circuitos_9200[1]

SERVICE MANUAL

SERVICE MANUAL SECTION 5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS Truck Model: 5000i Start Date: 11/04/2002 Truck Model: 9200i Start Date: 11/04/2002 Truck Model: 9400i Start Date: 11/04/2002 Truck Model: 9900i Start Date: 11/04/2002 s082252a, Formerly CTS-5298 11/01/2002

s082252a Copyright © 11/01/2002 International Truck and Engine Corporation

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

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Table of Contents

1. INSTRUCTIONS AND CHARTS (CHAPTER 1). .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .1 1.1. CIRCUIT IDENTIFICATION CHART, P. 1. .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . .1 1.2. CIRCUIT IDENTIFICATION CHART, P. 2. .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . .2 1.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . ..3 1.4. CIRCUIT DIAGRAM INSTRUCTIONS, P. 4. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . .. . .. . .. . . .. . .. . .. . .. . ..4 1.5. SCHEMATIC SYMBOLS, P. 5.. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . ..5 1.6. RELAY PINOUT, FUNCTION DATA & SEALED RELAY, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 1.7. LAMP BULB CHART, P. 7. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . ..7 2. 12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (CHAPTER 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 2.1. START FEED, P. 1. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . ..8 2.2. ACCESSORY, P. 2. .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . ..9 2.3. BATTERY, B1, P. 3. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . .. . .10 2.4. BATTERY, B2, P. 4. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . ..11 2.5. BATTERY, B2 (CONT.), P. 5. .. .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . ..12 2.6. 3+1 BATTERY SYSTEM (DEEP CYCLE BATTERY – B2 BATTERY), P. 6. . . . . . . . . . . . . . . . . . . . . . . .13 2.7. GROUND ADAPTER COMPOSITE, P. 7. .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . .14 2.8. GROUND STUD COMPOSITE, P. 8.. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . ..15 2.9. GROUND STUD COMPOSITE, P. 9.. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . ..16 2.10. IGNITION, P. 10. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . .17 2.11. PANEL LIGHTS ADAPTER COMPOSITE, P. 11. . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . .18 3. 12 VOLT CHARGING & CRANKING SYSTEM (CHAPTER 3). . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 3.1. W/CAT AND CUMMINS ENGINES, P. 1. . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . .19 3.2. W/OVERCRANK PROTECTION W/CAT AND CUMMINS ENGINES, P. 2. . . . . . . . . . . . . . . . . . . . . . . . .20 3.3. W/I6 HEUI ENGINE, P. 3. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. ..21 3.4. W/OVERCRANK PROTECTION W/I6 HEUI, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 4. ENGINE SYSTEMS (CHAPTER 4). .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. ..23 4.1. CATERPILLAR C10, C12, C15, AND C16 CRUISE CONTROL, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 4.2. CATERPILLAR C10, C12, C15 AND C16 – ENGINE BRAKE, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 4.3. CATERPILLAR C10, C12, C15 AND C16 – ENGINE CONTROLS, P. 3.. . . .. . .. . .. . .. . .. . .. . .. . .. .25 4.4. CUMMINS ISM , ISX — CRUISE CONTROL, P. 4.. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. ..26 4.5. CUMMINS ISM, ISX – ENGINE BRAKE, P. 5. .. . . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . .. . . . .. . .27 4.6. CUMMINS ISM, ISX – ENGINE CONTROLS, P. 6. .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. ..28 4.7. CUMMINS AHD AND ISM – ENGINE CONTROLS, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 4.8. I6 HEUI — CRUISE CONTROL, P. 8. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. .30 4.9. I6 HEUI — ENGINE BRAKE, P. 9. .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . .31 4.10. I6 HEUI — ENGINE CONTROLS, P. 10. . . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . . .. .32 4.11. I6 HEUI — MODULE POWER & GROUND SYSTEM, P. 11. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .33 4.12. I6 HEUI — ACCELERATOR, BAP, AMBIENT AIR TEMP SENSOR SYSTEM, P. 12. . .. . . .. . .. .34 4.13. I6 HEUI — SURGE TANK & EXHAUST BRAKE SOLENOID, P. 13. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. .35 5. FANS (CHAPTER 5). .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. .36 5.1. HORTON AND KYSOR ENGINE FAN WITH CAT C10, C12, C15 AND C16 W/ AND N/ A/C, W/ AND N/ MANUAL FAN OVERRIDE SWITCH, P. 1. .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . ..36

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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS 5.2. HORTON AND KYSOR ENGINE FAN WITH CUMMINS ISM, ISX W/ AND N/ A/C, W/ AND N/ MANUAL FAN OVERRIDE SWITCH, P. 2. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 5.3. HORTON AND KYSOR ENGINE FAN WITH I6 HEUI ENGINES W/SHUTTER, P. 3.. .. . .. . .. .. . .38

6. GAUGES AND SYSTEMS (CHAPTER 6). .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .39 6.1. 4X2 REAR AXLE OIL TEMPERATURE GAUGE, P. 1. . .. . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . .. .39 6.2. 6X4 AXLE FORWARD-REAR AND REAR-REAR TEMPERATURE GAUGE, P. 2. . . . .. . . . .. . . . ..40 6.3. ENGINE OIL PRESSURE GAUGE, P. 3. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . ..41 6.4. ENGINE OIL TEMPERATURE GAUGE, P. 4. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .42 6.5. ENGINE WATER TEMPERATURE GAUGE, P. 5. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .43 6.6. FUEL LEVEL GAUGE, P. 6. . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. .44 6.7. PYROMETER GAUGE, P. 7. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. . .45 6.8. SPEEDOMETER GAUGE — TACHOMETER GAUGE, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 6.9. TRANSMISSION OIL TEMPERATURE GAUGE, P. 9. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .47 6.10. VOLTMETER GAUGE, P. 10.. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .48 6.11. ETHER START, P. 11. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . ..49 6.12. MANIFOLD PRESSURE GAUGE, P. 12. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .50 7. WARNING LIGHTS (CHAPTER 7). . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .51 7.1. AIR SUSPENSION RELEASE WARNING LIGHT, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 7.2. ENGINE OIL PRESSURE WARNING LIGHT, P. 2.. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .52 7.3. ENGINE WATER TEMPERATURE WARNING LIGHT, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 7.4. LOW AIR PRESSURE WARNING LIGHT, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 7.5. LOW FUEL LEVEL WARNING LIGHT, P. 5.. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .. . . . . .. . . . ..55 7.6. POWER DIVIDER LOCK (PDL) WARNING LIGHT AND BUZZER, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . .56 7.7. DIFFERENTIAL LOCK WARN LIGHT — 4X2, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 7.8. DIFFERENTIAL LOCK WARN LIGHT — 6X4, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 8. CAB ACCESSORIES (CHAPTER 8). . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . .. .59 8.1. CIGAR LIGHTER, P. 1. . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . ..59 8.2. CLOCK, P. 2.. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .60 8.3. ELECTRIC WINDOW — RIGHT, P. 3. . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. . . .61 8.4. ELECTRIC WINDOW — RIGHT AND LEFT, P. 4.. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .62 8.5. DEFROSTER FAN(S), P. 5. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . ..63 8.6. ELECTRIC WINDSHIELD WIPERS WITH INTERMITTENT WIPE AND WASH, P. 6. . . . . . . . . . . . .64 8.7. HORN, P. 7. .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..65 8.8. MIRROR LIGHTS AND HEATED MIRRORS, P. 8. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .66 8.9. RIGHT MOTORIZED MIRROR, P. 9.. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .67 8.10. DUAL AXIS MOTORIZED MIRRORS, P. 10. .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . ..68 8.11. POWER SOURCE (CB), P. 11.. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .69 8.12. RADIO-CB, ACCOMMODATION PACKAGE, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 8.13. RADIO-CAB, SPEAKERS, P. 13.. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .71 8.14. OWNER/OPERATOR SPARE SWITCH, P. 14. . .. .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .72 8.15. ELECTRIC LOCK — RIGHT AND LEFT, P. 15. .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .73 8.16. INTERVISION DISPLAY, P. 16.. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. . .. .. .74 8.17. EATON VORAD — COLLISION AVOIDANCE, P. 17. .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..75 8.18. EATON VORAD — COLLISION AVOIDANCE, P. 18. .. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..76 8.19. TEMPERATURE/COMPASS DISPLAY, P. 19. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .77 8.20. ROAD RELAY IV, P. 20.. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .78 8.21. HEATED SEAT — DRIVER, P. 21. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .79 8.22. HEATED SEAT — PASSENGER, P. 22. . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . .. .80 9. CHASSIS ACCESSORIES (CHAPTER 9). . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .. .81 s082252a

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9.1. AIR DRYER, P. 1. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. ..81 9.2. ABS/ATC (BENDIX), P. 2. .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. .82 9.3. ABS/ATC (BENDIX) (CONT.), P. 3. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. ..83 9.4. ABS/ATC (BENDIX) (CONT.), P. 4. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. ..84 9.5. ABS/ATC (WABCO), P. 5. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ..85 9.6. ABS/ATC (WABCO) (CONT.), P. 6. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . .86 9.7. ABS/ATC (WABCO) (CONT.), P. 7. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . .87 9.8. TRAILER CONNECTION — BACK OF SLEEPER MOUNTED W/TRACTOR ABS, P. 8. . . .. . .. .88 9.9. TRAILER CONNECTION W/FOUR WHEEL TRAILER — FRAME MOUNTED, P. 9. .. .. .. . .. .. ..89 9.10. TWO SPEED AXLE WIRING, P. 10.. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. .90 9.11. TRUCK BODY CONNECTION, P. 11. .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . .91 9.12. TRAILER CONNECTION N/SLEEPER — BACK OF CAB MOUNTED, P. 12. . . . . . . .. . . . .. . . .. . .92 9.13. TRAILER CONNECTION W/FOUR WHEEL TRAILER — FRAME MOUNTED W/5000, P. 13. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. ..93 9.14. MERITOR G SERIES TRANSMISSION, P. 14. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . ..94 9.15. EATON AUTOSHIFT TRANSMISSION — CAB WIRING, P. 15. . . .. . . . .. . . . .. . . .. . . . .. . . . .. . . . .. . .95 9.16. EATON AUTOSHIFT TRANSMISSION — TRANSMISSION WIRING, P. 16. . . . . . . . . . . . . . . . . . . . .96 9.17. EATON LIGHTNING TRANSMISSION — TRANSMISSION WIRING, P. 17. . . . .. . . . . . . . . . . . . . . . .97 10. SLEEPER LIGHTING AND ACCESSORIES (CHAPTER 10). . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .98 10.1. AUXILIARY CIRCULATION FAN (LOW ROOF), P. 1. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. ..98 10.2. AUXILIARY CIRCULATION FAN (HIGH ROOF), P. 2. . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . .99 10.3. AUXILIARY CIRCULATION FAN (SKYRISE), P. 3. . . . .. . . . . . . .. . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . .100 10.4. BUNK FLUORESCENT AND READING LIGHTS, P. 4. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . .101 10.5. BUNK SPEAKERS, P. 5. .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. . . .102 10.6. LUGGAGE COMPARTMENT LIGHTS, P. 6. .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .103 10.7. POWER SOURCE, P. 7. .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .104 10.8. REFRIGERATOR WIRING, P. 8.. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. . .. .. .. .. . .. .. .. .. . .. .. .. .105 10.9. TV/VCR WIRING, P. 9. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .106 10.10. OVERHEAD CABINETS, ACCENT LIGHTS, P. 10. .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .107 10.11. OPTIONAL SLEEPER MOUNTED RADIO CONTROLS, P. 11.. . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .108 10.12. SHORE POWER WIRING WITHOUT DC/AC INVERTER, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 10.13. SHORE POWER WIRING WITH DC/AC INVERTER, P. 13. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. . . . . .. .110 11. LIGHT SYSTEMS (CHAPTER 11).. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . .111 11.1. BACK-UP LIGHTS, P. 1.. . .. . . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .111 11.2. CAB AND TRAILER LIGHTS SWITCH AND RELAYS WIRING, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .112 11.3. CAB CLEARANCE AND IDENTIFICATION LIGHTS, P. 3. .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . . .. . ..113 11.4. WORK LIGHT N/SLEEPER, P. 4. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. .. . .. .. .. . .. .. ..114 11.5. CAB DOME, READING AND COURTESY LIGHTS N/SKYRISE, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . .115 11.6. CAB DOME, READING AND COURTESY LIGHTS W/SKYRISE, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . .116 11.7. DAYTIME RUNNING LIGHTS (DRL) — USA, P. 7. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. ..117 11.8. FOGLIGHTS — CAB/FRONT END EFFECTS, P. 8. .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . .118 11.9. HEADLIGHT SWITCH AND DIMMER SWITCH WIRING, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 11.10. HEADLIGHTS, P. 10. . . .. . . .. . . .. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .120 11.11. PANEL LIGHTS, P. 11. . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .121 11.12. PARK/TURN/SIDE MARKER LIGHTS — WITH DRL, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 11.13. SPOTLIGHT, P. 13.. . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . .123 11.14. STOP, TAIL, TURN AND HAZARD SIGNAL LIGHTS WITH FLASHER, P. 14. . . . . . . . . . . . . . . .124 11.15. WORK LIGHT W/SLEEPER, P. 15.. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . .125 12. HEATER AND AIR CONDITIONER (CHAPTER 12).. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . .. . . . .126 12.1. AIR CONDITIONER — CAB, P. 1. . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .126 s082252a

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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS 12.2. 12.3. 12.4. 12.5. 12.6.

