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7/30/2019 circuitos_9200[1]
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SERVICE MANUAL
SERVICE MANUAL SECTION
5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
Truck Model: 5000iStart Date: 11/04/2002
Truck Model: 9200iStart Date: 11/04/2002
Truck Model: 9400iStart Date: 11/04/2002
Truck Model: 9900iStart Date: 11/04/2002
s082252a, Formerly CTS-5298
11/01/2002
s082252a
Copyright 11/01/2002 International Truck and Engine Corporation
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7/30/2019 circuitos_9200[1]
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7/30/2019 circuitos_9200[1]
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
i
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, B 1, P. 3 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.4. BATTERY, B 2, 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.........................203.3. 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...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..314.10. 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
s082252a
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7/30/2019 circuitos_9200[1]
4/88
ii 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 L EVEL G AUGE, 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 L IGHTER, P. 1 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
8.2. C LOCK, P. 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .608.3. 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.... .. ... ... ... .. .. .. .. ... ... ... ... ... .. ... ... ... .. .. ..738.16. 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
http://-/?-http://-/?- -
7/30/2019 circuitos_9200[1]
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
iii
9.1. AIR D RYER, 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.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..10810.12. 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... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .11911.10. 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
http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?-http://-/?- -
7/30/2019 circuitos_9200[1]
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iv 5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
12.2. HEATER CAB, P. 2... ... ... ... ... .... .... .... ... .... .... ... .... .... ... .... .... ... .... .... ... .... ....127
12.3. HEATER BUNK AUXILIARY BLOWER, P. 3.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..128
12.4. HEATER BUNK W/STANDARD TEMPERATURE CONTROL, P. 4.. .. .. .. . .. . .. . .. .. . .. .. .. .129
12.5. HEATER BUNK W/THERMOSTAT TEMPERATURE CONTROL, P. 5. .. .. .. .. .. .. .. .. .. .. ..130
12.6. 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)..........................................................14213.12. 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).........................................15513.25. 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).... .. .. .. ... .. .. .. ... .. .. .. .. .. .. .. ... .. .. .. ... .16813.38. 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).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..19513.65. CONNECTOR COMPOSITES (955), (956), (962), (963), (992), (993), (994).. . . . . . . . . . . . . . . . .196
13.66. CONNECTOR COMPOSITES (995999), (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)...........................20713.77. 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)..........................21913.89. 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
s082252a
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ELECTRICAL CIRCUIT DIAGRAMS
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1
1. INSTRUCTIONS AND CHARTS (CHAPTER 1)
1.1. CIRCUIT IDENTIFICATION CHART, P. 1
CHANGE
RELEASE NO.
NAME
ELECTRICAL CIRCUIT DIAGRAM
DATE
DATE REV
NAVISTAR INTERNATIONALTRANSPORTATION CORP.
SHEET
THIS PRINT IS PROVIDED ONA RESTRICTEDBASISAND
IS NOT TOBE USEDIN ANYWAY DETRIMENTAL TO THE
INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.
DRAWN
PART NO.
CHK REFERENCE
P52600M
NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR
29JUL98 1
INSTRUCTIONS AND CHARTS FOR ALL MODELSRROEPKE
AE08-52011
CHAPTER 1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
CIRCUIT
NUMBERDESCRIPTION - COLOR
GENERATOR - CHARGE - RED
GROUND - WHITE
BATTERYFEED - RED
STARTER CONTROL - PINK
ENGINE SHUT-OFF - GRAY
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
ETHER START - TAN
ENGINE COOLING - TAN
ENGINE BRAKE GRAY
VOLTMETER - TAN
INSTRUMENT FEED - TAN
ENGINE WATER TEMPERATURE - TAN
ENGINE OILTEMPERATURE - TAN
TRANSMISSION OIL TEMPERATURE - TAN
AXLE OIL TEMPERATURE - TAN
WATER LEVEL - TAN
ENGINE OILPRESSURE - TAN
FUEL LEVEL - TAN
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
LOW AIR PRESSURE WARNING - GRAY
POWER DIVIDER LOCK (PDL) - GRAY
SPEEDOMETER - GRAY
TACHOMETER - GRAY
HEADLIGHT - HIGH BEAM - YELLOW
TURN SIGNAL - ORANGE
CLEARANCE AND IDENTIFICATION LIGHTS - BROWN58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
PANEL LIGHTS - DARK BLUE
COURTESYAND DOME LIGHTS - DARK BLUE
AUXILIARYLIGHTS - YELLOW
5TH WHEEL/WORK LIGHT - ORANGE
DAYTIME RUNNING LIGHTS - YELLOW
TAILLIGHTS - BROWN
STOP LIGHTS - ORANGE
BACK-UP LIGHTS - ORANGE
CIRCUIT
NUMBERDESCRIPTION - COLOR
IGNITION FEED - PINK
KEY SWITCH FEED - RED
AIR DRYER - GRAY
LIGHT SWITCH FEED - YELLOW
DIMMER SWITCH - YELLOW
HEADLIGHT - LOW BEAM - YELLOW
TURN SIGNAL LIGHTS - LEFT - ORANGE
TURN SIGNAL LIGHTS - RIGHT - ORANGE
TRAILER AUXILIARY - ORANGE
PYROMETER - TAN
DIFFERENTIALLOCK - GRAY
PARKING/MARKER LIGHTS - BROWN
HAZZARD LIGHTS - ORANGE
ALTERNATOR - RESISTANCE - RED
ACCESSORY FEED - LIGHT BLUE
FRONT AXLE - GRAY
FUEL PUMP - TANGENERATOR - FIELD - LIGHT BLUE
GLOW PLUG/PRE-HEATER - PINK
AMMETER - TAN
ENGINE OILLEVEL - TAN
PARK BRAKE WARNING - GRAY
ANTI-THEFT WARNING - LIGHT GREEN
POWER TAKE-OFF WARNING - GRAY
AIR SUSPENSION - GRAY
LICENSE PLATE LIGHT - BROWN
Figure 1 Circuit Identification Chart, page 1
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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
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
P 526 00M 2 9J UL98 02
INSTRUCTIONS AND CHARTS FOR A LL MODELSRROEPKEGSC2 ADDED CIR 73 DESC
AE08-52011
CHAPTER 1
A P53583SJPM 10DEC01
ADDED SEAT BELTS. B 55093FJ KP 4MAR 02
73
74
75
76
77
78
79
80
81
82
83
84
85
86
CIRCUITNUMBER
DESCRIPTION - COLOR
HEATER BLOWER MOTOR - LIGHT GREEN
87
88
89
90
91
92
93
94
95
96
97
98
99
CIRCUITNUMBER
DESCRIPTION - COLOR
AIR CONDITIONER - LIGHT GREEN
MIRRORS - HEATED * MOTORIZED - LIGHT GREEN
POWER WINDOW - LIGHT GREEN
CIGAR LIGHTER - LIGHT GREEN
HORN - ELECTRIC - GRAY
RADIO - ENTERTAINMENT - LIGHT GREEN
WINDSHIELD WASHER - GRAY
CLOCK/HOURMETER - LIGHT GREEN
DATA LINK AND DIAGNOSTICS - BLACK
AXLE SHIFT CONTROL - TAN
THROTTLE POSITION SENSOR - VIOLET
CRUISE CONTROL AND ELECTRONIC ENGINE - VIOLET
AUXILIARY FAN - LIGHT GREEN
POWER DOOR LOCKS - LIGHT GREEN
WINDSHIELD WIPERS - GRAY
TRANSMISSION (ELECTRONIC) - TAN
ANTILOCK BRAKES - GRAY
EXHAUST EMISSION - TAN
SNOW PLOW LIGHTS - YELLOW
* NOTE:
NOT ALL CIRCUITS MAY BE USED.
COLORS ABOVE ARE NEW STD COLORSFOR MAJOR HARNESSES.
INTERCOMMUNICATIONS - VIOLET
HYDRAULIC BRAKE PUMP - GRAY
COLLISION AVOIDANCE SYSTEM - LIGHT BLUE
NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR
SEAT BELTS - LIGHT GREEN
Figure 2 Circuit Identification Chart, page 2
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
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1.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3
P52600M 3
INSTRUCTIONS AND CHARTS FOR ALL MODELSRROEPKE
29JUL98
INSTRUCTIONS
AE08-52011
CHAPTER 1
A - SWITCH AND RELAY POSITIONS AS
SHOWN ON CIRCUIT DIAGRAMS
INDICATE NORMAL POSITION WITH
IGNITION OFF UNLESS OTHERWISE
NOTED.
B - MULTIPLE CONNECTORS ARE
DISPLAYED ON SCHEMATIC AS
SHOWN. REFER TO CONNECTOR
COMPOSITE WITH APPLICABLE
NUMBER FOR MORE COMPLETE
INFORMATION.
12 AND/OR 12
SINGLE IN-LINE CONNECTORS
DISPLAYED AS SHOWN WITHOUT
CONNECTOR NUMBER.
