK
530 BK 700 DB/WT 500 BK
280 LB/RD 280 LB/RD
8 7 8 7 4 280 LB/RD 710 DG
1 254 YL D C
258 LB/WT 253 DB/WT 256 RD
3 710 DG 2 280 LB/RD
150 RD 1 4 110 PK/BK 1 4
2 700 DB/WT 3 530 BK A B
257 LB 255 DB
1 4

3 6 3 6

C331 C340
C330 HVAC CONN.(SCS) AUX. HTR(SCS)
C303 C304 HVAC CONN. 770209-1 12015024
AUXILIARY SW(BATTERY) AUXILIARY SW(IGNITION) 770019-1
999-16716.001 999-16716.001

Aeromaster on Navistar International—Body Wiring Manual


NOTE: All connectors are shown in the load (wire lead insertion) position. Connector Loading Diagrams (2 of 5) 58231015a03 SHEET 3
220 YL 220 YL
220 YL
222 YL/BK 224 YL/WT 224 YL/WT 222 YL/BK
200 DB 224 YL/WT 222 YL/BK 200 DB
(NOT USED) 231 BR/WT
231 BR/WT (NOT USED)
1 2 3 200 DB 3 2 1
254 DG 231 BR/WT (NOT USED) 350 BK/PK
3 2 1
4 5 6 350 BK/PK 6 5 4
520 BK 520 BK
(continued)

6 5 4 (NOT USED)
(NOT USED) 7 8 9 520 BK 9 8 7
Connectors

350 BK/PK (NOT USED) 9 8 7 254 DG


10 11 12 256 DG/WT 12 11 10 256 DG/WT
150 RD 254 DG 12 11 10 256 DG/WT 258 LB/WT
13 14 15 258 LB/WT 15 14 13 150 RD
258 LB/WT
15 14 13 150 RD
234 RD 180 PK 180 PK/BK 234 RD
180 PK/BK 234 RD
500 BK 257 LB 500 BK 257 LB
500 BK 257 LB
C410
"A" PILLAR(DASH)
770029-1
C411 C412
"A" PILLAR(PILLAR) "A" PILLAR(PILLAR)
770022-1 770022-1

220 YL/BK

234 RD
224 YL/BK
231 BR/WT
1 2 3 232 DG
231 BR/WT
231 BR/WT 236 LG
350 BK 4 5 6 238 YL
1 4
7 8 9 230 BR

Aeromaster on Navistar International—Body Wiring Manual


STEREO (BATT) 2 5
10 11 12
3 6
13 14 15
C414
"A" PILLAR(ROOF) 500 BK
234 RD MOLDED CONN. C415
"A" PILLAR(ROOF)
STEREO (IGN) MOLED CONN.
C418
C413 INTERIOR ROUTED
"A" PILLAR(ROOF) REAR LIGHTING
770029-1 770020-1

234 RD 232 DG 120 OR 840 GY 830 RD


890 VT 120 OR
238 YL
236 LG 820 DG
4 1 230 BR 830 RD
840 GY A B C D
5 2
E F G H
6 3
A B C D E F

890 VT 820 DG
500 BK

C510 C510
C419
STD WIPER SWITCH INTERMITTENT
INTERIOR ROUTED
06288539 WIPER SWITCH
REAR LIGHTING
02965972
770027-1

NOTE: All connectors are shown in the load (wire lead insertion) position.

47
Connector Loading Diagrams (3 of 5) 58231015a04 SHEET 4
230 BR 230 BR 230 BR 230 BR
232 DG 232 DG

48
236 LG
238 YL 238 YL
236 LG
B B A A A A
A E
E A

C D D C
(continued)

C620 C621 C622 C623


234 BK LICENCE PLATE LAMP LICENCE PLATE LAMP LICENCE PLATE LAMP LICENCE PLATE LAMP
Connectors

230 BR 234 RD 230 BR 12010996 12010996 12010996 12010996


C610 C611
REAR LAMP DIST REAR LAMP FEED
12065158 12034342

500 BK 230 BR 18 500 BK


500 BK 500 BK
500 BK
236 LG 238 GY
236 LG 232 GY 238 YL 236 LG
232 DG 236 LG
B A B
B B
B E A C
E A A E
A E
C D
C D D C
D C
li
234 RD
234 RD 230 BR 234 RD
230 BR 234 RD
234 RD
230 BR
230 BR
C631
RT REAR LAMP FEED C632 C633
C634 C635
12034342 RT REAR LAMP DIST LT REAR LAMP FEED
LT REAR LAMP DIST RT STOP/TURN/TAIL
12065158 12034342
12065158 MOLDED CONN.

