Chassis Electrical

C h a s s i s E l ec t r i c a l
Charging System
The charging system provides electrical current for the lights, radio, heater blower
and the engines electrical systems. It also maintains the batteries in a charged state,
recharging them as necessary to provide cranking power.
The charging system has three main components, or component areas: the alter-
nator, the voltage regulator, and the battery.
The alternator is driven by a belt from the engine crankshaft and produces the
electrical power to operate the systems on the bus. It also recharges the battery.
The voltage regulator acts as a control valve for the alternator output. It senses
the current load and maintains a constant voltage in the charging system, indepen-
dent of the current load, up to its rated output. The Leece Neville alternator on the
Blue Bird Vision has a built in voltage regulator. It is excited (started) by the ignition
system.
The battery is the reservoir of chemical electrical power. Its primary purpose is to
crank the engine. It also supplies power to the accessories for a short time when the
demand is too high for the alternator alone (i.e., while the bus is at idle). Another key
role of the battery is to act as a filter for the charging system.
The Blue Bird Vision has a 12-volt electrical system. The alternator is a 175-am-
pere, 12-volt device. Leece Neville model number A0014834LC is standard.
Maintenance
Clean the alternator and all connection points. Dirt buildup restricting air flow
through to the alternator will cause excessive heat and premature failure. Corrosion
at any connecting point will produce resistance to current flow, heat and diminished
power for the starter and accessories.
Ensure that all the components in the charging system are mounted securely.
Check the torque at all mounting bolts both the bolts that hold the alternator in
the mounting bracket and the bolts that secure the mounting brackets to the engine.
The torque value for mounting bolts at the engine and at the alternator should be 70
80 ft lb (95 108 Nm)
723
Blue Bird Vision buses are equipped with an automatic belt tensioner. Ensure
that all the grooves fit properly into the pulleys in the correct path. The drive belt
should be inspected every 11,000 miles (17,700 km), 250 hours of service life, or ev-
ery 3 months; whichever occurs first.
Also check:
Battery voltage
Alternator output
Starter current draw
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Troubleshooting
Timely preventive maintenance of the charging system should keep it running
smoothly. However, when a problem occurs, effective troubleshooting procedures
will help locate and correct the problem quickly and economically.
[Warning] Batteries emit an explosive gas. Never smoke while working on

the charging system. Batteries can explode from a spark. Always remove the
negative battery cable at the battery post before removing any other wires in
the charging system. Be careful not to short the system while you are working
on it. Do not wear jewelry.
Before you begin to analyze the charging system, it is necessary that you ensure the
battery is properly tested and charged to at least 75% of their rated capacity. Failure
to confirm the condition of the battery will make the results of any diagnostic testing
unreliable. Refer to the battery manufacturers publications on battery maintenance
Digital Volt/Ohm Meter
and testing.
Alternator Performance Test
1. Connect a digital volt/ohmmeter (VOM) to the output ter-

minals of the alternator.
Ammeter
[Caution] Ensure that the test leads are connected prop-

erly. Observe the polarity and make secure connections.
2. Connect an ammeter to the positive terminal of the alter-

nator. Observe that the clamp on the ammeter is located
at least 6 inches (15 cm) from the alternator to lessen the
724 possibility of faulty readings due to spurious emissions.
3. Verify that the voltage output from the alternator is be-

tween 13.6 and 14.2 volts with the engine at operating
RPM (1700 RPM minimum) and not idle.
4. Ensure that all loads are in the off position. The reading on the ammeter
should be less than 20 amps.
If the amp reading is higher than 20 amps, ensure all accessories are
turned off.
Ensure the battery is charged to at least 75% of their rated capacity.
5. Record the voltage. If the voltage is not within the specified range or the
amperage is not within the specified range, the alternator is defective.
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chassis electrical
6. If the alternator is determined to be defective, repair or replace it in accor-

dance with the instructions below. See Alternator Removal.
7. If the alternator is determined to be functioning properly, proceed as fol-

lows:
8. Continue to operate the engine at about 1700 RPM, and with the test equip-
ment set up as illustrated.
9. Turn on vehicle loads (accessories) until the ammeter displays 132 amps,
which is 75% of the rated capac-ity (175 amps). Record the voltage at this
point.
10. Compare the voltage reading with the voltage reading observed in Step 3
above.
11. If the alternator voltage drops more than .5 (1/2) volt, the alternator is defec-
tive.
An alternate method of checking the alternator under load is to use a carbon pile
load. Connect the carbon pile across the battery and adjust it until the ammeter
reads 75% of the alternator rated capacity. Record the voltage at this point, shut off
the engine, and compare the readings.
Alternator Cable Tests

To test the positive alternator cable:
1. Clamp the ammeter on the positive cable at least 6

Digital Volt/Ohm Meter
inches (15 cm) from the alternator. See Figure 2.
725
2. Connect the negative lead of the VOM to the positive
post of the alternator.
3. Connect the positive lead of the VOM to the positive

battery post.
4. Start the engine and let it run at about 1700 RPM.

Ammeter
5. Turn on accessories until the ammeter reads 132 amps,

which is 75% of the rated alternator capacity (175 amps).
Use a carbon pile if necessary to achieve the load.
6. Record the voltage reading on the VOM.
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7. If the VOM reads more than -.25 volts, there is a problem

Volt/Ohm Meter
with the positive cable.
Check and clean all the connections and the condi-

tion of all the cables/wires in the circuit.
Re-test the circuit.
8. If the reading is less than -.25 volts, the cable and con-
Ammeter
nections are good.
Solenoid
9. Connect the lead negative of the VOM to the negative
terminal of the battery.
10. Connect the positive lead of the VOM to the negative

Starter
terminal of the alternator.
11. Repeat Steps 4 through 8 for the negative cable.
726
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Bosch Alternator Removal
[Warning] Always disconnect the negative (-) cable from the bat-
tery terminal first to avoid arcing, which could ignite explosive battery
gases.
1. Park the bus on a smooth, flat surface.
2. Chock the wheels in both directions.
3. Ensure the engine is not running, the ignition switch is in the OFF
position and the key is removed.
4. Disconnect the negative (ground) cable from the battery

post.
5. Lift the automatic belt tensioner to remove the drive belt

from the alternator.
6. Remove the drive belt.

Caterpillar
7. Inspect the drive belt; discard it if any signs of wear are present.
A few minor cracks across the belt are acceptable. Longitudinal cracks are NOT ac-
ceptable. Replace the drive belt when any crack is observed to be running length-
wise or with the belt, or when the belt appears frayed.
[Warning] Always disconnect the negative (-) battery cable at the battery
before removing any wiring from the alternator.
727
8. Remove the negative (-) cable from the alternator.
Cummins
9. Remove the positive (+) cable from the alternator.
10. Remove the bottom mounting bolts.
Exciter Post
11. Support the alternator and remove the top bolts.
12. Remove the alternator.
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Alternator Reinstallation
Installation of the alternator is accomplished in the reverse order of the removal in-
structions above.
1. Position the alternator and install the top and bottom bolts. Torque bolts to
33-35 ft. lbs.
2. Install the positive cable on the positive (B+) post. Carefully tighten to avoid
breaking or stripping the stud.
3. Install the negative cable on the negative (B -) post. Carefully tighten to avoid
breaking or stripping the stud.
4. Using a square drive tool, position the automatic tensioner so that the drive
belt can be installed. Inspect the drive belt carefully. Replace the belt if any
signs of wear are present.
5. Install the drive belt. Ensure that the grooves in the belt fit into the proper
places on all the pulleys.
6. Start the engine and test the alternator output.
728
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Automatic Belt Tensioner

The automatic tensioner is spring loaded to provide the proper tension for the drive
belt.
The automatic tensioner should travel at least 71, and the torque to move the
tensioner 25 from the at rest position must be 9 11 ft lb (12.4 15.8 Nm). In-
spect the belt tensioner for any unusual noise, excessive looseness and shaking at
the bearings.
Automatic Tensioner Removal
1. Remove the drive belt in accordance with the instruc-tions above.
2. Remove the capscrew (1) from the automatic ten-sioner. See Figure 8.
To install a new automatic tensioner, reverse the removal instructions. Torque the
capscrew (1) to 28 42 ft lb (38 56 Nm).
729
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Starter
There are 5 main components or component areas in the starting system: the igni-
tion switch, a neutral safety switch, the starter solenoid, the starter motor and the
batteries.
When the key is turned to the start position, electrical current flows to the starter
solenoid from the batteries. The flow is interrupted if the transmission shift lever is
not in the neutral position or if the neutral sensor switch is defective.
The starter solenoid is an electromagnetic switch mounted on the starter motor.
When electric current energizes coils inside the solenoid, a magnetic field is induced
which pulls a plunger. At one end of this plunger is a shift lever. The lever is con-
nected to the drive pinion and clutch assembly of the starter motor. The plunger also
connects the electrical power from the batteries to the starter motor as it engages
the flywheel ring gear.
The starter motor is a relatively small electric motor, but it can deliver large
amounts of torque for a short time.
When the operator releases the ignition switch it returns to the run position. The
solenoid is disconnected from the batteries and the magnetic field collapses. This
allows the spring in the solenoid to move the plunger in the opposite direction, dis-
engaging the flywheel and removing electrical current from the starter motor.
The Blue Bird Vision has a 12-volt electrical system. The starter motor is Model
35261110, Presto-lite/Leece/Neville M100R series. The Starter motor is capable of
4kw cranking power for peak loads of no more than 30 seconds duration.
Preventative Maintenance
There are two preventative maintenance procedures that can greatly enhance the
efficiency of the starting system. These two steps are also the first two steps taken
when troubleshooting a malfunctioning starting system.
730 An engine that needs a tune up will be difficult to crank; over cranking will
lead to starter motor failure.
Poor connections due to road dirt, grease, corrosion, loose connectors, or bro-
ken insulation at any connecting point rob the starting system of electrical
power and cause it to over-crank.
Troubleshooting
Before beginning to troubleshoot the starting system, ensure the batteries are prop-
erly maintained and charged to at least 75% of their rated capacity. A drained battery
will cause any further diagnostic tests to be inaccurate. Common causes of starting
system malfunction include:
1. A battery that is low, poorly charged, or defective places high demands on

the starting system; voltage at the battery should be 12.4 volts or greater to
crank the engine. If the batteries arent adequately charging, a problem in
the charging system. Refer to the Alternator section of this Service Manual
for information on the charging system.
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2. A starter motor can be damaged by heat that is generated by excessive

cranking. The starter should never be engaged for more than 30 seconds. It
must rest (cool off) a minimum of 2 minutes between starting attempts.
3. Loose, dirty, or corroded connections in the starting system rob the system
of the power needed to turn the engine. The case of the starter motor is the
ground or return connection for the starter motor and solenoid.
4. A loose starter motor will allow vibration that can damage the motor. In ad-
dition, the ring gear could be damaged.
5. Improper or excessive use of starting fluid will cause extra stress on the start-
ing system.
6. A defective solenoid will fail to engage the starter motor. A failed pull-up coil
will cause the plunger to fail to pull in. A failed hold-in coil may cause the
starter to fail to stay engaged, or may fail to switch the starter motor on. If
the solinoid is suspect, test the wiring of the solenoid circuit before replacing
the solenoid.
The starting circuit is among those incorporated into the Visions Multiplex System.
Therefore, Multiplex diagnostics procedure can help to quickly isolate the root cause
of most starting problems, and thereby minimize downtime. Refer to the Multiplex
chapter for full details on performing Multiplex diagnostics.
1. Refer to the Multiplex Output Table to find out which Port/Pin (B3-07) and
which Output LED (B3-O02) pertain to the Starter Signal Output. The chart
also shows which Ladder Logic Line (#20) describes the logic of the circuit.
2. Use the Diagnostic Switch to cycle the MPX Module to the appropriate Diag-
731
nostic Mode (Showing B3 Outputs). Check the LED to see if the Starter Signal
Output (B3-O03) is Active. If the Output LED is Inactive, refer to Ladder Logic
line #20 to systematically verify that each requirement for an Active Output
is true.
3. Once the Output is Active, if the starter is still not operating, verify a ground
at Pin B3-07 on the MPX Module. If the ground output is present, the problem
exists downstream of the Multiplex system, and the starter itself is suspect.
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Volt/Ohm Meter
Ignition/Run Test
Begin by determining whether the problem is with the ignition
switch or the pilot relay, and their associated wiring; or if it is in
the solenoid and/or starting motor. To begin with the ignition
switch:
1. Connect the positive lead of a VOM to the ignition switch

terminal on the solenoid.
Solenoid
2. Connect the negative lead of the VOM to the chassis
Alternator
ground.
3. While attempting to crank the engine, record the voltage

Starter
displayed on the VOM. Observe the following:
No voltage
Low voltage
Normal voltage with slow cranking
Normal voltage with no cranking at all.
4. Connect a remote start switch to the positive battery post.
5. Connect the other end of the remote start switch to the ignition post of the
solenoid.
6. Attempt to crank the engine with the remote switch. Record the voltage dis-
played on the VOM. If there is less than 1 volt difference from the previous
reading, the ignition switch is okay. If there is more than 1 volt difference, the
732 switch is defective.
7. With the VOM negative lead connected to the chassis ground, move through
the switch system one connection at a time. If your first voltage test has re-
vealed low voltage, the starter motor may be shorted.
8. If the first voltage test indicated normal voltage, but there is slow cranking or
no cranking at all, a problem with the batteries, battery cables, or a damaged
starter motor is indicated.
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Volt/Ohm Meter
Low Voltage Test
There are various reasons for low voltage but the troubleshooting meth-
ods are the same. If the solenoid clicks, it means that either current is
flowing through the solenoid contacts but not through the main con-
tacts; or that the current through the main contacts is insufficient due
Solenoid
to low batteries.
1. Connect the positive lead of the VOM to the starter motor terminal
Alternator
of the solenoid.
2. Connect the negative lead of the VOM to the chassis ground.

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

played on the VOM, the main contacts are not functioning properly.
4. If there is voltage present at the solenoid terminal during Step 3, the prob-
lem is in the starter motor or its cabling.
5. If the first voltage check in Step 3 under Ignition/Run Test indicated nor-
mal voltage but slow or no cranking, the next step is to check the starter
motor and its connections.
6. If the drive pinion jumps out of mesh with the flywheel ring gear, check
for a broken or loose ground wire at the solenoid.
7. While attempting to crank the engine, place an ammeter on the positive

Main Contacts
battery cable. If the power drain is higher than the OEM specifications,
the starter motor is defective. An exception would be if the engine was
not properly tuned or is difficult to turn over; in which case, a new starter
motor would be a temporary fix.
733
Ammeter
Solenoid
Alternator
Starter
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Volt/Ohm Meter
Slow Cranking
Sluggish cranking can be caused by a small amount of extra re-
sistance in the cranking circuit. This extra resistance can come
from loose or dirty (corroded) connections, or broken wires
and/or cables. First check the positive cables and connections
Ammeter
of the starter motor, then the negative circuit.
1. Connect the positive lead of a VOM to the positive battery

terminal.
Solenoid
Alternator
2. Position an ammeter between the solenoid and the posi-
tive terminal of the solenoid.
3. Connect the negative lead of the VOM to the positive ter-

Starter
minal of the solenoid.
4. Connect the negative lead of the VOM to the negative

Carbon Pile Tester
battery post. This is the unloaded voltage. Record the
reading; leave the VOM connected.
5. Connect one lead of a carbon pile tester to chassis ground.
6. Connect the other lead from the carbon pile tester to the positive terminal of
the solenoid.
7. Adjust the carbon pile tester until the ammeter on the tester reads 500
amps.
734 8. Record the voltage display on the VOM; it should not be less than 0.4-volts
less than the unloaded value.
9. Turn the carbon pile tester to the OFF position.
10. Connect the positive lead of the VOM to chassis ground.
11. Connect the negative lead of the VOM to the negative battery post. Record
the reading; leave the VOM connected.
12. Position the ammeter in on the negative battery cable.
13. Turn on the carbon pile tester and adjust it to read 500 amps.
14. Record the voltage on the VOM; it should not drop more than 0.4-volts from
the unloaded reading.
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15. Turn the carbon pile tester to the OFF position.
16. If the voltage drop was more than 0.4-volts in step 8, the positive cabling is
defective. Look for a broken cable or a loose or corroded connection.
17. If the voltage drop in step 14 is more than 0.4 volts, look for a problem in the
negative cabling; look for broken or defective cables, and loose or corroded
connections.
Final check at solenoid terminals.
Volt/Ohm Meter
1. Disconnect the carbon pile tester.
2. Disconnect the VOM.
3. Remove the ammeter.
4. Connect the positive lead of the VOM to the positive (bat-

Solenoid
tery) terminal of the solenoid.
Alternator
5. Set the VOM so that it can read the full battery volt-age; at
least 14 volts.
Starter
6. Connect the negative VOM lead to the starter motor ter-
minal of the solenoid.
7. Crank the engine and record the voltage while cranking. There should be no
more than 0.2 volts drop between the solenoid contacts while cranking.
8. The voltage reading in these last three tests (the positive cable check, the
735
negative cable check and the solenoid test), should not total more than 1.0
volts. If the voltage drop is more than allowable, repeat the cable tests using
a jumper cable. If the tests then indicate an acceptable drop, the cable(s) is
(are) defective.
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Starter Motor Removal
1. Disconnect the negative (ground) cable from the battery. Wrap it with
tape or other suitable insulation to prevent shorts.
2. Disconnect positive cable from the battery. Wrap it with tape or other
suitable insulation to prevent shorts.
3. Identify and tag each wire on the starter motor for reinstallation.
4. Remove all electrical connections from the starter motor. Be sure to

identify and tag all electrical connection locations.
5. Remove 3 capscrews.
6. Remove starter motor from flywheel housing.
Starter Motor Installation

The starter motor is installed in the reverse order of the removal instructions above.
1. Carefully place the starter motor into position on the flywheel hous-
ing.
2. Install 3 capscrews (1). Torque to 32 ft lb (43 Nm). See Figure 8.
3. Being careful to observe the identification of the electrical wires, con-

nect the wires to the appropriate terminal on the starter motor. See
Figure 7.
736 [Warning] Always remove the negative (-) cable from the battery terminal
first. Always connect the negative (-) cable to the battery terminal last to avoid
arcing that could ignite explosive battery gases.
4. Install the positive cable on the battery post.
5. Install the negative cable on the battery post.
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Chassis Harness Routing Diagrams

The following pages illustrate the routings of the main chassis wiring harnesses ap-
plicable to most Vision chassis.
737
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Shunt Battery Side

(Engine harness)
Torque to 8 ft lb
125A
Ammeter Bat Fuse To Intake Heater
(Engine Harness)
To Alt Power To PDU Power
200A
To Alt Ground To PDU Ground
To PDU Ground
See Sheet 3
Shunt Alternator Side
(Engine harness) To PDU Ground Without Ammeter
See Sheet 3
To PDU Power
Ammeter Alt Fuse See Sheet 3 Alternator
(Engine Harness) Exciter
To To Alt To Alt
Intake Power Ground
Heater
With Ammeter
Torque to 100 in lb Torque to 50 in lb
+ -
Torque to 8 ft. Lbs. (typ)
Ammeter bat fuse
To Intake Heater Engine harness
To Alt Power To PDU Power
Shunt Bat Side
Engine Harness To PDU Power
Ammeter Alt Fuse
To Alt Ground To PDU Power
Alternator Connections
With Ammeter Breakout of engine harness.
Routing goes back to the PDU panel.
Routes along with Cat engine harness, Right
along valve cap. Dir Light
Crs Mir Connector
Heat
Right Connector
Headlights
738 Connector
To PDU Panel.
See Sheet 3.
Right
Park Light
Connector
Viewed From Inside Hood

Right Side Of Bus
To PDU Panel
To Engine Ecu
1sheet
To Transmission Ecu
To Engine Compartment Interface ABS Harness
Frame Harness
Abs & Frame Harness
To Frame Component Harness.
0074133
See Sheet 2
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Torque harness connection

to 53 in lb.
To PDU Ground.
See Sheet 3.
To PDU Power.
See Sheet 3
To Main Panel.
Exciter wire See Sheet 3.
not required
with 320 amp
alternator.
To PDU Panel.
See Sheet 3.
To PDU Panel.
See Sheet 3.
739
To
PDU Ground
Torque To12 ft lb
To To PDU
Engine Power
Mount
Starter
Power
Torque To 25 in lb
Starter Ground
Starter Connections
Chassis Harness Routing Sheet 1 of 5
0074133
DIAGRAM, RTG, HARNESS W/AUTOMATIC TRANS
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5P5SBOT *OUFSGBDF
7FIJDMF)BSOFTT
5P1%6
)BSOFTT
5P5SBOT4IJGUFS)BSOFTT
4FMFDU 1VTI#VUUPO
5P"#4)BSOFTT
5P"#4)BSOFTT
5P1%*1)BSOFTT
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$POUSPM
"#4)BSOFTT
6OJU
'SBNF)BSOFTT

