Wire Number
101 102 103 105 107 109 112 113 115 120 121 122 123 124 126 129 132 135 138 139 149
Wire Color
RD BU YL BR WH OR PU OR PK YL YL BU WH GN PK BU PK BU GN OR PU BATTERY HEAD LAMP AUX CKT KEY SW
Description
Power Circuits
Wire Number
600 601 602 604 605 606 607 608 610 611 612 614 619 620 622 623 631 632 635 635 636 639 640
Description
Lighting Circuits
Connector
37 Contacts
Machine Location
*
Schematic Location
E-5
Connector
Machine Location
Schematic Location
F-6
Part No.
2M9346 3L6306
Function
Stop Lamp Press (Module) Service/Retarder Press (Tractn) Service/Retarder Press (Trans) Parking Brake Press (EMS) Secondary Brake Press (Trans) Torque Converter Outlet Screen (EMS) Transmission Supply (EMS) Retarder Press (Warning) Nitrogen Actuator Press (Fire) Engine Oil Press (EMS) Engine Oil Press (Serv Meter) Fuel Filter Press (EMS) Torque Converter Inlet Filter (EMS) Brake Oil Temp (EMS) Converter/Retarder Temp (EMS) Engine Coolant Temp (EMS) Fire Detection Temp Agent Press (Fire) Aftercooler Temp (EMS) Transmission Filter (EMS) Brake System Air Press (EMS) Fuel Press (EMS) Engine Coolant Flow (EMS) Hoist Screen Bypass Press (EMS) Steering Press (EMS)
Actuate
45 kPa MAX (6.5 psi MAX) 55.2 13.8 kPa (8 2 psi) 656 35 kPa (95 5 psi) 210 70 kPa (30 10 psi) 27.6 3.4kPa (4.0 .5 psi) 1930 138 kPa (279.5 20.0 psi) 93 21 kPa (13.5 3.0 psi) 119 14 kPa (17.0 2.0 psi) 123.89 2.78C (255 5F) 107.2 2.8C (225 5F) 193.3 8C (380 14.4F) 2270 kPa MAX (330 psi MAX) 82.2 2.8C (180 5F) 51.7 2.8C (125 5F) 517 35 kPa (75.0 5.0 psi) 93 21 kPa (13.5 .0 psi) 362 29 mN (45.6 mm ID point) (1.3 .1 oz, 1.8 in ID point) 210 70 kPa (30 10 psi) 8963 379 kPa (1300 200 psi)
Deactuate
5 kPa MIN (0.5 psi MIN) 552 35 kPa (80 5 psi) 1655 138 kPa (240.5 20.0 psi) 69 21 kPa (10.0 3.0 psi) 112.78C MIN (235F MIN) 91.0C MIN (196F MIN) 1655 138 kPa (240 20 psi) 74C MIN (165F MIN) 43.0C MIN (110F MIN) 448 35 kPa (65.0 5.0 psi) 69 21 kPa (10.0 3.0psi) 303 mN MIN (1.1 oz MIN) 6890 345 kPa (1000 50 psi)
Contact Position
N.O. N.C. N.O. N.O. N.O. N.O. N.O. N.C. N.C. N.C. N.O. N.O. N.C. N.C. N.O. N.C. N.O. N.O. N.C. & N.O.
17
B
E-12
E-4
ENG SHUT -DOWN/AUTO FIRE SUPPR CONT ALTERNATOR OUTPUT (+) TERM MAIN POWER RELAY OUTPUT OPR MON PANEL/VMIS B+ SWITCHED AUX CKT AUX CKT BACKUP ALARM/LAMP AUX CKT AUX CKT A/C XMSN CONT AUX CKT AETA CONT AUX CKT AUTO LUBE PUMP/PAYLOAD MON AUX CKT AUX CKT Ground Circuits
1 2 3
H H H
A - 8X5294 B - 8X6189 YY - 8X3704 ZZ - 8X5017 A - 8X5294 C - 8X6369 A - 8X5294 Diagnostic Connector A - 8X5294 Operator Monitor (EMS)
3T3195
E-3
B-7
B-12
18 19
6 Contacts
3T9343
C-6
4D4785
A-6
B-8
F-10
20 21
6T6085
A-11
6T7663
B-4
D-4
7N4447 7N7854
A-6
B-10
7N9785
B-2
D-2
5 6 7
*
H H E
D - 5T8598 E - 5T9412 W - 8W0638 X - 8W0708 A - 8X5294 H - 5T8619 F - 8W7984 Shift lever Switch G - 8W9931 V - 7T3418 V-7T3418 Transmission Switch
7T4785
B-3
B-9
200 201 202 203 207 209 210 212 213 214 215 216 217 218 219 226 227 231 237 245 246 247 248 250 251
BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK
MAIN CHASSIS OPR MON PANEL/VMIS/CMS XMSN CONT CHASSIS DIAGNOSTIC STARTER DIAGNOSTIC FIRE SUPP SYSTEM GROUND CONVERTER OUTPUT (24/12 VOLT) AETA CODING PIN 16 AETA CODING PIN 17 AETA CODING PIN 18 AETA CODING PIN 19 AETA CODING PIN 20 XMSN CODING PIN 17 XMSN CODING PIN 18 XMSN CODING PIN 19 HYD OIL TEMP SENSOR XMSN CODING PIN 37 XMSN SW KBI ETHER CONT GROUND ETHER CONT HARNESS CODE 0 ETHER CONT HARNESS CODE 1 ETHER CONT HARNESS CODE 2 ETHER CONT HARNESS CODE 3 PAYLOAD MON- CUSTOMER GROUND PAYLOAD MON- SYSTEM GROUND Basic Machine Circuits
B-8
22
F
A - 8X5294 D - 5T8598 A - 8X5294 UU - 8W7193 A - 8X5294 WW - 8X6292 AAA - 8X5014 YY - 8X3704 NN - 8X5293 YY - 8X3704 R - 6T4301 S - 6T4300 QQ - 8W3841 Customer Data Connector
8C5436
C-9
8N1425
E-4
700 703 704 705 706 707 709 710 711 712 713 714 715 716 720 721 722 723 724 725 726 733 734 735 736 737 767 768 769 770 772 773 774 775 777 794 799 801 803 807 808 809 810 811 812 813 814 816 818 819 820 858 859 860 861 863 864 865 866 867 891 918 919 A717 A718 A720 B748 B922 B923 B924 B925 B941 B942 B943 B944 B945 B946 B947 B954 B998