HEATER — CAB, P. 2. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. ..127 HEATER — BUNK AUXILIARY BLOWER, P. 3. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128 HEATER — BUNK W/STANDARD TEMPERATURE CONTROL, P. 4. . .. . .. .. . .. .. . .. .. . .. .. . ..129 HEATER — BUNK W/THERMOSTAT TEMPERATURE CONTROL, P. 5. . . . . . . . . . . . . . . . . . . . . . .130 LOWERED HEATER BOX, P. 6. .. .. . .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . ..131

13. CONNECTOR COMPOSITES (CHAPTER 13). . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . .132 13.1. LEFT GAUGE CLUSTER (CONNECTOR 423). . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . .132 13.2. LEFT GAUGE CLUSTER (CONNECTOR 424). . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . . . .. . . . . .. . .133 13.3. LEFT GAUGE CLUSTER — GAUGE INFORMATION.. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .. . ..134 13.4. LEFT GAUGE CLUSTER — TERMINAL INFORMATION.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..135 13.5. LEFT GAUGE CLUSTER — TERMINAL INFORMATION.. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . .. . ..136 13.6. RIGHT GAUGE CLUSTER (CONNECTOR 420). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137 13.7. RIGHT GAUGE CLUSTER — GAUGE INFORMATION. . . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . .138 13.8. RIGHT GAUGE CLUSTER — TERMINAL INFORMATION. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .139 13.9. SPEEDOMETER/TACHOMETER MODULE — TERMINAL INFORMATION. . . . . . . . . . . . . . . . . . .140 13.10. SPEEDOMETER/TACHOMETER MODULE — TERMINAL INFORMATION. . . . . . . . . . . . . . . . . .141 13.11. CONNECTOR COMPOSITES (1), (2), (3).. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. . . .. . .. .142 13.12. CONNECTOR COMPOSITES (4), (9), (11), (15), (20), (27). . . . . .. . . . . .. . . . . .. . . . .. . . . . .. . . . . .. . .143 13.13. CONNECTOR COMPOSITES (40), (41), (42), (43), (48), (65).. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. .144 13.14. CONNECTOR COMPOSITES (66), (71), (72), (76), (77), (94).. . . .. . . . .. . . . .. . . .. . . . .. . . .. . . . .. .145 13.15. CONNECTOR COMPOSITES (100), (100A), (105), (111), (112), (113), (115). . . . . . . . . . . . . . . . .146 13.16. CONNECTOR COMPOSITES (116), (117), (118), (127A), (128). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 13.17. CONNECTOR COMPOSITES (137), (141), (142), (143), (144), (145), (146), (147), (148). . .148 13.18. CONNECTOR COMPOSITES (149), (150), (151), (152), (161), (162). . . . . . . . . . . . . . . . . . . . . . . . . .149 13.19. CONNECTOR COMPOSITES (165), (166), (167), (170), (171), (180). . . . . . . . . . . . . . . . . . . . . . . . . .150 13.20. CONNECTOR COMPOSITE (190). .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . .. . . .. . . .. . . .. . .. . . .. . . .. . .. .151 13.21. CONNECTOR COMPOSITES (196), (199), (200), (201), (209), (211), (214), (216). . . . . . . . . . .152 13.22. CONNECTOR COMPOSITES (217), (218), (220), (221). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 13.23. CONNECTOR COMPOSITES (227), (228), (229). . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. .154 13.24. CONNECTOR COMPOSITES (230), (231), (236), (241). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155 13.25. CONNECTOR COMPOSITES (243), (244), (249), (250), (251).. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . ..156 13.26. CONNECTOR COMPOSITES (252), (260), (267). . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. .157 13.27. CONNECTOR COMPOSITES (268), (273), (275), (278), (282), (289). . . . . . . . . . . . . . . . . . . . . . . . . .158 13.28. CONNECTOR COMPOSITES (290), (291), (292), (293), (294), (296). . . . . . . . . . . . . . . . . . . . . . . . . .159 13.29. CONNECTOR COMPOSITES (298), (299), (311), (312), (313), (315, 316). . . . . . . . . . . . . . . . . . . .160 13.30. CONNECTOR COMPOSITES (316), (318), (320), (321), (322), (323). . . . . . . . . . . . . . . . . . . . . . . . . .161 13.31. CONNECTOR COMPOSITES (325), (345), (350), (351), (352), (353), (354). . . . . . . . . . . . . . . . . .162 13.32. CONNECTOR COMPOSITES (355), (360), (363), (379), (393), (396). . . . . . . . . . . . . . . . . . . . . . . . . .163 13.33. CONNECTOR COMPOSITES (400), (402), (403), (404), (406), (409). . . . . . . . . . . . . . . . . . . . . . . . . .164 13.34. CONNECTOR COMPOSITES (417), (420), (421). . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. .165 13.35. CONNECTOR COMPOSITES (422), (423), (424), (425), (426).. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . ..166 13.36. CONNECTOR COMPOSITES (427), (428), (429), (430). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167 13.37. CONNECTOR COMPOSITES (433), (434), (435). . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. .168 13.38. CONNECTOR COMPOSITES (436), (437), (440), (441), (442).. .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . ..169 13.39. CONNECTOR COMPOSITES (453), (454). .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. ..170 13.40. CONNECTOR COMPOSITES (455), (456), (460), (462). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171 13.41. CONNECTOR COMPOSITES (462), (463). .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. ..172 13.42. CONNECTOR COMPOSITES (463). . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . .173 13.43. CONNECTOR COMPOSITES (464). . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . .174 13.44. CONNECTOR COMPOSITES (464), (465), (466), (468), (470), (1000).. .. .. .. .. .. . .. .. .. .. .. ..175 13.45. CONNECTOR COMPOSITES (474), (480), (481), (482), (483), (489). . . . . . . . . . . . . . . . . . . . . . . . . .176 13.46. CONNECTOR COMPOSITES (491), (492), (494), (495), (497), (498), (499), (501). . . . . . . . . . .177 s082252a

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13.47. CONNECTOR COMPOSITES (502), (503), (504), (506). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178 13.48. CONNECTOR COMPOSITES (509), (511), (512), (513), (514), (515). . . . . . . . . . . . . . . . . . . . . . . . . .179 13.49. CONNECTOR COMPOSITES (517), (520), (521), (522), (523), (524), (525), (526). . . . . . . . . . .180 13.50. CONNECTOR COMPOSITES (528), (529), (530), (531), (560), (562), (574). . . . . . . . . . . . . . . . . .181 13.51. CONNECTOR COMPOSITES (575), (576), (577), (578), (579), (582). . . . . . . . . . . . . . . . . . . . . . . . . .182 13.52. CONNECTOR COMPOSITES (584), (585), (587).. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .183 13.53. CONNECTOR COMPOSITES (592), (592F), (593), (594), (600). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184 13.54. CONNECTOR COMPOSITES (603), (604), (605), (606), (607), (610), (611). . . . . . . . . . . . . . . . . .185 13.55. CONNECTOR COMPOSITES (612), (613), (640), (642), (643), (659). . . . . . . . . . . . . . . . . . . . . . . . . .186 13.56. CONNECTOR COMPOSITES (662), (675), (676), (690). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187 13.57. CONNECTOR COMPOSITES (720), (753), (755), (766), (767), (768). . . . . . . . . . . . . . . . . . . . . . . . . .188 13.58. CONNECTOR COMPOSITES (769), (770), (771), (774), (775), (776), (777), (778), (789). . .189 13.59. CONNECTOR COMPOSITES (791), (823), (851), (854), (884), (885), (887). . . . . . . . . . . . . . . . . .190 13.60. CONNECTOR COMPOSITES (904), (905), (906).. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .191 13.61. CONNECTOR COMPOSITES (907), (909), (912), (913), (914), (915), (916), (918). . . . . . . . . . .192 13.62. CONNECTOR COMPOSITES (922), (923), (925).. . . . .. . . .. . . .. . . . .. . . .. . . . .. . . .. . . .. . . . .. . . .. . . .193 13.63. CONNECTOR COMPOSITES (926), (930), (935), (936), (937). .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .194 13.64. CONNECTOR COMPOSITES (938), (939), (940), (941), (942). .. . .. . .. .. . .. . .. .. . .. . .. .. . .. . .. .195 13.65. CONNECTOR COMPOSITES (955), (956), (962), (963), (992), (993), (994). . . . . . . . . . . . . . . . . .196 13.66. CONNECTOR COMPOSITES (995–999), (1000), (1033), (1034). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197 13.67. CONNECTOR COMPOSITES (1039), (1040), (1041), (1042), (1043), (1044). . . . . . . . . . . . . . . . .198 13.68. CONNECTOR COMPOSITES (1045), (1046), (1047), (1048). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199 13.69. CONNECTOR COMPOSITES (1049), (1050), (1051). .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .200 13.70. CONNECTOR COMPOSITES (1053), (1054), (1056), (1057). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201 13.71. CONNECTOR COMPOSITES (1058), (1059), (1060), (1084), (1085), (1086), (1088), (1090F).. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .202 13.72. CONNECTOR COMPOSITES (1090M), (1091), (1093), (1094), (1095). . . . . . . . . . . . . . . . . . . . . . . .203 13.73. CONNECTOR COMPOSITES (1097), (1098), (1099), (1108). .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .204 13.74. CONNECTOR COMPOSITES (1110), (1112), (1113), (1125), (1126). . . . . . . . . . . . . . . . . . . . . . . . . . .205 13.75. CONNECTOR COMPOSITES (1127), (1128), (1130), (1135). . . . .. . . . . . . . . . .. . . . . . . . . .. . . . . . . . . .206 13.76. CONNECTOR COMPOSITES (1137), (1138), (1139), (1140), (1141). . . . . . . . . . . . . . . . . . . . . . . . . . .207 13.77. CONNECTOR COMPOSITES (1155), (1156), (1157), (1158), (1159), (1170). . . . . . . . . . . . . . . . . .208 13.78. CONNECTOR COMPOSITES (1171), (1188), (1189), AND JUNCTION POINTS J7 AND J4.. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .. . . .. . .. . .. . .. . .. . .. . .209 13.79. CONNECTOR COMPOSITES (1190), (1193), (1194), (1195), (1223), (1224), (1225). . . . . . . . .210 13.80. CONNECTOR COMPOSITES (1227), (1229), (1239A, B, C), (1239), (1240) . . . . . . . . . . . . . . . . .211 13.81. CONNECTOR COMPOSITES (1241), (1243), (1244), (1258), (1260), (1261). . . . . . . . . . . . . . . . .212 13.82. CONNECTOR COMPOSITES (1262), (1263), (1264), (1265), (1279). . . . . . . . . . . . . . . . . . . . . . . . . .213 13.83. LEFT BLANK INTENTIONALLY. . . . . .. . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . . .. . . . . .. . . . . .. . . . . .214 13.84. CONNECTOR COMPOSITE (1285). .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .215 13.85. CONNECTOR COMPOSITES (1286), (1287), (1288), (1289), (1290). . . . . . . . . . . . . . . . . . . . . . . . . .216 13.86. CONNECTOR COMPOSITES (1304), (1305), (1306), (1307). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217 13.87. CONNECTOR COMPOSITES (1310), (1311), (1312), (1313), (1315). . . . . . . . . . . . . . . . . . . . . . . . . .218 13.88. CONNECTOR COMPOSITES (1322), (1323), (1324), (1327), (1328). . . . . . . . . . . . . . . . . . . . . . . . . .219 13.89. CONNECTOR COMPOSITES (1331), (1332). .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. . .. .. .. . .. .. .. . .. .. .220 14. FUSES, CIRCUIT BREAKERS, RELAYS (CHAPTER 14). . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . .221 14.1. POWER DISTRIBUTION CENTER, FUSE AND CIRCUIT BREAKER LOCATION, P. 1. . . . . .221 14.2. FUSE AND CIRCUIT BREAKER LOCATION (CONT.), P. 2. . .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. .. .222 14.3. RELAY LOCATION, P. 3.. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . . .. . .. . . .. . .. . . .. . .223 14.4. PRO SLEEPER FUSE INDEX, P. 4. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. . .. .. .. . .. .. . .. .. . .. .. . .. .. . .. .224

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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

1. INSTRUCTIONS AND CHARTS (CHAPTER 1) 1.1. CIRCUIT IDENTIFICATION CHART, P. 1 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 1

NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

CIRCUIT

CIRCUIT

DESCRIPTION - COLOR

NUMBER

1

GENERATOR - FIELD - LIGHT BLUE

37

2

GENERATOR - CHARGE - RED

38

39

AIR DRYER - GRAY

4

40

LOW AIR PRESSURE WARNING - GRAY

5

41

42

FRONT AXLE - GRAY

43

POWER DIVIDER LOCK (PDL) - GRAY

8

44

PARK BRAKE WARNING - GRAY

9

45

ANTI-THEFT WARNING - LIGHT GREEN

10

46

POWER TAKE-OFF WARNING - GRAY

7

ALTERNATOR - RESISTANCE - RED

11

GROUND - WHITE

47

SPEEDOMETER - GRAY

12

ACCESSORY FEED - LIGHT BLUE

48

TACHOMETER - GRAY

13

IGNITION FEED - PINK

49

DIFFERENTIAL LOCK - GRAY

14

BATTERY FEED - RED

50

LIGHT SWITCH FEED - YELLOW

15

KEY SWITCH FEED - RED

16

51

DIMMER SWITCH - YELLOW

52

HEADLIGHT - HIGH BEAM - YELLOW

17

STARTER CONTROL - PINK

53

HEADLIGHT - LOW BEAM - YELLOW

18

GLOW PLUG/PRE-HEATER - PINK

54

PARKING/MARKER LIGHTS - BROWN

19

ENGINE SHUT-OFF - GRAY

55

TURN SIGNAL - ORANGE

56

TURN SIGNAL LIGHTS - LEFT - ORANGE

20

21

ETHER START - TAN

22

57

TURN SIGNAL LIGHTS - RIGHT - ORANGE

58

CLEARANCE AND IDENTIFICATION LIGHTS - BROWN

23

ENGINE COOLING - TAN

59

24

ENGINE BRAKE GRAY

60

25

PYROMETER - TAN

61

26

AMMETER - TAN

62

PANEL LIGHTS - DARK BLUE

27

VOLTMETER - TAN

63

COURTESY AND DOME LIGHTS - DARK BLUE

28

INSTRUMENT FEED - TAN

64

AUXILIARY LIGHTS - YELLOW

29

ENGINE WATER TEMPERATURE - TAN

65

5TH WHEEL/WORK LIGHT - ORANGE

30

ENGINE OIL TEMPERATURE - TAN

66

DAYTIME RUNNING LIGHTS - YELLOW

31

TRANSMISSION OIL TEMPERATURE - TAN

67

32

AXLE OIL TEMPERATURE - TAN

68

TAIL LIGHTS - BROWN

33

ENGINE OIL LEVEL - TAN

69

LICENSE PLATE LIGHT - BROWN

34

WATER LEVEL - TAN

70

STOP LIGHTS - ORANGE

35

ENGINE OIL PRESSURE - TAN

71

BACK-UP LIGHTS - ORANGE

72

TRAILER AUXILIARY - ORANGE

36

DATE

FUEL PUMP - TAN

3

6

CHK

DESCRIPTION - COLOR

NUMBER

FUEL LEVEL - TAN

CHANGE

REV

REFERENCE

DRAWN

RROEPKE RELEASE NO.