PS
"
5P&$6 5P&$6#MBDL
(SFZ
.BJO5SBOTNJTTJPO
$POOFDUPS
5P&$6#MVF
"CT'SBNF
)BSOFTT
1

&OHJOF
sheet
4QFFE4FOTPS

0074133
0VUQVU 1545SBOTNJTTJPO
4QFFE4FOTPS
Chassis Harness Routing Sheet 1 of 5 (continued)

0074133
740
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741
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0074133
Frame Rail
Typical at
Crossmembers
Exhaust Bracket
Typical at
Exhaust Brackets
Exhaust Bracket
Typical at
Exhaust Brackets
Crossmember
Start of
Hydraulic Harness
742
To PDU Panel.
To Abs Connection See Sheet 3.
on Front Hub
Air Dryer Typical at
Wiring Supports
To Abs Connection
on Front Hub
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chassis electrical
Left Frame Rail Left Frame Rail
Harness Routing
To Front For Hydraulic
TO FRONT
OF BUS
Fuel Filter Modulator Assy
Hydraulic Brakes
DETAIL H
(HYD BRAKE)
Fuel Tank Area

Fuel Tank Hydraulic Brakes
Left Frame Rail
Left Frame Rail

Air Brakes
743
Harness Routing
Air Brakes To Front For ABS
Filter Assy To ABS Modules

Valve Assy
2sheet
0074133
Fuel Tank
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0074133
Power Ammeter
Ground On units with Ammeter,
item 24, 26, or 27
attaches to Ammeter Stud.
On units without Ammeter,
item 24, 26, or 27
attaches to Power Stud.
ace
erf
24, Int
m ent
26, 24, art
mp ace
27 Co erf ace
26, gin
e Int fac
e erf
E n e 1 ter S Int
27 To i n I n
n/A
B
Eng ine
2
sio nk
Stud Mounting Blocks To Eng mis tali
on Engine Compartment To ra n s
9 Da
T 3
To J19
Side of Firewall To
Components
of Harness
744 24,
26,
27
Electronic
Power Chassis
Power
3sheet
0074133
From Electronic Chassis

Battery Ground Torque Studs Ground
to 11-15 ft lb.
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Frame Rails
A: Electronic Power To Disconnect Switch

B: Battery To Disconnect Switch
C: Electronic Ground To PDU
D: Battery Ground
E: Disconnect Switch (Electronic Power) To PDU
F: Disconnect Switch (Battery) To Rem Pwr
Cables Fuel Lines
To Batteries E F
To PDU Panel
B A
See Detail
on Sheet 1
C
D
On back of B A
Transmission C
Bell housing D
Route
Battery Cable
Torque bolt to Thru Tie Wrap Pos
21 ft lb.
To Electronic Power Stud (See Sheet 3) Coat connection Neg
To Rem Power Stud (See Sheet 3) With Glyptal sealant. Pos
To Electronic Ground Stud (See Sheet 3)
To Pdu Ground Stud (See Sheet 3) Neg
Using 2 8D Batteries
(Feature 40142-04)
E F
746 A
B
C
D
B A
C
D
Neg
Neg Pos
Pos
Neg
Pos
Using 3 Delco Group 31 Batteries

(Feature 40142-06)
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4/0 Positive Cable

4/0 Positive Cable 4 Ga Positive Cable
4 Ga Positive Cable
With
Heavy Duty
Box Only
Battery Tray
From
Positive
Battery With Battery Disconnect Switch
(Feature 40142-01)
SEE DETAIL C & E
DU
oP
w er t
o
ic P DU
SEE DETAIL E
Ele
ctr
on
on
ic G
ro un
dt
oP
747
ctr
Ele
Supplied
with
Switch
(For Delphi)
4
(For 8D Batt)
sheet
Torque 1/2" stud to 100 in lb.

Torque10-32 stud to 14 in lb.
Remove the two 10/32 nuts
supplied with switch.
0074133
Install lock washers

supplied with switch
(For Delphi) on bottom and
between cables.

0074133
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Frame Rail
Cables Fuel Lines

A: Electronic Power To PDU
B: Battery To Remote Power
C: Electronic Ground To PDU
D: Battery Ground
To Batteries
To
PDU Panel
A
B
C
D
On back of B A
Transmission C
Bell housing D
To Electronic Power Stud (See Sheet 3)

Route
To Rem Power Stud (See Sheet 3) Torque bolt to Battery Cable See Detail A Pos
To Electronic Ground Stud (See Sheet 3) 21 ft lb. Thru Tie Wrap
To Pdu Ground Stud (See Sheet 3) Coat connection Neg
With Glyptal sealant.
Pos
Neg
Using 2 8D Batteries
(Feature 40142-04)
748
AB
CD
B A
C
D
Neg
Pos
Neg
Pos
Neg
Pos
Using 3 Delco Group 31 Batteries

(Feature 40142-06)
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4/0 Positive Cable

4/0 Positive Cable 4 Ga Positive Cable
4 Ga Positive Cable
With
Heavy Duty
Box Only
Battery Tray
749
5sheet
0074133

0074133
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Power Distribution Unit Layout

The PDU houses the Main Bus Controller of the Multiplex system
(MPX Module), chassis fuses, relays and interface connections to
some of the main chassis harnesses. The diagram shown here is
representative of standard equipment Visions with air or hydraulic
brakes. Although some differences occur in the cases of specific
equipment options (such as circuit breakers in lieu of fuses, ex-
haust brake, or manual transmission), the general layout of the
PDU components is the same.
750
0089022
L
chassis electrical
IGN PWR
F1 HTD FUEL PWR (20A)
F2 INTERLOCK PWR (10A)
F3 AIR DRYER PWR (10A)
F4 SPARE Units with Air Brakes
BRAKE WARN IGN (15A) Units with Hydraulic Brakes
F5 HTD DRAIN PWR (20A)
F6 BODY IGN (15A)
BATT PWR
BRK BOOST (40A) Units with Hydraulic Brakes
F8 START REL PWR (5A)
F9 REV SENS+ (10A)
F10 STOP LIGHT PWR (15A)
HYD INTLK (30A) Units with Hydraulic Brakes
F12 ABS BATT (30A) Units with Air Brakes
MOD PMP BATT (30A) Units with Hydraulic Brakes
F13 DPWR (3A)
F14 SPARE
ELEC PWR
F15 TRANS BATT (10A)
F16 EECM PWR (40A)
F17 MBC PWR (10A)
ABS BATT (25A) Units with Hydraulic Brakes
751
ECM IGN
F19 EJ170 IGN (10A)
F20 TRANS IGN (40A)
F21 ABS IGN (10A)
F22 DASH IGN (10A)
0089022
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1 service manual
752
L
chassis electrical
Chassis Wiring Schematics

The following pages contain the main wiring schematics applicable to most Blue Bird
Vision chassis. Two sets of schematics are provided in this chapter, one set for Cater-
pillar-equipped Visions, and another for Cummins-equipped Visions.
The schematics are provided for your convenience when you are limited to use of
the print manual. Additional schematics specific to your bus may be viewed, printed,
or downloaded in Adobe PDF format by pointing your web browser to the Cus-
tomer Access website at:
http://service.blue-bird.com/TechPubs/SchematicsRequest.html
753
L
1 service manual
Hydraulic Brake Booster Harness

This schematic describes the wiring of the Bendix HydroMax brake master cylinder/
booster harness on Blue Bird Visions equipped with hydraulic brakes.
Buffer
Warning Signal
(output to IP)
Ground
Ignition
Warning Signal Input
Brake Light Signal
Brake Light Signal
To ground stud
on HydroMax body
Ignition
Warning Signal to IP
Ground
Brake Light Signal
754
L
chassis electrical
Electrical Diagrams for Caterpillar C7-07 Engines
Description Sheet Drawing Number Wire Colors

Index 1 0116467F BL BLUE
Starting And Charging, Cat 2007 C7 2 0116401C BK BLACK
Starting And Charging (with Florida circuit breakers) 3 0115329C BN BROWN
2007 Cat C7 Engine 4 0113152A TN TAN
Allison Gen 4 2000 Transmission 5 0116646 WH WHITE
Allison Gen 4 3000 Transmission 6 0116649A YL YELLOW
Dimmer / Backlights 7 0116651 PK PINK
ABS - Bendix (air) 8 0116652 OR ORANGE
ABS Hyd-E (hydraulic) 9 0118822A RD RED
AA Multiplex Module 10 0116694C GN GREEN
AB Multiplex Module 11 0116695A PU PURPLE
AC Multiplex Module 12 0116696 GY GRAY
Mirror Heat / Exterior Speaker / Wiper Washer 13 0116697
Hydraulic Brake Boost, Cat 14 0116698
Frame Components 15 0116699 Schematic Legend
Crossing Arm 16 0116700 PD PDU PANEL
Instrument Cluster 17 0119063 AC AIR CLEANER BRACKET
Drivers Control Module, Cat, Air 18 0116702 IP INSTRUMENT PANEL
Drivers Control Module, Cat, Hydraulic 19 0116703 FW FIREWALL
MBC Module 20 0116704 SP SHIFTER PANEL
Body Interface 21 0116705 DC DCM
J1939 Datalink, Hyd-E 22 0118820
J1939 Datalink, Air 23 0116707
Electrical Component Index
755
CAT C7-07
Micro Relay Heavy Duty Relay Fuse Voltage Stud Shunt Switch Ngr Rocker 3 Wire Twisting
(Non-typical)
2 Wire Twisting 2 Wire Twisting Mini Relay Horn Speaker Light Circuit Breaker
with Shield
Multiplex Wire Indexing (Circuit Number Code)

Zone
Connector
Voltage (0 = Ground, 1 = 12 Volts)
Connector Pin Number
Sheet 1
Example: (Zone A, Connector A, 12 Volts, Pin #11) 0116467F
SCHEMATIC, WRG, 2007 CAT C7, INDEX
L
1 service manual
12V ECM
IGNITION RELAY
30/40A
C9
87A
ELEC PWR (BK)
30 ECM IGN (PK)
87
86 85 RLY GND A (WH)
S26
PDU
PD 12V GROUND
BATTERY STUD
DISCONNECT
SWITCH
(ONLY WITH
OPTION 40142-01)
PD
12V ELEC PWR (BK)

- + ELEC
DIAG PWR (OR)
- + ELEC PWR A (BK)
MBC GND A (WH)

MBC GND B (WH)
S25 MBC PWR 2 (RD)
PDU
DIO PWR (RD) MBC PWR 1 (RD)
GROUND
STUD PD CB1 60A
CURRENT SENSOR DC PD
12V 12V BATT PWR (RD)

PD BATT IGN PWR (RD)
A B C D
A
DC MAIN BODY &

STARTER FUSE
TO LIFT/AC 12V 200A
COPPER BUS BAR
756 PD
STARTER PWR (RD)
MAIN BODY 12V

GRID HTR FEED TO SOLENOID
AA-114 (RD)
FUSE 125A IN BODY ELEC PANEL
C14 30 86
TO GRID HEATER STARTER 12
ON ENGINE BLOCK RELAY PD
70A 87 85
C704
STARTER (RD) STARTER (RD)
W
START REL GND (WH)
EX STARTER
TO DCM GND GND B MOTOR
GROUND 2/0 CABLE
ALTERNATOR FROM GND STUD ON FRAME
12V
GROUND BK 1 GA
TO ENGINE BLOCK
L
chassis electrical
5A
F19 EJ170 IGN (OR) CAT C7
SHT. 4
10A
F20 TRANS IGN (OR) TRANS
SHT. 5/6
5A
F21 ABS IGN (OR) ABS
SHT. 8/9
PD 10A
12V ECM F22 DASH IGN (PK) IP
IGNITION BUS SHT. 17
5A HYD BRAKE BOOST
F23 BRAKE WARN IGN (OR)
SHT. 14
AA-111 (OR)
AA MODULE, SHT 10
MBC GND A (WH)
MBC GND B (WH)

MBC MODULE
MBC PWR 2 (RD) SHT. 20
MBC PWR 1 (RD)
DIAG PWR (OR) DIAGNOSTIC,

SHT. 22/23
10A
F15 TRANS BATT (RD) TRANS
SHT. 5/6
40A
F16 EECM PWR (RD) CAT C7
SHT. 4
10A
F17 MBC BATT (RD) MBC MODULE
SHT. 20
PD 25A B
12V ELEC F18 ABS BATT (RD) ABS
PWR BUS SHT. 9
3A
F13 DPWR (BK) IP
SHT. 17
15A
F10 STOP LGT PWR (RD) AA MODULE,
SHT. 10
30A
F12 MOD PMP BATT (RD) ABS
SHT. 9
PD 40A
12V F7 BRAKE BOOST BATT (RD) ENGINE CAT C7
BATTERY BUS SHT. 4
30A
F11 HYD INTLK PWR (RD) DRIVER'S CNTRL MODULE
SHT. 19
10A DRIVERS CONTROL MOD
F11 INTERLOCK PWR (RD)
SHT. 18
SEN IGN (RD) F9 REV SENS + (RD) SEE DIAGRAM,WRG
FEA 2226
3A
F14 D DIAG PWR (BK) DRIVER'S CNTRL MODULE
SHT 18/19
10A F8 BRAKE SW PWR (RD)
DRIVER'S CNTRL MODULE,
SHT 18/19
757
AMMETER + (RD) CAT C7
SHT 4
AA-114 (RD)
AA MODULE,
AA-113A (PK) SHT 10
AA-113 (PK) AA MODULE,
CAT C7-07
C13
30 86 SHT. 11/10
IGNITION 12
RELAY PD AA-113C (OR) CAT C7
70A 87 85 SHT. 4
20A
F1 HTD FUEL PWR (PK) FRAME COMPOMENTS
SHT 15
IGN REL GND (WH) 20A
F5 HTD DRAIN PWR (BN) FRAME COMPONETS
IGN PWR (RD) SHT. 15
10A
F3 AIR DRYER PWR (BL) FRAME COMPONETS
SHT. 15
PD 15A
12V F6 BODY IGN (OR) BODY INTERFACE
PDU
GROUND
STUD
Sheet 2
0116401C
STARTING AND CHARGING,CAT 2007 C7
L
1 service manual
12V ECM
IGNITION RELAY
30/40A
C9
87A
ELEC PWR (BK)
30 ECM IGN (PK)
87
S26
PDU
PD 12V GROUND
BATTERY STUD
DISCONNECT
SWITCH
(ONLY WITH
OPTION 40142-01)
PD
12V ELEC PWR (BK)

- + ELEC
DIAG PWR (OR)

- +
ELEC PWR A (BK)
MBC GND A (WH)

MBC GND B (WH)
S25 MBC PWR 2 (RD)
PDU
DIO PWR (RD) MBC PWR 1 (RD)
GROUND
STUD PD CB1 60A
CURRENT SENSOR DC PD
BATT PWR (RD)
12V 12V
PD BATT IGN PWR (RD)
A B C D
DC MAIN BODY &

STARTER FUSE
TO LIFT/AC 12V 200A
COPPER BUS BAR
758 PD
STARTER PWR (RD)
MAIN BODY 12V

GRID HTR FEED TO SOLENOID
FUSE 125A IN BODY ELEC PANEL AA-114 (RD)
C14 30 86
TO GRID HEATER STARTER 12
ON ENGINE BLOCK RELAY PD
70A 87 85
C704
W
START REL GND (WH)
EX
TO DCM GND GND B STARTER
MOTOR
ALTERNATOR GROUND 2/0 CABLE
12V FROM GND STUD ON FRAME
GROUND BK 1 GA
TO ENGINE BLOCK
L
chassis electrical
5A
F19 EJ170 IGN (OR) CAT C7
SHT. 4
10A
SHT. 5/6
5A
SHT. 8/9
PD 10A
12V ECM CB22 DASH IGN (PK) IP
7.5 HYD BRAKE BOOST
CB23 BRAKE WARN IGN (OR)
SHT. 14
AA-111 (OR) AA MODULE,

SHT. 10
MBC GND A (WH)
MBC GND B (WH)

MBC MODULE
MBC PWR 1 (RD)
DIAG PWR (OR) DIAGNOSTICS,

SHT. 22/23
10A
SHT. 5/6
40A
F16 EECM PWR (RD) CAT C7
SHT. 4
10A
CB17 MBC BATT (RD) MBC MODULE
SHT. 20
PD 25A B
PWR BUS SHT. 9
7.5A
CB13 DPWR (BK) IP
SHT. 17
15A
CB10 STOP LGT PWR (RD) AA MODULE,
SHT. 10
30A
CB12 MOD PMP BATT (RD) ABS
SHT. 9
PD 40A
12V F7 BRAKE BOOST BATT (RD) ENGINE CAT C7
BATTERY BUS SHT. 4
30A
CB11 HYD INTLK PWR (RD) DRIVER'S CNTRL MODULE
SHT. 19
10A
CB11 INTERLOCK PWR (RD) DRIVER'S CNTRL MODULE
SHT. 18
SEN IGN (RD) 10A
CB9 REV SENS + (RD) SEE DIAGRAM,WRG
FEA 2226
7.5A
CB14 D DIAG PWR (BK) DRIVER'S CNTRL MODULE
SHT 18/19
10A
CB8 BRAKE SW PWR (RD) DRIVER'S CNTRL MODULE
759
SHT 18/19
AMMETER + (RD) CAT C7

SHT 4
CAT C7-07
AA-114 (RD) AA MODULE,
SHT 10
AA-113A (PK)
AA-113 (PK) AA MODULE,
86 C13 SHT. 10
30
12 IGNITION
PD AA-113C (OR) CAT C7
RELAY
87 85 SHT. 4
70A
20A
CB1 HTD FUEL PWR (PK) FRAME COMPONETS
SHT. 15
IGN REL GND (WH) 20A
CB5 HTD DRAIN PWR (BN) FRAME COMPONETS
IGN PWR (RD) SHT. 15
10A
CB3 AIR DRYER PWR (BL) FRAME COMPONETS
SHT. 15
PD 15A
12V CB6 BODY IGN (OR) BODY INTERFACE
PDU
GROUND
STUD
Sheet 3
0115329C
STARTING AND CHARGING,CAT 2007 C7
W/FEA 40142-11 (Florida circuit breakers)
L
1 service manual
DIMMER/BACKLIGHTING ILLUM J
SHT. 7
DIMMER/BACKLIGHTING GND 3H (WH)
SHT. 7
7 9
TO DRIVER'S CONTROL SEN COM B (TN) SEN COM B 2B 3
MODULE. SHT 18/19 S39 (TN) 1
5B 6
4
8 10
PDU
INTERFACE
CONNECTOR
C701
A
FAN CLUTCH AA-MODULE AA-103 (OR) AA-103 (OR) AA-103 (OR)
SHT. 10 B
VGT SW (BL) C VGT SW (BL)
S1 D
SENS COM B (TN) SENS COM A (TN) E SENS COM B (TN)
THROT PWR (BL) THROT PWR (BL) F THROT PWR (BL)
DRIVERS CTL MOD THROT COM (PK) THROT COM (PK) THROT COM (PK)
SHT. 18/19 G
THROT SIG (BN) THROT SIG (BN) H THROT SIG (BN)
J
COOLING FAN DISABLE AA-MODULE AA-008 (PK) AA-008 (PK) K AA-008 (PK)
SHT. 10
FAST IDLE AB-MODULE L
AB-001B (OR) AB-001B (OR) M AB-001 (OR)
SHT. 11
N
I/P EJ1587 EJ1587+ (YL) EJ1587+ (YL) O EJ1587+ (YL)
SHT. 22/23 EJ1587- (BL) EJ1587- (BL) P EJ1587- (BL)
Q
ENGINE CONTROLS IP AMMETER + (RD) AMMETER + (RD) R AMMETER + (RD)
SHT. 17 AB-009 (BN) AB-009 (BN)
S
THROTTLE INTERLOCK AB-MODULE AB-009 (BN) ENG BRAKE LT (RD) T ENG BRAKE LT (RD)
SHT. 11
U
VGT BRAKE MODELE AA ENG BRAKE LT (RD) V
SHT 10
W
STARTER LOCKOUT AC-MODULE AC-102 (RD) AC-102 (RD) X AC-102 (RD)
SHT. 12
PDU
INTERFACE
CONNECTOR
C704
R
EECM GND (WH) S EECM GND (WH)
START/CHARGE AA-113C (OR) AA-113C (OR) T AA-113C (OR)
SHT. 2/3 EECM PWR (RD) EECM PWR (RD)
U
EECM POWER START/CHARGE EECM PWR (RD) EJ170 IGN (OR) V EJ170 IGN (OR)
SHT. 2/3 BRAKE BOOST BAT (RD) BRAKE BOOST BAT (RD)
X
EJ170 IGN START/CHARGE EJ170 IGN (OR) Y
SHT. 2/3
Z
BRAKE BOOST BAT START/CHARGE BRAKE BOOST BAT (RD)
SHT. 2/3
N.O.
REGENERATION SWITCH
760
START/CHARGE SEN IGN (RD) S1