PK BU GY PK BR PU OR GN BR WH OR YL GN BU PU BR WH OR YL GN BU BR WH OR YL GN WH OR BU GN BR GY YL BR PU YL WH PK BU BR PU GN BU GY GN PK YL BR BR GY BU GY YL PK PU BU BR GY PK PU BU OR GN OR PU PK BR WH YL BU BR GY OR PK PU WH YL BU YL BU
AETA TEST SW XMSN UP SOL XMSN DOWN SOL XMSN LCL SOL BASIC XMSN RETARDER SW XMSN BED RAISE SW XMSN PICKUP POWER XMSN SPEED PICKUP SIGNAL XMSN LEVER CODE 1 XMSN LEVER CODE 2 XMSN LEVER CODE 3 XMSN LEVER CODE 4 XMSN LEVER CODE 5 XMSN LEVER CODE 6 XMSN BRAKE SW XMSN GEAR CODE 1 XMSN GEAR CODE 2 XMSN GEAR CODE 3 XMSN GEAR CODE 4 XMSN GEAR CODE 5 XMSN GEAR CODE 6 SWITCHING GEAR CODE 1 FRONT SWITCHING GEAR CODE 2 FRONT SWITCHING GEAR CODE 3 FRONT SWITCHING GEAR CODE 4 FRONT SWITCHING GEAR CODE 5 FRONT AETA PICKUP POWER AETA PICKUP XMSN WHEEL SPEED PICKUP LEFT WHEEL SPEED PICKUP RIGHT AETA RETARDER SW AETA SERVOVALVE AETA SOL - LEFT AETA SOL - RIGHT BRAKE RELEASE MOTOR PAYLOAD MON XMSN SPEED SENSOR POWER AUTO LUBE SOL AUTO FIRE SUPPR SYSTEM SW POWER AUTO FIRE SUPPR NITROGEN SW TO CONT AUTO FIRE SUPPR NITROGEN SW TO NITROGEN SW AUTO FIRE SUPPR SYSTEM WARNING CKT AUTO FIRE SUPPR SYSTEM FAILURE CKT AUTO FIRE SUPPR TEST CKT AUTO FIRE SUPPR NITROGEN ACTUATOR SOL AUTO FIRE SUPPR AGENT CYLINDER SW TO NITROGEN SW AUTO FIRE SUPPR AGENT SW TO AGENT SW AUTO FIRE SUPPR ALARM SERIAL DATA (TRANSMIT) SERIAL DATA (RECEIVE) TRANSMIT KEY PAYLOAD MON RIGHT FRONT SENSOR PAYLOAD MON LEFT FRONT SENSOR PAYLOAD MON RIGHT REAR SENSOR PAYLOAD MON LEFT REAR SENSOR PAYLOAD MON TRANSMIT LCD OUT PAYLOAD MON CLOCK LCD OUT PAYLOAD MON LATCH LCD OUT PAYLOAD MON TEST/SET PAYLOAD MON MODE NEUT START CONT TO PAYLOAD MON SYSTEM ENG OVERSPEED LIGHT AND HORN ENG OVERSPEED TEST SW START AID SENSOR SUPPLY START AID COOLANT SENSOR SIGNAL START AID ENGINE SPEED SIGNAL STEERING SPEED CONTROL SPEED IN START AID LAMP RESET SW #1 START AID LAMP RESET SW #2 START AID LAMP RESET SW #3 START AID LAMP RESETSW #4 START AID CONT SOL 1 & 2 RET START AID CONT SOL 3 & 4 RET START AID CONT LAMP 1 OUTPUT START AID CONT ALARM OUTPUT START AID CONT SENSOR 1 START AID CONT SENSOR 2 START AID CONT SENSOR 3 START AID CONT TEST SW INPUT START AID CONT LAMP 2 OUTPUT 7 Contacts 8 Contacts 9 Contacts 10 Contacts
D-10
9G3341
C-10
E-5
C 5 Contacts
9G8009
8
*
A-10
24 25 26
D
A-5
9W3187
A-10 A-11
9X3040
9 10
B
E E
C-6
C-3
9X7781
C-6 D-11
9X8199
D-3
27 26 28
* 4 Contacts
D-6
F-4
D-3
11 12 13 14
*
D-12
A-7
Component Location
Component Alarm - Backup Schematic Location A-12 C-4 D-5 C-2 C-1 A-3 A-2 E-11 E-6 D-2 E-6 D-12 F-4 D-10 D-9 E-5 C-12 E-6 B-11 F-5 D-11 D-4 D-4 D-5 E-10 B-9 A-3 B-6 A-9 E-5 C-5 E-5 D-5 D-3 D-3 D-6 B-11 D-5 E-2 D-5 B-11 C-2 C-4 A-3 E-12 E-12 C-3 D-2 B-8 A-3 A-10 A-12 B-12 B-2 B-2 A-4 A-9 A-4 A-9 B-11 A-2 B-10 A-11 A-3 A-2 A-2 A-10 D-11 F-8 B-11 A-7 Machine Location 1 B C G G 2 3 D C F C E C E E C E C 4 C D B B C E 5 2 6 7 B B C C B B C 8 F G B 9 A B 10 E E A G 11 12 13 14 15 12 16 17 18 19 20 21 22 23 24 25 26 27 24 E E 21 28 D = Components behind seat E = Components in rear compartment F = Components in front compartment G = Components in headliner
T
E-1
B-11
Component Solenoid - Up Shift Speedometer Switch - Aftercooler Temp (EMS) Switch - Agent Press (Fire) Switch - Agent Press (Fire) Switch - Backup Alarm Switch - Backup Lamp Switch - Blower Switch - Body Raise (Trans) Switch - Brake Master Cylinder Overstroke (EMS) Switch - Brake Master Cylinder Overstroke (EMS) Switch - Brake Master Cylinder Overstroke (EMS) Switch - Brake Oil Temp (EMS) Switch - Brake Retract Switch - Brake System Air Press (EMS) Switch - Converter/Retarder Temp (EMS) Switch - Disconnect Switch - Dome Lamp Switch - Dome Lamp Switch - Engine Coolant Flow (EMS) Switch - Engine Coolant Temp (EMS) Switch - Engine Flood Lamp Switch - Engine Oil Press (EMS) Switch - Engine Oil Press (Serv Meter) Switch - Engine Overspeed Test Switch - Ether Bottle 1 Reset Switch - Ether Bottle 2 Reset Switch - Fire Detection Temp Switch - Fire Detection Temp Switch - Fire Detection Temp