C - PHANTOM LINES INDICATE PRINTED CIRCUITS OR BUSSED
CIRCUITS. THESE CIRCUITS EXIST IN THE INSTRUMENT CLUSTERS
AND FUSE/CIRCUIT BREAKER CONNECTORS.
VOLTMETER
PRINTED
CIRCUIT
IN
INSTRUMENT
CLUSTER
13
16PK
A
B
F1
20A
BUSS IN FUSE
CIRCUIT BREAKER
CONNECTOR
INDICATES
BASIC FEED
WIRE CIRCUIT
IDENTIFICATION
FUSE RATING
LOCATION IN
FUSE/CIRCUIT
BREAKER
CONNECTOR
D - MULTIPLE CIRCUIT NUMBERS ON A LINE INDICATE ONE WIRE
DISTRIBUTING CURRENT TO TWO CIRCUITS.
FLASHER
55A/60
16OR
55
16OR
60
16OR
55A
16OR
30
A
87
87
86
85A
87
RELAY-SUPPRESSED
SWITCH-MANUAL MAGNETIC SWITCH
INDICATES
CASE GROUND
WIRE GAUGE &
COLOR
CIRCUIT
NUMBER
E - SWITCHES , RELAYS & COMPONENTS INDICATE EXTERNAL WIRE
CONNECTIONS AND/OR INTERNAL CONNECTIONS OR CONTACTS.
UP
DOWN
83-E
83-C
83-H83-F
83-GB
SWITCH
WINDOW
WIRE
CONNECTION
INTERNAL
CONTACT 20A
F19
75A
F18
78
BUSSED
CONTACTWIRE
CONNECTIONINTERNAL
CONTACT
ETHER
SWITCH
16RD
16BN
PIG-TAIL
IGN (24)
16LTGN
16LTGN
16WH
16LTGN16LTGN16LTGN 14LTGN
14LTBL
12B
Figure 3 Circuit Diagram Instructions, page 3
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4 5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
1.4. CIRCUIT DIAGRAM INSTRUCTIONS, P. 4
P52600M 4
INSTRUCTIONS AND CHARTS FOR ALL MODELSRROEPKE
29JUL98
INSTRUCTIONS
AE08-52011
CHAPTER 1
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.
STUD
OR
ADAPTER
J6
GROUND JUNCTION
THIS VEHICLE USES BUSSED CONNECTORS
AND ARE REFERRED TO AS ADAPTERS -
GROUND, FEED, IGNITION, ACCESSORY OR BATTERY.
A B C D E F G H J K
BUS ADAPTER
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).
GROUND CIRCUITS ARE DESCRIBED THUS:
11-G
11-GA
11-GB
97-G
97-GA
97-GB
SUFFIX
G IS NOT A SUFFIX BUT
INDICATES A GROUND CIRCUIT
COMMON GROUND
CIRCUIT NUMBER
H - ABBREVIATIONS: COLOR,NOUN AND ENGINE
COLOR ABBREVIATION NOUN ABBREVIATION
NOTE: FOR CIRCUIT DESCRIPTION OTHER THAN
GROUNDS, NEITHER THE LETTER G OR
THE COLOR WHITE WILL BE USED.
SUFFIX
G IS NOT A SUFFIXBUT
INDICATES A GROUND CIRCUIT
DEDICATED GROUND
CIRCUIT NUMBER
AQ - AQUA
BK - BLACK
BL - BLUE
BN - BROWN
DK GN - DARK GREEN
GD - GOLD
GY - GRAY
GN - GREEN
LT BL - LIGHT BLUE
LT GN - LIGHT GREEN
OR - ORANGE
PK - PINK
PL - PURPLE
RD - RED
SIL - SILVER
TN - TAN
VT - VIOLET
WH - WHITE
YL - YELLOW
A
ACC
AC - AIR CONDITIONER
AUX - AUXILIARY
AWG - AMERICAN WIRE GAUGE
B
BAT
CONN - CONNECTION OR CONNECTOR
DRL- DAYTIME RUNNING LIGHTS
ENG - ENGINE
FWD - FORWARD
GA - GAUGE
G
GND
I
IGN
IND - INDICATOR
L- LEFT
LT - LIGHT
N/ - NOT WITH
OPT - OPTIONAL
R - RIGHT
S - START OR SENDER
THERMO - THERMOSTAT
W/ - WITH
ACCESSORY
BATTERY
GROUND
IGNITION
FL - FUSIBLE LINK
W/O - WITHOUT
Figure 4 Circuit Diagram Instructions, page 4
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
5
1.5. SCHEMATIC SYMBOLS, P. 5
RROEPKE
529JUL98
INSTRUCTIONS AND CHARTS FOR ALL MODELS
P52600M
SCHEMATIC SYMBOL CHART
AE08-52011
CHAPTER 1
SYMBOL DESCRIPTION