SHT. 2/3
C807
SHUTTER SW PWR (RD) A SHUTTER IGN (OR)
SHUTTER GND (WH) B SHUTTER GND (WH)
N.C.
SHUTTER STAT AIR
SHUTTER COM (OR)
SHUTTER PWR (RD) S2
N.C.
STARTER GND (WH)
FAN CL GND (WH)
SHUTTER STAT WATER

AA-103 (OR)
A B C2 A B
SHUTTER GROUND C815
SOLENOID STUD
ON FAN
STARTER CLUTCH
L
chassis electrical
AMMETER + (RD) TO CURRENT SENSOR

SHT. 2/3
C800 (EJ1)
CAT C7 ECM CONN
1
COOL LVL PWR (OR) 2 COOL LEVEL + 5V
3
THROT PWR (BL) 4 THROTTLE + 8V
THROT COM (PK) EJ105 (PK) EJ105 (PK) 5 SENSOR/SWITCH COM
S3 REGEN SW (OR)
6 REGENERATION SWITCH
7
EJ1587+ (YL)
8 J1587(+)
EJ1587- (BL) 9 J1587(-)
10
11
ENG BRAKE LT (RD) 12 AUX BRAKE LIGHT
AC-102 (RD) 13 STARTER LOCKOUT
14
15
16
17
SEN COM B (TN) 18 SENSOR COMMON
19
20
AA-008 (PK) 21 COOLING FAN
S7 EJ123 (OR) 22 SET SPEED B
VGT SW (BL) 23 VGT BRAKE SWITCH
24
25
COOL LVL (BL) 26 COOL LEVEL
27
28
29
30
31
32
33
EJ1939- (GN) 34 J1939(-)
35
36
37
38
39
EJ140 (OR) 40 FAST IDLE
41
42
43
44
45
46
S5 47
EJ148 PWR (RD) 48 +12V BATTERY POWER
49
EJ1939+ (YL) 50 J1939(+)
51
54
AB-009 (BN) 56 THROTTLE INTERLOCK
761
57
58
59
60
61
S6 62
EJ163 GND (WH) 63 GND
CAT C7-07
64
THROT SIG (BN) 66 THROTTLE POSITION
68
EJ170 IGN (OR) 70 +12V IGNITION
ALT IGN (OR) ALTERNATOR EXCITER START/CHARGE

SHT. 2/3
BRAKE BOOST BAT (RD) HYD BRAKE BOOST
SHT. 14
DCM GND HYD BRAKE BOOST
SHT. 14
COOL LVL PWR (OR)
COOL LVL RET (PK)
EJ1939+ (YL)
EJ1939- (GN)
COOL LVL (BL)
EJ149 (BL)
A B C N U C701
C816 Sheet 4
COOLANT EJ1939- (GN)
J1939 DATALINK
LEVEL
SENSOR
EJ1939+ (YL) SHT. 22/23 0113152
2007 CAT C7 ENGINE
L
1 service manual
PDU
INTERFACE
IP TJ1939, SHT 17 C702
IP TJ1939, SHT 17 A TRANS TEMP/164 (BL)
NOT USED B NOT USED
C CHECK TRANS/129 (GN)
NOT USED D NOT USED
NOT USED E NOT USED
AB MODULE, SHT 11 AB-004 (BL) F B2-016/165 (TN)
NOT USED G NOT USED
TJ1939+ (YL) H TJ1939+ (YL)
AB MODULE, SHT 11 AB-107 (RD) J B1-112/141 (TN)
TJ1939- (GN) K TJ1939- (GN)
RESERVED L RESERVED
RESERVED M RESERVED
AB MODULE, SHT 11 AB-003 (RD) N B1-002/105 (OR)
TELEG GNDA (WH) P 169 (GY)
TRANS BATT START/CHARGE, SHT 2/3 TRANS BAT (RD) R TRANS BAT (PK)
TRANS IGN START/CHARGE, SHT 2/3 TRANS IGN (OR) S TRANS IGN/163 (YL)
S14 TELEC GND B (WH) T 109 (GY)
IP TJ1587, SHT 17 TJ1587+ (YL) U NOT USED
IP TJ1587, SHT 17 TJ1587- (BL) V NOT USED
SHIFT INHIBIT IN AB MODULE, SHT 11 AB-005 (GN) W B3-015/101 (BL)
X 124 (WH)
TELEC GND (WH)
MAIN TRANSMISSION C906

LSD SS1 1 152 (GN)
LSD SS2 2 133 (YL)
LSD SS3 3 151 (WH)
762
PS1 4 117 (BL)
ELECTRONIC 5
PS3 6 157 (WH)
GROUND
PS2 7 179 (PK)
SUMP TEMP 8 154 (TN)
SIGNAL RETURN 9 158 (GN)
LSD TCC 10 178 (WH)
PS4 11 177 (GN)
12
13
HSD1 14 111 (OR)
LSD PCS1 15 155 (WH)
HSD2 16 171 (YL)
LSD PCS2 17 136 (OR)
DIGITAL SIGNAL NS 18 138 (OR)
LSD MAIN MOD 19 174 (BL)
DIGITAL SIGNAL C 20 114 (GY)
DIGITAL SIGNAL B 21 153 (YL)
DIGITAL SIGNAL A 22 173 (BL)
DIGITAL SIGNAL P 23 134 (WH)
TRANS ID 24 176 (YL)
L
chassis electrical
C926 TRANSMISSION TCM CONNECTOR

B3-015/101 (BL) 1 AUX FUNCTION RANGE INHIBIT
2
3
4
B1-002/105 (OR) 5 3 MPH SIGNAL
6
TJ1939+ (YL) 7 J1939+
TJ1939- (GN) 8 J1939-
109 (GY) 9 GROUND
110 (PK) 10 BATTERY
111 (OR) 11 HSD1
12
13
114 (GY) 14 DIGITAL SIGNAL C
15
16
117 (BL) 17 PS1
18
19
120 (BL) 20 TURBINE SPEED LOW
21
22
23
124 (WH) 24 RANGE INHIBIT LIGHT
25
26
27
28
CHECK TRANS/129 (GN) 29 CHECK TRANS
30
31
32
133 (YL) 33 LSD SS2
134 (WH) 34 DIGITAL SIGNAL
35
136 (OR) 36 LSD PCS2
37
138 (OR) 38 DIGITAL SIGNAL NS
139 (OR) 39 ENGINE SPEED LOW
140 (GN) 40 OUTPUT SPEED LOW
B1-112/141 (TN) 41 NEUTRAL SAFETY
42
43
44
45
46
47
48
49
50
151 (WH) 51 LSD SS3
152 (GN) 52 LSD SS1
153 (YL) 53 DIGITAL SIGNAL B
154 (TN) 54 SUMP TEMP
S1 155 (WH) 55 LSD PCS1
56
157 (WH) 57 PS3
158 (GN) 58 SIGNAL RETURN
159 (TN) 59 ENGINE SPEED HIGH
160 (YL) 60 OUTPUT SPEED HIGH
61
62
TRANS IGN/163 (YL) 63 IGNITION
TRANS TEMP/164 (BL) 64 TRANS TEMP LIGHT
B2-016/165 (TN) 65 REVERSE SIGNAL
66
67
68
169 (GY) 69 GROUND
170 (PK) 70 BATTERY
171 (YL) 71 HSD2
763
72
173 (BL) 73 DIGITAL SIGNAL A
174 (BL) 74 LSD MAIN MOD
75
176 (YL) 76 TRANS ID
177 (GN) 77 PS4
CAT C7-07
178 (WH) 78 LSD TCC
179 (PK) 79 PS2
180 (OR) 80 TURBINE SPEED HIGH
140 (GN)
139 (OR)
180 (OR)
159 (TN)
160 (YL)
120 (BL)
C905 B A C902 B A C928 B A

ENGINE OUTPUT TURBINE
Sheet 5
SPEED SPEED SPEED
SENSOR SENSOR SENSOR 0116646
ALLISON GEN 4 2000 TRANSMISSION
L
1 service manual
TO CONNECTOR C6
IP, SHT 21
C6 A B
SHIFT SELECTOR C932

1
2
ILLUMINATION ILLUM (BL)
3
4
GROUND 5 GND (WH)
6
7
J1939+ SJ1939+ (YL)
8
9
10
DIRECTIONAL SIGNAL 11 134 (YL)
IGNITION 12 TRANS IGN A (OR)
BATTERY POWER 13 TRANS BAT A (RD)
14
TRANS BAT (RD) SJ1939- (GN)
15
16
ENGINE
COMPARTMENT
INTERFACE
IP TJ1939, SHT 17 C702
B
D
E
G
J1939+ (YL) H J1939+ (YL)
J1939- (GN) K J1939- (GN)
L
M
TELEC GNDA (WH) P 169 (GY)
TRANS BATT START/CHARGE, SHT 2/3 TRANS BAT (RD) R TRANS BAT (RD)
TRANS IGN START/CHARGE, SHT 2/3 TRANS IGN (OR) S TRANS IGN (OR)
IP TJ1587, SHT 17 TJ1587+ (YL) U TJ1587+ (YL)
IP TJ1587, SHT 17 TJ1587- (BL) V TJ1587- (BL)
X
TELEC GND (WH)
764 MAIN TRANSMISSION CONNECTION

HSD1
LSD PCS4
C906
1
2
111 (OR)
155 (WH)
177 (GN)
DIGITAL SIGNAL 3
LSD PCS1 4 136 (OR)
LSD PCS2 5 152 (GN)
ELECTRONIC 171 (YL)
GROUND HSD2 6
7
LSD PCS3 9 133 (YL)
LSD SS1 10 151 (WH)
HSD3 11 131 (YL)
LSD TCC 12 137 (WH)
TURBINE SPEED HIGH 13 180 (OR)
TURBINE SPEED LOW 14 120 (BL)
OIL LEVEL 15 116 (BL)
OIL LEVEL SIGNAL 16 112 (PK)
118 (BK)
OIL LIFE MONITOR 17
SUMP TEMP SIGNAL 18 154 (TN)
ANALOG RETURN 19 158 (GN)
L
chassis electrical

B3-015/101 (BL)
1 AUX FUNCTION RANGE INHIBIT
2
3
4
B1-002/105 (OR)
5 3 MPH SIGNAL
6
TJ1939+ (YL)
7 J1939+
TJ1939- (GN)
8 J1939-
109 (GY)
9 GROUND
110 (RD)
10 BATTERY POWER
111 (OR)
11 HSD1
112 (PK)
12 OIL LEVEL SIGNAL
13
14
15
116 (BL)
16 OIL LEVEL
17
118 (BK) OIL LIFE MONITOR
18
19
120 (BL)
20 TURBINE SPEED LOW
21
22
23
S3
24
25
S4
26
27
28
CHECK TRANS/129 (GN)
29 CHECK TRANS
30
131 (YL)
31 HSD3
TJ1587+ (YL)
32 J1587+
133 (YL)
33 LSD PCS3
134 (YL)
34 DIRECTIONAL SIGNAL
35
136 (OR)
36 LSD PCS1
137 (WH)
37 LSD TCC
38
139 (OR)
39 ENGINE SPEED LOW
140 (GN)
40 OUTPUT SPEED LOW
B1-112/141 (TN)
41 NEUTRAL SAFETY
42
43
44
45
46
47
48
49
50
151 (WH)
51 LSD SS1
152 (GN)
52 LSD PCS2
53
154 (TN)
54 SUMP TEMP SIGNAL
S1 155 (WH)
55 LSD PCS4
S2
56
57
158 (GN)
58 ANALOG RETURN
159 (TN)
59 ENGINE SPEED HIGH
160 (YL)
60 OUTPUT SPEED HIGH
61
62
163 (OR)
63 IGNITION POWER
TRANS TEMP/164 (BL)
64 TRANS TEMP
B2-016/165 (TN)
65 REVERSE SIGNAL
66
67
169 (GY)
170 (RD)
171 (YL)
68
69
70
GROUND
BATTERY POWER
765
71 HSD2
TJ1587- (BL)
72 J1587-
CAT C7-07
73
174 (BL)
74 LSD MAIN MOD
75
176 (YL)
76 TRANS JD
177 (GN)
77 DIGITAL SIGNAL
78
79
180 (OR)
80 TURBINE SPEED HIGH
140 (GN)
139 (OR)
159 (TN)
160 (YL)
C905 B A C902 B A
ENGINE OUTPUT Sheet 6
SPEED SPEED
SENSOR SENSOR
0116649A
L
1 service manual
766
L
chassis electrical
TO ALL OTHER ILLUM
ILLUM B (BL)
BODY INTERFACE, SHT 21
ILLUM H (BL) INSTRUMENT CLUSTER, SHT 17
ILLUM C (BL)
7 9 7 9 7 9 C12
3 3 3 C
2B 2B 2B AB-106C (BN)
A AB MODULE, SHT 11
1 1 1
6 6 6 D
5B 5B 5B B
4 4 4 F
8 10 8 10 8 10
DIMMER
SWITCH
TYPICAL DASH SWITCH BACKLIGHTING/DIMMER CIRCUITS.

DIMMER POWER AND GROUNDS CONTINUE TO LOOP FROM SWITCH TO SWITCH.
767
CAT C7-07
Sheet 7
0116651
DIMMER/BACKLIGHTS
L
1 service manual
ABS BAT (RD)

ABS ABS IGN (OR)
POWER/START/CHARG
SHT. 2/3
LEFT FRONT RIGHT FRONT

MOD VALVE MOD VALVE
ABS GND (WH)

SENSOR SENSOR S S
ABS LGT (GN)

ABS IGN (OR)
ABS BAT (RD)

ATC SLS (RD)
H E H E
C504 A B C D E F
C511 1 2 C501 1 2 C512 1 2 3 4 C500 1 2 3 4
RF MOD HOLD (GN)
LF MOD COM (GY)

LF MOD HOLD (BL)
LF MOD EXH (TN)
RF SENSOR RTN (BK)
LF SENSOR RTN (BK)
LF SENSOR IN (PU)
RF SENSOR IN (PK)
RF MOD COM (GY)
RF MOD EXH (OR)

ABS GND (WH)
LEFT REAR RIGHT REAR

MOD VALVE MOD VALVE
SENSOR SENSOR S S
H E H E
ABS
GROUND
768 C509 1 2 C503 1 2 C510 1 2 3 4 C502 1 2 3 4

RR SENSOR RTN (BK)
LR SENSOR RTN (BK)
RR MOD COM (GY)

LR SENSOR IN (PU)
RR SENSOR IN (PK)
LR MOD COM (GY)
RR MOD HOLD (GN)

RR MOD EXH (OR)
LR MOD HOLD (BL)
LR MOD EXH (TN)
TRACTION C514
CONTROL VALVE
TCV RTN
B
TCV IN
A
L
chassis electrical
STOP LIGHT SIGNAL

ATC SLS (RD) ZONE B PORT 1
C513 SHT. 10
AJ1587+ (YL) AJ1587+ (YL) AJ1587+ (YL) I/P
A
AJ1587- (BL) AJ1587- (BL) AJ1587- (BL) AJ1587
B SHT. 17
ABS/ATC LIGHTS
ABS LGT (GN) IP
SHT. 17
C507
AJ1939+ (YL) A AJ1939+
J1939 DATALINK
AJ1939- (GN) B AJ1939- (AIR)
SHT. 23
ABS LGT (GN)

ABS BATT (RD)
ABS GND (WH)
ABS IGN (OR)
C505
ATC SLS (RD)
1 X1
ABS GND (WH) 1 ABS/ATC GROUND
2 TRAILER ABS WL (NOT CONNCTED)
ABS IGN (OR) 3 IGNITION (5A FUSED)
TCV RTN 4 TCV RTN
TCV IN 5 TCV IN
6 ATC LAMP/ATC ORS (ATC ONLY)
AJ1939-(GN) 7 J1939-LO
AJ1939+(YL) 8 J1939-HI
ATC SLS (RD) 9 SLS (ATC ONLY)
RR SENSOR IN (PK) 10 RIGHT REAR SENSOR +
RR SENSOR RTN (BK) 11 RIGHT REAR SENSOR -
ABS LGT GND (WH)
12 ABS W/L GND
AJ1587- (BL)
13 J1587-B
AJ1587+ (YL)
14 J1587-A
15 WL INTERLOCK (NOT CONNCTED)
ABS BATT (RD) 16 BATTERY (30A FUSED)
17 RETARDER (NOT CONNECTED)
ABS LGT (GN) 18 ABS WL ABS ECU
X2 BENDIX EC-60
C506
LF MOD HOLD (BL) CAB MOUNT
1 LEFT FRONT MOD HOLD
LF MOD EXH (TN) 2 LEFT FRONT MOD EXHAUST
LF MOD COM (GY) 3 LEFT FRONT MOD COMMON
RF MOD HOLD (GN) 4 RIGHT FRONT MOD HOLD
LF SENSOR IN (PU) 5 LEFT FRONT SENSOR (+)
RF MOD COM (GY) 6 RIGHT FRONT MOD COMMON
RF MOD EXH (OR) 7 RIGHT FRONT MOD EXHAUST
LF SENSOR RTN (BK) 8 LEFT FRONT SENSOR (-)
RR MOD COM (GY) 9 RIGHT MOD COMMON
RR MOD HOLD (GN) 10 RIGHT MOD HOLD
RF SENSOR IN (PK)
LR MOD COMMON (GY)
RR MOD EXH (OR)
11
12
13
RIGHT FRONT SENSOR (+)
LEFT REAR MOD COMMON
RIGHT REAR MOD EXHAUST
769
RF SENSOR RTN (BK)
14 RIGHT FRONT SENSOR (-)
LR SENSOR IN (PU)
CAT C7-07
15 LEFT REAR SENSOR +
LR MOD HOLD (BL) 16 LEFT REAR MOD HOLD
LR MOD EXH (TN) 17 LEFT REAR MOD EXHAUST
LR SENSOR RTN (BK) 18 LEFT REAR SENSOR -
X3 (NOT CONNECTED)
1 ABS ORS
2 DIFF
3 DIFF_CMN
TRACTION 4 NOT USED
C515 B A CONTROL VALVE 5 RESERVED
6 NOT USED
ATC HARNESS 7 ADDITIONAL MOD EXHAUST
ABS HARNESS SEE CHART 0104429 8 RESERVED
9 ADDITIONAL MOD COMMON
10 ADDITIONAL MOD HOLD
11 ADDITIONAL LEFT SENSOR(+)
12 ADDITIONAL RIGHT SENSOR(+)
13 NOT USED
14 ADDITIONAL LEFT SENSOR(-)
15 ADDITIONAL RIGHT SENSOR(-)
Sheet 8
0116652
ABS - BENDIX
L
1 service manual
ABS ECU
16 WAY
CONNECTOR
C513
I/O DIAG SW & I/P ABS LT (TN) ABS LT (TN)
A
SHT 17 MOD PMP BAT (RD) PMP MTR BAT (RD)
B
C
ABS IGN (OR) ABS IGN (OR)
D
J1939 TJ1939- (GN) TJ1939- (GN)
E
TRANSMISSION TJ1939+ (YL) TJ1939+ (YL)
F
SHT 5/6 AJ1587- (BL) J1587- (BL)
G
AJ1587+ (YL) J1587+ (YL)
H
J
K
ABS BAT (RD) ABS BAT (RD)
L
ABS POWER
M
START/CHARGE
N
SHT 2/3 ABS GND (WH) ABS REF GND (WH)
P
AJ1939- (GN) AJ1939- (GN)
R
AJ1939+ (YL) AJ1939+ (YL) S4
S
S3
I/P
J1587
J1939
SHT 17
770 RR SENS GND (BK)

LR SENS GND (BK)
LF SENS GND (BK)
RR SENS IN (BN)
LR SENS IN (BN)
LF SENS IN (BN)
C511 1 2 C509 1 2 C503 1 2
LEFT FRONT LEFT REAR RIGHT REAR