Switch - Fire Detection Temp Switch - Fire Detection Temp Switch - Fog Lamp Switch - Fuel Filter Press (EMS) Switch - Fuel Press (EMS) Switch - Headlight Dimmer Switch - Key Switch - Ladder Lamp Switch - Ladder Lamp Switch - Left Hoist Screen Press (EMS) Switch - Nitrogen Actuator Press (Fire) Switch - Nitrogen Actuator Press (Fire) Switch - Operator Monitor Test (EMS) Switch - Panel Dimmer Switch - Parking Brake Press (EMS) Switch - Refrigerant Press (AC) Switch - Retarder Press (Warning) Switch - Right Hoist Screen Press (EMS) Switch - Running Lamp Switch - Secondary Brake Press (Trans) Switch -Service/Retarder Press (Tractn) Switch - Service/Retarder Press (Trans) Switch - Shift Lever Switch - Steering Press (EMS) Switch - Stop Lamp Press (Module) Switch - System Test/Disable/Manual (Ether) Switch - Thermostat Switch - Torque Converter Inlet Filter (EMS) Switch - Torque Converter Outlet Screen (EMS) Switch - Traction Aid Test Switch - Transmission Switch - Transmission Filter (EMS) Switch - Transmission Supply (EMS) Switch - Turn Signal Tachograph Tachometer
A - 8X5294 H - 5T8619 C - 8X6369 HH - 8X2286 QQ - 8W3841 Payload Monitor Operator Panel UU - 8W7193 Engine Overspeed Monitor UU - 8W7193 Engine Overspeed Monitor
E-10
29
*
F - 8W7984 Body Raise Switch F - 8W7984 Transmission Gear Indicator HH - 8X2286 Stop/Tail Lamp Module QQ - 8W3841 RR - 8W3843
Schematic Location A-11 C-3 A-6 A-1 E-2 E-4 D-5 C-3 C-9 A-8 A-9 A-9 B-9 D-5 C-11 A-7 A-2 D-2 F-4 A-3 A-3 E-1 A-6 A-6 D-5 A-5 A-4 A-3 A-4 A-7 B-2 B-3 D-2 B-5 B-5 F-3 D-5 D-1 D-2 A-7 E-2 F-9 C-4 E-2 C-12 B-2 E-3 A-7 E-2 C-12 C-11 C-11 E-5 A-8 C-10 E-5 C-3 A-7 A-7 D-5 A-10 A-8 A-8 F-3 F-9 D-4
Machine Location 24 B 29 30 31 C C A D 32 33 33 11 C E 34 35 G A 36 12 37 38 38 B 26 27 39 39 39 39 39 G 40 40 A C 37 G 41 42 E B G E 43 B 41 G E E E C 44 E C A 45 46 C 47 48 48 A D B
D-9
B-12
E-5
306 307 308 310 311 321 326 327 328 334 335 336
GN OR YL PU WH BR PU PK OR BU BR GY
STARTER RELAY COIL TO NEUT START SW OR KEY SW KEY SW TO NEUT START SW OR VMIS SENSOR MODULE MAIN POWER RELAY COIL START AID SW TO START AID SOL START AID SOL TO TEMP SW BACKUP ALARM/LAMP/TRAVEL ALARM KEY SW -C- TERM SHUTDOWN SOL SHUTDOWN MODULE "OFF" START AID SOL #2 START AID SOL #3 START AID SOL #4 Monitoring Circuits
C-4
B-11
D-4
21
B-4
D-4
Control - Autolube Control - Automatic Fire Suppression Control - Engine Shutdown Control - Ether Control - Neutral/Start Control - Payload Monitor
15
*
A - 8X5294 DD - 5T9326 A - 8X5294 Engine Shutdown Control A - 8X5294 L - 8W0637 A - 8X5294 L - 8W0637 A - 8X5294 Transmission Speed Distributor BB - 8W0636 Fire Suppression Monitor F - 8W7984 Transmission Gear Indicator
C-12
E-6
16 16
*
F-2
F-2
400 403 405 406 407 408 409 410 411 412 413 415 417 418 419 426 437 438 441 446 449 450 451 454 470 472 473 474 475 481 A489 A491 A492 A493
GN GN GY PU PK WH OR WH PK BU BR GN GY WH YL BR BR YL OR PU BU YL BR GN PU OR GY WH BR 'GN BU WH OR YL
SERVICE METER SW ALTERNATOR (R) TERM OPR MON OIL PRESS (LO SETTING) OPR MON COOLANT TEMP OPR MON CONVERTER/RETARDER OIL TEMP OPR MON BRAKE PRESS (AIR) OPR MON NEUT OPR MON ACTION ALARM OPR MON MASTER FAULT LAMP OPR MON COOLANT FLOW OPR MON FUEL PRESS OPR MON TEST SW PRIMARY STER SW OPR MON OIL PRESS (HI SETTING) OPR MON PARKING BRAKE OPR MON POWER TRAIN OIL FILTER OPR MON FUEL LEVEL TO FUEL FILTER JUMPER OPR MON COOLANT TEMP JUMPER ENG COOLANT TEMP GAGE BRAKE OIL TEMP GAGE SPDOM SENDER (SIGNAL NO 1) TACH SENDER (+) TACH SENDER (-) RETARDER INDICATOR LAMP CANE SW NEUT PARKING BRAKE SW TO OVERSTROKE SW OVERSTROKE SW TO OVERSTROKE SW OVERSTROKE SW TO OVERSTROKE SW OVERSTROKE Sw TO TRAILING UNIT CONVERTER TEMP SW TO BRAKE OIL TEMP SW OPR MON STEERING SPEED CONTROL SW XMSN SUPPLY SW TO CONVERTER FLTR INLET SW HOISt FLTR SW TO HOIST FLTR SW HOIST FL TE SW TO TORQUE CONVRTR SW Accessory Circuits
E-6
E-2
E-5
Vehicle locations are repeated for connectors located close together. * = Connector is located at the component. B = Connectors behind dash. C = Connectors in console. D = Connectors behind seat.
