2011 Terrastar - Elec.circ - Diag

SERVICE MANUAL
SERVICE MANUAL SECTION
TerraStar Model Built 2010 – Electrical Circuit Diagrams
Model: TerraStar
Start Date: November, 2010
S08362
08/15/2011
S08362
Copyright © 08/15/2011 Navistar, Inc.
TABLE OF CONTENTS
TABLE OF CONTENTS
1. TABLE OF CONTENTS (CHAPTER 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. INSTRUCTIONS AND CHARTS (CHAPTER 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.1. ABBREVIATIONS, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.2. ACRONYMS, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4. CIRCUIT NUMBER IDENTIFICATION AND COLOR, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5. CIRCUIT NUMBER IDENTIFICATION AND COLOR (CONT.), P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6. CIRCUIT NUMBER IDENTIFICATION AND COLOR (CONT.), P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7. LAMP BULB CHART, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8. RELAY FUNCTION AND WIRING DIAGRAM, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.9. SCHEMATIC SYMBOL CHART, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.10. SCHEMATIC SYMBOL CHART (CONT.), P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.11. SCHEMATIC SYMBOL CHART (CONT.), P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.12. SCHEMATIC SYMBOL CHART (CONT.), P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3. 12 VOLT POWER DISTRIBUTION, GROUNDS, DATA BUS AND ELECTRICAL SYSTEM CONTROLLER
(CHAPTER 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.1. BATTERY FEED, DUAL, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2. IGNITION FEED – STANDARD, THEFT DETERRENT, REMOTE START / STOP, P. 2. . . . . . . . . . . . .14
3.3. J1708 DATA LINK – PUBLIC EFFECTS, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.4. J1708 DATA LINK – PRIVATE W/ POWER WINDOW & LOCK, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
3.5. J1939 DATA LINK, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3.6. GROUND – IP, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.7. ZERO VOLT REFERENCE, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.8. BATTERY FEED, SINGLE, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
3.9. J1939 DATA LINK – V8 ENGINE, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.10. ACCESSORY FEED, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.11. J1939 DATA LINK – W/ OPTIONS, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.12. IGNITION FEED – RELAY 1, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.15. BATTERY FEED, DUAL (CONT.), P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.16. BATTERY FEED, DUAL (CONT.), P. 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.17. BATTERY FEED, SINGLE (CONT.), P. 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.18. LATCHING RELAY, P. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.19. GROUND – SEAT AND SEATBELT SENSOR, P. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.20. GROUND – IP, P. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.21. GROUND – IP (CONT.), P. 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
3.22. GROUND – IP (CONT.), P. 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3.23. GROUND – CHASSIS, P. 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
3.24. GROUND – IP (CONT.), P. 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3.25. GROUND – IP (CONT.), P. 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
4. CAB ACCESSORIES (CHAPTER 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

4.1. CIGAR LIGHTER AND POWER FEED, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4.2. CIGAR LIGHTER AND POWER FEED (CONT.), P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
4.3. COMPASS DISPLAY, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
4.4. FRONT DOOR WINDOWS AND LOCKS (POWER), P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
4.5. FRONT DOOR WINDOWS AND LOCKS (POWER) FOR CREW, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362) i

TABLE OF CONTENTS
TABLE OF CONTENTS (CONT.)

4.6. HORN – ELECTRIC AND AIR (CONT.), P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
4.7. MIRRORS (HEATED, LIGHTED & POWER), P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
4.8. 2 – WAY RADIO, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
4.9. WASHER PUMP, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4.10. SELF CONTAINED AIR SEAT, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.11. RADIO (ENTERTAINMENT) SPEAKERS – W/ 16 WAY CONNECTOR, P. 11. . . . . . . . . . . . . . . . . . . . . . . .48
4.12. SATELLITE COMMUNICATION – MOBILEMAX, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.13. COMPUTER PREWIRED – XATA SYSTEM, P. 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
4.14. CADEC GPS SYSTEM, P. 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
4.15. SATELLITE COMMUNICATION – TRIPMASTER, P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
4.16. SATELLITE COMMUNICATION – QUALCOMM IMCT, P. 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
4.17. ROOF AUX LOAD, P. 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
4.18. MIRRORS (HEATED, LIGHTED & POWER) (CONT.), P. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
4.19. SATELLITE COMMUNICATION – QUALCOMM IMCT W/ MVPC KEYBOARD, P. 19. . . . . . . . . . . . . . .56
4.20. SATELLITE COMMUNICATION – QUALCOMM OMNIVISION, P. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
4.21. MIRRORS (HEATED, LIGHTED & POWER) (CONT.), P. 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
4.22. CB POWER RADIO, P. 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
4.23. BACK-UP CAMERA, P. 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
4.24. HEATED SEATS, P. 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
4.25. SWITCH PACK OPTIONAL GAUGE RACK, P. 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
4.26. WINDSHIELD WIPER, P. 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
4.27. SEATBELT & SEAT SENSOR, P. 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
4.28. SEATBELT & SEAT SENSOR (CONT.), P. 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
5. 12V CHARGING AND CRANKING SYSTEM (CHAPTER 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

5.1. STARTING & CRANKING ENGINE W/ ALLISON TRANSMISSION, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
5.2. ROCKER START, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
6. FANS AND ENGINE ACCESSORIES (CHAPTER 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

6.1. FAN WIRING – V8 ENGINE, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
6.2. SNOWVALVE, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7. ELECTRONIC ENGINES (CHAPTER 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

7.1. ELECTRONIC ENGINE CONTROLS – V8 ENGINE, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
7.2. ELECTRONIC ENGINE CONTROLS – V8 ENGINE (CONT.), P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
7.5. ELECTRONIC ENGINE CONTROLS – V8 ENGINE CRUISE CONTROLS, P. 5. . . . . . . . . . . . . . . . . . . . .76
8. GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8). . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
8.1. BRAKE SWITCH & PARK BRAKE SWITCH, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
8.2. GAUGES & WARNING LIGHTS – AMMETER, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
8.3. AIR PARK BRAKE, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
8.4. AIR PRESSURE INPUT CIRCUIT, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
8.5. IP GAUGES & WARNING LIGHTS – GAUGE CLUSTER, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
8.6. IP / GAUGES, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
8.7. WARNING LIGHTS LIST, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
8.8. WARNING LIGHTS CONTROLLING BY ENGINE, TRANSMISSION, ABS CONTROLLER, P. 8. . .84
ii TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362)

TABLE OF CONTENTS

8.9. ENG OIL PRESS & TEMP, SPEEDOMETER, TACH, VOLTMETER & WATER TEMP GAUGE
CIRCUITS, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
8.10. FUEL GAUGE CIRCUITRY (SINGLE TANK AND DUAL TANK), P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
9. LIGHTS (CHAPTER 9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

9.1. BACK-UP – W/ ALLISON TRANSMISSION, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
9.2. LIGHT SYSTEM – CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS, P. 2. . . . . . . . . . .88
9.3. LIGHT SYSTEM – CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS (CONT.), P.
3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
9.4. LIGHT SYSTEM, FOG LIGHT, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
9.5. HEADLIGHTS, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
9.6. PANEL LIGHTS, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
9.7. LIGHT SYSTEM, WORK LIGHT, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
9.10. AUX HEADLIGHTS, SNOWPLOW LIGHTS, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
10. CHASSIS ACCESSORIES (CHAPTER 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

10.1. TRW ABS BRAKES, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
10.2. TRW ABS BRAKES (CONT.), P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
10.3. TRW ABS BRAKES (CONT.), P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
10.4. BODY BUILDER & TRAILER – TURN, MARKERS & STOP, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 .
10.5. BODY BUILDER & TRAILER – TURN, MARKERS & STOP (CONT.), P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . .101 .
10.6. BODY BUILDER ACC FEED WIRING, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 .
10.7. BODY BUILDER CONNECTIONS, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 .
10.8. TWO SPEED AXLE SWITCH, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 .
10.9. REMOTE POWER MODULE – CAB MOUNTED, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 .
10.10. FUEL / HEATER RELAY, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 .
10.11. ELECTRIC TRAILER BRAKE, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 .
10.12. HOUR METER – PTO, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 .
10.13. AIR DRYER, P. 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
.
10.14. REMOTE START / STOP, P. 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 .
10.15. AUX & POWER SOURCE, P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 .
10.16. WHEELCHAIR LIFT INTERLOCK, P. 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 .
10.17. AUX INPUTS & DRIVERS, P. 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 .
10.18. TRANSFER CASE EFFECTS, P. 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 .
10.19. FUEL TRANSFER PUMP, P. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 .
10.20. TRAILER SOCKET – EOF, P. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 .
10.21. BODY BUILDER & TRAILER SOCKET – BOC & EOF, P. 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 .
10.22. AUX TRAILER CIRCUIT, P. 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 .
10.23. LIFT AXLE W/ CONTROLS FOR ONE LIFT AXLE, P. 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 .
10.24. LIFT AXLE (NON – STEERABLE), P. 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 .
10.25. LIFT AXLE (STEERABLE), P. 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 .
10.26. POWER SOURCE, CUSTOMER INSTALLED LIFT GATE, P. 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 .
11. TRANSMISSION (CHAPTER 11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

.
11.1. ALLISON GEN 4 1/2000 TRANSMISSION, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 .
11.2. ALLISON GEN 4 1/2000 TRANSMISSION (CONT.), P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 .
TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362) iii

TABLE OF CONTENTS

11.3. ALLISON GEN 1/2000 TRANSMISSION, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 .
11.4. TRANSMISSION ALLISON MD (WTEC) (CONT.), P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 .
11.5. ALLISON TRANSMISSION 3/4000 GEN4 W/ AUTO NEUTRAL, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 .
11.6. TRANSMISSION RETARDER CONTROLS WIRING W/ MD XMSN HARD WIRED EFFECTS, P.
6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
.
12. AIR CONDITIONING (CHAPTER 12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 .

12.1. HVAC SYSTEM, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
.
12.2. HVAC SYSTEM, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
.
12.3. AIR CONDITIONING, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 .
12.4. AIR CONDITIONING (CONT.), P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 .
13. INSTRUCTIONS AND CHARTS (CHAPTER 13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

.
13.1. CONNECTOR BODY COMPOSITES MATING VIEW SHOWN, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 .
13.10. CONNECTOR BODY COMPOSITES MATING VIEW SHOWN, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 .
iv TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362)

TABLE OF CONTENTS
13.38. CONNECTOR BODY COMPOSITES MATING VIEW SHOWN, P. 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170

.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362) v

vi TerraStar Model Built 2010 – Electrical Circuit Diagrams
S08362
INSTRUCTIONS AND CHARTS (CHAPTER 2)
1. TABLE OF CONTENTS (CHAPTER 1)

2. INSTRUCTIONS AND CHARTS (CHAPTER 2)
2.1. ABBREVIATIONS, P. 1
NAVISTAR, INC ELECTRICAL CIRCUIT DIAGRAM

CHAPTER 2
THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF
ABBREVIATIONS
NAVISTAR, INC.
ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION

ACCESS ACCESSORY CRUS CRUISE PWR POWER
ACCUM ACCUMULATOR CUR CURRENT PRESS PRESSURE
AC AIR CONDITIONING DPNL DASHPANEL RAD RADIO
AIR CLNR AIR CLEANER DFTR DEFLECTOR RR REAR
ALT ALTERNATOR DFR DEFROSTER RLY RELAY
ACCEL ACCELERATOR DEG DEGREE RES RESISTOR
AC ALTERNATING CURRENT DIAG DIAGRAM REGEN REGENERATE
AFTR AFTERTREATMENT DSL DIESEL R RIGHT
AMM AMMETER DIFF DIFFERENTIAL RTR ROTOR
AMP AMPERE DIMR DIMMER SNSR SENSOR
AMP HR AMPERE HOUR ELEC ELECTRICAL SHLD SHIELD
AMPL AMPLIFIER ELEX ELECTRONICS SHFT SHIFTER
ARM ARMATURE ENG ENGINE SLPR SLEEPER
ARSR ARRESTER EXH EXHAUST SLV SLEEVE
ASSY ASSEMBLY FL FLUID SPKR SPEAKER
AUX AUXILIARY FWD FORWARD SPR SPRING
B/U BACK-UP FR FRONT STD STANDARD
BTRY BATTERY FREQ FREQUENCY STRG STEERING
BM BENCHMARKING GA GAUGE STLITE SATELLITE
BLK BLOCK GEN GENERATOR SUNSH SUNSHADE
BOOS BOOSTER GND GROUND SW SWITCH
BOT BOTTOM HARN HARNESS SYS SYSTEM
BK BRAKE HDLP HEADLAMP TACH TACHOMETER
BRKR BREAKER HTD HEATED TEMP TEMPERATURE
BRTHR BREATHER HT TR HEAT TREAT TERM TERMINAL
BRI BRIGHT HTR HEATER THROT THROTTLE
BUZ BUZZER HP HORSEPOWER THRU THROUGH
CA CABLE HYD HYDRAULIC TRAC TRACTION
CD CANDELA ID IDENTIFICATION TRLR TRAILER
CP CANDLEPOWER IGN IGNITION XDCR TRANSDUCER
CAP CAPACITOR ILLUM ILLUMINATION XFER TRANSFER
CAT CATERPILLAR IND INDICATOR XFMR TRANSFORMER
CHAS CHASSIS INST INSTRUMENT XSTR TRANSISTOR
CH CHOKE INT INTERMITTENT XMSN TRANSMISSION
CIRC CIRCUIT L LEFT XMTR TRANSMITTER
CLK CLOCK LT LIGHT TRK TRUCK
CW CLOCKWISE LTR LIGHTER UPR UPPER
CLSTR CLUSTER LWR LOWER VLV VALVE
CL CLUTCH MAG MAGNET VERT VERTICAL
COL COLUMN MOD MODULATOR VM VOLTMETER
COMM COMMUTATOR MDL MODULE VOL VOLUME
CMPNT COMPONENT MOT MOTOR WSHR WASHER
CPRSR COMPRESSOR MTD MOUNTED WHL WHEEL
CONN CONNECTOR NEG NEGATIVE WDO WINDOW
CONT CONTINUED N/ NOT WITH WSHLD WINDSHIELD
CSL CONSOLE NO. NUMBER WPR WIPER
CONT CONTACT PASS PASSENGER W/ WITH
CONT CONTROL POSN POSITION W/O WITHOUT
CONV CONVERTER POS POSITIVE
CLR COOLER POT POTENTIOMETER
CTSY COURTESY
CHK DATE CHANGE REV REFERENCE DRAWN NAME
U01A133 CIRCUIT DIAGRAM, TERRASTAR

CNA1 11NOV10 INITIAL RELEASE. A 67696A
RELEASE NO. DATE PART NO. SHEET
67696A 04AUG10 AE08064593 001
TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362) 1

INSTRUCTIONS AND CHARTS (CHAPTER 2) ACRONYMS, P. 2
2.2. ACRONYMS, P. 2

CHAPTER 2
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF ACRONYMS
NAVISTAR, INC.
DESCRIPTION ACRONYM DESCRIPTION ACRONYM

ANTILOCK BRAKING SYSTEM ABS HEAVY DUTY DIESEL HDD
ANTENNA COMMUNICATION UNIT ACU HIGH PERFORMANCE TRUCK HPT
ALTERNATING CURRENT AC HEATING, VENTILATION, AND
HVAC
AXLE TO BACK OF CAB AC AIR CONDITIONING
AXLE TO FRAME AF INJECTOR DRIVE MODULE IDM
ACCELERATOR PEDAL MODULE APM INPUT/OUTPUT I/O
ACCELERATOR POSITION SENSOR APS INTEGRATED MOBILE

IMCT
COMMUNICATION TERMINAL
AUXILIARY POWER UNIT APU
INSTRUMENT PANEL I/P
AMERICAN TRUCKING ASSOCIATION ATA
INDEPENDENT POWER TAKE-OFF IPTO
AUTOMATIC TRACTION CONTROL ATC
INTERNATIONAL BIG BORE ENGINE IBBE
AUDIO VIDEO INTERFACE AVI
LIGHT COMMERCIAL TRANSMISSION LCT
BAROMETRIC ATMOSPHERE PRESSURE BAP
LOW PRESSURE MODULE LPM
BRAKE HORSEPOWER BHP
MEDIUM DUTY MD
BACK OF CAB BOC
MALFUNCTION INDICATION LAMP MIL
CITIZEN BAND CB
MULTIPLEX SWITCH MODULE MSM
COLD CRANKING AMPERES CCA
PYROMETER AMMETER MODULE PAM
CLEAN POWER ELECTRICAL CONNECTOR CEC
POWER DISTRIBUTION CENTER PDC
CENTRAL PROCESSING UNIT CPU
PROGRAMMABLE LOGIC CONTROLLER PLC
CAB OVER ENGINE COE
POWER TAKE-OFF PTO
DIRECT CURRENT DC
PULSE WIDTH MODULATION PWM
DRIVER CONTROL MODULE DCM
REAR AXLE RA
DIGITAL DATA LINK DDL
RADIO FREQUENCY RF
DIESEL OXIDATION CATALYST INLET
DOCT ROLL STABILITY PROGRAM RSP
TEMPERATURE
DIESEL PARTICULATE FILTER DPF SEVERE SERVICE SS
DIESEL PARTICULATE FILTER TRANSMISSION CONTROL MODULE TCM

DPFDP
DELTA PRESSURE TERRESTRIAL COMMUNICATION UNIT TCU
DIESEL PARTICULATE TERRESTRIAL MOBILE
DPFT TMCT
FILTER TEMPERATURE COMMUNICATION TERMINAL
DIESEL TURBOCHARGED DT THERMAL OVERCRANK PROTECTION TOCP
DAY TIME RUNNING LIGHTS DTRL THROTTLE POSITION SENSOR TPS
ELECTRONIC CONTROL MODULE ECM WORLD TRANSMISSION
WTEC
ELECTRONIC CONTROL UNIT ECU ELECTRONIC CONTROLS
EXHAUST GAS RECIRCULATION EGR VEHICLE SPEED OUTPUT VSO
EXHAUST GAS TEMPERATURE EGT VEHICLE SPEED SENSOR VSS
ELECTRO MAGNETIC INTEFERENCE EMI ZERO VOLT REFERENCE ZVR
END OF FRAME EOF VEHICLE SPEED OUTPUT VSO
ELECTRIC TRAILER BRAKE ETB VEHICLE SPEED SENSOR VSS
FRONT AXLE FA ZERO VOLT REFERENCE ZVR
FRONT END FE
FRONT OF DASH FOD
FULL POWER BRAKE FPB
GLOBAL POSITIONING SYSTEM GPS
HYDRAULIC CONTROL UNIT HCU
HEAVY DUTY HD

67696A 04AUG10 AE08064593 002
2 TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362)

CIRCUIT DIAGRAM INSTRUCTIONS, P. 3 INSTRUCTIONS AND CHARTS (CHAPTER 2)
2.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3

CHAPTER 2
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF CIRCUIT DIAGRAM INSTRUCTIONS
NAVISTAR, INC.
A - SWITCH AND RELAY POSITIONS AS SHOWN ON B - MULTIPLE CONNECTIONS ARE DISPLAYED

CIRCUIT DIAGRAMS INDICATE NORMAL POSITION ON SCHEMATIC AS SHOWN WITH R/D NUMBER
WITH IGNITION OFF UNLESS OTHERWISE NOTED. & CAVITY NUMBER. REFER TO CONNECTOR
COMPOSITE FOR MORE INFORMATION
R/D NUMBER CAVITY NUMBER
86
30 CAVITY NUMBER R/D NUMBER
B
(12-A) AND/OR D C B A (12)

87
A 87A
85
SWITCH, SINGLE IN-LINE CONNECTORS DISPLAYED

SOLENOID RELAY - SUPPRESSED
MECHANICAL AS SHOWN BELOW WITH R/D NUMBER
(12)
C - PHANTOM LINES INDICATE PRINTED CIRCUITS OR BUSSED CIRCUITS.

THESE CIRCUITS EXIST IN THE INSTRUMENT
CLUSTER AND FUSE / CIRCUIT BREAKER CONNECTORS.
A B
LOCATION / CIRCUIT NUMBER
WIRE GAUGE / WIRE COLOR F1
20A
+
VOLTMETER LOCATION IN FUSE RATING
PRINTED A B
FUSE / CIRCUIT
CIRCUIT IN BREAKER F2
INSTRUMENT - CONNECTION 20A
CLUSTER
D - MULTIPLE CIRCUIT NUMBERS ON A LINE INDICATE ONE CIRCUIT

DISTRIBUTING CURRENT TO TWO CIRCUITS.
SPLICE
E - SWITCHES, RELAYS AND COMPONENTS INDICATE EXTERNAL

WIRE CONNECTIONS AND / OR INTERNAL CONNECTIONS OR CONTACTS.
EXTERNAL WIRE
A12 A12A
CONNECTIONS
WIRE CONNECTION PIGTAIL
A B D C A B
A128
S IGN ACC F18
20A
OFF BUSSED CONTACT 16RD
A B
F19
20A 16WH
BATT
KEY SWITCH INTERNAL BODY CONTROLLER

(1101M) CONNECTION (1602)
F - CIRCUIT "11" DENOTES ANY COMMON GROUND (MORE THAN ONE CIRCUIT). ANY INDIVIDUAL
GROUND CIRCUIT IS IDENTIFIED WITH THAT PARTICULAR CIRCUIT NUMBER.(E.G. CIRCUIT
32 CRUISE CONTROL IS IDENTIFIED AS PER EXAMPLE)
11-G R32-G
11-GA R32-GA
11-GB R32-GB
SUFFIX BEGINNING LOCATION SUFFIX BEGINNING

COMMON GROUND INDIVIDUAL GROUND WITH G INDICATES
WITH G INDICATES
CIRCUIT NUMBER CIRCUIT NUMBER A GROUND CIRCUIT
A GROUND CIRCUIT
NOTE: FOR CIRCUIT DESCRIPTION OTHER THAN GROUNDS NEITHER

THE LETTER "G" NOR THE COLOR WHITE SHALL BE USED

67696A 04AUG10 AE08064593 003

INSTRUCTIONS AND CHARTS (CHAPTER 2) CIRCUIT NUMBER IDENTIFICATION AND COLOR, P. 4
2.4. CIRCUIT NUMBER IDENTIFICATION AND COLOR, P. 4

CHAPTER 2
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF CIRCUIT NUMBER IDENTIFICATION AND COLOR
NAVISTAR, INC.
CIRCUIT
COLOR DESCRIPTION
NUMBER
1 LTBL ALTERNATOR-FIELD
2 RD ALTERNATOR-CHARGE
DKBL SERIAL / DATA COMMUNICATION J1587 / J1708 (+)
3
GY SERIAL / DATA COMMUNICATION J1587 / J1708 (-)
DKBL SERIAL / DATA COMMUNICATION J1922 (+)
4
GY SERIAL / DATA COMMUNICATION J1922 (-)
YL SERIAL / DATA COMMUNICATION J1939/11 / J1939/15 (+)
5
GN SERIAL / DATA COMMUNICATION J1939/11 / J1939/15 (-)
6 GY LOW VOLTAGE ELECTRONIC FEED (LESS THAN 9 VOLTS)
7 RD ALTERNATOR-RESISTANCE
8
9 GY ZERO VOLT REFERENCE (ZVR)
10 WH CHASSIS / ENGINE GROUND
11 WH CAB / SLEEPER GROUND
12 LTBL ACCESSORY FEED
PK IGNITION FEED
13
BK IGNITION FEED (BODY BUILDER CONNECTOR)
14 RD BATTERY FEED
15 RD KEY SWITCH FEED
16
17 PK STARTER CONTROL
18 PK GLOW PLUG / PREHEATER
19 GY ENGINE SHUTDOWN
20 LTGN REMOTE POWER MODULE
21 TN COLD START CONTROLS (ETHER)
22 TN TIRE PRESSURE MONITORING / CONTROL
23 TN ENGINE FAN / SHUTTERS
24 GY ENGINE EXHAUST BRAKE
25 TN PYROMETER
26 TN AMMETER
27 TN VOLTMETER
28 TN INSTRUMENT & GAUGES
29 TN ENGINE WATER TEMPERATURE
30 TN ENGINE OIL TEMPERATURE
31 TN TRANSMISSION OIL TEMPERATURE
32 TN AXLE OIL TEMPERATURE
33 TN ENGINE OIL LEVEL
34 TN COOLANT LEVEL
35 TN ENGINE OIL PRESSURE
36 TN FUEL LEVEL
37 TN FUEL PUMP
38 GY LIFT AXLE
39 GY AIR DRYER HEATER
40 GY LOW AIR PRESSURE WARNING

67696A 04AUG10 AE08064593 004

CIRCUIT NUMBER IDENTIFICATION AND COLOR (CONT.), P. 5 INSTRUCTIONS
AND CHARTS (CHAPTER 2)
2.5. CIRCUIT NUMBER IDENTIFICATION AND COLOR (CONT.), P. 5

CHAPTER 2
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF CIRCUIT NUMBER IDENTIFICATION AND COLOR (CONT)
NAVISTAR, INC.
CIRCUIT
COLOR DESCRIPTION
NUMBER
41 TN AIR TEMPERATURE
42 GY FRONT AXLE ENGAGED
43 GY POWER DIVIDER LOCK (PDL) WARNING
44 GY PARK BRAKE WARNING
45 LTGN ANTITHEFT WARNING
46 GY POWER TAKEOFF WARNING
47 GY SPEEDOMETER
48 GY TACHOMETER
49 GY DIFFERENTIAL LOCK WARNING
50 YL LIGHT SWITCH FEED
51 YL DIMMER SWITCH FEED
52 YL HEADLIGHT HI - BEAM
53 YL HEADLIGHT LO - BEAM
54 BN PARKING / MARKER LIGHTS
55 OR TURN SIGNAL - FEED
OR TURN SIGNAL LIGHTS - LEFT
56
YL TURN SIGNAL LIGHTS - LEFT (BODY BUILDER CONNECTION)
OR TURN SIGNAL LIGHTS - RIGHT
57
LTGN TURN SIGNAL LIGHTS - RIGHT (BODY BUILDER CONNECTION)
58 BN CLEARANCE / IDENTIFICATION LIGHTS
59 GY SOLENOID
60 OR HAZARD LIGHTS
61 GY AIR SUSPENSION
62 DKBL PANEL LIGHTS
63 DKBL COURTESY / DOME LIGHTS
64 YL FOG / DRIVING LIGHTS
65 OR CAB REAR FLOOD LIGHTS
66 YL DAYTIME RUNNING LIGHTS
67 GY OBSTACLE AVOIDANCE / REMOTE SENSOR
68 BN TAIL LIGHTS
69 BN LICENSE PLATE LIGHT
OR STOP LIGHTS
70
RD STOP LIGHTS (BODY BUILDER CONNECTION)
OR BACK-UP LIGHTS
71
LTBL BACK-UP LIGHTS (BODY BUILDER CONNECTION)
72 OR TRAILER AUXILIARY FEED - BATTERY
73 LTGN PWM
74 LTGN HEATER RECIRC MOTOR
75 LTGN HEATER BLOWER MOTOR
76 LTGN AUXILIARY FAN
77 LTGN AIR CONDITIONER
78 LTGN MIRRORS - HEATED, MOTORIZED
79 GY SEAT BELTS
80 BK SLEEPER BOX RELAY - FEED

67696A 04AUG10
AE08064593 005

INSTRUCTIONS AND CHARTS (CHAPTER 2) CIRCUIT
NUMBER IDENTIFICATION AND COLOR (CONT.), P. 6
2.6. CIRCUIT NUMBER IDENTIFICATION AND COLOR (CONT.), P. 6

CHAPTER 2
CIRCUIT NUMBER IDENTIFICATION AND COLOR (CONT)
NAVISTAR, INC.
CIRCUIT
COLOR DESCRIPTION
NUMBER
81 LTGN POWER DOOR LOCKS

82 GY WINDSHIELD WIPER
83 LTGN POWER WINDOWS
84 LTGN CIGAR LIGHTER
85 GY HORN
86 LTGN RADIO - ENTERTAINMENT / CLOCK
87 GY WINDSHIELD WASHER
88 LTGN CLOCK / HOURMETER
89 VT AIR BAG
90 GY HYDRAULIC BRAKE PUMP
91 VT INTERCOMMUNICATION
92 TN TRANSMISSION CONTROLS - ELECTRONICS
93 TN AXLE SHIFT CONTROL
94 GY ANTILOCK BRAKE SYSTEM
95 TN EXHAUST EMISSION
96 YL SNOW PLOW LIGHTS / CRUISE CONTROLS
97 VT ENGINE CONTROLS - ELECTRONIC
98 BK DATALINK AND DIAGNOSTICS
99 VT ACCELERATOR POSITION SENSOR (APS)
100 GY AIR HORN (ELECTRIC SOLENOID ACTUATED)
101 TN BRAKE APPLICATION AIR
102 YL FLASH TO PASS
103 LTGN BODY BUILDER AUXILIARY FEED
104 DKBL REMOTE START / STOP
105 LTGN HEATED SEATS
106 OR HIGH VOLTAGE ALTERNATOR AC CHARGE
107 GY INTRUMENT CLUSTER ELECTRONIC FEED (5V)
108 GY BRAKE PAD WEAR SENSOR
109 GY BRAKE STROKE / SLACK ADJUSTER
110 GY INTRUMENT CLUSTER ELECTRONIC GROUND
111 TN FUEL FILTER RESTRICTION TRANSDUCER
112 GY LIFT GATE
PREFIX LOCATION
A CAB - INSTRUMENT PANEL MODULE
B CAB - DRIVER CONTROL MODULE
C CAB - HEADER / CLEARANCE LIGHTS
D CAB - ROOF / REAR PANEL
E CAB - LEFT DOOR / DOORS
F CAB - RIGHT DOOR / DOORS
H CAB - SLEEPER
J CAB - DASH (OUTSIDE)
K ENGINE / RADIATOR
L TRANSMISSION
M CHASSIS / FRONT END (CAB DASH PANEL FORWARD)
N CHASSIS / CENTER SECTION (CAB DASH PANEL TO CAB REAR XMBR)
P CHASSIS / WHEEL BASE SECTION
R CHASSIS / SUSPENSION / REAR AXLE / AXLES
S CHASSIS / AF SECTION / STOP / TAIL / TURN LIGHTS
T TRAVEL DOORS
U HOOD MTD HEADLIGHTS / MARKER LIGHTS
V SLEEPER ROOF / BACK PANEL WIRING
W WARDROBE CABINET WIRING

67696A 04AUG10 AE08064593 006

LAMP BULB CHART, P. 7 INSTRUCTIONS AND CHARTS (CHAPTER 2)
2.7. LAMP BULB CHART, P. 7

CHAPTER 2
LAMP BULB CHART
NAVISTAR, INC.
BULB TRADE
BULB APPLICATION CANDLEPOWER OR WATT
NUMBER
BACK-UP LIGHTS 32 CP GE1156
CLEARANCE & IDENTIFICATION SMALL 3 CP GE168
COURTESY LIGHT 21 CP 1142
DOME LIGHTS 21 CP 1142
FOG LIGHTS 100 WATT 4921 - 1
LOW BEAMS 55 WATT GE9007
HIGH BEAMS 60 WATT GE9007
CIGAR LIGHTER 1 CP 1455
MAP LIGHT 3 CP 1816
SIDE MARKER 2548
STOP & TURN / TAIL & LICENSE PLATE 32 / 3 CP 3157
TURN SIGNAL / MARKER (FENDER) 32 / 3 CP 3157
TURN SIGNAL & MARKER LIGHT 2356
WORK (TRAILER HOOK) 35 WATT 4411
BACK-UP LIGHTS UPPER AND LOWER BUNK READING LIGHT 15 CP 1003
CABINET / WARDROBE LIGHT 5W 7575
UNDER BUNK LIGHT 21 CP / 2(12 CP) 577 / 211
ACCENT LIGHT 2 (12 CP) 211
DOME LIGHT LAMP 15 WATT F15T8 - CW
SLEEPER FLOOR LIGHT 4 CP W5W
HEATER AND AIR CONDITIONER CONTROL 3 CP 168
LUGGAGE COMPARTMENT LIGHT 6 CP 99
READING LIGHT 15 CP 1003

67696A 04AUG10 AE08064593 007

INSTRUCTIONS AND CHARTS (CHAPTER 2) RELAY FUNCTION AND WIRING DIAGRAM, P. 8
2.8. RELAY FUNCTION AND WIRING DIAGRAM, P. 8

CHAPTER 2
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF RELAY FUNCTION AND WIRING GUIDE
NAVISTAR, INC.
RELAY VIEWED FROM INSERTION END RELAY SCHEMATIC
MINIATURE - ISO (1)

ENERGIZING COIL
86
NORMALLY CLOSED
87A CONTACT
30
NORMALLY OPEN
87 CONTACT
85
COMMON CONTACT
ENERGIZING COIL
MINIATURE - 280 (1)
30 86 86
30
87
85 87A 87 87A
85
MICRO - 280 (1)
30 86
85 87A 87
MICRO - ISO (1)

NORMALLY OPEN
ENERGIZING COIL CONTACT
1
2 3
5 3
NORMALLY CLOSED 4
CONTACT 5
1 COMMON CONTACT 4
ENERGIZING COIL 2
MICRO - 4 PIN (1)
30 86
85 87
86
30
MINI MICRO - 4 PIN (2) 87
30 86 85
85 87
NOTES:
1. RELAY CONTAINS A 680 OHM SUPPRESSION RESISTOR
2. RELAY CONTAINS A 1000 OHM SUPPRESSION RESISTOR

CNA1 09FEB11 INITIAL RELEASE. A 67696A
67696A 04AUG10 AE08064593 008

SCHEMATIC SYMBOL CHART, P. 9 INSTRUCTIONS AND CHARTS (CHAPTER 2)
2.9. SCHEMATIC SYMBOL CHART, P. 9

CHAPTER 2
SCHEMATIC SYMBOL CHART
NAVISTAR, INC.
SYMBOL DESCRIPTION SYMBOL DESCRIPTION
A B
CIGAR LIGHTER
AIR DRYER
TYPE 1 TYPE 2 OR 3
ALARM A A
CIRCUIT BREAKER
B
B
DIODE
G ALTERNATOR
B
DIODE, LIGHT
AMMETER
+ - EMITTING
BATTERY FAN SOLENOID

+ -
BLUNT CUT CIRCUIT

FEMALE TERMINAL
B
BUSBAR FUSE

67696A 04AUG10 AE08064593 009

INSTRUCTIONS AND CHARTS (CHAPTER 2) SCHEMATIC SYMBOL CHART (CONT.), P. 10
2.10. SCHEMATIC SYMBOL CHART (CONT.), P. 10

CHAPTER 2
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF SCHEMATIC SYMBOL CHART (CONT)
NAVISTAR, INC.
FUSES W/ BUSBAR HORN
BATT
FUSIBLE LINK
OFF
S IGN ACC KEY SWITCH
A B D C
GROUND N/ STUD
S S S S
I A I A I A I A KEY SWITCH,
COMPLEX
OFF OFF OFF OFF
GROUND W/ STUD
F B A C E
LIGHT W/ SWITCH
HEATER
HOLDER, FUSE LIGHT, DOUBLE

W/ BUSBAR FILAMENT
LIGHT, SINGLE
BRACE FILAMENT

67696A 04AUG10 AE08064593 010

SCHEMATIC SYMBOL CHART (CONT.), P. 11 INSTRUCTIONS AND CHARTS (CHAPTER 2)

CHAPTER 2
NAVISTAR, INC.
MALE TERMINAL RESISTOR
A B
MOTOR
SENDER - FUEL,
OIL, WATER
PASS THRU
CONNECTION
SENSOR, PRESSURE.
ABS 6
PRESSURE SWITCH
SENSOR, MAGNETIC
86
30
RELAY, FIVE
TERMINAL
87
87A
85
86
30
RELAY, FOUR
TERMINAL SENSOR, YAW
87
85
SOLENOID
B1
RELAY, LATCHING
B2
SOLENOID W/ DIODE

67696A 04AUG10 AE08064593 011

INSTRUCTIONS AND CHARTS (CHAPTER 2) SCHEMATIC SYMBOL CHART (CONT.), P. 12

CHAPTER 2
NAVISTAR, INC.
SWITCH, PUSH
SPEAKER
BUTTON
OHMS
120
TERMINATING RESISTOR
C
SPLICE
THERMOSTAT
STUD
VALVE, ETHER
BOTTLE
B
B
S S
S
M
START MOTOR
A W/ TOCP B
G
A
B
VALVE, MODULATOR
C
SWITCH, MECHANICAL
(NORMALLY OPEN)
DIODE ASSEMBLY
SWITCH, MECHANICAL B
(NORMALLY CLOSED)

67696A 04AUG10 AE08064593 012

12 VOLT POWER DISTRIBUTION, GROUNDS,
DATA BUS AND ELECTRICAL SYSTEM CONTROLLER (CHAPTER 3)
3. 12 VOLT POWER DISTRIBUTION, GROUNDS, DATA BUS AND

ELECTRICAL SYSTEM CONTROLLER (CHAPTER 3)
3.1. BATTERY FEED, DUAL, P. 1

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF BATTERY FEED, DUAL
NAVISTAR, INC.
FUSE F7-C (1016) HEAT SHRINK

STARTER B+
A14MA F3 E3 A14G BATTERY OWNER

TERMINAL
12RD 16RD OPERATOR

15A
CH5_01
FUSE F8-C (1017) CENTER CHASSIS /

A14MB F3 E3 A20 RPM JUMPER
12RD 16LTGN (4410D / 4410DF)
10A CH10_09
FUSE F2-B (1011)

C2 CIGAR LIGHTER
K14H
BATTERY E2 F2
4RD
A14MC A84
POWER (1854)
FEED 12RD 16LTGN
15A CH4_01
CH3_15
MEGA FUSE
(1001)
100A
(1000)
100A
MEGA
FUSE
A14MD ACCESSORY RELAY #1

A14M
A14F
A14K
8RD
8RD
12RD
8RD
(1013 / 1011) CH3_10
A86PA CIGAR LIGHTER

A14W
POWER SOURCE
6RD
A14
16LTGN
6RD
FUSE F3-C (1012) (1901) CH4_02
A14ME D3 C3 A86N TWO POST POWER SOURCE

12RD 14LTGN (1861) CH4_02
20A
CIGAR LIGHTER PWR SOURCE
A86R
14LTGN / TWO POST PWR SOURCE
(1901 / 1861) CH4_01
A14N
8RD
IGNITION RELAY #2
A14NA
(1012 / 1014)
12RD
CH3_02
IGNITION RELAY #3
A14J A14NC (1012 / 1014)
CH3_15 12RD CH3_02
8RD
A14T
CH3_15
8RD
FUSE F7-F (1016)

A14P
CH3_16 A14ND A2 B2 A94L CENTER CHASSIS/IP
8RD
12RD 12GY (1701) CH10_01
15A
A14H
CH3_16
8RD A1 C1 E1 F1
A14NE A92FB COLUMN SHIFTER
12RD 16TN RELAY
10A (1017) CH11_02
FUSE F8-A (1017)

CNA1 26JUL11 A86PA WAS A86R. C 80257V
67696A 04AUG10 AE08064594 001

12 VOLT POWER DISTRIBUTION, GROUNDS, DATA BUS AND ELECTRICAL SYSTEM CONTROLLER
(CHAPTER 3) IGNITION FEED – STANDARD, THEFT DETERRENT, REMOTE START / STOP, P. 2
3.2. IGNITION FEED – STANDARD, THEFT DETERRENT, REMOTE START / STOP, P. 2

CHAPTER 3
IGNITION FEED - STANDARD, THEFT DETERRENT,
NAVISTAR, INC. REMOTE START / STOP
KEY SWITCH
(1100/1100MA)
BATT
W/ THEFT
BODY
DETERRENT
CONTROLLER #J4
OFF
(1601)
S IGN ACC
A B D C
THEFT
BATTERY A15 DETERRENT
FEED 18RD RD5 (LSD)
CH3_16 A13XA
N/ REMOTE OR 16PK
N/ THEFT DETERRENT E4
A13DB 86
FUSE F1-A (1010) 18PK
ENGINE ECM 5 85
A97UA F1 E1 A13F 2 A104A
(6020M)
16PL 18PK W/ THEFT 18DKBL
CH7_01 5A DETERRENT
& N/ REMOTE
START STOP AUX POWER
RELAY
A13FN
18PK
A13F A13F 1 3 (1873)