SPEED SENS SPEED SENS SPEED SENS
L
chassis electrical
MODULATOR PUMP
31 WAY
CONNECTOR
C521
ABS IGN (OR)
1 +12V IGNITION
2
3
4
5
ABS REF GND (WH)
6 GROUND
7
8
9
10
11
12
13
J1939+ (YL)
14 J1939+
J1939- (GN)
15 J1939-
PMP MTR BAT (RD)
16 PUMP MOTOR PWR
ABS BAT (RD)
17 +12 BATTERY PWR
PMP MTR GND (WH)
18 PUMP MOTOR
SOL VLV GND (WH)
19 SOLENOID VALVE
20
ABS LT (TN)
21 ABS LIGHT
RR SENS IN (BN)
22 RR SENSOR INPUT
LR SENS IN (BN)
23 LR SENSOR INPUT
LF SENS IN (BN)
24 LF SENSOR INPUT
RF SENS IN (BN)
25 RF SENSOR INPUT
J1587+ (YL)
26 J1587(-)
RR SENS GND (BK)
27 RR SENSOR GND
LR SENS GND (BK)
28 LR SENSOR GND
LF SENS GND (BK)
29 LF SENSOR GND
RF SENS GND (BK)
30 RF SENSOR GND
J1587- (BL)
31 J1587(+)
771
CAT C7-07
RF SENS GND (BK)
RF SENS IN (BN)
C501 1 2
PUMP MOTOR SOLENOID
GROUND VALVE
GROUND
RIGHT FRONT Sheet 9

SPEED SENS 0118822A
ABS Hyd-E
L
1 service manual
BODY INTERFACE, AA-101A (BN)

SHT 21
DRIVER CONTROL MODULE AA-101B (BN)

SHT 18/19
CAT, SHT 4 AA-108 (OR)
AA-107 (BL)
STOP LGT PWR (RD)
START/CHARGE,
SHT 2/3
STOP LGT PWR A

STOP LIGHT
RELAY
INSTRUMENT CLUSTER, STOP LGT A (RD) C7
(RD)
SHT 17 4
3
STOP LGT B (RD) STOP LGT PWR 5
STOP LGT PWR B (RD)

BODY INTERFACE,
SHT 21 (RD)
AA-109A 1 2 RLY GND C
C701 (RD) (WH)
AA-109C (RD)
VGT BRAKE
772 LIGHT RELAY
4
C15
3
5
CAT C7 ENG BRK LT (RD) ENG BRK LT (RD) 1 2 RLY GND D

T
SHT 4 (WH)
- +
7 9
AA-004 (BN)
PARK LGT GND (WH) 2B 3
1
5B 6 AC-006 (OR)
HEAD LGT GND (WH)
4
8 10
- +
HEADLIGHT
SWITCH
C423
CAT C7 AA-103 (OR)
SHT 4
L
HARNESS CONN C2
I/O SEQ
PORT #
AA-101 (BN)
1
WIPER MOTOR
2
OUT 1
INTERMITTANT
AA-102 (BN) LOW BEAM HEAD

2
1
OUT 1
LGT (LEFT)
AA-103 (OR) FAN CONTROL

3
2
OUT 2
POWER
AA-004 (BN) PARK/TAIL

1
4
IN 7
LGT SWITCH
AA-105 (PK)
2
PARK BRAKE
OUT 3
AA-106 (OR) LOW BEAM HEAD

6
1
OUT 2
LGT (RIGHT)
AA-107 (BL)
2
BACK-UP LIGHT
CV-CCM-C
OUT 4
AA-108 (OR) COOLING FAN

1
IN 8
8
DISABLE
AA-109 (RD) STOP LIGHT

2
RELAY
OUT 5
C715
C709
C703
AA-102 (BN) AA-102 (BN) AA-102 (BN)
AA-110 (RD) AA-110 (RD) AA-110 (RD) HIGH BEAM HEAD
A B
1
10
LGT (LEFT)
OUT 3
LEFT
AA-110 (RD) AA-106 (OR)
A B C
HEADLIGHT
AA-112A (PU)
1 2 3 4
AA-111(OR)
2
11
IGNITION
OUT 6
AA-112 (PU) HIGH BEAM HEAD

1
12
LGT (RIGHT)
OUT 4
C718
C706
AA-106 (OR) AA-106 (OR)
AA-112 (PU) AA-113 (PK) IGNITION
2
A B
13
OUT 7
AA-112 (PU) DROP-OUT
RIGHT
A B C
HEADLIGHT
AA-114 (RD)
2
14
STARTER RELAY
OUT 8
chassis electrical
AA-112B (PU)
AA-113 (PK)
AA-105 (PK)
AC-006 (OR)
AA-111 (OR)
AA-114 (RD)
Sheet 10
0116694A
AA MULTIPLEX MODULE
17
SHT 12
SHT 2/3
AC-MODULE,
CLUSTER, SHT
INSTRUMENT
START/CHARGE,
L
773
CAT C7-07
1 service manual
CV-CCM-C
LEFT TURN LAMPS
REVERSE SIGNAL
WASHER PUMP
SHIFT INHIBIT
3 MPH SPEED
PARK LIGHTS
RIGHT TURN
LAMPS
INTERLOCK
THROTTLE
HIGH IDLE
NEUTRAL
SWITCH
SIGNAL
SIGNAL
PORT # 3 1 1 1 3 1 1 1 3 1
1/0 SEQ. OUT 1 OUT 5 IN 1 IN 2 OUT 2 OUT 6 IN 3 IN 4 OUT 3 OUT 7
HARNESS CONN C4 1 2 3 4 5 6 7 8 9 10
AB-005 (GN)
AB-001 (OR)
AB-106 (BN)
AB-009 (BN)
AB-003 (RD)
AB-107 (RD)
AB-110X (GN)
AB-108 (PK)
AB-004 (BL)
AB-102X (YL)
AB-001A (OR)
AC MODULE, SHT 12 F2 F1
10A 10A
AB-001B (OR) FUSE FUSE
ENGINE, SHT 4
AB-003 (RD)
TRANSMISSION, SHT 5/6
AB-004 (BL)
AB-005 (GN)
AB-107 (RD)
AB-009 (BN)
ENGINE, SHT 4
AB-012 (PK)
DRIVERS CONTROL MODULE, SHT 18/19
AB-111B (RD)
AB-111A (RD)
HYDRAULIC BRAKE BOOST, SHT 14
AB-110B (GN)
BODY INDTERFACE, SHT 21
AB-110D (GN)
INSTRUMENT CLUSTER, SHT 17
AB-106B (BN)
774 DIMMER/BACKLIGHTING, SHT 7

AB-106C (BN)
AB-102B (YL)
AB-102D (YL)
AB-110A (GN)
AB-106A (BN)
AB-102A (YL)
LT DIR GND (WH)
FT LT PK LGT (BN)
FT LT PK LGT (BN)
LT PK GND (WH)
AB-102A (YL)
AB-102B (YL)
GND C (WH)
AB-102 (YL)
C703 14 C703 5 C703 16
C712 B A C B A C713 E D C C709

AB-106A (TN)
AB-102A (YL) AB-110A (GN)

FT LT PK LGT (TN) S3 FT RT PK LGT (TN)
DIRECTIONAL DIR/PARK GND C (WH)
LIGHT LIGHT
L
chassis electrical
PARKING BRAKE
WIPER WASHER
SERVICE BRAKE
LAMP SWITCH
LIFT ENABLE
INTERLOCK
ACC HOT
SWITCH
BRAKE
PUMP
HORN
1 1 3 1 3 3 3 3
CNETA CNETB VIN GND
IN 5 IN 6 OUT 4 OUT 8 OUT 5 OUT 8 OUT 6 OUT 7
11 12 13 14 15 16 17 18 19 20 21 22
AB-015 (WH)
AB-116 (GN)
AB-111 (RD)
AB-021 (RD)
AB-122 (TN)
AB-012 (PK)
AB-114X (BK)
AB-122 (TN) DRIVER CONTROL MODULE, SHT 18/19

F3
10A
FUSE AB-021 (RD) BODY INTERFACE, SHT 21
AB-116 (GN) BODY INTERFACE, SHT 21
AB-015A (WH) DRIVER CONTROL MODULE, SHT 18/19
AB-015B (WH) INSTRUMENT CLUSTER, SHT 17
AB-108 (PK) DRIVER CONTROL MODULE, SHT 18/19
C703 9
GND A (WH)
HORN GND (WH)
GND (WH)
AB-114 (BK)
GND B (WH)
GND C (WH)
A B 725
775
CAT C7-07
HORN
S2
S1
FT RT PK LGT (BN)
RT DIR GND (WH)

FT RT PK LGT (BN)
RT PK GND (WH)
AB-110A (GN)
AB-110B (GN)
GND B (WH)
AB-110 (GN)
C706 C D E C717 A B C A B C716
Sheet 11
GND B (WH) DIR/PARK DIRECTIONAL
LIGHT LIGHT 0116695A
AB MULTIPLEX MODULE
L
1 service manual
STARTER LOCKOUT
IGNITION SWITCH
START SWITCH
ACCESSORY
HIGH IDLE
SIGNAL
SWITCH
SWITCH
PORT# 2 2 2 2 2
I/O SEQ IN 1 IN 2 IN 3 IN 4 IN 5
HARNESS CONN C1 1 2 3 4 5
AC-001 (GN)
AC-102 (RD)
AC-005 (PU)
AA-004 (PK)
AC-003 (YL)
AC HI IDLE (GN)
AC-102 (RD)
CAT, SHT 4
AC-003 (YL)
DRIVER CONTROL MODULE, SHT 18/19
AC-004 (PK)
AC-005 (PU)
AC-006 (OR)
AC MODULE, SHT 12
AC-007 (OR)
AC-008A (YL)
AC-009A (GN)
AC-010 (GY)
AB-001A (OR)
AB MODULE, SHT 11
776 HIGH IDLE GND (WH)

7
2B
3
9
AC-001A (GN)
1
6
5B
4 HIGH IDLE SW
8 10 C425
ILLUM F (BL)
DIMMER/BACKLIGHTS, SHT 7
7 9
3 AC-008B (YL)
GND (WH) 2B
1
6 AC-009B (GN)
GND (WH)
5B
4 HAZARD SW
8 10 C424
ILLUM E (BL)
7 9
3 AC-015 (GN)
GND (WH) 2B
1
6
ABS LT GND (WH)
5B ABS LT (TN)
4
8 10
C422
ABS DIAGNOSTIC SWITCH
L
chassis electrical
CV-CCM-C
HEADLAMP SWITCH
EXTERIOR DOOR
I/O DIAGNOSTIC
HORN BUTTON
INTERMITTANT
WIPER SWITCH
VANDAL LOCK
RIGHT TURN
HIGH BEAM
SCC ALARM
INTERLOCK
LEFT TURN
FEEDBACK
SWITCH
SWITCH
SWITCH
SWITCH
SIGNAL
2 2 2 3 3 3 3 3 3 3 3
N/A N/A
IN 6 IN 7 IN 8 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8
6 7 8 9 10 11 12 13 14 15 16 17 18
AC-009 (GN)
AC-014 (GN)
AC-015 (GN)
AC-010 (GY)
AC-006 (OR)
AC-007 (OR)
AC-013 (OR)
AC-016 (TN)
AC-112 (BK)
AC-008 (YL)
AC-011 (BL)
AC-016 (TN)
AC-014 (GN)
AC-013 (OR)
AC-112 (BK)
AC-011 (BL)
ABS LT (TN)
777
CAT C7-07
Sheet 12
0116696
AC MULTIPLEX MODULE
L
1 service manual
CRS MR HT LT(PU)
S6
CRS MR HT(PU)
778
C700
C711
G
TO OUT SPKR +(YL) OUT SPKR +
J B
HEATER STEPWELL OUT SPKR -(PU) OUT SPKR -
HARNESS K A
N
L
M
WASH MTR PWR(YL) WASH MTR PWR
WASHER MOTOR GROUND A
WASH MTR GND(WH) WASH MTR GND(WH) WASH MTR GND
FRAME COMPONETS B
SHT. 15
C708
2302J(GY)
A
M
1213X(WH)
B
HEATER PUMP
C726 MOTOR
L
chassis electrical
C714
CRS MR GND (WH)
A
CRS MR HT LT (PU)
B
C
C709 LEFT CROSS

CRS MR HT LT (PU) CRS MR HT LT (PU) MIRROR HEAT
F
C719
CRS MR GND (WH)
A
CRS MR HT RT (PU)
B
C
C706 LEFT CROSS

CRS MR HT RT(PU) CRS MR HT RT(PU) MIRROR HEAT
F
779
CAT C7-07
OUT SPKR +
EXTERIOR
OUT SPKR - SPEAKER
WASH MTR PWR

WASHER
WASH MTR GND BOTTLE
Sheet 13
0116697
MIRROR HEAT/EXTERIOR SPEAKER/WIPER WASHER
L
1 service manual
780
L
chassis electrical
C703
BRAKE WARNING IGNITION
START/CHARGE BRAKE WARN IGN (OR) BRAKE WARN IGN (OR) 18 BRAKE WARN IGN (OR)
SHT. 2/3
C729
BRAKE WARN IGN (OR) A
C703 BRAKE WARN LGT (TN) TO
S25 B HYDRAULIC BRAKE
BRAKE WARN GND (WH) 15 BRAKE WARN GND (WH) BRAKE WARN GND (WH) C BOOST HARNESS
AB-111A (RD) D
GROUND PDU
GROUND
STUD
C703
BRAKE WARNING LIGHT
IP BRAKE WARN LGT (TN) BRAKE WARN LGT (TN) 13 BRAKE WARN LGT (TN)
SHT. 17
SERVICE BRAKE C703

AB MODULE, AB-111A (RD) AB-111A (RD) 17 SERVICE BRAKE LAMP SW - 111A (RD)
SHT. 11
C818
ENGINE C7 DCM GND (WH) DCM GND (WH) HYD
A BRAKE
SHT. 4 BRAKE BOOST BAT (RD) BRAKE BOOST BAT (RD) B BOOST
781
CAT C7-07
Sheet 14
0116698
HYDRAULIC BRAKE BOOST,CAT
L
1 service manual
AIR DRYER POWER

START/CHARGE AIR DRYER PWR (BL)
SHT. 2/3
HEATED DRAIN POWER

START/CHARGE HTD DRAIN PWR (BN)
SHT. 2/3
HEATED FUEL POWER

START/CHARGE HTD FUEL PWR (PK)
SHT. 2/3
FUEL TANK SIGNAL FUEL TANK SIG (BK)

IP
SHT. 17
S25
FUEL TANK GND (WH)
GROUND PDU
GROUND
STUD
WATER IN FUEL C703

SENSOR LT WIF SENSOR (YL)
11
SHT. 17
FUEL TANK GND (WH)
FUEL TANK SIG (BK)
WIF SENSOR (YL)
782 12V DC (RD)

SEN GND (BK)
C710 A B C
C730
LT (YL) A LT (YL)
FUEL TANK GND (WH)
FUEL TANK SIG (BK)
HTD FUEL GND A

HTD FUEL PWR A
A B C A B
WATER IN HEATED
FUEL FUEL FUEL
SENDER SENSOR FILTER
NOTE: DASHED LINES INDICATE THAT THERE IS AN ADDITIONAL

HARNESS INSTALLED FOR THE WATER IN FUEL OPTION.
L
chassis electrical
S4 GND
GND A
GROUND
WASHER MOTOR GROUND

WASH MTR GND (WH) WASH MTR GN (WH) MIRROR HEAT
S5 SHT. 13
C703 6 7 8 10 12
FUEL TANK GND (WH)
HTD DRAIN PWR (BN)

FUEL TANK SIG (BK)
AIR DRYER PWR (BL)
HTD DRAIN GND (WH)
AIR DRYER GND (WH)

HTD FUEL PWR (PK)
HTD FUEL GND (WH)
CONNECTS TO
ENGINE HARNESS
C705 A B C D E F 1 2 C736
HTD DRAIN GND (WH)
HTD DRAIN PWR (PU)
C726
A
B
HTD FUEL PWR (PK)
HTD FUEL GND (WH) 783
HTR DRAIN PWR C (PU) S2
CAT C7-07
HTD DRAIN GND C (WH)
HTR DRAIN PWR B (PU) S1
HTD DRAIN GND B (WH)
HTD DRAIN GND A (WH)
HTD DRAIN PWR A (PU)
AIR DRYER GND (WH)

AIR DRYER PWR (BL)
WIF RTN (YL)

WIF 2 (WH)
C734 A B C733 A B CUMMINS

C727 B A C728 A B C735 A B
FUEL FILTER
HEATER HEATER AT FRAME RAIL
HEATED AIR
DRAIN DRAIN DRAIN DRYER
VALVE VALVE VALVE
Sheet 15
0116699
FRAME COMPONENTS
L
1 service manual
C700
CRS ARM MG PWR(OR)

A
CRS ARM CTL(BL) CRS ARM CTL(BL) S2 CRS ARM CTL B(BL)
TO C
HEATER/STEPWELL CRS ARM HEAT(PU)
HARNESS D
CRS ARM PWR(BK)
E
CRS ARM LGT(YL)
F
CRS ARM GND(WH)
P
CRS ARM CTL A(BL)
784
L
chassis electrical
C730
CRS ARM MG PWR(OR)

A
CRS ARM GND B(WH) CROSSING ARM
B
CRS ARM CTL B(BL) MAGNET
C
D
CRS ARM GND B(WH)
CRS ARM GND(WH) S1

CRS ARM GND A(WH)
C723
CRS ARM PWR(BK)

A
CRS ARM GND A(WH)
B
CRS ARM CTL A(BL)
CRS ARM HEAT(PU)
C CROSSING ARM 785
D
CAT C7-07
C722
CRS ARM LGT(YL)
A
CROSSING ARM
LIGHT
Sheet 16
0116700
CROSSING ARM
L
1 service manual
INSTRUMENT CLUSTER
C302
PROGRAM 1 (RD)
13
PROGRAM 2 (RD)
14
D PWR (BK)
1
D IGN (RD)
3
D RETURN (YL)
4
DESC (OR)
5
"A" CONNECTOR C302 DUP (GN)
6
22 WAY CONNECTOR D DOWN (BL)
7
GREEN AB-110D (GN)
21
DCHASS GND (WH)
2
J1939+ (YL)
15
J1939- (GN)
16
J1587+A (YL)
17
J1587-A (BL)
18
C300
FUEL TANK SIG (BK)
3
AB-102D (YL)
25
AA-105 (PK)
23
AA-112B (PU)
28
F AIR IN (GN)
13
"B" CONNECTOR C300 F AIR +5V (OR)
20
30 WAY CONNECTOR R AIR IN (GN)
GREEN 14
R AIR +5V (OR)
21
ILLUM H (BL)
9
24
WIF SENSOR (YL)
10
AMMETER+ (RD)
6
C301
ABS HYD 1 (TN)
3
BRAKE WARN LGT (TN)
5
HYD INTLK AML (YL)
23
STOP LGT A (RD)
8
ABS AIR 1 (TN)
10
12
HIGH IDLE (OR)
"C" CONNECTOR C301 1
FAA IN (GN)
30 WAY CONNECTOR 13
BLUE FAA +5V (OR)
20
RAA IN (GN)
14
RAA +5V (OR)
21
AB-015B (WH)
22
CC ON/OFF (GY)
24
786
CC SET (BN)
25
CC RESUME (GN)
26
R AIR GND (WH)
F AIR GND (WH)
FAA GND (WH)

R AIR +5V (OR)
F AIR +5V (OR)
FAA +5V ((OR)

R AIR IN (GN)
F AIR IN (GN)
FAA IN (GN)
C304 A B C C305 A B C C306 A B C
FRONT AIR REAR AIR FRONT APPLIED

TRANSDUCER TRANSDUCER AIR TRANSDUCER
L
chassis electrical
C303
PROGRAM 1 (RD)
B
PROGRAM 2 (RD) DASH PROGRAM PORT
A
D PWR (BK)
DASH POWER, SHT 2/3
D IGN (RD)
DASH POWER, SHT 2/3
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
AB-110D (GN)
R/TURN SIGNAL, AB MODULE, SHT 11
J1939+ (YL)
J1939 DIAGNOSTIC INTERFACE, SHT 22/23
J1939- (GN)
J1587+A (YL)
J1587-A (BL)
FUEL TANK SIG (BK)

FUEL TANK SIGNAL, FRAME COMPONETS, SHT 15
AB-102D (YL)
L/TURN SIGNAL, AB MODULE, SHT 11
AA-105 (PK)
PARK BRAKE SIGNAL, AA MODULE, SHT 10
AA-112B (PU)
HIGH BEAM INPUT, AA MODULE, SHT 10
ILLUM H (BL)
PANEL DIMMER, SHT 7
WIF SENSOR (YL)