P52600M

HAZZARD LIGHTS - ORANGE

AIR SUSPENSION - GRAY

NAME

INSTRUCTIONS AND CHARTS FOR ALL MODELS DATE

29JUL98

Figure 1 Circuit Identification Chart, page 1

s082252a

PART NO.

SHEET

AE08-52011

1

1

2

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

1.2. CIRCUIT IDENTIFICATION CHART, P. 2

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM

CHAPTER 1

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CIRCUIT NUMBER

CIRCUIT NUMBER

DESCRIPTION - COLOR

COLLISION AVOIDANCE SYSTEM - LIGHT BLUE

73 74

DESCRIPTION - COLOR

87

WINDSHIELD WASHER - GRAY

88

CLOCK/HOURMETER - LIGHT GREEN

75

HEATER BLOWER MOTOR - LIGHT GREEN

89

76

AUXILIARY FAN - LIGHT GREEN

90

HYDRAULIC BRAKE PUMP - GRAY

77

AIR CONDITIONER - LIGHT GREEN

91

INTERCOMMUNICATIONS - VIOLET

78

MIRRORS - HEATED * MOTORIZED - LIGHT GREEN

92

TRANSMISSION (ELECTRONIC) - TAN

79

SEAT BELTS - LIGHT GREEN

93

AXLE SHIFT CONTROL - TAN

94

ANTILOCK BRAKES - GRAY

80 81

POWER DOOR LOCKS - LIGHT GREEN

95

EXHAUST EMISSION - TAN

82

WINDSHIELD WIPERS - GRAY

96

SNOW PLOW LIGHTS - YELLOW

83

POWER WINDOW - LIGHT GREEN

97

CRUISE CONTROL AND ELECTRONIC ENGINE - VIOLET

84

CIGAR LIGHTER - LIGHT GREEN

98

DATA LINK AND DIAGNOSTICS - BLACK

85

HORN - ELECTRIC - GRAY

99

THROTTLE POSITION SENSOR - VIOLET

86

RADIO - ENTERTAINMENT - LIGHT GREEN

*

NOTE: NOT ALL CIRCUITS MAY BE USED. COLORS ABOVE ARE NEW STD COLORS FOR MAJOR HARNESSES.

CHK

JPM JKP

DATE

10DEC01 4MAR02

Figure 2

CHANGE

GSC2 ADDED CIR 73 DESC ADDED SEAT BELTS.

REV

REFERENCE

A

P53583S

B

55093F

DRAWN

RROEPKE RELEASE NO.

P52600M

NAME

INSTRUCTIONS AND CHARTS FOR ALL MODELS PART NO.

DATE

29JUL98

AE08-52011

Circuit Identification Chart, page 2

s082252a

SHEET

02

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

1.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3 CHAPTER 1 INSTRUCTIONS

A

- SWITCH AND RELAY POSITIONS AS

B

- MULTIPLE CONNECTORS ARE

SHOWN ON CIRCUIT DIAGRAMS INDICATE NORMAL POSITION WITH

DISPLAYED ON SCHEMATIC AS SHOWN. REFER TO CONNECTOR

IGNITION OFF UNLESS OTHERWISE NOTED.

COMPOSITE WITH APPLICABLE NUMBER FOR MORE COMPLETE INFORMATION.

SWITCH-MANUAL

MAGNETIC SWITCH

12

86

30

87 A

12

AND/OR

87

85

INDICATES

SINGLE IN-LINE CONNECTORS DISPLAYED AS SHOWN WITHOUT

CASE GROUND

CONNECTOR NUMBER.

RELAY-SUPPRESSED

C

- PHANTOM LINES INDICATE PRINTED CIRCUITS OR BUSSED CIRCUITS. THESE CIRCUITS EXIST IN THE INSTRUMENT CLUSTERS AND FUSE/CIRCUIT BREAKER CONNECTORS. IGN (24) INDICATES BASIC FEED WIRE CIRCUIT IDENTIFICATION

CIRCUIT WIRE GAUGE & 13

16PK

NUMBER BUSS IN FUSE

COLOR

CIRCUIT BREAKER

PRINTED

LOCATION IN

CONNECTOR

CIRCUIT

FUSE/CIRCUIT

IN

BREAKER

INSTRUMENT CLUSTER

CONNECTOR

F1 A

B

VOLTMETER

20A

FUSE RATING

D

- MULTIPLE CIRCUIT NUMBERS ON A LINE INDICATE ONE WIRE DISTRIBUTING CURRENT TO TWO CIRCUITS.

60

55A/60

16OR

55

16OR

16OR

55A 16OR

FLASHER

E

- SWITCHES , RELAYS & COMPONENTS INDICATE EXTERNAL WIRE CONNECTIONS AND/OR INTERNAL CONNECTIONS OR CONTACTS. WINDOW SWITCH

BUSSED 83-E

WIRE

16LTGN

CONTACT

CONNECTION

12B 14LTBL

83-C

83-GB

16LTGN

16WH

INTERNAL

ETHER

CONTACT

SWITCH

WIRE CONNECTION

UP

DOWN

F18

F19

16BN

INTERNAL

20A

CONTACT

16RD 78 83-F 16LTGN

83-H 16LTGN

75A

16LTGN

PIG-TAIL

14LTGN

RROEPKE

INSTRUCTIONS AND CHARTS FOR ALL MODELS

P52600M

29JUL98

Figure 3 Circuit Diagram Instructions, page 3

s082252a

AE08-52011

3

3

4

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

1.4. CIRCUIT DIAGRAM INSTRUCTIONS, P. 4 CHAPTER 1 INSTRUCTIONS

F - JUNCTIONS ARE USED TO IDENTIFY MULTIPLE CONNECTIONS WITH A COMMON FEED OR GROUND. THE JUNCTION MAY BE A STUD OR A CONNECTOR WITH ALL CIRCUITS CONNECTED INTERNALLY BY BUS BAR.

A

B

C

D

E

F

G

H

J

K J6

STUD OR

GROUND JUNCTION

BUS ADAPTER

ADAPTER

THIS VEHICLE USES BUSSED CONNECTORS AND ARE REFERRED TO AS ADAPTERS GROUND, FEED, IGNITION, ACCESSORY OR BATTERY.

G

- CIRCUIT 11 DENOTES ANY COMMON GROUND, (MORE THAN ONE CIRCUIT). ANY DEDICATE GROUND CIRCUIT IS IDENTIFIED WITH THAT PARTICULAR SYSTEM CIRCUIT NUMBER. (E.G CIRCUIT 97 CRUISE CONTROL, IS IDENTIFIED PER EXAMPLE). NOTE: FOR CIRCUIT DESCRIPTION OTHER THAN GROUNDS, NEITHER THE LETTER G OR THE COLOR WHITE WILL BE USED.

GROUND CIRCUITS ARE DESCRIBED THUS: 11-G

97-G

11-GA

97-GA

11-GB

97-GB SUFFIX

SUFFIX

G IS NOT A SUFFIX BUT

G IS NOT A SUFFIX BUT

INDICATES A GROUND CIRCUIT

INDICATES A GROUND CIRCUIT

H

COMMON GROUND

DEDICATED GROUND

CIRCUIT NUMBER

CIRCUIT NUMBER

- ABBREVIATIONS: COLOR,NOUN AND ENGINE COLOR ABBREVIATION

NOUN ABBREVIATION A

AQ - AQUA BK - BLACK

LT GN - LIGHT GREEN OR - ORANGE

BL - BLUE

PK - PINK

BN - BROWN

PL - PURPLE

DK GN - DARK GREEN

RD - RED

GD - GOLD

SIL - SILVER

GY - GRAY GN - GREEN LT BL - LIGHT BLUE

TN - TAN VT - VIOLET WH - WHITE YL - YELLOW

G ACCESSORY

GROUND

ACC

GND

AC - AIR CONDITIONER

I

AUX - AUXILIARY

IGN

AWG - AMERICAN WIRE GAUGE

IND - INDICATOR

B

L - LEFT

IGNITION

BATTERY BAT

LT - LIGHT

CONN - CONNECTION OR CONNECTOR

N/ - NOT WITH

DRL - DAYTIME RUNNING LIGHTS

OPT - OPTIONAL

ENG - ENGINE

R - RIGHT

FL - FUSIBLE LINK

S - START OR SENDER

FWD - FORWARD

THERMO - THERMOSTAT

GA - GAUGE

W/ - WITH W/O - WITHOUT

Figure 4

RROEPKE

INSTRUCTIONS AND CHARTS FOR ALL MODELS

P52600M

29JUL98

Circuit Diagram Instructions, page 4

s082252a

AE08-52011

4

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

1.5. SCHEMATIC SYMBOLS, P. 5 CHAPTER 1 SCHEMATIC SYMBOL CHART

DESCRIPTION

SYMBOL

DESCRIPTION

SYMBOL

MALE/FEMALE IN-LINE CONNECTION ALARM-ELECTRONIC FEMALE TERMINAL

MALE TERMINAL

SOLENOID-GENERAL USAGE

GROUND

FUSE / CIRCUIT BREAKER

TYPE 1 TYPE 2 OR 3

A

A CIRCUIT BREAKER MOTOR-ELECTRIC

B

B

DIODE

CIGAR LIGHTER LIGHT EMITTING DIODE (LED)

FUSIBLE LINK

RESISTOR HORN

SWITCH CONTACT, NORMALLY OPEN

SWITCH CONTACT, NORMALLY CLOSED

JUNCTION POINT SPEAKER-SOUND SYSTEM

SPLICE

SWITCH-PUSH BUTTON

FLASHER-TURN SIGNAL,HAZARD

SWITCH-PRESSURE

SWITCH-MANUAL/MECHANICAL

MAGNETIC SWITCH

SWITCH-WITH LIGHT

LIGHT-SINGLE FILAMENT

LIGHT-DOUBLE FILAMENT

86

30

RELAY-SUPPRESSED 87 A

87

85

SENDER-OIL,WATER,FUEL,TEMPERATURE

ACCELERATOR POSITION SENSOR

Figure 5

RROEPKE

INSTRUCTIONS AND CHARTS FOR ALL MODELS

P52600M

29JUL98

Schematic Symbols

s082252a

AE08-52011

5

5

6

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

1.6. RELAY PINOUT, FUNCTION DATA & SEALED RELAY, P. 6 CHAPTER 1 RELAY PINOUT AND FUNCTION DATA SEALED MINIATURE RELAY DATA

DATA RELAY AND FUNCTION DATA

TYPICAL RELAY(INSERTION END)

RELAY SCHEMATIC 1

5

ENERGIZING COIL

86

30

86

87 87

A 3

4

NORMALLY OPEN

87

30

85

CONTACT

COMMON

2

CONTACT

87A

NORMALLY CLOSED CONTACT

85 ENERGIZING COIL

RELAY INSERTION END

CABLE INSERTION END

85 A/2 C/4

A

E/1

C

E

87 D

D/3 30

87A

B/5

B 86

FUSEBLOCK SOCKET

FUSEBLOCK SOCKET

CONNECTOR SOCKET

CONNECTOR SOCKET

SEALED MINIATURE RELAY DATA RELAY SCHEMATIC

86

30

COMMON

ENERGIZING COIL

30

86

CONTACT 87

NORMALLY OPEN

87

A

85

COIL

85

NORMALLY CLOSED

87A

87

FUNCTION

ENERGIZING COIL

COIL

WHEN 12V IS APPLIED TO THE RELAY COIL,THE SWITCH WIPER IS PULLED FROM THE NORMALLY CLOSED POSITION TO THE NORMALLY OPEN POSITION.

TYPICAL RELAY (INSERTION END)

NOTE: THE RELAY IS PRINTED WITH

30

86 86

30

THE NUMBERS 85,86,87,87A AND 30. THE CONNECTOR BODY IS PRINTED WITH 85,86,87,87A AND 30.

85

87A

87

87

87A

85

FUSEBLOCK SOCKET

FUSEBLOCK SOCKET CONNECTOR SOCKET

CONNECTOR SOCKET

CABLE INSERTION END

RELAY INSERTION END

RROEPKE

INSTRUCTIONS AND CHARTS FOR ALL MODELS

P52600M

29JUL98

Figure 6 Relay Pinout, Function Data & Sealed Relay

s082252a

AE08-52011

6

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

1.7. LAMP BULB CHART, P. 7

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 1

LAMP BULB CHART

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

BULB APPLICATION

WATTS OR CANDLEPOWER

TRADE NUMBER

AIR RESTRICTION GAUGE..............................

2 CANDLEPOWER..........................

57

BACK-UP LIGHTS.....................................

32 CANDLEPOWER.........................

1156

CIGAR LIGHTER......................................

1 CANDLEPOWER..........................

CLOCK - ANALOG.....................................

2 WATTS............................

CLEARANCE/IDENTIFICATION LIGHTS - SMALL............

2 CANDLEPOWER..........................

CLEARANCE/IDENTIFICATION LIGHTS - LARGE............

4 CANDLEPOWER..........................

904

COURTESY LIGHT.....................................

21 CANDLEPOWER.........................

1142

1455 VDO-600 802 194

DOME LIGHT.........................................

21 CANDLEPOWER.........................

1142

EXTERIOR MIRROR LIGHT..............................

2 CANDLEPOWER..........................

1895

FOG LIGHT..........................................

100 WATTS..............................

4921-1

32/3 CANDLEPOWER.......................

3157

65/35 WATTS............................

6053

FRONT TURN SIGNAL 9200/9400/9900..................................... HEADLIGHTS 9200/9400/9900 INCANDESCENT HIGH/LOW BEAMS.............................. HALOGEN (OPTIONAL) 65/35 WATTS............................

H5054

HEATER AND AIR CONDITIONER CONTROLS................

HIGH/LOW BEAM...............................

3 CANDLEPOWER..........................

168

HIGH BEAM INDICATOR...............................

0.5 CANDLEPOWER........................

37

ILLUMINATION LIGHT.............................

1 CANDLEPOWER..........................

161

WARNING LIGHT.................................

0.5 CANDLEPOWER........................

37

READING LIGHT......................................

15 CANDLEPOWER.........................

1003

SIDE TURN SIGNAL - 9200/9400/9900..................

32/3 CANDLEPOWER.......................

3157

SPEEDOMETER.......................................