REMOTE-STOP RELAY
18PK 16PK
(1018) CH10_14 30 87A
(A13FC)
W/ REMOTE A13FD THEFT DETERRENT

START / STOP 18PK J3 J4 W/ REMOTE START / STOP
85
87 87A A104J
REMOTE STOP RELAY
IGNITION 16DKBL
(1018) CH10_14
RELAY #1
(1011 / 1013)
30 FUSE F4-D
86
(1013) CH3_12
A13-GBN A4 A3
18WH
A14JB BATTERY FEED
A11-GBA
12RD CH3_15,17
10WH
(A13FB) FUSE F5-B

(1014) CH3_13
J1 J2
A13-GFD
85
18WH
A13FE
87 87A
18PK
IGNITION
RELAY#2
(1012 / 1014)
A11-GKJ
30
86
6WH
A2 A1
A14NA BATTERY FEED
12RD CH3_01,08
TRAILER
ABS ECU
A13FF IGNITION FEED
RELAY (A13FA)
18PK CH3_14
(1017) J4
LEFT J3
CH10_01,
SIDE 85
05,10
A13-GFE
CAB GND
87A IGNITION
18WH
(4081) 87
CH3_06 RELAY#3
(1012 / 1014)
30
86
A4 A3
TRAILER ABS
A13-GFF A14NC BATTERY FEED
ECU RELAY
18WH 12RD CH3_01,17
(1017)
CH10_05

CNA1 26JUL11 RMVD R/D 1006;REVISED C 80257V
CIRCUITS. 67696A 04AUG10 AE08064594 002

J1708 DATA LINK – PUBLIC EFFECTS, P. 3 12 VOLT POWER DISTRIBUTION, GROUNDS,
3.3. J1708 DATA LINK – PUBLIC EFFECTS, P. 3

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF J1708 DATA LINK - PUBLIC EFFECTS
NAVISTAR, INC.
DIAGNOSTIC
CONN
(1650)
BATTERY FEED
CH3_08,16 A98H
B
18BK
GROUND
ADAPTER A98-G
18WH A
(1005)
CH3_20
A3AA(+) A3CC(+) F
ENGINE ECM 18DKBL 18DKBL
(6020M) CH7_01 A3AA(-) A3CC(-)
G
18GY 18GY
J1708
J1708
PUBLIC (+)
PUBLIC (-)
(1660)
(1661)
A3BB(-)
A A3BB(+)
18GY A
18DKBL
A3D(-)
F A3D(+)
20GY F
20DKBL
SEATBELT DATA
RECORDER
(8998) CH4_29

CNA1 25MAR11 REVISED AND REDRAWN. B 76076F
67696A 29OCT10 AE08064594 003

(CHAPTER 3) J1708 DATA LINK – PRIVATE W/ POWER WINDOW & LOCK, P. 4
3.4. J1708 DATA LINK – PRIVATE W/ POWER WINDOW & LOCK, P. 4

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF J1708 DATA LINK - PRIVATE W/ POWER WINDOW
NAVISTAR, INC. & LOCK
J1708
DOOR POD SIGNAL
PRIVATE (+) IP DOOR POD / DOOR (3202)
(1927) (3200)
(DRIVER)
DOOR POD
B A
A3D(+) E3W(+) DATA +
D
18DKBL 18DKBL
B
C E3X(-) DATA -
A3E(+) C
18GY
18DKBL
D
A3F(+)
18DKBL
E
A3C(+)
18DKBL
DOOR POD SIGNAL
IP DOOR POD / DOOR
A (3202)
A3B(+) (3204)
(PASSENGER)
18DKBL
DOOR POD
A
E3W(+)
D DATA +
18DKBL
B
E3X(-)
C DATA -
18GY
BODY
CONTROLLER #J5
(1602)
SW DATA
LINK(+)
E2 SWITCH PACK
SWDL+
(1101)
(J1708+)
CH4_25
SW DATA
LINK(-) E1
SWDL-
(1708-)
RIGHT CREW DOOR POD

(2602)
DATA
(+) A
DATA B
J1708 (-)
D3BB(+)
D3CC(-)
PRIVATE (-)
18GY
18GY
(1929)
A
A3B(-) IP DOOR POD / DOOR
18GY (2600)
E B
A3C(-) D3Y(+)
18GY 18DKBL
D E
A3F(-) D3Z(-)
18GY 18GY
D3AA(-)
D3B(+)
C
18GY
18GY
A3E(-)
LEFT CREW DOOR POD
18GY
(2601)
B
A3D(-)
18GY DATA B
(-)
DATA A
(+)

CNA1 25MAR11 REVISED SWITCH PACK B 76076F
CONNECTIONS. 67696A 29OCT10 AE08064594 004

J1939 DATA LINK, P. 5 12 VOLT POWER DISTRIBUTION, GROUNDS,
3.5. J1939 DATA LINK, P. 5

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF J1939 DATA LINK
NAVISTAR, INC.
J1939
TERMINATING
TRW ABS EHCU
RESISTOR-A
(9511)
(9530)
120 OHMS J1939 J1939

(+) (-)
5 6
A C
N5B(-)
N5C(+)
N5C(-)
N5B(+)
18GN
18YL
18GN
18YL
N5A(+)
N5A(-)
18YL
18GN
CENTER
CHASSIS /
62 61
IP
(1701)
A5A(-)
A5A(+)
18GN
18YL
A5RK(+) ECM
A5RL(+) A5R(+)
18YL (6020M)
18YL 18YL
CH3_09
A5RL(-) A5RK(-) A5R(-) ECM

18GN 18GN 18GN (6020M)
CH3_09
A5D(+)
A5D(-)
18YL
18GN
A5(+)
A5(-)
18YL
18GN
A5B(-)
A5B(+)
18GN
18YL
12 11
F3 F2
J1939+ J1939-
J1939+ J1939-
DATALINK
C D
DATALINK
DIAGNOSTIC
CLUSTER
BODY CONNECTOR
CONNECTOR
CONTROLLER #J5 (1650)
(1501)
(1602)

CNA1 25MAR11 REMOVED CONN 1943, B 76076F
1025,6020M,1657,1700. 67696A 04AUG10 AE08064594 005

(CHAPTER 3) GROUND – IP, P. 6
3.6. GROUND – IP, P. 6

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF GROUND - IP
NAVISTAR, INC.
A11-GBA A11-GKJ LEFT SIDE CAB GROUND

10WH 6WH (4081)
A11-GBJ BODY BUILDER CONN

12WH (4450M) CH10_07
A12-GBK ACCESSORY RELAY #1

18WH (1013 / 1011) CH3_10
A86-GBL TWO POST POWER SOURCE

14WH (1861) CH4_02
TWO POST POWER SOURCE /

A86-GBL CIGAR LIGHTER POWER SOURCE
14WH (1861 / 1860) CH4_01
A13-GBN
IGNITION RELAY #1
18WH
(1011 / 1013) CH3_05
310615 CIRCUIT DIAGRAM, TERRASTAR

CIRCUITS. 61229V 05JUN09 AE08064594 006

ZERO VOLT REFERENCE, P. 7 12 VOLT POWER DISTRIBUTION, GROUNDS,
3.7. ZERO VOLT REFERENCE, P. 7

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF ZERO VOLT REFERENCE
NAVISTAR, INC.
BODY CONTROLLER #J5

(1602)
A9ZA
E3 ZVR
18GY
A9ZB
IP/FORWARD CHASSIS
18GY
(1700) CH8_04
A75ZD HVAC SYSTEM

18GY (1210) CH12_01
A9ZF FUSE INPUTS DRIVER

18GY CH10_17
ZERO VOLT REFERENCE

(6747)
A
K95NN
18TN
C
K95A1 ELECTRONIC ENGINE
18TN CONTROLS
D CH7_03
K95F4
18TN
ENGINE / IP
J (1702-2) BODY CONTROLLER #J5
K9E A9E
(1602)
18GY 20GY
CH8_01
L
K9A AC PRESSURE TRANSDUCER
18GY (8602) CH12_02
B
K34-GG LOW COOLANT SENSOR
18WH (6400) CH7_02

CNA1 26JUL11 RMVD CONN 1620. ADDED C 80257V
SPLICE AND REVISED CIRCUITS. 67696A 04AUG10 AE08064594 007

(CHAPTER 3) BATTERY FEED, SINGLE, P. 8
3.8. BATTERY FEED, SINGLE, P. 8

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF BATTERY FEED, SINGLE
NAVISTAR, INC.
STARTER B+
TERMINAL
CH5_01
FUSE F7-C (1016) HEAT SHRINK
A14MA F3 E3 A14G
OWNER OPERATOR
12RD 16RD
15A
FUSE F2-B (1011)

A14MC E2 F2 A84 CIGAR LIGHTER POWER
K14H
4RD
12RD 16LTGN (1854) CH4_01

15A
A14MD
MEGA FUSE
ACCESSORY RELAY #1
(1000B)
12RD (1013 / 1011) CH3_10

150A
A86R CIGAR LIGHTER

16LTGN POWER SOURCE
A14M
8RD
FUSE F3-C (1012) (1901) CH4_02
A14ME D3 C3 A86N TWO POST POWER SOURCE

12RD 14LTGN (1861) CH4_02
20A
CIGAR LIGHTER PWR SOURCE
A86R
6RD
A14
/ TWO POST PWR SOURCE

14LTGN
(1901 / 1861) CH4_01
FUSE F10-C (1019)
A14KD E3 F3 A70BF BODY STOP RELAY
12RD 14RD (1020) CH10_05
20A
A14P
8RD
A14J
A14H
A14T
8RD
8RD
8RD
IGNITION RELAY #2
A14NA
(1012 / 1014)
12RD
CH3_02
FUSE F2-G (1011)
A14PA C3 D3 A28 CLUSTER CONNECTOR
12RD 16TN (1500) CH8_05
15A
FUSE F3-A (1012)

A14PB D1 C1 A98H DIAGNOSTIC CONN
BATTERY FEED
12RD 18BK (1650) CH3_03
SINGLE 10A
CH3_17
KEY SWITCH
A15 (1100) CH3_02
18RD CH10_14
CH5_01
A15 KEY SWITCH W/CENTER

16RD PANEL CONTROLS
(1100MA) CH3_10
FUSE F7-F (1016)

A14ND A2 B2 A94L CENTER CHASSIS/IP
12RD 12GY (1701)
15A CH10_01

CNA1 25MAR11 REMOVED BTRY, FUSE B 76076F
F6-C,F8-D,F8-F. 67696A 04AUG10 AE08064594 008

J1939 DATA LINK – V8 ENGINE, P. 9 12 VOLT POWER DISTRIBUTION, GROUNDS,
3.9. J1939 DATA LINK – V8 ENGINE, P. 9

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF J1939 DATA LINK - V8 ENGINE
NAVISTAR, INC.
J1939
RESISTOR
(7801M)
A
OHMS
J1939
120
DATA LINK
CH3_05
C
A5R(-)
A5R(+)
K5D(-)
K5D(+)
18GN
18YL
18YL
18GN
ECM
IP / (6020M)
ENGINE
(1702)
11
K5A(+) K5B(+)
53 J1939 H
18YL 18YL
K5C(+)
18YL
17
K5A(-) K5B(-)
54 J1939 L
18GN 18GN
K5C(-)
18GN
K5#128
K5#108
18YL
18GN
TRANSMISSION
CONTROL
MODULE
(7151)
8 J1939 -
28 J1939 +

CNA1 25MAR11 REMOVED OPTIONS B 76076F
AND XMSN MODULE. 67696A 04AUG10 AE08064594 009

(CHAPTER 3) ACCESSORY FEED, P. 10
3.10. ACCESSORY FEED, P. 10

CHAPTER 3
ACCESSORY FEED
NAVISTAR, INC.
KEY SWITCH
(1100MA)
BATT
OFF
ACC IGN S
C A
D B
A15 BATTERY FEED
16RD CH3_08,16
18LTBL
A12
BODY CONTROLLER #J3

(1600)
FUSE F4-J (1013)

ACCESSORY
A12B A1 B1 SWITCH
A12C
A1
18LTBL 18LTBL INPUT
5A DIN1
18LTBL
W/ BODY BUILDER
A12A
EFFECTS
A14MD BATTERY FEED
12RD CH3_01,08
BODY ACCESSORY
RELAY A12Q
(1016) CH10_05 18LTBL
J1 A1
86
30
ACCESSORY
RELAY #1
(1013 / 1011) 87
87A
85
A2 J2
A12-GBK
18WH
B2 SWITCH PACK
A2 A12F
18LTBL (1101) CH4_25
10A
FUSE F4-F (1013)

C2 D2 CB RADIO
A86F
POWER CONNECTOR
A11-GBA
18LTGN
10A (2303) CH4_22
10WH
A86 RADIO
18LTGN (1300)
CH4_11
FUSE F4-B (1013)

A11-GKj
G2 H2 DRIVER
(A12V) A78V DOOR
6WH
18LTGN (3000)
10A
CH4_07
LEFT SIDE
CAB GROUND
(4081)
CH3_06

CIRCUITS. 67696A 15OCT10 AE08064594 010

J1939 DATA LINK – W/ OPTIONS, P. 11 12 VOLT POWER DISTRIBUTION, GROUNDS,
3.11. J1939 DATA LINK – W/ OPTIONS, P. 11

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF J1939 DATA LINK - W/ OPTIONS
NAVISTAR, INC.
COMPASS MODULE
J1939 ADAPTER (1912)
(1025) CH4_03
A
A5RF(-)
18GN
C J1939 ADAPTER
A5RH(-) (1026)
18LTGN
D
C
SEATBELT DATA
A5D(-) A5RE(-)
RECORDER (8998)
18GN 18GN
E CH4_29
D
SEATBELT DATA
A5(-) E
RECORDER W/DISPLAY
18GN
(8881) CH4_30 A5CA(-)
18GN
F F
A5F(-)
18GN
RESISTOR-A
G CH3_05 G
A5F(+)
18YL
SEATBELT DATA H
A5(+)
18YL RECORDER W/DISPLAY A5CA(+)
(8881) CH4_30 18YL
J
H
A5RE(+)
18YL
SEATBELT DATA
A5D(+) K
RECORDER (8998)
18YL
J CH4_29
K
A5RH(+)
18YL
M
A5RF(+)
18YL

67696A 14OCT10 AE08064594 011

(CHAPTER 3) IGNITION FEED – RELAY 1, P. 12
3.12. IGNITION FEED – RELAY 1, P. 12

CHAPTER 3
IGNITION FEED - RELAY 1
NAVISTAR, INC.
IGNITION
RELAY #1 (A13FC)
(1011 / 1013) G4
CH3_02
(1013)
E4
FUSE F4-H (1013) A87MB IP/CENTER CHASSIS

C4 18GY (1701) CH4_26
10A D4
FUSE F4-M (1013)

BODY CONTROLLER #J3
A13 (1600)
A4 B4 16PK CH 12_03
A13FC
12PK
HVAC CONTROL
A73A
(1200)
18LTGN
CH 12_03
FUSE F4-L (1013) CLUSTER CONNECTOR

A28A
18TN (1500) CH8_05
A3 10A
B3
(1013)
C3
(1013)
FUSE F9-A (1018)
E3
A13FM E1 F1 OVERHEAD MTD 2-WAY RADIO /
A86P
12PK FLOOR MTD 2-WAY RADIO
16LTGN
5A CONNECTIONS
A86P
(6900) CH4_08
16LTGN
A92A163 T HANDLE SHIFTER

16TN (422F) CH11_02
A92#163 T HANDLE SHIFTER

16TN (1702)
CH11_01
FUSE F4-C (1013)
H3
G3
10A
COLUMN MTD SHIFTER
A92A163 (1828)
18TN CH11_02
A92FN COLUMN SHIFTER

16TN RELAY (1017)
CH11_02

67696A 14OCT10 AE08064594 012

IGNITION FEED – RELAY 2, P. 13 12 VOLT POWER DISTRIBUTION, GROUNDS,

CHAPTER 3
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

CNA1 25MAR11 REMOVED GEOMETRY. B 76076F
67696A 15OCT10 AE08064594 013

(CHAPTER 3) IGNITION FEED – RELAY 3, P. 14

CHAPTER 3
NAVISTAR, INC.
FUSE F5-D
IGNITION (1014)
SEATBELT DATA RECORDER
RELAY #3 A13P (8998) CH4_29
(A13FA)
(1012 / 1014) H4 18RD (8881) CH4_30
G4
CH3_02 10A
(1014)
E4
FUSE F5-H (1014)

A28V COMPASS MODULE
C4 D4 16TN (1912) CH4_03
10A
FUSE F5-M (1014)
A4 B4 A71 BACK-UP LAMP RELAY
16OR (1010) CH9_01
10A
A13FA
12PK
(1014)
A3
(A13FA)
HEAT SHRINK
FUSE F5-G (1014) A13B OWNER OPERATOR

16PK (1919)
C3 10A D3
(A13FA)
FUSE F11-B (1020)

A13FR A13FS E2 F2 A97DF ENGINE/IP
(1014) E3
12PK 12PK 18PL (1702)
5A CH7_01
G3 H3 A90L DIODE CONN

FUSE F5-C (4041) CH10_03
18G
(1014) 5A

CNA1 26JUL11 MOVED SEATBELT DATA C 80257V
RECORDER CIRCS FROM R/D 1014 E3 TO G4. 67696A 15OCT10 AE08064594 014

BATTERY FEED, DUAL (CONT.), P. 15 12 VOLT POWER DISTRIBUTION, GROUNDS,
3.15. BATTERY FEED, DUAL (CONT.), P. 15

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF BATTERY FEED, DUAL (CONT)
NAVISTAR, INC.
FUSE F6-D (1015)

A14FA B1 A1 A19V FUEL HEATER RELAY
12RD 12GY (1018) CH10_10
30A
TRAILER W/ BODY BUILDER &

N/ 7 WAY SOCKET
FUSE F7-B (1016)
BODY / ACCESSORY
A14FB F2 E2 A14BA TRAILER AUX RELAY
12RD 16RD (1016)
BATTERY FEED 20A CH10_05
CH3_01
FUSE F7-A (1016)

A14FD E1 DOOR POD SIGNAL
A14F F1 A81C
12RD (2600) CH4_05
8RD 30A 12LTGN
DRIVER ONLY SELF
CONTAINED AIR SEAT
FUSE F7-E (1016)
B1 DRIVER & PASS
A14FE A1
SELF CONTAINED AIR SEAT
12RD
*20A
OR 30A A14A
SELF CONTAINED
14RD
AIR SEATS
A14A
CH4_10
FUSE F7-H (1016) 12RD
A14KA A4 B4 A81D DOOR POD SIGNAL
12RD 12LTGN (2600) CH4_05
30A
FUSE F8-G (1017)
A14K A14KC A3 B3 A14NS ETB CONTROLLER
8RD 12RD 30A TYPE I CB12BK (1923) CH10_11
FUSE F10-C (1019)

A14KD E3 F3 A70BF BODY STOP RELAY
12RD 14RD (1020) CH10_05
20A
FUSE F1-B (1010)
A14JA E2 F2 A75D HVAC CONTROL
12RD 18LTGN (1200) CH12_03
5A
A14JB IGNITION RELAY #1
12RD (1011 / 1013) CH3_02
FUSE F2-A (1011)
BATTERY FEED
A14JC F1 E1 TRAILER LEFT
CH3_01 (A56J)
12RD TURN RELAY
15A
(1011) CH10_04
FUSE F2-C (1011)
A14JD F3 E3 TRAILER RIGHT
(A57J) TURN RELAY
12RD
15A (1011) CH10_04
FUSE F2-E (1011)
A14J A14JF C1 D1 A86A RADIO
8RD 12RD 18LTGN (1300) CH4_11
10A
FUSE F6-A (1015)
A14JE B4 A4 A75 HVAC LPM
12RD 12LTGN (1220) CH12_04
30A
FUSE F4-E (1013)

D1 PASSENGER DOOR
A14TD C1 A81A POD SIGNAL
12RD 12LTGN (3204) CH4_04
30A
FUSE F4-A (1013) DRIVER DOOR
A14T A14TC G1 H1 A81B POD SIGNAL
8RD 12RD 12LTGN (3200) CH4_04
30A

67696A 14OCT10 AE08064594 015

(CHAPTER 3) BATTERY FEED, DUAL (CONT.), P. 16
3.16. BATTERY FEED, DUAL (CONT.), P. 16

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF BATTERY FEED, DUAL (CONT)
NAVISTAR, INC.
FUSE F2-G (1011)

A14PA C3 D3 A28 CLUSTER CONNECTOR
12RD 16TN (1500) CH8_05
15A
KEY SWITCH
A15 (1100) CH3_02,
FUSE F3-A (1012) 18RD CH10_14,CH5_01
D1 C1
A14PB
BATTERY FEED 12RD A15 KEY SWITCH
10A 16RD (1100MA) CH3_10
CH3_01
A98H J1708 DATALINK

12BK (1650) CH3_03
FUSE F8-D (1017)
A14P A14PC F4 E4 A94UA TRAILER ABS ECU

8RD 12RD 12GY RELAY (1017)
30A CH10_05
BATTERY FEED
CH3_01
FUSE F3-D (1012)

A14HA D4 C4 TRAILER MARKER
(A54J) LIGHT RELAY
12RD
20A (1012) CH10_04
FUSE F3-B (1012)
A14HB D2 C2 TRAILER TAIL
A14H (A68J)
12RD LIGHT RELAY
8RD
20A (1012) CH10_04
FUSE F7-D (1016)

A14HC F4 E4 TRAILER STOP
(A70J) RELAY (1016)
12RD
30A CH10_05

67696A 14OCT10 AE08064594 016

BATTERY FEED, SINGLE (CONT.), P. 17 12 VOLT POWER DISTRIBUTION, GROUNDS,
3.17. BATTERY FEED, SINGLE (CONT.), P. 17

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF BATTERY FEED, SINGLE (CONT)
NAVISTAR, INC.
A14JB IGNITION RELAY#1

12RD (1011 / 1013) CH3_02
FUSE F2-E (1011)

RADIO
A14JF C1 D1 A86A (1300)
12RD 18LTGN CH4_11
10A
A14J
8RD
FUSE F4-A (1013)

G1 H1 DRIVER DOOR
A14TC A81B
POD SIGNAL
BATTERY 12RD 12LTGN
30A (3202) CH4_04
FEED A14T
SINGLE 8RD FUSE F4-E (1013)
CH3_08
A14TD C1 D1 PASSENGER DOOR
A81A
12RD POD SIGNAL
12LTGN
30A (3202) CH4_04
A14H
8RD
IGNITION RELAY#3
A14NC (1012 / 1014)
12RD CH3_02

67696A 14OCT10 AE08064594 017

(CHAPTER 3) LATCHING RELAY, P. 18
3.18. LATCHING RELAY, P. 18

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF LATCHING RELAY
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 01NOV10 AE08064594 018

GROUND – SEAT AND SEATBELT SENSOR, P. 19 12 VOLT POWER DISTRIBUTION, GROUNDS,
3.19. GROUND – SEAT AND SEATBELT SENSOR, P. 19

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF GROUND - SEAT AND SEATBELT SENSOR
NAVISTAR, INC.
GROUND ADAPTER
(8995)
1
A11-GAN A11-GAA
18WH 12WH
LEFT SIDE
CAB GROUND
(1004)
CH3-24
3
A11-GAA
18WH
9
A11-GGA
18WH
4 ROOF IP (1)
A11-GBA
18WH SEAT CONNECTION
(8996)
10 CH4_27
A11-GHA
18WH
5
A11-GCA
18WH
11
A11-GJA
18WH
6
A11-GDA
18WH
12
A11-GKA
18WH
7
A11-GEA
18WH
ROOF IP (2)
13 SEAT CONNECTION
A11-GLA (8997)
18WH CH4_28
8
A11-GFA
18WH
14
A11-GMA
18WH
SEAT BELT DATA RECORDER
2
A11-G (8998) CH4_29
18WH (8881) CH4_30

CNA1 26JUL11 CAV 1 AND 2:REVISED B 80257V
CIRCUITS. GROUPED ROOF CIRCUITS. 76076F 16FEB11 AE08064594 019

(CHAPTER 3) GROUND – IP, P. 20
3.20. GROUND – IP, P. 20

CHAPTER 3
NAVISTAR, INC.
MARKER AND CLEARANCE LIGHT

A63-GA
(2000)
16WH
CH9_09
BODY CONTROLLER #J5

(1602)
A11-GT A11-GAC AC COUPLED

E16 GROUND
12WH 18WH
A11-GKD SWITCH PACK

18WH (1101A) CH4_25
A11-GF CB RADIO POWER CONNECTOR

16WH (2000) CH4_22
A11-GS A28-G CLUSTER CONNECTOR

12WH 16WH (1500) CH8_05
A98-G DIAGNOSTIC CONNECTOR

18WH (1650) CH3_03
A74-G HVAC CONTROL

18WH (1200) CH12_03
LEFT SIDE A11-GA TURN SIGNAL SWITCH

CAB GROUND 18WH (1810) CH4_26
(1005)
A81-GA DRIVER DOOR POD

12WH (3202) CH4_04
A81-GB
12WH
A81-GH DOOR POD SIGNAL
** (3209) CH4_05
** A81-GC
8WH 4 DOORS 12WH
10WH 2 DOORS
12WH 1 DOOR A81-G PASSENGER DOOR POD
12WH (3202) CH4_04
A81-GH DOOR POD SIGNAL

12WH (3202) CH4_04
U01A133 CIRCUIT DIAGRAM, TERRASTAR,

CNA1 26JUL11 ADDED 1602, CIRCUITS B 80257V
A81-G,A81-GA,A81-GB,A81-GC. 76076F 16FEB11 AE08064594 020

GROUND – IP (CONT.), P. 21 12 VOLT POWER DISTRIBUTION, GROUNDS,
3.21. GROUND – IP (CONT.), P. 21

CHAPTER 3
NAVISTAR, INC.
A11-GBA GROUND SPLICE

LEFT SIDE 10WH CH3_06
CAB GROUND
(4081) A11-GCA GROUND SPLICE
10WH CH3_25
A11-GKJ
6WH
A75-G HVAC LPM

OUTSIDE DASH
12WH (1220) CH12_04
A82-G WIPER MOTOR

14WH (4500) CH4_26
K11-G
16WH
ENGINE
LEFT SIDE
GROUND PLATE
(6304A)
U01A133 CIRCUIT DIAGRAM, TERRASTAR,

CNA1 26JUL11 ADDED 6304A. REVISED B 80257V
GROUND SPLICE CIRCUITS. 76076F 16FEB11 AE08064594 021

(CHAPTER 3) GROUND – IP (CONT.), P. 22

CHAPTER 3
NAVISTAR, INC.
RIGHT HEADLIGHT
M11-GA T/S HARNESS CONN (8000)
14WH CH9_03,05
LEFT SIDE CAB LEFT HEADLIGHT

M11-GB
GROUND-CHASSIS T/S HARNESS CONN (8001)
14WH
(4307) CH9_03,05
M11-G
12WH
M11-GD GROUND ADAPTER

12WH (8800) CH3_23
M85-GA ELECTRIC HORN

16WH (8301/8310) CH4_06

CNA1 26JUL11 REMOVED GROUND STUD B 80257V
1004. 76076F 16FEB11 AE08064594 022

GROUND – CHASSIS, P. 23 12 VOLT POWER DISTRIBUTION, GROUNDS,
3.23. GROUND – CHASSIS, P. 23

CHAPTER 3
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF GROUND - CHASSIS
NAVISTAR, INC.
GROUND
ADAPTER #01
(8800)
LEFT SIDE
A CAB GROUND
M11-GD
12WH CHASSIS
(4307)
CH3_22
B LEFT FOG LIGHT

M64-GA
(8201)
16WH
CH9_04
C RIGHT FOG LIGHT

M64-GB
16WH (8200)
CH9_04
D LEFT GUIDE POST LIGHT

M54-GA
(8150)
16WH CH9_03
E
M54-GB RIGHT GUIDE POST LIGHT
16WH (8151)
CH9_03
GROUND
ADAPTER #01
(8807)
A
N11-GA GROUND AT DASH
12WH (9717B)
B N10-G CENTER/REAR CHASSIS

12WH (9800) CH9_01,08
C
N87-G WASHER LEVEL SENSOR
18GY (9746) CH4_26
D
N10-GR CENTER CHASSIS RPM
14WH (4410D) CH10_09
BODY BUILDER (BOC)
F
N11-GD BODY BUILDER
12WH (4450M) CH10_07
N11-GBB
BODY BUILDER CONN
12WH
(4450AM) CH10_07
BODY BUILDER (EOF)

CNA1 25MAR11 INITIAL RELEASE. A 76076F
76076F 16FEB11 AE08064594 023

(CHAPTER 3) GROUND – IP (CONT.), P. 24

CHAPTER 3
NAVISTAR, INC.
BODY CONTROLLER #J2

(1604)
NEGATIVE STUD
(1004)
(LEFT SIDE DASH MOUNTED DUAL
A11-GB DC
POST GROUND PLATE) E
12WH GROUND
A11-GAA
12WH A86-G RADIO
18WH (1300) CH4_11
A28-GAD COMPASS
16WH (1912) CH4_03
A84-GAF CIGAR LIGHTER

16WH (1854) CH4_01
A92-GAH COLUMN MOUNTED SHIFTER

18WH (1828) CH11_02
A11-GAM ETB CONTROLLER

16WH (1923) CH10_11
A11-GAN GROUND ADAPTER

18WH (8995) CH3_19

CNA1 26JUL11 RMVD R/D 1003;REVISED B 80257V
CIRCUITS. 76076F 16FEB11 AE08064594 024

GROUND – IP (CONT.), P. 25 12 VOLT POWER DISTRIBUTION, GROUNDS,

CHAPTER 3
NAVISTAR, INC.
A11-GCA A11-GKJ LEFT SIDE CAB GROUND

10WH 6WH (4081)
A78-GCF PASSENGER DOOR

16WH (3003) CH4_07
A78-GCE DRIVER DOOR

16WH (3000) CH4_07
A19-GCG FUEL HEATER RELAY

18WH (1018) CH10_10
A11-GCH TRAILER TURN RELAYS

16WH (1011) CH10_04
A72-GCL BODY / ACCESSORY

18WH TRAILER AUX RELAY
(1016) CH10_05
A11-GCN
12WH SELF CONTAINED
AIR SEATS
*A11-GCN (1918 / 1935)
14WH CH4_10
* - AIR SEAT N/ PASSENGER SEAT
310615 CIRCUIT DIAGRAM, TERRASTAR,

CNA1 26JUL11 RMVD R/D 1008; B 80257V
REVISED CIRCUITS. 61229V 05JUN09 AE08064594 025

CAB ACCESSORIES (CHAPTER 4)
4. CAB ACCESSORIES (CHAPTER 4)

4.1. CIGAR LIGHTER AND POWER FEED, P. 1

CHAPTER 4
CIGAR LIGHTER AND POWER FEED
NAVISTAR, INC.
CIGAR LIGHTER
CIGAR LTR POWER

(1854)
A
A84 FUSE F2-B
16LTGN CH3_01,08
A
A84-GAF
16WH
A11-GAA
12WH
CIGAR LTR GND
(1853)
LEFT SIDE
CAB GROUND
(1004)
CH3_24
POWER SOURCE & CIGAR LIGHTER TYPE
FUSE F3-C
(1012)
CH3_01,08
14LTGN
A86R
CIGAR LIGHTER
POWER SOURCE
AUX POWER
(1860)
(1901)
B A
A86M A86RC
14LTGN 14LTGN
A B
A86-GA A86-GRC A86-GBL A11-GBA
14WH 14WH 14WH 10WH
TWO POST
A11-GKJ
POWER SOURCE
(1861)
6WH
A
A86S
14LTGN
B
A86-GS
14WH
LEFT SIDE
CAB GROUND
(4081)
CH3_06

CNA1 26JUL11 RMVD R/D 1003,1006; C 80257V
REVISED CIRCUITS. 67696A 04AUG10

AE08064595 001

CIGAR LIGHTER AND POWER FEED (CONT.), P. 2 CAB ACCESSORIES (CHAPTER 4)
4.2. CIGAR LIGHTER AND POWER FEED (CONT.), P. 2

CHAPTER 4
NAVISTAR, INC.
CIGAR LIGHTER AND POWER FEED (CONT)
POWER SOURCE - TWO POST
TWO POST
POWER SOURCE
(1861)
A
FUSE F3-C A86N
CH3_01,08 14LTGN
B
A11-GBA A86-GBL
10WH 14WH
A11-GKJ
6WH
LEFT SIDE
CAB GROUND
(4081)
CH3_06
POWER SOURCE - CIGAR LIGHTER TYPE
CIGAR LIGHTER
AUX POWER POWER SOURCE
(1901) (1860)
A B
FUSE F3-C A86R A86M
CH3_01,08 14LTGN 14LTGN
B A
A11-GBA A86-GBL A86-GA
10WH 14WH 14WH
A11-GKJ
6WH
LEFT SIDE
CAB GROUND
(4081)
CH3_06

CNA1 26JUL11 RMVD R/D 1006; C 80257V
REVISED CIRCUITS. 67696A 04AUG10 AE08064595 002

CAB ACCESSORIES (CHAPTER 4) COMPASS DISPLAY, P. 3
4.3. COMPASS DISPLAY, P. 3

CHAPTER 4
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF COMPASS DISPLAY
NAVISTAR, INC.
COMPASS MODULE
(1912)
FUSE F5-H
A28V
1 (1014)
16TN
CH3_14
A5CA(+)
2
18YL J1939 ADAPTER
(1026)
A5CA(-) CH3_11
3
18GN
A28-GAD
4
16WH
A11-GAA
12WH
LEFT SIDE
CAB GND
(1004)
CH3_24

CNA1 26JUL11 RMVD R/D 1003; C 80257V

FRONT DOOR WINDOWS AND LOCKS (POWER), P. 4 CAB ACCESSORIES (CHAPTER 4)
4.4. FRONT DOOR WINDOWS AND LOCKS (POWER), P. 4

CHAPTER 4
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF FRONT DOOR WINDOWS AND LOCKS (POWER)
NAVISTAR, INC.
FUSE F4-A FUSE F4-E

(1013) (1013)
CH3_15,17 CH3_15,17
J1708 A3D(-) A3E(-) J1708

PRIVATE (+) / (-) 18GY 18GY PRIVATE (+) / (-)
(1927 / 1929) (1927 / 1929)
CH3_04 A3D(+) A3E(+) CH3_04
18DKBL 18DKBL
12LTGN
12LTGN
A81A
A81B
DOOR POD
DOOR POD DOOR / IP SIGNAL
DOOR / IP
SIGNAL DOOR POD (3202)
DOOR POD
(3202) (3200) (3204)
A A
E3W(+) E3W(+) DATA +
DATA + D D
18DKBL 18DKBL
B B
DATA - E3X(-) E3X(-)
C C DATA -
18GY 18GY
DOOR POD
C C
POWER E81B E81B
DOOR POD
G G POWER
12LTGN 12LTGN
D D
E81-GA A81-GA A81-G E81-GA
GND E E GROUND
12WH 12WH 12WH 12WH
A81-GH
PASSENGER
A81-GH
A81-GH
12WH
10WH
DRIVER
8WH
POWER WINDOW N/ CREW

DOOR POD DOOR POD
LEFT FRONT DOOR
LOAD LOAD
(3201) (3201)
A A WINDOW
WINDOW
WINDOW B B WINDOW
LEFT SIDE
C CAB GROUND C LOCK
LOCK
(1005)
CH3_20
LOCK D D LOCK
14LTGN
14LTGN
14LTGN
14LTGN
14LTGN
14LTGN
E81A
14LTGN
E81E
E83E
E83A
14LTGN
E83A
E83E
E81A
E81E
B A A B B A A B
DOOR LOCK WINDOW MOTOR WINDOW MOTOR DOOR LOCK

(3203) (3100) (3100) (3203)

CNA1 26JUL11 R/D 1005 WAS GROUND C 80257V
ADAPTER. 67696A 04AUG10 AE08064595 004

CAB ACCESSORIES (CHAPTER 4) FRONT DOOR WINDOWS AND LOCKS (POWER) FOR CREW, P. 5
4.5. FRONT DOOR WINDOWS AND LOCKS (POWER) FOR CREW, P. 5
NAVISTAR, INC ELECTRICAL CIRCUIT CHAPTER

DIAGRAM 4
FRONT DOOR WINDOWS AND LOCKS (POWER) FOR CREW
NAVISTAR, INC.
A3F(-)
18GY J1708
PRIVATE (+) / (-)
A3F(+) (1927 / 1929)
18DKBL CH3_04
FUSE F7-H
(1016) A81D
CH3_15 12LTGN
A81-GC
12WH A81-GH
FUSE F7-A A81C 8WH
A81-GB
(1016) 12LTGN 12WH
CH3_15
DOOR / IP LEFT SIDE

DOOR POD A E B F D C CAB GND (1005)
(2600) CH3_20
D3Z(-)
RIGHT CREW
12LTGN
D81-GB
D3Y(+)
D81-GC
12LTGN
18DKBL
DOOR POD LEFT CREW
18GY
DOOR POD
D81C
12WH
12WH
D81D
DOOR POD
SIGNAL DOOR POD SIGNAL
(2602)
(3209) (2601) (3209)
G C C G
T81E T81E
POWER POWER
12LTGN 12LTGN
DOOR POD
DOOR POD
C B C
T3AA(-) D3AA(-) D3CC(-) T3AA(-)
DATA - DATA -
18GY 18GY 18GY 18GY
D A A D
T3BB(+) D3B(+) D3BB(+) T3BB(+)
DATA + DATA +
18DKBL 18DKBL 18DKBL 18DKBL
E D D E
T81-GD D81-GF D81-GD T81-GD
GND GND
12WH 12WH 12WH 12WH
B F E A
T8B D81-GG D81-GE T8A
ADDRESS 1 18WH ADDRESS 2
18WH 18WH 18WH
DOOR POD DOOR POD

LOAD LOAD
(3201) (3201)
WINDOW A A WINDOW
LEFT CREW
RIGHT CREW
WINDOW B B WINDOW
LOCK C C LOCK
LOCK D D LOCK
14LTGN
14LTGN
14LTGN
14LTGN
14LTGN
14LTGN
14LTGN
14LTGN
F81A
F81E
E81A
F83A
F83E
E83E
E81E
E83A
B A A B B A A B
DOOR LOCK WINDOW MOTOR WINDOW MOTOR DOOR LOCK

(3203) (3100) (3100) (3203)

CNA1 26JUL11 R/D 1005 WAS GROUND C 80257V
ADAPTER. 67696A 04AUG10 AE08064595 005

HORN – ELECTRIC AND AIR (CONT.), P. 6 CAB ACCESSORIES (CHAPTER 4)
4.6. HORN – ELECTRIC AND AIR (CONT.), P. 6

CHAPTER 4
HORN - ELECTRIC AND AIR (CONT)
NAVISTAR, INC.
ELECTRIC HORN W/O CRUISE CONTROL
BODY CONTROLLER #J3

CLOCK SPRING
(1600) IP / DCM (1809)
(1800) ELECTRIC
HORN
ELECTRIC B10
D
A85B B85B
HORN A5 20
20GY 18GY
SWITCH
DIN6
20
A
20
ELECTRIC HORN
ELECTRIC
HORN
BODY CONTROLLER #J1 (8301 / 8310)
(1603)
IP / CHASSIS
FORWARD
ELECTRIC (1700-21)
A
HORN A85E M85E
E 16GY
10A2 16GY
B
M85-GA
16WH
M11-G
12WH
LEFT SIDE
DASH MOUNTED
DUAL POST STUD
(4307) CH3_22

