ADDING LIGHTS OR ELECTRICAL DEVICES Page M29

Although there are many points in the truck electrical system to connect additional circuits, certain connection points are recommended for reliability and convenience. This section defines the recommended connection points
for each Louisville Ford Truck model and the maximum electrical loads allowable. Alternative connections or wiring practices are not recommended as certain modifications may result in other circuits becoming nonfunctional.
Disconnect the battery negative (ground) cable and remove it from the battery carrier prior to any vehicle modification. Upon completion of body or equipment installation, all wiring should be checked for proper routing, etc., to
preclude electrical shorts upon reinstallation of the battery negative cable.
No additional electrical connections are allowed to any electronic engine control (e.g., 3176/3406B PEEC, CELECT) system circuits. This includes all electronic engine control circuits to sensors, switches,
ground, battery (+) or battery (–). Proper grounding of vehicle and engine electrical systems is necessary for correct vehicle performance and reliability. Refer to the Engine Manufacturer’s Service Information
for each engine as required or contact the nearest Engine Manufacturer’s Service Center.

1. ADDED LIGHTS CONTROLLED BY HEADLAMP/PARKLAMP
SWITCH
NOTE: For customer access circuit see Figure 1, Appendix page
M31.
Connections to any point in the circuits controlled by the head-
lamp switch will be on the customer access connectors, except
connections to the #12 circuit (headlamp hi-beam, green wire —
black stripe), the #13 circuit (headlamp low-beam, red wire —
black stripe) and the #15 circuit (feed wire to dimmer switch, red
wire — yellow stripe). Connections to the 12-13 or 15 circuits
(headlamp bulb circuits) must be avoided.
The maximum load on this circuit is 24 amps.
TRACTOR: Engine compartment customer access connectors
— Connect to circuit #491, wire color R-W, in cavity
“A” of connector “A” or Stud #2 in RPO
Customer Access Box
TRUCK: Rear chassis customer access connectors
— Connect to circuit #491, wire color R-W, in cavity
“A” of connector “A” or Stud #2 in RPO
Customer Access Box
TRUCK or TRACTOR: Rear of cab customer access circuits
— Circuit #491, wire color R-W, will also be
available in rear of cab in cavity “A” of connector
“A.” This is in addition to the above locations.
2. ADDED LIGHTS CONTROLLED BY MARKER LAMP SWITCH
The maximum load on this circuit is 24 amps.
TRUCK: Rear chassis customer access connectors
— Connect to circuit #490, wire color BL-R, in
cavity “C” of connector “B” or Stud #5 in RPO
Customer Access Box
TRUCK or TRACTOR: Rear of cab customer access circuits
— Circuit #490, wire color BL-R, will also be
available in rear of cab in cavity “C” of connector
“B.” This is in addition to the above locations.
3A. LIGHTS CONTROLLED BY TURN INDICATOR SWITCH
NOTE: The load on each circuit is limited to the 4.0 amps.
TRUCK or TRACTOR: Engine Compartment or Rear chassis
customer access connectors
— RH Stop /Turn Function
Connect to circuit #2, wire color W1–BL, in
cavity “C” of connector “C” or Stud #8 in RPO
Customer Access Box
— LH Stop /Turn Function
Connect to circuit #3, wire color GR-W, in cavity
“D” of connector “C” or Stud #9 in RPO
Customer Access Box
TRACTOR or TRUCK: Rear of cab customer access CRTS
— RH Turn Function
Connect to circuit #2, wire color W-BL, in cavity
“C” of connector “C.”
— LH Turn Function
Connect to circuit #3, wire color GR-W, in cavity
“D” of connector “C.”
3B. STOP LAMPS (ONLY) SWITCH
The stop lamp SW controls customer access stop lamp relay
R13.

Connection outside cab with rear of cab customer access
TRACTOR or TRUCK:
— Connect to circuit #809, wire color R-BK, in
cavity “B” of connector “C.”
— This circuit is controlled by relay R13 and
protected with a 15jamp. fuse. Fuse #33.
TRUCK:
— Connect to circuit #809, wire color R-BK, in
cavity “B” of connector “C” in rear chassis
customer access or Stud #7 in RPO Customer
Access Box. This circuit is protected with a 15
amp. fuse. Fuse #33.

