ELECTRICAL SYSTEM GROUP 700

ELECTRICAL SYSTEM
1. INTRODUCTION
The entire electrical system operates on a 12-volt
system and is supplied by two 12-volt batteries hooked-
up in parallel. The alternators, driven off the engine,
have the capability of delivering 12-volts, high
amperage, for the vehicle electrical system. The
batteries are mounted in a battery box located inside the
RH rear engine compartment. The master switch must
be ON in order to start the engine or to operate electrical
equipment in the vehicle. The vehicle’s electrical circuits
are protected against overloads by manual reset circuit
breakers (head light and wiper circuit breakers are
automatic reset), located inside the cab power
distribution panel. See the cab power distribution panel
drawing in the appendix of this manual. Cab wiring is
routed through an opening on the cab floor to connect to
the chassis wiring. A junction panel, located inside the
cab, has six multiple plug connectors which serve to
connect the cab wiring to the chassis wiring. Electrically
operated components and vehicle accessories include:
headlights, taillights, identification lights, turn signals,
spotlights, cab interior and compartment lighting,
instrument and control lighting, emergency beacons,
engine starting motor, sire/speaker, agent system
solenoid valves, gauges, instrument senders and
warning devices, heater/defroster blower, and water and
foam tank level light systems. For detail of electrical
component connection and operation, refer to the
electrical system schematic in the appendix of this
manual.
2. CHARGING AND STARTING CIRCUITS
The 12-volt electrical starting system power is provided
by two 12-volt batteries connected in parallel. The
alternators have the capability of delivering 12-volt
power for the vehicle’s electrical system and maintaining
the charge of both batteries.
The engine starting electrical circuit incorporates a
series of switches which must close in order to engage
the cranking motor. The system is designed to ensure
operator safety and preclude mechanical damage to the
engine. The vehicle master switch must be in the ON
position prior to any starting operations. With the master
switch on, four switches must be closed before engine
cranking begins. The ignition switch must be ON, the
main transmission shift lever must be in neutral, and the
engine start/prime switch must be closed. The normally
closed, fuel pressure switch, remains closed until the
engine is running; then fuel pressure opens the switch,
preventing starter engagement while the engine is
running. The starter relay enables current from the 12-
volt system to power the cranking motor.
The fuel pressure switch opens when the fuel pressure
reaches 10 psi. The starter relay and starting motor with
solenoid, are located on the right hand side of the
engine. For further details, refer to the electrical system
schematic in the appendix of this manual.

12 Volt
System

Ignition
Switch Neutral Engine
Safety Starting Fuel
Switch N.O. Switch Pressure
Swith Open
at 10 PSI

Magnetic
Solenoid
Switch

To Magnetic
Starting Switches

Figure 1. Engine Starting Circuit

700-47, Page 1
GROUP 700
3. BATTERY MAINTENANCE
CAUTION
If welding on the vehicle, disconnect the
batteries, then reconnect the wire ends positive
to positive and negative to negative to
complete the ground loop. Failure to do so
could cause malfunctions in electronic
equipment mounted on the vehicle.
Alternators, radios, electronic speedometers
and tachometers, electronic controls, and any
solid state equipment, are especially sensitive
to welding without the vehicle electrical system
grounded.
Figure 2. Welding Caution Label
Figure 3. Battery Caution Label
CAUTION
Hydrogen gases are produced during normal
battery operation or charging. Sparks or flame
can cause this to ignite and explode, if they are
brought near vent openings. Sulfuric acid in
battery can cause serious burns, if spilled on
skin or in eyes. Flush or wash away
immediately with clear water.
CAUTION
Place a small piece of tape or cloth over filler
cap vent openings to prevent cleaning solution
from entering battery.
700-47, Page 2
ELECTRICAL SYSTEM
NOTE
A battery that constantly requires addition of
water is likely being overcharged.
Batteries will give the best service and maximum lift if
they are kept as close as possible to maximum charge.
The procedures outlined below will help to prevent early
failure of batteries:
1. Check electrolyte level frequently. Maintain
electrolyte level 1/4 to 1/2-inch above the top of
the separators. Use distilled water in areas
where water has a high mineral content. Do not
over-fill.
2. Use a hydrometer to check the battery
electrolyte solution.
3. Make sure that the vent holes in the filler caps
are clear of obstruction.
4. Clean battery posts, cable terminals, battery top,
and hold-down clamps with a solution of sodium
bicarbonate, 1/2-pound to a gallon of warm
water. Use a fiber bristle brush to scrub
corrosive deposits away.
5. After cleaning and drying thoroughly, apply a
thin coating of vaseline or automotive grease to
the battery posts and cable terminals to inhibit
further corrosion.
6. Keep cable terminals tight on posts and well
secured to the cables at all times.
7. A load test should be made on a battery that
discharges very rapidly in use. This test will
determine whether the battery is in poor
condition, or if the cause is elsewhere within the
electrical system.
ELECTRICAL SYSTEM GROUP 700

4. POWER DISTRIBUTION PANELS

There are three power distribution panels on the vehicle
that house all of the key vehicle electrical components.
See Figure 1 for the location of each panel and the
following sections for panel darwings and component
information. See the Appendix of this manual for a
schematic of each power panel.