CNA1 26JUL11 ADDED SPLICE,M11-G, C 80257V
GROUND STUD. 67696A 04AUG10 AE08064595 006

CAB ACCESSORIES (CHAPTER 4) MIRRORS (HEATED, LIGHTED & POWER), P. 7
4.7. MIRRORS (HEATED, LIGHTED & POWER), P. 7

CHAPTER 4
MIRRORS (HEATED, LIGHTED & POWER)
NAVISTAR, INC.
BODY
PASSENGER CONTROLLER #J2
POWER (1604)
MIRROR
HEATER
LIGHT
PARK MARKER
ATN GND
CLEARANCE
IDENTIFICATION
AXIS
LAMP
U/D
AXIS
L/R
10A17
G
CLUSTER A B C D F E G
CONNECTOR
(1500)
18LTGN
18YL
18BN
16BL
18OR
18RD
18BK
CH8_05
16BN
A58
DIMR
OUT2 A62DA
5 BASE 1
PANEL 18DKBL PASS
ADAPTER
LT A B C D H F DOOR
J (1623)
(3003)
18LTGN
BODY A
18LTGN
16LTGN
18DKBL
A78E
A62DD
A78F
18LTGN
A78B
CONTROLLER #J1
A78D
(1603) D
A58DB
18BN
RIGHT C
A58DA
HEATED
18BN
MIRROR
10A15 L FUSE F4-B
18DKBL
A62BD
LEFT (1013)
18LTGN
HEATED A78A CH3_10

A78V
MIRROR H 16LTGN A78-GCE

10A16 DRIVER 16WH
DOOR
A78-GCF
(3000)
16WH
A11-GCA
J 10WH
A B C D E F G H
20YL
A11-GKJ
6WH
20BLGN
20WHBL
16BL
18DKGN
20YL
18BK
20YL
20BN
18RD
20OR
20WH
18BK
20OR
LEFT SIDE
CAB GND
MIRROR SW (4081)
CONN CH3_25
DRIVER POWER (254F) A1 A2 A3 A4 B1 B2 B3 B4
MIRROR
A B C D F E G
AXIS
ATN GND
L/R
AXIS
U/D
20LTGN
A78-GD
20DKBL
20LTGN
20LTGN
20LTGN
20LTGN
A78F
A62D
20WH
A78K
A78L
20RD
A78C
A78D
A78A
HEATER
LIGHT
MIRROR SWITCH
(254M)
CH4_21

CNA1 26JUL11 RMVD R/D 1002,1008; C 80257V

2 – WAY RADIO, P. 8 CAB ACCESSORIES (CHAPTER 4)
4.8. 2 – WAY RADIO, P. 8

CHAPTER 4
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF 2 - WAY RADIO
NAVISTAR, INC.
2-WAY RADIO BATT RADIO

BATTERY FEED FUSE POSITIVE CONN
N14HB A B N14HC
+ 10RD 10RD
20A
N14HC
10RD
BATT RADIO
NEGATIVE CONN
N14-GD N14-GD
- 10WH 10WH
2 WAY RADIO
B A IP / ENGINE
FUSE F9-A
CONNECTION
(1018)
(6334)
CH3_12
A11-GAP
A11-GAP
16LTGN
16LTGN
16WH
A14HF
A14HC
A86P
16WH
16RD
A86P
16RD
HEAT SHRINK
B A C
IGN GND BATTERY
OVERHEAD MTD
2 WAY RADIO FLOOR MOUNTED
CONNECTION 2-WAY RADIO
(6900) CONNECTIONS
(6334)

CNA1 25MAR11 REVISED FUSE B 76076F
CONNECTIONS. 67696A 04AUG10 AE08064595 008

CAB ACCESSORIES (CHAPTER 4) WASHER PUMP, P. 9
4.9. WASHER PUMP, P. 9

CHAPTER 4
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF WASHER PUMP
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 04AUG10 AE08064595 009

SELF CONTAINED AIR SEAT, P. 10 CAB ACCESSORIES (CHAPTER 4)
4.10. SELF CONTAINED AIR SEAT, P. 10

CHAPTER 4
NAVISTAR, INC.
SELF CONTAINED AIR SEAT
DRIVER SEAT PASSENGER

A B POWER A B SEAT POWER
(1918) (1935)
**A11-GR
**A14C
14WH
12WH
14RD
**A11-GP
*AH
12RD
*AD
**A14B
12WH
12RD
**A14A
12RD
FUSE F7-E
(1016)
CH3_15 *A14A
A11-GCN
14RD
*A11-GCN
12WH
14WH
A11-GCA
10WH
A11-GKJ
6WH
* W/DRIVER ONLY SELF CONTAINED AIR SEAT

** W/DRIVER & PASSENGER SELF CONTAINED
AIR SEATS
LEFT SIDE
CAB GROUND
(4081)
CH3_25

CNA1 26JUL11 RMVD R/D 1008. ADDED C 80257V
SPLICE. REVISED CIRCUITS. 67696A 04AUG10 AE08064595 010

CAB ACCESSORIES (CHAPTER 4) RADIO
(ENTERTAINMENT) SPEAKERS – W/ 16 WAY CONNECTOR, P. 11
4.11. RADIO (ENTERTAINMENT) SPEAKERS – W/ 16 WAY CONNECTOR, P. 11

CHAPTER 4
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF RADIO (ENTERTAINMENT), SPEAKERS - W/ 16 WAY
NAVISTAR, INC. CONNECTOR
RADIO
(1300)
FUSE F4-F
A86
RADIO POWER 4 (1013)
18LTGN
CH3_10
FUSE F2-E
A86A (1011)
RADIO MEMORY 7
18LTGN CH3_15,17
REAR TURNS
PANEL ADAPTER CLUSTER CONNECTOR
(1625) (1500)
M J
A62E A62 DIMR OUT1
PANEL LIGHT 6 4
18DKBL 18DKBL PANEL LT
BASE 1
ADAPTER BODY CONTROLLER #J2
(1623) (1604)
B A
PARK MARKER
A54D A58
PARK LIGHTS 3 G CLEARANCE
18BN 16BN ID LAMP
10A17
PREMIUM ROOF RIGHT CONSOLE SPEAKER

W/ PREMIUM
(2503) (2304)
TRIM
9 A
A86K C86K
RIGHT FRONT + 11
20LTGN 18LTGN
+
6 B -
A86L C86L
RIGHT FRONT - 12
20LTGN 18LTGN
LEFT CONSOLE
W/ PREMIUM
SPEAKER
TRIM
(2305)
8 A
A86H C86H
LEFT FRONT + 13
20LTGN 18LTGN
+
7 B -
A86J C86J
LEFT FRONT - 14
20LTGN 18LTGN
IP / ROOF RIGHT REAR

CONNECTION SPEAKER
(2000) (2301)
5 A
A86DA D86D
RIGHT REAR + 9 20LTGN 18LTGN
+
4 B -
A86EA D86E
RIGHT REAR - 10
20LTGN 18LTGN
LEFT REAR
SPEAKER
(2302)
13 A
LEFT REAR + A86BA D86B
15
20LTGN 18LTGN
+
1 B -
LEFT REAR - A86CA D86C
16
20LTGN 18LTGN
A86-G LEFT SIDE CAB

GROUND 8
18WH GROUND-CHASSIS
(1004)
CH3_24

CNA1 26JUL11 R/D 1004 WAS CH3_22. C 80257V
67696A 04AUG10 AE08064595 011

SATELLITE COMMUNICATION – MOBILEMAX, P. 12 CAB ACCESSORIES (CHAPTER 4)
4.12. SATELLITE COMMUNICATION – MOBILEMAX, P. 12

CHAPTER 4
SATELLITE COMMUNICATION - MOBILEMAX
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064595 012

CAB ACCESSORIES (CHAPTER 4) COMPUTER PREWIRED – XATA SYSTEM, P. 13
4.13. COMPUTER PREWIRED – XATA SYSTEM, P. 13

CHAPTER 4
COMPUTER PREWIRED - XATA SYSTEM
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064595 013

CADEC GPS SYSTEM, P. 14 CAB ACCESSORIES (CHAPTER 4)
4.14. CADEC GPS SYSTEM, P. 14

CHAPTER 4
CADEC GPS SYSTEM
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064595 014

CAB ACCESSORIES (CHAPTER 4) SATELLITE COMMUNICATION – TRIPMASTER, P. 15
4.15. SATELLITE COMMUNICATION – TRIPMASTER, P. 15

CHAPTER 4
SATELLITE COMMUNICATION - TRIPMASTER
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064595 015

SATELLITE COMMUNICATION – QUALCOMM IMCT, P. 16 CAB ACCESSORIES (CHAPTER 4)
4.16. SATELLITE COMMUNICATION – QUALCOMM IMCT, P. 16

CHAPTER 4
SATELLITE COMMUNICATION - QUALCOMM IMCT
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064595 016

CAB ACCESSORIES (CHAPTER 4) ROOF AUX LOAD, P. 17
4.17. ROOF AUX LOAD, P. 17

CHAPTER 4
ROOF AUX LOAD
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

CNA1 25MAR11 REMOVED GEOMETRY B 76076F
67696A 15OCT10 AE08064595 017

MIRRORS (HEATED, LIGHTED & POWER) (CONT.), P. 18 CAB ACCESSORIES (CHAPTER 4)
4.18. MIRRORS (HEATED, LIGHTED & POWER) (CONT.), P. 18
NAVISTAR, INC ELECTRICAL CIRCUIT DIAGRAM4

CHAPTER
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF MIRRORS (HEATED, LIGHTED & POWER) (CONT)
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064595 018

CAB ACCESSORIES (CHAPTER 4) SATELLITE
COMMUNICATION – QUALCOMM IMCT W/ MVPC KEYBOARD, P. 19
4.19. SATELLITE COMMUNICATION – QUALCOMM IMCT W/ MVPC KEYBOARD, P. 19

CHAPTER 4
SATELLITE COMMUNICATION - QUALCOMM
IMCT W/ MVPC KEYBOARD
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064595 019

SATELLITE COMMUNICATION – QUALCOMM OMNIVISION, P. 20 CAB ACCESSORIES (CHAPTER 4)
4.20. SATELLITE COMMUNICATION – QUALCOMM OMNIVISION, P. 20

CHAPTER 4
SATELLITE COMMUNICATION - QUALCOMM OMNIVISION
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064595 020

CAB ACCESSORIES (CHAPTER 4) MIRRORS (HEATED, LIGHTED & POWER) (CONT.), P. 21
4.21. MIRRORS (HEATED, LIGHTED & POWER) (CONT.), P. 21

CHAPTER 4
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF MIRRORS (HEATED, LIGHTED & POWER) (CONT)
NAVISTAR, INC.
MIRROR SWITCH
(254M)
A1
A62D
20DKBL
A2
A78L
20RD
A3
A78K
20LTGN
DRIVER / PASSENGER A4
A78-GD
POWER MIRROR 20WH
(3000 / 3003) B1
A78A
CH4_07
20LTGN
A78D B2
20LTGN
B3
A78C
20LTGN
A78F B4
20LTGN

CNA1 25MAR11 REMOVED HEATED MIRROR B 76076F
CIRCUITRY. 67696A 15OCT10 AE08064595 021

CB POWER RADIO, P. 22 CAB ACCESSORIES (CHAPTER 4)
4.22. CB POWER RADIO, P. 22

CHAPTER 4
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF CB POWER RADIO
NAVISTAR, INC.
FUSE F4-F
(1013)
CH3_10
18LTGN
A86F
CB RADIO ROOF / IP
CONSOLE / ROOF
POWER CONNECTOR CONNECTION
(2502)
(2303) (2000)
12
A
C86F D86F
A
16LTGN 16LTGN
B 11
C86-GF C11-GF D11-GF
B
16WH 16WH 16WH
A11-GF
16WH
A11-GS
10WH
LEFT SIDE
CAB GROUND
(1005)
CH3_20

CNA1 26JUL11 ADDED SPLICE, A11-GS C 80257V
AND GROUND STUD. 67696A 15OCT10 AE08064595 022

CAB ACCESSORIES (CHAPTER 4) BACK-UP CAMERA, P. 23
4.23. BACK-UP CAMERA, P. 23

CHAPTER 4
NAVISTAR, INC.
BACK-UP CAMERA
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064595 023

HEATED SEATS, P. 24 CAB ACCESSORIES (CHAPTER 4)
4.24. HEATED SEATS, P. 24

CHAPTER 4
NAVISTAR, INC.
HEATED SEATS
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064595 024

CAB ACCESSORIES (CHAPTER 4) SWITCH PACK OPTIONAL GAUGE RACK, P. 25
4.25. SWITCH PACK OPTIONAL GAUGE RACK, P. 25

CHAPTER 4
NAVISTAR, INC.
SWITCH PACK OPTIONAL GAUGE PACK
SWITCH PACK
(1101)
LEFT SIDE DASH MOUNTED A11-GS A11-GKD A

DUAL POST GROUND PLATE 12WH 18WH GROUND
(1005) CH3_20
B
FUSE F4-K A12F
(1013) CH3_10 18LTBL POWER
REAR TURN PANEL ADAPTER C TO PREVIOUS

AA62DB
BACKLIGHT
(1625) CH9_06 18DKBL SWITCH PACK
A3A(+)
E2 18DKBL
J1708
A3C(+) D SW DATA
PRIVATE (+)
18DKBL LINK (+)
(1927)
CH3_04
A3A(-)
E1
18GY
J1708 A3C(-) E SW DATA
BODY CONTROLLER PRIVATE (-) LINK (-)
18GY
(1602) (1929)
CH3_04
SWITCH PACK
(1101A)
C
BACKLIGHT
TO NEXT
SWITCH PACK
OR OPTIONAL
B
ACCESSORY GAUGE PACK
POWER
A
GROUND
NOTES:
1. FOR MULTIPLE SWITCH
PACKS, CONNECT 1101
OF NEXT SWITCH PACK
TO 1101A OF PREVIOUS
SWITCH PACK.
2. CONNECT OPTIONAL GAUGE

PACK TO LAST SWITCH
PACK.

CNA1 26JUL11 ADDED SPLICE, A11-GS, C 80257V
AND GROUND STUD. 67696A 01NOV10 AE08064595 025

WINDSHIELD WIPER, P. 26 CAB ACCESSORIES (CHAPTER 4)
4.26. WINDSHIELD WIPER, P. 26

CHAPTER 4
WINDSHIELD WIPER
NAVISTAR, INC.
C/B WINDSHIELD
A82 WIPER POWER
A 10A20
16GY
A
B+ A82D A82E
16GY 16GY BODY
CONTROLLER
B
PRK A82V #J2 (1604)
WV50V 16GY
A
2.2uFx2
C LEFT SIDE
GND A82-G CAB GROUND
14WH (4081)
4.4uH x3 CH3_21
D
HIGH A82K
16GY
A82M
16GY
A82N
16GY
E
LOW A82L
16GY
WIPER MOTOR
(4500)
WIPER HIGH / LOW WIPER POWER

BODY CONTROLLER RELAY RELAY
#J4 (1601) (1012) (1012)
WINDSHIELD G3 G1
WIPER
85 86 86 85
HIGH / LOW A82H J4 J2
SPEED E6 18GY
RD2 (LSD)
G4 G2
87 87
H4 J3 A82P J1 H2
16GY
87A 30 30 87A
WASHER PUMP
WINDSHIELD (9745)
WIPER POWER A82F
E7
RD1 (LSD) 18GY TURN SIGNAL
IP / DCM
(1800) SWITCH
BODY CONTROLLER (1810)
#J5 (1602)
A4 7
A9AA A9V B9V B9S
ZVR E5 18GY 18GY 18GY 18GY
20WH
WIPER 0
BODY CONTROLLER
#J3 (1600) 20GN 2 1
C9 8
WIPER SW 'O' A82A B82
A9 WIPER 1
DIN10 20GY 18GY
C1 11 20RD
WIPER SW '1' A82B B82A
A10
DIN11 20GY 18GY
WIPER 2
A82C B1 B82B 5
WIPER SW '2'
A11 20GY 18GY 20OR
DIN12
A5 12
WASHER PUMP A987B A87A B87A
A15 20YL
DIN16 20GY 20GY 20GY WASHER
A3 6
LEFT A11-GA B11-GAA
SIDE 18WH 18WH 20WH
CAB GND
(1005) IP/CENTER
CH3_20 58 (1701)
A87DB N87DB
18GY 18GY
FUSE F4-H 59
(1013) A87MB N87MB
CH3_12 18GY 16GY
WASHER FLUID GROUND
N87EA 41
LOW SWITCH A8 N87EA N87-G ADAPTER
DIN9 18GY 18GY 18GY
1 2 #01 (8807)
CH3_23
WASHER LEVEL
SENSOR (9746)

- - R/D 1005 WAS ADAPTER. B 80257V
76076F 16FEB11 AE08064595 026

CAB ACCESSORIES (CHAPTER 4) SEATBELT & SEAT SENSOR, P. 27
4.27. SEATBELT & SEAT SENSOR, P. 27

CHAPTER 4
NAVISTAR, INC.
SEATBELT & SEAT SENSOR
FRONT FRONT
CENTER CENTER
SEATBELT SEAT
SWITCH SWITCH
(3000) (3001)
A B A B
D11-GJA
D11-GCA
D11-GC
D11-GJ
18WH
18WH
18WH
18WH
ROOF IP (1)
SEAT 1 9 10 11 12
3 5 7 2 4 6 8
CONNECTION
(8996)
A11-GHA
A11-GGA
A11-GBA
A11-GJA
A11-GAA
A11-GCA
A11-GA
A11-GG
A11-GB
A11-GH
A11-GJ
A11-GC
18WH
18WH
18WH
18WH
18WH
18WH
18WH
18WH
18WH
18WH
18WH
18WH
SEATBELT
SEAT
INDICATOR
GROUND (8999)
ADAPTER CH4_29
(8995) (8882)
CH3_19 CH4_30

CNA1 25MAR11 INITIAL RELEASE A 76076F
76076F 16FEB11 AE08064595 027

SEATBELT & SEAT SENSOR (CONT.), P. 28 CAB ACCESSORIES (CHAPTER 4)
4.28. SEATBELT & SEAT SENSOR (CONT.), P. 28

CHAPTER 4
NAVISTAR, INC.
SEATBELT & SEAT SENSOR (CONT)
ROOF IP(2)
SEAT 1 3 5 7 9 11 2 4 6 8 10 12
CONNECTION
(8997)
A11-GFA
A11-GLA
A11-GEA
A11-GMA
A11-GDA
A11-GKA
A11-GK
A11-GE
A11-GL
A11-GD
A11-GF
A11-GM
18WH
18WH
18WH
18WH
18WH
18WH
18WH
18WH
18WH
18WH
18WH
18WH
SEATBELT
SEAT
INDICATOR
GROUND
(8999)
ADAPTER
CH4_29
(8995)
(8882)
CH3_19
CH4_30

76076F 16FEB11 AE08064595 028

CAB ACCESSORIES (CHAPTER 4) SEATBELT & SEAT SENSOR (CONT.), P. 29
NAVISTAR, INC ELECTRICAL CIRCUITCHAPTER

DIAGRAM 4
NAVISTAR, INC.
SEATBELT
SEAT INDICATOR
(8999) *
A11-GM
7 18WH
6 A11-GF
18WH
A11-GL ROOF IP (2)

8 18WH SEAT CONNECTION
(8997)
A11-GE CH4_28
5 18WH
A11-GK
9
18WH
A11-GD
4 18WH
A11-GJ
10 18WH
3 A11-GC
18WH
A11-GH ROOF IP (1)

11
(8996)
A11-GB CH4_27
2
18WH
A11-GG
12
18WH
A11-GA
1
18WH
SEATBELT
DATA RECORDER N/DISPLAY
(8998) *
GROUND ADAPTER
A11-G
12 (8995)
18WH
CH3_19
A13P FUSE F5-D

10 18RD (1014) CH3_14
A3D(+) J1708 PUBLIC(+)

4 (1660) CH3_03
20DKBL
A3D(-) J1708 PUBLIC(-)

5
20GY (1661) CH3_03
A5D(+)
6
18YL J1939 ADAPTER
(1025)
A5D(-) CH3_11
7
18GN
* PREWIRE ONLY

CNA1 26JUL11 A13P WAS A14R. FUSE B 80257V
F5-D WAS F7-G. 76076F 16FEB11 AE08064595 029

SEATBELT & SEAT SENSOR (CONT.), P. 30 CAB ACCESSORIES (CHAPTER 4)

DIAGRAM 4
NAVISTAR, INC.
SEATBELT
SEAT INDICATOR
(8882)
A11-GM
9 18WH
4 A11-GF
18WH
A11-GL ROOF IP (2)

8 18WH SEAT CONNECTION
(8997)
A11-GE CH4_28
5
18WH
A11-GK
10
18WH
A11-GD
3 18WH
A11-GJ
7 18WH
6 A11-GC
18WH
A11-GH ROOF IP (1)

11
(8996)
A11-GB CH4_27
2
18WH
A11-GG
12
18WH
A11-GA
1
18WH
SEATBELT
DATA RECORDER W/DISPLAY
(8881)
A5(+)
8
18YL J1939 ADAPTER
(1025)
A5(-) CH3_11
5
18GN
A5A
6 A
18GN
A5B
7 B
18YL
A11A A11AA C
12
18WH 18WH
A11-G GROUND ADAPTER

18WH (8995) CH3_19
A13A A13AA
10 D
18RD 18RD
A13P FUSE F5-D (1014) (8883)

18RD CH3_14 IP/ROOF

CNA1 26JUL11 UPDATED IGN AND GND B 80257V
CIRCS AT R/D 8881 AND 8883. 76076F 16FEB11 AE08064595 030

12V CHARGING AND CRANKING SYSTEM (CHAPTER 5)
5. 12V CHARGING AND CRANKING SYSTEM (CHAPTER 5)

5.1. STARTING & CRANKING ENGINE W/ ALLISON TRANSMISSION, P. 1

CHAPTER 5
STARTING & CRANKING
NAVISTAR, INC.
ENGINE W/ ALLISON TRANSMISSION
KEY SWITCH
(1100)
FUSE F3-A
(1012) CH3_08,16 BATT
18RD
ALTERNATOR
A15
MEGA FUSE OFF
CH3_01,08 S IGN ACC
R
CH10_01,03
A B D C
G B
K2 START RELAY
A17H
K14H
4RD
(1010)
16PK
87A
30
SEE NOTE
K2-G
SEE NOTE B3 A4
87
A17A
18PK
LEFT SIDE
ENGINE
BLOCK B4
86
GROUND A3
85
A17C
16PK
A17M
18PK
K11-GL
FUSIBLE
2WH
LINKS
A104CC HOOD SWITCH

18DKBL (8805) CH10_14
IP / ENGINE
16 18 (1702)
LEFT SIDE
DASH MTD
W/ REMOTE
DUAL POST
START STOP
GND PLATE
K17C
16PK
K17K
18PK
BATTERIES
K17M
18PK
ECM
K17M
18PK
1/ORD (6020M)
+ + 2/ORD
ENGINE
B 64 CRANK
B
S S INHIBIT
1/OBK
- - S
M N/ THERMAL
ECM
OVERCRANK
(6020M)
B PROTECTION
G
ENGINE
A 7 CRANK
K17L INHIBIT
18PK
THERMAL W/ THERMAL
2/0BK
OVERCRANK OVERCRANK
2/0BK
(6316M) PROTECTION
LEFT SIDE FRAME GND

(LOCATED AT LEFT FRAME
RAIL NEAR STARTER)
NOTE: WITH 4 GAUGE CHARGE CIRCUITS K2-G & K2 FUSIBLE LINKS ARE 2 - 12BL
WITH 2 GAUGE CHARGE CIRCUITS K2A-G & K2A FUSIBLE LINKS ARE 2 - 10RS
WITH 1 GAUGE CHARGE CIRCUITS K2-GB & K2B FUSIBLE LINKS ARE 3 - 10RS
FOR CIRCUIT K14H FUSIBLE LINKS ARE 2-12BL

CNA1 25MAR11 REVISED FUSE CONN. B 76076F
REMOVED V8 ENGINE LABEL. 67696A 04AUG10 AE08064596 001

ROCKER START, P. 2 12V CHARGING AND CRANKING SYSTEM (CHAPTER 5)
5.2. ROCKER START, P. 2

CHAPTER 5
ROCKER START
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064596 002

FANS AND ENGINE ACCESSORIES (CHAPTER 6)
6. FANS AND ENGINE ACCESSORIES (CHAPTER 6)

6.1. FAN WIRING – V8 ENGINE, P. 1

CHAPTER 6
FAN WIRING - V8 ENGINE
NAVISTAR, INC.
FAN RELAY
(1015) ECM
IP / ENGINE (6020M)
D4 (1702)
85
86
C3 29
A23B K23L ENGINE FAN
91
A23C
18TN
18TN 18TN CONTROL
24
D3
87
A23A K23E K23C ENGINE FAN

58
18TN 18VT 18TN CONTROL
FUSE F10-A C4
A23
(1019)
18TN
30
CH7_01
87A
E-FAN
(6561)
GROUND
SPLICE K23D
(6704M) A
16TN
D
K10-GG
B
16WH
C
K10-GB
14WH
ENGINE BLOCK GND

(6304A)

CNA1 25MAR11 REMOVED I6 ENGINE B 76076F
CIRCUITRY. 67696A 15OCT10 AE08064597 001

SNOWVALVE, P. 2 FANS AND ENGINE ACCESSORIES (CHAPTER 6)
6.2. SNOWVALVE, P. 2

CHAPTER 6
SNOWVALVE
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064597 002

ELECTRONIC ENGINES (CHAPTER 7)
7. ELECTRONIC ENGINES (CHAPTER 7)

7.1. ELECTRONIC ENGINE CONTROLS – V8 ENGINE, P. 1

CHAPTER 7
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF ELECTRONIC ENGINE CONTROLS - V8 ENGINE
NAVISTAR, INC.
ENGINE ECM
ENGINE / IP
(6020M)
(1702)
35
K3A(+) A3AA(+)
J1708 (+) 32 J1708
18DKBL 18DKBL PUBLIC (+) / (-)
36 (1660 / 1661)
K3A(-) A3AA(-)
CH3_03
J1708 (-) 31 18GY 18GY
37 FUSE F1-A
IGNITION K97UB A97UA (1010)
97
KEY POWER 18PL 16PL CH3_02
FUSE F10-A(1019)
ENGINE /
1 E1 F1 FAN RELAY
MELROSE K97NA A97Z A23
(1015)
(6011) 10PL 10VT 18TN
5A CH6_01
CH7_04
IP / DCM ACCELERATOR
(1800) PEDAL MODULE
(1804)
23 B4 B
APS SIGNAL K97B A97B B97Y
4 18PL
GND 18PL 18PL
28 C4 A
ACCELERATOR K99B A99B B99V
POSITION 72 18PL
18PL 18PL
SIGNAL
22 C5 C
K97C A97C B97P
5V REF 25 18PL 18PL
18PL
30 B5 D
IDLE K97FU A97M B99U
VALIDATION 67 18PL 18PL
18PL
SWITCH E
32 B6
K97WC A97WC B99W
MAT 47 18PL 18PL 18PL
33 C6 F
K97M A97M B99E
SIG_RTNI_2 6
18PL 18PL 18PL
38
K47DF FUSE F11-B

9 IGN A97DF
18PL (1020)
18PL
CH3_14
K47B
INJ_E_R 89 6 VSO
18GY
K46A
MAF_RTN 75 2 RAS
18GY
K46B
77 4 SCS
18GY
INJ_D_R K97AR
92 5 TACH
18PL
ENG ECM BODY
79 K97CB 1 BUILDER (7207M)
RPRE
18PL
K97CC
CAN1H 13 3 RVAR
18PL
K97FV
68 8 VREF3
18PL
EGRVP 46 K97WA 10 SR3-GND
18PL
34 K97XC 11 XCS
18PL
K99F
74 12 RPS
18PL
ENG ECM BODY

TBVC 41 K97EW 1 BUILDER 2 (7208M)
18PL
35 K97SE 2
18PL
ENGINE / MELROSE
MAP 9 K97T (6011)
18PL CH7_04


ELECTRONIC ENGINE CONTROLS – V8 ENGINE (CONT.), P. 2 ELECTRONIC ENGINES (CHAPTER 7)
7.2. ELECTRONIC ENGINE CONTROLS – V8 ENGINE (CONT.), P. 2

CHAPTER 7
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF ELECTRONIC ENGINE CONTROLS (V8 ENGINE) (CONT)
NAVISTAR, INC.
ECM XMSN CONTROL

(6020M) MODULE
(7151)
K92#141 NEUTRAL
EGRTCL 60 41 START
18TN
N/ENGINE BODY BUILDER

XMSN CONTROL
MODULE
W/ENGINE BODY BUILDER
(7151)
K47#125 SPEEDO
25
18TN METER
K47B125 K47#125
IAT 69
18TN 18TN
ALLISON
K47C125 SPEEDO 1 / 2000 ENGINE
18TN D BODY BUILDER
METER
(7205F)
K97N ENGINE / MELROSE

K97JC
63 10PL (6011)
18PL
5 4 3 CH7_04
85 87A
ECM MAIN
POWER RELAY 87
(6022)
30
86
K14KA K97XB 2 1
INJ_H_D 98
18RD 16VT
K97XA
10PL
ENGINE / MELROSE
K97T
MAP 9 (6011)
18PL LOW COOLANT SENSOR
CH7_04
(6400)
K34AA LOW COOLANT

8 2
18TN SENSOR
ZERO VOLT K34-GG
1 GND2
REFERENCE 18WH
(6747)
CH3_07

CNA1 26JUL11 CONN 6400: CAVITIES C 80257V
WERE A AND B. 67696A 04AUG10 AE08064598 002

ELECTRONIC ENGINES (CHAPTER 7) ELECTRONIC ENGINE CONTROLS – V8 ENGINE (CONT.), P. 3

CHAPTER 7
ELECTRONIC ENGINE CONTROLS (V8 ENGINE) (CONT)
NAVISTAR, INC.
ECM EGT1 SENSOR BLACK

(6020M) (6260T)
VREF1_1 K95KK
7 2 EGT1
18TN
K95S4
1 SIG GND
18TN
ZERO VOLT
K95NN REFERENCE
5 18TN (6747)
CH3_07
EGT2 SENSOR
LIGHT GREY
(6261T)
K95JJ
EOP 73 2 EGT2
18TN
K95F3
1 SIG GND
18TN
EXHAUST DELTA P
SENSOR
(6263T)
K95A1 K95F1 SIG

1
18TN 18TN GND
K95JT
VREF1_2 26 3 5V REF
18TN
K95HH
51 2 DELTA P
18TN
EGT3 SENSOR
DARK GREY
(6262T)
K95F2 1 SIG GND

18TN
K95LL
SIG_RTN1_1 29 2 EGT3
18TN

CNA1 25MAR11 REVISED ZVR B 76076F

ELECTRONIC ENGINE CONTROLS – V8 ENGINE (CONT.), P. 4 ELECTRONIC ENGINES (CHAPTER 7)

CHAPTER 7
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF ELECTRONIC ENGINE CONTROLS (V8 ENGINE) (CONT)
NAVISTAR, INC.
ENGINE / MELROSE
(6011)
ECM
K97T
SIG_RTNI_2 6 (6020M)
18PL
CH7_01,02 ENGINE LEFT
SIDE BLOCK
GROUND
(6304A)
IP / ENGINE
CKP- K19-GM K19-GP
1 (1702)
14GY 12GY
K19BA K19B
8 34
14GY 12GY
ECM MAIN
K97NC K97NB K97N POWER RELAY
FVCV 16
14PL 10PL 10PL (6022)
CH7_02
ENGINE / IP
K97NA (1702)
10PL
CH7_01
(6405)
K97D FUEL
B
16PL COOLER
K59A A SOLENOID
18GY
ECM
(6020M)
14
K97ND
16PL 83
K97NE
84
16PL
K97NF
85
16PL
K97-GH K97-GK
MAP 9 87
14WH 18WH
K97-GL
86
18WH
K97-GM
18WH 88
K97X K14KA
98
8VT 18RD
BATTERY
K97AA
10RD
+ -
BTRY ECM
ENG ECM FUSE
POSITIVE
(9254)
(9261-A)
B A
N14BA N14AY
10RD 10RD
40A
ECM
NEGATIVE
(9260-C)
K97-GN K97-GP N14-G
8WH 10WH 10WH

CNA1 26JUL11 9260-C WAS 6260-C. C 80257V
67696A 15OCT10 AE08064598 004

ELECTRONIC ENGINES (CHAPTER 7) ELECTRONIC
ENGINE CONTROLS – V8 ENGINE CRUISE CONTROLS, P. 5
7.5. ELECTRONIC ENGINE CONTROLS – V8 ENGINE CRUISE CONTROLS, P. 5

CHAPTER 7
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF ELECTRONIC ENGINE CONTROLS-V8
NAVISTAR, INC. ENGINE CRUISE CONTROLS
STEERING WHEEL SWITCHES
CRUISE OFF
CRUISE ON
CITY HORN
RESUME
SET
BODY CONTROLLER J3
(1600)
6190 OHM
2370 OHM
1210 OHM
ELECTRIC
HORN SW
A5
A85B
20GY
D C B A
IP/DCM
(1800)
CLOCK
B10
SPRING
(1809)
D C B A
CLUTCH
D C B A SWITCH
(1807)
B85B
B17H
B9VB
18GY
18PK
B96A
18VT
B17J
18PK
18GY
18GY
B9R
STOP LIGHT
(1814A)
B
B9VF
6.8V
18GY
OHMS
150
18GY
18VT
18RD
B9V
B96
B70
TURN
SIGNAL B9S
7 18GY
SWITCH
(1810)
C11
B12
DCM
D8
D7
A9V A4
B9
CONN
(1800)
18GY
20RD
20GY
A70
A97
A9AA
20GY
BODY BODY
CONTROLLER CONTROLLER J5
B16 E14 E5
(1600) (1602)

76076F 16FEB11 AE08064598 005

GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8)
8. GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER

8)
8.1. BRAKE SWITCH & PARK BRAKE SWITCH, P. 1

DIAGRAM 8
BRAKE SWITCH & PARK BRAKE SWITCH
NAVISTAR, INC.
BODY DCM
CONTROLLER #J5 CONN
(1602) (1800) BRAKE
SWITCH
(1814A)
B9
A70 B70 A
E14
20RD 20RD
A9AA A9V A4 B9VF

B9V
E5 B
18GY 18GY 18GY 18GY
IP/ENGINE
ZERO VOLT (1702-2)
REFERENCE K9E A9E
(6747) 18GY 20GY
CH3_07
IP/ROOF A9L
(2000-14) 18GY
BODY
CONTROLLER #J3
(1600)
B7
A44A
A12
18GY

TITLE WAS HYDRAULIC. 67696A 04AUG10 AE08064599 001

GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8) GAUGES &
WARNING LIGHTS – AMMETER, P. 2
8.2. GAUGES & WARNING LIGHTS – AMMETER, P. 2

CHAPTER 8
GAUGES & WARNING LIGHTS - AMMETER
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 04AUG10 AE08064599 002

AIR PARK BRAKE, P. 3 GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8)
8.3. AIR PARK BRAKE, P. 3

CHAPTER 8
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF AIR PARK BRAKE
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 04AUG10 AE08064599 003

GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8) AIR
PRESSURE INPUT CIRCUIT, P. 4
8.4. AIR PRESSURE INPUT CIRCUIT, P. 4

DIAGRAM 8
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF AIR PRESSURE INPUT CIRCUIT
NAVISTAR, INC.
BODY CONTROLLER#J5
(1602) IP / FORWARD AIR COMPRESSOR
CH3_07 CHASSIS HYD BRAKES
(1700) (8505)
27 A
ZVR A9ZA A9ZB S9A
E3
18GY 18GY 18GY
BODY 28 B
+5V OUTPUT A6A S6A
CONTROLLER#J5 E8 18GY
SSOUT 18GY
(1602)
29 C
BODY PRIMARY AIR A40 S40
CONTROLLER#J3 PRESSURE B2 18GY 18GY
(1600) AIN2

CNA1 26JUL11 A9ZB WAS A9A. ADDED C 80257V
A9ZA AND R/D 1602. 67696A 15OCT10 AE08064599 004

IP GAUGES & WARNING LIGHTS – GAUGE CLUSTER, P. 5 GAUGES WITH AND
WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8)
8.5. IP GAUGES & WARNING LIGHTS – GAUGE CLUSTER, P. 5

CHAPTER 8
IP GAUGES & WARNING LIGHTS - GAUGE CLUSTER
NAVISTAR, INC.
CLUSTER CONNECTOR
(1500)
A28 FUSE F2-G

BATTERY 2 (1011)
16TN
CH3_08,16
REAR TURNS
DIMR OUT1 A62 PANEL ADAPTER
4
PANEL LT 18DKBL (1625) CH9_06
A62BD DRIVER DOOR

18DKBL CONN (3000)
CH4_07
DIMR OUT2 A62DA PANEL LIGHT FEED

5
PANEL LT 18DKBL SPLICE CH9_06
FUSE F4-L
A28A (1013)
IGNITION 7
18TN CH3_12
A28-G A11-GS
GROUND 1 12WH
16WH LEFT SIDE
CAB GND
(1005)
CH3_20
BODY CONTROLLER #J5

(1602)
HEAD LIGHT
HEADLIGHT A52C
14 E11 ENABLE
ENABLE 20YL
HLE
TEMPERATURE
SENDER
IP / FWD CHASSIS
(8601)
(1700)
25 B
A110AD NJ110AD
ZVR 8 18GY
18GY
CLUSTER CONNECTOR
(1501)
16 A
OUTSIDE A41 NJ41
9
TEMP 18GY 18GY
(AIN3)

CNA1 26JUL11 ADDED SPLICE, A11-GS, C 80257V

GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8) IP / GAUGES, P. 6
8.6. IP / GAUGES, P. 6

CHAPTER 8
IP / GAUGES
NAVISTAR, INC.
INSTRUMENT PANEL GAUGES
WARN SENSOR
GAUGE SIGNAL PATH
LIGHT LOCATION
RPM (TACH) NO ENGINE CTRLR / DRIVE TRAIN J1939 / CLUSTER ENGINE
MPH/KPH (SPD) NO ENGINE CTRLR / DRIVE TRAIN J1939 / CLUSTER TRANSMISSION
FUEL YES SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER FUEL TANK
VOLT YES SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER -
INSIDE CAB-DASH
AIR 1 (PRES) YES SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER
PNL
STEERING COL
AIR 2 (PRES) YES SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER
AREA
WATER (TEMP) YES ENGINE CTRLR / DRIVE TRAIN J1939 / CLUSTER ENGINE
ENG OIL (TEMP) YES ENGINE CTRLR / DRIVE TRAIN J1939 / CLUSTER ENGINE
OIL (PRES) YES ENGINE CTRLR / DRIVE TRAIN J1939 / CLUSTER ENGINE
TRANS (TEMP) YES SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER TRANSMISSION
AIR APPLICATION NO SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER FWD CHASSIS
REAR AXLE TEMP YES SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER AXLE
NOTES:
1. WARNING LIGHTS ARE PART OF THE GAUGES AND ARE LOCATED IN THE GAUGE
U00KDD2 CIRCUIT DIAGRAM, TERRASTAR