Connection inside cab; auxiliary switch package or auxiliary
circuit package.
TRUCK OR TRACTOR:
— Connect to circuit #809, wire color R-BK, at stud
“M” in I/P fuse relay panel. This circuit is
protected with a 15 amp. fuse. Fuse #33.
4. ADDED LIGHTS OR ACCESSORIES CONTROLLED BY ADD-
ED SWITCHES
This section describes the connection points for added electrical
accessories when these accessories are to be controlled by
added switches not a part of the Ford-released vehicle. The
added switches and wiring must have sufficient electrical capac-
ity for the accessory load and must be protected by appropriate
fuses or circuit breakers. Also, added current draw must not
cause total loads to exceed capabilities of the base vehicle wir-
ing.

Key “On/Ign” or “Hot” in Run and Accy Function
TRUCK or TRACTOR:
— Connect to customer access stud “B” in the I/P
fuse relay panel. Circuit #297, wire color BK-GR.
This circuit is protected with a 25 amp. fuse.
Fuse #25.

“Battery” Power Function
TRUCK or TRACTOR:
— Connect to customer access stud “A” in the I/P
fuse panel. Circuit #37. This circuit is protected
with a 30 amp. maxi fuse. Maxi fuse “X” in power
distribution box.

“Ground” Function
TRUCK or TRACTOR:
— Connect to customer access stud “C” in the I/P
fuse panel. Circuit #57, wire color BK.

HEAVY TRUCK
APPENDIX

ADDING LIGHTS OR ELECTRICAL DEVICES
4A. ADDITIONAL CIRCUITS
NOTE: The following circuits are not connected to the vehicle
electrical system, and so can be used for any purpose. If it is to
be a power circuit, a fuse consistent with the Wire Size and Fuse
Selection Table (see Appendix page M28), MUST be installed
within 6 inches of the connection to the source of the power.
The circuits may be connected between studs in the I/P to pro-
vide specific functions. Refer to Figure 1, Appendix page M31.

Auxiliary Circuit (Tractor only engine compartment cus-
tomer access circuits connector): The auxiliary circuit
passes through the tractor/trailer plug at the back of the cab.
Connect to circuit #200, wire color BL, cavity “C”, connector
“B”, or stud #5, circuit #490 in RPO customer access circuits
box.

Feed from I/P fuse panel to chassis:
TRACTOR:
Feed #1: A 14GA wire, circuit #384, wire color W-BL, exists
between stud “D” in the fuse panel to cavity “B” of
connector “A” in the engine compartment customer
access connectors, or stud #2 in RPO customer
access box.
Feed #2: A 12GA wire, circuit #385, wire color W-R, exists
between stud “E” in the fuse panel to cavity “C” of
connector “A” in the engine customer access con-
nector, or stud #3 in RPO customer access box.
TRACTOR: Rear of cab customer access connectors
Feed #1: Circuit #384, wire color W-BL, also exists in cavity
“B” of connector “A”, or stud #2 in RPO customer
access box.
Feed #2: Circuit #385, wire color W-R, also exists in cavity
“B” of connector “A”, or stud #3.
TRUCK:
Feed #1: A 14GA wire, circuit #384, wire color W-BL, exists
between stud “D” in the fuse panel to cavity “B” of
connector “A” in the rear chassis customer access
connectors, or stud #2 in RPO customer access
box.
Feed #2: A 12GA wire, circuit #385, wire color W-R, exists
between stud “E” in the fuse panel to cavity “C” of
connector “A” in the rear chassis customer access
connectors, or stud #3 in RPO customer access
box.
TRUCK: Rear of cab customer access connector
5.
Feed #1: Circuit #384, wire color W-BL, also exists in cavity
“B” of connector “A”, or stud #2 in RPO customer
access box.
Feed #2: Circuit #385, wire color W-R, also exists in cavity
“C” of connector “A”, or stud #3 in RPO customer
access box.
A

Vehicle Data Link Connections
TRUCK or TRACTOR: With customer access circuits
— Connect to customer access stud “K” positive
signal circuit #716, color Y, and to stud “L”
negative signal, circuit #712, wire color P, in
the I/P fuse relay panel.

Start Circuit
TRACTOR: Or tractor engine compartment customer access
connector.
— Connect to circuit #32, wire color R-BL, at
terminal “E” connector “C” in the engine
compartment customer access connector, or
stud #10 in RPO customer access box.