WATER IN FUEL, SHT 15
AMMETER+ (RD)
CURRENT SENSOR, SHT 2/3
ABS LT (TN)
HYD ABS DIAG LIGHT; AC MODULE , SHT 12
ABS HYD (TN)
HYD ABS LIGHT, SHT 9
BRAKE WARN LGT (TN)
BRAKE WARNING LIGHT, SHT 14
HYD INTLK AML (YL)
STOP LGT A (RD)
STOPLIGHT, AB MODULE, SHT 10
ABS AIR (TN)
AIR ABS LIGHT, SHT 8
HIGH IDLE (OR)
HIGH IDLE INPUT, AB MODULE, SHT 11
ABS LT (TN)
AIR ABS DIAG LIGHT; AC MODULE, SHT 12
AB-015B (WH)
SHIFT INHIBIT SIGNAL, AB MODULE, SHT 11
CC ON/OFF (GY)
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT 18/19
787
CC SET (BN)
CC RESUME (GN)
CAT C7-07
RAA GND (WH)
RAA +5V (OR)
RAA IN (GN)
C307 A B C
REAR APPLIED
Sheet 17
AIR TRANSDUCER 0119063
INSTRUMENT CLUSTER
L
1 service manual
AC MODULE, HORN BUTTON, SHT 12
AC MODULE, HIGH BEAM SWITCH, SHT 12

CAT 7, SHT 4
AC MODULE, LEFT TURN SWITCH, SHT 12

AC MODULE, RIGHT TURN SWITCH, SHT 12
AB MODULE, PARK BRAKE SWITCH, SHT 11

INSTRUMENT CLUSTER, CRUISE CONTROL,SHT 17
AB MODULE, SERVICE BRAKE, SHT 11
START/CHARGE SHT 2/3
AC MODULE, ACCESSORY SWTICH, SHT 12

AC MODULE, IGNITION SWITCH, SHT 12
AC MODULE, START SWITCH, SHT 12
AC MODULE, INTERLOCK FEEDBACK, SHT 12

INTERLOCK POWER, SH 2/3
BRAKE INTERLOCK POWER, SHT 2/3
CAT 7, SHT 4
CAT 7, SHT 4
CAT 7, SHT 4
AA-101B
AA MODULE,WIPER MOTOR INTERMITTANT,SHT 10
WIPER + (BK) 86 30
BODY INTERFACE, SHT 18/19 WIPER
WIPER INT (GN) PARK
BODY INTERFACE, SHT 18/19 87
RELAY 85 87A
C200
2112 (RD) WIPER HI (RD)
WINDSHIELD HIGH 2 A
WIPER LOW 1 2111 (DK GN) WIPER LOW A (GN)
B
2115 (YL) WIPER PARK 2 (BL)
788
MOTOR PARK 4 C
1124SS (BK) WIPER +A (BK)
12V 3 D
1216DD (WH) WIPER GND (WH)
GND 5 E
AB-122 (TN)
F
WIPER
WASHER M
PUMP
AC MODULE, WIPER WASHER PUM, SHT 13
AC MODULE, INTERMITTANT WIPER SWITCH, SHT 12

AB MODULE, WASHER PUMP SWITCH, SHT 11
DIAGNOSTICS INSTRUMENT CLUSTER SHT 17

START CHARGE SHT 2/3
L
chassis electrical
DCM HORN AND HAZARD

C5 HORN SIG #2
1 COLUMN GND
COLUMN GND (WH)
1 2
AC-010 (GY) HORN SIG HORN SIG #1
2 3 HORN SIGNAL
TURN SIG GND (WH) TURN SIG GND
3
AC-007 (OR) HIGH BEAM
4
SEN COM B (TN) SENS COMA AIR BRAKE PARK SWITCH
5
WIPER+B (BK) WIPER+A
6 A
AC-008A (YL) LH DIR
7 B
AC-009A (GN) RH DIR
8 D PARK BRAKE GROUND
PARK BK GND (WH) PARK BK GND
9 C PARK BRAKE SIGNAL
AB-012 (PK) PARK BRAKE SIG
10
CC ON/OFF (GY) EJ159 STOP LIGHT SWITCH #2
11
CC RESUME (GN) EJ144
12 A
CC SET (BN) EJ135
13 B
AB-111B (RD) STOP LGT SIG
14 D STOP LIGHT
BRAKE SW PWR (RD) STOP LGT PWR
15 C STOP LIGHT POWER
IGN SW GND (WH) IGN SW GND
16
AC-003 (YL) ACC
17
AC-004 (PK) IGN
18
AC-005 (PU) START SW TO BVA
19 PRESSURE SWITCH
INTLK FB GND (WH) BVA PRESSURE SW
20
AC-013 (OR) BVA PRESSURE SW BVA SOLENOID
21
AB-015A (WH) BVA GND
22 B BVA GROUND
INTLK PWR (RD) BVA POWER
23 A BVA POWER
24
25 THROTTLE
THROT SIG (BN) THROT SIG
26 A THROTTLE
THROT COM (PK) THROT COM
27 B SENSOR
THROT PWR (BL) THROT PWR PEDAL
28 C
29
30
31
STOP LIGHT SWITCH #1
A
B
C STOP LIGHT POWER
START SWITCH D STOP LIGHT
BAT TURN SIGNAL

START 1 COM
IGN 1 2 ON
IGN 2 3 RESUME/COAST
ACC 1 4 SET -
5
6
SET +/ ACCEL
789
7
8
CAT C7-07
9
10 HIGH BEAM INDICATOR
11 HIGH BEAM SIGNAL
12 LEFT TURN SIGNAL
13 RIGHT TURN SIGNAL
14 GROUND
DCM STEERING COLUMN SWITCH

C16 WIPER/INST
A 1 +12V SUPPLY
WIPER HI (RD) WIPER HI (RD)
B 2 HIGH SPEED WIPER
WIPER LOW A (GN) WIPER LOW A (GN)
C 3 LOW SPEED WIPER
WIPER PARK 1 (BL) WIPER PARK (BL)
D 4 PARK CONTROL WIPER
AC-112 (BK) AC-112 (BK)
E 5 INTERMITTENT WIPER
AB-108 (PK) AB-108 (PK)
F 6 WASHER MOTOR
G 7
D RETURN (YL) D RETURN (YL)
H 8 RETURN
DESC (OR) DESC (OR)
J 9 ESC
DUP (GN) DUP (GN)
K 10 UP
D DOWN (BL) D DOWN (BL)
L 11 DOWN
D DIAG PWR (BK) D DIAG PWR (BK)
M 12 COM
Sheet 18
0116702
DRIVERS CONTROL MODULE,CAT,AIR
L
1 service manual

CAT 7, SHT 4



HYDRAULIC INTERLOCK ALARM, SHT 17
HYDRAULIC INTERLOCK POWER, SH 2/3
AB MODULE, BRAKE INTERLOCK, SHT 11
CAT 7, SHT 4
CAT 7, SHT 4
CAT 7, SHT 4
AA-101B
86 30
WIPER + (BK) WIPER
BODY INTERFACE, SHT 18/19 PARK
WIPER INT (GN) 87
BODY INTERFACE, SHT 18/19 RELAY 85 87A
C200
WINDSHIELD HIGH 2 A
WIPER LOW 1 2111 (DK GN) WIPER LOW A (GN)
B
MOTOR 2115 (YL) WIPER PARK 2 (BL)
PARK 4 C
790
12V 3 D
GND 5 E
AB-122 (TN)
F
WIPER
WASHER M
PUMP


L
chassis electrical
DCM HORN AND HAZARD

C5 HORN SIG #2
1 COLUMN GND
COLUMN GND (WH)
1 2
2 3 HORN SIGNAL
3
4
SEN COM B (TN) SENS COMA
5
6
AC-008A (YL) LH DIR
7
AC-009A (GN) RH DIR HYDRAULIC PARK BRAKE SWITCH
8
9 A CHASSIS GROUND
AB-012 (PK) HYD PARK BRAKE SIG
10 B PARK BRAKE SIG
CC ON/OFF (GY) EJ159
11
12
CC SET (BN) EJ135 HYDRAULIC STOP LIGHT SWITCH
13
14 B STOP LIGHT SIGNAL
15 A STOP LIGHT POWER
16
AC-003 (YL) ACC
17
AC-004 (PK) IGN
18
AC-005 (PU) START MICO HYD BRAKE INTERLOCK MODULE
19
HYD INTLK ALM (YL) ALARM OUT
20 23 DIRECT ALARM OUTPUT
AC-013 (OR) LOCKED OUT
21 15 LOCKED OUTPUT
HYD INTLK PWR (RD) HYD INTLK PWR
22 1 12V BATT
HYD INTLK GND (WH) HYD INTLK GND
23 17 GROUND
AB-015A (WH) HYD INTLK ACT INPUT
24 8 ACTIVATION INPUT
25
THROT SIG (BN) THROT SIG
26 A THROTTLE
THROT COM (PK) THROT COM
27 B SENSOR
THROT PWR (BL) THROT PWR PEDAL
28 C
29
30
31 TURN SIGNAL
1 COM
2 ON
START SWITCH 3 RESUME/COAST
4 SET -
BAT 5 SET +/ACCEL
START 6
IGN 1 7
IGN 2 8
ACC 1 9
11
12
HIGH BEAM SIGNAL
LEFT TURN SIGNAL
791
14 GROUND
CAT C7-07
C16 WIPER/INST
A 1 +12V SUPPLY
C 3 LOW SPEED WIPER
AC-112 (BK) AC-112 (BK)
AB-108 (PK) AB-108 (PK)
F 6 WASHER MOTOR
G 7
H 8 RETURN
DESC (OR) DESC (OR)
J 9 ESC
DUP (GN) DUP (GN)
K 10 UP
L 11 DOWN
M 12 COM
Sheet 19
0116703
DRIVERS CONTROL MODULE,CAT,HYD
L
1 service manual
792
L
chassis electrical
MBC POWER START/CHARGE, MBC PWR 2 (RD)

SHT 2/3
MBC POWER START/CHARGE, MBC GND A (WH)

SHT 2/3

SHT 2/3
MBC POWER START/CHARGE, MBC BATT (RD) C3 1 2 3

SHT 2/3 CONN. E
C8
MBC POWER START/CHARGE, MBC GND B (WH) 9 CONN. D CV-CCM-C
SHT 2/3 10 MBC/DIO
MODULE
Sheet 20
0116704
MBC MODULE
C11
START/CHARGE, SHT 2/3 BODY IGN (OR) BODY IGN (OR) A +12V IGNITION
AA MODULE, SHT 11 AB-116 (RD) AB-116 (RD) B ACCESSORY HOT
C
SCC OPTION 30195-13,19 AC-014 (RD) AC-014 (RD) D SCC ALARM
AC MODULE SHT 12
E
F
AB MODULE, SHT 11 AB-106B (BN) AB-106B (BN) G PARK/TAIL LIGHTS
793
AA MODULE, SHT 10 AA-107 (BL) AA-107 (BL) H BACK-UP LIGHTS
AB MODULE, SHT 11 AB-110 (GN) AB-110 (GN) J RIGHT TURN LAMPS
AB MODULE, SHT 11 AB-102B (YL) AB-102B (YL) K LEFT TURN LAMPS
L
AC MODULE, SHT 12 AC-011 (PK) AC-011 (PK) M DOOR SWITCH SIGNAL TO BODY
DIMMER/BACKLIGHTS, SHT 7 ILLUM B (BL) ILLUM B (BL) N PANEL DIMMER
AB-021 (RD) AB-021 (RD)
CAT C7-07
AB MODULE, SHT 11 P LIFT ENABLE
R
AA MODULE, SHT 10 STOP LGT B (RD) STOP LGT B (RD) S STOP LIGHTS
AB MODULE, SHT 12 AC-016 (TN) AC-016 (TN) T VANDAL LOCK
SEE REVERSE MOTION SENSOR DIAGRAM REV SENS SIG (GN) REV SENS SIG (GN) U REVERSE SENSOR
BCHASS GND (WH) V GROUND
DRIVERS CONTROL MODULE, SHT 18/19 WIPER INT (GN) WIPER INT (GN) W 2109A (GN)
AA MODULE, SHT 10 AA-101 (BN) AA-101 (BN) X 2109 (GN)
DRIVERS CONTROL MODULE, SHT 18/19 WIPER + (BK) WIPER + (BK) Y 1124PP (BK)
12V BATT.
AC MODULE, SHT 12 AC HIGH IDLE (GN) AC HIGH IDLE (GN) Z AC HIGH IDLE 25A
INTERMITTANT 86 30
WIPER
RELY 87
85 87A
Sheet 21
0116705
BODY INTERFACE
L
1 service manual
J1587 EJ1587 + (YL)

ENGINE EJ1587 - (BL)
SHT 4
J1587 TJ1587 + (YL) S15

TRANS TJ1587 - (BL) S16
SHT 5/6
J1587 AJ1587 + (YL)

ABS AJ1587 - (BL)
SHT 8/9
EJ1939+ (YL)
ENGINE EJ1939- (GN)
SHT. 4
TJ1939+ (YL) S34 J1939+A (YL)

TRANS ECU TJ1939- (GN) J1939-A (GN)
SHT. 5/6 S35
TJ1939+ (YL)
S
TJ1939- (GN)
R
794 TJ1939+ (YL)

J1939
TRANS ECU TJ1939- (GN)
SHT. 5/6
L
chassis electrical
J1587
J1587+A (YL) INSTRUMENT
J1587-A (BL) CLUSTER
SHT. 17
DIAGNOSTIC
DIAG PWR (RD) POWER
SHT 2/3
DIAG GND (WH)
DIAG GND
A
DIAG PWR
B
DJ1939+ (YL)
C
DJ1939- (GN)
D 9-PIN
E DIAGNOSTIC
J1587+ (YL) S8 J1587+ B
S9 F TOOL
J1587- (GN) J1587- B
G
H
J
J1939
J1939+A (YL) S33 J1939+ (YL) DIAGNOSTIC
J1939-A (GN) S32 J1939- (GN) INTERFACE
SHT. 17
795
CAT C7-07
Sheet 22
0118820
J1939 DATALINK,HYD-E
L
1 service manual
J1587 EJ1587 + (YL)

SHT 4
J1587 TJ1587 + (YL) S15

SHT 5/6
J1587 AJ1587 + (YL)

ABS AJ1587 - (BL)
SHT 8/9
EJ1939+ (YL)
ENGINE
SHT. 4 EJ1939- (GN)
TJ1939+ (YL) S36 J1939+B (YL) S34 J1939+A (YL)

TRANS ECU TJ1939- (GN) J1939-B (GN) J1939-A (GN)
SHT. 5/6 S37 S35
796
ABS ECU AJ1939+ (YL)
BENDIX AJ1939- (GN)
SHT. 8
L
chassis electrical
J1587
J1587+A (YL)
INSTRUMENT
SHT. 17
DIAGNOSTIC
DIAG PWR (RD) POWER
SHT 2/3
DIAG GND (WH)
DIAG GND
A
DIAG PWR
B
DJ1939+ (YL)
C
DJ1939- (GN)
D 9-PIN
E DIAGNOSTIC
J1587+ (YL) S8 J1587+ B
F TOOL
J1587- (GN) S9 J1587- B
G
H
J
J1939
J1939+A (YL) S33 J1939+ (YL)
DIAGNOSTIC
J1939-A (GN) J1939- (GN) INTERFACE
S32
797
SHT. 17
CAT C7-07
Sheet 23
0116707
J1939 DATALINK,AIR
L
1 service manual
798
L
chassis electrical
Electrical Diagrams for Cummins ISB-07 Engines
Description Sheet Drawing Number Wire Colors

Index 1 0117178C BL BLUE
Starting And Charging, Cummins 2 0117347A BK BLACK
Starting And Charging (with Florida circuit breakers) 3 0117348A BN BROWN
Cummins ISB07 Engine 4 0112291C TN TAN
Allison Gen 4 2000 Transmission 5 0112276 WH WHITE
Allison Gen 4 3000 Transmission 6 0112292A YL YELLOW
Dimmer / Backlights 7 0112293 PK PINK
ABS - Bendix (air) 8 0112294 OR ORANGE
ABS - Wabco (hydraulic) 9 0117179A RD RED
AA Multiplex Module 10 0112296C GN GREEN
AB Multiplex Module 11 0112297B PU PURPLE
AC Multiplex Module 12 0112298 GY GRAY
Mirror Heat / Exterior Speaker / Wiper Washer 13 0112299
Hydraulic Brake Boost 14 0112300
Frame Components 15 0112301A Schematic Legend
Crossing Arm 16 0112302 PD PDU PANEL
Instrument Cluster 17 0117181 AC AIR CLEANER BRACKET
Drivers Control Module - Air 18 0112304A IP INSTRUMENT PANEL
Drivers Control Module - Hydraulic 19 0112305A FW FIREWALL
MBC Module 20 0112306A SP SHIFTER PANEL
Body Interface 21 0112307 DC DCM
J1939 Datalink, Hydraulic 22 0117183
J1939 Datalink, Air 23 0112310
Electrical Component Index
799
CUM ISB-07
Heavy Duty Relay Fuse Voltage Stud Shunt Switch Ngr Rocker 3 Wire Twisting
(Non-typical)
2 Wire Twisting Mini Relay Horn Speaker Light Circuit Breaker

with Shield
Multiplex Wire Indexing (Circuit Number Code)

Zone
Connector
Voltage (0 = Ground, 1 = 12 Volts)
Connector Pin Number
Sheet 1
Example: (Zone A, Connector A, 12 Volts, Pin #11) 0117178C
SCHEMATIC, WRG, CUM ISB07, INDEX
L
1 service manual
12V ECM IGNITION

RELAY 30/40A
C9
87A
ELEC PWR (BK)
30
87
S26
PDU
BATTERY PD 12V GROUND
DISCONNECT STUD
SWITCH
(ONLY WITH
OPTION 40142-01)
PD
12V ELEC PWR (BK)

- + ELEC
DIAG PWR (OR)
ELEC PWR A (BK)
MBC GND A (WH)

MBC GND B (WH)
S25 MBC PWR 2 (RD)
PDU DIO PWR (RD) MBC PWR 1 (RD)
GROUND
STUD PD CB1 60A
CURRENT
SENSOR DC PD

- +
PD
BATT IGN PWR (RD)
A B C D
MAIN BODY &
STARTER FUSE
200A
FRAME COPPER BUSBAR STARTER PWR (RD)
AMMETER SIG (RD)
GND
PD
SEN GND (WH)
SEN IGN (RD)
MAIN BODY 12V

FEED TO SOLENOID
IN BODY ELEC PANEL
DC
800 GND GND
PDU GND C14

30 86
STUD STARTER 12
RELAY PD
70A 87 85
STARTER
MOTOR C704
W
START REL GND (WH)
EX
GND B
STARTER GND
ALTERNATOR
12V
ENGINE GND STUD

(HOT SIDE)
SHUTTER SW PWR (RD)
C704
AA-113C (PK) AA-113C (PK)
T
L
chassis electrical
5A
F19 5A ENG IGN (OR) CUMMINS ISB07
SHT. 4
10A
ECM IGN (PK) SHT. 5/6
5A
SHT. 8/9
PD 10A
12V ECM F22 DASH IGN (PK) IP
5A
F23 BRAKE WARN IGN (OR) HYD BRAKE BOOST
SHT. 14
AA-111 (OR) AA MODULE,
SHT 10
MBC GND A (WH)
MBC GND B (WH)