CNA1 26JUL11 INITIAL RELEASE. A 80257V
80257V 24JUN11 AE08064599 006

WARNING LIGHTS LIST, P. 7 GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8)
8.7. WARNING LIGHTS LIST, P. 7

CHAPTER
WARNING LIGHTS LIST
NAVISTAR, INC.
IP WARNING LIGHTS
WARNING LIGHT
SIGNAL PATH SENSOR LOCATION
TITLE
RANGE INHIBITED TRANS CTRLR / DRIVE TRAIN J1939 / CLUSTER
FUEL FILTER SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER FUEL FILTER
ENGINE
ENGINE CTRLR / DRIVE TRAIN J1939 / CLUSTER
(YELLOW LED)
ENGINE
ENGINE CTRLR / DRIVE TRAIN J1939 / CLUSTER
(RED LED)
BRAKE PRESSURE (O) SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER SWITCH
BRAKE FLUID SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER BRK RESERVOIR
TRAC CTRL TRUCK ABS CTRLR / DRIVE TRAIN J1939 / CLUSTER
CHECK TRANS TRANS CTRLR / DRIVE TRAIN J1939 / CLUSTER
TRAILER ABS TRLR ABS CTRLR / DRIVE TRAIN J1939 / CLUSTER
WASHER FLUID SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER WASHER BOTTLE
(LEFT TURN) SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER TURN SIG SW
AIR BAG DISCRETE NOT ON DATA BUS
WATER IN FUEL SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER FUEL FILTER
COOLANT LEVEL ENGINE CTRLR / DRIVE TRAIN J1939 / CLUSTER SURGE TANK
CHECK ELECT SYS SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER
PARK (P) SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER SWITCH
CRUISE SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER
ABS TRUCK CTRLR / DRIVE TRAIN J1939 / CLUSTER
(RIGHT TURN) SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER
WAIT TO START ENGINE CTRLR / DRIVE TRAIN J1939 / CLUSTER
FASTEN BELTS SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER
(HIGH BEAM IND) SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER
COLD AMB PROT SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER
RETARD OVERHEAT TRANS CTRLR / DRIVE TRAIN J1939 / CLUSTER TRANSMISSION
CHECK AC SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER
AUTO NEUTRAL DISCRETE NOT ON DATA BUS SWITCH
ALTERNATOR DISCRETE NOT ON DATA BUS
PTO/THROTTLE SYSTEM CTRLR / DRIVE TRAIN J1939 / CLUSTER
OPTIMIZED IDLE DISCRETE NOT ON DATA BUS
SNOW VALVE DISCRETE NOT ON DATA BUS SNOW VALVE
FR AXLE DIFF LOCK DISCRETE NOT ON DATA BUS FWD RR AXLE
RR AXLE DIFF LOCK DISCRETE NOT ON DATA BUS RR RR AXLE
MESSAGE WAIT DISCRETE NOT ON DATA BUS
PTO DISCRETE NOT ON DATA BUS
CONVERTER TEMP DISCRETE NOT ON DATA BUS
TOUCH LOC RELEASE DISCRETE NOT ON DATA BUS
PARK FLUID SYSTEM CTRLR/DRIVE TRAIN
FR AXLE ENGAGED DISCRETE NOT ON DATA BUS TRANSFER CASE

80257V 24JUN11 AE08064599 007

GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8) WARNING LIGHTS
CONTROLLING BY ENGINE, TRANSMISSION, ABS CONTROLLER, P. 8
8.8. WARNING LIGHTS CONTROLLING BY ENGINE, TRANSMISSION, ABS

CONTROLLER, P. 8

CHAPTER 8
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF WARNING LIGHTS CONTROLLED BY ENGINE,
NAVISTAR, INC. TRANSMISSION, ABS CONTROLLER
THE FOLLOWING WARNING LIGHTS ARE CONTROLLED BY THE ENGINE,TRANSMISSION,

OR ABS CONTROLLER OVER THE DATA BUS AND DO NOT HAVE INDEPENDENT CIRCUITS
THAT CAN BE OR NEEDS TO BE SHOWN:
DO NOT SHIFT
ENGINE (YELLOW LENS)
ENGINE (RED LENS)
TRAC CTRL
CHECK TRANS
TRAILER ABS
CHECK ELECTR SYS
ABS
WAIT TO START
RETARD OVERHEAT
AUTO NEUTRAL
OPTIMIZED IDLE

80257V 24JUN11 AE08064599 008

ENG OIL PRESS & TEMP, SPEEDOMETER, TACH, VOLTMETER & WATER TEMP GAUGE CIRCUITS, P.
9 GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8)
8.9. ENG OIL PRESS & TEMP, SPEEDOMETER, TACH, VOLTMETER & WATER TEMP
GAUGE CIRCUITS, P. 9

DIAGRAM 8
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF ENG OIL PRESS & TEMP, SPEEDOMETER, TACH,
NAVISTAR, INC. VOLTMETER & WATER TEMP GAUGE CIRCUITS
REFER TO CONSOLIDATED ENGINE / VEHICLE CONTROLLER

DIAGNOSTICS MANUAL EGES-175 (DT466E), EGES-190 (T444E), FOR CIRCUIT
DIAGRAMS SHOWING INPUT CIRCUIT FOR THE FOLLOWING DATALINK DRIVEN SYSTEM:
ENGINE OIL PRESSURE GAUGE
ENGINE OIL TEMPERATURE GAUGE
SPEEDOMETER GAUGE
TACHOMETER GAUGE
WATER TEMPERATURE GAUGE

80257V 21JUL11 AE08064599 009

GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8) FUEL GAUGE
CIRCUITRY (SINGLE TANK AND DUAL TANK), P. 10
8.10. FUEL GAUGE CIRCUITRY (SINGLE TANK AND DUAL TANK), P. 10

CHAPTER 8
FUEL GAUGE CIRCUITRY (SINGLE TANK AND
DUAL TANK)
NAVISTAR, INC.
BODY CONTROLLER #J3 BODY CONTROLLER #J5

(1600) (1602)
FUEL SNSR
A36A A9 A9B ZVR
SIGNAL 1 B8 E7
18TN 18GY 18GY
DRAW TANK
IP / CENTER
CHASSIS RIGHT SIDE
27 13
(1701) FUEL TANK
LEVEL SENSOR
(9101)
N9B
16GY B
N36A
18TN
A
AF MOUNTED
FUEL TANK REAR / CENTER
LEVEL SENSOR CHASSIS SENSOR RESISTANCE
(9100) (9800) FULL - 33.0 1.0 OHMS
EMPTY - 241.0 6.0 OHMS
A 5
R36 N36A
18TN 18TN
B 10
R9G N9G
18GY 16GY

80257V 24JUN11 AE08064599 010

LIGHTS (CHAPTER 9)
9. LIGHTS (CHAPTER 9)
9.1. BACK-UP – W/ ALLISON TRANSMISSION, P. 1

CHAPTER 9
BACK-UP LIGHT - W/ ALLISON TRANSMISSION
NAVISTAR, INC.
TURN SIGNAL BACK-UP

ADAPTER ALARM
(400) (102 DBA)
M
A71D BODY
18OR CONTROLLER #J5
(1602) CH9_07
16RD
16BK
CENTER CHASSIS /
IP / CENTER REAR CHASSIS
CHASSIS (9800)
(1701)
K 1 1
A71A S71A R71 STOP TAIL
16OR 14OR 14OR & TURN
12 (9303) BACK-UP
R10-G
ALARM A E
12WH
E A (1808)
A A
S71C
N10-G
12WH
14LTBL
E E
S10-GC
14WH
(71) (72)
GROUND
ADAPTER #01
(8807)
CH3_23
J
LEFT TAIL RIGHT TAIL
LIGHT LIGHT
BACK-UP
LIGHT
A71AB
16OR
TCM W/ LCT
(7151)
IP / ENGINE
(1702-7)
REVERSE K92#165 A92#165
65 18TN
WARNING 18TN
D2 D1
85
87A
87 BACK-UP LIGHT
RELAY
(1010)
30
86
C1 C2
A71C A71 FUSE F5-M

18OR 16OR (1014) CH3_14

67696A 04AUG10 AE08064600 001

LIGHTS (CHAPTER 9) LIGHT
SYSTEM – CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS, P. 2
9.2. LIGHT SYSTEM – CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS, P. 2

CHAPTER 9
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF LIGHT SYSTEM - CLEARANCE, MARKER, PARK, TAIL,
NAVISTAR, INC. TURN & STOP LIGHTS
TURN SIGNAL BODY CONTROLLER#J1

ADAPTER (1603)
(400)
A RIGHT FRONT
A57A
A TURN SIGNAL
16OR
10A4
B
A57D RIGHT FRONT
16OR MARKER & TURN LIGHT (8000)
CH9_03
E LEFT FRONT BODY

A56A
B TURN SIGNAL CONTROLLER#J1
16OR
10A3 (1603)
F LEFT FRONT
A56D
MARKER & TURN LIGHT (8801) /
16OR
CH9_03
G
A56BC BODY BUILDER TURN / STOP
16YL (4450BM)/(4460M)
CH10_07
J
A71AB
BACK-UP LIGHT RELAY (1010)
16OR
CH9_01
K
A71A STOP , TAIL & TURN LIGHTS
16OR (9303)
CH9_08
W/ TAIL LIGHT
STANDARD
STOP,TAIL & TURN LIGHTS
BODY (9303)
CONTROLLER#J2 CH9_08
(1604)
RADIO
TAIL LIGHTS A54D (1300)
A68
F 18BN CH4_11
10A18 16BN
A58DA DRIVER POWER MIRROR
18BN (3000) CH4_07
PARK MARKER A58DB PASSENGER POWER MIRROR
CLEARANCE 18BN (3003) CH4_07
IDENTIFICATION G
16BN
LAMP A58T
A58
CLEARANCE LIGHT
10A17 18BN (345) CH9_09
A54B
LEFT & RIGHT FRONT MARKER &
16BN
TURN LIGHT /
BASE 1 (8001/8000)
ADAPTER A B C D E F G CH9_03
(1623)

67696A 04AUG10 AE08064600 002

LIGHT SYSTEM – CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS (CONT.), P. 3 LIGHTS
(CHAPTER 9)
9.3. LIGHT SYSTEM – CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS
(CONT.), P. 3

CHAPTER 9
LIGHT SYSTEM - CLEARANCE, MARKER, PARK, TAIL,
TURN & STOP LIGHTS (CONT)
NAVISTAR, INC.
LEFT
GUIDE
POST RIGHT GUIDE
LIGHT POST LIGHT
LEFT FRONT A B (8150)

B A (8151)
MARKER & TURN RIGHT FRONT
LIGHT MARKER &
M54-GA
M54-GB
TURN LIGHT
16WH
16WH
TURN LIGHT
RIGHT
PARK LIGHT
FENDER
TURN LIGHT
LEFT FENDER
TURN LIGHT
M54J
16BN
GROUND
16BN
M54H
ADAPTER#01
(8800)
E D
CH3_23 (8000)B
LEFT SIDE
(8001) D E B M11-GA CAB GROUND-
LEFT SIDE 14WH CHASSIS
CAB GROUND- (4307)
BODY BUILDER M11-GB
CHASSIS CH3_22
(4450M) 14WH
(4307)
CH3_22
M57B
16OR
C M54D
14BN
M54B
B
14BN
M54C
14BN
16LTGN
N56BB
N57BB
16YL
M56B
16OR
FORWARD / IP
CHASSIS 14 5 15
(1700)
IP / CENTER A54B BASE 1
BODY ADAPTER PACK
CHASSIS 16BN
A57B
16OR
63 12 CONTROLLER #J1 (1623)

(1701)
(1603) CH9_02
LEFT REAR
D TURN SIGNAL
A56B
16OR
10A6
RIGHT REAR A57D

M TURN SIGNAL
A56BB
16LTGN
16OR TURN SIGNAL ADAPTER

16YL
A57BB
10A7 (400)
A56C
16OR
A57C
16OR
A56D CH9_02
16OR
C G E A B F A57J
16OR
REAR TURNS
PANEL ADAPTER A56J
(1625) 16OR
CH9_08
A57
16OR
A56
16OR

CNA1 25MAR11 REVISED GROUND B 76076F

LIGHTS (CHAPTER 9) LIGHT SYSTEM, FOG LIGHT, P. 4
9.4. LIGHT SYSTEM, FOG LIGHT, P. 4

CHAPTER 9
LIGHT SYSTEM, FOG LIGHT
NAVISTAR, INC.
BODY
CONTROLLER #J1
(1603)
RIGHT FOG LAMP A64B

K
10A9 16YL
LEFT FOG LAMP A64A

10A14 F 16YL
IP /
FORWARD
22 23
CHASSIS
GROUND (1700) GROUND
ADAPTER#01 ADAPTER#01
(8800) (8800)
CH3_23 CH3_23
M64-GA
M64-GB
M64B
16YL
16WH
M64A
16YL
16WH
LEFT FOG RIGHT FOG

B A LIGHT A LIGHT
B
(8201) (8200)

67696A 04AUG10 AE08064600 004

HEADLIGHTS, P. 5 LIGHTS (CHAPTER 9)
9.5. HEADLIGHTS, P. 5

CHAPTER 9
HEADLIGHTS
NAVISTAR, INC.
BODY
BODY
CONTROLLER #J2
CONTROLLER #J3
(1604)
(1600)
HIGH LOW HEADLIGHT

HIGH LOW FTP
BEAM BEAM DIMMER
BEAM BEAM SWITCH
LEFT LEFT SWITCH
RIGHT RIGHT DIN15
10A11 10A13 DIN4
10A10 10A12
C B K H A4 A14
14YL
A53B
14YL
A52D
14YL
14YL
A53
A102A
A52
20YL
A52A
20YL
IP / FORWARD
IP / DCM
CHASSIS 1 2 3 4 A7 A8
(1800)
(1700)
14YL
M53B
14YL
14YL
14YL
M52D
M52
M53
B102A
B52A
18YL
18YL
M11-GA
14WH
W/ GUIDE
POST LIGHTS
M11-GB
14WH
B A C A C B 3 4 7
LEFT SIDE
CAB GROUND-
CHASSIS
(4307)
CH3_22
DIMMER FTP
RIGHT HEADLIGHT TURN SIGNAL SWITCH

LEFT HEADLIGHT
TURN / SIGNAL HARNESS (1810)
TURN / SIGNAL HARNESS
(8001) (8000)

67696A 04AUG10 AE08064600 005

LIGHTS (CHAPTER 9) PANEL LIGHTS, P. 6
9.6. PANEL LIGHTS, P. 6

CHAPTER 9
NAVISTAR, INC. PANEL LIGHTS
CLUSTER
A62DA CONNECTOR
18DKBL (1500)
CH8_05
A62DD DRIVER DOOR

18DKBL (3000)
CH4_07
REAR TURNS
PANEL ADAPTER
(1625)
J A62 CLUSTER CONNECTOR

18DKBL (1500)
CH8_05
M RADIO
A62E
18DKBL (1300)
CH4_11
L SWITCH PACK
A62DB
18DKBL (1101)
CH4_25
K HVAC CONTROL
A62DA
18DKBL (1200)
CH12_03
C
A57BB
16LTGN BODY BUILDER
(4450M)
G CH10_07
A56BB
16YL

CNA1 26JUL11 REPLACED R/D 1002 C 80257V
WITH SPLICE. REVISED CIRCUITS. 67696A 04AUG10 AE08064600 006

LIGHT SYSTEM, WORK LIGHT, P. 7 LIGHTS (CHAPTER 9)
9.7. LIGHT SYSTEM, WORK LIGHT, P. 7

CHAPTER 9
LIGHT SYSTEM, WORK LIGHT
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064600 007

LIGHTS (CHAPTER 9) LIGHT SYSTEM –
CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS (CONT.), P. 8
(CONT.), P. 8

CHAPTER 9
NAVISTAR, INC.
CH9_03
CH9_02
CH9_03
A57J
16OR
A56J
16OR
A71A
16OR
16BN
16OR
16OR
A68
A56
A57
IP /
CENTER 4 1
2 3 30 28
CHASSIS
(1701)
N10-GC
14OR
16WH
14BN
S56
14OR
S71A
14OR
S68
S57
N56J
16OR
N57J
16OR
CHASSIS GND
N10-G ADAPTER
12WH (8807)
CH3_23
CENTER / REAR B C C B
CHASSIS
(9800) 3
2 4 12 1 (9315) (9316)
R10-G
14OR
12WH
14OR
14BN
14OR
R56
R71
R68
R57
LEFT RIGHT
MODESTY MODESTY
TURN LAMP TURN LAMP
STOP , TAIL
& TURN LIGHTS
(9303)
LEFT TAIL RIGHT TAIL
B D A C LIGHT LIGHT
E
(71) (72)
C C
S57B
14LTGN
B B
S68C
14BN
E E
S10-GC
TAIL LIGHT 14WH
A A
S71C
14LTBL
TURN / STOP BACK-UP LIGHT BACK-UP LIGHT

TURN / STOP
LIGHT LIGHT

CNA1 25MAR11 REVISED GROUND B 76076F

LIGHT SYSTEM – CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS (CONT.), P. 9 LIGHTS
(CHAPTER 9)
(CONT.), P. 9

DIAGRAM 9
NAVISTAR, INC.
W/ SUNSHADE
9 E
D58N D58L A58T
A 18BN BASE 1
CONNECT SUNSHADE (345) 18BN 18BN
2 ADAPTER
TO MID MARKER LAMP (2004) D58-GF D58-GA A63-GA
B (1623)
18WH 18WH 16WH A
A11-GT
12WH
ROOF / IP
(2000)
16BN
A58
LEFT SIDE
CAB GND
(1005)
CH3_20
PARK MARKER
CLEARANCE
IDENTIFICATION
LAMP
10A17
BODY
CONTROLLER#J2
(1604)
CAB MOUNTED - N/ SUNSHADE
BASE 1
A E ADAPTER
(1623)
A58T A63-GA
BODY 18BN 16WH
CONTROLLER #J2
A11-GT
(1604)
12WH
IP / ROOF 9 2
PARK MARKER (2000)
CLEARANCE
IDENTIFICATION A58
G
LAMP 16BN
10A17
LEFT SIDE
CAB GND
(1005)
CH3_20

CNA1 26JUL11 ADDED SPLICE, A11-GT, C 80257V

LIGHTS (CHAPTER 9) AUX HEADLIGHTS, SNOWPLOW LIGHTS, P. 10
9.10. AUX HEADLIGHTS, SNOWPLOW LIGHTS, P. 10

CHAPTER 9
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF AUX HEADLIGHTS, SNOWPLOW LIGHTS
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064600 010

CHASSIS ACCESSORIES (CHAPTER 10)
10. CHASSIS ACCESSORIES (CHAPTER 10)

10.1. TRW ABS BRAKES, P. 1

CHAPTER 10
TRW ABS BRAKES
NAVISTAR, INC.
(LOCATED NEAR
EXTERIOR DASH
TRW ABS LEFT SIDE)
EHCU
(9511) MEGAFUSE
MAXI-FUSE UNFUSED STUD
(9310) (1000)
PUMP B A M90K-FL
N90 N90J K14H STARTER B+
MOTOR 1
12GY 10RD 4RD TERMINAL
B+
40A 14GY CH5_01
N5C(+) J1939
J1939(+) 5
18YL TERMINATING
RESISTOR-A
J1939(-) N5C(-)
6 (9530)
18GN
CH3_05
CENTER CHASSIS / IP
(1701)
26 FUSE F7-F
N94L A94L
COIL B+ 25 (1016)
12GY 12GY
CH3_01,08
LEFT FRONT
IP / FWD CHASSIS HYD ABS
(1700) (8502)
WHEEL SENSOR
L FR WHL 14 30 1
N94L(+) A94L(+) M94L(+)
SPEED 27 18GY 18GY 18BK
SENSOR
15 31 2
L FR WHL N94L(-) A94L(-) M94L(-)
SPEED 28 18GY 18GY 18BN
SENSOR
RIGHT FRONT
HYD ABS
(8503)
WHEEL SENSOR
R FR WHL 16 35 1
N94R(+) A94R(+) M94R(+)
SPEED 3 18GY 18GY 18BK
SENSOR
17 36 2
R FR WHL N94R(-) A94R(-) M94R(-)
SPEED 4
18GY 18GY 18BN
SENSOR
TRAILER ABS
FUSE F1-C
ECU RELAY
(1010)
24 (1017-G3) IGNITION
N90E A90E F3 E3 A13FH A13FF
IGNITION 30 RELAY #3
18GY 18GY 18PK 18PK (1012/1014)
5A CH3_02
CENTER / REAR CHASSIS
(9800) (9812)
LOW RR WHL 16 2
N94N(-) R94(-)
SPEED 35
18GY 18GY
SENSOR SPEED SENSOR
15 1 REAR AXLE
HIGH RR WHL N94N(+) R94(+)
SPEED 36 18GY 18GY
SENSOR
PUMP MTR N90-GA

13 12WH
GND
N90-GB GND
COIL N90-G
38 14WH STUD
ECU GND 12WH
(9717D)
(LOCATED AT LEFT
EXTERIOR LOWER
CAB GROUND STUD)

67696A 04AUG10 AE08064601 001

CHASSIS ACCESSORIES (CHAPTER 10) TRW ABS BRAKES (CONT.), P. 2
10.2. TRW ABS BRAKES (CONT.), P. 2

CHAPTER
TRW ABS BRAKES(CONT)
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 04AUG10 AE08064601 002

TRW ABS BRAKES (CONT.), P. 3 CHASSIS ACCESSORIES (CHAPTER 10)
10.3. TRW ABS BRAKES (CONT.), P. 3

CHAPTER 10
NAVISTAR, INC. TRW ABS BRAKES (CONT)
W/HYDROMAX
BODY CONTROLLER
J4
(1601) FUSE F5-C
(1014) A90L
CH3_14 18GY
A
RELAY A90J DIODE

CONTROL F16 18GY (4041C)
B
A90K
16GY
C
DIODE CONN
(4041)
BODY CONTROLLER
J3
(1600)
HYD PUMP
MOTOR A90HB
B10
MONITOR 18GY MEGAFUSE
UNFUSED STUD
A14-FL
A14 STARTER B+
HYD PUMP K14H
12RD TERMINAL
FLOW/DIFF B6 4RD
16BK CH5_01
MONITOR
MOTOR
A90M SENSOR
18GY 5 1 (4034)
85
30 HYDROMAX
BOOST PUMP HYDRAULIC
RELAY CONN PUMP MOTOR
87 (4033)
87A
86
2 4 HYDRAULIC
A90F MOTOR GROUND
A90A
12GY (4035)
16GY
A90H
14GY
A90HA A90-GM
14GY 12WH
MOTOR SENSE
B A FUSE (4040)
FUSE CAP
5A
(4040C)
B A A B
(A90B) (A90C) A90CA A90-G A90-GA
16GY 16GY 16GY 16WH 12WH
GROUND
N.O. (4005)
DIFFERENTIAL CLOSES FLOW SWITCH N.C.
OPENS (LOCATED LEFT UPPER
PRESSURE SWITCH W/PRESSURE (4031)
W/FLOW EXTERIOR CAB GROUND STUD)
(4032) DIFFERENCE

67696A 04AUG10 AE08064601 003

CHASSIS ACCESSORIES (CHAPTER 10) BODY BUILDER & TRAILER – TURN, MARKERS & STOP, P. 4
10.4. BODY BUILDER & TRAILER – TURN, MARKERS & STOP, P. 4

DIAGRAM 10
NAVISTAR, INC. BODY BUILDER & TRAILER - TURN, MARKERS & STOP
BODY CONTROLLER #J4
(1601) W/ AUX TRAILER COMBINED
TRAILER
LEFT TURN F13 A56C
SIGNAL 18OR
REAR TURN SIGNAL W/ AUX TRAILER SEPARATE
RD29 (HSD) ADAPTER IP / CENTER
H (1625) A56T CHASSIS
A56K
12YL (1701)
16OR CH10_20,21
BODY H1 H2
CONTROLLER#J1 85
TRAILER
(1603)
87 LEFT TURN
E L FR RELAY
A56C
D TURN (1011)
16OR SIGNAL
10A3 30
86
A A57C R FR J2 J1
16OR M TURN
SIGNAL FUSE F2-A
(A56J) (1011)
10A4
D CH3_15
A57K
16OR
A56-GC W/ AUX TRAILER
18WH SEPARATE
TRAILER IP / CENTER
RIGHT TURN E15 A57C A57T CHASSIS
SIGNAL 18OR 12LTGN (1701)
RD11 (HSD) W/ AUX H3 H4 CH10_20,21
TRLR 85
COMBINED TRAILER RIGHT
87 TURN RELAY
(1011)
30 FUSE F2-C
86
J4 (1011)
J3 (A57J)
A57-GC CH3_15
18WH
*A54T
IP / CENTER CHASSIS
12BN
(1701)
CH10_20,21
TRAILER
MARKER F14 A54C
LIGHTS 18BN
E3 F3
RD27 (HSD)
85
A54-GC
18WH
TRAILER MARKER
87
LIGHT RELAY
A11-GCH
(1012)
16WH
30
86
F4 FUSE F3-D
E4 (A54J) (1012)
CH3_16
*A68T IP / CENTER CHASSIS

TRAILER 12BN
A68C (1701)
TAIL LIGHTS E10
A11-GCA
18BN CH10_20,21
RD10 (HSD)
10WH
E1 F1
A68-GC
85
18WH
TRAILER
87
TAIL LIGHT
A11-GKJ
RELAY
(1012)
6WH
30
86
F2 E2
A70-GT
FUSE F3-B
18WH
LEFT SIDE
(A68J) (1012)
CAB GROUND
CH3_16
(4081)
CH3_25
* TRAILER W/ 7 WAY SOCKET & N/ BODY BUILDER
# TRAILER W/ BODY BUILDER & N/ 7 WAY SOCKET
TRAILER STOP RELAY **TRAILER W/ BODY BUILDER & W/ 7 WAY SOCKET
(1016) CH10_05

CNA1 26JUL11 ADDED SPLICES,A11-GCH,C 80257V
A11-GCA,A11-GKJ,GROUND STUD. 67696A 04AUG10 AE08064601 004

BODY BUILDER & TRAILER – TURN, MARKERS & STOP (CONT.), P. 5 CHASSIS
ACCESSORIES (CHAPTER 10)
10.5. BODY BUILDER & TRAILER – TURN, MARKERS & STOP (CONT.), P. 5

DIAGRAM 10
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF BODY BUILDER & TRAILER - TURN, MARKERS & STOP
NAVISTAR, INC. (CONT)
BODY CONTROLLER #J5 ELECTRONIC TRAILER

A70E
(1602) BRAKE (1923)
10RD
CH10_11
ELECTRIC
TRAILER W/ ELECTRIC
A70ER
BRAKE F10 TRAILER BRAKE
18RD
CONTROLLER
INPUT *A70D A70ET A70T IP / CENTER
DIN23 18OR 10RD 10RD CHASSIS
A70D A70T (1701)
18OR 10RD CH10_20,21
G3 J3
85
**A70CA
N/ ELECTRIC
18OR
TRAILER 87
TRAILER BRAKE
STOP RELAY
BODY
(1016)
CONTROLLER #J4
(1601)
TRAILER 86 30
TAIL
TRAILER J4 G4 FUSE F7-D
LT RLY (A70J)
OR BODY A70-GT (1016) CH3_16
(1012)
BUILDER F15 18WH
CH10_04
STOP IP / CENTER CHASSIS
LIGHT **A70C A70BB (1701)
RD28 (HSD) 14RD 14RD CH10_07
*#A70C
18OR A70BB BODY BUILDER
D2 D1
14RD TURN / STOP
85
A70-GC
(4460M)
18WH
87 CH10_07
BODY STOP
RELAY
(1020)
86 30
C1 C2 A70BF FUSE F10-C
ACCESSORY
14RD (1019) CH3_08,15
RELAY #1
(1013 / 1011) *#A12Q
*#A12BB BODY BUILDER
CH3_10 18LTBL
16LTBL (4450M/4460BM)
CH10_07
G1 G2
BODY / 85
LEFT SIDE ACCESSORY
87
CAB GROUND TRAILER
(4081) AUX RELAY
CH3_25 (1016)
86 30
A11-GKJ A11-GCA A72-GCL
10WH 18WH J2 J1
6WH
A14BA FUSE F7-B

16RD (1016) CH3_15
IGNITION
RELAY#3 A13FF
(1012 / 1014) 18PK
CH3_02
FUSE F1-C
FUEL HEATER (1010)
A13FK A13FH A94T IP / CENTER CHASSIS
RELAY (1018)
18PK E3 18PK 10GY (1701)
CH10_10 G3 G4
CH10_20,21
85
87 TRAILER ABS
ECU RELAY
(1017)
86 30
J4 J3 A94UA FUSE F8-D
12GY (1017) CH3_16
IGNITION A13-GFF
RELAY #3 18WH
(1012 / 1014)
CH3_02
* TRAILER W/ 7 WAY SOCKET & N/ BODY BUILDER ** TRAILER W/ BODY BUILDER & W/ 7 WAY SOCKET
*# TRAILER W/ BODY BUILDER & N/ 7 WAY SOCKET

CNA1 26JUL11 ADDED SPLICES,A11-GCA,C 80257V
A11-GKJ,GND STUD. A72-GCL WAS A12-GR. 67696A 04AUG10 AE08064601 005

CHASSIS ACCESSORIES (CHAPTER 10) BODY BUILDER ACC FEED WIRING, P. 6
10.6. BODY BUILDER ACC FEED WIRING, P. 6

CHAPTER 10
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF BODY BUILDER ACC FEED WIRING
NAVISTAR, INC.
W/ ACC FEED WIRING
BODY BUILDER
ACC FEEDS FORWARD CHASSIS /
(7230) IP
(1700)
S103M
1 65
12LTGN
S103N
2 66
12LTGN
S103P
3 67
12LTGN

CNA1 25MAR11 REMOVED PREWIRE B 76076F
CIRCUITRY. M CIRCUITS WERE S. 67696A 04AUG10 AE08064601 006

BODY BUILDER CONNECTIONS, P. 7 CHASSIS ACCESSORIES (CHAPTER 10)
10.7. BODY BUILDER CONNECTIONS, P. 7

CHAPTER 10
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF BODY BUILDER CONNECTIONS
NAVISTAR, INC.
IP / CENTER CHASSIS BODY BUILDER

(1701) (4450M)
71
N68BB
14BN A
P68BB
12 14BN
REAR TURNS A56BB N56BB
B
PANEL 16YL 16YL
ADAPTER P56BB
(1625) 63 16YL
CH9_06 A57BB N57BB
C
16LTGN 16LTGN
P57BB
74 16LTGN
N54BB
D
TRLR MKR 14BN
P54BB
LT RELAY *A54BB
14BN
(1012) 16BN
73
CH10_04 N71BB
E
BODY / 16LTBL
P71BB
ACCESSORY 75 16LTBL
TRAILER A12BB N12BB
AUX RELAY F
16LTBL 14LTBL
(1016)
CH10_05 N11-GD
12WH G
GROUND
ADAPTER #01
(8807)
CH3_23
N11-GBB G
R11-GBB G
12WH 12WH
A
R68BB A
14BN
A11-GBJ
B
R56BB BODY
12WH
B
16OR BUILDER
C CONN
R57BB C (4460BM)
16OR
D
R58BB
D
14BN
E
R71BB
E
16OR
P12BB F
R12BB
14LTBL F
14LTBL
A11-GBA
BODY BUILDER
10WH
CONNECTION
BODY BUILDER (4450AM)
TURN / STOP
(4460AM / 4460BF)
A
R56BC
A
16OR
B
R57BC BODY
B BUILDER
16OR
C TURN / STOP
A11-GKJ
R70BB (4450BM)
C
6WH
14OR
TURN P56BC
SIGNAL 42 16YL
ADAPTER A56BC N56BC
A
(400) 16YL 16YL
P57BC
CH9_02
64 16LTGN BODY
N57BC BUILDER
B
16LTGN TURN / STOP
BODY STOP P70BB (4460M) LEFT SIDE
72
RELAY A70BB 14RD N70BB CAB GND
C
(1020) 14RD 14RD (4081)
BODY STOP RELAY A70BB
CH10_05 (1020) 14RD CH3_06
CH10_05
* TRAILER W/ BB INSIDE CAB & W/ 7-WAY SOCKET

CNA1 26JUL11 ADDED SPLICES,A11-GBA,C 80257V
A11-GKJ,GND STUD. A11-GBJ WAS A11-GBB. 67696A 04AUG10 AE08064601 007

CHASSIS ACCESSORIES (CHAPTER 10) TWO SPEED AXLE SWITCH, P. 8
10.8. TWO SPEED AXLE SWITCH, P. 8

CHAPTER 10
TWO SPEED AXLE SWITCH
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 04AUG10 AE08064601 008

REMOTE POWER MODULE – CAB MOUNTED, P. 9 CHASSIS ACCESSORIES (CHAPTER 10)
10.9. REMOTE POWER MODULE – CAB MOUNTED, P. 9

DIAGRAM 10
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF REMOTE POWER MODULE - CAB MOUNTED
NAVISTAR, INC.
J1939(-) J1939(+) BODY

DATA LINK DATA LINK CONTROLLER #J5
B1939- B1939+ (1602)
J1939 PRIVATE
F5 F6 TERMINATING RESISTOR
(1626)
A
A5EB(+)
18YL A5ET(+)
A5E(+)
OHMS
120
18YL 18YL
A5EB(-)
18GN C
A5E(-) A5ET(-)
18GN 18GN
A20 BATTERY
16LTGN FEED
CH3_01
IP / CENTER
52 53 51
CHASSIS
(1701)
R5E(+)
R5E(+)
R5E(-)
R5E(-)
16LTGN
16LTGN
18YL
18YL
18GN
18GN
R20
R20
CENTER CHASSIS /
RPM JUMPER
(4410D / 4410DF)
3 4 6
CHASSIS GROUND ADAPTER

(8807) CH3_23
N10-GR
14WH
CENTER CHASSIS RPM

(4410D)
(4411F-A) (4412F-A)
2 3 4 6
J1 Y14C Y14C
J5 4RD
J2 4RD 4RD
1 2 3 4 6 1ST REMOTE
POWER MODULE
(4410A)
*N11-GPM
FUSIBLE
LINK
*N59F
*N14W
14WH
14GY
16RD
*N5(-)
*N5(+)
18GN
18YL
START
MOTOR
BATTERY
2ND REMOTE TERMINAL
POWER MODULE
(4410B) *FUSIBLE
LINK
2 3 4 (4411M-A)
1 6 (4412F-A)
J1 *Y14H Y14H
J5 *4RD
4RD 4RD
J2
* W/ 2ND REMOTE POWER MODULE

67696A 04AUG10 AE08064601 009

CHASSIS ACCESSORIES (CHAPTER 10) FUEL / HEATER RELAY, P. 10
10.10. FUEL / HEATER RELAY, P. 10

CHAPTER 10
FUEL / HEATER RELAY
NAVISTAR, INC.
A11-GCA
10WH
A19-GCG
A11-GKJ
18WH
6WH
FUEL HEATER
RELAY
(1018)
F4
LEFT SIDE
IGNITION TRAILER ABS
FUSE F1-C CAB GROUND
ECU RELAY
85
RELAY #3
86
(1010) (4081)
(1012 / (1017) D3
A13FF A13FH A13FK CH3_25
1014) 18PK 18PK
18PK G3 E3
CH3_02
ENGINE/
A19A D4
87
K19BA K19B
MELROSE
14GY 12GY 16GY
(6011-8)
IP /ENGINE F3 A19V
FUSE F6-D
(1702-34) 30
12GY (1015) CH3_15

CNA1 26JUL11 ADDED SPLICES,A11-GCA,C 80257V
A11-GKJ,GND STUD. A19-GCG WAS A19-GB. 67696A 04AUG10 AE08064601 010

ELECTRIC TRAILER BRAKE, P. 11 CHASSIS ACCESSORIES (CHAPTER 10)
10.11. ELECTRIC TRAILER BRAKE, P. 11

CHAPTER 10
ELECTRIC TRAILER BRAKE
NAVISTAR, INC.
ETB FUSE F8-G

CONTROLLER A14NS
(1017)
(1923) 12BK
CH3_15
FUSE F10-B (1019)

ETB E2
A70NS F2 TRAILER STOP RELAY
CONTROLLER A70E
16RD 10RD (1016)
(1923)
15A CH10_05
ETB
CONTROLLER A94T IP/CENTER CHASSIS
(1923) 10DKBL (1701)
CH10_20,21
ETB A11-GAM
CONTROLLER 16WH
(1923)
A11-GAA
12WH
LEFT SIDE DASH MOUNTED

DUAL POST GROUND STUD
(1004)
CH3_24

CNA1 26JUL11 ADDED SPLICE,A11-GAA, C 80257V
GND STUD. A11-GAM WAS A11-GNA. 67696A 04AUG10 AE08064601 011

CHASSIS ACCESSORIES (CHAPTER 10) HOUR METER – PTO, P. 12
10.12. HOUR METER – PTO, P. 12

CHAPTER 10
HOUR METER - PTO
NAVISTAR, INC.
BODY
CONTROLLER #J3
(1600)
PTO PTO
STATE A88B K88B HOUR
B7 METER
INPUT 16LTGN 14LTGN
AIN8 (7950)
IP/ENG
(1702-14)
HEAT SHRINK

CNA1 25MAR11 REMOVED 422,7800,7801.B 76076F
67696A 04AUG10 AE08064601 012

AIR DRYER, P. 13 CHASSIS ACCESSORIES (CHAPTER 10)
10.13. AIR DRYER, P. 13

CHAPTER 10
AIR DRYER
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 04AUG10 AE08064601 013

CHASSIS ACCESSORIES (CHAPTER 10) REMOTE START / STOP, P. 14
10.14. REMOTE START / STOP, P. 14

CHAPTER 10
REMOTE START / STOP
NAVISTAR, INC.
KEY SWITCH
(1100) N/ THEFT DETERRENT
W/ THEFT DETERRENT
A104J A104J
AUX POWER RELAY
BATT 18DKBL 16DKBL
A104C (1873) CH3_02
16DKBL
A104JA
G3 J3 18DKBL
OFF
86
18DKBL
S IGN ACC 30
A104B
REMOTE - STOP RELAY
A D
B C (1018)
87
A15
18RD 87A
85
J4 G4 H4
FUSE F3-A A104AA KEYSWITCH IGN FEED
A13F
(1012) 18DKBL (1100)
18PK
CH3_16 CH3_02
BODY CONTROLLER#J5 A59RE

(1602) 18GY
REMOTE START/ PUMP RELAY
REMOTE START A104JD
STOP SWITCH (1020)
A104D RELAY 18DKBL
INPUT RELAY F15 18DKBL (1018)
A1 A2
A59CD
A1 C1
18GY
DIN18
86
86 30
30
A104CA
16DKBL
18DKBL
A104E
87
87
BODY CONTROLLER#J4 87A
87A 85
(1601) 85
B2 B1
C2 A2 B2
ENGINE STOP
RELAY E2 A59CE
RD4 (LSD) A59RC 18GY
18GY
A59RD
ENGINE START
16GY
A104L
RELAY E16 18DKBL PUMP
RD13 (HSD) INHIBIT
RELAY
PUMP INHIBIT A59RA
E1 (1018)
18GY
18DKBL
18DKBL
RELAY
A104F
A3 C3
A104N
RD7 (LSD)
A104CB
18DKBL
DIODE 86
30
IP / CENTER ASSY
CHASSIS (9915)
(1701) 87
1 2
43 87A
85
C4 A4 B4
44
S104CA
16DKBL
A59CA
16GY
16DKBL
A104JC
18DKBL
S59CA
A104H
16GY
AUX DASH CONNECTOR IP / FORWARD HOOD

(4305) CHASSIS SWITCH
(1700) (8805)
BODY BUILDER
B 44
N104CB B
18DKBL
43
REMOTE N104CC A
85
B+ 18DKBL
86
START / A
STOP G1
A104JB
18DKBL
SWITCH J2
B S
PUMP
87
G2
MOTOR REMOTE
SOLENOID M START / STOP START RELAY
(9778) J1 A104CC
(1010)
18DKBL
H2 CH5_01
30
87A
PUMP SWITCH RELAY

GROUND MOTOR (1018)


AUX & POWER SOURCE, P. 15 CHASSIS ACCESSORIES (CHAPTER 10)
10.15. AUX & POWER SOURCE, P. 15

CHAPTER 10
AUX & POWER SOURCE
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064601 015

CHASSIS ACCESSORIES (CHAPTER 10) WHEELCHAIR LIFT INTERLOCK, P. 16
10.16. WHEELCHAIR LIFT INTERLOCK, P. 16

CHAPTER 10
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF WHEELCHAIR LIFT INTERLOCK
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064601 016