Auxiliary I/P Switches
TRUCK or TRACTOR: RPO customer access circuits — aux-
iliary switch package.
Auxiliary Switch #1 Circuit #196, wire color R (16GA), runs
between feed side of the switch and stud
“F” in the fuse relay panel.
Circuit #197, wire color R-BL (16GA),
exists between the other side of the
switch and stud “G” in the fuse relay
panel.
Auxiliary Switch #2 Circuit #388, wire color Y-R (16GA), runs
between the feed side of the switch and
stud “N” in the fuse relay panel.
Circuit #832, wire color Y-BK (16GA), runs
between the switch and stud “P” in the
fuse relay panel.

Additional Battery Power
TRUCK or TRACTOR: RPO customer access circuits, —
auxiliary circuits pkg.
— Circuit is limited to max of 18 amps. Connect
to customer access stud “H” circuit #37, wire
color BK-Y, in the I/P fuse relay panel. This
circuit is protected with 30 amp. fuse #BB in
the power distribution box. Refer to Figure 2,
Appendix page M31.
RADIO FREQUENCY INTERFERENCE (RFI)
During modifications to the vehicle, manufacturers should take
the necessary precautions to maintain the RFI integrity of compo-
nents. (Canada has an RFI regulation in effect and the U.S.
Federal Communication Commission has rules and regulations
in effect on devices that emit RF energy. See Electrical Wiring
General Practices and Guidelines under heading titled “FCC,
F/CMVSS and Canadian RFI Requirements.”) Precautionary pro-
cedures and components listed below are examples and do not
necessarily represent a complete list.
Page M30

All components required to suppress RFI emissions, which
are removed during service, repair, or completion of the ve-
hicle, must be reinstalled in the manner in which they were
installed by Ford.

Metallic components installed on the body or chassis must be
grounded to the chassis.

Electronic circuits are to be located a minimum of 8 in. from
electrical noise sources, i.e., ignition wires, distributors, alter-
nator wiring, tachometer circuits, starter motor and associated
wiring as well as any other noise sources. With very sensitive
circuits, it may be necessary to shield the circuits as well.

Only “static conductive” accessory drive belts should be used.
Fan, water pump, power steering and other belts should be of
the OEM type or equivalent that will not build up a static elec-
trical charge.

If the distributor rotor tip is coated with silicone grease, do not
remove the coating.

Electrical grounds on all components must be retained.
6. GROUNDING OF ELECTRONIC DEVICES
To reduce the effects of intermittent operation and EMI, all elec-
tronic devices added to the vehicle are to be grounded at the
battery or ground plane.

If the ground plane method is selected, resistance between
the battery negative terminal and ground plane(s) must be
less than 200 MILLI OHMS.

When attaching to ground planes, use a serrated eyelet and
ground screw/bolt, zinc and iridescent chromate plating (S-36
Finish) minimum 72-hour corrosion requirement, protected
from the harsh environments, i.e., road splash, vehicle fluids.

Ground connections to sheet metal shall not be made via
punched/pierced hole but by extruded hole or weld nut: Drill
point screws are not recommended to ground low signal de-
vices.

Sensors and actuators of an electronic module are to be
grounded at the same vehicle location.

Metallic components installed on the body or chassis must be
grounded to the chassis.

Electrical circuits added to the vehicle should not be installed
near the high tension ignition components.

Only “static conductive” accessory drive belts should be used.

Fan, water pump, power steering and other belts should be of
the OEM type or equivalent that will not build up a static elec-
trical charge.