Fuses Gauge - Brake Oil Temp Gauge - Engine Coolant Temp Ground - Cab Ground - Cab Ground - Cab/Frame Ground - Engine (Alternator) Ground - Frame Ground - Frame/Engine Indicator - Transmission Gear Lamp - Engine Overspeed Warning Lamp - Ether 1 Out Lamp - Ether 2 Out
Printed in U.S.A.
A 1
AA
1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins.
1 2 Typical representation of a Sure-Seal connector. The plugand receptacle contain both pins and sockets.
35 30 6 19 39 25 2
16
Plug
T
Receptacle 2
14 39 45 38
19
48 20 41 11 39 34 32 9 33
14 21 20 8 4724
36
16 10
Pressure Symbol
Temperature Symbol
Level Symbol
Flow Symbol
Pin or Socket Number Wire, Cable, or Harness Assembly Identification Component Part Number
15
513 515 516 517 521 522 533 534 537 539 540
OR GY GN BU YL WH OR WH GN BU WH
A/C COMPRESSOR/REFRIGERANT PRESS SW BLOWER MOTOR (HI) BLOWER MOTOR (MEDIUM) BLOWER MOTOR (LO) A/C SW TO REFRIGERANT SW A/C CLUTCH TO THERMOSTAT SW FIRE SUPPR HEAT SENSOR/TEST SW FIRE SUPPR HEAT SENSOR/TEST SW TURN SIGNAL SW TO FLASHER TURN SIGNAL INDICATOR BASIC/RIGHT TURN SIGNAL INDICATOR LEFT
Sender - Brake Oil (Gauge) Sender - Engine Coolant Temp (Gauge) Sender - Transmission Speed
Normally open switch that will close with an increase of a specific condition (temp-press-etc.).
C A
26
A
325-PK-14
AA 1
325-PK-14
9X-1123
F B
C D
Sender - Wheel Speed (Tractn) Sender - Wheel Speed (Tractn) Sensor - Engine Coolant Temp (Ether) Sensor - Engine Speed (Ether) Sensor - Left Front Strut Press (Payld) Sensor - Left Rear Strut Press (payld) Sensor - Right Front Strut Press (Payld)
REAR COMPARTMENT (AREA E) REAR VIEW
Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition.
Pin
Socket
Wire Color
SENR4285-00
37 42 12 31
27 26 24 12 22 43
29 40 28 39 44 23 4 46
13 8
7 39 25 17 28 5 21 H
18
Normally closed switch that will open with an increase of a specific condition.
200-BK-14
4 5
13
Sensor - Right Rear Strut Press (Payld) Solenoid - 4 Way Solenoid - Air Conditioner Clutch
29
17 9 15
11 18 27 22 10
6 3
1 2
Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition.
Wire Gauge
G A B 26 F 3 26 27 35 6
16 24
H E 28 5 21 25 17 39 39 19 C D
19 16
Solenoid - Nitrogen Actuator (Fire) Solenoid - Proportional Solenoid - Steering BIeed (Eng Shtdwn)
No circle indicates that the wire cannot be disconnected from the component.
SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure.
Vehicle locations are repeated for components located close together A = Components in operators compartment
12 25 2 36
40
38 10
29 48 9 32 39 20 41 1114 21 33 13 8
8
42 12 37 30 31
43 22 28
4 46 44 2345 7 34
1 18 20 15 14
24 47
This indicates that the component has a wire connected to it that is connected to ground.
RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay.
This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.
CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work. MAGNETIC LATCH SOLENOID - A magnetic latch solenoid is an electrical component that is activated by electricity and held latch by a permanent magnet. It has two coils (latch and unlatch) that make electromagnet when current flows through them. It also has an internal switch that places the latch coil circuit open at the time the coil latches.
20 Page, REM
12
11
10
DIAGNOSTIC CONNECTOR 12 8 1 16 9 20 17 13 14 3 10 11 5 6 2 4 15 18 19 7 A
8
L21 L55 L20 623-BU-14 607-PK-14 610-OR-14 622-PU-14 441-OR 522-WH-14 513-OR-14 631-GY-14 632-WH-14 450-YL 451-BR 123-WH 200-BK-14 200-BK-14 601-GY 124-GN-14 201-BK 149-PU-14 619-GN-14 614-PU
5
L55
4
L21 L20 PAYLOAD MONITOR RED LAMP 8T9683