AUX INPUTS & DRIVERS, P. 17 CHASSIS ACCESSORIES (CHAPTER 10)
10.17. AUX INPUTS & DRIVERS, P. 17

CHAPTER 10
AUX INPUTS & DRIVERS
NAVISTAR, INC.
BODY CONTROLLER#J5
(1602)
A103A TEM AUX INPUT 1

F14
18LTGN DIN19
A103B TEM AUX INPUT 2

F12
18LTGN DIN21
BODY CONTROLLER#J4
HEAT
(1601)
SHRINK
A103C TEM AUX RELAY DRIVER 1

E2
18LTGN RD4 (LSD)
A103D
E1 TEM AUX RELAY DRIVER 2
18LTGN
RD7 (LSD)
A9ZF A9ZA BODY CONTROLLER#J5

E3 ZVR
18GY 18GY (1602)
CH3_07

CNA1 26JUL11 ADDED SPLICE,A9ZA,R/D C 80257V
1602 CAV E3, A9ZF WAS A9ZVR. 67696A 15OCT10 AE08064601 017

CHASSIS ACCESSORIES (CHAPTER 10) TRANSFER CASE EFFECTS, P. 18
10.18. TRANSFER CASE EFFECTS, P. 18

CHAPTER
TRANSFER CASE EFFECTS
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064601 018

FUEL TRANSFER PUMP, P. 19 CHASSIS ACCESSORIES (CHAPTER 10)
10.19. FUEL TRANSFER PUMP, P. 19

CHAPTER 10
FUEL TRANSFER PUMP
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064601 019

CHASSIS ACCESSORIES (CHAPTER 10) TRAILER SOCKET – EOF, P. 20
10.20. TRAILER SOCKET – EOF, P. 20

CHAPTER 10
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF TRAILER SOCKET - EOF
NAVISTAR, INC.
IP / CENTER
CHASSIS TRAILER TRAILER
(1701) SOCKET#2 SOCKET#2
(9716) (9779F)
TRAILER 5 B
LEFT TURN A56T N56T R56A
B
RELAY 12YL 10YL 10YL
(1011)
CH10_04
TRAILER
RIGHT TURN 6 C
A57T N57T R57A
RELAY C
12LTGN 10LTGN 10LTGN
(1011)
CH10_04
TRAILER 7 A
MARKER A54T N54T R58A
A
LIGHT RELAY 12BN 10BN 10BK
(1012)
CH10_04
TRAILER TRAILER
SOCKET#1 SOCKET#1
(9715) (9780M)
TRAILER TAIL 8 B
LIGHT RELAY A68T N68T R68A
B
(1012) 12BN 10BN 10BN
CH10_04
TRAILER STOP
RELAY 9 A
A70T N70T R70A
(1016) A
10RD 10RD 10RD
CH10_05
AUX TRAILER N/ ETB
TRAILER ABS
10 C
ECU RELAY A94T N94T R94A
(1017) C
10GY 10GY 10DKBL
CH10_05
A94T
ETB
10DKBL
CONTROLLER
(1923)
CH10_11
AUX TRAILER
W/ ETB

67696A 15OCT10 AE08064601 020

BODY BUILDER & TRAILER SOCKET – BOC & EOF, P. 21 CHASSIS ACCESSORIES (CHAPTER 10)
10.21. BODY BUILDER & TRAILER SOCKET – BOC & EOF, P. 21

CHAPTER 10
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF BODY BUILDER & TRAILER SOCKET - BOC & EOF
NAVISTAR, INC.
IP/CENTER
CHASSIS
(1701)
TRAILER SOCKET#2
(9716)
5
TRAILER LEFT B
A56T N56T
TURN RELAY R56
12YL 10YL
(1011) CH10_04 10YL
TRAILER MARKER A
A54T 7
LIGHT RELAY N54T R58 EOF
12BN 10BN 10BN
(1012) CH10_04 BODY
6 C CIRCUIT
TRAILER RIGHT A57T N57T R57
TURN RELAY 12LTGN 10LTGN 10LTGN
(1011) CH10_04
TRAILER
T10
GROUND
8WH
(9717F)
R10A
8WH
TRAILER
SOCKET GROUND
(9778F)
N10E
8WH
N10D
8WH TRAILER
SOCKET GROUND
TRAILER SOCKET#1 (9717)
(9715)
TRAILER TAIL 8
A68T N68T B
LIGHT RELAY R68
(1012) CH10_04 12BN 10BN 10BN
TRAILER STOP 9 A EOF

RELAY (1016) A70T N70T R70 BODY
CH10_05 10RD 10RD 10RD CIRCUIT
AUX TRAILER N/ ETB
TRAILER ABS 10 C
A94T N94T R94
ECU RELAY
10GY 10GY 10GY
(1017) CH10_05
10DKBL
A94T
ETB
CONTROLLER
(1923)
CH10_11
AUX TRAILER W/ ETB

67696A 15OCT10 AE08064601 021

CHASSIS ACCESSORIES (CHAPTER 10) AUX TRAILER CIRCUIT, P. 22
10.22. AUX TRAILER CIRCUIT, P. 22

CHAPTER 10
NAVISTAR, INC.
AUX TRAILER CIRCUIT
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064601 022

LIFT AXLE W/ CONTROLS FOR ONE LIFT AXLE, P. 23 CHASSIS ACCESSORIES (CHAPTER 10)
10.23. LIFT AXLE W/ CONTROLS FOR ONE LIFT AXLE, P. 23

CHAPTER 10
LIFT AXLE W/ CONTROLS FOR ONE LIFT AXLE
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064601 023

CHASSIS ACCESSORIES (CHAPTER 10) LIFT AXLE (NON – STEERABLE), P. 24
10.24. LIFT AXLE (NON – STEERABLE), P. 24

CHAPTER 10
LIFT AXLE (NON - STEERABLE)
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064601 024

LIFT AXLE (STEERABLE), P. 25 CHASSIS ACCESSORIES (CHAPTER 10)
10.25. LIFT AXLE (STEERABLE), P. 25

CHAPTER 10
LIFT AXLE (STEERABLE)
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064601 025

CHASSIS ACCESSORIES (CHAPTER 10) POWER SOURCE, CUSTOMER INSTALLED LIFT GATE, P. 26
10.26. POWER SOURCE, CUSTOMER INSTALLED LIFT GATE, P. 26

CHAPTER 10
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF POWER SOURCE, CUSTOMER INSTALLED LIFT GATE
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 15OCT10 AE08064601 026

TRANSMISSION (CHAPTER 11)
11. TRANSMISSION (CHAPTER 11)

11.1. ALLISON GEN 4 1/2000 TRANSMISSION, P. 1

DIAGRAM 11
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF ALLISON GEN 4 1/2000 TRANSMISSION
NAVISTAR, INC.
XMSN CONTROL MODULE

(7151)
ECM
POSITIVE TRANS ECU FEED FUSE BATTERIES
K92#170
VPWR 70 (9261-B) (9255)
18PK
K92A110 K92B110 N14BB B A N14AZ
VPWR 10
18PK 10PK 10RD
10A
10RD +
ECM NEGATIVE
(9260-B)
K92#109 K92-G N14-GA
GND 9 18GY 10GY 10WH -
K92#169
GND 69
18GY
FUSE F4-C
A92#163
W/ T-HANDLE (1013)
16TN
SHIFTER CH3_12
COLUMN SHIFTER RELAY

K92#163 A92#163
IGNITION 63 (1017)
18YL 16TN
CH11_02
ENGINE / IP
W/ COLUMN SHIFTER
(1702 - 8)
N/BODY BUILDER
K92#103 ALLISON
ENGINE / IP BODY BUILDER
18YL
(1702) (7205M)
W/ LCT BODY K92B103
CH11_02
INPUT BUILDER 18YL
SIGNAL K92#103 K92C103
A INPUT SIGNAL
RETURN 3 18YL 18YL RETURN
K92#143
INPUT 3 43 B INPUT 3
18LTBL
K92#150
OUTPUT 7 50 C OUTPUT 7
18PK
K92#105
OUTPUT 5 5 18OR H OUTPUT 5
K92#101
INPUT 6 1 E INPUT 6
18LTBL
K92#123
INPUT 1 23 18LTGN F INPUT 1
K92#145
OUTPUT 3 45 G OUTPUT 3
18OR
A
K48#159
ENGINE SPEED 59
18TN ENGINE SPEED
HIGH
SENSOR
K48#139 (7604M)
ENGINE SPEED
39
LOW 18OR
B
A
K47#160
OUTPUT SPEED 60
18YL OUTPUT SPEED
HIGH
SENSOR
OUTPUT SPEED K47#140 (7600M)
40
LOW 18LTGN B
TURBINE A
SPEED K92#180
80 18OR TURBINE SPEED
HIGH
SENSOR
TURBINE K92#120 (7607M)
SPEED 20 18LTBL
LOW B
K92#142 T HANDLE SHIFTER / COLUMN MTD SHIFTER

INPUT 5 42 18WH (422F / 1828)
CH11_02

67696A 04AUG10 AE08064602 001

TRANSMISSION (CHAPTER 11) ALLISON GEN 4 1/2000 TRANSMISSION (CONT.), P. 2
11.2. ALLISON GEN 4 1/2000 TRANSMISSION (CONT.), P. 2

DIAGRAM 11
ALLISON GEN 4 1/2000 TRANSMISSION
(CONT)
NAVISTAR, INC.
FUSE F4-C 87A 30 G2 ENGINE/IP

A92FN H1 A92#163
(1013) (1702)
COLUMN MOUNTED 16TN 16TN
CH3_12 CH11_01
SHIFTER J1
A92FB
(1828) 87 COLUMN
BATTERY 16TN BODY
SHIFTER
FEED CONTROLLER #J4
RELAY
CH3_01 (1601)
A92FBA J2 (1017)
16TN LCT COLUMN
85 86 G1 SHIFTER
A92RD E3 IGNITION
16TN RELAY
FUSE F4-C RD3 (LSD)
C A92A163 (1013)
18TN CH3_12 LCT SHIFTER
PB POSITION
A92D
D E8 UNLOCK
18TN
T HANDLE SHIFTER SOLENOID
(422F) RD6 (LSD)
A92D
B 18TN
A92A163 FUSE F4-C
A N/BODY BUILDER
16TN (1013)
CH3_12
W/BODY BUILDER
A92#103
D IP / ENGINE
18TN
(1702)
A92#142
C
18TN
21
K92#103
18YL
A92#103 XMSN
F 18TN K92B103 CONTROL
18YL MODULE
(7151)
CH11_01
19
A92#142 K92#142
E 18TN 18WH
A92-GAH A11-GAA
B
18WH 12WH
LEFT SIDE DASH MTD

DUAL POST GND STUD
(1004)
CH3_24

CNA1 26JUL11 ADDED SPLICE,A11-GA, C 80257V
GND STUD. A92-GAH WAS A92-GG. 67696A 04AUG10 AE08064602 002

ALLISON GEN 1/2000 TRANSMISSION, P. 3 TRANSMISSION (CHAPTER 11)
11.3. ALLISON GEN 1/2000 TRANSMISSION, P. 3

CHAPTER 11
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF ALLISON GEN 1/2000 TRANSMISSION
NAVISTAR, INC.
XMSN CONTROL MODULE XMSN BULKHEAD

(7151) (7350)
SHIFT PH92#152 SHIFT

52 18LTGN 1 SOLENOID 1
SOLENOID 1

33 2
SOLENOID 2 18YL SOLENOID 2

51 3
SOLENOID 3 18WH SOLENOID 3
PRESSURE 17 PH92#117 PRESSURE

4
SWITCH 1 18LTBL SWITCH 1
PRESSURE PH92#157 PRESSURE

57 18WH 6
SWITCH 3 SWITCH 3
PRESSURE PH92#179
79 PRESSURE
18PK 7
SWITCH 2 SWITCH 2
PH31#154
SUMP TEMP 54 8 SUMP TEMP
18TN
SIGNAL PH92#158 SIGNAL

58 9
RETURN 18LTGN RETURN
TORQUE CONVERTOR PH92#178 TORQUE CONVERTOR

78 10
CLUTCH 18WH CLUTCH
PH92#177 PRESSURE
PRESSURE 77 11 SWITCH 4
18LTGN
SWITCH 4
HIGH SIDE PH92#111 HIGH SIDE

DRIVER 1 11 180R 14
DRIVER 1
PRESS CONTROL PH92#155 PRESS CONTROL

55 15
SOLENOID 1 18WH SOLENOID 1
HIGH SIDE PH92#171 HIGH SIDE

71 16
DRIVER 2 18YL DRIVER 2
PRESS CONTROL 36 PH92#136 PRESS CONTROL

17
SOLENOID 2 18OR SOLENOID 2
INTERNAL MODE PH92#138 INTERNAL MODE

38 18
SWITCH NS 18OR SWITCH NS
MAIN MOD 74 PH92#174 19 MAIN MOD

18LTBL
PH92#114 INTERNAL MODE

INTERNAL MODE 14 20
18GY SWITCH C
SWITCH C

53 21
SWITCH B 18YL SWITCH B

73 22
SWITCH A 18LTBL SWITCH A

34 23
SWITCH P 18WH SWITCH P
PH92#176
TRANS ID 76 24 TRANS ID
18YL

67696A 04AUG10
AE08064602 003

TRANSMISSION (CHAPTER 11) TRANSMISSION ALLISON MD (WTEC) (CONT.), P. 4
11.4. TRANSMISSION ALLISON MD (WTEC) (CONT.), P. 4

CHAPTER 11
TRANSMISSION ALLISON MD (WTEC) (CONT)
NAVISTAR, INC.
INTENTIONALLY
LEFT BLANK

67696A 04AUG10
AE08064602 004

ALLISON TRANSMISSION 3/4000 GEN4 W/ AUTO NEUTRAL, P. 5 TRANSMISSION (CHAPTER 11)
11.5. ALLISON TRANSMISSION 3/4000 GEN4 W/ AUTO NEUTRAL, P. 5

CHAPTER 11
ALLISON TRANSMISSION 3/4000 GEN4
NAVISTAR, INC. W/ AUTO NEUTRAL
INTENTIONALLY
LEFT BLANK

67696A 15OCT10
AE08064602 005

TRANSMISSION (CHAPTER 11) TRANSMISSION
RETARDER CONTROLS WIRING W/ MD XMSN HARD WIRED EFFECTS, P. 6
11.6. TRANSMISSION RETARDER CONTROLS WIRING W/ MD XMSN HARD WIRED

EFFECTS, P. 6

CHAPTER 11
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF TRANSMISSION RETARDER CONTROLS WIRING
NAVISTAR, INC. W/ MD XMSN HARD WIRED EFFECTS
INTENTIONALLY
LEFT BLANK

67696A 15OCT10
AE08064602 006

AIR CONDITIONING (CHAPTER 12)
12. AIR CONDITIONING (CHAPTER 12)

12.1. HVAC SYSTEM, P. 1

DIAGRAM 12
HVAC SYSTEM
NAVISTAR, INC.
GND ADAPTER
(6704M)
B
K77-G
18WH
C
A K10-GB
14WH
FREON
ENGINE LEFT SIDE
COMPRESSOR
GROUND STUD
(6200)
(6304A)
B
BODY CONTROLLER#J1
(1603)
A/C
K77A A77A
C COMPRESSOR
16LTGN 16LTGN
10A1
ENGINE / IP
(1702-10)
HVAC UNIT
(1210) BODY CONTROLLER#J3
(1600)
G A/C ACCUMULATOR
A75E
20LTGN B13 OUTLET SENSOR
AIN14
J
A77D A/C ACCUMULATOR
B5
20LTGN INLET SENSOR
AIN6
H
A5ZVRA
18GY
K
A75ZVRB A75ZD A9ZA ZVR
E3
18GY 18GY 18GY
BODY CONTROLLER #J5

(1602)
CH3_07

CNA1 26JUL11 ADDED SPLICE,A9ZA,R/D C 80257V
1602. A75ZD WAS A75ZVR. 67696A 04AUG10 AE08064603 001

AIR CONDITIONING (CHAPTER 12) HVAC SYSTEM, P. 2
12.2. HVAC SYSTEM, P. 2

DIAGRAM 12
HVAC SYSTEM
NAVISTAR, INC.
BODY CONTROLLER #J3

ENGINE / IP (1600)
(8602) (1702)
C 4 A/C PRESSURE
K77B A77B
B12 TRANSDUCER
18LTGN 20LTGN
SIGNAL
A/C PRESSURE
TRANSDUCER
BODY CONTROLLER #J5
(1602)
B 3 +5V
K6A A6A
20GY E6 OUTPUT
18GY
SSOUT
ZERO VOLT
A REFERENCE
K9A (6747)
18GY CH3_07

67696A 15OCT10 AE08064603 002

AIR CONDITIONING, P. 3 AIR CONDITIONING (CHAPTER 12)
12.3. AIR CONDITIONING, P. 3

DIAGRAM 12
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF AIR CONDITIONING
NAVISTAR, INC.
HVAC CONTROL
(1200)
A75D FUSE F1-B

BATTERY A2 (1010)
18LTGN
CH3_15
A73A FUSE F4-L

SW IGN A1 (1013)
18LTGN
CH3_12
GROUND A74-G
B6
18WH
A11-GS
12WH
LEFT SIDE
CAB GND
(1005)
CH3_20
REAR TURNS
PANEL ADAPTER BODY CONTROLLER #J3
A62DA (1600)
PANEL DIM I/P A12 18DKBL
(1625)
CH9_06
A77 A/C REQUEST

AC REQUEST OUTPUT A4 A2 DIN2
20LTGN
A/C
A75C
DIAGNOSTICS A9 A3 DIAGNOSTICS
20LTGN
DIN3
FUSE F4-M IGN SWITCH

(1013) A13
A16 INPUT
CH3_12 16PK
DIN5

CNA1 26JUL11 ADDED SPLICE, A11-GS, B 80257V
AND GROUND STUD. 76076F 16FEB11 AE08064603 003

AIR CONDITIONING (CHAPTER 12) AIR CONDITIONING (CONT.), P. 4
12.4. AIR CONDITIONING (CONT.), P. 4

DIAGRAM 12
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF AIR CONDITIONING (CONT)
NAVISTAR, INC.
HVAC LPM
(1220)
LEFT SIDE
CAB GROUND A75-G
5
(4081) CH3_21 12WH
BLOWER
MOTOR
HVAC CONTROL FUSE F6-A 6
A75
(1200) (1015)
12LTGN
CH3_15 B
4
A75A
BLOWER FAN CNTRL A11 18LTGN A
HVAC UNIT
(1210)
MODE
ACTUATOR
A B
MODE DOOR A74
B9 18LTGN
MOTOR +
B A
MODE DOOR A74A
B10
MOTOR - 18LTGN
TEMP
ACTUATOR
C B
TEMP SEN A74B
B11
MOTOR 1 + 18LTGN
D A
TEMP SEN A74C
B12
MOTOR - 18LTGN
HVAC RECIRC
MOTOR
(4017)
E A
RECIRC MOTOR + B1 A74D
18LTGN
F F
A74E
RECIRC MOTOR - B2
18LTGN

76076F 16FEB11 AE08064603 004

INSTRUCTIONS AND CHARTS (CHAPTER 13)
13. INSTRUCTIONS AND CHARTS (CHAPTER 13)

13.1. CONNECTOR BODY COMPOSITES MATING VIEW SHOWN, P. 1

DIAGRAM 13
CONNECTOR BODY COMPOSITES MATING VIEW SHOWN
NAVISTAR, INC.
MIRROR SWITCH CONN (254F) CAV CIRC GAUGE COLOR TERMINAL

(LOCATED IN INSTRUMENT
A1 A62D 20 DKBL 3662109C1
PANEL LEFT SIDE)
A2 A78L 20 RD 3662109C1
A3 A78K 20 LTGN 3662109C1
B4 A4
A4 A78-GD 20 WH 3662109C1
B1 A78A 20 LTGN 3662109C1
B2 A78D 20 LTGN 3662109C1
B3 A78C 20 LTGN 3662109C1
B4 A78F 20 LTGN 3662109C1
B1 A1
CONNECTOR 3662108C1
MIRROR SWITCH CONN (254M)

(LOCATED IN INSTRUMENT PANEL
CAV CIRC GAUGE COLOR TERMINAL
BEHIND CENTER PANEL)
A1 A62D 20 DKBL 3535805C1
A2 A78L 20 RD 3535805C1
B1 A1 A3 A78K 20 LTGN 3535805C1
A4 A78-GD 20 WH 3535805C1
B1 A78A 20 LTGN 3535805C1
B2 A78D 20 LTGN 3535805C1
B3 A78C 20 LTGN 3535805C1
B4 A4
B4 A78F 20 LTGN 3535805C1
CONNECTOR 3510243C1
TURN SIGNAL ADAPTER (400)

CAV CIRC GAUGE COLOR TERMINAL SEAL/SLEEVE
(LOCATED ON MODULE BRACKET)
A A57A 16 OR 3535303C1 3535424C1
B A57D 16 OR 3535303C1 3535424C1
M C A57BC 16 LTGN 3535303C1 3535424C1
L
D PLUG - - 3535425C1 -
K
J E A56A 16 OR 3535303C1 3535424C1
H
F A56D 16 OR 3535303C1 3535424C1
G
F G A56BC 16 YL 3535303C1 3535424C1

E
H PLUG - - 3535425C1 -
D
C J A71B 16 OR 3535303C1 3535424C1
B
A
K A71A 16 OR 3535303C1 3535424C1
L PLUG - - 3535425C1 -
M A71D 18 OR 3535303C1 3535424C1
CONNECTOR 3543733C1
BODY LOCK 3543732C1
U00KDD2 CIRCUIT DIAGRAM,TERRASTAR

80257V 27JUN11 AE08068784 001

INSTRUCTIONS AND CHARTS (CHAPTER 13) CONNECTOR
BODY COMPOSITES MATING VIEW SHOWN, P. 2

DIAGRAM 13
BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF CONNECTOR BODY COMPOSITES MATING VIEW SHOWN
NAVISTAR, INC.
LCT T HANDLE SHIFTER (422F) PANEL LIGHT FEED (1002)

(LOCATED IN INSTRUMENT PANEL) (LOCATED IN INSTRUMENT PANEL)
K CONNECTOR 2007315C1
A
J BODY LOCK 2007316C1
B H CAV CIRCUIT GAUGE COLOR TERMINAL

C A A62B 18 DKBL 1661208C1
G
D B - - - -
F C - - - -
E D A62BD 18 DKBL 1661208C1
CONNECTOR 3540756C1 E - - - -
D
BODY LOCK 3540758C1 F - - - -
C G - - - -
CAV CIRC GAUGE COLOR TERMINAL SEAL/SLEEVE H - - - -
B
A A92A163 16 TN 1661875C1 1661872C1 J - - - -
B A92D 18 TN 1661875C1 3568570C1 K - - - -
C A92#142 18 TN 1661875C1 3568570C1
A
D A92#103 18 TN 1661875C1 3568570C1
INTENTIONALLY
LEFT BLANK

80257V 27JUN11 AE08068784 002

CONNECTOR BODY COMPOSITES MATING VIEW SHOWN, P. 3 INSTRUCTIONS

DIAGRAM 13
NAVISTAR, INC.
FUSE BLOCK #1 (1010)

RIGHT SIDE)
* MUTUALLY EXCLUSIVE
A CAV CIRCUIT GAUGE COLOR TERMINAL

B1 - - - -
B
B2 - - - -
C B3 A17C 16 PK 3573312C1
4
B4 A17M 18 PK 3534164C1
D
3 C1 A71C 18 OR 3534164C1
4 3 2 1
A71 16 OR 3573312C1
2 C2
A71C 18 OR 3573312C1
1 C3 A12-GC 16 WH 3573312C1
F E
C4 A12Z 16 LTBL 3573312C1
D1 A71AB 16 OR 3573312C1
D2 A92#165 18 TN 3534164C1
D3 A12U 16 LTBL 3573312C1
D4 A12Y 18 LTBL 3534164C1
A13F 18 PK 3573312C1
CONNECTOR 3599539C1 E1
BODY LOCK 3599541C1 A13FN 18 PK 3573312C1
E2 A14JA 12 RD 3573311C1
A13FH 18 PK 3573312C1
CAV CIRCUIT GAUGE COLOR TERMINAL E3
A13FK 18 PK 3573312C1
A1 - - - - E4 - - - -
A2 - - - - F1* A97UA 16 PL 3573312C1
A104CC 18 DKBL 3573312C1 F1* A97AA 16 PL 3573312C1
A3
A17A 18 PK 3573312C1 F2 A75D 18 LTGN 3534164C1
A17H 16 PK 3573312C1 F3 A90E 18 GY 3534164C1
A4
A17A 18 PK 3573312C1 F4 - - - -
FUSE LOCATION CAVITY RATING PART NUMBER DESCRIPTION

FUSE BREAKER
F1-A E1, F1 5 3534208C1 - ENGINE CONTROL UNIT
F1-B E2, F2 5 3534208C1 - CAB HVAC CONTROL
F1-C E3, F3 5 3534208C1 - TRW HYD ABS-IGN
RELAY LOCATION - CAVITY PART NUMBER DESCRIPTION

A1, A2, B1, B2 3600330C1 NOT USABLE FOR RELAY
A3, A4, B3, B4 3600330C1 START RELAY
C1, C2, D1, D2 3600330C1 BACK-UP LAMP RELAY
C3, C4, D3, D4 3600330C1 AUX ROOF LOAD RELAY

CNA1 26JUL11 INITIAL RELEASE A 80257V
80257V 27JUN11 AE08068784 003


DIAGRAM 13
NAVISTAR, INC.

(LOCATED IN INSTRUMENT PANEL RIGHT SIDE)
H F D B
4
CAV CIRCUIT GAUGE COLOR TERMINAL
3
D4 - - - -
2
E1 (A56J) - - 3536301C1
1
J G E C A E2 (A14MC) - - 3536299C1
E3 (A57J) - - 3536301C1
E4* (A14TA) - - 3536299C1
E4* A14TA 12 RD 3573311C1
CONNECTOR 3534572C1
F1 A14JC 12 RD 3573311C1
BODY LOCK1 3536085C1
BODY LOCK2 3599541C1 F2 A84 16 LTGN 3573312C1
F3 A14JD 12 RD 3573311C1
F4 A63 18 DKBL 3534164C1
G1 (A56J) - - 3536301C1
G2 - - - -
A1 A14MD 12 RD 3573311C1
G3 (A57J) - - 3536301C1
A2 A12-GBK 18 WH 3534164C1
G4 - - - -
A3 A14JB 12 RD 3573311C1
H1* A56C 18 OR 3534164C1
A13-GBN 18 WH 3573312C1
A4 H1* A56K 16 OR 3573312C1
A13-GFD 18 WH 3573312C1
H1* A56A 18 YL 3534164C1
B1 - - - -
H2* A56T 12 YL 3573311C1
B2 - - - -
H2* A56B 16 YL 3573312C1
B3 - - - -
H3* A57C 18 OR 3534164C1
B4 - - - -
H3* A57K 16 OR 3573312C1
C1 A14JF 12 RD 3573311C1
H3* A57A 18 LTGN 3534164C1
C2 A14MC 12 RD 3536299C1
H4* A57T 12 LTGN 3573311C1
C3 A14PA 12 RD 3573311C1
H4* A57B 16 LTGN 3573312C1
C4 A14TA 12 RD 3573311C1
J1* (A56J) - - 3536301C1
D1 A86A 18 LTGN 3534164C1
J1* A55D 16 OR 3515517C1
D2 - - - -
J2* A56-GC 18 WH 3534164C1
A12-GBK
D3 A28 16 TN 3573312C1
J2* A56-GC 18 WH 3534164C1
18WH
J3* (A57J) - - 3536301C1

* MUTUALLY EXCLUSIVE J3* A55C 16 OR 3515517C1
A57-GC 18 WH 3573312C1
J4*
A54-GC 18 WH 3573312C1
J4* A57-GC 18 WH 3534164C1
A11-GB

10WH
FUSE BREAKER
F2-A E1, F1 15 3534210C1 3536179C1 TRAILER LEFT TURN
F2-B E2, F2 15 3534210C1 3536179C1 CIGAR LIGHTER
F2-C E3, F3 15 3534210C1 3536179C1 TRAILER RIGHT TURN
F2-D E4, F4 10 3534209C1 3536178C1 CAB DOME / MAP LIGHTS
F2-E C1, D1 10 3534209C1 3536178C1 ENTERTAINMENT RADIO MEMORY
A11-GK
6WH
F2-G C3, D3 15 3534210C1 3536179C1 INSTRUMENT CLUSTER

A1, A2 3600329C1 LEFT SIDE ACCESSORY RELAY #1
A3, A4 3600329C1 CAB GROUND
IGNITION RELAY #1 @
(4081)
H1, H2, J1, J2 3600330C1 TRAILER LEFT TURN RELAY
CH3-18
H3, H4, J3, J4 3600330C1 TRAILER RIGHT TURN RELAY
@ ALSO SEE CONNECTOR 1013

80257V 27JUN11 AE08068784 004


DIAGRAM 13
NAVISTAR, INC.

H F D B
4
3 CONNECTOR 3534572C1
2
1
J G E C A

A1 A14NA 12 RD 3573311C1 CAV CIRCUIT GAUGE COLOR TERMINAL
A13-GFD 18 WH 3573312C1 F1* A68A 12 BN 3573311C1

A2 F1* A68T 12 BN 3573311C1
A13-GFE 18 WH 3573312C1
A3 A14NC 12 RD 3573311C1 F1* A68BB 14 BN 3573312C1
A13-GFE 18 WH 3573312C1 A68-GC 18 WH 3573312C1

A4 F2
A13-GFF 18 WH 3573312C1 A70-GT 18 WH 3573312C1
B1 - - - - F3* A54 12 BN 3573311C1
B2 - - - - F3* A54T 12 BN 3573311C1
B3 - - - - F3* A54BB 16 BN 3573312C1
B4 - - - - F3* A58BB 14 BN 3573312C1
A15 18 RD 3573312C1 A54-GC 18 WH 3573312C1

C1* F4*
A98H 18 BK 3573312C1 A68-GC 18 WH 3573312C1
A15 16 RD 3573312C1 F4* A58-GC 18 WH 3534164C1

C1* G1 A82M 16 GY 3573312C1
A98H 18 BK 3573312C1
C2 (A68J) - - 3536299C1 G2 A82E 16 GY 3573312C1
C3* A86PA 16 LTGN 3573312C1 G3 A82N 16 GY 3573312C1
C3* A86N 14 LTGN 3573312C1 G4 A82K 16 GY 3573312C1
C3* A86R 14 LTGN 3573312C1 H1 - - - -
C4* (A54J) - - 3536299C1 H2 A82V 16 GY 3573312C1
C4* A58J 18 WH 3515517C1 H3 - - - -
D1 A14PB 12 RD 3573311C1 H4 A82L 16 GY 3573312C1
D2 A14HB 12 RD 3573311C1 J1 A82P 16 GY 3573312C1
D3 A14ME 12 RD 3573311C1 J2 A82F 18 GY 3534164C1
D4 A14HA 12 RD 3573311C1 J3 A82P 16 GY 3573312C1
E1 A68C 18 BN 3534164C1 J4 A82H 18 GY 3534164C1
E2 (A68J) - - 3536299C1
E3* A54C 18 BN 3534164C1
E3* A58 18 BN 3534164C1
E4* (A54J) - - 3536299C1
E4* A58J 18 WH 3515517C1

FUSE BREAKER
F3-A C1, D1 10 3534209C1 3536178C1 KEY SWITCH / DIAGNOSTIC
F3-B C2, D2 20 3534211C1 3536180C1 TRAILER / BODY TAIL LIGHT
F3-C C3, D3 20 3534210C1 3536179C1 AUXILIARY POWER SOURCES
F3-D C4, D4 20 3534211C1 3536180C1 TRAILER / BODY MARKER LIGHT

A1, A2 3600329C1 IGNITION RELAY # 2 @
A3, A4 3600329C1 IGNITION RELAY # 3 @
E1, E2, F1, F2 3600330C1 TRAILER TAIL LIGHT RELAY
E3, E4, F3, F4 3600330C1 TRAILER MARKER LIGHT RELAY
G1, G2, H2, J1, J2 3519350C1 WIPER POWER RELAY
G3, G4, H4, J3, J4 3519350C1 WIPER HI / LO RELAY

80257V 27JUN11 AE08068784 005


DIAGRAM 13
NAVISTAR, INC.

H F D B
4
J G E C A

E3 (A13FC) - - 3536304C1
CONNECTOR 3534572C1
BODY LOCK1 3536085C1 E4 (A13FC) - - 3536306C1
BODY LOCK2 3599541C1 F1 - - - -
F2 - - - -
CAV CIRCUIT GAUGE COLOR TERMINAL F3 - - - -
A1 A12B 18 LTBL 3534164C1 F4 - - - -
A2 A12V 12 LTBL 3536306C1 G1 A14TC 12 RD 3573311C1
A3 A13FC 12 PK 3536304C1 G2 (A12V) - - 3536306C1
A4 A13FC 12 PK 3536306C1 (A13FC) - - 3536304C1
G3
B1 A12C 18 LTBL 3534164C1 A13FM 12 PK 3536304C1
B2 A12F 18 LTBL 3534164C1 G4 (A13FC) - - 3536306C1
A73A 18 LTGN 3573312C1 H1 A81B 12 LTGN 3573311C1
B3
A28A 18 TN 3573312C1 H2 A78V 18 LTGN 3534164C1
B4 A13 16 PK 3573312C1 A92#163 16 TN 3573311C1
H3*
C1 A14TD 12 RD 3573311C1 A92A163 16 TN 3573311C1
C2 (A12V) - - 3536306C1 A92A163 18 TN 3573311C1
H3*
C3 (A13FC) - - 3536304C1 A92FN 16 TN 3573312C1
C4 (A13FC) - - 3536306C1 A92#163 18 TN 3573312C1
H3*
D1 A81A 12 LTGN 3573311C1 A92A163 18 TN 3573312C1
A86 20 LTGN 3573312C1 H4 - - - -
D2*
A86F 18 LTGN 3573312C1 J1* A12A 18 LTBL 3534164C1
A86 18 LTGN 3573312C1 A12A 18 LTBL 3573312C1
D2* J1*
A86F 18 LTGN 3573312C1 A12Q 18 LTBL 3573312C1
D3 A13B 18 PK 3534164C1 J2 (A12V) - - 3536306C1
D4* A87KA 18 GY 3534164C1 A13FD 18 PK 3573312C1
J3
D4* A87MB 18 GY 3534164C1 A13FN 18 PK 3573312C1
E1 - - - - J4 (A13FC) - - 3536306C1
(A12V) - - 3536306C1
E2
A12D 12 LTBL 3536306C1 * MUTUALLY EXCLUSIVE

FUSE BREAKER
F4-A G1, H1 30 3534213C1 3536182C1 POWER WINDOW / DOOR-DRIVER
F4-B G2, H2 10 3534209C1 3536178C1 POWER MIRRORS
F4-C G3, H3 10 3534209C1 3536178C1 TRANSMISSION CONTROL UNIT
F4-E C1, D1 30 3534213C1 3536182C1 POWER WINDOW / DOOR PASSENGER
F4-F C2, D2 10 3534209C1 3536178C1 CB RADIO / ENTERTAINMENT RADIO
F4-G C3, D3 10 3534209C1 3536178C1 OPTIONAL WARNING LIGHTS
F4-H C4, D4 10 3534209C1 3536178C1 WINDSHIELD WASHER PUMP
F4-J A1, B1 5 3534208C1 - BODY CONTROLLER
F4-K A2, B2 10 3534209C1 3536178C1 SWITCH PACK
F4-L A3, B3 10 3534209C1 3536178C1 CLUSTER / CAB HVAC CONTROLLER
F4-M A4, B4 10 3534209C1 3536178C1 BODY CONTROLLER / CAB HVAC LPM
RELAY LOCATION
PART NUMBER DESCRIPTION
- CAVITY
J1, J2 3600329C1 ACCESSORY RELAY # 1 @
J3, J4 3600329C1 IGNITION RELAY # 1 @

80257V 27JUN11 AE08068784 006


DIAGRAM 13
NAVISTAR, INC.

A C E G J (LOCATED IN INSTRUMENT PANEL RIGHT SIDE)
1
4
B D F H
CONNECTOR 3534572C1
BODY LOCK2 3599541C1 CAV CIRCUIT GAUGE COLOR TERMINAL
D3 A13B 16 PK 3573312C1
D4 A28V 16 TN 3573312C1
E1 (A13FB) - - 3536304C1
CAV CIRCUIT GAUGE COLOR TERMINAL E2 (A13FB) - - 3536306C1
A1 A13FB 12 PK 3536304C1 (A13FA) 3536301C1
E3
A2 A13FB 12 PK 3536306C1 A13FR 12 PK 3536301C1
A3 A13FA 12 PK 3536301C1 E4 (A13FA) - - 3536306C1
A4 A13FA 12 PK 3536306C1 F1 - - - -
B1 - - - - F2 - - - -
A39 16 GY 3573311C1 F3 - - - -
B2
A39A 16 GY 3573311C1 F4 - - - -
B3 - - - - (A13FB) - - 3536304C1
G1
B4 A71 16 OR 3573312C1 A13FL 12 PK 3536304C1
C1 (A13FB) - - 3536304C1 G2 (A13FB) - - 3536306C1
C2 (A13FB) - - 3536306C1 G3 (A13FA) - - 3536304C1
C3 (A13FA) - - 3536301C1 G4 (A13FA) - - 3536306C1
C4 (A13FA) - - 3536306C1 H1 - - - -
D1 - - - - H2 A13X 16 PK 3573312C1
D2 - - - - H3 A90L 18 GY 3534164C1
H4 - - - -
A13FD 18 PK 3573312C1
J1
A13FE 18 PK 3573312C1
J2 (A13FB) - - 3536306C1
A13FE 18 PK 3573312C1
J3
A13FF 18 PK 3573312C1
J4 (A13FA) - - 3536306C1

FUSE BREAKER
F5-B G2, H2 10 3534209C1 3536178C1 AUX POWER SOURCE
F5-C G3, H3 5 3534208C1 - ACCELERATOR
F5-G C3, D3 10 3534209C1 3536178C1 OWNER OPERATOR
F5-H C4, D4 10 3534209C1 3536178C1 COMPASS MODULE
F5-K A2, B2 20 3534211C1 3536180C1 AIR DRYER
F5-M A4, B4 10 3534209C1 3536178C1 BACK-UP LIGHTS


80257V 27JUN11
AE08068784 007


DIAGRAM 13
NAVISTAR, INC.
FUSE BLOCK #6
(1015)
D C
CONNECTOR 3599501C1
BODY LOCK 3599541C1
4
1 2 3 4
B

A1 A19V 12 GY 3573311C1
A2 A37V 18 TN 3534164C1
A3 A12Z 16 LTBL 3573312C1
A4 A75 12 LTGN 3573311C1
B1 A14FA 12 RD 3573311C1
B2 A14KB 12 RD 3573311C1
B3 A14NB 12 RD 3573311C1
B4 A14JE 12 RD 3573311C1
C1 A37 18 TN 3534164C1
C2 A37D 16 TN 3573312C1
C3* A44 18 GY 3515517C1
C3* A23B 18 TN 3534164C1
C4* A46C 18 GY 3515517C1
A23 18 TN 3573312C1
C4*
A23C 18 TN 3573312C1
D1 A37V 18 TN 3534164C1
D2 A37-GCD 18 WH 3534164C1
D3* A46D 18 GY 3515517C1
D3* A23A 18 TN 3534164C1
D4* A23C 18 TN 3534164C1
D4* A44-GBJ 18 WH 3515517C1

FUSE BREAKER
F6-A A4, B4 30 3534213C1 3536182C1 CAB HVAC BLOWER MOTOR
F6-B A3, B3 20 3534211C1 3536180C1 AUXILIARY ROOF LOAD

F6-C A2, B2 10 3534209C1 3536178C1 FUEL TRANSFER PUMP
F6-D A1, B1 30 3534213C1 3536182C1 FUEL HEATER

C1, C2, D1, D2 3600330C1 FUEL TRANSFER PUMP RELAY
C3, C4, D3, D4 3600330C1 PARK BRAKE/FAN RELAY

80257V 28JUN11 AE08068784 008


DIAGRAM 13
NAVISTAR, INC.
FUSE BLOCK #7 (1016) * MUTUALLY EXCLUSIVE

(LOCATED IN INSTRUMENT PANEL RIGHT SIDE) & W/ AUX SWITCH
H F D B
4 CAV CIRCUIT GAUGE COLOR TERMINAL
E2* A72K 12 OR 3573311C1
3 E2&* A72A 12 OR 3573311C1
E2&* A72E 18 OR 3515517C1
2 E3 A14G 16 RD 3573312C1
E4 (A70J) - - 3536299C1
1 F1 A81C 12 LTGN 3573311C1
F2 A14FB 12 RD 3573311C1
J G E C A
F3 A14MA 12 RD 3573311C1
F4 A14HC 12 RD 3573311C1
G1* A12Q 18 LTBL 3534164C1
CONNECTOR 3534572C1
G1* A72E 18 OR 3534164C1
CAV CIRCUIT GAUGE COLOR TERMINAL G1&* A72EF 18 OR 3515517C1
A1 A14FE 12 RD 3573311C1 G1&* A72F 16 OR 3573312C1
A2 A14ND 12 RD 3573311C1 G2* A72AA 12 OR 3573311C1
A3 A13FT 12 PK 3573311C1 G2* A12BB 16 LTBL 3573312C1
A4 A14KA 12 RD 3573311C1 G2&* A72V 12 DKBL 3573311C1
B1* A14A 14 RD 3573312C1 G2&* A94TA 12 GY 3573311C1
B1* A14A 12 RD 3573311C1 G3 A70D 18 OR 3534164C1
B2* A72C 12 OR 3573311C1 G4 (A70J) - - 3536299C1
B2* A94L 12 GY 3573311C1 H1 - - - -
B3* A105 18 LTGN 3534164C1 H2 - - - -
B3* A105 16 LTGN 3573312C1 H3 - - - -
B3* A13AA 18 RD 3534164C1 J1* A14BA 16 RD 3573312C1
B3* A13AB 18 RD 3534164C1 J1* A72K 12 OR 3573311C1
B3* A14R 18 RD 3534164C1 J1&* A72A 12 OR 3573311C1
B4 A81D 12 LTGN 3573311C1 J1&* A94TC 12 GY 3573311C1
C1 - - - - J2&* A72-GCL 18 WH 3534164C1
C2 - - - - A72-GB 18 WH 3573312C1
J2&*
C3 - - - - A72-GCL 18 WH 3573312C1
C4 - - - - J2&* A12-GCL 18 WH 3534164C1
D1 - - - - J2&* A72-GAL 16 WH 3573312C1
D2 - - - - J2&* A12-GCL 18 WH 3515517C1
D3 - - - - J3* A70ET 10 RD 3573311C1
D4 - - - - J3* A70T 10 RD 3573311C1
E1 A14FD 12 RD 3573311C1 A70-GT 18 WH 3573312C1
J4
E2* A14BA 16 RD 3573312C1 A70-GC 18 WH 3573312C1
NOTE : 20A W/ BODY ACCESSORY

25A W/ TRAILER AUX CENTER PIN - ACC OR BAT
30A W/ TRAILER AUX FEED

FUSE BREAKER
F7-A E1, F1 30 3534213C1 3536182C1 POWER WINDOW / DOOR - LEFT REAR
3534211C1 3536180C1
F7-B E2, F2 SEE NOTE 3534212C1 3536181C1 BODY ACCESSORY / TRAILER AUX
3534213C1 3536182C1
F7-C E3, F3 15 3534210C1 3536179C1 OWNER OPERATOR
F7-D E4, F4 30 3534213C1 3536182C1 TRAILER STOP LIGHTS
F7-E A1, B1 10 3534209C1 3536178C1 DISPLAY SYSTEMS / DRIVER AIR SEAT
F7-F A2, B2 15 3534210C1 3536179C1 TRW ABS COIL B+
3534209C1 3534209C1
F7-G A3, B3 10/20 DRIVER SEAT / PASSENGER SEAT
3536180C1 3536180C1
F7-H A4, B4 30 3534213C1 3536182C1 POWER WINDOW / DOOR - RIGHT REAR

G1, G2, J1, J2, H2 3600329C1 BODY ACC / TRAILER AUX RELAY
G3, G4, J3, J4, H4 3600329C1 TRAILER STOP RELAY

80257V 28JUN11 AE08068784 009

INSTRUCTIONS AND CHARTS (CHAPTER 13) CONNECTOR BODY
COMPOSITES MATING VIEW SHOWN, P. 10

DIAGRAM 13
NAVISTAR, INC.