500 BK 230 BR 500 BK 500 BK 500 BK 230 BR 500 BK


230 BR

A B A B A B A B A B
C C C C C

li li li li li
236 LG 234 RD 236 LG 232 GY 238 GY

C636 C637 C638 C641 C642


RT BACK-UP LAMP LT STOP/TURN/TAIL LT BACK-UP LAMP RT STOP/TURN/TAIL LT STOP/TURN/TAIL
MOLDED CONN. MOLDED CONN. MOLDED CONN. MOLDED CONN. MOLDED CONN.

Aeromaster on Navistar International—Body Wiring Manual


NOTE: All connectors are shown in the load (wire lead insertion) position. Connector Loading Diagrams (4 of 5) 58231015a05 SHEET 5
240 LG/BK 500 BK 240 LG/BK 240 LG/BK 500 BK

500 BK
242 RD/BK
B A B A
(continued)

C ABC C
Connectors

242 RD/BK 242 RD/BK


C711
C710 LT RECT. INCAD. HDLP
C710 12077384
RT HALOGEN HDLP
RT RECT. INCAD. HDLP
12048369
12077384

240 LG/BK
230 BR 500 BK 230 BR 500 BK
500 BK
242 RD/BK
A B A B

C C

A BC li li
233 GY 235 GY

Aeromaster on Navistar International—Body Wiring Manual


C712 C713
C711 RT FRONT TURN LAMP LT FRONT TURN LAMP
LT HALOGEN HDLP MOLDED CONN. MOLDED CONN.
12048369

231 BR/WT
235 GY 230 BR
233 GY 230 BR 230 BR
87

86 87a 85
B A B A

30
500 BK

170 RD
C714 C715
RT FRONT SDMRKR LAMP LT FRONT SDMRKR LAMP C720
MOLDED CONN. MOLDED CONN. CLEARANCE LIGHT RELAY
3-334-485-007

NOTE: All connectors are shown in the load (wire lead insertion) position. Connector Loading Diagrams (5 of 5) 58231015a06 SHEET 6

49
Reporting Safety Defects
United States Only Canada Only
If you believe that your vehicle has a defect that If you believe that your Canadian-registered
could cause a crash, injury, or death, you should vehicle has a defect that could cause a crash,
immediately inform the National Highway Traffic injury, or death, you should immediately inform
Safety Administration (NHTSA), in addition to Transport Canada, in addition to notifying Utili-
notifying Utilimaster. master.
If NHTSA receives similar complaints, it may To contact Transport Canada, call 800-333-0510 (or
open an investigation, and if it finds that a safety 613-993-9851 in the Ottawa region) or write to:
defect exists in a group of vehicles, it may order a Transport Canada
recall and remedy campaign. However, NHTSA Motor Vehicle Defect Investigation
cannot become involved in individual problems PO Box 8880
between you, your dealer, or Utilimaster. Ottawa, Ontario, K1G 3J2
To contact NHTSA, you may either call the Auto
Safety Hotline toll-free at 800-424-9393 (or 202-
366-0123 in the Washington, D.C., area) or write to:
NHTSA
U.S. Department of Transportation
400 Seventh Street
Washington, DC 20590
You can also obtain other information about
motor vehicle safety from the Hotline.

50 Aeromaster on Navistar International—Body Wiring Manual


More Information
Download Files
Many support documents, including those described here, are downloadable (as
Adobe® Acrobat® PDF files) from our award-winning web site at
www.utilimaster.com. Click on the Technical Manuals button, to access
the download page. To view the files you must have the Adobe Acrobat
Reader version 4.0 or higher installed on your computer. Acrobat readers are
available free for all leading computer operating systems on the Adobe web site
(www.adobe.com). Browse our site for more information about
Utilimaster and its products

Utilimaster Detailed Parts, Service, and Wiring Manuals


Find parts, routine maintenance procedures, troubleshooting, proper adjustment
methods, vehicle repair, aftermarket upgrades, and much more in the
Aeromaster parts, service, and wiring manuals.