109-OR
203-BK
207-BK
BK RD
W DD L37 601-GY 123-WH 1 2 3 NITROGEN ACTUATOR SW 6T6085 BK-18 BK-18 1 2 808-PU 807-BR W BK BK 2 1 808-PU 807-BR 812-GN 209-BK
L29 L34
L29 L34
L30
L32
L31
L48
L48
307-OR 409-OR 200-BK 306-GN 126-PK 470-PU 891-BU 321-BR 121-YL 470-PU 710-GN 126-PK 202-BK
L18
FLASHER 8D6946
2 1
L18
2 1 QQ
L33
419-YL 408-WH 407-PK 113-OR 426-BR A489-BU 226-BK 418-WH 406-PU 412-BU 413-BR 405-GY 403-GN 410-WH 437-BR 409-OR
L49
A 3 5 6 4 1 2
F
103-YL 105-BR 107-WH L1
200-BK
BK RD
TACHOGRAPH 7D1513
L16
610-OR-14 614-PU
L28 L28
L A 1 6 3 2 4 5 7 A 3 2 6 5 4 1 7 L 149-PU-14 607-PK-14 622-PU-14 623-BU-14 513-OR-14 521-YL-14 L 614-PU 540-WH 611-PU-14 619-GN-14 631-GY-14 632-WH-14 539-BU 1 2 RD BR
L 2 1 BR RD
A 3 2 1 1 9 4 2 5 6 7 8 3
L54
L54
L24 L34 101-RD-10 105-BR 105-BR H 10A GG 101-RD-10 ENGINE SHUTDOWN BREAKER 9G9487 GG 101-RD-10 10A KEY BREAKER 9G9487 H L29 10A GG 101-RD-10 DOME, STOP & TURN LAMP BREAKER 9G9487 GG H 102-BU-14 15A HEAD LAMP (HIGH) BREAKER 3T2662 15A H 115-PK-14 L34 L34 307-OR 307-OR 307-OR 321-BR 121-YL 612-GY 308-YL L26 L27 L15 L42 L42
L24 L26 720-PU 706-BR 202-BK 711-BR-18 712-WH-18 713-OR-18 714-YL-18 715-GN-18 716-BU-18 202-BK-18 470-PU-18 707-PU 202-BK 707-PU 706-BR 720-PU 126-PK 709-OR 721-BR 722-WH 723-OR 724-YL 725-GN 726-BU 703-BU 704-GY 705-PK 227-BK 217-BK 218-BK 219-BK 710-GN 710-GN 711-BR-18 712-WH-18 713-OR-18 714-YL-18 715-GN-18 716-BU-18 L15 202-BK 202-BK 202-BK 202-BK-18 202-BK 202-BK DOME LAMP 7X6398 J 3 4 5 8 9 1 2 10 6 7
200-BK-14 619-GN-14 631-GY-14 632-WH-14 L21 200-BK-14 149-PU-14 607-PK-14 622-PU-14 623-BU-14 513-OR-14 522-WH-14 124-GN-14 601-GY 201-BK 441-OR
Q 619-GN-14
1 4
6 5
3 2
602-WH 103-YL
103-YL
15A
L18
BODY RAISE RETARDER BRAKE + BATTERY +10V GEAR 1 GEAR 2 GEAR 3 GEAR 4 GEAR 5 GND VERIFY UP SOL DOWN SOL LKUP SOL ID CODE 3 ID CODE 2
GROUND
GR GR GR GR GR
L22
L18
ID CODE 1
BK-18 BK-18
112-PU-10 112-PU-12
101-RD-10
124-GN-14 15A AIR CONDITIONER BREAKER 6N8589 20A A 139-OR-10 BRAKE RETRACT BREAKER 3T8728 ALT BREAKER 9S4693 109-OR
202-BK
202-BK
L56
L56
451-BR 450-YL 201-BK 446-PU-14 449-BU 123-WH 202-BK A 7 449-BU 2 202-BK 5 B748-BR 6 710-GN 1 123-WH 4 768-OR 794-YL 3
2 8 27 28 7 6 20 1 9 21 22 23 24 25 26 3 4 5 37 17 18 19 10 29 30 31 32 33 34 35 36 11 12 13 14 15 16
L20
L20 L52
OPERATOR STATION
WH WH
A H
2 1
814-YL 813-PK
ZZ TEST SW OUT HORN START MANUAL OUT LAMP 2 OUT LAMP 1 GROUND + BATTERY SPARE SOL RET 3&4 SOL RET 1&2 SENSOR 1 SENSOR 2 RESET SW 1 RESET SW 2 RESET SW 3 RESET SW 4 COOL TEMP SOL 4 SOL 3 SOL 2 SOL 1 SENSOR +V ENG SPD CODE 0 CODE 1 CODE 2 CODE 3 Z Y N X T B R V S M D P O A C K L F G H E U J a W I b c d e B954-YL B944-PU 307-OR B946-OR B998-BU B943-PK 237-BK 308-YL-14 B942-OR B941-GY B945-WH B947-BU B922-WH B923-YL B924-BU B925-BR A718-PU 336-GY 335-BR 334-BU 310-PU A717-OR A720-PK 248-BK 247-BK 246-BK 245-BK
308-YL
10A
10A
1 5 6 3 4
L58
L58 139-OR-10
3 2 1 +
1 2
601-GY
BACKUP ALARM 121-YL CIGAR LIGHTER 129-PU CONVERTER 120-YL GAGES AIR DRYER AUTO LUBE 10A
123-WH 122-BU 138-GN OPERATOR MONITOR XMSN CONTROL TRACTION AID FUSES 3K8782 10A FUSE HOLDERS 4K5122
L1
4 1 2 5 7 3 8 6
614-PU
107-WH-14
112-PU-12 112-PU-12
112-PU-12
112-PU-12 112-PU-12
112-PU-12
10A
112-PU-12
112-PU-12
A 1 2
614-PU
L6
112-PU-12
112-PU-12
112-PU-12
112-PU-12
601-GY 600-BR
1 2
10A
1 5 8 7 9 10 4 6 3 2 A L53
446-PU
3 1 A
BASE 2G0151
ENG OIL PR PARK BRAKE ENG OIL PR PRIM STER ID CODE FUEL FILTER FUEL PR COOL FLOW ALARM BK AIR PR TC/RET TEMP COOL TEMP NEUTRAL XMSN FILTER ALTERNATOR + BATTERY
4 0 1 2 3
BRAKE + 12V