1 2

1 2

1. Cab power distribution panel

2. Body power distribution panel
3. Engine power distribution panel
Figure 4.

700-47, Page 3
GROUP 700 ELECTRICAL SYSTEM

4.1 Cab Power Distribution Panel. The cab power See Figure 5. Remove the four screws from the cover
distribution panel is located in the cab on the back wall. and remove the cover to access the panel.

Figure 5. Cab Power Distribution Panel

700-47, Page 4
ELECTRICAL SYSTEM GROUP 700

Table 1. Cab Power Distribution Panel Circuit Description Rating

Ignition #1 Heater/AC 30 AMP
Circuit Description Rating
Ignition #2 Heater/AC 30 AMP
Battery #1 Eng ECU Diag 7.5 AMP
Ignition #3 Misc. Dash 25 AMP
Battery #2 Master/IGN 15 AMP
Ignition #4 Suspension (Hendrickson) 7.5 AMP
Battery #3 Dome Lights 10 AMP
Ignition #5 Suspension 25 AMP
Battery #4 Headlight DRL/MRKR 10 AMP
Ignition #6 Water/Foam 7.5 AMP
Battery #5 Headlight DRL 15 AMP
Ignition #7 Roof Turret 7.5 AMP
Battery #6 Misc Dash 25 AMP
Ignition #8 Bumper Turret 7.5 AMP
Battery #7 Test Lights 10 AMP
Ignition #9 Interaxle/Shifter 7.5 AMP
Battery #8 Accessory Outlet 10 AMP
Low Oil/HI Temp/ Low
Battery #9 Accessory Outlet 10 AMP Ignition #10 7.5 AMP
Coolant Lights
Master #1 Misc Dash 25 AMP Ignition #11 ABS 10 AMP
Master #2 Auxiliary Agent 7.5 AMP Ignition #12 ABS 10 AMP
Master #3 Spotlights 15 AMP Ignition #13 Low Voltage 7.5 AMP
Master #4 Turret Lights 20 AMP Ignition #14 CTI 15 AMP
Master #5 Fog Lights 15 AMP Ignition #15 Neutral Start 7.5 AMP
Master #6 Driving Lights 15 AMP
Master #7 Cab Fans 10 AMP
Master #8 Wipers 25 AMP
Master #9 Electric Horn 15 AMP
Master#10 Siren/PA 20 AMP
Master #11 Flashers 15 AMP
Master #12 Water/Foam Level Lights 10 AMP
Master #13 Mirrors 15 AMP
Master #14 Spot Lights 15 AMP
Master #15 Clearance Lights 10 AMP
Master #16 Work Lights 10 AMP
Master #17 Headlights 15 AMP
Master #18 Compartment Lights 15 AMP
Master #19 Video Reset 15 AMP
Master #20 Dash Lights 15 AMP
Master #21 Open Compartment 10 AMP
Master #22 Right-Hand Power Window 15 AMP
Master #23 Left-Hand Power Window 15 AMP

700-47, Page 5
GROUP 700 ELECTRICAL SYSTEM

4.2 Body Power Distribution Panel.

T1

T2

T3
L E D1 LED2 LED3 LED4 LED5
R1 R3

D1 D2

CB1

CB2

CB3
87 87 87 D3 D4
R2 CON1

R4
D5 D6

R5
87A 87A 87A
10 12
D7 D8

STRUCT

SPARE

SPARE
85 86 85 86 85 86
D9 D10
D11 D12
30 30 30 1 3 D13 D14
D15 D16

RLY1 C B4 RLY2 RLY3 C B5 D17 D18

NEUTRAL SAFETY LED6 R6 R7 LED7

T4 T5 T6 UNDERTRUCK OPEN
LED8 R8 R9 LED9
LH HANDLINE RH HANDLINE
DELUGE SIDE DISCHARGE LED10 R10 R11 LED11
FLOW SWITCH BMPR TURRET RF TURRET
LED12 R12 R13 LED13
FRT HANDLINE OPEN
LED14 R14 R15 LED15
T7 T8 T9 T10 T11 T12 T14 T16 PUMPING SPD SIDE DISCH
CB6

CB7

CB8

CB9

D19

D20

D21
SPARE
SPARE

SPARE

SPARE

T13 T15 T17 OSHKOSH TRUCK CORP.