H F D B
4
2
CONNECTOR 3534572C1
BODY LOCK 3536085C1
1
J G E C A
CAV CIRCUIT GAUGE COLOR TERMINAL CAV CIRCUIT GAUGE COLOR TERMINAL
A1 A14NE 12 RD 3536301C1 G2 A92#163 16 TN 3573312C1
A2* A14PE 10 RD 3573311C1 A13FF 18 PK 3573312C1
G3
A2* A14PE 12 RD 3573311C1 A13FH 18 PK 3573312C1
A3 A14KC 12 RD 3573311C1 G4* A94T 10 GY 3573311C1
A4 A14PD 10 RD 3573311C1 G4* A72 12 OR 3573311C1
B1 - - - - G4* (A94TC) - - 3536299C1
B2 - - - - H1 A92FN 16 TN 3573312C1
B3 A14NS 12 BK 3573311C1 H2 - - - -
B4 - - - - H3 - - - -
C1 (A14NE) - - 3536301C1 H4 - - - -
C2 - - - - A92FB 16 TN 3573311C1
J1
C3 - - - - A92FBA 16 TN 3573311C1
C4 - - - - J2 A92FBA 16 TN 3573312C1
D1 - - - - J3* A94UA 12 GY 3573311C1
D2 - - - - J3* A72J 12 OR 3573311C1
D3 - - - - J3* A94TB 12 GY 3573311C1
D4 - - - - J4 A13-GFF 18 WH 3515517C1
E1 (A14NE) - - 3536301C1
E2 - - - -
E3 A20 16 LTGN 3573312C1
E4* A94UA 12 GY 3573311C1
E4* A72J 12 OR 3573311C1
E4* A94TC 12 GY 3573311C1
F1 A92FB 16 TN 3573312C1
F2 A14HE 12 RD 3573311C1
F3 A14MB 12 RD 3573311C1
F4 A14PC 12 RD 3573311C1
G1 A92RD 16 TN 3573312C1

FUSE BREAKER
F8-A E1, F1 10 3534209C1 3536178C1 TRANSMISSION SHIFTER
F8-C E3, F3 10 3534209C1 3536178C1 REMOTE POWER UNIT
F8-D E4, F4 30 3534213C1 3536182C1 TRAILER AIR ABS / ETB AUX
F8-F A2, B2 NOTE 2 3534209C1 3536178C1 TRANSMISSION CONTROL UNIT
F8-G A3, B3 30 3534213C1 3536182C1 ELECTRIC TRAILER BRAKES

G1, G2, J1, J2, H2 3519350C1 OPTIONAL RELAY SEE NOTE 1
G3, G4, J3, J4, H4 3519350C1 TRAILER ABS ECU RELAY
NOTE 1: AUTO NEUTRAL

START ENABLE RELAY
COLUMN SHIFTER

80257V 01JUL11 AE08068784 010


DIAGRAM 13
NAVISTAR, INC.

H F D B
4
1
BODY LOCK 3536085C1
J G E C A

* MUTUALLY EXCLUSIVE E2 A12V 12 LTBL 3573311C1
E3 - - - -
E4 - - - -
A1* A96RB 18 YL 3534164C1
F1 A86P 16 LTGN 3573312C1
A104L 18 DKBL 3573312C1
A1* F2 A12X 18 LTBL 3534164C1
A104F 18 DKBL 3573312C1
F3 A19V 12 GY 3573311C1
A104CB 18 DKBL 3573312C1
A2* F4 A19-GCG 18 WH 3534164C1
A104N 18 DKBL 3573312C1
A96RA 18 YL 3573312C1
A2* A52E 14 YL 3573312C1 G1*
A96RB 18 YL 3573312C1
A3* A96LA 18 YL 3534164C1
A104JC 18 DKBL 3573312C1
A96LA 18 YL 3573312C1 G1*
A3* A104JB 18 DKBL 3573312C1
A96LB 18 YL 3573312C1
G2* A53F 14 YL 3573312C1
A4 A52B 14 YL 3573312C1
G2* A104C 16 DKBL 3573312C1
B1 - - - -
G3* A96LB 18 YL 3534164C1
B2* A52D 14 YL 3573312C1
A104C 16 DKBL 3573312C1
B2* A59RC 18 GY 3534164C1 G3*
A104B 18 DKBL 3534164C1
B3 - - - -
G4* A104B 18 DKBL 3534164C1
B4* A52 14 YL 3573312C1
G4* A53E 14 YL 3573312C1
B4* A59CA 16 GY 3573312C1
H2 A53B 14 YL 3573312C1
A104JD 18 DKBL 3573312C1
B4* H1 - - - -
A104JC 18 DKBL 3573312C1
H3 - - - -
C1* A52PD 14 YL 3573312C1
H4* A53 14 YL 3573312C1
C2* A96-GC 18 YL 3534164C1
H4* A13F 18 PK 3534164C1
C2* A104E 18 DKBL 3534164C1
J1* A53PA 14 YL 3573312C1
C3* A52PC 14 YL 3573312C1
A104JB 18 DKBL 3573312C1
C3* A59RD 16 GY 3573312C1 J1*
A104JA 18 DKBL 3573312C1
A96-GB 18 YL 3573312C1
C4* A96-GD 18 YL 3573312C1
A96-GD 18 YL 3573312C1 J2*
A96-GC 18 YL 3573312C1
C4* A104JD 18 DKBL 3534164C1
J2* A96-GD 18 YL 3534164C1
D1 - - - -
J2* A104H 16 DKBL 3573312C1
D2 - - - -
A104J 16 DKBL 3573312C1
A13FK 18 PK 3573312C1 J3*
D3 A104JA 18 DKBL 3573312C1
A13FP 18 PK 3573312C1
J3* A53PB 14 YL 3573312C1
D4 A19 12 GY 3573311C1
A104J 18 DKBL 3573312C1
E1 A13FM 12 PK 3573311C1 J3*
A104JA 18 DKBL 3573312C1
A96-GCC 18 YL 3573312C1
J4*
A96-GB 18 YL 3573312C1
J4* A104AA 18 DKBL 3534164C1

FUSE BREAKER
F9-A E1, F1 5 3534208C1 - 2 WAY RADIO
F9-B E2, F2 5 3534208C1 - AUX ROOF LOAD

G1, G2, H2, J1, J2 3519350C1 RIGHT LOW BEAM OR SWITCH RELAY
G3, G4, H4, J3, J4 3519350C1 LEFT LOW BEAM OR REMOTE-S RELAY
A1, A2, B2, C1, C2 3519350C1 RIGHT HIGH BEAM OR REMOTE-S RELAY
A3, A4, B4, C3, C4 3519350C1 LEFT HIGH BEAM OR PUMP-I RELAY
D3, D4, E4, F3, F4 3519350C1 FUEL HEATER RELAY

80257V 01JUL11 AE08068784 011


DIAGRAM 13
NAVISTAR, INC.

H F D B
4
J G E C A
CONNECTOR 3534572C1
BODY LOCK 3536085C1

C2 A78AC 16 LTGN 3573312C1
A78-GBH 18 WH 3573312C1
A1* C3 - - - -
A78-GC 18 WH 3573312C1
C4 - - - -
A78-GC 16 WH 3573312C1
A1* D1 - - - -
A78-GBH 18 WH 3573312C1
D2 - - - -
A2 A78C 14 BK 3573312C1
D3 - - - -
A3 - - - -
D4 - - - -
A4 - - - -
E1* A97Z 10 VT 3573311C1
B1 - - - -
E1* A94PM 12 GY 3573311C1
B2 - - - -
E2* A70E 10 RD 3573311C1
B3 - - - -
E2* A94PE 16 GY 3573312C1
B4 - - - -
E3 A14KD 12 RD 3573311C1
C1 A78A 14 LTGN 3573312C1
E4* A14TB 12 RD 3573311C1
E4* A14TF 12 RD 3573311C1
F1* A23 18 TN 3534164C1
F1* A94TM 12 GY 3573311C1
F2* A70NS 16 RD 3573312C1
F2* A94TE 16 GY 3573312C1
F3 A70BF 14 RD 3573312C1
F4 - - - -
G1 - - - -
G2 - - - -
G3 - - - -
G4 - - - -
H1 - - - -
H2 - - - -
H3 - - - -
H4 - - - -
J1 - - - -
J2 - - - -
J3 - - - -
J4 - - - -

FUSE BREAKER
F10-A E1, F1 5 3534208C1 3536178C1 FAN SOLENOID
F10-B E2, F2 15 3534210C1 3536179C1 ELECTRIC TRAILER BRAKES

F10-C E3, F3 20 3534211C1 3536180C1 BODY STOP
RELAY LOCATION -CAVITY PART NUMBER DESCRIPTION

A1, A2, B2, C1, C2 3519350C1 LEFT WINDSHIELD RELAY

80257V 01JUL11 AE08068784 012


DIAGRAM 13
NAVISTAR, INC.


B1# A59RD 16 GY 3573312C1
A
B1% A78B 14 BK 3516158C1
B2# A59CE 18 GY 3534164C1
B
B2% A78-GBH 18 WH 3515517C1
B3 - - - -
C
B4 - - - -
4
C1 A70-GC 18 WH 3534164C1
D
C2 A70BF 14 RD 3573312C1
3
C3 - - - -
4 3 2 1
C4 - - - -
2
D1 A70BB 14 RD 3573312C1
D2* A70C 18 OR 3534164C1
1 D2* A70C 14 RD 3573312C1
D3 - - - -
F E
D4 - - - -
A14HD 14 RD 3573311C1
E1
A14HH 16 RD 3573312C1
E2 A13FS 12 PK 3573311C1
E3 A13FL 12 PK 3573311C1
E4 A14HH 16 RD 3573312C1
CONNECTOR 3599540C1
F1 - - - -
BODY LOCK 3599541C1
F2 A97DF 18 PL 3534164C1
F3 - - - -
F4 A14FF 16 RD 3573312C1
A1# A59RE 18 GY 3534164C1
A1% A78BC 16 LTGN 3515517C1
A2# A59CD 18 GY 3534164C1
A2% A78 16 LTGN 3515517C1
A3 A12D 12 LTBL 3573311C1
A4 - - - -
# W/ ALLISON W/ RMT SS
% W/ MIRROR-HTD W/ WHLD

FUSE
F11-B E2, F2 5 3534208C1 ENGINE BODY BUILDER
F11-D E4, F4 5 3534208C1 AGSP
RELAY LOCATION CAVITY PART NUMBER DESCRIPTION

A1, A2, B1, B2 3600330C1 PUMP RELAY / HEATED WINDSHIELD
A3, A4, B3, B4 NOT USABLE FOR RELAY
C1, C2, D1, D2 3600330C1 BODY STOP RELAY

80257V 01JUL11 AE08068784 013


DIAGRAM 13
NAVISTAR, INC.
J1939 ADAPTER
(1025) CAV CIRCUIT GAUGE COLOR TERMINAL
(LOCATED IN INSTRUMENT PANEL CENTER) A A5RF(-) 18 GN 3534164C1
B A5FA(-) 18 GN 3534164C1
C A5RH(-) 18 LTGN 3534164C1
D A5RH(-) 18 LTGN 3534164C1
E* A5(-) 18 GN 3534164C1
E* A5D(-) 18 GN 3534164C1
A M F* A5RJ(-) 18 GN 3534164C1
B L F* A5F (-) 18 GN 3534164C1

G* A5RJ(+) 18 YL 3534164C1
C K G* A5F(+) 18 YL 3534164C1
D J H* A5(+) 18 YL 3534164C1
H* A5D(+) 18 YL 3534164C1
E H J A5RH(+) 18 YL 3534164C1
K A5RH(+) 18 YL 3534164C1
F G L A5FA(+) 18 YL 3534164C1
M A5RF(+) 18 YL 3534164C1
CONNECTOR 3601838C1
BODY LOCK 3601839C1
J1939 ADAPTER (1026)

(LOCATED IN INSTRUMENT PANEL CENTER)
A M
B L
C K
D J
E H
F G
CONNECTOR 3601838C1
BODY LOCK 3601839C1

A* A5RD(-) 18 GN 3534164C1
A* A5R(-) 18 GN 3534164C1
B A5C(-) 18 GN 3534164C1
C A5RE(-) 18 LTGN 3534164C1
D A5RE(-) 18 LTGN 3534164C1
E A5CA(-) 18 GN 3534164C1
F A5RF(-) 18 GN 3534164C1
G A5RF(+) 18 YL 3534164C1
H A5CA(+) 18 YL 3534164C1
J A5RE(+) 18 YL 3534164C1
K A5RE(+) 18 YL 3534164C1
L A5C(+) 18 YL 3534164C1
M* A5RD(+) 18 YL 3534164C1
M* A5R(+) 18 YL 3534164C1

80257V 05JUL11 AE08068784 014


DIAGRAM 13
NAVISTAR, INC.
KEY SWITCH CONN (1100MA)

KEY SWITCH (1100)
A D A D
B B
C C
CONNECTOR 3546518C1
CONNECTOR 3546518C1 BODY LOCK 3546519C1
BODY LOCK 3546519C1

A A15 18 RD 1661208C1 CAV CIRCUIT GAUGE COLOR TERMINAL
B A17H 16 PK 1661208C1 A A15 16 RD 1661208C1
C A12 18 LTBL 1661208C1 B* A17H 16 PK 1661208C1
D* A13DB 18 PK 1661208C1 B* A17H 18 PK 1661208C1
D* A13F 18 PK 1661208C1 C A12 18 LTBL 1661208C1
D* A104J 18 DKBL 1661208C1 D A13F 18 PK 1661208C1
LOC 1 & 2 SWITCH PACK (1101)

D C
E B
F A
CONNECTOR 2031871C1
BODY LOCK 2031873C1

A A11-GKD 18 WH 1661261C1
B A12F 18 LTBL 1661261C1
C A62DB 18 DKBL 1661261C1
D* A3C(+) 18 DKBL 1661261C1
D* A3A(+) 18 DKBL 1661261C1
E* A3C(-) 18 GY 1661261C1
E* A3A(-) 18 GY 1661261C1
F - - - -

80257V 05JUL11 AE08068784 015


DIAGRAM 13
NAVISTAR, INC.
ROCKER START SWITCH (1105) IP AUX ROOF LOAD SWITCH (1106)

(LOCATED IN INSTRUMENT PANEL CENTER) (LOCATED IN INSTRUMENT PANEL CENTER)
10 8
10 8
3 6
3 6
2B 5B
2B 5B
1 4
1 4
9 7
9 7
CONNECTOR 3520850C1
CONNECTOR 3520850C1
1 - - - - 1 - - - -
2B A13FJ 18 PK 1661224C1 2B A12X 18 LTBL 1661224C1
3 A17BA 16 PK 1661224C1 A12Y 18 LTBL 3541250C1

3
4 - - - - A12V 18 LTBL 3541250C1
5B - - - - 4 - - - -
6 - - - - 5B - - - -
7 - - - - 6 - - - -
8 A62DH 18 DKBL 1661224C1 7 A12V 18 LTBL 1661224C1
9 - - - - 8 A62DJ 18 DKBL 1661224C1
10 A62-GCB 18 WH 1661224C1 9 A12-GA 16 WH 1661224C1

10 - - - -
SNOWVALVE SWITCH (1107)

10 8
3 6
2B 5B
1 4
9 7
CONNECTOR 3520850C1

1 A23M 18 TN 1661224C1
2B A13DA 18 PK 1661224C1
3 A23J 18 TN 1661224C1
4 A23L 18 TN 1661224C1
5B A23-GAK 18 WH 1661224C1
6 A23K 18 TN 1661224C1
7 A23H 18 TN 1661224C1
8 A62ODG 18 LTBL 1661224C1
9 - - - -
10 - - - -

80257V 05JUL11 AE08068784 016


DIAGRAM 13
NAVISTAR, INC.
HVAC CONTROL (1200)

AUX TRAILER SOCKET SWITCH
(1110)
A
1 2 3 4 5 6 7 8 9 101112
8 6 5B 4 7 CONNECTOR 3534302C1
CONNECTOR 3520850C1 BODY LOCK2 3539893C1
@ MUTUALLY EXCLUSIVE
10 3 2B 1 9 CAV CIRCUIT GAUGE COLOR TERMINAL

A1 A73A 18 LTGN 3522073C1
A2 A75D 18 LTGN 3522073C1
1 A72D 18 OR 1661224C1
A3 - - - -
2B A110C 18 GY 1661224C1
A4 A77 20 LTGN 3534303C1
3@ A72CA 18 OR 1661224C1
A5 - - - -
3@ A72FA 18 OR 1661226C1
A6 - - - -
3@ A72F 16 OR 1661226C1
A7 - - - -
3@ A72ED 18 OR 3541250C1
A8 - - - -
3@ A72EC 18 OR 3541250C1
A9 A75C 20 LTGN 3534303C1
4 - - - -
A10 - - - -
5B - - - -
A11 A75A 18 LTGN 3522073C1
6 - - - -
A12 A62DA 18 DKBL 3522073C1
7@ A72B 14 OR 1661226C1
B1 A74D 18 LTGN 3522073C1
7@ A72FA 18 OR 1661224C1
B2 A74E 18 LTGN 3522073C1
7@ A72ED 18 OR 1661224C1
B3 - - - -
8 A62DK 18 DKBL 1661224C1
B4 - - - -
9@ A72-GAM 18 WH 1661224C1
B5 - - - -
A72-GB 18 WH 3541250C1
10 B6 A74-G 18 WH 3522073C1
A72-GD 18 WH 3541250C1
B7 - - - -
B8 - - - -
B9 A74 18 LTGN 3522073C1
HVAC UNIT (1210) B10 A74A 18 LTGN 3522073C1
B11 A74B 18 LTGN 3522073C1
B12 A74C 18 LTGN 3522073C1
A K
B J HVAC LPM (1220)
(LOCATED ON RIGHT SIDE KICK PANEL HVAC LPM)
C H
D G
E F 4
6
CONNECTOR 3837771C1 3
BODY LOCK 3540614C1 2
5
CAV CIRCUIT GAUGE COLOR TERMINAL 1
A A74 18 LTGN 1661261C1
B A74A 18 LTGN 1661261C1 CONNECTOR 3627940C1
C A74B 18 LTGN 1661261C1
D A74C 18 LTGN 1661261C1 CAV CIRCUIT GAUGE COLOR TERMINAL
E A74D 18 LTGN 1661261C1 1 - - - -
F A74E 18 LTGN 1661261C1 2 - - - -
G A75E 20 LTGN 3544254C1 3 - - - -
H A75ZVRA 18 GY 1661261C1 4 A75A 18 LTGN 3544884C1
J A77D 20 LTGN 3544254C1 5 A75-G 12 WH 3605694C1
K A75ZVRB 18 GY 1661261C1 6 A75 12 LTGN 3605694C1

80257V 05JUL11 AE08068784 017


DIAGRAM 13
NAVISTAR, INC.
RADIO (1300)
RADIO CONNECTOR (1301)
(LOCATED IN INSTRUMENT PANEL)
(LOCATED IN INSTRUMENT PANEL - RADIO)
1 7
9 10 1 2
2 8
11 12 3 4 CONNECTOR 3597143C1 3 9
13 14 5 6 4 10
5 11
15 16 7 8 * W/ PREM TRIM
6 12

CONNECTOR 3580403C1
1 - - - -
2 - - - -
3 A54D 18 BN 3597102C1 CAV CIRCUIT GAUGE COLOR TERMINAL
4 A86 18 LTGN 3597102C1 1 A86H 20 LTGN 3580404C1
5 - - - - 2 A86J 20 LTGN 3580404C1
6 A62E 18 DKBL 3597102C1 3 A86BA 20 LTGN 3580404C1
7 A86A 18 LTGN 3597102C1 4 A86CA 20 LTGN 3580404C1
8 A86-G 18 WH 3597102C1 5 A86-G 20 WH 3580404C1
9 A86DA 20 LTGN 3597102C1 6 A86 20 LTGN 3580404C1
10 A86EA 20 LTGN 3597102C1 7 A86K 20 LTGN 3580404C1
11* A86K 20 LTGN 3597102C1 8 A86L 20 LTGN 3580404C1
12* A86L 20 LTGN 3597102C1 9 A86DA 20 LTGN 3580404C1
13* A86H 20 LTGN 3597102C1 10 A86EA 20 LTGN 3580404C1
14* A86J 20 LTGN 3597102C1 11 - - - -
15 A86BA 20 LTGN 3597102C1 12 A86AA 20 LTGN 3580404C1
16 A86CA 20 LTGN 3597102C1
CLUSTER CONNECTOR (1500) CLUSTER CONNECTOR (1501)

7 1 5 12
8 2 4 11
9 3 CONNECTOR 2018590C1
CONNECTOR 3548792C1 10
10 9
11
3 8
12 4 2 7
13 5 1 6
14 6

1 A28-G 16 WH 2018639C1 CAV CIRCUIT GAUGE COLOR TERMINAL
2 A28 16 TN 2018639C1 1 - - - -
3 - - - - 2 - - - -
4 A62 18 DKBL 2018639C1 3 - - - -
*5 A62DA 18 DKBL 2018639C1 4 - - - -
*5 A62BD 18 DKBL 2018639C1 5 - - - -
*6 A62P 18 DKBL 2018639C1 6 - - - -
*6 A62BE 18 GY 2018639C1 7 - - - -
7 A28A 18 TN 2018639C1 8 - - - -
8 A110AD 18 GY 2018639C1 9 A41 18 GY 2018639C1
9 A72CA 18 OR 2018639C1 10 - - - -
10 A72D 18 OR 2018639C1 11 A5D(-) 18 GN 2018639C1
11 - - - - 12 A5D(+) 18 YL 2018639C1
12 - - - -
13 - - - -
14 A52C 20 YL 2018639C1

80257V 05JUL11 AE08068784 018


DIAGRAM 13
NAVISTAR, INC.
GAUGE SWITCH PACK (1512)

(LOCATED IN INSTRUMENT PANEL BEHIND CENTER PANEL CAV CIRCUIT GAUGE COLOR TERMINAL
1 A11-GJ 18 WH 2018639C1
2 A62S 18 DKBL 2018639C1
3 - - - -
7 1 4 A11-GAB 18 WH 2018639C1
8 2
5 - - - -
9 3
6 - - - -
10 7 A14FF 16 RD 2018639C1
11 8 A12FC 18 LTBL 2018639C1
12 4 9 - - - -
13 5 10 A5C(-) 18 GN 2018639C1
14 6 11 A5C(+) 18 YL 2018639C1
12 - - - -
CONNECTOR 3548792C1 13 - - - -
14 - - - -
BODY CONTROLLER #J3 (1600)

(LOCATED ON LEFT SIDE KICK PANEL - BODY CONTROLLER)
B1 A1
CONNECTOR 3598706C1
B16 A16
A1 A12C 18 LTBL 3522073C1 B1 - - - -
A2 A77 20 LTGN 3534303C1 B2 A40 18 GY 3522073C1
A3 A75C 20 LTGN 3534303C1 B3 A40A 18 GY 3522073C1
A4 A52A 20 YL 3534303C1 B4 - - - -
A5 A85B 20 GY 3534303C1 B5 A77D 20 LTGN 3534303C1
A6 A57R 20 OR 3534303C1 B6 A90M 18 GY 3522073C1
A7 A56L 20 OR 3534303C1 B7 A88B 16 LTGN 3522073C1
A8 A87EA 18 GY 3522073C1 B8 A36A 18 TN 3522073C1
A9 A82A 20 GY 3534303C1 B9 - - - -
A10 A82B 20 GY 3534303C1 B10 A90HB 18 GY 3522073C1
A11 A82C 20 GY 3534303C1 B11 - - - -
A12 A44A 16 GY 3522073C1 B12 A77B 20 LTGN 3534303C1
A13 A63DF 18 DKBL 3522073C1 B13 A75E 20 LTGN 3534303C1
A14 A102A 20 YL 3534303C1 B14 - - - -
A15 A87B 20 GY 3534303C1 B15 - - - -
A16 A13 16 PK 3522073C1 B16 A97 20 GY 3534303C1

80257V 05JUL11 AE08068784 019


DIAGRAM 13
NAVISTAR, INC.

(LOCATED ON LEFT SIDE KICK PANEL - BODY CONTROLLER)
F1 E1
F16 E16
CONNECTOR 3598707C1

E1* A59RA 18 GY 3522073C1 CAV CIRCUIT GAUGE COLOR TERMINAL
E1* A103D 18 LTGN 3522073C1 F1* A44 18 GY 3522073C1
E2* A104AA 18 DKBL 3522073C1 F1* A44 16 GY 3522073C1
E2* A103C 18 LTGN 3522073C1 F2 - - - -
E3 A92RD 16 TN 3522073C1 F3 - - - -
E4* A104A 18 DKBL 3522073C1 F4 A59H 18 GY 3522073C1
E4* A92#161 18 TN 3522073C1 F5 A59K 18 GY 3522073C1
E5* A103AA 18 LTGN 3522073C1 F6 A59M 18 GY 3522073C1
E5* A12BC 18 LTBL 3522073C1 F7 - - - -
E6 A82H 18 GY 3522073C1 F8 A59E 18 GY 3522073C1
E7 A82F 18 GY 3522073C1 F9 - - - -
E8 A92D 18 TN 3522073C1 F10 A59C 18 GY 3522073C1
E9 A59J 18 GY 3522073C1 F11 A37 18 TN 3522073C1
E10 A68C 18 BN 3522073C1 F12 - - - -
E11 A72E 18 OR 3522073C1 F13 A56C 18 OR 3522073C1
E12 A59D 18 GY 3522073C1 F14 A54C 18 BN 3522073C1
E13 A59G 18 GY 3522073C1 F15* A70D 18 OR 3522073C1
E14 A96RA 18 YL 3522073C1 F15* A70CA 18 OR 3522073C1
E15 A57C 18 OR 3522073C1 F15* A70C 18 OR 3522073C1
E16 A104L 18 DKBL 3522073C1 F15* A70T 18 RD 3522073C1
F16 A90J 18 GY 3522073C1

80257V 05JUL11 AE08068784 020


DIAGRAM 13
NAVISTAR, INC.
BODY CONTROLLER #J5

(1602)
(LOCATED ON LEFT SIDE KICK PANEL)
F1 E1
F16 E16
CONNECTOR 3598705C1
E1* A3B(-) 18 GY 3522073C1 F1 - - - -
E1* A3A(-) 18 GY 3522073C1 F2 A5(-) 18 GN 3522073C1
E2* A3B(+) 18 DKBL 3522073C1 F3 A5(+) 18 YL 3522073C1
E2* A3A(+) 18 DKBL 3522073C1 F4 - - - -
E3 A9ZA 18 GY 3522073C1 F5 A5EB(-) 18 GN 3522073C1
E4 A6 18 GY 3522073C1 F6 A5EB(+) 18 YL 3522073C1
E5 A9AA 18 GY 3522073C1 F7 - - - -
E6* A6A 20 GY 3534303C1 F8 - - - -
E6* A6A 18 GY 3522073C1 F9 - - - -
E7 A9B 18 GY 3522073C1 F10 A70ER 18 RD 3522073C1
E8 A6A 18 GY 3522073C1 F11 - - - -
E9 - - - - F12 A103B 18 LTGN 3522073C1
E10 - - - - F13 - - - -
E11 A52C 20 YL 3534303C1 F14 A103A 18 LTGN 3522073C1
E12 - - - - F15 A104D 18 DKBL 3522073C1
E13 - - - - F16 - - - -
E14 A70 20 RD 3534303C1
E15 - - - -
E16 A11-GAC 18 WH 3522073C1

80257V 05JUL11 AE08068784 021


DIAGRAM 13
NAVISTAR, INC.

(LOCATED ON LEFT SIDE KICK
(LOCATED ON LEFT SIDE KICK
PANEL)
PANEL)
F A E A
M G K F
CONNECTOR 3598711C1 CONNECTOR 3598710C1
A A82 16 GY 3544876C1
A A57A 16 OR 3544876C1
B A56A 16 OR 3544876C1 B* A53AA 14 YL 3544877C1
B* A53PB 14 YL 3544877C1
C A77A 16 LTGN 3544876C1
B* A53 14 YL 3544877C1
D A56C 16 OR 3544876C1
C* A52AA 14 YL 3544877C1
E A85E 16 GY 3544876C1
C* A52PC 14 YL 3544877C1
F A64A 16 YL 3544876C1
C* A52 14 YL 3544877C1
G - - - -
D - - - -
H* A78A 16 LTGN 3544876C1
E A11-GB 12 WH 3544877C1
H* A78AA 16 LTGN 3544876C1
F A68 16 BN 3544876C1
J - - - -
G A58 16 BN 3544876C1
K A64B 16 YL 3544876C1
H* A53B 14 YL 3544877C1
L* A78B 16 LTGN 3544876C1
H* A53PA 14 YL 3544877C1
L* A78BA 16 LTGN 3544876C1
J A63A 18 DKBL 3544876C1
M A57C 16 OR 3544876C1
K* A52D 14 YL 3544877C1
K* A52PD 14 YL 3544877C1
BASE 1 ADAPTER (1623) REAR TURNS PANEL ADAPTER (1625)

G
M L K J H G F E D C B A
F
E
D CONNECTOR 2006789C1
BODY LOCK 2006792C1 CONNECTOR 3543733C1
C BODY LOCK 3543732C1
B
CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE
A A57C 16 OR 3535303C1 3535424C1
A B A57 16 OR 3535303C1 3535424C1
C A57BB 16 LTGN 3535303C1 3535424C1
D A57K 16 OR 3535303C1 3535424C1
CAV CIRCUIT GAUGE COLOR TERMINAL E A56C 16 OR 3535303C1 3535424C1
A A58 16 BN 1661208C1 F A56 16 OR 3535303C1 3535424C1
B A54D 18 BN 1661208C1 G A56BB 16 YL 3535303C1 3535424C1
C A58DA 18 BN 1661208C1 H A56K 16 OR 3535303C1 3535424C1
D A58DB 18 BN 1661208C1 J A62 18 DKBL 3535303C1 3535424C1
E A58T 18 BN 1661208C1 K A62DA 18 DKBL 3535303C1 3535424C1
F A54B 16 BN 1661208C1 L A62DB 18 DKBL 3535303C1 3535424C1
G - - - - M A62E 18 DKBL 3535303C1 3535424C1

80257V 05JUL11 AE08068784 022


DIAGRAM 13
NAVISTAR, INC.
J1939 PRIVATE TERMINATING RESISTOR (1626) J1939 TERMINATING RESISTOR (1657)

C
C
B
B
A
A

BODY LOCK 1667771C1 BODY LOCK 1667771C1
CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE
A A5ET(+) 18 YL 1661875C1 3568570C1 A A5LI(+) 18 YL 1661875C1 3568570C1

B PLUG - - 3568570C1 - B PLUG - - 2025431C1 -
C A5ET(-) 18 GN 1661875C1 3568570C1 C A5LI(-) 18 GN 1661875C1 3568570C1
J1708 PUBLIC (+) (1660)

(LOCATED IN INSTRUMENT PANEL LEFT SIDE)
DIAGNOSTIC CONNECTOR (1650)
(LOCATED UNDER INSTRUMENT PANEL
LEFT OF STEERING COLUMN)
G CONNECTOR 2006789C1
BODY LOCK 2006792C1
F
D
E E
C
D CAV CIRCUIT GAUGE COLOR TERMINAL
F A B A A3BB(+) 18 DKBL 1661208C1
J
C B - - - -
G B
H C - - - -
D - - - -
E - - - -
A
F A3D(+) 20 DKBL 1661208C1
G - - - -
CONNECTOR 3544066C1
CAV CIRCUIT GAUGE COLOR TERMINAL J1708 PUBLIC (-) (1661)

A A98-G 18 WH 1651968C1 (LOCATED IN INSTRUMENT PANEL LEFT SIDE)
B A98H 18 BK 1651968C1
C A5B(+) 18 YL 1651968C1
CONNECTOR 2006789C1
D A5B(-) 18 GN 1651968C1 G BODY LOCK 2006792C1
E PLUG - - 2025431C1
F
F A3CC(+) 18 DKBL 1651968C1
E CAV CIRCUIT GAUGE COLOR TERMINAL
G A3CC(-) 18 GY 1651968C1
A A3BB(-) 18 GY 1661208C1
H PLUG - - 2025431C1 D
B - - - -
J PLUG - - 2025431C1
C C - - - -
B D - - - -
E - - - -
F A3D(-) 20 GY 1661208C1
A G - - - -

80257V 06JUL11 AE08068784 023


DIAGRAM 13
NAVISTAR, INC.
FORWARD CHASSIS / IP
(1700)
(LOCATED ON DASH PANEL LEFT SIDE UPPER)
76
64
12
50
38
26
CONNECTOR 3595624C1
13
39
27
51
65
1 M52 14 YL 3549416C1 26 PLUG - - 3598922C1
2 M53 14 YL 3549416C1 27 M9A 18 GY 3549418C1
3 M52D 14 YL 3549416C1 28 M6A 18 GY 3549418C1
4 M53B 14 YL 3549416C1 29 M40 18 GY 3549418C1
5 M54B 14 BN 3549416C1 30 M94L(+) 18 BK 3549418C1
6 PLUG - - 3598922C1 31 M94L(-) 18 BN 3549418C1
7 PLUG - - 3598922C1 32 PLUG - - 3598921C1
8 M53E 14 YL 3549416C1 33 PLUG - - 3598921C1
9 M53F 14 YL 3549416C1 34 PLUG - - 3598921C1
10 M52B 14 YL 3549416C1 35 M94R(+) 18 BK 3549418C1
11 M52E 14 YL 3549416C1 36 M94R(-) 18 BN 3549418C1
12 PLUG - - 3598922C1
13 PLUG - - 3598922C1
14 M56B 16 OR 3549417C1 CHART CONTINUED ON SHEET 25
15 M57B 16 OR 3549417C1
16 M41 18 GY 3549418C1
17 PLUG - - 3598921C1
18 PLUG - - 3598921C1
19 PLUG - - 3598921C1
20 PLUG - - 3598921C1
21 M85E 16 GY 3549417C1
22 M64A 16 YL 3549417C1
23 M64B 16 YL 3549417C1
24 PLUG - - 3598921C1
25 M110AD 18 GY 3549418C1

80257V 06JUL11 AE08068784 024


DIAGRAM 13
NAVISTAR, INC.
FORWARD CHASSIS / IP
(1700)
(LOCATED ON DASH PANEL LEFT SIDE UPPER)
76
64
12
50
38
26
CONNECTOR 3595624C1
13
39
27
51
65
CHART CONTINUED FROM SHEET 24

54* PLUG - - 3598921C1
37 PLUG - - 3598921C1
55 PLUG - - 3598921C1
38 PLUG - - 3598921C1
56 PLUG - - 3598921C1
39 PLUG - - 3598921C1
57 PLUG - - 3598921C1
40 PLUG - - 3598921C1
58 PLUG - - 3598921C1
41 PLUG - - 3598921C1
59 PLUG - - 3598921C1
42 PLUG - - 3598921C1
60 PLUG - - 3598921C1
43 M104CC 18 DKBL 3549418C1
61 PLUG - - 3598922C1
44 M104CB 18 DKBL 3549418C1
62 PLUG - - 3598922C1
45 PLUG - - 3598921C1
63 PLUG - - 3598922C1
46 PLUG - - 3598921C1
64 PLUG - - 359892C1
47 PLUG - - 3598921C1
65 M103M 12 LTGN 3549415C1
48 PLUG - - 3598921C1
66 M103N 12 LTGN 3549415C1
49 PLUG - - 3598921C1
67 M103P 12 LTGN 3549415C1
50 PLUG - - 3598921C1
68 PLUG - - 3598921C1
51 PLUG - - 3598922C1
69 PLUG - - 3598922C1
52 PLUG - - 3598921C1
70 PLUG - - 3598922C1
53 PLUG - - 3598921C1
71 PLUG - - 3598922C1
72 PLUG - - 3598922C1
73 PLUG - - 3598922C1
74 PLUG - - 3598922C1
75 PLUG - - 3598922C1
76 PLUG - - 3598922C1

80257V 06JUL11 AE08068784 025


DIAGRAM 13
NAVISTAR, INC.
IP / FORWARD CHASSIS (1700)