1 CANDLEPOWER..........................

161

SPOTLIGHT..........................................

30 WATTS...............................

4405

STOP-TAIL-TURN SIGNAL..............................

32/3 CANDLEPOWER.......................

1157

TACHOMETER.........................................

1 CANDLEPOWER..........................

161

TURN SIGNAL INDICATOR.............................

0.5 CANDLEPOWER........................

37

WORK LIGHT.........................................

35 WATTS...............................

4411

INSTRUMENT CLUSTER

SLEEPER

CHK

JKP

DOME LIGHT.........................................

15 WATTS...............................

F15T8-CW

LUGGAGE COMPARTMENT LIGHT..........................

12 CANDLEPOWER.........................

211-2

READING LIGHT......................................

12 CANDLEPOWER.........................

912

OVERHEAD CABINET LIGHT.............................

12 CANDLEPOWER.........................

211-2

TV/VCR & MICROWAVE CABINET LIGHT...................

12 CANDLEPOWER.........................

211-2

DATE

4MAR02

CHANGE

ADDED & EDITED SLPR ITEMS

REV

A

REFERENCE

55093F

DRAWN

RROEPKE RELEASE NO.

P52600M

NAME

INSTRUCTIONS AND CHARTS FOR ALL MODELS PART NO.

DATE

29JUL98

AE08-52011

Figure 7 Lamp Bulb Chart

s082252a

SHEET

07

7

8

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2. 12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (CHAPTER 2) 2.1. START FEED, P. 1 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 2

12V POWER DISTRIBUTION - START FEED

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

B1 BAT

14FB

14C

8RD

10RD

STUD

F7-A

15

12RD

25A

B A

S

A

A I

I

I

I

A

(40) I

S

OFF

OFF

OFF

GND

OFF

44 18GY

S

S

S

FROM DRL PARK BRAKE

KEY SWITCH

44A

SWITCH

17

14PK

16GY

(CH 11,PG 7)

PUSH BUTTON 17

START

14PK

SWITCH SWITCH

START

START

17

W/KEY

BUTTON

14PK

17A

W/PUSH

14PK

(41)

START FEED ADAPTER

17B

14PK

17B

16PK

(509)

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 8

(CH 3,PG 1-5)

START MAGNETIC SWITCH

(2)

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Start Feed

s082252a

PART NO.

SHEET

AE08-52502

1

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2.2. ACCESSORY, P. 2 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 2

12V POWER DISTRIBUTION - ACCESSORY

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

B1 BAT

14FB

14C

8RD

10RD

STUD

15 12RD

F7-A 25A

B A

KEY SWITCH A

A I

I

I

I

A

10RD

I

S

OFF

OFF

OFF

GND

OFF

14AJ

S

S

S

S

(40)

F5-B

16LT GN

16LT GN

(CH 8,PG 13)

12M

12

TO RADIO

86

12LT BL

(426)

12LT BL

15A

D 86

E 86E

TO CB RADIO

12F

86E

16LT GN

12LT BL

16LT GN

(CH 8,PG 12)

12A

14BJ

12AC

10RD

12LT BL

12LT BL

(428)

F6-C ACCESSORY

A1

ADAPTER 87 87

A

ACCESSORY

RELAY

ADAPTER

85

(145)

(499) 12F

16WH

12-GH

12AD

10LT BL

*

12LT BL

86

30

30A

LOCATIONS VARY -

ELECTRIC WIPER INTERMITTENT

12P

* FUSE AND RELAY

RELAY

(CH 8,PG 6)

(CH 8,PG 14)

W/FUSE

ONWER/OPERATOR SPARE SWITCH

(CH 8,PG 3)

RIGHT ELECTRIC WINDOW RELAY

(CH 11,PG 8)

FOG LIGHTS FUSE

12LT BL

(CH 12,PG 1)

12S

12W

CONTROL RELAY

(501)

12LT BL

TO 4C

ADAPTER

12LT BL

A3 ACCESSORY

CHECK INSIDE POWER DISTRIBUTION CENTER FOR ACTUAL LOCATION. CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 9

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Accessory

s082252a

PART NO.

SHEET

AE08-52502

2

9

10

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2.3. BATTERY, B1, P. 3 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 2

12V POWER DISTRIBUTION - BATTERY

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

*

FUSE LOCATIONS VARY CHECK INSIDE POWER DISTRIBUTION CENTER

06BK

FOR ACTUAL LOCATION.

CRANKING

S

B

MOTOR M

SOLENOID

BATTERIES COPPER

STARTER

BUS BAR

MAGNETIC

N/3+1 BAT

SWITCH

FUSIBLE LINKS

FROM

2

ALTERNATOR

04RD

B1 BAT

150A

B2 BAT

STUD

MEGA FUSE

STUD

(CH 3,PG 1-5) 14

14A

14A

02RD

02RD

02RD

F10-A 30A 14CP

94AH

10RD

10GY

TO TRAILER ABS RELAY (CH 9,PG 8,9)

TYPE I ONLY

F4-D 15A FROM STARTER

A

B

MAGNETIC SWITCH

14AL

82K

10RD

16GY

TO ELECTRIC WIPER

(CH 3,PG 1-5)

INTERMITTENT RELAY (CH 8,PG 6)

14A

2RD

F7-A 25A 14C

15

10RD

12RD

TO KEY SWITCH (CH 2,PG 2)

F7-C 15A 14L

57H

10RD

14FB

TO RIGHT TURN RELAY

12OR

(CH 11,PG 14)

8RD

F7-B 15A 56H

TO LEFT TURN RELAY

12OR

B1 BAT

(CH 11,PG 14)

STUD

14AJ

TO A3 ACC ADAPTER RELAY

10RD

8RD

14K

(CH 8,PG 2)

F2-C 30A 14S

14R

TO IGNITION RELAY

12RD

10RD

(CH 2,PG 10)

F2-D 20A 55

TO FLASHER

12OR

(CH 11,PG 14)

F7-D 30A 70E

14F 10RD

TO STOP LIGHT RELAY

10OR

(CH 11,PG 14)

F5-C 15A 14AM

85

10RD

16GY

TO HORN RELAY (CH 8,PG 7)

14V

10RD

14J

88B

16RD

TO RADIO BATTERY

16LT GN

B1 BAT

FEED

ADAPTER

14AN

(497)

10RD

14G

TO ABS RELAY

(CH 8,PG 13)

TO SPEEDOMETER/

18RD

TACHOMETER MODULE

(CH 9,PG 2)

(CH 6,PG 3,5,6,8,10 14BD 14RD

CH 7,PG 2-5

TO RIGHT ELECTRIC WINDOW FUSE

CH 9,PG 10)

(CH 8,PG 3) 14BC 14RD

TO CATERPILLAR RUN RELAY FUSE (CH 4,PG 3)

F9-C 15A 66A

TO DRL MODULE (USA)

14YL

(CH 11,PG 7)

B2 BAT

14BL 14RD

STUD

F9-A 15A

CHK

DATE

14W

14AD

6RD

16RD

CHANGE

REV

REFERENCE

TO AIR DRYER FUSE

39A

((CH 9, PG 1)

16GY

DRAWN

U00EDL2 RELEASE NO.

P50317A

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Figure 10 Battery, B1

s082252a

PART NO.

SHEET

AE08-52502

3

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2.4. BATTERY, B2, P. 4

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 2

12V POWER DISTRIBUTION - BATTERY

F10-A 30A * 14AR 10RD

14AS 10RD A

F8-A 10A

B

TO OWNER/OPERATOR SPARE (CH 8,PG 14) SWITCH W/FUSE

TYPE 1 ONLY

14D 10RD

50A 18YL

TO HEADLIGHT SWITCH (CH 11,PG 9)

F8-B 25A

B2 BATTERY STUD

A

TYPE 1 ONLY

B

51 14YL

TO HEADLIGHT RELAY (CH 11,PG 9)

14AA 14RD

86K 14LT GN

TO POWER SOURCE

F5-D 20A

(CH 8,PG 11)

14BW 6RD

TO DATA LINK

97DL 14VT

(CH 4,PG 3,6,10,14)

F3-C 30A 14B 10RD

68 10BN

TO CAB & TRAILER TAIL RELAY (CH 11,PG 2)

F3-D 10A 50 18YL

14W 6RD

TO HEADLIGHT SWITCH (CH 11,PG 9)

F3-A 20A 14E 10RD

58D 12BN

TO TRAILER MARKER RELAY (CH 11,PG 2)

F3-B 20A 70 12OR

TO STOP LIGHT SWITCH (CH 11,PG 14)

F6-A 20A 14AH 10RD

14M 10RD

XXX

TO OWNER/OPERATOR OPTION

**

XXX

TO OWNER/OPERATOR OPTION

**

F6-B 10A F2-A 15A 14T 10RD

65A 14OR

TO WORK LIGHT (CH 11,PG 15)

84 14LT GN

B2 BATTERY ADAPTER (498)

TO CAB CIGAR LIGHTER (CH 8,PG 1)

F2-B 10A 63 18DK BL

TO DOME & COURTESY LIGHTS (CH 11,PG 5)

14AX 18RD

TO REFRIGERATOR FUSE (CH 10,PG 8)

14Y 14RD

14H 6RD

F1-D 15A 14X 10RD

F1-A 30A

63P 16DK BL

TO SPOTLIGHT & READING (CH 11,PG 5,13) LIGHTS

75 10LT GN

TO HIGH SPEED RELAY (CH 12,PG 2)

F1-B 10A 14Z 10RD

77T 14LT GN

TO A/C CONTROL RELAY

75A 14LT GN

TO HEATER CONTROL RELAY

(CH 12,PG 1)

(CH 12,PG 2)

F1-C 20A

** CHK

*

EXTRA FUSES PROVIDED FOR OWNER/OPERATOR CONNECTION

DATE

CHANGE

SEB//ADDED 14BW

REV

REFERENCE

A

P52739E

DRAWN

U00EDL2 RELEASE NO.

JKP

4MAR02

RMVD 14N, ADDED 14AX.

B

55093F

P50317A

FUSE LOCATIONS VARY CHECK INSIDE POWER DISTRIBUTION CENTER FOR ACTUAL LOCATION.

NAME

5000/9100/9200/9400/9900 PART NO.

DATE

12FEB99

AE08-52502

Figure 11 Battery, B2

s082252a

SHEET

04

11

12

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2.5. BATTERY, B2 (CONT.), P. 5

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 2

12V POWER DISTRIBUTION - BATTERY

*

TO OVERHEAD CABINET LIGHTS

F10-D 30A

(CH 10,PG 10) 14AX 10RD

14AV 10RD

B2 BATTERY STUD

TO AUX CIRCULATION FAN (CH 10,PG 1-3)

TO TV/VCR WIRING

* 14AK 6RD

(CH 10,PG 9)

F10-C 20A

14AW 10RD

14AY 12RD

*

TO SLEEPER POWER SOURCE (CH 10,PG 7)

F10-B 15A 75AX 14LT GN

* 14AU 10RD

TO AUX BUNK BLOWER RELAY (CH 12,PG 3)

F10-A 30A 75AW 10LT GN

TO SLEEPER BLOWER RELAYS (CH 12,PG 3)

F8-D 20A 14AP 14RD

63AA 14DK BL

TO SLEEPER LIGHTS/LUGGAGE COMPARTMENT LIGHTS (CH 10,PG 4,6)

*

CHK

JKP

FUSE LOCATIONS VARY CHECK INSIDE POWER DISTRIBUTION CENTER FOR ACTUAL LOCATION.

DATE

4MAR02

CHANGE

ADDED O/H CABINET LTS TO

REV

A

REFERENCE

55093F

DRAWN

U00EDL2 RELEASE NO.

F10-D & AUX CIR FAN PG WAS 1, F8-D WAS CH 10, PG 3,5.

Figure 12

P50317A

NAME

5000/9100/9200/9400/9900 PART NO.

DATE

12FEB99

AE08-52502

Battery, B2 (cont.)

s082252a

SHEET

05

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2.6. 3+1 BATTERY SYSTEM (DEEP CYCLE BATTERY – B2 BATTERY), P. 6 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 2

12V POWER DISTRIBUTION - 3 + 1 BATTERY SYSTEM

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

POWER DISTRIBUTION CENTER

FROM MEGA

14A

B1

2RD

FUSE (CH 3,PG 1-5)

ALTERNATOR

G

B

6RD

B2

6RD

14A

14AB

6RD

GND

10WH

11-GG

14-FL

STUD

16RD

7

14A

10 RUST

7

16RD

7

16RD

R

7V ISOLATED BATTERY

1/0 RD

14WH

GND STUD

1/0 BK

11H

11-G

SWITCH

8WH

MAGNETIC

(RIGHT DASH

+

+

+

4/0BK

+

PANEL)

DEEP CYCLE

TO

BATTERY

CRANKING

1ST

2ND

3RD

-

-

MOTOR SOLENOID

-

(CH 3,PG 1-5)

CHK

DATE

CHANGE

REV

REFERENCE

-

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 13

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

PART NO.