MBC MODULE
MBC PWR 1 (RH)
DIAG PWR (OR) DIAGNOSTIC, SHT 22/23

10A
SHT.5/6
30A
F16 EECM PWR (RD) CUMMINS ISB07
SHT. 4
10A
F17 MBC PWR (RD) MBC MODULE
SHT. 20
PD 25A
PWR BUS SHT. 9
3A
F13 DPWR (BK) IP
SHT. 17
15A
F10 STOP LGT PWR (RD) AA MODULE
BATT PWR (RD) SHT. 10
30A
F12 PMP MTR BATT (RD) ABS
SHT. 9
PD 40A
12V F7 BRAKE BOOST BATT (RD) HYD BRAKE BOOST
BATTERY BUS SHT. 14
30A
F11 HYD INTLK PWR (RD) DRIVER'S CNTRL MODULE
SHT. 18
F11 INTERLOCK PWR (RD)
SHT. 19
10A
F9 REV SENS + (RD) SEE DIAGRAM,WRG
FEA 2226
3A
F14 D DIAG PWR (BK) DRIVER'S CNTRL MODULE,
SHT 18/19
10A
F8 BRAKE SW PWR (RD) DRIVER'S CNTRL MODULE,
SHT 18/19
AA-114 (RD)
AA MODULE, SHT 10 801
AA-113A (PK) AA-113 (PK) AA MODULE, SHT 10
C13
CUM ISB-07
30 86 20A
12 IGNITION F1 HTD FUEL PWR (PK) FRAME COMPONETS
PD RELAY SHT. 15
87 85 70A 20A
F5 HTD DRAIN PWR (BN) FRAME COMPONETS
SHT. 15
S26 10A
IGN REL GND (WH) F3 AIR DRYER PWR (BL) FRAME COMPONETS
SHT. 15
IGN PWR (RD) PD
12V
IGNITION BUS
10A CUMMINS ISB07
F4 FAN PWR (RD)
SHT. 4
PDU 15A BODY INTERFACE
F6 BODY IGN (OR)
GROUND SHT. 21
STUD
AMMETER SIG (RD)
CUMMINS ISB07 SHT. 4

SHT. 14
SHUTTER GND
CUMMINS ISB07
SHUTTER SW PWR (RD) SHT. 4
Sheet 2
0117347A
STARTING AND CHARGING,CUMMINS
L
1 service manual
12V ECM IGNITION

RELAY 30/40A
C9
87A
ELEC PWR (BK)
30
87
S26
PDU
BATTERY PD 12V GROUND
DISCONNECT STUD
SWITCH
(ONLY WITH
OPTION 40142-01)
PD
12V ELEC PWR (BK)

- + ELEC
DIAG PWR (OR)
ELEC PWR A (BK)
MBC GND A (WH)

MBC GND B (WH)
S25 MBC PWR 2 (RD)
PDU DIO PWR (RD) MBC PWR 1 (RD)
GROUND
STUD PD CB1 60A
CURRENT
SENSOR DC PD
- +
PD
BATT IGN PWR (RD)
A B C D
MAIN BODY &
STARTER FUSE
200A
FRAME COPPER BUSBAR STARTER PWR (RD)
AMMETER SIG (RD)
GND
PD
SEN GND (WH)
SEN IGN (RD)
MAIN BODY 12V

FEED TO SOLENOID
IN BODY ELEC PANEL
DC
GND GND C14 86
802
STARTER 30
12
PDU GND RELAY PD
70A 87 85
STUD
STARTER
MOTOR
START REL GND (WH)
C704
W
EX
GND B
STARTER GND
ALTERNATOR
12V
ENGINE GND STUD

SHUTTER SW PWR (RD)
(HOT SIDE)
C704
AA-113C (PK) AA-113C (PK)
T
L
chassis electrical
5A CUMMINS ISB07
F19 5A ENG IGN (OR)
SHT. 4
10A TRANS
F20 TRANS IGN (OR)
ECM IGN (PK) SHT. 5/6
5A ABS
F21 ABS IGN (OR)
PD SHT. 8/9
12V ECM 10A
CB22 DASH IGN (PK) IP
7.5A
CB23 BRAKE WARN IGN (OR) HYD BRAKE BOOST
SHT. 16
AA-111 (OR) AA MODULE, SHT 10
MBC GND A (WH)
MBC GND B (WH)

MBC MODULE
MBC PWR 1 (RD)
DIAG PWR (OR) DIAGNOSTICS, SHT 22/23

10A TRANS
F15 TRANS BATT (RD)
SHT. 5/6
30A CUMMINS ISB07
F16 EECM PWR (RD)
SHT. 4
10A
CB17 MBC BATT (RD) MBC MODULE
SHT. 20
PD 25A
PWR BUS SHT. 9
7.5A
CB13 DPWR (BK) IP
SHT. 17
15A
CB10 STOP LGT PWR (RD) AA MODULE, SHT 10
BATT PWR (RD)
30A
CB12 PMP MTR BATT (RD) ABS
SHT. 9
PD 40A
12V F7 BRAKE BOOST BATT (RD) HYD BRAKE BOOST
BATTERY BUS SHT. 14
30A
CB11 HYD INTLK PWR (RD) DRIVER'S CNTRL MODULE
SHT. 18
CB11 INTLK PWR (RD)
SHT. 19
10A
CB9 REV SENS + (RD) SEE DIAGRAM,WRG
FEA 2226
3A
CB14 D DIAG PWR (BK) DRIVER'S CNTRL MODULE,
SHT 18/19
10A
CB8 BRAKE SW PWR (RD) DRIVER'S CNTRL MODULE,
SHT 18/19
803
AA-114 (PK) AA MODULE, SHT 10
AA-113A (PK) AA-113 (PK) AA MODULE, SHT 10

30 86 C13 20A
CB1 HTD FUEL PWR (PK) FRAME COMPONETS
CUM ISB-07
12 IGNITION
PD RELAY SHT. 15
87 85 20A
70A CB5 HTD DRAIN PWR (BN) FRAME COMPONETS
SHT. 15
S26 10A
IGN REL GND (WH) CB3 AIR DRYER PWR (BL) FRAME COMPONETS
SHT. 15
IGN PWR (RD) PD
12V
IGNITION BUS
10A CUMMINS ISB07
CB4 FAN PWR (RD)
SHT. 4
PDU 15A BODY INTERFACE
CB6 BODY IGN (OR)
GROUND SHT. 21
STUD
AMMETER SIG (RD) CUMMINS ISB07

SHT. 4
SHT. 14
SHUTTER GND
CUMMINS ISB07
SHUTTER SW PWR (RD) SHT. 4
Sheet 3
0117348A
STARTING AND CHARGING, CUMMINS W/FEA 40142-11
(Florida circuit breakers)
L
1 service manual
EECM POWER START CHARGE SHT. 2/3

ENGINE IGN START CHARGE SHT. 2/3
INSTRUMENT PANEL SHT. 19

MODULE AB SHT. 11
MODULE AC SHT. 12
MODULE AC SHT. 12
MODULE AC SHT. 12
DRIVER'S CONTROL MODULE

SHT. 18/19
DIMMER/BACKLIGHTS SHT. 7 GND 3H GND 3H

DIMMER/BACKLIGHTS SHT. 7 ILLUM K ILLUM K
7 9
2B 3 VGT SW (BL)
1
5B 6
4
8 10
VGT BRAKE
SWITCH
C426 VGT RET SW (WH)
910RESISTOR
.5W 5%
C10
FAN RELAY
4
START CHARGE SHT. 2/3 FAN PWR (RD) 3
5
1 2
J1939 DATALINK SHT. 22/23
804
J1939 DATALINK SHT. 22/23
START/CHARGE SHT. 2/3
250A FUSE
START/CHARGE SHT. 2/3 2 GA (RD)
INTAKE AIR
HEATER SOLENOID
2 1
INTAKE AIR
HEATER
85 86
START/CHARGE SHT. 2/3 SHUTTER SW PWR (RD)

START/CHARGE SHT. 2/3 SHUTTER GND (WH)
SHUTTER PWR (OR) SHUTTER COM (OR)
C807 B A
NC NC
SHUTTER AIR TEMP WATER TEMP
SOLENOID SHUTTER SWITCH SWITCH
L
chassis electrical
C808
ENG GND 1 (WH) 1
ENG GND 2 (WH) 2 ENGINE
POWER
ENGINE BLOCK EECM PWR 1 (RD) 3 CONNECTOR
GROUND S5 EECM PWR 2 (RD) 4
C704 ENGINE CONTROL MODULE (ECM)
EECM PWR (RD) U C800 (ENGINE J1 - 60 PIN CONNECTOR)
5A ENG IGN (OR) V 5A ENG IGN1 (OR) 5A ENG IGN2 (OR) 45 KEYSWITCH
S10
C701
WAIT START (GN) 1 WAIT START (GN) 53 WAIT TO START LAMP
AC-102 (RD) 23 AC-102 (RD) 2 STARTER LOCKOUT
AB-009 (BN) 18 AB-009 (BN) 17 THROTTLE INTERLOCK
VGT BRK SIG 24 VGT BRK SIG (RD) 55 VGT BRAKE LGT
AB-001A 12 HI IDLE (OR) 18 REMOTE PTO ON/OFF SW
THROT PWR 1 (BL) 6 THROT PWR 1 (BL) 27 APS 1 SOURCE

THROT SIG 1 (BN) 8 THROT SIG 1 (BN) 35 APS 1 SENSOR
THROT RET 1 (PK) 7 THROT RET 1 (PK) 28 APS 1 RET
THROT RET SENS (PK) 5 ECM RET SENS-B1 (PK) S9 ECM RET SENS-B (TN) 22 ECM RET (SENSOR)
THROT SIG 2 (BN) 13 THROT SIG 2 (BN) 25 APS 2 SENSOR
SENSOR PWR (BL) 20 SENSOR PWR-C1 (BL) SENSOR PWR-C (BL) 26 SENSOR SUPPLY +5V
S6
SENSOR PWR-C2 (GN)
SENSOR PWR-C3 (GN)
VGT SW (BL) 3 VGT SW (BL) 5 VGT BRAKE SWITCH

REGENERATION SWITCH
REGEN SIG (OR) 20 DIAGNOSTIC/REGEN SW
ECM RET SW-A1 (TN)

ECM RET SW (TN) 4 ECM RET SW-A2 (TN) S7 ECM RET SW-A (TN) 41 ECM RETURN
C821
1 DPF TEMP 1 (RD) 49 DPF TEMPERATURE SENSOR 1 (INLET)
2 DPF TEMP 2 (OR) 40 DPF TEMPERATURE SENSOR 2 (MID)
3 DPF TEMP 3 (YL) 9 DPF TEMPERATURE SENSOR (OUTLET)
TO DPF 6 PRES SENSOR SIG (BL) 34 CST DELTA PRESSURE SENSOR SIG
4 ECM RET TL-D2 (TN)
7 ECM RET SENS-B2 (TN)
5 SENSOR PWR-C3 (GN)
C816
COOLANT A
LEVEL B COOL LVL (PK) 60 COOLANT LEVEL SENSOR
PROBE C ECM RET TL-D1 (WH) S8 ECM RET TL-D (TN) 38 ECM RETURN (SENSOR)
C815
A FAN CL +A (OR)
FAN
CONTROLLER
C FAN CL GND (WH)
C701
FAN CL +A (OR) 25
ECM FAN +(BL) 26 ECM FAN + (BL) 52 FAN CLUTCH OUTPUT
ECM RET GEN (WH) 27 ECM RET GEN-E (WH) 32 ECM RETURN
EJ1939+ (YL) 30 J1939+ (YL) 1 J1939 DIAGNOSTIC +
805
EJ1939- (GN) 31 J1939- (GN) 21 J1939 DIAGNOSTIC -
EJ1587+ (YL) 14 EJ1587+ (YL) 39 J1587 DIAGNOSTIC +
EJ1587- (BL) 15 EJ1587- (BL) 29 J1587 DIAGNOSTIC -
AMMETER SIG (RD) 17
CUM ISB-07
AMMETER SIG (RD)
C802
A
1536 (TN) B IAH OUT (TN) 54 INTAKE AIR HEATER OUTPUT
1208D (WH) C ECM RET GEN-F (WH) 44 ECM RETURN
WIF2 WH 16 GA
WIF RTN YL 16 GA
C823 1 2 C822 1 2
WATER IN FUEL RETURN
WATER IN FUEL RETURN

WATER IN FUEL
WATER IN FUEL
WIF ENGINE WIF FRAME HARNESS

INTERFACE INTERFACE
Sheet 4
0112291C
CUMMINS ISB07 ENGINE
L
1 service manual
PDU
INTERFACE
IP TJ1939, SHT 17 C702
NOT USED B NOT USED
NOT USED D NOT USED
NOT USED E NOT USED
NOT USED G NOT USED
TJ1939+ (YL) H TJ1939+ (YL)
TJ1939- (GN) K TJ1939- (GN)
RESERVED L RESERVED
RESERVED M RESERVED
TELEG GNDA (WH) P 169 (GY)
TRANS BATT START/CHARGE, SHT 2/3 TRANS BAT (RD) R TRANS BAT (PK)
TRANS IGN START/CHARGE, SHT 2/3 TRANS IGN (OR) S TRANS IGN/163 (YL)
IP TJ1587, SHT 17 TJ1587+ (YL) U NOT USED
IP TJ1587, SHT 17 TJ1587- (BL) V NOT USED
X 124 (WH)
TELEC GND (WH)
806 MAIN TRANSMISSION

LSD SS1
LSD SS2
C906
1
2
152 (GN)
133 (YL)
151 (WH)
LSD SS3 3
PS1 4 117 (BL)
ELECTRONIC 5
PS3 6 157 (WH)
GROUND
PS2 7 179 (PK)
SUMP TEMP 8 154 (TN)
SIGNAL RETURN 9 158 (GN)
LSD TCC 10 178 (WH)
PS4 11 177 (GN)
12
13
HSD1 14 111 (OR)
LSD PCS1 15 155 (WH)
HSD2 16 171 (YL)
LSD PCS2 17 136 (OR)
DIGITAL SIGNAL NS 18 138 (OR)
DIGITAL SIGNAL C 20 114 (GY )
DIGITAL SIGNAL B 21 153 (YL)
DIGITAL SIGNAL A 22 173 (BL)
DIGITAL SIGNAL P 23 134 (WH)
L
chassis electrical

B3-015/101 (BL)
1 AUX FUNCTION RANGE INHIBIT
2
3
4
B1-002/105 (OR)
5 3 MPH SIGNAL
6
TJ1939+ (YL)
7 J1939+
TJ1939- (GN)
8 J1939-
109 (GY)
9 GROUND
110 (PK)
10 BATTERY
111 (OR)
11 HSD1
12
13
114 (GY)
14 DIGITAL SIGNAL C
15
16
117 (BL)
17 PS1
18
19
120 (BL)
20 TURBINE SPEED LOW
21
22
23
124 (WH)
24 RANGE INHIBIT LIGHT
25
26
27
28
CHECK TRANS/129 (GN)
29 CHECK TRANS
30
31
32
133 (YL)
33 LSD SS2
134 (WH)
34 DIGITAL SIGNAL
35
136 (OR)
36 LSD PCS2
37
138 (OR)
38 DIGITAL SIGNAL NS
139 (OR)
39 ENGINE SPEED LOW
140 (GN)
40 OUTPUT SPEED LOW
B1-112/141 (TN)
41 NEUTRAL SAFETY
42
43
44
45
46
47
48
49
50
151 (WH)
51 LSD SS3
152 (GN)
52 LSD SS1
153 (YL)
53 DIGITAL SIGNAL B
154 (TN)
54 SUMP TEMP
S1 155 (WH)
55 LSD PCS1
56
157 (WH)
57 PS3
158 (GN)
58 SIGNAL RETURN
159 (TN)
59 ENGINE SPEED HIGH
160 (YL)
60 OUTPUT SPEED HIGH
61
62
TRANS IGN/163 (YL)
63 IGNITION
TRANS TEMP/164 (BL)
64 TRANS TEMP LIGHT
B2-016/165 (TN)
65 REVERSE SIGNAL
66
807
67
68
169 (GY)
69 GROUND
170 (PK)
70 BATTERY
171 (YL)
71 HSD2
72
CUM ISB-07
173 (BL)
73 DIGITAL SIGNAL A
174 (BL)
74 LSD MAIN MOD
75
176 (YL)
76 TRANS ID
177 (GN)
77 PS4
178 (WH)
78 LSD TCC
179 (PK)
79 PS2
180 (OR)
80 TURBINE SPEED HIGH
140 (GN)
139 (OR)
180 (OR)
159 (TN)
160 (YL)
120 (BL)
C905 B A C902 B A C928 B A

ENGINE OUTPUT TURBINE Sheet 5
SPEED SPEED SPEED
SENSOR SENSOR SENSOR
0112276
L
1 service manual
TO CONNECTOR C6
IP, SHT 17
C6 A B
SHIFT SELECTOR C932

1
2
ILLUMINATION 3 ILLUM (BL)
4
GROUND 5 GND (WH)
6
7
J1939+ 8 SJ1939+ (YL)
9
10
DIRECTIONAL SIGNAL 11 134 (YL)
IGNITION 12 TRANS IGN A (OR)
BATTERY POWER 13 TRANS BAT A (RD)
14
TRANS BAT (RD) 15 SJ1939- (GN)
16
ENGINE
COMPARTMENT
INTERFACE
IP TJ1939, SHT 17 C702
B
D
E
G
J1939+ (YL) H J1939+ (YL)
J1939- (GN) K J1939- (GN)
L
M
TELEC GNDA (WH) P 169 (GY)
TRANS BATT START/CHARGE, SHT 2/3 TRANS BAT (RD) R TRANS BAT (RD)
TRANS IGN START/CHARGE, SHT 2/3 TRANS IGN (OR) S TRANS IGN (OR)
IP TJ1587, SHT 17 TJ1587+ (YL) U TJ1587+ (YL)
IP TJ1587, SHT 17 TJ1587- (BL) V TJ1587- (BL)
X
TELEC GND (WH)
808 MAIN TRANSMISSION CONNECTION C906

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

B3-015/101 (BL) 1 AUX FUNCTION RANGE INHIBIT
2
3
4
B1-002/105 (OR) 5 3 MPH SIGNAL
6
TJ1939+ (YL) 7 J1939+
TJ1939- (GN) 8 J1939-
109 (GY) 9 GROUND
110 (RD) 10 BATTERY POWER
111 (OR) 11 HSD1
112 (PK) 12 OIL LEVEL SIGNAL
13
14
15
116 (BL) 16 OIL LEVEL
17
118 (BK) 18 OIL LIFE MONITOR
19
120 (BL) 20 TURBINE SPEED LOW
21
22
23
S3
24
25
S4
26
27
28
CHECK TRANS/129 (GN) 29 CHECK TRANS
30
131 (YL) 31 HSD3
TJ1587+ (YL) 32 J1587+
133 (YL) 33 LSD PCS3
134 (YL) 34 DIRECTIONAL SIGNAL
35
136 (OR) 36 LSD PCS1
137 (WH) 37 LSD TCC
38
139 (OR) 39 ENGINE SPEED LOW
140 (GN) 40 OUTPUT SPEED LOW
B1-112/141 (TN) 41 NEUTRAL SAFETY
42
43
44
45
46
47
48
49
50
151 (WH) 51 LSD SS1
152 (GN) 52 LSD PCS2
53
154 (TN) 54 SUMP TEMP SIGNAL
S1 155 (WH) 55 LSD PCS4
S2
56
57
158 (GN) 58 ANALOG RETURN
159 (TN) 59 ENGINE SPEED HIGH
160 (YL) 60 OUTPUT SPEED HIGH
61
62
163 (OR) 63 IGNITION POWER
TRANS TEMP/164 (BL) 64 TRANS TEMP
B2-016/165 (TN) 65 REVERSE SIGNAL
66
169 (GY)
170 (RD)
67
68
69 GROUND
809
70 BATTERY POWER
171 (YL) 71 HSD2
TJ1587- (BL)
CUM ISB-07
72 J1587-
73
174 (BL) 74 LSD MAIN MOD
75
176 (YL) 76 TRANS JD
177 (GN) 77 DIGITAL SIGNAL
78
79
180 (OR) 80 TURBINE SPEED HIGH
140 (GN)
139 (OR)
159 (TN)
160 (YL)
C905 B A C902 B A
ENGINE OUTPUT Sheet 6
SPEED SPEED
SENSOR SENSOR
0112292A
L
1 service manual
810
L
chassis electrical
ILLUM J (BL)
TO ALL OTHER ILLUM
ILLUM B (BL)
ILLUM H (BL)
ILLUM C (BL)
S12
7 9 7 9 7 9 C12
3 3 3 C
2B 2B 2B AB-106C (BN)
A AB MODULE, SHT 11
1 1 1
6 6 6 D AB-106D (BN)
5B 5B 5B B
4 4 4 F
8 10 8 10 8 10
DIMMER
SWITCH
TYPICAL DASH SWITCH BACKLIGHTING/DIMMER CIRCUITS.
DIMMER POWER AND GROUNDS CONTINUE TO LOOP FROM SWITCH TO SWITCH.
811
CUM ISB-07
Sheet 7
0112293
DIMMER/BACKLIGHTS
L
1 service manual
ABS BAT (RD)

ABS ABS IGN (OR)
POWER/START/CHARG
SHT. 2/3

MOD VALVE MOD VALVE
SENSOR SENSOR S S
H E H E
C511 1 2 C501 1 2 C512 1 2 3 4 C500 1 2 3 4
RF MOD HOLD (GN)
LF MOD COM (GY)