LINK GND TX OUT TX KEY OUT RX IN BED RAISE +24V (IN) RED LAMP GREEN LAMP XMSN SPD L FRONT PR R FRONT PR L REAR PR R REAR PR TX LCD OUT LCD CLOCK NEUTRAL LCD LATCH TEST/SET MODE GROUND
772-BR 767-WH
103-YL
123-WH 113-OR
SIG
209-BK-14
115-PK-14
102-BU-14
801-PK
251-BK
202-BK
608-GN
200-BK
601-GY 601-GY
441-OR 200-BK
449-BU 113-OR
L31
SECONDARY/PARKING BRAKE TEE GROUND + BATTERY WH/BK-18 GROUND WH/RD-18 +12 VOLT 123-WH 601-GY DD A 105-BR 601-GY 449-BU 450-YL 451-BR 123-WH 200-BK F 720-PU 202-BK 201-BK SECONDARY BRAKE SW 3T3195 A 472-OR PARKING BRAKE SW 3T3195
SERVICE/RETARDER BRAKE TEE L39 F 706-BR 767-WH 767-WH SERVICE/ RETARDER SW 3L6306 202-BK BRAKE SYSTEM AIR SW 9G8009 SERVICE/ RETARDER SW 3L6306 706-BR 202-BK 720-PU 105-BR A 604-OR 103-YL 408-WH 201-BK GY A STOP LAMP SW 2M9346 BK PU PU BU
L51
200-BK 918-OR UU
1 2
K SEND GRD
BR
BK-18 RD-18
L37
772-BR
D 4 5 2 3 1
BASE 3T0304
UU
IGN
103-YL 102-BU-14 200-BK 610-OR-14 619-GN-14 614-PU 601-GY 201-BK 410-WH 623-BU-14 622-PU-14 149-PU-14 631-GY-14 632-WH-14 115-PK-14 135-BU 210-BK 607-PK-14
1 2 6 3 4 5
PP 2 3 4 1
L31
L57
BK
ENGINE OVERSPEED MONITOR 7T3821 919-GN 200-BK LAMP 7N1996 ENGINE OVERSPEED WARNING LIGHT
L52
L44
2 1 3 4
L13
772-BR 767-WH
L14
620-WH-14 620-WH-14
6 5 4 1 9 3 2 7 8
454-GN
ZZ
307-OR 308-YL
L58
250-BK 818-BR 820-BU 819-GY 707-PU 799-WH 635-BU 636-GN 794-YL 859-YL 858-GY 861-PU 860-PK 863-BU 864-BR 891-BU 865-GY 866-PK 867-PU 251-BK 799-WH
105-BR
601-GY
5 13 14 15 20 1 3 4 6 7 8 9 10 11 12 16 17 18 19 2
139-OR-10 777-PU-10 A 2 1
QQ 1 3 4 2
ID CODE TEST SW
GN RD OR YL BR BU PU GY
450-YL
L27
LAMP 5D0019
L42
115-PK-14
9 5 4 6 10 12 13 7 15 20 16 17 18 19 14 11 2 3 1 8
L40
L40
A BK BK 1 2 801-PK 200-BK
200-BK 601-GY
ID ID ID ID ID
L40 A AIR PRESSURE GAGE 1W3306 A 1 612-GY 3 121-YL A 608-GN 2 A BACKUP LAMP SW 6T3991
K SEND GRD
BASE 3T0304
12 R J 9 8
L45
1 3 4 2
L42
KEY SW 9G7641
WH OR YL BU GN BK PK
539-BU 540-WH
405-GY 419-YL 418-WH A489-BU 226-BK 437-BR 413-BR 412-BU 410-WH 408-WH 407-PK 406-PU 409-OR 426-BR 403-GN 113-OR 415-GN 411-PK 201-BK
103-YL
L19
L19
L23
306-GN 326-PU
ID CODE 3 ID CODE 2
12 11
601-GY
1 3 2 4
202-BK 202-BK
405-GY
109-OR-4 109-OR-4
101-RD-4 109-OR-4
L19 L18
L19
RETARDER SW 4D4785 A
619-GN-14
J 9 8 3
2 J
813-PK 808-PU
80A
768-OR
L54
L54
5 J
102-BU-14
TO CAB
610-OR-14
2 1
101-RD 101-RD-10
GG
200-BK
Z X
Z X
WH WH
101-RD-10
L12
6 1 3 9 8 7 4 5 2
BK-18 BK-18
SPEEDOMETER GROUND
TRANSMISSION CONTROL 9W0009 + BATTERY TRANSMISSION FRONT GR 1 GEAR INDICATOR FRONT GR 2 8C9609 FRONT GR 3 SYSTEM TEST/ FRONT GR 4 DISABLE/ FRONT GR 5 MANUAL SW A 3 2 A GROUND 8C9812 1 A ID CODE 1
3 5 4 1 2
F 1 3 4 5 6 7 2
UU
BB 103-YL 102-BU-14
1 2 3
L M
OR-14
112-PU-10
321-BR 121-YL
1 2
200-BK-8
200-BK-8 202-BK
5 2 3 4 7 6 1
1 2
L55 F
209-BK 816-BR
L57
L57
611-PU-14
202-BK 202-BK
202-BK
1 4 5 6 2 3
200-BK-14
VV
1 2 3 4 5
ABBREV RD WH OR YL PK BK GY PU BR GN BU SYMBOL
COLOR RED WHITE ORANGE YELLOW PINK BLACK GRAY PURPLE BROWN GREEN BLUE DESCRIPTION
10A
10A
10A
4 2 5 6 1 7 3 8 9
L16 L17
A K
BK-14
A 2 K
Q 607-PK-14
L17
LAMP 5D0019 COOLANT TEMP GAGE 4W0483 LEFT TURN LAMP 7N5876
2 1
IGN
LAMP 5D0019
2 J 3 11
J 1 2
AUTOMATIC FIRE SUPPRESSION CONTROL 6T5619 2 209-BK GROUND SHUT DN SOL 3 327-PK START (KEY) 5 306-GN OFF (KEY) 6 326-PU 1 107-WH + BATTERY 7 807-BR SYS PRESS. 12 812-GN ACT. SOL 20 803-BU DSCH PR + 19 803-BU + BAT OUT 9 809-GN ALERT 10 810-BU SYS FAIL 11 811-GY FIRE TEST 17 533-OR DETECT IN 4 534-WH DETECT OUT 15 DSCH PR MON 18 328-OR DSCH PRESS. 8 328-OR 16 SHUTDN ID 13 533-OR DETECT IN DETECT OUT 14 534-WH W
L23