SHEET

AE08-52502

3+1 Battery System (Deep Cycle Battery – B2 Battery)

s082252a

6

13

14

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2.7. GROUND ADAPTER COMPOSITE, P. 7

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 2

12V POWER DISTRIBUTION - GROUND ADAPTER COMPOSITE

TO ENG GND

11-GA 6WH

(CH 3,PG 1-4)

GND STUD

(RIGHT DASH PANEL)

11-G 8WH

G1 GROUND ADAPTER (453)

11-GT 18WH

11-GA 12WH

CRUISE ON/OFF SWITCH

62-GK 18WH

CRUISE SET/RESUME SWITCH

62-GN 18WH

ENG BRAKE ON/OFF

62-GL 18WH

ENG BRAKE SELECT

62-GR 18WH 11-GAE 18WH

11-GX 18WH

11-GC 10WH

DATA LINK 6-WAY

62-GJ 18WH

62-GQ 18WH

G4 GROUND ADAPTER (456) 11-GB 8WH

11-GR 14WH

(CH 4,PG 3,6,10,14) (CH 4,PG 1,4,8) (CH 4,PG 1,4,8) (CH 4,PG 2,5,9) (CH 4,PG 2,5,9) CUMMINS & DET. INC/DEC IDLE DIAG DEIS. ONLY (CH 4,PG 10,14) CUMMINS ONLY

DIAG ON/OFF (CH 4,PG 14)

RIGHT POWER MIRROR (CH 8,PG 8)

13-GCP 14WH

ABS TRAILER RELAY (CH 9,PG 8)

11-GZ 18WH

11-GAD 18WH

LEFT POWER MIRROR (CH 8,PG 8)

RIGHT MOTORIZED MIRROR (CH 8,PG 9)

GND STUD

G3 GROUND ADAPTER (455)

(LEFT DASH PANEL)

11-GD 8WH

11-GAW 14WH

RIGHT WINDOW SWITCH & RELAY

13-GAD 18WH

AIR DRYER RELAY

94-G 16WH 11-GAC 14WH 38-G 18WH 38-GB 18WH

G2 GROUND ADAPTER (454) 11-GI 10WH

(CH 8,PG 3) (CH 9,PG 1)

11-GE 12WH

ABS RELAYS (CH 9,PG 2,5)

FOG LIGHT RELAY & SWITCH (CH 11,PG 8)

DRIVER HEATED SEAT (CH 8,PG 21)

PASSENGER HEATED SEAT (CH 8,PG 22)

11-GBC 12WH

AUXILIARY BUNK BLOWER RELAY & SLEEPER OPTIONS

11-GAV 18WH

CLOCK

(CH 12,PG 3 ; CH 10,PG 6-10)

11-GY 10WH

25-G 18WH

(CH 8,PG 2 CH 11,PG 11)

PYROMETER CONTROL MODULE (CH 6,PG 7)

11-GBD 12WH

SLEEPER OPTIONS (CH 10,PG 1-4)

*NOTE - A GROUND ADAPTER AS REFERRED TO IN THIS MANUAL IS AN INTERNALLY BUSSED CONNECTOR USED TO CONNECT & DISTRIBUTE GROUND CIRCUITS TO VARIOUS POINTS IN THE VEHICLE. CHK

JKP

CHANGE

DATE

4MAR02

REVISED 11-GBC &

REV

A

REFERENCE

55093F

DRAWN

U00EDL2 RELEASE NO.

11-GBD. ADDED 38-G & 38-GB.

P50317A

NAME

5000/9100/9200/9400/9900 PART NO.

DATE

12FEB99

AE08-52502

Figure 14 Ground Adapter Composite

s082252a

SHEET

07

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2.8. GROUND STUD COMPOSITE, P. 8 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 2

GROUND STUD COMPOSITE

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

FUSE BLOCK

11-GG 10WH

ASSY GND

75-G

TO

HEATER CONN #1

10WH

(CH 12,PG 2)

ENG

57-G

GND

RIGHT TURN RELAY

18WH

(CH 11,PG 14)

(CH 3,PG 1-5)

56-G

LEFT TURN RELAY

18WH

(CH 11,PG 14) 70-G

STOP LIGHT RELAY

18WH

(CH 11,PG 14) 58-G

TRAILER TAIL RELAY

18WH

(CH 11,PG 2) 6WH

11-GA

58-GA

TRAILER MARKER RELAY

18WH

GND

(CH 11,PG 2) 77-G

STUD

AIR CONDITIONING RELAY

18WH

(CH 12,PG 1)

(RIGHT

13-GT

DASH

HEATER CONTROL RELAY

18WH

PANEL)

(CH 12,PG 2) 50-GB

11-G

HEADLIGHT RELAY

18WH

8WH

(CH 11,PG 9) 75-GC

MED SPEED RELAY

18WH

(CH 12,PG 2) 75-GB

HIGH SPEED RELAY

18WH

(CH 12,PG 2) 13-GA

IGNITION RELAY

18WH

(CH 2,PG 20)

11-GA 12WH

G1 GND ADAPTER (CH 2,PG 7)

75-GL 18WH

HVAC CONTROL (CH 12,PG 2)

75-GM 18WH

AIR DIST (CH 12,PG 2)

75-GK 18WH

RECIRC (CH 12,PG 2)

14WH

MERITOR G XMSN (CH 9,PG 14)

57-GA 16WH

RIGHT SIDE TURN LIGHT (CH 11,PG 12)

11-GAB

11-GB

16WH

8WH

DOME,READING,CLEARANCE & ID LIGHTS (CH 11,PG 3-6)

38-G 18WH

AIR SUSPENSION RELEASE SWITCH (CH 7,PG 1)

43-G 18WH

PDL SWITCH (CH 7,PG 6)

11-GC 10WH

G4 GND ADAPTER (CH 2,PG 7)

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Figure 15 Ground Stud Composite

s082252a

PART NO.

SHEET

AE08-52502

8

15

16

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2.9. GROUND STUD COMPOSITE, P. 9 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 2

GROUND STUD COMPOSITE

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

62-GAS 11-GE 12WH

18WH 62-GAR

(CH 2,PG 7) 84-G 16WH

16WH 62-GW

(CH 8,PG 1)

18WH

16WH

16WH

11-GS 16WH

16WH

GND

PANEL LGT SWITCH (CH 2,PG 11 ; CH 11,PG 11)

LOW AIR SWITCH 1 11-GP

(CH 7,PG 4) 40-GB

PANEL LGT SWITCH (CH 2,PG 11 ; CH 11,PG 11)

11-GD 40-GA

CAB/TRAILER LGT SWITCH (CH 11,PG 2)

CIGAR LIGHTER

11-GK

8WH

CAB/TRAILER LGT SWITCH (CH 11,PG 2)

G3 GND ADAPTER

12WH

L4 PANEL GND ADAPTER (CH 2,PG 11)

LOW AIR SWITCH 2 (CH 7,PG 4)

STUD

56-GA 16WH

66-GA

LT SIDE TURN LGT (CH 11,PG 12)

(LEFT

14WH

66-G

44-GB

DASH

16WH 11-GY

PANEL)

10WH

10WH

10WH

DRL PARK BRAKE SWITCH

TO G2 GROUND ADAPTER

(CH 11,PG 7)

(CH 2,PG 7) 11-GN

11-GI

DRL MODULE (CH 11,PG 7)

14WH

TO GROUND TERMINAL (B-PILLAR) (CH 9,PG 9 ; CH 12,PG 4,5)

86-GK 14WH

TO AUX POWER (CH 8,PG 11)

62-GB 18WH

RIGHT GAUGE CLUSTER PANEL LIGHTS (CH 11,PG 11)

62-GD 18WH

11-GF

SPEEDO/TACH MODULE PANEL LIGHTS (CH 11,PG 11,14)

10WH

62-GC 18WH

LEFT GAUGE CLUSTER PANEL LIGHTS (CH 11,PG 11)

52-GE 12WH

HEADLIGHTS (CH 11,PG 9)

11-GJ

RIGHT SIDE CLUSTER

18WH

(CH 6,PG 1,2,9) 77-GS

A/C CONTROL RELAY

18WH

(CH 12,PG 1) 82-GB

WASH/WIPE INTERMITTENT SWITCH

16WH

(CH 8,PG 6)

11-GQ 16WH

82-GC

WIPER MOTOR

16WH

(CH 8,PG 6) 11-GM

LEFT SIDE CLUSTER

18WH

(CH 6,PG 4) 11-GL

SPEEDO/TACH MODULE

18WH

(CH 6,PG 3,5,6,8,10 CH 7,PG 2-5 CH 9,PG 10)

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 16

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Ground Stud Composite

s082252a

PART NO.

SHEET

AE08-52502

9

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2.10. IGNITION, P. 10

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

TO BACK-UP LIGHTS

14R 10RD

87 A

30

IGNITION RELAY (462-R1)

F2-C 30A

14K 8RD

(CH 11,PG 1)

14S 12RD

13H 12PK

85

15 12RD

F7-A 25A

86

87

14C 10RD

71 18OR

14FB 8RD

B1 BAT STUD

CHAPTER 2

12V POWER DISTRIBUTION - IGNITION

A

13-GA 18WH

B S A I

I

S

OFF

OFF

OFF

13 12PK

13A 12PK

CHANGE

2 SPEED AXLE SW WAS GOING

B

REFERENCE

55093F

Figure 17

P50317A

(CH 6,PG 11)

ETHER START FUSE

13L 12PK

13X 18PK

PDL BUZZER

(CH 7,PG 6)

(CH 6,PG 7)

13AB 14PK

I1 IGNITION ADAPTER (494)

PYROMETER FUSE

13W 14PK (CH 9,PG 2,6)

ABS IGNITION RELAY

PASSENGER HEATED SEAT

(CH 8,PG 22)

13EF 18PK

13EG 18PK

(CH 8,PG 21)

(CH 9,PG 10)

DRIVER HEATED SEAT

93 14TN

2 SPEED AXLE SWITCH

(CH 12,PG 3)

13AT 18PK

DRAWN

U00EDL2

AUX BUNK BLOWER RELAY

(CH 9,PG 14)

(CH 9,PG 1) 13Y 14PK

AIR DRYER RELAY

ECM

(CH 4,PG 3,7,10,15)

MERITOR G XMSN FUSE REV

RELEASE NO.

TO CH 11, PG 10. ADDED 13EF & 13EG AT (495).

13F 12PK

13AH 14PK

13Z 12PK

13CP 14PK (CH 9,PG 8)

(CH 11,PG 7)

(CH 12,PG 2)

IGN-DRL FEED

HVAC CONTROL FEED

(CH 5,PG 1) (CH 4,PG 3,6,10,14)

28D 18TN

ENGINE FAN

13P 12PK

I2 IGNITION ADAPTER (495)

LEFT GAUGE CLUSTER

28C 18TN (CH 6,PG 1,2,9 CH 7.PG 1,4-8 CH 9,PG 2,5 CH 11,PG 7)

RIGHT GAUGE CLUSTER

(CH 6,PG 3,5,6,8,10 CH 7,PG 2-5 CH 9,PG 10)

28B 18TN

13V 16PK DATE

4MAR02

SPEEDO/TACH CLUSTER

28A 18TN

JKP

(CH 4,PG 3,6,14 CH 6,PG 4 CH 7,PG 2 CH 11,PG 4,15)

LEFT GAUGE CLUSTER CHK

13BN 12PK

(CH 8,PG 8) 13BL 14PK

13BM 16PK

13U 12PK

TO MOTORIZED AND HEATED MIRRORS

ABS TRAILER RELAY

GND

OFF

(CH 12,PG 2)

13B 12PK

F4-A 10A

TO HIGH SPEED RELAY (462-R2)

13J 12PK

A

I

I

A

S I

S

S

KEY SWITCH (40)

F4-C 10A

NAME

5000/9100/9200/9400/9900 PART NO.

DATE

12FEB99

AE08-52502

Ignition

s082252a

SHEET

10

17

18

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

2.11. PANEL LIGHTS ADAPTER COMPOSITE, P. 11

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

62S 16DK BL 62AE 16DK BL

62M 16DK BL

62A 16DK BL

62W 16DK BL

62A 16DK BL

A C

L2 PANEL LTS FEED ADAPTER (504)

L4 PANEL LTS GND ADAPTER (506)

B

11-GS 16WH

F

L1 PANEL LTS FEED ADAPTER (503)

11-GD 8WH

11-GK 16WH

(LEFT DASH PANEL)

GND STUD 11-GF 10WH CHK

JKP

DATE

4MAR02

CHANGE

ADDED CIR 62X & 86-GK

62T 16DK BL

CIGAR LIGHTER LIGHT

62AG 16DK BL

WIPER SWITCH

62D 18DK BL

SPEEDO/TACH MODULE

62C 18DK BL

LEFT SIDE CLUSTER

62B 18DK BL

RIGHT SIDE CLUSTER

62P 16DK BL

HEATER CONTROL PANEL LIGHT

62AR 16DK BL

TRAILER LIGHTS SWITCH

62AS 16DK BL

HEADLIGHT SWITCH

62AP 16DK BL

DOME LIGHT SWITCH

62AB 16DK BL

GAUGE PANEL LIGHT

62AN 16DK BL

FOG LIGHT SWITCH

62AL 16DK BL

RIGHT WINDOW SWITCH

62AQ 16DK BL 62BP 16DK BL 62M 16DK BL

CLOCK (CH 11,PG 11) BUNK CONTROL PNL SWITCH

62AW 16DK BL

RT MOTO MIRRORS SW

62AY 16DK BL

ETHER START SWITCH

62AV 16DK BL

CRUISE/DIAGNOSTIC/ENG BRAKE SWITCHES

62U 16DK BL

SPARE SWITCH W/FUSE

62H 16DK BL

SPARE SWITCH N/FUSE

62X 16DK BL

REFRIGERATOR SWITCH

11-GAL 18WH

SPARE SWITCH W/FUSE

62-GH 18WH

SPARE SWITCH N/FUSE

(CH 11,PG 11) (CH 8,PG 6) (CH 11,PG 11) (CH 11,PG 11) (CH 11,PG 11)

(CH 11,PG 11) (CH 11,PG 2) (CH 11,PG 9)

(CH 11,PG 11) (CH 11,PG 8) (CH 8,PG 3)

(CH 10,PG 3,8,9)

ENGINE FAN OVERRIDE SWITCH (CH 5,PG 3,4)

(CH 8,PG 9) (CH 6,PG 11)

(CH 4,PG 1,2,4-6,8-10,12-14) (CH 8,PG 14) (CH 8,PG 14) (CH 10,PG 6)

(CH 8,PG 14) (CH 8,PG 14)

62-GAB 18WH

GAUGE PANEL LIGHT

62-GAY 18WH

ETHER START SWITCH

(CH 11,PG 11)

(CH 6,PG 11)

11-GT 18WH

CRUISE/DIAGNOSTIC/ENG BRAKE SWITCHES

86-GK 18WH

REFRIGERATOR SWITCH

(CH 4,PG 1,2,4-6,8-10,12-14) 11-GP 12WH

D

62-GW 18WH

PANEL LIGHT SWITCH (425)

62 16DK BL

62W 16DK BL

(CH 11, PG 11)

CHAPTER 2

12V POWER DISTRIBUTION - PANEL LIGHTS ADAPTER COMPOSITE

REV

A

REFERENCE

55093F

(CH 10,PG 6)

62-GAS 18WH

HEADLIGHT SWITCH

62-GAR 16WH

TRAILER LIGHTS SWITCH

(CH 11,PG 9) (CH 11,PG 2)

62-GC 18WH

LEFT SIDE CLUSTER

62-GB 18WH

RIGHT SIDE CLUSTER

62-GD 18WH

SPEEDO/TACH MODULE

DRAWN

U00EDL2 RELEASE NO.