LF MOD EXH (TN)
LF MOD HOLD (BL)

RF SENSOR RTN (BK)
LF SENSOR RTN (BK)
LF SENSOR IN (PU)
RF SENSOR IN (PK)
RF MOD COM (GY)
RF MOD EXH (OR)

ABS GND (WH)

MOD VALVE MOD VALVE
SENSOR SENSOR S S
H E H E
ABS
GROUND
812 C509 1 2 C503 1 2 C510 1 2 3 4 C502 1 2 3 4

RR SENSOR RTN (BK)
LR SENSOR RTN (BK)
RR MOD COM (GY)

LR SENSOR IN (PU)
RR SENSOR IN (PK)
LR MOD COM (GY)
RR MOD HOLD (GN)

RR MOD EXH (OR)
LR MOD EXH (TN)
LR MOD HOLD (BL)
TRACTION C514
CONTROL VALVE
TCV RTN
B
TCV IN
A
L
chassis electrical
STOP LIGHT SIGNAL

ATC SLS (RD) AA MODULE
C513 SHT. 10
AJ1587+ (YL) AJ1587+ (YL) AJ1587+ (YL) I/P
A
AJ1587- (BL) AJ1587- (BL) AJ1587- (BL) AJ1587
B SHT. 17
ABS/ATC LIGHTS
ABS AIR (GN) IP
SHT. 17
ABS GND (WH)
ABS IGN (OR)
ABS AIR (GN)

ABS BAT (RD)
C507
ATC SLS (RD)
AJ1939+ (YL) A AJ1939+

J1939 DATALINK
AJ1939- (GN) B AJ1939- (AIR)
SHT. 23
C504 A B C D E F
ABS LGT (GN)

ABS BATT (RD)
ABS GND (WH)
ABS IGN (OR)
C505
ATC SLS (RD)
1 X1
ABS GND (WH) 1 ABS/ATC GROUND
2 TRAILER ABS WL (NOT CONNCTED)
ABS IGN (OR) 3 IGNITION (5A FUSED)
TCV RTN 4 TCV RTN
TCV IN 5 TCV IN
6 ATC LAMP/ATC ORS (ATC ONLY)
AJ1939-(GN) 7 J1939-LO
AJ1939+(YL) 8 J1939-HI
ATC SLS (RD) 9 SLS (ATC ONLY)
RR SENSOR IN (PK) 10 RIGHT REAR SENSOR +
RR SENSOR RTN (BK) 11 RIGHT REAR SENSOR -
ABS LGT GND (WH) 12 ABS W/L GND
AJ1587- (BL) 13 J1587-B
AJ1587+ (YL) 14 J1587-A
15 WL INTERLOCK (NOT CONNCTED)
ABS BATT (RD) 16 BATTERY (30A FUSED)
17 RETARDER (NOT CONNECTED)
ABS LGT (GN) 18 ABS WL ABS ECU
X2 BENDIX EC-60
C506
LF MOD HOLD (BL) CAB MOUNT
1 LEFT FRONT MOD HOLD
LF MOD EXH (TN) 2 LEFT FRONT MOD EXHAUST
LF MOD COM (GY) 3 LEFT FRONT MOD COMMON
RF MOD HOLD (GN) 4 RIGHT FRONT MOD HOLD
LF SENSOR IN (PU) 5 LEFT FRONT SENSOR (+)
RF MOD COM (GY) 6 RIGHT FRONT MOD COMMON
RF MOD EXH (OR) 7 RIGHT FRONT MOD EXHAUST
LF SENSOR RTN (BK) 8 LEFT FRONT SENSOR (-)
RR MOD COM (GY) 9 RIGHT MOD COMMON
RR MOD HOLD (GN)
813
10 RIGHT MOD HOLD
RF SENSOR IN (PK) 11 RIGHT FRONT SENSOR (+)
LR MOD COMMON (GY) 12 LEFT REAR MOD COMMON
RR MOD EXH (OR) 13 RIGHT REAR MOD EXHAUST
RF SENSOR RTN (BK) 14 RIGHT FRONT SENSOR (-)
CUM ISB-07
LR SENSOR IN (PU) 15 LEFT REAR SENSOR +
LR MOD HOLD (BL) 16 LEFT REAR MOD HOLD
LR MOD EXH (TN) 17 LEFT REAR MOD EXHAUST
LR SENSOR RTN (BK) 18 LEFT REAR SENSOR -
X3 (NOT CONNECTED)
1 ABS ORS
2 DIFF
3 DIFF_CMN
TRACTION 4 NOT USED
C515 B A CONTROL VALVE 5 RESERVED
6 NOT USED
ATC HARNESS 7 ADDITIONAL MOD EXHAUST
ABS HARNESS SEE CHART 0104429 8 RESERVED
9 ADDITIONAL MOD COMMON
10 ADDITIONAL MOD HOLD
11 ADDITIONAL LEFT SENSOR(+)
12 ADDITIONAL RIGHT SENSOR(+)
13 NOT USED
14 ADDITIONAL LEFT SENSOR(-)
15 ADDITIONAL RIGHT SENSOR(-)
Sheet 8
0112294
ABS - BENDIX
L
1 service manual
ABS ECU
16 WAY
CONNECTOR
C513
I/O DIAG SW & I/P ABS LT (TN) ABS LT (TN)
A
SHT 17 MOD PMP BAT (RD) PMP MTR BAT (RD)
B
C
ABS IGN (OR) ABS IGN (OR)
D
J1939 TJ1539- (GN) TJ1939- (GN)
E
TRANSMISSION TJ1939+ (YL) TJ1939+ (YL)
F
SHT 5/6 AJ1587- (BL) J1587- (BL)
G
AJ1587+ (YL) J1587+ (YL)
H
J
K
ABS BAT (RD) ABS BAT (RD)
L
ABS POWER
M
START/CHARGE
N
SHT 2/3 ABS GND (WH) ABS REF GND (WH)
P
AJ1939- (GN) AJ1939- (GN)
R
AJ1939+ (YL) AJ1939+ (YL) S4
S
S3
I/P
J1587
J1939
SHT 17
814
LR SENS GND (BK)
LF SENS GND (BK)
LR SENS IN (BN)
LF SENS IN (BN)
C511 1 2 C509 1 2
LEFT FRONT LEFT REAR

SPEED SENS SPEED SENS
L
chassis electrical
MODULATOR PUMP
31 WAY
CONNECTOR
C521
ABS IGN (OR)
1 +12V IGNITION
2
3
4
5
ABS REF GND (WH)
6 GROUND
7
8
9
10
11
12
13
J1939+ (YL)
14 J1939+
J1939- (GN)
15 J1939-
PMP MTR BAT (RD)
16 PUMP MOTOR PWR
ABS BAT (RD)
17 +12 BATTERY PWR
PMP MTR GND (WH)
18 PUMP MOTOR
SOL VLV GND (WH)
19 SOLENOID VALVE
20
ABS LT (TN)
21 ABS LT
RR SENS IN (BN)
22 RR SENSOR INPUT
LR SENS IN (BN)
23 LR SENSOR INPUT
LF SENS IN (BN)
24 LF SENSOR INPUT
RF SENS IN (BN)
25 RF SENSOR INPUT
J1587- (BL)
26 J1587(-)
RR SENS GND (BK)
27 RR SENSOR GND
LR SENS GND (BK)
28 LR SENSOR GND
LF SENS GND (BK)
29 LF SENSOR GND
RF SENS GND (BK)
30 RF SENSOR GND
J1587+ (YL)
815
31 J1587(+)
CUM ISB-07
RR SENS GND (BK)
RF SENS GND (BK)

RR SENS IN (BN)
RF SENS IN (BN)
PUMP MOTOR SOLENOID

GROUND VALVE
GROUND
C503 1 2 C501 1 2
RIGHT REAR RIGHT FRONT Sheet 9

SPEED SENS SPEED SENS
0117179A
ABS - WABCO
L
1 service manual
BODY INTERFACE, AA-101A (BN)

SHT 21
DRIVERS CONTROL MODULE AA-101B (BN)

SHT 22/23
AA-107 (BL)
START/CHARGE, STOP LGT PWR (RD)

SHT 2/3
INSTRUMENT CLUSTER STOP LGT A (RD)

SHT 17
4
3
BODY INTERFACE, STOP LGT B (RD) 5
SHT 21
AA-109A (RD) 1 2
S31
VGT BRK SIG (RD)
ENGINE
STOP LIGHT
SHT. 4
RELAY
816
C7
- +
7 9
AA-004 (BN)
PARK LGT GND (WH) 2B 3
1
5B 6 AC-006 (OR)
HEAD LGT GND (WH)
4
8 10
- +
HEADLIGHT
SWITCH
C423
L
HARNESS CONN C2
I/O SEQ
PORT #
AA-101 (BN)
1
WIPER MOTOR
2
OUT 1
INTERMITTANT
AA-102 (BN) LOW BEAM HEAD
2
1
OUT 1
LGT (LEFT)
3
2
OUT 2
AA-004 (BN) PARK/TAIL

1
4
IN 7
LGT SWITCH
AA-105 (PK)
2
PARK BRAKE
OUT 3
AA-106 (OR) LOW BEAM HEAD

6
1
OUT 2
LGT (RIGHT)
AA-107 (BL)
2
BACK-UP LIGHT
OUT 4
CV-MBC-2424
1
IN 8
8
AA-109 (RD) STOP LIGHT

2
RELAY
OUT 5
C715
C709
C703
AA-102 (BN) AA-102 (BN) AA-102 (BN)
AA-110 (RD) AA-110 (RD) AA-110 (RD) HIGH BEAM HEAD
A B
1
10
LGT (LEFT)
OUT 3
LEFT
AA-110 (RD) AA-106 (OR)
A B C
HEADLIGHT
AA-112A (PU)
1 2 3 4
AA-111(OR)
2
11
IGNITION
OUT 6
AA-112 (PU) HIGH BEAM HEAD

1
12
LGT (RIGHT)
OUT 4
C718
C706
AA-106 (OR) AA-106 (OR)
AA-112 (PU) AA-113 (PK) IGNITION
2
A B
13
OUT 7
AA-112 (PU) DROP-OUT
RIGHT
A B C
HEADLIGHT
AA-114 (RD)
2
14
STARTER RELAY
OUT 8
chassis electrical
AA-112B (PU)
AA-113 (PK)
AA-105 (PK)
AC-006 (OR)
AA-111 (OR)
AA-114 (RD)
Sheet 10
0112296C
17
SHT 12
AA MULTIPLEX MODULE
SHT 2/3
AC-MODULE,
CLUSTER, SHT
INSTRUMENT
START/CHARGE,
L
817
CUM ISB-07
1 service manual
CV-MBC-2424
LEFT TURN LAMPS
REVERSE SIGNAL
WASHER PUMP
SHIFT INHIBIT
3 MPH SPEED
PARK LIGHTS
INTERLOCK
THROTTLE
HIGH IDLE
NEUTRAL
SWITCH
SIGNAL
SIGNAL
PORT # 3 1 1 1 3 1 1 1 3
1/0 SEQ. OUT 1 OUT 5 IN 1 IN 2 OUT 2 OUT 6 IN 3 IN 4 OUT 3
HARNESS CONN C4 1 2 3 4 5 6 7 8 9
AB-005 (GN)
AB-001 (OR)
AB-106 (BN)
AB-009 (BN)
AB-003 (RD)
AB-107 (RD)
AB-108 (PK)
AB-004 (BL)
AB-102X (YL)
AB-001A (OR)
AC MODULE, SHT 12 F2
10A
AB-001B (OR) FUSE
ENGINE, SHT 4
AB-003 (RD)
AB-004 (BL)
AB-005 (GN)
AB-107 (RD)
AB-009 (BN)
ENGINE, SHT 4
AB-012 (PK)
AB-111B (RD)
AB-111A (RD)
HYDRAULIC BRAKE BOOST, SHT 14
AB-110B (GN)
AB-110D (GN)
AB-106B (BN)
AB-106C (BN)
DIMMER/BACKLIGHTING, SHT 7
818 BODY INTERFACE, SHT 21

AB-102B (YL)
AB-102D (YL)
AB-106A (BN)
AB-102A (YL)
LT DIR GND (WH)
FT LT PK LGT (BN)
FT LT PK LGT (BN)
LT PK GND (WH)
AB-102A (YL)
AB-102B (YL)
GND C (WH)
AB-102 (YL)
C703 14 C703 5
C712 B A C B A C713 E D C C709

AB-106A (TN)
AB-102A (YL)
FT LT PK LGT (TN) S3
DIRECTIONAL DIR/PARK GND C (WH)
LIGHT LIGHT
L
chassis electrical
PARKING BRAKE
WIPER WASHER
SERVICE BRAKE
LAMP SWITCH
LIFT ENABLE
RIGHT TURN
LAMPS
INTERLOCK
ACC HOT
SWITCH
BRAKE
PUMP
HORN
1 1 1 3 1 3 3 3 3
CNETA CNETB VIN GND
OUT 7 IN 5 IN 6 OUT 4 OUT 8 OUT 5 OUT 8 OUT 6 OUT 7
10 11 12 13 14 15 16 17 18 19 20 21 22
AB-015 (WH)
AB-116 (GN)
AB-111 (RD)
AB-021 (RD)
AB-122 (TN)
AB-110X (GN)
AB-012 (PK)
AB-114X (BK)
AB-122 (TN) DRIVER CONTROL MODULE, SHT 18/19

F1 F3
10A 10A
FUSE FUSE AB-021 (RD) BODY INTERFACE, SHT 21
AB-116 (GN) BODY INTERFACE, SHT 21
AB-015A (WH) DRIVER CONTROL MODULE, SHT 18/19
AB-015B (WH) INSTRUMENT CLUSTER, SHT 17
AB-108 (PK) DRIVER CONTROL MODULE, SHT 18/19
C703 9
GND A (WH)
HORN GND (WH)
GND (WH)
AB-114 (BK)
GND B (WH)
GND C (WH)
A B 725
819
CUM ISB-07
HORN
S2
S1
AB-110A (GN)
FT RT PK LGT (BN)
RT DIR GND (WH)

FT RT PK LGT (BN)
RT PK GND (WH)
AB-110A (GN)
AB-110B (GN)
GND B (WH)
AB-110 (GN)
C703 16
C706 C D E C717 A B C A B C716
AB-110A (GN)
FT RT PK LGT (TN)
Sheet 11
GND B (WH) DIR/PARK DIRECTIONAL
LIGHT LIGHT 0112297B
AB MULTIPLEX MODULE
L
1 service manual
HEADLAMP SWITCH
STARTER LOCKOUT
IGNITION SWITCH
START SWITCH
ACCESSORY
HIGH BEAM
HIGH IDLE
SIGNAL
SWITCH
SWITCH
SWITCH
PORT# 2 2 2 2 2 2 2
I/O SEQ IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7
HARNESS CONN C1 1 2 3 4 5 6 7
AC-001 (GN)
AC-102 (RD)
AC-006 (OR)
AC-007 (OR)
AC-005 (PU)
AA-004 (PK)
AC-003 (YL)
AC HI IDLE (GN)
AC-102 (RD)
ENGINE SHT 4
AC-003 (YL)
AC-004 (PK)
AC-005 (PU)
AC-006 (OR)
AC MODULE, SHT 12
AC-007 (OR)
AC-008A (YL)
AC-009A (GN)
AC-010 (GY)
ILLUM D
DIMMER/BACKLIGHTS SHT 8
7 9
3 AC-001A (GN)
HIGH IDLE GND (WH) 2B
820 1
6
5B
4 HIGH IDLE SW
8 10 C425
ILLUM F (BL)
7 9
3 AC-008B (YL)
GND 2B
1
6 AC-009B (GN)
GND
5B
4 HAZARD SW
8 10 C424
ILLUM E (BL)
7 9
3 AC-015 (GN)
GND 2B
1
ABS LT GND 6
5B ABS LT (TN)
4
8 10 I/O DIAGNOSTIC SW
C422
L
chassis electrical
CV-MBC-2424
EXTERIOR DOOR
I/O DIAGNOSTIC
HORN BUTTON
INTERMITTANT
WIPER SWITCH
VANDAL LOCK
RIGHT TURN
SCC ALARM
INTERLOCK
LEFT TURN
FEEDBACK
SWITCH
SWITCH
SWITCH
SIGNAL
2 3 3 3 3 3 3 3 3
N/A N/A
IN 8 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8
8 9 10 11 12 13 14 15 16 17 18
AC-009 (GN)
AC-014 (GN)
AC-015 (GN)
AC-010 (GY)
AC-013 (OR)
AC-016 (TN)
AC-112 (BK)
AC-008 (YL)
AC-011 (BL)
AC-016 (TN)
AC-014 (GN)
AC-013 (OR)
AC-112 (BK)
AC-011 (BL)
ABS LT (TN)
I/P, SHT 17
821
CUM ISB-07
Sheet 12
0112298
AC MULTIPLEX MODULE
L
1 service manual
C714
CRS MR GND (WH)
A
CRS MR HT LT (PU)
B
C
C709 LEFT CROSS

CRS MR HT LT (PU) CRS MR HT LT (PU) MIRROR HEAT
F
CRS MR HT LT(PU)
C719
CRS MR GND (WH)
A
CRS MR HT RT (PU)
B
C
C706 LEFT CROSS

CRS MR HT RT(PU) CRS MR HT RT(PU) MIRROR HEAT
S6 F
CRS MR HT(PU)
C700
C711
G
TO OUT SPKR +(YL) OUT SPKR + OUT SPKR +
J B EXTERIOR
HEATER STEPWELL OUT SPKR -(PU) OUT SPKR - OUT SPKR -
HARNESS K A SPEAKER
N
L
M
WASH MTR PWR(YL) WASH MTR PWR WASH MTR PWR
WASHER MOTOR GROUND A WASHER
WASH MTR GND(WH) WASH MTR GND(WH) WASH MTR GND WASH MTR GND BOTTLE
FRAME COMPONETS B
SHT. 15
C708
2302J(GY)
A
M
1213X(WH)
B
HEATER PUMP
C726 MOTOR
822
Sheet 13
0112299
MIRROR HEAT/EXTERIOR SPEAKER/WIPER WASHER
L
chassis electrical
C703
BRAKE WARNING IGNITION
START/CHARGE BRAKE WARN IGN (OR) BRAKE WARN IGN (OR)
18
SHT. 2/3
C729
BRAKE WARN IGN (OR)
A TO
C703 BRAKE WARN LGT (TN)
S25 B HYDRAULIC BRAKE
BRAKE WARN GND (WH) BRAKE WARN GND (WH) BRAKE WARN GND (WH) BOOST HARNESS
15 C
AB-111 (RD)
D
GROUND PDU
GROUND
STUD
C703
BRAKE WARNING LIGHT
IP BRAKE WARN LGT (TN) BRAKE WARN LGT (TN)
13
SHT. 17
C703
SERVICE BRAKE
AB MODULE, AB-111 (RD) AB-111 (RD)
17
SHT. 11
C818
BRAKE BOOSTER +12V DCM GND (WH) DCM GND (WH) HYD
A BRAKE
START/CHARGE BRAKE BOOST BAT (RD) BRAKE BOOST BAT (RD) B BOOST
SHT. 2/3
823
CUM ISB-07
Sheet 14
0112300
HYDRAULIC BRAKE BOOST, CUMMINS
L
1 service manual
AIR DRYER POWER

START/CHARGE AIR DRYER PWR (BL)
SHT. 2/3
HEATED DRAIN POWER

START/CHARGE HTD DRAIN PWR (BN) S4 GND
SHT. 2/3
GROUND
GND A
HEATED FUEL POWER
START/CHARGE HTD FUEL PWR (PK)
SHT. 2/3
WASHER MOTOR GROUND
WASH MTR GND (WH) MIRROR HEAT
FUEL TANK SIGNAL S5 SHT. 13
FUEL TANK SIG (BK)
IP
SHT. 17
S25 FUEL TANK GND (WH)
PDU WIF 2 (WH) CUMMINS ISB07 ENGINE

GROUND GROUND SHT 4
STUD
WIF RTN (YL) CUMMINS ISB07 ENGINE
C703 6 7 8 10 12
SHT 4
(WH)
(BN)
(BK)
(BL)
(PK)
HTD DRAIN GND (WH)
AIR DRYER GND (WH)

HTD FUEL GND (WH)
HTD DRAIN PWR
FUEL TANK GND
AIR DRYER PWR

HTD FUEL PWR
FUEL TANK SIG
WATER IN FUEL C703

WIF SENSOR (YL)
SENSOR LT 11
SHT. 17
C705 A B C D E F C736 1 2
FUEL TANK GND (WH)
FUEL TANK SIG (BK)
HTD DRAIN GND (WH)