BLADE, SPADE, RING, OR SCREW TERMINAL CIRCUIT CONNECTED CIRCUIT NOT CONNECTED ELECTRICAL CONNECTION TO MACHINE STRUCTURE INTERNAL ELECTRICAL CONNECTION TO SURFACE OF COMPONENT CONNECTOR ATCH WIRE, CABLE, COMPONENT CIRCUIT GROUPING DESIGNATION
+ -
L#
IDENT K SPEEDOMETER 3T3408 LAMP 7N5876 L52 L12 L54 L54 L11
LOC
NOTE
816-BR 209-BK
1 2 BB
L36
L26
410-WH 201-BK J
1 2
RD BK
L25
L68
L37
A L37
L30
251-BK
L40
L48 L32
L40 L32
L38
607-PK-14
L36 L38 L6
L52
L26 201-BK 202-BK 123-WH L40 L39 L36 L20 L33 L36 L33
S T BLOWER SW J 6P3236 1 RED 2 BLK 5 BLU GRN 4 OR 3 124-GN-14 521-YL-14 515-GY-14 515-GY-14 516-GN-14 517-BU-14
408-WH 472-OR
408-WH 472-OR
408-WH 419-YL
L30
103-YL 410-WH 631-GY-14 632-WH-14 149-PU-14 610-OR-14 622-PU-14 614-PU 201-BK 601-GY 210-BK 135-BU 607-PK-14 623-BU-14 200-BK 102-BU-14 115-PK-14 619-GN-14
2 1
2 1 3
L25
L54
522-WH-14 200-BK-14
BK-14 MOTOR R 200-BK-14 515-GY-14 1 2 WH/RD-14 BK-14 MOTOR R 200-BK-14 515-GY-14 2 1 BLOWER 9G8697 L44 L45 L47 YY BLOWER 9G8693
L38
L53
L6
L13
L35
5 4 3 2 1
L24
ZZ YY
327-PK-14
22 19 23 14 24 8 11 15 13 17 10 4 5 7 9 21 18 6 2 3 1 16 20 12
L28
113-OR
OPERATOR STATION L66 L41 AIR DRYER 2G2159 4 WAY SOLENOID PROPORTIONAL 9G9988 SOLENOID (R) (L) 3T0062 S-1 S-2 C T AIR START SOLENOID 5T4434 122-BU F G L66 L41
L49
202-BK 202-BK
L15
L15
L31
KK
L50
L44
534-WH 533-OR 807-BR 812-GN 803-BU 803-BU 326-PU 306-GN 107-WH 327-PK 209-BK 810-BU 811-GY 809-GN
L68 BK
103-YL 604-OR
L13
L68
BK-14
1 2 3 4 5 6 W BB
L40 L50
L40
891-BU 794-YL 635-BU 636-GN 799-WH 799-WH 863-BU 864-BR 865-GY 866-PK 867-PU 858-GY 859-YL 251-BK 861-PU 860-PK
QQ 138-GN 799-WH 867-PU 863-BU 864-BR 865-GY 866-PK 251-BK 1 3 8 4 5 6 7 2 GN-18 WH-18 PU-18 BU-18 BR-18 GY-18 PK-18 BK-18 + BATTERY +24V (OUT) MODE TX LCD OUT LCD CLOCK LCD LATCH TEST/SET GROUND L44
WH/RD-14
L45 LADDER FLOOD LAMP 3T4411 L47 L46 L47 A720-PK A717-OR A718-PU L49 237-BK 308-YL 237-BK A720-PK A717-OR 237-BK YY A718-PU 308-YL 237-BK C A B YL-18 OR-18 BK-18 533-OR 534-WH 533-OR 534-WH X 203-BK L75 L47 C A B SIGNAL V+ GROUND ENGINE SPEED SENSOR 6T4361 SIGNAL COOLANT V+ SENSOR GROUND 9X0377 4 2 5 3 6 1 OR-18 WH-18 OR-18 WH-18 T TT REFRIGERANT SW (NOTE A) 9W0549 FIRE DET SW 7T4785
WHEEL SIGNAL SPEED GROUND SENDER +V 3T2470 TURN LAMP 3T3968 HH 605-YL
202-BK 709-OR 710-GN 721-BR 722-WH 723-OR 724-YL 725-GN 726-BU 705-PK 704-GY 703-BU 219-BK 217-BK 218-BK 227-BK 202-BK
327-PK
1 24 12 2 7 3 14 15 25 4 17 10 8 6 19 20 21 22 5 16 23 9
13 18
MM D E
BK-4 6 11 12 9 1 2 10 8 4 5 7 3 W X 533-OR 534-WH 808-PU 803-BU 122-BU 306-GN 472-OR 419-YL 608-GN 201-BK 200-BK
L50
L44 L45 A B L47 L46 L49 QQ OPERATOR STATION 200-BK-8 207-BK 200-BK-10 209-BK BK-4 200-BK B 1 2 B 1 2 310-PU 311-WH 1 2 FUEL FILTER SW 7N4447 B 201-BK 437-BR FUEL PRESS SW 9W3187 413-BR 201-BK B RR 860-PK 861-PU 251-BK 799-WH 251-BK 859-YL 858-GY 4 3 2 1 2 3 4 6 5 1 QQ SS
L44 L45
L56
521-YL-14 513-OR-14 TT
1 2
777-PU-10 200-BK-8 201-BK 407-PK 327-PK-14 226-BK 403-GN 406-PU 412-BU 418-WH 405-GY 413-BR 441-OR 311-WH 109-OR-4 101-RD-4 203-BK
231-BK 709-OR 710-GN 721-BR 722-WH 723-OR 724-YL 725-GN 726-BU 705-PK 704-GY 703-BU
202-BK
202-BK
767-WH
606-GY 605-YL 426-BR 417-GY 604-OR 612-GY 614-PU 207-BK 327-PK 450-YL 451-BR
533-OR 534-WH
L66
777-PU-10
201-BK
446-PU
L5
200-BK-10
BK GN
L66
202-BK 773-GY
L41
2 1
L41 L67
L10
L4
3 2 1
3 2 4 1
BK WH
BK WH BK WH
L7
L77
L76
L71
L66
L80
L9
M 1 2 3
L72
639-WH
3 4 2 1
481-GN
L10
L75
L75 T
808-PU 814-YL
HH
HH
C MOTOR
L78
631-GY-14
STOP/TAIL LAMP MODULE 7X1670 LEFT LAMP RIGHT LAMP TAIL IN STOP IN
FRAME GROUND
JJ TO FRAME
L23
L67
L66
11
11 18 16 20 19 10 1 2 3 4 5 6 15 14 13 9 7 8 17 12