(LOCATED ON FRONT LEFT DASH PANEL (UPPER))
12 1
26 13
38 27
50 39
64 51
76 65
CONNECTOR 3595625C1
1 A52 14 YL 3574288C1 23 A64B 16 YL 3574285C1
2 A53 14 YL 3574288C1 24 - - - -
3 A52D 14 YL 3574288C1 25 A110AD 18 GY 2003343C1
4 A53B 14 YL 3574288C1 26 - - - -
5 A54B 16 BN 3574288C1 27 A9A 18 GY 2003343C1
6 - - - - 28 A6A 18 GY 2003343C1
7 - - - - 29 A40 18 GY 2003343C1
8 A53E 14 YL 3574288C1 30 A94L(+) 18 GY 2003343C1
9 A53F 14 YL 3574288C1 31 A94L(-) 18 GY 2003343C1
10 A52B 14 YL 3574288C1 32 - - - -
11 A52E 14 YL 3574288C1 33 - - - -
12 - - - - 34 - - - -
13 - - - - 35 A94R(+) 18 GY 2003343C1
14 A56B 16 OR 3574285C1
15 A57B 16 OR 3574285C1
16 A41 18 GY 2003343C1
17 - - - -
18 - - - -
19 - - - -
20 - - - -
21 A85E 16 GY 3574285C1
22 A64A 16 YL 3574285C1
CHART CONTINUED ON SHEET 27

80257V 06JUL11 AE08068784 026


DIAGRAM 13
NAVISTAR, INC.
IP / FORWARD CHASSIS (1700)

(LOCATED ON FRONT LEFT DASH PANEL (UPPER))
12 1
26 13
38 27
50 39
64 51
76 65
CONNECTOR 3595625C1
36 A94R(-) 18 GY 2003343C1 56 - - - -
37 - - - - 57 - - - -
38 - - - - 58 - - - -
39 - - - - 59 - - - -
40 - - - - 60 - - - -
41 - - - - 61 - - - -
42 - - - - 62 - - - -
43 A104CC 18 DKBL 2003343C1 63 - - - -
44 A104CB 18 DKBL 2003343C1 64 - - - -
45 - - - - 65 A103M 12 LTGN 3574287C1
46 - - - - 66 A103N 12 LTGN 3574287C1
47 - - - - 67 A103P 12 LTGN 3574287C1
48 - - - - 68 - - - -
49 - - - - 69 - - - -
50 - - - - 70 - - - -
51 - - - - 71 - - - -
52 - - - - 72 - - - -
53 - - - - 73 - - - -
54 - - - - 74 - - - -
55 - - - - 75 - - - -
76 - - - -

80257V 06JUL11 AE08068784 027


DIAGRAM 13
NAVISTAR, INC.
IP / CENTER CHASSIS
(1701)
(LOCATED ON FRONT LEFT DASH PANEL (LOWER))
12 1
26 13
38 27
50 39
64 51
76 65
CONNECTOR 3595623C1
1 A71A 16 OR 3574288C1 20 - - - -
2 A56 16 OR 3574288C1 21 - - - -
3 A57 16 OR 3574288C1 22 - - - -
4 A68 16 BN 3574288C1 23 - - - -
5 A56T 12 YL 3574287C1 24 A90E 18 GY 2003343C1
6 A57T 12 LTGN 3574287C1 25 - - - -
7 A54T 12 BN 3574287C1 26 A94L 12 GY 3574287C1
8 A68T 12 BN 3574287C1 27 A36A 18 TN 2003343C1
9 A70T 10 RD 3574287C1 28 - - - -
10 A94T 10 GY 3574287C1 29 - - - -
11 - - - - 30 - - - -
12 A56BB 16 YL 3574288C1 31 A39B 16 GY 3574285C1
13 A9 18 GY 3574289C1 32 A59B 18 GY 2003343C1
14 A94L(+) 18 GY 2003343C1 33 A59C 18 GY 2003343C1
15 A94L(-) 18 GY 2003343C1 34 A59D 18 GY 2003343C1
16 A94R(+) 18 GY 2003343C1 35 A59E 18 GY 2003343C1
17 A94R(-) 18 GY 2003343C1 36 A59G 18 GY 2003343C1
18 - - - - 37 A59H 18 GY 2003343C1
19 - - - - 38 A59J 18 GY 2003343C1
39 A59K 18 GY 2003343C1
40 - - - -

80257V 06JUL11 AE08068784 028


DIAGRAM 13
NAVISTAR, INC.
IP / CENTER CHASSIS (1701)

(LOCATED ON FRONT LEFT DASH PANEL (LOWER))
12 1
26 13
38 27
50 39
64 51
76 65
CONNECTOR 3595623C1
41 A87EA 18 GY 2003343C1 56 - - - -
42 A56BC 16 YL 3574285C1 57 - - - -
43 A104CA 16 DKBL 3574285C1 58 - - - -
44 A59CA 16 GY 3574285C1 59 A87MB 18 GY 2003343C1
45 - - - - 60 - - - -
46 - - - - 61 A5A(-) 18 GN 2003343C1
47 - - - - 62 A5A(+) 18 YL 2003343C1
48 - - - - 63 A57BB 16 LTGN 3574285C1
49 - - - - 64 A57BC 16 LTGN 3574288C1
50 - - - - 65 - - - -
51 A20 16 LTGN 3574288C1 66 - - - -
52 A5E(+) 18 YL 2003343C1 67 - - - -
53 A5E(-) 18 GN 2003343C1 68 - - - -
54 - - - - 69 - - - -
55 - - - - 70 - - - -
71 A68BB 14 BN 3574288C1
72 A70BB 14 RD 3574288C1
73 A71BB 16 LTBL 3574288C1
74 A54BB 16 BN 3574288C1
75 A12BB 16 LTBL 3574288C1
76 - - - -

80257V 06JUL11 AE08068784 029


DIAGRAM 13
NAVISTAR, INC.
CENTER CHASSIS / IP (1701F)

(LOCATED ON FRONT
LEFT DASH PANEL (LOWER))
76
64
12
50
38
26
13
39
27
51
65
CONNECTOR 3595622C1
CAV CIRC GAUGE COLOR TERMINAL CAV CIRC GAUGE COLOR TERMINAL
1 N71A 14 OR 3549416C1 15 N94L(-) 18 GY 3549418C1
2 N56 14 OR 3549416C1 16 N94R(+) 18 GY 3549418C1
3 N57 14 OR 3549416C1 17 N94R(-) 18 GY 3549418C1
4 N68 14 BN 3549416C1 18 PLUG - - 3598921C1
5 N56T 10 YL 3549415C1 19 PLUG - - 3598921C1
6 N57T 10 LTGN 3549415C1 20 PLUG - - 3598921C1
7 N54T 10 BN 3549415C1 21 PLUG - - 3598921C1
8 N68T 10 BN 3549415C1 22 PLUG - - 3598921C1
9 N70T 10 RD 3549415C1 23 PLUG - - 3598921C1
10 N94T 10 GY 3549415C1 24 N90E 16 GY 3549417C1
11 PLUG - - 3598922C1 25 PLUG - - 3598921C1
12 N56BB 16 YL 3549416C1 26 N94L 12 GY 3549415C1
13* N9G 16 GY 3549416C1 27 N36A 18 TN 3549418C1
13* N9B 16 GY 3549416C1 28 PLUG - - 3598921C1
14 N94L(+) 18 GY 3549418C1 29 PLUG - - 3598921C1

30 PLUG - - 3598921C1
31 N39B 16 GY 3549417C1
32 N59B 18 GY 3549418C1
33 N59C 18 GY 3549418C1
34 N59D 18 GY 3549418C1
35 N59E 18 GY 3549418C1
36 N59G 18 GY 3549418C1
37 N59H 18 GY 3549418C1
38 N59J 18 GY 3549418C1
39 N59K 18 GY 3549418C1
40 PLUG - - 3598921C1

80257V 06JUL11 AE08068784 030


DIAGRAM 13
NAVISTAR, INC.
CENTER CHASSIS / IP (1701F)

(LOCATED ON FRONT
LEFT DASH PANEL (LOWER))
76
64
12
50
38
26
13
39
27
51
65
CONNECTOR 3595622C1
CAV CIRC GAUGE COLOR TERMINAL

CAV CIRC GAUGE COLOR TERMINAL 53 N5E(-) 18 GN 3549418C1
41 N87EA 18 GY 3549418C1 54 PLUG - - 3598921C1
42 N56BC 16 YL 3549417C1 55 PLUG - - 3598921C1
43 N104CA 16 DKBL 3549417C1 56 PLUG - - 3598921C1
44 N59CA 16 GY 3549417C1 57 PLUG - - 3598921C1
45 PLUG - - 3598921C1 58 N87DB 18 GY 3549418C1
46 PLUG - - 3598921C1 59 N87MB 16 GY 3549417C1
47 PLUG - - 3598921C1 60 PLUG - - 3598921C1
48 PLUG - - 3598921C1 61 N5A(-) 18 GN 3549418C1
49 PLUG - - 3598921C1 62 N5A(+) 18 YL 3549418C1
50 PLUG - - 3598921C1 63 N57BB 16 LTGN 3549417C1
51 N20 16 LTGN 3549416C1 64 N57BC 16 LTGN 3549416C1
52 N5E(+) 18 YL 3549418C1 65 PLUG - - 3598922C1
66 PLUG - - 3598922C1
67 PLUG - - 3598922C1
68 PLUG - - 3598922C1
69 PLUG - - 3598922C1
70 PLUG - - 3598922C1
71 N68BB 14 BN 3549416C1
72 N70BB 14 RD 3549416C1
73 N71BB 16 LTBL 3549416C1
74 N54BB 14 BN 3549416C1
75 N12BB 14 LTBL 3549416C1
76 PLUG - - 3598922C1

80257V 06JUL11 AE08068784 031


DIAGRAM 13
NAVISTAR, INC.
ENGINE / IP INTERCONNECT (1702)

(LOCATED ON FRONT CENTER DASH PANEL)
34 42
38
28 33
30 31
22 24 25 27
16 18 19 21
10 12 13 15
5
1 9
CONNECTOR 3595620C1
BODY LOCK 3598916C1
BODY LOCK 3598917C1
% MUTUALLY EXCLUSIVE

CAV CIRCUIT GAUGE COLOR TERMINAL 21% K92B103 18 YL 3549418C1
1 K97NA 10 PL 3549415C1 21% K92#103 18 YL 3549418C1
2 K9E 18 GY 3549418C1 22 K97C 18 PL 3549418C1
3 K6A 18 GY 3549418C1 23 K97B 18 PL 3549418C1
4 K77B 18 LTGN 3549418C1 24 K23E 16 TN 3549417C1
5 PLUG - - 3598921C1 25 PLUG - - 3598921C1
6 PLUG - - 3598921C1 26 PLUG - - 3598921C1
7 K92#165 18 TN 3549418C1 27 PLUG - - 3598921C1
8 K92#163 18 YL 3549418C1 28 K99B 18 PL 3549418C1
9 PLUG - - 3598922C1 29 K23L 18 TN 3549418C1
10 K77A 16 LTGN 3549417C1 30 K97FU 18 PL 3549418C1
11 K5A(+) 18 YL 3549418C1 31 PLUG - - 3598921C1
12 PLUG - - 3598921C1 32 K97WC 18 PL 3549418C1
13 PLUG - - 3598921C1 33 K97M 18 PL 3549418C1
14 K88B 14 LTGN 3549417C1 34 K19B 12 GY 3549415C1
15 PLUG - - 3598921C1 35 K3A(+) 18 DKBL 3549418C1
16 K17C 16 PK 3549417C1 36 K3A(-) 18 GY 3549418C1
17 K5A(-) 18 GN 3549418C1 37 K97UB 18 VT 3549418C1
18 K17M 18 PK 3549418C1 38 K97DF 18 PL 3549418C1
19 K92#142 18 WH 3549418C1 39 PLUG - - 3598921C1
20 PLUG - - 3598921C1 40 K5G(+) 18 YL 3549418C1
41 K5G(-) 18 GN 3549418C1
42 PLUG - - 3598922C1

80257V 06JUL11 AE08068784 032


DIAGRAM 13
NAVISTAR, INC.
IP / ENGINE INTERCONNECT (1702)

(LOCATED ON FRONT CENTER DASH PANEL)
9 2127 42
15 33
19 25
BODY LOCK 3598918C1
5 38 BODY LOCK 3598919C1
12 30
18 24
10 28
1 34
16 22

1 A97Z 10 VT 3574287C1
24 A23A 18 TN 2003343C1
2 A9E 20 GY 2003343C1
25 - - - -
3 A6A 20 GY 2003343C1
26 - - - -
4 A77B 20 LTGN 2003343C1
27 - - - -
5 - - - -
28 A99B 18 PL 2003343C1
6 A71 16 OR 3574285C1
29 A23B 18 TN 2003343C1
7 A92#165 18 TN 2003343C1
30 A97FU 18 PL 2003343C1
8 A92#163 18 TN 2003343C1
31 - - - -
9 - - - -
32 A97WC 18 PL 2003343C1
10 A77A 16 LTGN 3574285C1
33 A97M 18 PL 2003343C1
11 A5R(+) 18 YL 2003343C1
34 A19 12 GY 3574287C1
12 - - - -
35 A3AA(+) 18 DKBL 2003343C1
13 A31 18 TN 2003343C1
36 A3AA(-) 18 GY 2003343C1
14 A88B 16 LTGN 3574285C1
37 A97UA 16 PL 3574285C1
15 - - - -
38 A97DF 18 PL 2003343C1
16 A17C 16 PK 3574285C1
39 - - - -
17 A5R(-) 18 GN 2003343C1
40 - - - -
18 A17M 18 PK 2003343C1
41 - - - -
19 A92#142 18 TN 2003343C1
42 - - - -
20 - - - -
21 A92#103 18 TN 2003343C1
22 A97C 18 PL 2003343C1
23 A97B 18 PL 2003343C1

80257V 06JUL11 AE08068784 033


DIAGRAM 13
NAVISTAR, INC.
CAB CONNECTOR (1800) DCM HARNESS CONNECTOR (1800F)

(LOCATED IN INSTRUMENT PANEL (LOCATED IN INSTRUMENT PANEL TO THE
TO THE RIGHT OF STEERING COLUMN) RIGHT SIDE OF STEERING COLUMN)
D D
1 2 3 4 5 6 7 8
D 8 7 6 5 4 3 2 1 D
C C
1 2 3 4 5 6 7 8 91011
12
C 121110 9 8 7 6 5 4 3 2 1 C
1 2 3 4 5 6 7 8 9 101112
B 121110 9 8 7 6 5 4 3 2 1 B
B B
A 1 2 3 4 5 6 7 8 A
A 8 7 6 5 4 3 2 1 A
CONNECTOR 3553649C1
CONNECTOR 3612512C1
BODY LOCK 3553650C1
@ MUTUALLY EXCLUSIVE
A1 B56A 18 OR 3544886C1
A1 A56L 20 OR 3544883C1
A2 B57A 18 OR 3544886C1
A2 A57R 20 OR 3544883C1
A3 B11-GAA 18 WH 3544880C1
A3 A11-GA 18 WH 3544876C1
A4 B9V 18 GY 3544880C1
A4 A9V 18 GY 3544876C1
A5 B87A 18 GY 3544880C1
A5 A87A 20 GY 3544875C1
A6 - - - -
A6 - - - -
A7 B52A 18 YL 3544886C1
A7 A52A 20 YL 3544883C1
A8 B102A 18 YL 3544886C1
A8 A102A 20 YL 3544883C1
B1 B82B 18 GY 3544886C1
B1 A82C 20 GY 3544883C1
B2 - - - -
B2 - - - -
B3 - - - -
B3 - - - -
B4 B97Y 18 PL 3544886C1
B4 A97B 18 PL 3544884C1
B5 B99U 18 PL 3544886C1
B5 A97FU 18 PL 3544884C1
B6 B99W 18 PL 3544886C1
B6 A97WC 18 PL 3544884C1
B7 B44BB 18 WH 3544886C1
B7 A44A 16 GY 3544884C1
B8 - - - -
B8 - - - -
B9 B70 18 OR 3544886C1
B9 A70 20 RD 3544883C1
B10 B85B 18 GY 3544886C1
B10 A85B 20 GY 3544883C1
B11 B85C 18 GY 3544886C1
B11@ A85K 18 GY 3544884C1
B12 B96 18 PL 3544886C1
B11@ A85C 18 GY 3544884C1
C1 B82A 18 GY 3544886C1
B12 A97 20 GY 3544883C1
C2 - - - -
C1 A82B 20 GY 3544883C1
C3 - - - -
C2 - - - -
C4 B99V 18 PL 3544886C1
C3 - - - -
C5 B97P 18 PL 3544886C1
C4 A99B 18 PL 3544884C1
C6 B99E 18 PL 3544886C1
C5 A97C 18 PL 3544884C1
C7 - - - -
C6 A97M 18 PL 3544884C1
C8 - - - -
C7 - - - -
C9 B82 18 GY 3544886C1
C8 - - - -
C10 - - - -
C9 A82A 20 GY 3544883C1
C11 B96A 18 PL 3544886C1
C10 - - - -
C12 - - - -
C11 A97A 18 PL 3544884C1
D1 - - - -
C12 - - - -
D2 - - - -
D1 - - - -
D3 - - - -
D2 - - - -
D4 - - - -
D3 - - - -
D5 - - - -
D4 - - - -
D6 - - - -
D5 - - - -
D7 B17J 18 PK 3544886C1
D6 - - - -
D8 B17H 18 PK 3544886C1
D7 A17B 18 PK 3544884C1
D8 A17HB 18 PK 3544884C1

80257V 07JUL11 AE08068784 034


DIAGRAM 13
NAVISTAR, INC.
DUAL ANALOG ACCELERATOR

(1804)
(LOCATED ABOVE ACCELERATOR PEDAL)

F A B99V 18 PL 1651943C1
E B B97Y 18 PL 1651943C1
D C B97P 18 PL 1651943C1
C D B99U 18 PL 1651943C1
B E B99W 18 PL 1651943C1
A F B99E 18 PL 1651943C1
CONNECTOR 1687790C1
CLUTCH SWITCH
(1807)
(LOCATED ON CLUTCH PEDAL)
A
A B17J 18 PK 1667742C1 3568570C1
B B B17H 18 PK 1667742C1 3568570C1
C C B96A 18 PL 1667742C1 3568570C1
D D B9VB 18 GY 1667742C1 3568570C1
CONNECTOR 3540757C1
BODY LOCK 3540758C1
CLOCK SPRING
(1809)
(LOCATED IN STEERING COLUMN)

D A B9R 18 GY 1661261C1
C
B B96 18 PL 1661261C1
B
C B85C 18 GY 1661261C1
A
D B85B 18 GY 1661261C1
CONNECTOR 3547870C1
BODY LOCK 3515764C1

TURN SIGNAL SWITCH
(1810) 1 B56A 18 OR 3571717C1
(LOCATED ON STEERING COLUMN) 2 B57A 18 OR 3571717C1
3 B52A 18 YL 3571717C1
4 B102A 18 YL 3571717C1
5 B82B 18 GY 3571717C1
6 B11-GAA 18 WH 3571717C1
6
1 7 B9S 18 GY 3571717C1
12 8 B82 18 GY 3571717C1
7
9 - - - -
10 - - - -
11 B82A 18 GY 3571717C1
CONNECTOR 3539212C1
12 B87A 18 GY 3571717C1

80257V 07JUL11 AE08068784 035


DIAGRAM 13
NAVISTAR, INC.
BRAKE SWITCH PARK BRAKE SWITCH

(1814A) (1815)
(LOCATED AT BASE OF STEERING COLUMN) (LOCATED AT PARK BRAKE LEVER)
B A
A B
CONNECTOR 1661259C1
A B70 18 RD 2036586C1 A WHITE 18 WH 1661261C1
B B9VF 18 GY 2036586C1 B BLK1 18 BK 1661261C1
LCT COLUMN SHIFTER (1828)

(LOCATED ON THE BACK OF LCT SHIFT SELECTOR) TWO POST POWER SOURCE (1861)
E (JUMPER HARNESS)
F
D A B
CONNECTOR 3525872C1
C
BODY LOCK 3525873C1
B
A
G * W/ CIGAR
@ N/ CIGAR
H CONNECTOR 3517473C1

A PLUG - - 2025431C1
A* A86S 14 LTGN 3517476C1
B A92-GAM 18 WH 1661875C1 A@ A86N 14 LTGN 3517476C1
C A92A163 18 TN 1661875C1 B* A86-GS 14 WH 3517476C1
D A92D 18 TN 1661875C1 B@ A86-GB 14 WH 3517476C1
E A92#142 18 TN 1661875C1
F A92#103 18 TN 1661875C1
G A44L 18 GY 1661875C1
H A44J 18 GY 1661875C1
AUX-POWER CONNECTOR (1872) * MUTUALLY EXCLUSIVE

(LOCATED AT INSTRUMENT PANEL CENTER)

A103BA 16 LTGN 1661228C1
1*
B CONNECTOR 0587568C91 A103C 10 LTGN 1661228C1
A14WB 12 RD 1661228C1
1*
A A14WC 14 RD 1661228C1
A13F 16 PK 2018946C1
1*
A104J 16 DKBL 2018946C1
CAV CIRCUIT GAUGE COLOR TERMINAL 1* A72C 12 OR 2022374C1
A A72A 12 OR 1673747C1 2* A104A 18 DKBL 1659673C1
B A72-GY 12 WH 1673747C1 2* A13X 16 PK 1661709C1
2* A12BC 18 LTBL 1659673C1
2* A103AA 18 LTGN 1659673C1
AUX-POWER RELAY (1873)
(LOCATED AT INSTRUMENT PANEL CENTER) 3 A13XA 16 PK 2018946C1
4* A72A 12 OR 2022374C1
4* A103D 12 LTGN 1661710C1
1 4* A12BD 12 LTBL 1661710C1
A13XA 16 PK 1661709C1
3 CONNECTOR 0593385C1 5*
5 2 A13DB 18 PK 1661709C1
BODY LOCK 0593387C1
4 5* A11-GX 18 WH 1659673C1
5* A14WC 14 RD 2018946C1
5* A103BA 16 LTGN 2018946C1

80257V 07JUL11 AE08068784 036


DIAGRAM 13
NAVISTAR, INC.
COMPASS MODULE (1912)

AUX POWER (1901) (LOCATED IN INSTRUMENT PANEL BY FUSE PANEL)
(LOCATED AT INSTRUMENT PANEL CENTER)
A 5
4
B
3
CONNECTOR 1661196C1
2
1

A* A86RC 14 LTGN 3566715C1 CONNECTOR 3609957C1
A* A86R 16 LTGN 1661208C1 CAV CIRCUIT GAUGE COLOR TERMINAL

B* A86-GRC 14 WH 3566715C1 1 A28V 16 TN 3614754C1
B* A86-GP 16 WH 1661208C1 2 A5CA(+) 18 YL 3614754C1
3 A5CA(-) 18 GN 3614754C1
4 A28-GAD 16 WH 3614754C1
5 - - - -
DRIVER SEAT POWER (1918)

J1708 PRIVATE (+) (1927)
(LOCATED BEHIND DRIVER SEAT ON FLOOR)
LEFT OF KEY SWITCH)
G
F
A
E
B D A A3B(+) 18 DKBL 1661208C1
C B A3D(+) 18 DKBL 1661208C1
C A3E(+) 18 DKBL 1661208C1
CONNECTOR 0587567C91
B
D A3F(+) 18 DKBL 1661208C1
* MUTUALLY EXCLUSIVE E A3C(+) 18 DKBL 1661208C1
A F - - - -
CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE G - - - -
A* A105-GB 16 WH 0587577C1 1652325C1
A* A105-G 18 WH 0587578C1 3517771C1 CONNECTOR 2006789C1
A* AD 14 RD 0587577C1 0589391C1 BODY LOCK 2006792C1
A* A14B 12 RD 1673748C1 0589391C1
B* A105B 16 LTGN 0587577C1 1652325C1
B* A105 18 LTGN 0587578C1 3517771C1
B* AH 14 WH 0587577C1 0589391C1 HEATED SEAT PASSENGER (1935)
(LOCATED BEHIND PASSENGER SEAT ON FLOOR)
B* A11-GP 12 WH 1673748C1 0589391C1
J1708 PRIVATE (-) (1929)

(LOCATED IN INSTRUMENT PANEL A
LEFT OF KEY SWITCH)
G CONNECTOR 2006789C1 B
F BODY LOCK 2006792C1
E CONNECTOR 0587567C91
D A A3B(-) 18 GY 1661208C1 * MUTUALLY EXCLUSIVE
C B A3D(-) 18 GY 1661208C1
B C A3E(-) 18 GY 1661208C1
A* A105-GA 16 WH 0587577C1 1652325C1
D A3F(-) 18 GY 1661208C1
A* A14C 12 RD 1673748C1 0589391C1
E A3C(-) 18 GY 1661208C1
B* A105A 16 LTGN 0587577C1 1652325C1
A F - - - -
B* A11-GR 12 WH 1673748C1 0589391C1
G - - - -

80257V 07JUL11 AE08068784 037


DIAGRAM 13
NAVISTAR, INC.
ROOF / IP CONNECTION (2000)

(LOCATED IN INSTRUMENT PANEL LEFT SIDE) IP / AUX ROOF (2021)
(LOCATED IN INSTRUMENT
1 2 3 4 5 6 PANEL RIGHT SIDE)
A B
CONNECTOR 3554817C1
7 8 9 10 11121314 BODY LOCK 3554820C1
CONNECTOR 3544690C1

1 A86C 20 LTGN 3544692C1 CAV CIRCUIT GAUGE COLOR TERMINAL
2 A63-GA 16 WH 3544694C1 A A12U 16 LTBL 3534165C1
3 A63DF 18 DKBL 3544692C1 B A12-GB 16 WH 3534165C1
4 A86EA 20 LTGN 3544692C1
5 A86DA 20 LTGN 3544692C1
6* A63DA 18 DKBL 3544692C1
6* A63A 18 DKBL 3544692C1
7 - - - -
8 - - - -
9 A58T 18 BN 3544692C1 IP / PREMIUM ROOF (2503)
10 A63 18 DKBL 3544692C1 (LOCATED IN INSTRUMENT
PANEL LEFT SIDE)
11 A11-GF 16 WH 3544694C1
12 A86F 18 LTGN 3544692C1
1 2 3 4
13 A86BA 20 LTGN 3544692C1
14 A9L 18 GY 3544692C1
5 6 7 8 9 10
CONNECTOR 3544688C1
ROOF / IP CREW ROOF (2600)
1 - - - -
2 - - - -
3 - - - -
4 - - - -
5 - - - -
F E D C B A 6# A86L 20 LTGN 3544692C1
6& A86L 20 LTGN 3544692C1
7# A86J 20 LTGN 3544692C1
7& A86J 20 LTGN 3544692C1
CONNECTOR 3550639C1
8# A86H 20 LTGN 3544692C1
8& A86H 20 LTGN 3544692C1
9# A86K 20 LTGN 3544692C1
A A81C 12 LTGN 3544877C1
9& A86K 20 LTGN 3544692C1
B A3F(+) 18 DKBL 3544876C1
10 - - - -
C A81D 12 LTGN 3544877C1
D A81-GB 12 WH 3544877C1 # W/ 12 WAY W/ PREM TRIM
E A3F(-) 18 GY 3544876C1 & W/ 16 WAY W/ PREM TRIM
F A81-GC 12 WH 3544877C1

80257V 07JUL11 AE08068784 038


DIAGRAM 13
NAVISTAR, INC.
DRIVER DOOR CONNECTOR (3000)

BY DRIVER DOOR) CAV CIRCUIT GAUGE COLOR TERMINAL
A A78D 18 LTGN 1661261C1
B A78E 18 LTGN 1661261C1
A K C A78F 18 LTGN 1661261C1
B J D& A78A 16 LTGN 1661261C1
C H D* A78AB 16 LTGN 1661261C1
D G E A62BD 18 DKBL 1661261C1

E F F A58DA 18 BN 1661261C1
G A78V 18 LTGN 1661261C1
H A78-GA 16 WH 1661261C1
J - - - -
CONNECTOR 3540612C1 K - - - -
BODY LOCK 3540614C1
& W/ POWER MIRROR - HEATED

* W/ DUAL HOOD MTD MIRROR - HEATED

PASSENGER DOOR (3003)
(LOCATED IN INSTRUMENT PANEL A A78D 18 LTGN 1661261C1
BY PASSENGER DOOR) B A78E 18 LTGN 1661261C1
C A78F 18 LTGN 1661261C1
D# A78B 16 LTGN 1661261C1
A K
D# A78BB 16 LTGN 1661261C1
B J E - - - -
C H F A58DB 18 BN 1661261C1
D G G - - - -
E F
H A78-GB 16 WH 1661261C1
J - - - -
K - - - -
CONNECTOR 3540612C1
BODY LOCK 3540614C1
# MUTUALLY EXCLUSIVE
IP CONNECTOR (3200)
(LOCATED IN INSTRUMENT PANEL BY DRIVER DOOR)

A A3D(+) 18 DKBL 1661208C1
B A3D(-) 18 GY 1661208C1
D C
C A81B 12 LTGN 3566715C1
E B D* A81-GA 12 WH 3566715C1
D* A81-GH 12 WH 3566715C1
F A
E A63-GDW 18 WH 1661208C1
F A63DB 18 DKBL 1661208C1
CONNECTOR 1661200C1 * MUTUALLY EXCLUSIVE

80257V 07JUL11 AE08068784 039


DIAGRAM 13
NAVISTAR, INC.
MAXI FUSE HOLDER (4004)

DOOR / IP DOOR POD (3204)
BY PASSENGER DOOR)
D C
A
E B & W/ 40A AUX CIRCUIT
# W/ 30A AUX CIRCUIT
F A
B
CONNECTOR 1661200C1
CAV CIRCUIT GAUGE COLOR TERMINAL CONNECTOR 3525613C1
A A3E(+) 18 DKBL 1661208C1

B A3E(-) 18 GY 1661208C1
A* M14L 10 RD 3515526C1 3515525C1
C A81A 12 LTGN 3566715C1
A* M14L 12 RD 3614762C1 3541256C1
D A81-G 12 WH 3566715C1
B& M103C 12 LTGN 3614762C1 3541256C1
E A63-GDV 18 WH 1661208C1
B# M14WB 12 RD 3614762C1 3541256C1
F A63DC 18 DKBL 1661208C1
HYDROMAX FLOW SWITCH (4031) HYDROMAX DIFFERENTIAL PRESSURE SWITCH (4032)

(LOCATED ON HYDROMAX UNIT ON (LOCATED ON HYDROMAX UNIT ON
LEFT SIDE OF DASH) LEFT SIDE OF DASH)
A
B
A B
CONNECTOR 2036584C1
CAV CIRCUIT GAUGE COLOR TERMINAL CONNECTOR 3518873C91
A A90CA 16 GY 2036586C1
B A90-G 16 WH 2036586C1
A A90C 16 GY ASSY
HYDROMAX BOOST PUMP RELAY(4033)
(LOCATED ON HYDROMAX UNIT ON B A90B 16 GY ASSY
LEFT SIDE OF DASH)
HYDROMAX MOTOR SENSE FUSE(4040)

(LOCATED NEAR HYDROMAX UNIT ON
4 LEFT SIDE OF DASH)
2 3 5
B
1
A
CONNECTOR 1667739C1
CAV CIRCUIT GAUGE COLOR TERMINAL FUSE 5A 3534208C1
1 A14 12 RD 1661708C1
2 A90A 16 GY 3895713C1
3 - - - -
A A90H 14 GY 1661707C1
4 A90F 12 GY 1661708C1
B A90HA 14 GY 1661707C1
5 A90K 16 GY 3895713C1

80257V 07JUL11 AE08068784 040


CHAPTER 13
NAVISTAR, INC.
REMOTE POWER MODULE

HYDROMAX DIODE (4041C) DATALINK & LOGIC POWER (4410D)
(LOCATED NEAR HVAC MODULE IN IP) (LOCATED NEAR LEFT FRAME RAIL BACK OF CAB)
B
1 6
C CONNECTOR 3572899C1
2 5 BODY LOCK 2005242C1
A
3 4
CONNECTOR 598839C1
CAV CIRCUIT GAUGE COLOR TERMINAL 1 PLUG - - 0453133C1
A A90L 18 GY 333732C1 2 N10-GR 14 WH 2034787C1
B A90J 18 GY 333732C1 3 N5E(+) 18 YL 1680205C1
C A90K 18 GY 333732C1 4 N5E(-) 18 GN 1680205C1
5 PLUG - - 0453133C1
6 N20 16 LTGN 1680205C1
BODY BUILDER CONNECTION (4450AM) BODY BUILDER TURN / STOP (4450BM)

(LOCATED BETWEEN CENTER CHASSIS (LOCATED BETWEEN CENTER CHASSIS
AND REAR CHASSIS) AND REAR CHASSIS)
F A
E G CONNECTOR 2039311C91
A BODY LOCK 2039342C1
D B B
C
C
CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE CONNECTOR 1686834C1

BODY LOCK 1664408C1
A N68BB 14 BN 3535486C1 0589391C1
B N56BB 16 YL 2039343C1 1652325C1
C N57BB 16 LTGN 2039343C1 1652325C1
A R56BC 16 OR 2033819C1 1652325C1
D N54BB 16 BN 2039343C1 1652325C1
B R57BC 16 OR 2033819C1 1652325C1
E N71BB 16 LTBL 2039343C1 1652325C1
C R70BB 14 OR 2033816C1 0589391C1
F N12BB 14 LTBL 3535486C1 0589391C1
G N11-GBB 12 WH 2039344C1 0589390C1
BODY BUILDER CONNECTION (4450M)

(LOCATED NEAR LEFT FRAME RAIL BACK OF CAB)
BODY LOCK 2039342C1

F
A N68BB 14 BN 3535486C1 0589391C1
E G
B N56BB 16 YL 2039343C1 1652325C1
A
D B C N57BB 16 LTGN 2039343C1 1652325C1
C D N54BB 14 BN 3535486C1 0589391C1
E N71BB 16 LTBL 2039343C1 1652325C1
F N12BB 14 LTBL 3535486C1 0589391C1
G N11-GBB 12 WH 2039344C1 0589390C1

80257V 08JUL11 AE08068784 041


DIAGRAM 13
NAVISTAR, INC.
BODY BUILDER TURN/STOP (4460BF)

BODY BUILDER TURN / STOP (4460AM) (LOCATED AT MAIN TO REAR CHASSIS INTERCONNECT)
(LOCATED BETWEEN CENTER
CHASSIS AND REAR CHASSIS)
A
A B CONNECTOR 3553961C1
BODY LOCK 1664408C1
B C
C
A R56BC 16 OR 2033911C1 1652325C1
CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE B R57BC 16 OR 2033911C1 1652325C1
A N56BC 16 YL 2033819C1 1652325C1 C R70BB 14 OR 2033912C1 0589391C1
B N57BC 16 LTGN 2033819C1 1652325C1
C N70BB 14 RD 2033816C1 0589391C1
BODY BUILDER TURN / STOP (4460M)
(LOCATED NEAR LEFT FRAME RAIL BACK OF CAB)
BODY BUILDER CONNECTION (4460BM / 4450BF)
(LOCATED AT END OF FRAME NEAR REAR AXLES)
A
CONNECTOR 1686834C1
B BODY LOCK 1664408C1
F
E BG BODY LOCK 2039342C1
A C
D B
C
A N56BC 16 YL 2033819C1 1652325C1
B N57BC 16 LTGN 2033819C1 1652325C1
C N70BB 14 RD 2033816C1 0589391C1
A R68B 14 BN 3535486C1 0589391C1
B R56B 16 OR 2039343C1 1652325C1 ENGINE / MELROSE (6011)
C R57B 16 OR 2039343C1 1652325C1 (LOCATED ON THE LEFT SIDE OF ENGINE)
D R58B 14 BN 3535486C1 0589391C1

E R71B 16 OR 2039343C1 1652325C1
F R12B 14 LTBL 3535486C1 0589391C1 16 8
G R11-GB 12 WH 2039344C1 0589390C1
15 7
14 6
WINDSHIELD WIPER MOTOR (4500) 13 5
(LOCATED UNDER HOOD) 12 4
11 3
E 10 2
C 9 1
CONNECTOR 1661375C2
BODY LOCK 1661376C1
B
CONNECTOR 3849648C1
A CAVITIES 2,3,5,7,10-15 ARE MOLDED SHUT.
CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE 1 K19-GM 14 GY 3850092C1 3578677C1
A A82D 16 GY 2033819C1 1652325C1 4 PLUG - - - -
B A82V 16 GY 2033819C1 1652325C1 6 K97T 18 PL 3849648C1 -
C A82-G 14 WH 2033816C1 1652325C1 8 K19BA 14 GY 3850092C1 3578677C1
D A82K 16 GY 2033819C1 1652325C1 9 K97-GH 14 WH 3850092C1 3578677C1
E A82L 16 GY 2033819C1 1652325C1 16 K97NC 14 PL 3850092C1 3578677C1

80257V 08JUL11 AE08068784 042


DIAGRAM 13
NAVISTAR, INC.
ECM (6020M)
(LOCATED ON THE RIGHT SIDE OF TRUCK)
82 43 21
98 64
93
14
CONNECTOR 6086794C1
88
7
83
44 22 1
65

1 K5G(+) 18 YL 6086793C1
33 PLUG - - 6086793C1
2 PLUG - - 6086793C1
34 K97XC 18 PL 6086791C1
3 PLUG - - 6086793C1
35 K97SE 18 PL 6086791C1
4 K97B 18 PL 6086791C1
36 PLUG - - 6086793C1
5 K97NN 18 TN 6086791C1
37 PLUG - - 6086793C1
6 K97M 18 PL 6086791C1
38 PLUG - - 6086793C1
7 K95KK 18 TN 6086791C1
39 PLUG - - 6086793C1
8 K34AA 18 TN 6086791C1
40 PLUG - - 6086793C1
9 K97T 18 PL 6086791C1
41 K97EW 18 PL 6086791C1
10 PLUG - - 6086793C1
42 PLUG - - 6086793C1
11 PLUG - - 6086793C1
43 PLUG - - 6086793C1
12 PLUG - - 6086793C1
44 PLUG - - 6086793C1
13 K97CC 18 PL 6086791C1
45 PLUG - - 6086793C1
14 K59A 18 GY 6086793C1
46 K97WA 18 PL 6086791C1
15 PLUG - - 6086793C1
47 K97WC 18 PL 6086791C1
16 PLUG - - 6086793C1
48 PLUG - - 6086793C1
17 PLUG - - 6086793C1
49 PLUG - - 6086793C1
18 PLUG - - 6086793C1
50 PLUG - - 6086793C1
19 PLUG - - 6086793C1
51 K95HH 18 TN 6086791C1
20 PLUG - - 6086791C1
52 PLUG - - 6086793C1
21 PLUG - - 6086793C1
53 K5B(+) 18 YL 6086791C1
22 K5G(-) 18 GN 6086793C1
54 K5B(-) 18 GN 6086791C1
23 PLUG - - 6086793C1
55 PLUG - - 6086793C1
24 PLUG - - 6086793C1
56 PLUG - - 6086793C1
25 K97C 18 PL 6086791C1
57 PLUG - - 6086793C1
26 K97JT 18 TN 6086791C1
58 K23C 18 TN 6086791C1
27 PLUG - - 6086791C1
59 97ES 18 PL 6086791C1
28 PLUG - - 6086793C1
60 K92#141 18 TN 6086791C1
29 K95LL 18 TN 6086793C1
30 PLUG - - 6086791C1
31 K3A(-) 18 GY 6086791C1
32 K3A(+) 18 DKBL 6086791C1