P/N 3384771
IGNITION REV. E
POWER DATE:

GROUND LIGHTS SPARE 1 SPARE 2 SPARE 3 S P A RE 4

86 85 86 85 86 85 86 85
30 30 30 30
T18

T20

T23

T25

T28

T30

T33

T35
T19 T24 T29 T34
RLY_ CB__

30 30 30 30 30

86 85 86 85 86 85 86 85 86 85

87 A 87A 87A 87A 87A

R1 7

87 87 87 87 87

RLY4 RLY5 RLY6 R L Y7

R 18
L ED1 7 L E D1 8
T21

T22

T26

T27

T31

T32

T36

T37
NO NC NO NC NO NC NO NC
T54

T55

STRUCTURAL
THROTTLE
T44

T45

30

BATTERY
C B1 0

C B1 1

C B1 2

C B1 3

C B1 4

C B1 5

C B1 6

C B1 7

C B1 8

C B1 9
86 85
POWER

WINTERIZATION
87A

LEVEL LTS TEST

COMPT LTS

SPARE

SPARE

SPARE

SPARE
LEVEL LTS

D2 2

R1 6
SPARE

SPARE

87

RLY8

MASTER LED16
POWER
T46

T47

T48

T49

T38 T39 T40 T41 T42 T43 T50 T51 T52 T53

DECK LIGHTS LH WORK LTS RH WORK LTS WINT FANS WINT FANS

WINT RUN WINT POWER

RLY9 CB20 RLY10 CB21 RLY11 CB22 RLY12 RLY13 RLY14 CB2 3 RLY15 C B2 4

30 30 30 30 30 30 30

86 85 86 85 86 85 86 85 86 85 86 85 86 85

87 A 87A 87A 87A 87A 87A 87A

R27

R29

GROUND
R17

R19

R21

R25

87 87 87 87 87 87 87

R 18 R20 R22 R24

L ED1 7 L E D1 8 LED19 LED20 LED21 LED22 LED24 LED25 R26 LED26 LED27 R28 LED28 LED29 R30 LED30
T54

T55

T56

T57

T58

T59

T60

T61

T62

T63

T64

T65

T66

TST 290-0317

Figure 6. Body Power Distribution Panel

700-47, Page 6
ELECTRICAL SYSTEM GROUP 700

Table 2. Body Power Distribution Panel

Circuit Description Rating
Battery #1 Level Lights Test 7.5 AMP
Battery #2 Winterization 30 AMP
Battery #3 Winterization Fans 15 AMP
Battery #4 Winterization Fans 15 AMP
Master #1 Right-Hand Work Lights 15 AMP
Master #2 Left-Hand Work Lights 15 AMP
Master #3 Deck Lights 15 AMP
Master #4 Compartment Lights 15 AMP
Master #5 Level Lights 7.5 AMP
Master #6 Ground Lights 15 AMP
Ignition #1 Deluge 20 AMP
Ignition #1
Structural 7.5 AMP
(N.S.)
Ignition #2
Handlines 7.5 AMP
(N.S.)