8 12 13 10 6 7 5 14 9 4 3 2 1 11
20 5 16 14 19 3 9 1 13 11 12 15 8 17 6 10 7 2 18 4
620-WH-14
1 4 3 6 2 5
HARNESS AS. 01 A 8X5294 B 00 8X6188 00 C 8X6368 01 D 5T8598 01 E 5T8888 02 F 8W7984 G 8W9825 00 04 H 5T8619 04 J 8W0639 06 K 5T8599 02 L 8W1803 03 M 8W1805 01 N 8W1801 Q 8W1804 03 R 6T4301 02 S 6T4300 02 T 6G9462 02 U 5T8887 02 V 7T3418 03 W 8W0638 05 X 8W1469 01 Y 8C9677 01 Z 8W0635 03 02 BB 8W0636 5T9326 DD 00 EE 8X4281 00 HH 8X2286 00 LL 8W3048 00 QQ 8W3841 04 RR 8W3843 01 SS 8W3844 03 TT 5T7897 01 UU 8W7193 01 00 8X6292 WW 00 8X3705 YY 00 8X5017 ZZ WIRE AS. FF 8W4826 00 GG 5T8580 04 KK 5T3943 01 NN 8X5293 00 8W8354 PP 00 VV 5C5382 01 XX 8W9561 00 AAA 8X5014 00 BBB 8X5013 00 CABLE AS. 343735 5T4666 318761 7G1060
B-8 B-7 B-8 B-9 B-9 B-10 B-10 D-10 C-6 E-3 F-2 E-1 B-1 E-1 C-2 C-2 F-3 A-11 A-10 C-8 B-8 B-2 A-1,F-2 C-5 C-12 A-8 A-12 A-6 C-4 C-4 B-4 B-2 D-5 C-10 B-12 B-12 A-3 E-11 C-10 A-12 C-6 B-1,E-1 F-11 A-5 A-4
5 6 7 2 3 1 4
L48
2 1
B
AA CC JJ MM 04 02 02 00 A-2 A-1 A-2 B-9
L10 M
L76
L76
L74
VV OR-14
SENR4285-00
419-YL UP SHIFT SOLENOID 6T9290 BK BK BK BK DOWN SHIFT SOLENOID 6T9290 BK BK LOCKUP SOLENOID 6T9290 XMSN SPEED SENDER 9X7000 475-BR BRAKE MASTER CYLINDER OVERSTROKE SW 7V5647 LEFT REAR STRUT SENSOR 9W3352 GN +V GY GROUND YL SIGNAL 310-PU 334-BU B941-GY A718-PU A720-PK A717-OR B923-YL B945-WH B922-WH 105-BR L66 L47 L46 L43 RIGHT REAR STRUT SENSOR 9W3352 +V GROUND SIGNAL GN GY YL C 474-WH BRAKE MASTER CYLINDER OVERSTROKE SW 7V5647 L72 L76 L77 799-WH 251-BK 861-PU 860-PK 201-BK 417-GY RR 1 799-WH 2 251-BK 3 861-PU L72 C 1 2 3 426-BR 201-BK EE 201-BK 417-GY TRANSMISSION SUPPLY SW 3T9343 C B A C EE 473-GY C BRAKE MASTER CYLINDER OVERSTROKE SW 7V5647
L3 L3 L76 201-BK 201-BK L69 L72 L76 L77 201-BK 438-YL 237-BK 237-BK 308-YL 237-BK 237-BK 308-YL 237-BK 105-BR ENGINE OIL SW 6T7663 LL L43 L47 L46 L41 L43 105-BR B923-YL B945-WH B922-WH 308-YL 237-BK B945-WH B922-WH 105-BR 1 2 3 4 5 B923-YL 105-BR YY ETHER BOTTLE RESET SW 1 3T3133 B922-BR 105-BR 2 1 3 B923-BR 105-BR BBB L4 L49 799-WH 251-BK 859-YL 799-WH 251-BK 858-GY 533-OR 534-WH 533-OR 534-WH L71 L3
BK-18 BK-18
L8
L78
513-OR-14 522-WH-14
HH
Y L4 201-BK 109-OR-4 441-OR 412-BU L5 406-PU 403-GN 226-BK 327-PK-14 L76 L69 L78 L69 L76
619-GN-14 611-PU-14
539-BU 614-PU
WH WH
1 2
L9
L9
L10
L10
FOG LAMP 8T8752 FOG LAMP 8T8752 HIGH BEAM HEAD LAMP 8T8753
VV M N Q
L80
1 2
L77
200-BK 327-PK
101-RD-4
412-BU
5 4 3 2 1
725724723722721-
+V GROUND SIGNAL
JJ ENGINE GROUND
B427-BU
C T
+V GROUND SIGNAL
403-GN B ALT + R B
BK-4
+V GROUND SIGNAL
10 1 9 2 3 6 7 8 5 4 V
G H I F E C B A D J V G
231-BK 726-BU
BK RD
FRAME GROUND
BK RD
201-BK 405-GY
400-GN 201-BK
2 1
2 1
2 1
AFTERCOOLER SW 8N1425
GN GY YL
GN GY YL
HH 606-GY
202-BK 202-BK
L78
LL
4 5 1 6 2 3
3 6 2 5 1 4
A493-YL
A492-OR
1 2 3
1 2 3
L41
SS
RD-14 BK-14
202-BK
X 2 5 3 6 1 4
BK-4 203-BK
202-BK
1 2
1 2
BK BU
3 4 2 1 6 5
1 2
BK BU
BK WH
3 6 2 5 4 1
HH
1 2
2 1
2 1
YY
YY
AGENT SW 8C5436 N RD 1 BR 2
539-BU 614-PU
451-BR 450-YL
L67
L8
B GROUND C SIGNAL A +V
B941-GY 310-PU
B941-GY 334-BU
L71
L69
1 2
L7
B 2 1
441-OR COOLANT SENDER T 6N5926 B 438-YL 406-PU T COOLANT SW 7N9785 201-BK BK-18 BK-18 B 2 1
THIS SCHEMATIC IS FOR THE 785 TRUCK (7T1960 CHG 05) COMPONENTS ARE SHOWN INSTALLED ON A FULLY OPERABLE MACHINE WITH THE KEY AND EN GINE OFF, AND XMSN SHIFTER IN NEUTRAL UNLESS OTHERWISE NOTE A: NORMALLY NOTE B: NORMALLY NOTE C: NOT USED SPECIFIED: ALL WIRE IS 16 GAGE OPEN BEFORE REFRIGE RANT CHARGE CLOSED WHEN DOOR OP EN WITH AUTOMATIC FIRE SUPPRESSION
B 1 2
LL
YY
AAA
COOLANT SW 9X3040
AA CC NEG POS
BK-4
12
11
10