P50317A

(CH 11,PG 11) (CH 11,PG 11) (CH 11,PG 11) NAME

5000/9100/9200/9400/9900 PART NO.

DATE

12FEB99

AE08-52502

Figure 18 Panel Lights Adapter Composite

s082252a

SHEET

11

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

3. 12 VOLT CHARGING & CRANKING SYSTEM (CHAPTER 3) 3.1. W/CAT AND CUMMINS ENGINES, P. 1

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM

CHAPTER 3

CHARGING AND CRANKING (12V) W/CAT AND CUMMINS ENGINES

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

START FEED ADAPTER (509)

14A 02RD

17B 14PK

B1 BATTERY STUD

14 02RD 2 04RD

(2)

150A MEGA FUSE

ALTERNATOR B

BATTERIES

06BK

2-G 04WH

(CH 4,PG 2,7)

14A 02RD

-

06BK

+

+

-

TO ECM POWER CONN W/CAT

01BK

TO ECM POWER CONN

17B 16PK

11-G 12WH

G

14C 12RD

14D 12RD

(CH 4,PG 2)

FRAME GROUND

14 02RD

STARTER MAGNETIC SWITCH

15A

17C

06BK

-

2 04RD

08PK

06BK

-+

14B 12RD

14A 12RD

15A

06BK

06BK

4/0 BK

(2) 12GA, BL FUSIBLE LINKS

+

-

B

S

4/0 BK 4/0 BK

M

4/0 BK

CRANKING MOTOR

2-G 04WH

2/O BK

11-GA 06WH

FROM ECM GROUND W/ISX,ISM

11-GS 02BK 11-GU 12WH

11-G 12WH

DATE

CHANGE

ENGINE GROUND REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 19

FROM SENSOR GROUND SPLICE

FRAME GROUND

(CH 3,PG 2 CH 5,PG 2 CH 6,PG 4,9 CH 12,PG 1)

(CH 4,PG 7)

CAB J4 GROUND CHK

CRANKING MOTOR SOLENOID

NAME

5000/9200/9400/9900 PART NO.

DATE

26JUL01

AE08-54038

W/Cat and Cummins Engines

s082252a

SHEET

01

19

20

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

3.2. W/OVERCRANK PROTECTION W/CAT AND CUMMINS ENGINES, P. 2

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM

CHAPTER 3

12V CRANKING SYSTEM W/OVERCRANK PROTECTION W/CAT AND CUMMINS

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

START FEED ADAPTER (509)

14A 02RD

17B 14PK

B1 BATTERY STUD

(2)

17B 16PK

150A MEGA FUSE

(CH 3,PG 1)

14A 02RD

14 02RD

TO ALTERNATOR

2 04RD

14 02RD

STARTER MAGNETIC SWITCH

17C FL B

S

M

CRANKING MOTOR

CRANKING MOTOR SOLENOID

17D 18PK

12BL

FL

12BL

8PK

17D 18PK

2 04RD

(275) 17D 18PK 17-G 18WH

11-GU 12WH

17-G 18WH

FOR REMAINDER OF CRANK MOTOR SOLENOID AND CRANK MOTOR WIRING SEE CHARGING & CRANKING SECTION.

ENGINE GROUND CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 20

NAME

5000/9200/9400/9900 PART NO.

DATE

26JUL01

AE08-54038

W/Overcrank Protection W/Cat and Cummins Engines

s082252a

SHEET

02

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

3.3. W/I6 HEUI ENGINE, P. 3

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 3

CHARGING AND CRANKING (12V) W/I6 HEUI ENGINE

START FEED ADAPTER (509)

14A 02RD

17B 14PK

B1 BATTERY STUD

2 4RD

14B 10RD

150A MEGA FUSE

TO MODULE POWER

11-G 10WH

2

40A 14A 10RD

(CH 4,PG 11)

BATTERIES

17B 16PK

ALTERNATOR

14A 02RD

B

-

+

-

2 04RD 01BK

14-FL 02RD

+

STARTER MAGNETIC SWITCH

FRAME GROUND

17C 08PK

06BK

-

06BK

+

06BK

06BK

-

06BK

+

06BK

11-GL

06BK

G

4/0 BK

S

B

4/0 BK M

CRANKING MOTOR SOLENOID

CRANKING MOTOR

4/0 BK

11-GA 06WH

MAIN GROUND CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 21

NAME

5000/9200/9400/9900 PART NO.

DATE

26JUL01

AE08-54038

W/I6 HEUI Engine

s082252a

SHEET

03

21

22

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

3.4. W/OVERCRANK PROTECTION W/I6 HEUI, P. 4

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 3

12V CRANKING SYSTEM W/OVERCRANK PROTECTION W/I6 HEUI

14A 02RD

B1 BATTERY STUD

17B 14PK

START FEED ADAPTER (509)

TO ALTERNATOR

2

17B 16PK

14A 02RD

150A MEGA FUSE

2 04RD

(CH 3,PG 3)

2 04RD

S

CRANKING MOTOR SOLENOID

M

CRANKING MOTOR

17D 18PK

17C B

8PK

17D 18PK

14 02RD

STARTER MAGNETIC SWITCH (4 TERM)

275 17D 18PK 17-G 18WH

11-GU 14WH

17-G 18WH

FOR REMAINDER OF CRANK MOTOR SOLENOID AND CRANK MOTOR WIRING SEE CHARGING & CRANKING SECTION.

STARTER MOTOR GROUND CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 22

NAME

5000/9200/9400/9900 PART NO.

DATE

26JUL01

AE08-54038

W/Overcrank Protection W/I6 HEUI

s082252a

SHEET

04

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4. ENGINE SYSTEMS (CHAPTER 4) 4.1. CATERPILLAR C10, C12, C15, AND C16 CRUISE CONTROL, P. 1

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

THROTTLE POSITION SENSOR RD

BK

62AV 16DK BL

11-GX 18WH

PANEL LTS FEED ADAPTER (504)

WH

G4 GROUND ADAPTER (456)

CHAPTER 4

CAT C10, C12, C15 & C16 - CRUISE CONTROL

99A(8V) 18VT

CRUISE ON/OFF (435)

99 18VT 97AE 18VT

5

7

CLUTCH SWITCH

2

6

4

(PEDAL IN RELEASED POSITION)

3

1

18BK

(294)

97AH 18VT

97-GF 18VT 97-GH 18VT

97-GB 18VT

97-GA 18VT

24-G 18GY

99 18VT

FROM ENGINE BRAKE ON/OFF SWITCH

99A(8V) 18VT

62-GK 18WH

97-GC 18VT

18BK

BRAKE SWITCH (141) (PEDAL IN RELEASED POSITION)

99-GA 18VT

62-GJ 18WH

62K 16DK BL

8

97AE 18VT

11-GT 18WH

62J 16DK BL

(404)

VEHICLE SPEED SENSOR (1099)

(CH 4,PG 2) 7 1

97AL 18VT

5

2 3

6

4

B

97AJ 16VT

22

59

66

4

33

32

97-G 16VT

97-GA 16VT

A

97AK 16VT

35

J

99 16VT

44

(190)

R

99A(8V) 16VT

97AB 16VT

45

V

97AE 16VT

I

97AH 16VT

K

97AA 16VT

97AB 18VT

F

97AL 16VT

97AA 18VT

8

CRUISE SET/ RESUME (436)

5

ECM (400) CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 23

NAME

5000/9200/9400/9900 PART NO.

DATE

26JUL01

AE08-54039

Caterpillar C10, C12, C15 and C16 – Cruise Control

s082252a

SHEET

01

23

24

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.2. CATERPILLAR C10, C12, C15 AND C16 – ENGINE BRAKE, P. 2

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 4

CAT C10, C12, C15 & C16 - ENGINE BRAKE

ECM POWER (1094) A 14C 12RD

TO BATTERIES

14C 14RD

PANEL LTS FEED ADAPTER (504)

B 14D 12RD

(CH 3,PG 1)

14D 14RD

62AV 16DK BL

C 11-G 10WH

11-G 12WH

62N 16DK BL

J1939 BACKBONE (1097)

5

TO SPLICE

24AD 16GY

J1939 TERM RESISTOR (1098)

6 8

(CH 4,PG 1) C

B

C

A

B

ENGINE BRAKE ON/OFF SWITCH (434)

7

4

A

62-GN 18WH

24AD 16GY

98YL(+) 20YL

98SHD 14BK

2

5 4

62L 16DK BL

6

7

1

3 8

FRONT & REAR SOLENIODS

14D 14RD

14C 14RD

14E 14RD

24AE 16GY

24AF 16GY

50

97-GB 14WH

98YL(+) 20YL

42

63

67

65

53

52

48

40

23

CENTER SOLENOID

ECM CONN (400) G4 GROUND ADAPTER (456)

J1939 DATA LINK

CHK

DATE

11-GT 18WH

L

97-GJ 14WH

98SHD 20

34

M

97-GK 14WH

98GN(-) 20GN

(190)

24AF 16GY

62-GL 18WH

24AE 16GY

11-G 10WH

ENGINE BLOCK GROUND

ENGINE BRAKE SELECTOR 2,1,3 SWITCH (433)

11-GX 18WH

98SHD 20

98GN(-) 20GN

98YL(+) 20YL

98SHD 20

98GN(-) 20GN

24-G 18GY

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

NAME

5000/9200/9400/9900 PART NO.

DATE

26JUL01

AE08-54039

Figure 24 Caterpillar C10, C12, C15 and C16 – Engine Brake

s082252a

SHEET

02

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.3. CATERPILLAR C10, C12, C15 AND C16 – ENGINE CONTROLS, P. 3

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 4

CAT C10, C12, C15 & C16 - ENGINE CONTROLS

11-GX 18WH

G4 GROUND ADAPTER (456)

TO SPEEDO/ TACH MODULE

F6-D

(CH 6,PG 8, CH 7,PG 2,3)

13Z 12PK

TO KEY SWITCH

13 12PK

5A

11-GT 18WH

(CH 2,PG 10)

47/48(-) 18GY

GND

PWR

POS

11-GR 14WH

F5-D

98A(+) 14BK

98C(-) 14BK

47/48(+) 18GY

NEG

DATA LINK (137)

97DL 14VT

BAT STUD 14AA 14RD

14W 06RD

20A (423)

DATA LINK POSITIVE (514)

28A 18TN

FROM FUSE F4-A

13V 16PK

28D 18TN

A

(CH 2,PG 10)

B A C B

LEFT GAUGE CLUSTER

C

SERV/ CHECK ENG

(423)

10

C

97AZ 18VT

97AT 18VT

98B(-) 18BK

13D 20PK

LOW COOLANT LEVEL SWITCH (402)

WARN ENG

13

98(+) 18BK

DATA LINK NEGATIVE (515)

NO LIQUID PRESENT A

D

B

28

29

DASH CONN (190)

ECM (400)

70

34A 16TN 97-G 16WH

34B 16TN

34 16TN

8

U

34-G 16WH

9

N

97AT 16VT

T

97AZ 16VT

S

98(+) 16BK

P

13D 16PK

(2)

98B(-) 16BK

LIQUID PRESENT

2

5

54

49

* RELAY LOCATIONS VARYCHECK INSIDE POWER DISTRIBUTION CENTER FOR ACTUAL LOCATION. CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 25

NAME

5000/9200/9400/9900 PART NO.

DATE

27JUL01

AE08-54039

Caterpillar C10, C12, C15 and C16 – Engine Controls

s082252a

SHEET

03

25

26

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.4. CUMMINS ISM , ISX — CRUISE CONTROL, P. 4

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

97-GB 18VT

TO SPLICE

97-GC 18VT

PANEL LTS FEED ADAPTER (504)

97-GH 18VT

62AV 16DK BL

(294)

18BK

62J 16DK BL 5

2 3

1

4

7 6

CLUTCH SWITCH W/PEDAL RELEASED (294)

62K 16DK BL

8

CRUISE ON/OFF SWITCH (435)

B

97-GB 18VT

(CH 4,PG 6)

CHAPTER 4

CUMMINS ISM, ISX - CRUISE CONTROL

2

7 62-GJ 18WH

A

5

1

3

4

CRUISE SET/ RESUME SWITCH (436)

18BK

62-GK 18WH

8

6

VEHICLE SPEED SENSOR (1099)

97AB 18VT

97AE 18VT

97AA 18VT

97AH 18VT

11-GT 18WH

(294)

A

CHK

DATE

CHANGE

REV

I

16

24

25

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 26

97AK 16VT

15

K

97AB 18VT

ECM CONN (1086)

J

97AA 18VT

R

97AH 18VT

DASH CONN (190)

97AE 18VT

G4 GROUND ADAPTER (456)

97AJ 16VT

11-GX 18WH

B

36

27

NAME

5000/9200/9400/9900 PART NO.

DATE

27JUL01

AE08-54039

Cummins ISM, ISX – Cruise Control

s082252a

SHEET

04

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.5. CUMMINS ISM, ISX – ENGINE BRAKE, P. 5

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 4

CUMMINS ISM, ISX - ENGINE BRAKE

62AV 16DK BL

PANEL LTS FEED ADAPTER (504)

62L 16DK BL

62N 16DK BL

24AD 18GY

5

2 1

3

4

7 6

5

2

4

6

1

ENGINE BRAKE SELECTOR 2-1-3 SWITCH (433)

7 3 8

62-GL 18WH

24-G 18GY

8

ENGINE BRAKE ON/OFF SWITCH (434)

11-GT 18WH

11-GX 18WH

62-GN 18WH

TO SPLICE

24AE 18GY

G4 GROUND ADAPTER (456)

A

98SHD 20

98GN(-) 20GN

B

98YL(+) 20YL

C

A

98SHD 20

98GN(-) 20GN

B

98YL(+) 20YL

C

24AP 18GY

J1939 BACKBONE (1097)

J1939 TERM RESISTOR (1098)

24AF 18GY

(CH 4,PG 6)

FRT & REAR SOLENOID

98GN(-) 20GN 98SHD 20 98YL(+) 20YL

REAR SOLENOID

CHK

46

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 27

M

24AE 18GY

98YL(+) 20YL

37

L

24AF 18GY

98SHD 20

47

ENGINE BLOCK GROUND

Q

24AP 18GY

98GN(-) 20GN

98SHD 14BK

7

18

8

(190)

ECM CONN (1086)

NAME

5000/9200/9400/9900 PART NO.