For any completed vehicle, additional measures may be need-
ed to adequately suppress RFI emissions.
 OUTSIDE CAB RPO CUSTOMER ACCESS BOX
ENGINE COMPARTMENT
Engine
Compartment
(TRUCK OR TRACTOR) ADDING LIGHTS OR ELECTRICAL DEVICES Page M31
Customer
Access 10 8 6 4 2
Stud No.
Wire Color Pin Connector
R – W – 491 A A 1 FUSE / CIRCUIT BREAKER & RELAY IDENTIFICATION
2
W – BL – 384 B “A” B
C AMP RELAY DESCRIPTION
W – R – 385 C 3
9 7 5 3 1 FUSE RATING DESCRIPTION
R-A Fuel Heater
BK – 57 A A 4
A 40 Fuel Heater Relay R-A R-B Customer Access Park Lamps
B “B” B –
IN CAB B 40 Fuse* 1 Fuel Solenoid &
BL – 200 C C R-C Customer Access Marker Lamps
5 Instrument Fuse* 2 ABS
Panel R-N Trailer Left Turn Signal
A A 6 C 40 Customer Acc, Marker & Park
Customer Lamp Relays, R-B & R-C
B B Access R-P Trailer Right Turn Signal
7
W – BL – 2 C “C” C Wire Color Pin D 40 Fuse* 13 Dome LP & Lighter, R-R Trailer Park Lamps
GR – W – 3 D 8 Fuse* 14 Mirrors & Diagnostic Conn ,
D BK –Y – 37 A R-U Trailer Marker Lamps
R – BL – 32 E 9 Fuse* 15 Audio/Phone
E BK – GR – 297 B
10 E 40 LH Pwr Window Relay** R2 R-V Trailer Stop Lamps
BK – 57 C
W – BL – 384 D F 40 Run Relay** R4, Fuse* F36, R-W Heated Moisture Ejectors
W –R – 385 E Flash to Pass & Trailer
Auxiliary Hookup Lamp
Switch R – 196 F
Back of Cab #1 R – BL – 197 G G 40 Heater/AC Blower Relay** R8
Customer H 40 Run Relay** R6 RELAY RELAY RELAY RELAY RELAY
Access R-W R-V R-U R-R R-P R-N
Wire Color Pin Connector J 40 Ign Switch & Run /Acc
Auxiliary Relay** R5
R – W – 491 A Instrument
Panel K 40 Fuse* 31 Courtesy Lamps,
W – BL – 384 B “A” Customer
GG FF EE DD CC BB AA Z Y X W V U T S
Fuse* 32 Cab Marker Lamps,
W – R – 385 C Access Fuse* 33 Cust Access Stop Lamps
NOTE: CUSTOMER Wire Color Pin
BK – 57 A ACCESS L 40 Headlamp Fuse* 37 & R P N M L K J H G F E D C B A
BOX NOT BK – Y – 37 H Headlamp Switch
B “B”
AVAILABLE GR – 715 J
BL – r – 490 C S 40 Fuse* 3, Horns & C/B* 4, Wiper
Y – 716 K
P – 712 L T 40 Trailer Turn Lamps Relay,
BK – R – 140 A R-P & R-N
R – BL – 809 B Auxiliary R – BK – 809 M RELAY RELAY RELAY
U 40 Fuses* 23 & 24, CB Hot Posts R-F R-E R-D R-C R-B R-A
W – BL – 2 C “C” Switch Y –R – 388 N
#2 Y – BK – 832 P V 40 RH Pwr Window Relay,** R1
GR – W – 3 D
E W 40 Trailer Marker & Park Lamps FRONT OF VEHICLE
Relays, R-U, R-R
Datalink
Diagnostic X 30 Customer Access,
Connector Stud “A”, I /P
Wire Color Pin Y 30 Heated Moisture Ejectors
Rear
Chassis Y – 716 A (+) Z 40 Fuse* 42, Turn Signals
Customer P – 712 B (–) AA 40 Customer Access, Run /ACC
Access Stud No. GY – 101 C Relay,** R10
Wire Color Pin Connector D BB 30 Customer Access,
R – W – 491 A A 1 BK – O – 25 E Stud “H”, I /P
“A” 2
W – BL – 384 B B
CC 40 Trailer Stop Lamps Relay R-V
W – R – 385 C C 3
** 1- 48 Fuses located in I/P fuse panel
BK – 57 A A 4 CUSTOMER ACCESS BOX ** 1- 22 Relays located in I/P fuse /relay panel
B “B” B – REAR OF FRAME
(TRUCK ONLY)
BL – R – 490 C C FIGURE 2: ENGINE COMPARTMENT POWER DISTRIBUTION BOX
5
10 8 6 4 2
BK – R – 140 A A 6
R – BK – 809 B B 7
W – BL – 2 C “C” C
GR – W – 3 D D 8
E E 9
9 7 5 3 1
10
BB0092
FIGURE 1: CUSTOMER ACCESS CIRCUITS
HEAVY TRUCK
APPENDIX