WIF SENSOR (YL)
HTD DRAIN PWR (PU)
824 12V DC (RD)

C726
A
HTD FUEL PWR (PK)
SEN GND (BK) HTD FUEL GND (WH)
B
C710 A B C HTR DRAIN PWR C (PU) S2

HTD DRAIN GND C (WH)
HTR DRAIN PWR B (PU) S1
LT (YL)
HTD DRAIN GND B (WH)
C730 A
HTD DRAIN GND A (WH)
HTD DRAIN PWR A (PU)
FUEL TANK GND (WH)
AIR DRYER GND (WH)

LT (YL)
AIR DRYER PWR (BL)

FUEL TANK SIG (BK)
HTD FUEL GND A

HTD FUEL PWR A
WIF RTN (YL)

WIF 2 (WH)
A B C A B C734 A B C733 A B C727 B A C728 A B C735 A B
WATER IN HEATED HEATER HEATER HEATED AIR RACOR

FUEL FUEL FUEL DRAIN DRAIN DRAIN DRYER SENSOR
SENDER SENSOR FILTER VALVE VALVE VALVE
NOTE: DASHED LINES INDICATE THAT THERE IS AN ADDITIONAL

HARNESS INSTALLED FOR THE WATER IN FUEL OPTION.
Sheet 15
0112301A
FRAME COMPONENTS
L
chassis electrical
C730
CRS ARM MG PWR(OR)

A
CRS ARM GND B(WH) CROSSING ARM
B
CRS ARM CTL B(BL)
C MAGNET
D
CRS ARM GND B(WH)

C700
CRS ARM MG PWR(OR)

A
CRS ARM CTL(BL) S2 CRS ARM CTL B(BL)
TO C
CRS ARM HEAT(PU)
HEATER/STEPWELL D
CRS ARM PWR(BK)
E
HARNESS CRS ARM LGT(YL)
F
CRS ARM GND(WH) CRS ARM GND(WH) S1
P
CRS ARM GND A(WH)

CRS ARM CTL A(BL)
C723
CRS ARM PWR(BK)

A
CRS ARM GND A(WH)
B
CRS ARM CTL A(BL) CROSSING ARM
C
CRS ARM HEAT(PU)
D
C722
CRS ARM LGT(YL)
A
CROSSING ARM
LIGHT
825
CUM ISB-07
Sheet 16
0112302
CROSSING ARM
L
1 service manual
INSTRUMENT CLUSTER
PROGRAM 1 (RD)
13
PROGRAM 2 (RD)
14
D PWR (BK)
1
D IGN (RD)
3
D RETURN (YL)
4
DESC (OR)
5
"A" CONNECTOR C302 DUP (GN)
6
22 WAY CONNECTOR D DOWN (BL)
GREEN 7
AB-110D (GN)
21
DCHASS GND (WH)
2
J1939+ (YL)
15
J1939- (GN)
16
J1587+A (YL)
17
J1587-A (BL)
18
FUEL TANK SIG (BK)

3
AB-102D (YL)
25
AA-105 (PK)
23
AA-112B (PU)
28
F AIR IN (GN) OR A5 IN (GN)
13
"B" CONNECTOR C300 F AIR +5V (OR) OR A5 +5V (OR)
20
30 WAY CONNECTOR R AIR IN (GN)
GREEN 14
R AIR +5V (OR)
28
ILLUM H (BL)
9
24
WIF SENSOR (YL)
10
AMMETER+ (RD)
6
ABS HYD (TN)

3
BRAKE WARN LGT (TN)
5
HYD INTLK AML (YL)
23
STOP LGT A (RD)
8
ABS AIR 1 (TN)
10
WAIT START (GN)
12
HIGH IDLE (OR)
"C" CONNECTOR C301 1
FAA +5V (OR)
30 WAY CONNECTOR 20
BLUE FAA IN (GN)
13
RAA +5V (OR)
21
RAA IN (GN)
826 14
22
24
AB-015B (WH)
CC ON/OFF (GY)
CC SET (BN)
25
CC RESUME (GN)
26
RAA GND (WH)
FAA GND (WH)
RAA +5V (OR)

FAA +5V (OR)
RAA IN (GN)
FAA IN (GN)
C306 A B C C307 A B C
FRONT AIR REAR AIR

TRANSDUCER TRANSDUCER
L
chassis electrical
C303
PROGRAM 1 (RD)
B
PROGRAM 2 (RD) DASH PROGRAM PORT
A
D PWR (BK)
DASH POWER, SHT 2/3
D IGN (RD)
DASH POWER, SHT 2/3
D RETURN (YL)
DESC (OR)
DUP (GN)
D DOWN (BL)
AB-110D (GN)
R/TURN SIGNAL, AB MODULE, SHT 11
J1939+ (YL)
J1939- (GN)
J1587+A (YL)
J1587-A (BL)
FUEL TANK SIG (BK)

FUEL TANK SIGNAL, FRAME COMPONETS, SHT 15
AB-102D (YL)
L/TURN SIGNAL, AB MODULE, SHT 11
AA-105 (PK)
PARK BRAKE SIGNAL, AA MODULE, SHT 10
AA-112B (PU)
HIGH BEAM INPUT, AA MODULE, SHT 10
ILLUM H (BL)
PANEL DIMMER, SHT 7
WIF SENSOR (YL)
WATER IN FUEL, SHT 15
AMMETER SIG (RD)
CURRENT SENSOR, SHT 4
ABS LGT (TN)
DIAGNOSTIC SW. AC MODULE, SHT 12
ABS HYD (TN)
HYD ABS LIGHT, SHT 9
BRAKE WARN LGT (TN)
BRAKE WARNING LIGHT, SHT 14
HYD INTLK AML (YL)
STOP LGT A (RD)
STOPLIGHT, AB MODULE, SHT 10
ABS AIR (TN)
S42 AIR ABS LIGHT, SHT 8
WAIT START (GN)
WAIT TO START LIGHT, SHT 4
HIGH IDLE (OR)
HIGH IDLE INPUT, AB MODULE, SHT 11
ABS LT (TN)
DIAGNOSTIC SW, AC MODULE, SHT 12
AB-015B (WH)
CC ON/OFF (GY)
SHIFT INHIBIT SIGNAL, AB MODULE, SHT 11
CRUISE CONTROL DRIVERS CONTROL MODULE, SHT18/19
827
CC SET (BN)
CC RESUME (GN)
CUM ISB-07
F AIR GND (WH) OR A5 GND (WH)
F AIR +5V ((OR) OR A5 +5V (OR)
F AIR IN (GN) OR A5 IN (GN)
R AIR GND (WH)

R AIR +5V (OR)
R AIR IN (GN)
C304 A B C C305 A B C
FRONT APPLIED REAR APPLIED Sheet 17

AIR TRANSDUCER AIR TRANSDUCER 0117181
INSTRUMENT CLUSTER
L
1 service manual




INTERLOCK POWER, SH 2/3
BRAKE INTERLOCK POWER, SHT 2/3
THROTTLE CUMMINS ISB ENGINE, SHT 4

AA-101B
WIPER + (BK) 86 30
BODY INTERFACE, SHT 21 WIPER
WIPER INT (GN) PARK
BODY INTERFACE, SHT 21 87
RELAY 85 87A
C200
HIGH 2 A
2111 (DK GN) WIPER LOW A (GN)
WINDSHIELD LOW 1 B
828
2115 (YL) WIPER PARK 2 (BL)
WIPER PARK 4 C
MOTOR 1124SS (BK) WIPER +A (BK)
12V 3 D
GND 5 E
AB-122 (TN)
F
WIPER
WASHER M
PUMP
AC MODULE, WIPER WASHER PUMP, SHT 13


L
chassis electrical
DCM HORN AND HAZARD

C5 HORN SIG #2
1 HORN SIGNAL
COLUMN GND (WH)
1 2
2 3 HORN SIGNAL
3
4
CC GND (WH) CC GND AIR BRAKE PARK SWITCH
5
6 A
AC-008A (YL) LH DIR
7 B
AC-009A (GN) RH DIR
8 D PARK BRAKE GROUND
9 C PARK BRAKE SIGNAL
AB-012 (PK) PARK BRAKE SIG
10
CC ON/OFF (GY) EJ159 STOP LIGHT SWITCH #2
11
12 A
CC SET (BN) EJ135
13 B
14 D STOP LIGHT
16
AC-003 (YL) ACC
17
AC-004 (PK) IGN
18
AC-005 (PU) START SW TO BVA PRESSURE SWITCH
19
INTLK FB GND (WH) BVA PRESSURE SW
20
AC-013 (OR) BVA PRESSURE SW BVA SOLENOID
21
AB-015A (WH) BVA GND
22 B BVA GROUND
INTLK PWR (RD) BVA POWER
23 A BVA POWER
24
25 THROTTLE
THROT SIG 1 (BN) THROT SIG 1
26 A
THROT RET 1 (PK) THROT RET 1 THROTTLE
27 B
THROT PWR 1 (BL) THROT PWR 1 SENSOR 1
28 C
SENSOR PWR (GY) SENSOR PWR
29 D
THROT SIG 2 (TN) THROT SIG 2 THROTTLE
30 E SENSOR 2
ECM RET SENS (TN) ECM RET SENS
31 F
STOP LIGHT SWITCH #1
A
B
C STOP LIGHT POWER
START SWITCH D STOP LIGHT
BAT TURN SIGNAL/CC

START 1 COM
IGN 1 2 ON
IGN 2 3 RESUME/COAST
ACC 1 4 SET -
5
6
SET +/ACCEL
829
7
CUM ISB-07
8
9
11 HIGH BEAM SIGNAL
12 LEFT TURN SIGNAL
14 GROUND

C16 WIPER/INST
A 1 +12V SUPPLY
C 3 LOW SPEED WIPER
AC-112 (BK) AC-112 (BK)
AB-108 (PK) AB-108 (PK)
F 6 WASHER MOTOR
G 7
H 8 RETURN
DESC (OR) DESC (OR)
J 9 ESC
DUP (GN) DUP (GN)
K 10 UP
L 11 DOWN
M 12 COM
Sheet 18
0112304A
DRIVERS CONTROL MODULE, AIR
L
1 service manual



HYDRAULIC INTERLOCK ALARM, SHT 17
HYDRAULIC INTERLOCK POWER, SH 2/3
AB MODULE, BRAKE INTERLOCK, SHT 11

AA-101B
86 30
WIPER
PARK
87
RELAY 85 87A
WIPER + (BK)
WIPER INT (GN)
830 BODY INTERFACE, SHT 21
C200
WINDSHIELD HIGH 2 A
2111 (DK GN) WIPER LOW A (GN)
WIPER LOW 1 B
MOTOR 2115 (YL) WIPER PARK 2 (BL)
PARK 4 C
12V 3 D
GND 5 E
AB-122 (TN)
F
WIPER
WASHER M
PUMP


L
chassis electrical
DCM HORN AND HAZARD

C5 HORN SIG #2
1 HORN SIGNAL
COLUMN GND (WH)
1 2
2 3 HORN SIGNAL
3
4
CC GND (WH) CC GND
5
6
AC-008A (YL) LH DIR
7
AC-009A (GN) RH DIR
8 HYDRAULIC PARK BRAKE SWITCH
9 B CHASSIS GROUND
AB-012 (PK) HYD PARK BRAKE SIG
10 A PARK BRAKE SIG
CC ON/OFF (GY) EJ159
11
12
CC SET (BN) EJ135
13 HYDRAULIC PARK LIGHT SWITCH
14 D STOP LIGHT SIGNAL
16
AC-003 (YL) ACC
17
AC-004 (PK) IGN
18
AC-005 (PU) START
19 MICO HYD BRAKE INTERLOCK MODULE
HYD INTLK ALM (YL) ALARM OUT
20 23 DIRECT ALARM OUTPUT
AC-013 (OR) LOCKED OUT
21 15 LOCKED OUTPUT
HYD INTLK PWR (RD) HYD INTLK PWR
22 1 12V BATT
HYD INTLK GND (WH) HYD INTLK GND
23 17 GROUND
AB-015A (WH) HYD INTLK ACT INPUT
24 8 ACTIVATION INPUT
25
THROT SIG 1 (BN) THROT SIG 1
26 A
THROT RET 1 (PK) THROT RET 1 THROTTLE
27 B
THROT PWR 1 (BL) THROT PWR 1 SENSOR 1
28 C
SENSOR PWR (GY) THROT PWR
29 D THROTTLE
THROT SIG 2 (TN) THROT SIG 2
30 E SENSOR 2
ECM RET SENS (TN) ECM RET SENS
31 F
TURN SIGNAL/ICC
1 COM
2 ON
START SWITCH 3 RESUME/COAST
4 SET -
BAT
START
5
6
SET +/ACCEL
831
IGN 1 7
IGN 2 8
CUM ISB-07
ACC 1 9
11 HIGH BEAM SIGNAL
12 LEFT TURN SIGNAL
14 GROUND

C16 WIPER/INST
A 1 +12V SUPPLY
C 3 LOW SPEED WIPER
AC-112 (BK) AC-112 (BK)
AB-108 (PK) AB-108 (PK)
F 6 WASHER MOTOR
G 7
H 8 RETURN
DESC (OR) DESC (OR)
J 9 ESC
DUP (GN) DUP (GN)
K 10 UP
L 11 DOWN
M 12 COM
Sheet 19
0112305A
DRIVERS CONTROL MODULE, HYD
L
1 service manual

SHT 2/3
MBC POWER START/CHARGE, MBC GND A (WH)

SHT 2/3

SHT 2/3
MBC POWER START/CHARGE, C3 1 2 3

MBC BATT (RD)
SHT 2/3
CONN. E
C8
MBC POWER START/CHARGE, MBC GND B (WH) 9 CONN. D CV-MBC-2424
SHT 2/3 10
MBC/DIO
MODULE
Sheet 20
0112306A
MBC MODULE
C11
BODY IGN (OR) BODY IGN (OR)
START/CHARGE, SHT 2/3 A +12V IGNITION
AB-116 (RD) AB-116 (RD)
AB MODULE, SHT 11 B ACCESSORY HOT
C
AC-014 (RD) AC-014 (RD)
SCC OPTION 30195-13,19 ONLY D SCC ALARM
E
F
832 AB MODULE, SHT 11

AA MODULE, SHT 10
AB-106B (BN)
AA-107 (BL)
AB-106B (BN)
AA-107 (BL)
G
H
PARK/TAIL LIGHTS
BACK-UP LIGHTS
AB-110B (GN) AB-110B (GN)
AB MODULE, SHT 11 J RIGHT TURN LAMPS
AB-102B (YL) AB-102B (YL)
AB MODULE, SHT 11 K LEFT TURN LAMPS
L
AC-011 (PK) AC-011 (PK) TO BODY
AC MODULE, SHT 12 M DOOR SWITCH SIGNAL
ILLUM B (BL) ILLUM B (BL)
DIMMER/BACKLIGHTS, SHT 7 N PANEL DIMMER
AB-021 (RD) AB-021 (RD)
AB MODULE, SHT 11 P LIFT ENABLE
R
STOP LGT B (RD) STOP LGT B (RD)
AA MODULE, SHT 10 S STOP LIGHTS
AC-016 (TN) AC-016 (TN)
AC MODULE, SHT 12 T VANDAL LOCK
REV SENS SIG (GN) REV SENS SIG (GN)
SEE REVERSE MOTION SENSOR DIAGRAM U REVERSE SENSOR
BCHASS GND (WH)
V GROUND
WIPER INT (GN) WIPER INT (GN)
DRIVERS CONTROL MODULE, SHT 18/19 W WIPER INTERMITTANT
AA-101 (BN) AA-101 (BN)
AA MODULE, SHT 10 X WIPER MOTOR LOW SPEED
WIPER + (BK) WIPER + (BK)
DRIVERS CONTROL MODULE, SHT 18/19 Y WIPER + 12V
AC HIGH IDLE (GN) AC HIGH IDLE (GN)
AC MODULE, SHT 12 Z AC HIGH IDLE
Sheet 21
0112307
BODY INTERFACE
L
chassis electrical
J1587+A (YL) J1587

INSTRUMENT
SHT. 17
J1587 EJ1587 + (YL)
SHT 4 DIAGNOSTIC
DIAG PWR (RD) POWER
SHT 2/3
J1587 TJ1587 + (YL) S15 DIAG GND (WH)

SHT 5/6
DIAG GND A
DIAG PWR B
J1587 AJ1587 + (YL) DJ1939+ (YL)
AJ1587 - (BL) C
ABS DJ1939- (GN)
SHT 8/9 D 9-PIN
E DIAGNOSTIC
J1587+ (YL) S8 J1587+ B F
J1587- (GN) S9 J1587- B TOOL
G
H
J
J1939 EJ1939+ (YL)

ENGINE EJ1939- (GN)
SHT. 4
S3 C513 J1939
ABS AJ1939+ (YL) J1939+ (YL) AJ1939+ (YL) S34 J1939+A (YL) S33 J1939+ (YL)
F S32 INSTRUMENT
ECU AJ1939- (GN) J1939- (GN) E AJ1939- (GN) S35 J1939-A (GN) J1939- (GN) CLUSTER
SHT 9 S4 SHT. 17
C513
TJ1939+ (YL) S
TJ1939- (GN) R
J1939 TJ1939+ (YL)

TRANS ECU TJ1939- (GN)
SHT. 5/6
Sheet 22
0117183
J1939 DATALINK, HYD
J1587
J1587+A (YL)
INSTRUMENT
J1587 EJ1587 + (YL)
SHT. 17
SHT 4 DIAGNOSTIC
DIAG PWR (RD) POWER
SHT 2/3
833
TJ1587 + (YL) S15 DIAG GND (WH)
J1587
SHT 5/6
CUM ISB-07
AJ1587 + (YL) DIAG GND
J1587 A
AJ1587 - (BL) DIAG PWR
ABS B
SHT 8/9 DJ1939+ (YL)
C
DJ1939- (GN)
D 9-PIN
E DIAGNOSTIC
J1587+ (YL) S8 J1587+ B
F TOOL
J1587- (GN) S9 J1587- B
G
H
J
EJ1939+ (YL)
ENGINE
EJ1939- (GN)
SHT. 4
J1939
TJ1939+ (YL) S36 J1939+B (YL) S34 J1939+A (YL) J1939+A (YL) S33 J1939+ (YL)
TRANS ECU DIAGNOSTIC
TJ1939- (GN) J1939-B (GN) J1939-A (GN) J1939-A (GN) J1939- (GN) INTERFACE
SHT. 5/6 S37 S32
S35 SHT. 17
ABS ECU AJ1939+ (YL)

BENDIX AJ1939- (GN)
SHT. 8 Sheet 23
0112310
J1939 DATALINK, AIR

Chassis Electrical

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Chassis Electrical

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C h a s s i s E l ec t r i c a l

[Warning] Batteries emit an explosive gas. Never smoke while working on

Alternator Performance Test

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

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

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

724 possibility of faulty readings due to spurious emissions.

3. Verify that the voltage output from the alternator is be-

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

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

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

Alternator Cable Tests

1. Clamp the ammeter on the positive cable at least 6

3. Connect the positive lead of the VOM to the positive

4. Start the engine and let it run at about 1700 RPM.

5. Turn on accessories until the ammeter reads 132 amps,

6. Record the voltage reading on the VOM.

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

Check and clean all the connections and the condi-

Re-test the circuit.

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

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

Bosch Alternator Removal

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

2. Chock the wheels in both directions.

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

5. Lift the automatic belt tensioner to remove the drive belt

6. Remove the drive belt.

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

10. Remove the bottom mounting bolts.

12. Remove the alternator.

6. Start the engine and test the alternator output.

Automatic Belt Tensioner

Automatic Tensioner Removal

1. Remove the drive belt in accordance with the instruc-tions above.

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

2. A starter motor can be damaged by heat that is generated by excessive

1. Connect the positive lead of a VOM to the ignition switch

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

4. Connect a remote start switch to the positive battery post.

732 switch is defective.

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

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

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

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

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

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

5. Connect one lead of a carbon pile tester to chassis ground.

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

10. Connect the positive lead of the VOM to chassis ground.

12. Position the ammeter in on the negative battery cable.

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

Final check at solenoid terminals.

2. Disconnect the VOM.

3. Remove the ammeter.

4. Connect the positive lead of the VOM to the positive (bat-

Starter Motor Removal

4. Remove all electrical connections from the starter motor. Be sure to

6. Remove starter motor from flywheel housing.

Starter Motor Installation

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

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

4. Install the positive cable on the battery post.

5. Install the negative cable on the battery post.