700-47, Page 7
GROUP 700 ELECTRICAL SYSTEM

4.2.1 Engine Power Distribution Panel.

T1

T2

T3

T4

T5

T_
D1

LED1 R1 LED2 LED3 R3 LE D4 LED5 R5 LED6 LE D 7 LED8 LED9 LED10 LED11

87 87 87 87 87 87 87

R6

R1 0
LED12

R8

R 11
R2

R4

R9
8 7A 87A 8 7A 8 7A 87 A 87 A 87 A

85 86 85 86 85 86 85 86 85 86 85 86 85 86

87

R7

R 12
30 30 30 30 30 30 30 87A

85 86

R L Y1 RLY2 RLY3 RLY4 RLY5 RLY6 RLY7

HIGH IDLE HIGH IDLE PUMPING SPEED D2
STRUCTURAL 30
KICKOUT SPEED
CUTOUT D3

D4
D5
D6
D7
D8
CB1 BACKUP CB2 EMERG ENG CB 3 HIGH IDLE RLY8
ENGINE
SHUTDOWN ACTIVATE PTO ENGAGED

T6 T7 T8 T9 T10 T11 T12 T__ T13 T14 T15

IGNITION

CB10

CB11

CB12

CB13
CB4

CB5

CB6

CB7

CB8

CB9
POWER

12

3
FUEL/WATER
ENG/XMSN

AIR DRYER

VOLTMTR/
T__
SPARE

SPARE

SPARE

SPARE

SPARE

SPARE
ENG DIA
ECU

SEP

1
10
CON1

T16 T17
OSHKOSH TRUCK CORP. GROUND
D9 SPARE 3 SPARE 4
P/N 3384702 86 85 86 85

REV. A BATTERY 30 30
POWER

T3 3

T3 5

T3 8

T4 0
D1 0
DATE: T34 T39
T18 T19

T25 T27
30 30
CB15
CB14

CB16

CB17

CB18

CB19

CB20

T29 T31 86 85 86 85

MASTER
ENGINE ECU
COMPT LTS

XMSN ECU
SPARE

SPARE

SPARE

SPARE

87 A 87 A

POWER 87 87

RLY9 RLY10
T30 T32

T3 6

T3 7

T4 1

T4 2
NO NC NO NC
T20 T21 T22 T23 T24 T26 T28

NEUTRAL TRANSMISSION XMSN SPARE 1 SPARE 2

CB21 REAR WRK LTS 86 85 86 85
AC STATUS DISCONNECT MODE SELECT DIFF LOCK PTO ENGAGED T58 30 30

T60

T63

T65
T45 T49 T52 T54 T57 T59 T64
R L Y1 1 RLY12 RLY13 RLY14 RLY15 RLY16 RLY17 RLY18

30 30 30 30 30 30 30 30

86 85 86 85 86 85 86 85 86 85 86 85 86 85 86 85

8 7A 8 7A 8 7A 87A 87A 87A 87 A 87 A

R18

R19

R20
R13

R15

R16

87 87 87 87 87 87 87 87

LED13 R1 4 LED14 LED15 LED16 R17 LED17 LED18 LED19 LED20

T61

T62

T66

T67
D 11

NO NC NO NC
D12
T43

T44

T46

T47

T48

T50

T51

T53

T55

T56

TST 290-0316

Figure 7. Engine Power Distribution Panel

700-47, Page 8
ELECTRICAL SYSTEM GROUP 700

Table 3. Engine Power Distribution Panel

Circuit Description Rating
Battery
Engine ECU Fuse 20
Fuse #1
Battery
Transmission ECU Fuse 10
Fuse #2
Battery #1 Volt Meter/Engine Diag. 7.5 AMP
Master #1 Compartment Lights 15 AMP
Master #2 Rear Work Lights 15 AMP
Ignition #1 Engine/Transmission ECU 10 AMP
Ignition #2 Reverse Lights 10 AMP
Ignition #3 Air Dryer 10 AMP
Ignition #4 Alt. Exc/HI Idle 7.5 AMP
Emergency Engine
Ignition #5 20 AMP
Shutdown
Ignition #6 Fuel/Water Separator 25 AMP
Ignition #7 Power Divider 7.5 AMP

700-47, Page 9
GROUP 700
5. TROUBLESHOOTING
Trouble
Batteries discharge rapidly
No battery voltage
Insufficient alternator output
Improper system voltage
Lights dim
Lights inoperative
Frequent lamp failures
Starter will not crank engine
700-47, Page 10
ELECTRICAL SYSTEM
Probable Cause Remedial Action
1. Alternator defective. 1. Repair or replace.
2. Loose or corroded battery 2. Clean and tighten terminals.
terminals.
3. Short circuit somewhere in 3. Locate short by performing continuity
electrical system. checks and correct. Refer to electrical
schematic in this manual.
4. Battery cable or wiring resistance 4. Replace defective cable or wire.
too high.
5. Low electrolyte level. 5. Refill to proper level.
6. Defective cell in battery. 6. Replace battery.
1. Batteries discharged. 1. Recharge batteries.
2. Circuit breaker open. 2. Reset circuit breaker. See the electrical
schematic in this manual.
3. Disconnected battery cable. 3. Connect cable.
1. Drive belts slipping. 1. Adjust to proper tension.
2. Defective alternator. 2. Repair or replace alternator.
1. Insufficient alternator output. 1. Repair or replace alternator.
1. Low battery voltage 1. Charge or replace batteries.
2. Poor electrical connection(s) 2. Clean and tighten connection(s).
1. Not grounded properly. 1. Tighten ground connection. See the
electrical schematic in this manual.
2. Open circuit breaker. 2. Reset circuit breaker. See the electrical
schematic in this manual.
3. Broken wire. 3. Repair wiring. See the electrical
schematic in this manual.
4. Defective switch. 4. Replace switch.
1. Improper electrical system voltage. 1. See ”Improper System Voltage”.
2. Poor battery connections. 2. Clean and tighten connections.
1. Batteries low. 1. Recharge or replace batteries.
2. Circuit breaker defective. 2. Replace circuit breaker.
3. Defective master switch, master 3. Test or replace as necessary. See the
relay, ignition switch, neutral switch, or electrical schematic in this manual.
wiring.