ACE (Access Control and Entry) System


See the ACE Service Manual (P/N 03102977) for information about Access
Control and Entry System operation, programming, and troubleshooting.

Vehicle Access Control System (VACS)


To obtain the Vehicle Access Controls System Operation and Service Manual
(P/N 03102103) refer to your VACS Operator’s Guide or contact Utilimaster’s
Customer Service Department.

Contact Utilimaster
Contact Utilimaster Customer Service by using one of the following
methods,
• Call 800-237-7806 (or 574-862-3219).
• Fax to 574-862-7637.
• Email to CustSvc@Utilimaster.com.
• Mail to the following address:
Utilimaster
Attn: Customer Service Department
65528 State Road 19
P.O. Box 585
Wakarusa, IN 46573-0585
U.S.A.

Aeromaster on Navistar International—Body Wiring Manual 51


Index
D
Door ajar system 16
E
A Email 51
A/C. See HVAC F
Accessory outlet 14
ACE System 51 Fan, dash 17, 39
Address Federal Certification Label 7
National Highway Traffic Safety Flood light 36
Administration 50 Fuses 10
Transport Canada 50 G
U.S. Department of Transportation 50
Utilimaster Glossary of terms 51
Customer Service 51 Grounding system 18
Air conditioning. See HVAC H
Alarm, back-up 33, 34
Auxiliary heater. See Heater Harness layout 13
Heated mirrors 37
B Heater 19, 20, 23. See also HVAC
Back-up. See Alarm and Light HVAC 21, 22, 24. See also Heater
Back-up camera 15 L
Battery
Access 9 Light
Disconnecting 9 Back-up 33, 34
Blower. See Heater Cab 39
Body serial number 7 Cargo 25, 26, 27, 28, 39
Center High Mount Stop Light
C (CHMSL). See Light: Supplemental High
Camera, back-up 15 Mount Stop Light
Cautions 8 Clearance 29, 30, 39
CHMSL (Center High Mount Stop Daytime running (DRL) 32
Light). See Light: Supplemental High Dome 25
Mount Stop Light Flood 36
Cigarette lighter. See Accessory outlet Forward 29, 30
Circuit number identification 12 Front 32
Codes 11 Head light 31, 32
Color codes 11, 12 HVAC panel 24
Connectors 45, 46, 47, 48, 49 License plate 33, 34
Master three-way switch 25, 26, 27, 28
Rear 33, 34

52 Aeromaster on Navistar International—Body Wiring Manual


S
Roof 39 Safety
Scene 36 Considerations 8
Side marker 31, 32 Defects, reporting 50
Spot 36 Scene light 36
Stop 33, 34 Serial number 7
Strobe 36 SHMSL (Supplemental High Mount Stop
Supplemental High Mount Stop Light 35, 39
(SHMSL) 35, 39 Spotlight 36
Tail 33, 34 Stereo system 40
Turn signal 31, 32, 33, 34 Strobe light 36
Supplemental High Mount Stop Light
M
(SHMSL) 35, 39
Mirrors, heated 37 Switches 41
Auxiliary 41
N
Cargo 25, 26, 27, 28
Notes 8 Dash 17
Numbers Heated mirror 37
Body serial number 7 Power vent 42
Phone 50, 51 Spotlight 36
VIN 7 Strobe 36
Work order 7 Symbols 11
O U
Outlet. See Accessory outlet Utilimaster Body Serial Number 7
Utilimaster Customer Service 51
P
Utilimaster Glossary of Terms 51
Panel, HVAC Control 24
V
Phone numbers
NHTSA 50 VACS 6, 51
Transport Canada 50 Vent, powered 42
Utilimaster Customer Service 51 VIN 7
Power distribution 38
W
R
Warnings 8
Relays 10 Web site 3, 51
Revision 3 Wiper system
Roof wiring 39 Intermittent 44
Standard 43
Work order number 7

Aeromaster on Navistar International—Body Wiring Manual 53


54 Aeromaster on Navistar International—Body Wiring Manual
Aeromaster on Navistar International—Body Wiring Manual 55
Aeromaster on Navistar International
Body Wiring Manual

Part Number: 03101939


Utilimaster Corporation, 65906 State Road 19, P.O. Box 585, Wakarusa, Indiana, 46573-0585, USA
©

56 Aeromaster on Navistar International—Body Wiring Manual