80257V 08JUL11 AE08068784 043


DIAGRAM 13
NAVISTAR, INC.
ECM (6020M)
(LOCATED ON THE RIGHT SIDE OF TRUCK)
82 43 21
98 64
93
14
CONNECTOR 6086794C1
88
7
83
44 22 1
65
63 K97JC 18 PL 6086791C1 80 PLUG - - 6086793C1
64 K17M 18 PK 6086791C1 81 PLUG - - 6086793C1
65 PLUG - - 6086793C1 82 PLUG - - 6086793C1
66 PLUG - - 6086793C1 83 K97ND 16 PL 3686944C1
67 K97FU 18 PL 6086791C1 84 K97NE 16 PL 3686944C1
68 K97FV 18 PL 6086791C1 85 K97NF 16 PL 3686944C1
K47B125 18 TN 6086791C1 86 K97-GL 18 WH 3686794C1

69 87 K97-GK 18 WH 3686943C1
K47#125 18 TN 6086791C1
70 PLUG - - 6086793C1 88 K97-GM 18 WH 3686943C1
71 PLUG - - 6086793C1 89 K47B 18 GY 3686943C1
72 K99B 18 PL 6086791C1 90 PLUG - - 6086793C1
73 K95JJ 18 TN 6086793C1 91 K23L 18 TN 3686943C1
74 K99F 18 PL 6086791C1 92 K97AR 18 PL 3686943C1
75 K46A 18 GY 6086791C1 93 PLUG - - 6086793C1
76 PLUG - - 6086793C1 94 PLUG - - 6086793C1
77 K46B 18 GY 6086791C1 95 PLUG - - 6086793C1
78 PLUG - - 6086793C1 96 PLUG - - 6086793C1
79 K97CB 18 PL 6086791C1 97 K97UB 18 PL 3686943C1

98 K14KA 18 RD 3686943C1

80257V 08JUL11 AE08068784 044


CHAPTER 13
NAVISTAR, INC.
ECM POWER RELAY (6022)

FREON COMPRESSOR (6200)
(LOCATED ON MEGAFUSE BRACKET)
(LOCATED ON AC COMPRESSOR FRONT
RIGHT SIDE OF ENGINE)
86 30
2 1 B
A
4
3 5
87 87A 85
CONNECTOR 1671610C1
BODY LOCK 1671608C1
1 K97XA 10 PL 3512334C1 0589390C1
2 K97XB 16 VT 2039343C1 1652325C1
3 PLUG - - 0587579C1 -
A K77-G 18 WH 2033819C1 1652325C1
4 K97N 10 PL 3512334C1 0589390C1
B K77A 16 LTGN 2033819C1 1652325C1
5 K97JC 18 PL 2039343C1 3517771C1
DOCT SENSOR BLACK (6260) DPF TEMP1 SENSOR LIGHT GREY (6261)
(LOCATED BY RIGHT FRAME RAIL (LOCATED BY RIGHT FRAME RAIL
NEAR TRANSMISSION AREA) NEAR TRANSMISSION AREA)
2 2
CONNECTOR 3626435C1
CONNECTOR 3626436C1
CAV CIRCUIT GAUGE COLOR TERMINAL 1

1 K95S4 18 TN 3613771C1
2 K95KK 18 TN 3613771C1
1 K95F3 18 TN 3613771C1
2 K95JJ 18 TN 3613771C1
DPF TEMP1 SENSOR DARK GREY (6262) EXHAUST DPF DELTA P (DPFDP) SENSOR (6263)
(LOCATED BY RIGHT FRAME RAIL (LOCATED BY RIGHT FRAME
NEAR TRANSMISSION AREA) RAIL NEAR TRANSMISSION AREA)
1 2 3
1
1 K95F1 18 TN 3626442C1
1 K95F2 18 TN 3613771C1
2 K95HH 18 TN 3626442C1
2 K95LL 18 TN 3613771C1
3 K95JT 18 TN 3626442C1

80257V 08JUL11 AE08068784 045


DIAGRAM 13
NAVISTAR, INC.
2-WAY RADIO BATTERY POWER (6334)

(LOCATED IN ENGINE AREA COOLANT LEVEL SENSOR (6400)
NEAR IP / ENGINE INTERCONNECT) (LOCATED ON SURGE TANK)
A CONNECTOR 1671610C1
2
BODY LOCK 1671608C1 CONNECTOR 3554317C1
1
B

A* A14HC 16 RD 2033819C1 1652325C1 CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE
A* A14HF 16 RD 2033819C1 1652325C1 1 K34-GG 18 WH 3554322C1 3554318C1
B* A11-GAP 16 WH 2033819C1 1652325C1 2 K34AA 18 TN 3554322C1 3554318C1
B* A11-GAP 16 WH 2033819C1 1652325C1
E-FAN(6561)
FUEL COOLER SOLENOID (6405)
(LOCATED AT ENGINE FAN)
(LOCATED ON LEFT SIDE OF RADIATOR)
A BODY LOCK 1661874C1
CONNECTOR 3582941C1
B B
A K59A 18 GY 1667742C1 3568570C1 A K23D 16 TN 1661875C1 1661872C1
B K97D 16 PL 1667742C1 1661872C1 B K10-GG 16 WH 1661875C1 1661872C1
GROUND ADAPTER (6704M)

(LOCATED NEAR THE ENGINE ECM CONNECTION)
BODY LOCK 3551897C1
C INTENTIONALLY
B
LEFT BLANK
A

A PLUG - - 0587579C1 -
B K77-G 16 WH 2033819C1 1652325C1
C K10-GB 14 WH 2033816C1 0589391C1
D K10-GG 16 WH 2033819C1 1652325C1
E PLUG - - 0587579C1 -
F PLUG - - 0587579C1 -

80257V 08JUL11 AE08068784 046


DIAGRAM 13
NAVISTAR, INC.
ECM ZERO VOLT REFERENCE (6747)

(LOCATED NEAR THE ENGINE ECM CONNECTION)
M
L
A K95NN 18 PL 3535303C1 3535424C1
K
B K34-GG 18 WH 3535303C1 3535424C1
J C K95A1 18 TN 3535303C1 3535424C1
CONNECTOR 3543733C1 D K95S4 18 TN 3535303C1 3535424C1
H
BODY LOCK 3543732C1
G E PLUG - - 3535425C1 -
F PLUG - - 3535425C1 -
F
G PLUG - - 3535425C1 -
E
H PLUG - - 3535425C1 -
D J K9E 18 GY 3535303C1 3535424C1
C K PLUG - - 3535425C1 -
B L K9A 18 GY 3535303C1 3535424C1
A M PLUG - - 3535425C1 -
2 WAY RADIO OVERHEAD (6900)

A
B
CONNECTOR 1661198C1
INTENTIONALLY
C LEFT BLANK

A A14HF 16 RD 1661208C1
B A11-GAP 16 WH 1661208C1
C A86P 16 LTGN 1661208C1
INTENTIONALLY
LEFT BLANK

80257V 18JUL11 AE08068784 047


DIAGRAM 13
NAVISTAR, INC.
CONTROL MODULE (7151)

(LOCATED AT TRANSMISSION TCM CONNECTION)
21 41
1 61
1 K92#101 18 LTBL 3686945C1 42 K92#142 18 WH 3686945C1
2 - - - - 43 K92#143 18 LTBL 3686945C1
3 K92#103 18 YL 3686945C1 44 - - - -
4 - - - - 45 K92#145 18 OR 3686945C1
20 80
5 K92#105 18 OR 3686945C1 46 - - - -
40 60 6 - - - - 47 - - - -
7 - - - - 48 - - - -
8 K5#108 18 GN 3686945C1 49 - - - -
CONNECTOR 3605713C1
BODY LOCK 3606525C1 9 K92#109 18 GY 3686945C1 50 K92#150 18 PK 3686945C1
10 K92A110 18 PK 3686945C1 51 K92#151 18 WH 3686945C1
11 K92#111 18 OR 3686945C1 52 K92#152 18 LTGN 3686945C1
12 - - - - 53 K92#153 18 YL 3686945C1
13 - - - - 54 K31#154 18 TN 3686945C1
14 K92#114 18 GY 3686945C1 55 K92#155 18 WH 3686945C1
15 - - - - 56 - - - -
16 - - - - 57 K92#157 18 WH 3686945C1
17 K92#117 18 LTBL 3686945C1 58 K92#158 18 LTGN 3686945C1
18 - - - - 59 K48#159 18 TN 3686945C1
19 - - - - 60 K47#160 18 YL 3686945C1
20 K92#120 18 LTBL 3686945C1 61 - - - -
21 - - - - 62 - - - -
22 - - - - 63 K92#163 18 YL 3686945C1
23 K92#123 18 LTGN 3686945C1 64 - - - -
24 - - - - 65 K92#165 18 TN 3686945C1
25 K47#125 18 TN 3686945C1 66 - - - -
26 - - - - 67 - - - -
27 - - - - 68 - - - -
28 K5#128 18 YL 3686945C1 69 K92#169 18 GY 3686945C1
29 - - - - 70 K92#170 18 PK 3686945C1
30 - - - - 71 K92#171 18 YL 3686945C1
31 - - - - 72 - - - -
32 - - - - 73 K92#173 18 LTBL 3686945C1
33 K92#133 18 YL 3686945C1 74 K92#174 18 LTBL 3686945C1
34 K92#134 18 WH 3686945C1 75 - - - -
35 - - - - 76 K92#176 18 YL 3686945C1
36 K92#136 18 OR 3686945C1 77 K92#177 18 LTGN 3686945C1
37 - - - - 78 K92#178 18 WH 3686945C1
38 K92#138 18 OR 3686945C1 79 K92#179 18 PK 3686945C1
39 K48#139 18 OR 3686945C1 80 K92#180 18 OR 3686945C1
40 K47#140 18 LTGN 3686945C1
41 K92#141 18 TN 3686945C1

80257V 18JUL11 AE08068784 048


DIAGRAM 13
NAVISTAR, INC.
ALLISON 1 / 2000 ENGINE ECM BODY BUILDER

(7205F) (7207M)
E 7 6
F
D
C CONNECTOR 3525872C1 CONNECTOR 3586750C1
B
A
G
H
12 1
A K92C103 18 YL 1661875C1 3568570C1
B K92#143 18 LTBL 1661875C1 3568570C1
C K92#150 18 PK 1661875C1 3568570C1 CAV CIRCUIT GAUGE COLOR TERMINAL
D K47C125 18 TN 1661875C1 3568570C1 1 K97CB 18 PL 3518963C1
E K92#101 18 LTBL 1661875C1 3568570C1 2 K46A 18 GY 3518963C1
F K92#123 18 LTGN 1661875C1 3568570C1 3 K97CC 18 PL 3518963C1
G K92#145 18 OR 1661875C1 3568570C1 4 K46B 18 GY 3518963C1
H K92#105 18 OR 1661875C1 3568570C1 5 K97AR 18 PL 3518963C1
6 K47B 18 GY 3518963C1
7 PLUG - - 3527676C1
ENGINE ECM BODY BUILDER 2 8 K97FV 18 PL 3518963C1

(7208M) 9 K97DF 18 PL 3518963C1
10 K97WA 18 PL 3518963C1
11 K97XC 18 PL 3518963C1
12 K99F 18 PL 3518963C1
CONNECTOR 3518182C1
2 1
BODY LOCK 3518184C1

1 K97EW 18 PL 3518963C1
2 K97SE 18 PL 3518963C1
1 K92#152 18 LTGN 3686945C1
2 K92#133 18 YL 3686945C1
3 K92#151 18 TN 3686945C1
4 K92#117 18 LTBL 3686945C1
TRANSMISSION BULKHEAD (7350) 5 - - - -

(LOCATED AT TRANSMISSION BULKHEAD CONNECTION) 6 K92#157 18 WH 3686945C1
7 K92#179 18 PK 3686945C1
8 K31#154 18 TN 3686945C1
9 K92#158 18 LTGN 3686945C1
12 10 K92#178 18 WH 3686945C1
1 20
6 14 11 K92#177 18 LTGN 3686945C1
12 - - - -
CONNECTOR 3605714C1 13 - - - -
5
11 19
24
BODY LOCK 3606526C1
14 K92#111 18 OR 3686945C1
13
15 K92#155 18 WH 3686945C1
16 K92#171 18 YL 3686945C1
17 K92#136 18 OR 3686945C1
18 K92#138 18 OR 3686945C1
19 K92#174 18 LTBL 3686945C1
20 K92#114 18 GY 3686945C1
21 K92#153 18 YL 3686945C1
22 K92#173 18 LTBL 3686945C1
23 K92#134 18 WH 3686945C1
24 K92#176 18 YL 3686945C1

80257V 18JUL11 AE08068784 049


DIAGRAM 13
NAVISTAR, INC.
ENGINE SPEED SENSOR (7604M)

OUTPUT SPEED SENSOR (7600M) (LOCATED ON RIGHT OF TRANSMISSION)
(LOCATED ON REAR OF TRANSMISSION)
B B CONNECTOR 3594124C91
A A
A K47#160 18 YL 3554322C1 3554318C1 A K48#159 18 TN 3554322C1 3554318C1
B K47#140 18 LTGN 3554322C1 3554318C1 B K48#139 18 OR 3554322C1 3554318C1
TURBINE SPEED SENSOR (7607M) J1939 RESISTOR (7801M)

(LOCATED ON RIGHT OF TRANSMISSION) (LOCATED NEAR THE ENGINE ECM CONNECTION)
B C CONNECTOR 1667741C1
A B BODY LOCK 1667771C1
A
A K92#180 18 OR 3554322C1 3554318C1 A K5C(+) 18 YL 1661875C1 3568570C1
B K92#120 18 LTBL 3554322C1 3554318C1 B PLUG - - 2025431C1 -
C K5C(-) 18 GN 1661875C1 3568570C1
RIGHT HEADLIGHT TURN / SIGNAL LEFT HEADLIGHT TURN / SIGNAL

HARNESS CONNECTOR (8000) HARNESS CONNECTOR (8001)
(LOCATED ON UNDERSIDE OF HOOD BY (LOCATED ON UNDERSIDE OF HOOD BY
HEADLIGHT MODULE - RIGHT SIDE) HEADLIGHT MODULE - LEFT SIDE)
E
E
D
CONNECTOR 1661375C2
B
B
A
A
A M52D 14 YL 2033816C1 0589391C1 A M52 14 YL 2033816C1 0589391C1
B M11-GA 14 WH 2033816C1 0589391C1 B M11-GB 14 WH 2033816C1 0589391C1
C M53B 14 YL 2033816C1 0589391C1 C M53 14 YL 2033816C1 0589391C1
D M57B 16 OR 2033819C1 1652325C1 D M56B 16 OR 2033819C1 1652325C1
E M54D 14 BN 2033816C1 0589391C1 E M54C 14 BN 2033816C1 0589391C1

80257V 18JUL11 AE08068784 050


DIAGRAM 13
NAVISTAR, INC.
LEFT GUIDE POST LIGHT (8150)

SNOWPLOW HARNESS CONNECTOR (8102)
(LOCATED ON HOOD LEFT SIDE)
(LOCATED BY LEFT FRAME RAIL NEAR HOOD)
A
F
E G B
A
D B
C
CONNECTOR 1661778C1
BODY LOCK 1661874C1
CONNECTOR 2039311C91 CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE

BODY LOCK 2039342C1 A M54H 16 BN 1661875C1 1661872C1
B M54-GA 16 WH 1661875C1 1661872C1
A M64HI 14 YL 3535486C1 0589391C1
B M11-GE 14 WH 3535486C1 0589391C1 RIGHT FOG LIGHT (8200)
C M64LO 14 YL 3535486C1 0589391C1 (LOCATED AT THE FORWARD END
OF RIGHT FRAME RAIL)
D M56D 16 YL 2039343C1 1652325C1
E M54F 14 BN 3535486C1 0589391C1
F M57D 16 LTGN 2039343C1 1652325C1
G PLUG - - 0587579C1 -
A
RIGHT GUIDE POST LIGHT (8151)
(LOCATED ON HOOD RIGHT SIDE)
B
CONNECTOR 1661778C1 CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE

BODY LOCK 1661874C1 A M64B 16 YL 0587577C1 1652325C1
B M64-GB 16 WH 0587577C1 1652325C1
A M54J 16 BN 1661875C1 1661872C1
B M54-GB 16 WH 1661875C1 1661872C1
LEFT FOG LIGHT (8201)

ELECTRIC HORN (8301)
(LOCATED AT THE FORWARD END
(LOCATED UNDER ENGINE CROSSMEMBER)
OF LEFT FRAME RAIL)
A
A B
B
CONNECTOR 1661778C1
BODY LOCK 1661874C1
A M64A 16 YL 0587577C1 1652325C1 A M85E 16 GY 1661875C1 1661872C1
B M64-GA 16 WH 0587577C1 1652325C1 B M85-GA 16 WH 1661875C1 1661872C1

80257V 18JUL11 AE08068784 051


DIAGRAM 13
NAVISTAR, INC.
LEFT FRONT HYD ABS WHEEL SENSOR (8502) RIGHT FRONT HYD ABS WHEEL SENSOR (8503)
(LOCATED AT LEFT FRONT WHEEL) (LOCATED AT RIGHT FRONT WHEEL)

1 2 1 2
1 M94L(+) 18 BK 2003343C1 1 M94R(+) 18 BK 2003343C1
2 M94L(-) 18 BN 2003343C1 2 M94R(-) 18 BN 2003343C1
AIR COMPRESSOR HYD BRAKES (8505) AMBIENT AIR TEMPERATURE SENDER (8601)
(LOCATED AT LEFT FRAME RAIL BY FRONT AXLE) (LOCATED NEAR RADIATOR)
CONNECTOR 3522068C1
B A
C
A B
A M9A 18 GY 1651943C1 A M41 18 GY 1661875C1
B M6A 18 GY 1651943C1 B M110AD 18 GY 1661875C1
C M40 18 GY 1651943C1
AC PRESSURE TRANSDUCER (8602)

(LOCATED ON AC LINE AT GROUND ADAPTER #01 (8800)
FRONT RIGHT OF ENGINE) (LOCATED BY LEFT FRAME RAIL NEAR HOOD)
B
C F
A
E
CONNECTOR 1678137C1
BODY LOCK 3551897C1
CAV CIRCUIT GAUGE COLOR TERMINAL C
A K9A 18 GY 1651943C1
B K6A 18 GY 1651943C1 B
C K77B 18 LTGN 1651943C1
A
HOOD SWITCH (8805)

(LOCATED ON HOOD LEFT SIDE)

B A M11-GD 12 WH 2033816C1 0589390C1
B M64-GA 16 WH 2033819C1 1652325C1
A C M64-GB 16 WH 2033819C1 1652325C1
D M54-GA 16 WH 2033819C1 1652325C1
E M54-GB 16 WH 2033819C1 1652325C1
F PLUG - - 587579C1 -
A M104CC 18 DKBL 0587576C1 1652325C1
B M104CB 18 DKBL 0587576C1 1652325C1

80257V 18JUL11 AE08068784 052


DIAGRAM 13
NAVISTAR, INC.
AIR SOLENOID ADAPTER (8805) CHASSIS GROUND ADAPTER (8807)

(LOCATED NEAR LEFT FRAME RAIL BACK OF CAB) (LOCATED NEAR LEFT FRAME RAIL BACK OF CAB)
F F
E E
D BODY LOCK 3551897C1 D BODY LOCK 3551897C1
C C
B B * MUTUALLY EXCLUSIVE
A A

A N11-GA 12 WH 2033816C1 0589390C1
A N11-GA 12 WH 2033816C1 0589390C1
B N10-G 12 WH 2033816C1 0589391C1
B N59A-G 14 WH 2033816C1 0589391C1
C N87-G 18 GY 2033819C1 1652325C1
C N59A-G1 14 WH 2033816C1 0589391C1
D PLUG - - 587579C1 -
D PLUG - - 587579C1 -
E PLUG - - 587579C1 -
E PLUG - - 587579C1 -
F* N11-GD 12 WH 2033816C1 0589390C1
F PLUG - - 587579C1 -
F* N11-GBB 12 WH 2033816C1 0589390C1
GROUND SEATBELT TO ROOF(1)

(8995) (8996)
14 7 12 5
CONNECTOR 3627614C1
CONNECTOR 3613769C1
8 1 6 1
1 A11-GAN 18 WH 3613771C1
2* A11-G 18 WH 3613771C1 CAV CIRCUIT GAUGE COLOR TERMINAL
2* A11AB 18 WH 3613771C1 1 A11-GAA 18 WH 3627612C1
3 A11-GAA 18 WH 3613771C1 2 A11-GA 18 WH 3627612C1
4 A11-GBA 18 WH 3613771C1 3 A11-GGA 18 WH 3627612C1
5 A11-GCA 18 WH 3613771C1 4 A11-GG 18 WH 3627612C1
6 A11-GDA 18 WH 3613771C1 5 A11-GBA 18 WH 3627612C1
7 A11-GEA 18 WH 3613771C1 6 A11-GB 18 WH 3627612C1
8 A11-GFA 18 WH 3613771C1 7 A11-GHA 18 WH 3627612C1
9 A11-GGA 18 WH 3613771C1 8 A11-GH 18 WH 3627612C1
10 A11-GHA 18 WH 3613771C1 9 A11-GCA 18 WH 3627612C1
11 A11-GJA 18 WH 3613771C1 10 A11-GC 18 WH 3627612C1
12 A11-GKA 18 WH 3613771C1 11 A11-GJA 18 WH 3627612C1
13 A11-GLA 18 WH 3613771C1 12 A11-GJ 18 WH 3627612C1
14 A11-GMA 18 WH 3613771C1

80257V 19JUL11 AE08068784 053


DIAGRAM 13
NAVISTAR, INC.
SEATBELT DATA RECORDER

SEATBELT TO ROOF(2)
(8998)
(8997)
9 20
8 19 7 6
7 18
6
17
CONNECTOR 3553404C1
16 BODY LOCK 3553460C1
14
5
13
4
3 12
2 11
1 10 12 1

1 PLUG - - 3527276C1
1 A11-GDA 18 WH 2018639C1
2 PLUG - - 3527276C1
2 A11-GD 18 WH 2018639C1
3 PLUG - - 3527276C1
3 A11-GKA 18 WH 2018639C1
4 A3D(+) 20 DKBL 3727971C1
4 A11-GK 18 WH 2018639C1
5 A3D(-) 20 GY 3727971C1
5 A11-GEA 18 WH 2018639C1
6 A5D(+) 18 YL 3518963C1
6 A11-GE 18 WH 2018639C1
7 A5D(-) 18 GN 3518963C1
7 A11-GLA 18 WH 2018639C1
8 PLUG - - 3527276C1
8 A11-GL 18 WH 2018639C1
9 PLUG - - 3527276C1
9 A11-GFA 18 WH 2018639C1
10 A14R 18 RD 3518963C1
10 A11-GF 18 WH 2018639C1
11 PLUG - - 3527276C1
11 A11-GMA 18 WH 2018639C1
12 A11-G 18 WH 3518963C1
12 A11-GM 18 WH 2018639C1
13 - - - -
14 - - - -
15 - - - - SEATBELT SEAT INDICATOR
(8999)
16 - - - -
17 - - - - 7 6
18 - - - -
19 - - - -
CONNECTOR 3586750C1
20 - - - -
BODY LOCK 3553460C1
12 1
INTENTIONALLY 1 A11-GA 18 WH 3518963C1

2 A11-GB 18 WH 3518963C1
LEFT BLANK 3 A11-GC 18 WH 3518963C1
4 A11-GD 18 WH 3518963C1
5 A11-GE 18 WH 3518963C1
6 A11-GF 18 WH 3518963C1
7 A11-GM 18 WH 3518963C1
8 A11-GL 18 WH 3518963C1
9 A11-GK 18 WH 3518963C1
10 A11-GJ 18 WH 3518963C1
11 A11-GH 18 WH 3518963C1
12 A11-GG 18 WH 3518963C1

80257V 19JUL11 AE08068784 054


DIAGRAM 13
NAVISTAR, INC.
AF FUEL LEVEL SENSOR (9100) RIGHT FUEL LEVEL SENSOR (9101)

(LOCATED ON AF MOUNTED FUEL TANK) (LOCATED ON RIGHT SIDE FUEL TANK)
A
A
B
B

A R36 18 TN 1661875C1 1661872C1 A N36A 18 TN 1661875C1 1661872C1
B R9G 18 GY 1661875C1 1661872C1 B N9B 16 GY 1661875C1 1661872C1
BATTERY ECM NEGATIVE (9260) BATTERY ECM POSITIVE (9261)
CONNECTOR 1667732C1
#1667733C1 CONNECTOR 1667733C1
BODY LOCK 1667734C1 C #1667732C1
A
BODY LOCK 1667734C1
B B
* MUTUALLY EXCLUSIVE A
C
A PLUG - - 1675751C1 - A K97AA 10 RD 2025425C1 1667735C1
B K92-G 10 GY 2025425C1 1667735C1 B K92B110 10 PK 2025425C1 1667735C1

C K92-GP 10 WH 1667737C1 1667735C1 C PLUG - - 1675451C1 -
STOP TAIL AND TURN (9303A) MAXI FUSE (9310)

(LOCATED AT REAR END OF LEFT FRAME RAIL) (LOCATED NEAR EXTERIOR DASH NEAR DCM)
D
CONNECTOR 1661375C2 A
BODY LOCK 1661376C1
C CONNECTOR 3525613C1
A B

A R71 14 OR 2033816C1 0589391C1
B R56 14 OR 2033816C1 0589391C1 CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE
C R57 14 OR 2033816C1 0589391C1 A N90J 10 RD 3515526C1 3515525C1
D R68 14 BN 2033816C1 0589391C1 B N90 12 GY 3614762C1 3541256C1
E R10-G 12 WH 2033816C1 0589391C1

80257V 19JUL11 AE08068784 055


DIAGRAM 13
NAVISTAR, INC.
LEFT MODESTY TURN LAMP (9315) RIGHT MODESTY TURN LAMP (9316)
(LOCATED BEHIND LEFT (LOCATED BEHIND RIGHT
C MODESTY TURN LAMP) MODESTY TURN LAMP)
C
B
B

A PLUG - - 0587579C1 -
A PLUG - - 0587579C1 -
B N56J 16 OR 0587575C1 1652325C1
B N57J 16 OR 0587575C1 1652325C1
C N10-GC 16 WH 0587575C1 1652325C1
C N10-GC 16 WH 0587575C1 1652325C1
TRW HYDRAULIC ABS CONNECTOR (9511)

(LOCATED NEAR LEFT FRAME RAIL BEHIND THE CAB)

1 N90 12 RD 3592382C1 3592377C1
3 N94R(+) 18 GY 3673333C1 -
25 26 37 38
4 N94R(-) 18 GY 3673333C1 -
24 14 5 N5C(+) 20 YL 3673333C1 -
6 N5C(-) 20 GN 3673333C1 -
1 13 13 N90-GA 12 WH 3592382C1 3592377C1
2 12
25 N94L 12 GY 3614546C1 3674545C1
27 N94L(+) 18 GY 3673333C1 -
28 N94L(-) 18 GY 3673333C1 -
30 N90E 18 GY 3673333C1 -
CONNECTOR 3874985C1 35 N94N(-) 18 GY 3673333C1 -
COVER 3875001C1 36 N94N(+) 18 GY 3673333C1 -
CAVITES 2,7-12,14-24,26,
29,31-34,37 ARE MOLDED SHUT. 38 N90-GB 14 WH 3592386C1 3578677C1
J1939 TERMINATING RESISTOR (9530)

(LOCATED ON LEFT FRAME RAIL UNDER CAB)
C
B
A
INTENTIONALLY
LEFT BLANK
CONNECTOR 1667741C1
BODY LOCK 1667771C1

A N5B(+) 18 YL 1661875C1 3568570C1
B PLUG - - 2025431C1 -
C N5B(-) 18 GN 1661875C1 3568570C1

80257V 19JUL11 AE08068784 056


DIAGRAM 13
NAVISTAR, INC.
TRAILER SOCKET #1 (9715)

TRAILER SOCKET #1 (9715F)
(LOCATED ON LEFT FRAME RAIL BEHIND CAB)
C
A
B B
A C

A* N70F 10 RD 1667737C1 1667735C1 A* R70A 10 RD 2025425C1 1667735C1
A# N70T 10 RD 1667737C1 1667735C1 A# R70 10 RD 2025425C1 1667735C1
B* N68F 10 BN 1667737C1 1667735C1 B* R68A 10 BN 2025425C1 1667735C1
B# N68T 10 BN 1667737C1 1667735C1 B# R68 10 BN 2025425C1 1667735C1
C* N94F 10 GY 1667737C1 1667735C1 C* R94A 10 DKBL 2025425C1 1667735C1
C# N94T 10 GY 1667737C1 1667735C1 C# R94 10 GY 2025425C1 1667735C1
* W/ TRAILER SOCKET * W/ TRAILER SOCKET

# W/ BODY BUILDER & TRAILER SOCKET # W/ BODY BUILDER & TRAILER SOCKET
TRAILER SOCKET #2 (9716)

TRAILER SOCKET #2 (9716M)
A C
B B
C A

CAV CIRCUIT GA COLOR TERMINAL SEAL/SLV CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE
A* N54F 10 BN 2025425C1 1667735C1 A* R58A 10 BK 1667737C1 1667735C1
A# N54T 10 BN 2025425C1 3575783C1 A# R58 10 BN 1667737C1 1667735C1
B* N56F 10 YL 2025425C1 1667735C1 B* R56A 10 YL 1667737C1 1667735C1
B# N56T 10 YL 2025425C1 1667735C1 B# R56 10 YL 1667737C1 1667735C1
C* N57F 10 LTGN 2025425C1 1667735C1 C* R57A 10 LTGN 1667737C1 1667735C1
C# N57T 10 LTGN 2025425C1 1667735C1 C# R57 10 LTGN 1667737C1 1667735C1
* W/ TRAILER SOCKET * W/ TRAILER SOCKET

# W/ BODY BUILDER & TRAILER SOCKET # W/ BODY BUILDER & TRAILER SOCKET

80257V 19JUL11 AE08068784 057


DIAGRAM 13
NAVISTAR, INC.
AIR SOLENOID 4 PACK (9736) AIR SOLENOID 4-PACK (9740)

(LOCATED INSIDE LEFT FRAME RAIL UNDER CAB) (LOCATED RIGHT FRAME RAIL)
E E
D D
C C
B B
A BODY LOCK 1661376C1 A BODY LOCK 1661376C1
A N59A-G 14 WH 2033816C1 0589391C1 A N59A-G1 14 WH 2033816C1 0589391C1
B N59B 18 GY 2033819C1 1652325C1 B N59G 18 GY 2033819C1 1652325C1
C N59C 18 GY 2033819C1 1652325C1 C N59H 18 GY 2033819C1 1652325C1
D N59D 18 GY 2033819C1 1652325C1 D N59J 18 GY 2033819C1 1652325C1
E N59E 18 GY 2033819C1 1652325C1 E N59K 18 GY 2033819C1 1652325C1
WASHER PUMP (9745) WASHER LEVEL SENSOR (9746)

(LOCATED AT WASHER PUMP UNDER CAB LEFT SIDE) (LOCATED AT WASHER PUMP UNDER CAB LEFT SIDE)
1 2 2
1
CONNECTOR 3536864C1
CONNECTOR 3554317C1
1 N87MB 16 GY 3561584C1 3536868C1 1 N87EA 18 GY 3554322C1 3554318C1
2 N87DB 18 GY 3561584C1 3536868C1 2 N87-G 18 GY 3554322C1 3554318C1
REMOTE START / STOP (9778)

TRAILER SOCKET #2 (9779F)
(LOCATED BACK OF CAB FOR
(LOCATED AT BACK OF CAB FOR
TRAILER SOCKET INTERCONNECT)
TRAILER SOCKET INTERCONNECT)
A
A B
CONNECTOR 1667732C1
B C BODY LOCK 1667734C1
CAV CIRC GA COLOR TERMINAL SEAL/SLV

A N59CA 16 GY 0587575C1 1652325C1
B N104CA 16 DKBL 0587575C1 1652325C1 CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE
A R58A 10 BK 2025425C1 1667735C1
B R56A 10 YL 2025425C1 1667735C1
TRAILER SOCKET #1 (9780M)
(LOCATED AT END OF FRAME C R57A 10 LTGN 2025425C1 1667735C1
NEAR REAR AXLES)
C
B CAV CIRCUIT GAUGE COLOR TERMINAL SEAL/SLEEVE

CONNECTOR 1667733C1 A R70A 10 RD 1667737C1 1667735C1
BODY LOCK 1667734C1
A B R68A 10 BN 1667737C1 1667735C1
C R94A 10 DKBL 1667737C1 1667735C1

80257V 20JUL11 AE08068784 058


DIAGRAM 13
NAVISTAR, INC.
CONNECTION TO REAR CHASSIS HARNESS (9800)

CONNECTION TO CENTER HARNESS (9800
24 13
12 1
CONNECTOR 3558026C1
CONNECTOR 3558022C1
BODY LOCK 3558056C1
BODY LOCK 3558056C1
24 13 12 1
CAV CIR GA COLOR TERMINAL SEAL/SLV CAV CIRCUIT GA COLOR TERMINAL SEAL/SLV
1 R71 14 OR 3559037C1 3575783C1 1 N71A 14 OR 3559035C1 3575783C1
2 R56 14 OR 3559037C1 3575783C1 2 N56 14 OR 3559035C1 3575783C1
3 R57 14 OR 3559037C1 3575783C1 3 N57 14 OR 3559035C1 3575783C1
4 R68 14 BN 3559037C1 3575783C1 4 N68 14 BN 3559035C1 3575783C1
5 R36 18 TN 3559036C1 3509903C1 5 N36A 18 TN 3509874C1 3509903C1
6 PLUG - - 3532129C1 - 6 PLUG - - 3532129C1 -
7 PLUG - - 3532129C1 - 7 PLUG - - 3532129C1 -
8 PLUG - - 3512129C1 - 8 PLUG - - 3532129C1 -
9 PLUG - - 3512129C1 - 9 PLUG - - 3532129C1 -
10 R9G 18 GY 3559036C1 3509903C1 10 N9G 18 GY 3509874C1 3509903C1
11 PLUG - - 3532129C1 3509903C1 11 PLUG - - 3532129C1 -
12 R10-G 12 WH 3559037C1 3575783C1 12 N10-G 12 WH 3559035C1 3575783C1
13 PLUG - - 3532129C1 - 13 PLUG - - 3532129C1 -
14 PLUG - - 3532129C1 - 14 PLUG - - 3532129C1 -
15 R94(+) 18 GY 3559036C1 3509903C1 15 N94N(+) 18 GY 3509874C1 3532128C1
16 R94(-) 18 GY 3559036C1 3509903C1 16 N94N(-) 18 GY 3509874C1 3532128C1
17 PLUG - - 3532129C1 - 17 PLUG - - 3532129C1 -
18 PLUG - - 3532129C1 - 18 PLUG - - 3532129C1 -
19 PLUG - - 3532129C1 - 19 PLUG - - 3532129C1 -
20 PLUG - - 3532129C1 - 20 PLUG - - 3532129C1 -
21 PLUG - - 3532129C1 - 21 PLUG - - 3532129C1 -
22 PLUG - - 3532129C1 - 22 PLUG - - 3532129C1 -
23 PLUG - - 3532129C1 - 23 PLUG - - 3532129C1 -
24 PLUG - - 3532129C1 - 24 PLUG - - 3532129C1 -

80257V 20JUL11 AE08068784 059


DIAGRAM 13
NAVISTAR, INC.
REAR AXLE SPEED SENSOR (9812) RIGHT REAR AIR DRYER (9900)
(LOCATED ON REAR AXLE) (LOCATED ON LEFT FRAME RAIL)
CONNECTOR 3920483C1 B
BODY LOCK 1673791C1
1 A
1 R94N(+) 18 GY 3600050C1 3665870C1 A N39B 16 GY 2033819C1 1652325C1
2 R94N(-) 18 GY 3600050C1 3665870C1 B N39-GB 16 WH 2033819C1 1652325C1
DIODE ASSY (9915)

(LOCATED IN INSTRUMENT PANEL NEAR CENTER)
INTENTIONALLY
LEFT BLANK

1 A104F 18 DKBL 1680205C1
2 A104N 18 DKBL 1680205C1
INTENTIONALLY
LEFT BLANK

80257V 20JUL11 AE08068784 060

2011 Terrastar - Elec.circ - Diag

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2011 Terrastar - Elec.circ - Diag

Uploaded by

Copyright:

Available Formats

SERVICE MANUAL

SERVICE MANUAL SECTION

TerraStar Model Built 2010 – Electrical Circuit Diagrams

2. INSTRUCTIONS AND CHARTS (CHAPTER 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4. CAB ACCESSORIES (CHAPTER 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362) i

TABLE OF CONTENTS (CONT.)

5. 12V CHARGING AND CRANKING SYSTEM (CHAPTER 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

6. FANS AND ENGINE ACCESSORIES (CHAPTER 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

7. ELECTRONIC ENGINES (CHAPTER 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

ii TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362)

TABLE OF CONTENTS (CONT.)

9. LIGHTS (CHAPTER 9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

10. CHASSIS ACCESSORIES (CHAPTER 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

11. TRANSMISSION (CHAPTER 11). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362) iii

TABLE OF CONTENTS (CONT.)

12. AIR CONDITIONING (CHAPTER 12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 .

13. INSTRUCTIONS AND CHARTS (CHAPTER 13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

iv TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362)

TABLE OF CONTENTS (CONT.)

13.38. CONNECTOR BODY COMPOSITES MATING VIEW SHOWN, P. 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170

TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362) v

1. TABLE OF CONTENTS (CHAPTER 1)

NAVISTAR, INC ELECTRICAL CIRCUIT DIAGRAM

ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION ABBREVIATION DESCRIPTION

CHK DATE CHANGE REV REFERENCE DRAWN NAME

U01A133 CIRCUIT DIAGRAM, TERRASTAR

67696A 04AUG10 AE08064593 001

TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362) 1

NAVISTAR, INC ELECTRICAL CIRCUIT DIAGRAM

DESCRIPTION ACRONYM DESCRIPTION ACRONYM

AXLE TO FRAME AF INJECTOR DRIVE MODULE IDM

ACCELERATOR PEDAL MODULE APM INPUT/OUTPUT I/O

ACCELERATOR POSITION SENSOR APS INTEGRATED MOBILE

DIESEL PARTICULATE FILTER TRANSMISSION CONTROL MODULE TCM

EXHAUST GAS RECIRCULATION EGR VEHICLE SPEED OUTPUT VSO

EXHAUST GAS TEMPERATURE EGT VEHICLE SPEED SENSOR VSS

ELECTRO MAGNETIC INTEFERENCE EMI ZERO VOLT REFERENCE ZVR

END OF FRAME EOF VEHICLE SPEED OUTPUT VSO

ELECTRIC TRAILER BRAKE ETB VEHICLE SPEED SENSOR VSS

FRONT AXLE FA ZERO VOLT REFERENCE ZVR

CHK DATE CHANGE REV REFERENCE DRAWN NAME

U01A133 CIRCUIT DIAGRAM, TERRASTAR

67696A 04AUG10 AE08064593 002

2 TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362)

2.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3

NAVISTAR, INC ELECTRICAL CIRCUIT DIAGRAM

A - SWITCH AND RELAY POSITIONS AS SHOWN ON B - MULTIPLE CONNECTIONS ARE DISPLAYED

(12-A) AND/OR D C B A (12)

SWITCH, SINGLE IN-LINE CONNECTORS DISPLAYED

C - PHANTOM LINES INDICATE PRINTED CIRCUITS OR BUSSED CIRCUITS.

D - MULTIPLE CIRCUIT NUMBERS ON A LINE INDICATE ONE CIRCUIT

E - SWITCHES, RELAYS AND COMPONENTS INDICATE EXTERNAL

KEY SWITCH INTERNAL BODY CONTROLLER

SUFFIX BEGINNING LOCATION SUFFIX BEGINNING

NOTE: FOR CIRCUIT DESCRIPTION OTHER THAN GROUNDS NEITHER

CHK DATE CHANGE REV REFERENCE DRAWN NAME

U01A133 CIRCUIT DIAGRAM, TERRASTAR

67696A 04AUG10 AE08064593 003

TERRASTAR MODEL BUILT 2010 – ELECTRICAL CIRCUIT DIAGRAMS (S08362) 3

2.4. CIRCUIT NUMBER IDENTIFICATION AND COLOR, P. 4

NAVISTAR, INC ELECTRICAL CIRCUIT DIAGRAM