DATE

27JUL01

AE08-54039

Cummins ISM, ISX – Engine Brake

s082252a

SHEET

05

27

28

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.6. CUMMINS ISM, ISX – ENGINE CONTROLS, P. 6

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

B2 BATTERY STUD

FROM FUSE F4-A GROUND

FEED 12V

E

C

14AA 14RD 97-GE 18VT

97-GF 18VT

(CH 4,PG 4)

BRAKE SWITCH W/PEDAL RELEASED (141)

11

DIAGNOSTIC ON/OFF SWITCH (241) 5

2 A

1

3

4

7 6 8

B

62-GR 18WH

C

H

S

T

G

97AP 18VT

98B(-) 18BK

98(+) 18BK

97AM 18VT

V

FROM A/C PRESSURE SWITCH

CHK

DATE

44

43

CHANGE

20

2

10

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 28

F

23-GB 16TN

(CH 5,PG 2)

ECM CONN (1086)

DASH CONN (190)

97-GA 18VT

U

97AT 18VT

(CH 6,PG 3,5,8 CH 7,PG 2,3)

97AL 18VT

97AM 18VT

G4 GND ADAPTER (456)

TO SPEEDO/ TACH MODULE

97-GA 18VT

47/48(+) 18 GY

11-GX 18WH

97-GAB 18VT

98B(-) 16BK

97AP 18VT

97AT 18VT

98(+) 16BK

47/48(-) 18 GY

PANEL LTS FEED ADAPTER (504)

DATA LINK NEG (515)

(141) 97AL 18VT

62AV 16DKBL

11-GT 18WH

10

FROM CLUTCH SWITCH

97-GH 18VT

62R 16DKBL

(423)

(CH 4,PG 7) 11-GX 18WH

DATA LINK POSITIVE (514)

C

FROM THROTTLE POSITION SENSOR

97DL 14VT

97-GA 18VT

B

FROM ENGINE BRAKE (CH 4,PG 5)

F5-D 20A

11-GR 14WH

A

(CH 4,PG 4)

99-GA 18VT

G4 GND ADAPTER (456)

STOP ENG

FROM CRUISE CONTROL

97-GC 18VT

24-G 18GY

11-GT 18WH

WARN ENG

97-GB 18VT 14W 6RD

DATA LINK (+)

A

98A(+) 14BK

B

98C(-) 14BK

28D 18TN

LEFT GAUGE CLUSTER

(423)

DATA LINK (-)

13V 16PK

(CH 2,PG 10)

DATA LINK (137)

CHAPTER 4

CUMMINS ISM, ISX - ENGINE CONTROLS

34

5

NAME

5000/9200/9400/9900 PART NO.

DATE

27JUL01

AE08-54039

Cummins ISM, ISX – Engine Controls

s082252a

SHEET

06

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.7. CUMMINS AHD AND ISM – ENGINE CONTROLS, P. 7

Figure 29 Cummins AHD and ISM – Engine Controls

s082252a

29

30

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.8. I6 HEUI — CRUISE CONTROL, P. 8

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 4

I6 HEUI - CRUISE CONTROL

PANEL LTS FEED ADAPTER (504) I1-IGN ADAPTER 97DS 16VT

13AA 16PK

62AV 16DK BL

97AD 18VT

F10-C 5A

62J 16DK BL 6

4

2 3

7

1 5

8

62K 16DK BL

CRUISE ON/OFF SWITCH (435)

2

5

3

97-GB 18VT

1

8

6

4

CRUISE SET/ RESUME SWITCH (436)

97DJ 18VT

97DK 18VT

K

I

VEHICLE SPEED SENSOR (303)

11-GX 18WH

97CF 18VT

11-GT 18WH

62-GK 18WH

97CR 18VT

97AE 18VT

62-GJ 18WH

7

CEC CONN (379)

CHK

DATE

CHANGE

24

35

REV

DRAWN

REFERENCE

U00CJB5 RELEASE NO.

54719V

Figure 30

31

32

39

47A 16VT

97CF 18VT

97DJ 18VT

J

47 16VT

R

97CR 18VT

DASH CONN (190)

97DK 18VT

G4 GND ADAPTER (456)

40

NAME

5000/9200/9400/9900 PART NO.

DATE

30JUL01

AE08-54039

I6 HEUI — Cruise Control

s082252a

SHEET

08

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.9. I6 HEUI — ENGINE BRAKE, P. 9

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 4

I6 HEUI - ENGINE BRAKE

G1 GND ADAPTER (453)

L2 PNL LGT ADAPTER (504) TO ABS CONTROL MODULE 62AX 16DK BL

62N 16DK BL

85

30

87A

87

86

I1 IGN ADAPTER (494)

24A 18GY

ENG BRAKE RELAY (286)

24AR 16GY

24-GA 18WH

(CH 9,PG 2)

62L 16DK BL

24AS 16GY

24AN 18GY

24AT 18GY

2

5

2

5

7

6

4 1

4

3

6

7

ENG BRAKE SELECT (433)

3

1

8

8

62-GL 18WH

24AM 16GY

ENG BRAKE ON/OFF (434)

24AF 16GY

24AD 18GY 24AE 16GY

B

C

D

E

F

RESISTOR PRINTED CIRCUIT BOARD CONNECTOR (390)

24 16GY

A

(PRINTED CIRCUIT BOARD)

11-GAX 18WH

62-GN 18WH

L

G4 GND ADAPTER (456)

(190) TO CEC CONN (379) (CH 4,PG 10)

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

NAME

5000/9200/9400/9900 PART NO.

DATE

30JUL01

AE08-54039

Figure 31 I6 HEUI — Engine Brake

s082252a

SHEET

09

31

32

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.10. I6 HEUI — ENGINE CONTROLS, P. 10

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

* FUSE LOCATIONS VARY CHECK INSIDE POWER DISTRIBUTION CENTER FOR ACTUAL LOCATIONS

C

A

A

5

97DT 16VT

F10-B 10A

97CT 16VT

11

POWER CONN (490)

(141) 98A(+) 14BK REFERENCE

97CT 16VT

11-G 10WH

97NM 18VT

87A

44

43

DRAWN

U00CJB5 RELEASE NO.

54719V

87

86

97CM 10PL

97NM 18VT

34

85

30

1

2

23

42

21

97AH 16VT

16

REV

11-GZ 14WH

15

11-GY 14WH

(CH 4, PG 17)

CEC MODULE RELAY (396)

11-GX 14WH

17

TO ENG BRAKE

(CH 4,PG 19)

11-GW 14WH

54

CHANGE

F

97N 18VT

55

P

97M 18VT

45

G

98 18BK

24 18GY

DASH CONN (190)

A

14B 10RD 98 18BK

98C(-) 14BK

T

S

CEC CONN (379)

B

98A(+) 18BK

H

98C(-) 18BK

97AF 18VT

97T 18VT

U

97AF 18VT

97AA 18VT

O

97T 18VT

97AA 18VT

(423)

97AL 14PL

10

B1 BAT ADAPTER (497)

14BB 14RD

LEFT GAUGE CLUSTER

13

DATE

97AL 16VT

BRAKE SW (141)

(CH 6,PG 3,5,8 CH 7,PG 2,3)

97CK 14PL

6

SPEEDOTACH MODULE (421)

WARN ENG

62-GR 18WH

PANEL LTS GND ADAPTER (506)

97CL 14PL

28D 18TN

28A 18TN

DATA LINK POSITIVE (514)

11-GT 18WH

C

98 18BK

B

C

47/48(-) 18GY

B

STOP ENG

CHK

DIAGNOSTIC ON/OFF SWITCH (241)

GND ADAPTER (453)

12

SERV/ CHECK ENG

7 6

4

8

(423) 3

3

1

47/48(+) 18 GY

28A 18TN

(CH 2,PG 10)

5

2 97DL 14VT

DATA LINK NEG (515)

TO FUSE F4-A

98-G 18VT

F10-D 5A

11-GR 14WH

F11-A 5A

62AV 16DK BL

GROUND

FEED 12V

E

PANEL LTS FEED ADAPTER (504)

14DLF 14RD

DATA LINK (+)

A

98B(-) 14BK

13V 16PK

B

98(+) 14BK

DATA LINK (137)

DATA LINK (-)

B1 BAT ADAPTER (497)

I1 IGN ADAPTER

CHAPTER 4

I6 HEUI - ENGINE CONTROLS

22

41

25

NAME

5000/9200/9400/9900 PART NO.

DATE

30JUL01

AE08-54039

Figure 32 I6 HEUI — Engine Controls

s082252a

SHEET

10

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.11. I6 HEUI — MODULE POWER & GROUND SYSTEM, P. 11

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 4

I6 HEUI - MODULE POWER & GROUND SYSTEM

TO BATTERY

11-G 10WH

14B 10RD

(CH 3,PG 6)

NEG BAT

11-G 10WH

14B 10RD

POS BAT

CEC MODULE CONN (379)

A

POWER CONN (490)

B

11-G 10WH

14B 10RD

13AA 16PK

97DS 16VT

F10-C * 5A

97CT 16VT

F

97CT 16VT

87

42

LOW PWR GND

23

HSO GND

11-GW 14WH

1

DC/DC(-)

11-GX 14WH

2

DC/DC(-)

A 86

97DT 16VT

87

(190)

14BB 14RD

85

B1 BATTERY ADAPTER (497) F10-B * 10A

30

MODULE POWER RELAY (396)

11-GZ 14WH 11-GY 14WH

97CR 16VT

97CM 10PL

97AL 14PL

41

V IGN-HSO

97CK 14PL

22

DC/DC(+)

97CL 14PL

21

DC/DC(+)

25

MPR

24

V IGN

97AH 16VT 97CR 16VT

V

I1 IGN ADAPTER (494) * FUSE LOCATIONS VARY CHECK INSIDE POWER DISTRIBUTION CENTER FOR ACTUAL LOCATIONS

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

NAME

5000/9200/9400/9900 PART NO.

DATE

30JUL01

AE08-54039

Figure 33 I6 HEUI — Module Power & Ground System

s082252a

SHEET

11

33

34

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.12. I6 HEUI — ACCELERATOR, BAP, AMBIENT AIR TEMP SENSOR SYSTEM, P. 12

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 4

I6 HEUI - ACCELERATOR,BAP,AMBIENT AIR TEMPERATURE SENSOR SYSTEMS

I1 IGN ADAPTER (494)

E

97 18VT

B A

APS/IVS SWITCH (267)

CLUTCH SWITCH (294) ENGINE CONN. (190)

D

B

A

C

N

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 34

8

11

12

ATS

99B 18VT

29

APS

97CD 18VT

26

VBREF GND

97A 18TN

97U(5V) 18VT

3

BAP

* FUSE AND RELAY LOCATIONS VARY. CHECK INSIDE POWER DISTRIBUTION CENTER FOR ACTUAL LOCATION

27

VREF

CEC MODULE CONN (379)

IVS

99D 18VT

97W 18VT

E

97CD 18VT

NC

99D 18VT 99E 18VT

97W 18VT

F

99B 18VT

C

99C(5V) 18VT

99D 18VT

D

97U(5V) 18VT

IDLE POSITION SWITCH

NO

B

97AX 16VT

99A 18VT

C

A

97BU 16VT

99B 18VT

3

97BW 18VT

B A

97A 18VT

ACCEL POSITION SENSOR

2

97AX 16VT

97AK 18VT

97Z 18VT

1

AMBIENT AIR TEMP SENSOR (463)

97CD 18VT

F10-A * 10A

97BL(5V) 18VT

13BB 16PK

BAROMETRIC PRESSURE SENSOR (1160)

NAME

5000/9200/9400/9900 PART NO.

DATE

30JUL01

AE08-54039

SHEET

12

I6 HEUI — Accelerator, BAP, Ambient Air Temp Sensor System

s082252a

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

4.13. I6 HEUI — SURGE TANK & EXHAUST BRAKE SOLENOID, P. 13

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 4

I6 HEUI - SURGE TANK & EXHUAST BRAKE SOLENOID

SURGE TANK (METAL TANKS)

CEC (379)

10

34 B TN

(400-A)

METAL SURGE TANK

EXHAUST BRAKE SOLENOID,I6 N/ABS, N/ALLISON WT TRANSMISSIONS

EXHAUST BRAKE SOLENOID (372) A B

(372)

A

(372)

23 16TN

24A 16GY

24B 16GY

B

KEY SWITCH (40)

47

F9-D A

13 12PK

13U 12PK

23 16TN

R

CEC MODULE CONN. (379)

(2)

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 35

NAME

5000/9200/9400/9900 PART NO.

DATE

30JUL01

AE08-54039

I6 HEUI — Surge Tank & Exhaust Brake Solenoid

s082252a

SHEET

13

35

36

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

5. FANS (CHAPTER 5) 5.1. HORTON AND KYSOR ENGINE FAN WITH CAT C10, C12, C15 AND C16 W/ AND N/ A/C, W/ AND N/ MANUAL FAN OVERRIDE SWITCH, P. 1

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM

ECM (400)

5

CHAPTER 5

HORTON & KYSOR ENGINE FAN W/CAT C10, C12, C15 & C16 W/ & N/ A/C, W/ & N/ MANUAL FAN OVERRIDE SWITCH

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

7

41

11 (2-J)

23C 16TN

23A 16TN

97-G 16WH

23B

(CH 2,PG 11)

(2-K) (228)

B

A

B

A

62M 16DK BL

(227) BATT

16BK

ENGINE FAN OVERRIDE SWITCH (659)

(7)

(5)

(8)

(4)

GRD

(1)

OFF

ON

(6)

A/C PRESSURE SWITCH

23B 16TN

11-GR 16WH

16BK

OPEN > 300 PSI CLOSE < 210 PSI

23-GY 16WH

ENGINE BLOCK GROUND

TO PANAL FEED ADAPTER (503)

23D 16TN

23-GA 16WH 23-GB 16TN

11-GU 12WH

23A 16TN

16BK

CAB GROUND

16RD

FAN SOLENOID N.O. HORTON N.C. KYSOR

SOLENOID

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

ON

OFF

OFF

ON

FAN

NAME

5000/9200/9400/9900 PART NO.

DATE

30JUL01

AE08-54040

SHEET

01

Figure 36 Horton and Kysor Engine Fan With Cat C10, C12, C15 and C16 W/ and N/ A/C, W/ and N/ Manual Fan Override Switch

s082252a

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

37

5.2. HORTON AND KYSOR ENGINE FAN WITH CUMMINS ISM, ISX W/ AND N/ A/C, W/ AND N/ MANUAL FAN OVERRIDE SWITCH, P. 2

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM

CHAPTER 5

HORTON AND KYSOR ENGINE FAN W/CUMMINS ISM, ISX W/ & N/ A/C, W/ & N/ MANUAL FAN OVERRIDE SWITCH

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

6

17

34

ECM (1086)

38

97-GAB 18VT

ENGINE BLOCK GROUND (2-J) 23A 16TN

TO PANAL FEED ADAPTER (503)

23D 16TN

23B 16TN

11-GU 12WH

23C 16TN

23-GB 16TN

23A 16TN

(CH 2,PG 11)

23-GA 16WH

(2-K)

62M 16DK BL

BATT

(228)

A

B

B

A

(7)

(5)

(8)

(4)

GRD

(1)

(227) OFF

ON

(6)

16BK

23B 16TN

16BK

11-GR 16WH

OPEN > 300 PSI CLOSE < 210 PSI

23-GY 16WH

ENGINE FAN OVERRIDE SWITCH (659)

A/C PRESSURE SWITCH

CAB GROUND 16BK

16RD

FAN SOLENOID N.O. HORTON N.C. KYSOR

CHK

DATE

CHANGE

SOLENOID

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

ON

OFF

OFF

ON

FAN

NAME

5000/9200/9400/9900 PART NO.

DATE

30JUL01

AE08-54040

SHEET

02

Figure 37 Horton and Kysor Engine Fan With Cummins ISM, ISX W/ and N/ A/C, W/ and N/ Manual Fan Override Switch

s082252a

38

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

5.3. HORTON AND KYSOR ENGINE FAN WITH I6 HEUI ENGINES W/SHUTTER, P. 3

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM

CHAPTER 5

HORTON & KYSOR ENGINE FAN W/I6 HEUI W/SHUTTER

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

FAN SOLENOID (227)

A 97EFS 16TN

B

A

97EFT 16TN

(2)

ENGINE FAN CONTROL CONN (1075)

(2)

K

J

23D 16TN

23A 16TN

23 16TN

B

FREON PRESSURE SWITCH (228)

23B 16TN

A

(2) 23 16TN

R

13 12PK

13U 12PK

23A 16TN

F9-A

A

33

KEY SWITCH (40)

CEC MOD CONN (379)

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00CJB5 RELEASE NO.

54719V

Figure 38

NAME

5000/9200/9400/9900 PART NO.

DATE

30JUL01

AE08-54040

SHEET

03

Horton and Kysor Engine Fan With I6 HEUI Engines W/Shutter

s082252a

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6. GAUGES AND SYSTEMS (CHAPTER 6) 6.1. 4X2 REAR AXLE OIL TEMPERATURE GAUGE, P. 1 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 6

4X2 REAR AXLE OIL TEMPERATURE GAUGE

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

FROM FUSE F4-A

13V

16PK

28C

18TN

(CH 2,PG 10)

(420) REAR AXLE TEMPERATURE GAUGE

I G

S

18WH

11-GJ

(420)

18TN

32

(420)

32

14RD

14BN

32-G

J4 CAB

16WH

11-GQ

(3)

11-GF

(298)

10WH

GND

(LEFT

14BN

14RD

GROUND

DASH

STUD

PANEL)

REAR AXLE TEMPERATURE SENDER

GROUNDS TO AXLE HOUSING

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 39

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

4x2 Rear Axle Oil Temperature Gauge

s082252a

PART NO.

SHEET

AE08-52506

1

39

40

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6.2. 6X4 AXLE FORWARD-REAR AND REAR-REAR TEMPERATURE GAUGE, P. 2 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 6

6X4 AXLE FORWARD-REAR AND REAR-REAR TEMPERATURE

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE

GAUGE

INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

FROM FUSE F4-A

13V

16PK

28C

18TN

(CH 2,PG 10)

FORWARD-REAR AXLE

REAR-REAR AXLE

(420)

TEMPERATURE GAUGE

TEMPERATURE GAUGE

I

I G

G

S

S

32A

18TN

16WH

14BN

32-GA

11-GQ 32

J4

14RD

14BN

J4 32-G

32A

18WH

11-GJ

(3)

(3)

CAB

14RD

(420)

(420)

18TN

32

(420)

CAB GND

GND

14RD

14BN

DASH

STUD

14BN

(LEFT

GROUND

14RD

11-GF

10WH

(299) (298)

PANEL)

REAR-REAR FORWARD-REAR

AXLE

AXLE

TEMPERATURE

TEMPERATURE

SENDER

SENDER

GROUNDS TO GROUNDS TO

AXLE HOUSING

AXLE HOUSING

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 40

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

PART NO.

SHEET

AE08-52506

6x4 Axle Forward-Rear and Rear-RearTemperature Gauge

s082252a

2

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6.3. ENGINE OIL PRESSURE GAUGE, P. 3 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 6

ENGINE OIL PRESSURE GAUGE

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

(+)

ENGINE OIL

FROM

FROM

FUSE

FUSE

F4-A

F5-C

(+)

S

C (CH 2.PG 10)

(CH 2,PG 3)

PRESSURE S

C

(-)

13V

16PK

14J

16RD

28B

14G

18RD

(-)

18TN

GAUGE

18TN

18TN

35C(+)

18TN

35C(-)

18TN

35S(-)

35S(+)

(424)

(422)

(421)

SPEEDOMETER/ TACHOMETER MODULE

(421)

18WH

11-GL

FROM ENGINE

16WH

11-GQ

18GY

47/48(-)

18GY

47/48(+)

(421)

CONTROLS

10WH

11-GF

(CH 4,PG 3,6,10,14,18)

GROUND STUD

(LEFT DASH PANEL)

NOTE: CIRCUITS 47/48(+) & 47/48(-) PROVIDE DATA FROM THE ECM FOR THE ENGINE OIL PRESSURE GAUGE.

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 41

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Engine Oil Pressure Gauge

s082252a

PART NO.

SHEET

AE08-52506

3

41

42

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6.4. ENGINE OIL TEMPERATURE GAUGE, P. 4

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 6

ENGINE OIL TEMPERATURE GAUGE

FROM FUSE F4-A

28A 18TN

13V 16PK

(CH 2,PG 10)

(423)

(423)

I

ENGINE OIL TEMPERATURE GAUGE

11-GM 18WH

G

11-GQ 16WH 11-GF 10WH

S

(423)

(LEFT DASH PANEL)

30

GROUND STUD

(2-B)

W/ISX

(2-B)

ENGINE OIL TEMP SENDER (316)

30 16TN

ENGINE OIL TEMP SENDER (316)

30 16TN

W/ISM,C10,C12 C15,C16

(2-B)

30 18TN

30 16TN

30-G 18WH

30-GB 16WH

11-GU 12WH

11-GU 12WH

30-GB 16WH

30-GB 16WH

(393)

ENGINE GROUND CHK

DATE

CHANGE

CJB5//RMVD SER 60,

ENGINE GROUND REV

B

REFERENCE

54719V

DRAWN

U00EDL2 RELEASE NO.

N14, AHD, ISM & 3406E.

P50317A

NAME

5000/9200/9400/9900 PART NO.

DATE

12FEB99

AE08-52506

Figure 42 Engine Oil Temperature Gauge

s082252a

SHEET

04

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6.5. ENGINE WATER TEMPERATURE GAUGE, P. 5 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 6

ENGINE WATER TEMPERATURE GAUGE

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

FROM

FROM FUSE

FUSE (+)

(+)

F4-A

ENGINE WATER

S

F5-C

C (CH 2,PG 10)

(CH 2,PG 3)

TEMPERATURE S

C

(-)

13V

16PK

14J

16RD

28B

14G

18RD

(-)

18TN

GAUGE

18TN

18TN

29C(+)

18TN

29C(-)

18TN

29S(-)

29S(+)

(424)

(421)

(422)

SPEEDOMETER/ TACHOMETER MODULE

(421)

18WH

11-GL

FROM ENGINE

16WH

11-GQ

18GY

47/48(-)

18GY

47/48(+)

(421)

CONTROLS

10WH

11-GF

(CH 4,PG 3,6,10,14,18)

GROUND

(LEFT DASH

STUD

PANEL)

NOTE: CIRCUITS 47/48(+) & 47/48(-) PROVIDE DATA FROM THE ECM FOR THE ENGINE WATER TEMPERATURE GAUGE.

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 43

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Engine Water Temperature Gauge

s082252a

PART NO.

SHEET

AE08-52506

5

43

44

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6.6. FUEL LEVEL GAUGE, P. 6 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 6

FUEL LEVEL GAUGE

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

FROM

FROM

FUSE (+)

FUSE

(+)

F4-A

FUEL

S

F5-C

C (CH 2,PG 10)

LEVEL S

C

13V

16PK

14J

16RD

14G

18RD

(-)

28B

(-)

18TN

GAUGE

(CH 2,PG 3)

18TN

18TN

36C(+)

18TN

36C(-)

18TN

36S(-)

36S(+)

(420)

(422)

(421)

SPEEDOMETER/ TACHOMETER MODULE

18WH

11-GL

36

18TN

36

(421)

14RD

(421)

16WH

11-GQ

(3)

FUEL

11-GF

SENDER (FULL 88.5 TO 94.5 OHMS)

10WH

LEVEL

(EMPTY 0 TO 1.5 OHMS)

GROUND

(LEFT DASH PANEL)

14BN

36-G

STUD

J4 CAB GROUND

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 44

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Fuel Level Gauge

s082252a

PART NO.

SHEET

AE08-52506

6

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6.7. PYROMETER GAUGE, P. 7 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 6

PYROMETER GAUGE

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

PYROMETER IGNITION G

ADAPTER (494)

D

14PK

13AB

A

* F10-A 10A

25B

18TN

18TN

25A

18TN

25

(423)

25-GA

I

A

PYROMETER

18WH

18BN

18BL

18RD

(15)

D

CONTROL MODULE

18GN

18YL

18RD

G

25-G 16YL-CHROMEL

16RD-ALUMEL

18WH

(15)

(492)

GROUND ADAPTER (454)

20YL-CHROMEL

20RD-ALUMEL

(491)

EXHAUST THERMO COUPLE

*

FUSE LOCATIONS VARY CHECK INSIDE POWER DISTRIBUTION CENTER FOR ACTUAL LOCATION.

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 45

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Pyrometer Gauge

s082252a

PART NO.

SHEET

AE08-52506

7

45

46

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6.8. SPEEDOMETER GAUGE — TACHOMETER GAUGE, P. 8 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 6

SPEEDOMETER GAUGE - TACHOMETER GAUGE

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

FROM

FROM

FUSE

FUSE

F4-A

F5-C

14J

16RD

13V

(CH 2,PG 3)

16PK

(CH 2,PG 10)

WITH DIGITAL ODOMETER

14G

18RD

28B

18TN

ONLY

(421)

SPEEDOMETER

TACHOMETER GAUGE

GAUGE

RPM

MPH

11-GL

18WH 16WH

11-GQ

18GY

18GY

47/48(-)

47/48(+)

(421)

FROM ENGINE CONTROLS

10WH

11-GF

(CH 4,PG 3,6,10,14,18)

(LEFT DASH PANEL)

GROUND STUD

NOTE: CIRCUITS 47/48(+) & 47/48(-) PROVIDE DATA FROM THE ECM FOR THE SPEEDOMETER GAUGE, TACHOMETER GAUGE, ENGINE OIL PRESSURE GAUGE & WARNING LIGHT, ENGINE WATER TEMPERATURE GAUGE & WARNING LIGHT.

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 46

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Speedometer Gauge — Tachometer Gauge

s082252a

PART NO.

SHEET

AE08-52506

8

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6.9. TRANSMISSION OIL TEMPERATURE GAUGE, P. 9

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 6

TRANSMISSION OIL TEMPERATURE GAUGE

FROM FUSE F4-A

28C 18TN

13V 16PK

(CH 2,PG 10)

(420)

I

TRANSMISSION OIL TEMPERATURE GAUGE

G S

(420)

11-GJ 18WH

31 18TN

(420)

31 16TN

11-GQ 16WH

(2-V)

TRANSMISSION OIL TEMPERATURE SENDER (236)

(LEFT DASH PANEL)

11-GF 10WH

31 16TN

31-G 16WH

31-G 16WH

GROUND STUD

11-GU 12WH

ENGINE GROUND

CHK

DATE

CHANGE

CJB5//RMVD W/3406,

REV

B

REFERENCE

54719V

DRAWN

U00EDL2 RELEASE NO.

W/SERIES60, W/M11,N14.

Figure 47

P50317A

NAME

5000/9200/9400/9900 PART NO.

DATE

12FEB99

AE08-52506

Transmission Oil Temperature Gauge

s082252a

SHEET

09

47

48

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6.10. VOLTMETER GAUGE, P. 10 NAVISTAR INTERNATIONALTRANSPORTATION CORP.

ELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 6

VOLTMETER GAUGE

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.

FROM

FROM FUSE

FUSE (+)

(+)

F4-A VOLTMETER

S

F5-C

C (CH 2,PG 10)

S

(CH 2,PG 3)

C

(-)

13V

16PK

14J

16RD

28B

18TN

14G

18RD

(-)

18TN

18TN

27C(+)

18TN

27C(-)

18TN

27S(-)

27S(+)

(424)

(422)

(421)

SPEEDOMETER/ TACHOMETER MODULE

18WH

16WH

11-GQ 11-GF

10WH

11-GL

(421)

(LEFT

GROUND STUD

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

U00EDL2 RELEASE NO.

P50317A

Figure 48

DASH PANEL)

NAME

5000/9100/9200/9400/9900 DATE

12FEB99

Voltmeter Gauge

s082252a

PART NO.

SHEET

AE08-52506

10

5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After — ELECTRICAL CIRCUIT DIAGRAMS

6.11. ETHER START, P. 11

INTERNATIONAL TRUCK AND ENGINE CORPORATION ELECTRICAL CIRCUIT DIAGRAM THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

CHAPTER 6

ETHER START

PANEL LTS FEED ADAPTER (504) 13L 12PK

IGNITION ADAPTER (494)

62AY 16DK BL

F10-A 10A

21H 18TN

*

ETHER START SWITCH (600)

5

7

4

6 8

(390) F F

(2-Q)

21A 18TN

OPEN >50 CLOSE