MALE/FEMALE I N-LINE CONNECTION
MALE TERMINAL
FEMALE TERMINAL
GROUND
LIGHT-SINGLE FILAMENT
LIGHT-DOUBLE FILAMENT
FUSE / CIRCUIT BREAKER
DIODE
JUNCTION POINT
SPLICE
SWITCH-PUSH BUTTON
SWITCH-MANUAL/MECHANICAL
SWITCH-PRESSURE
SWITCH-WITH LIGHT
RELAY-SUPPRESSED
ACCELERATOR POSITION SENSOR
SYMBOL DESCRIPTION
RESISTOR
SWITCH CONTACT, NORMALLY OPEN
SWITCH CONTACT, NORMALLY CLOSED
30
87
A 87
86
85
SENDER-OIL,WATER,FUEL,TEMPERATURE
ALARM-ELECTRONIC
SOLENOID-GENERALUSAGE
MOTOR-ELECTRIC
CIGAR LIGHTER
HORN
SPEAKER-SOUND SYSTEM
FLASHER-TURN SIGNAL,HAZARD
MAGNETIC SWITCH
FUSIBLE LINK
LIGHT EMITTING DIODE (LED)
BB
A
CIRCUIT BREAKER
TYPE 1 TYPE 2OR 3
A
BB
A
CIRCUIT BREAKER
A
Figure 5 Schematic Symbols
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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
RROEPKE
RELAY PINOUT AND FUNCTION DATA
SEALED MINIATURE RELAY DATA
29JUL98 6
INSTRUCTIONS AND CHARTS FOR ALL MODELS
P52600M AE08-52011
CHAPTER 1
85
TYPICAL RELAY(INSERTION END)
87A
85
87
30
A 87
86
NORMALLY OPEN
CONTACT
RELAY SCHEMATIC
RELAY INSERTION END
FUSEBLOCK SOCKET
CONNECTOR SOCKET
C/4
A/2
E/1
B/5
D/3
CABLE INSERTION END
FUSEBLOCK SOCKET
CONNECTOR SOCKET
C
A
E
B
D
COMMON
CONTACT
ENERGIZING COIL
ENERGIZING COIL
NORMALLY CLOSED
CONTACT
30
86
87
87
30
85
86
87A
1 5
3 4 2
FUSEBLOCK SOCKET
CONNECTOR SOCKET
RELAY INSERTION END
WHEN 12V IS APPLIED TO THE
RELAYCOIL,THE SWITCH WIPER IS
PULLED FROM THE NORMALLY CLOSED
POSITION TO THE NORMALLYOPEN
POSITION.
85
NOTE:
30
87A
THE RELAY IS PRINTED WITH
THE NUMBERS 85,86,87,87A AND 30.
THE CONNECTOR BODY IS PRINTED
WITH 85,86,87,87A AND 30.
ENERGIZINGCOIL
30
87A ENERGIZING
COIL
86
FUNCTION
COMMONCONTACT
A
86
85
86
87A87
CABLE INSERTION END
87
87
87
NORMALLY OPEN
COIL
SEALED MINIATURE RELAY DATA
86
TYPICAL RELAY (INSERTION END)
30
85
30
RELAY SCHEMATIC
85
NORMALLY CLOSED
COIL
FUSEBLOCK SOCKET
CONNECTOR SOCKET
87
DATA RELAY AND FUNCTION DATA
Figure 6 Relay Pinout, Function Data & Sealed Relay
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
7
1.7. LAMP BULB CHART, P. 7
INTERNATIONAL TRUCK AND ENGINE CORPORATION
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
RROEPKE
LAMP BULB CHART
29JUL98 07
INSTRUCTIONS AND CHARTS FOR A LL MODELS
P52600M AE08-52011
CHAPTER 1
A 55093FADDED & EDITED SLPR ITEMSJKP 4MAR02
BULB APPLICATION WATTS OR CANDLEPOWER TRADE NUMBER
2 CANDLEPOWER.......................... 57AIR RESTRICTION GAUGE..............................
BACK-UP LIGHTS.....................................
CIGAR LIGHTER......................................
CLOCK - ANALOG.....................................
COURTESY LIGHT.....................................
DOME LIGHT.........................................
FOG LIGHT..........................................
HEADLIGHTS
HIGH/LOW BEAMS..............................
HIGH BEAM INDICATOR...............................
INSTRUMENT CLUSTER
ILLUMINATION LIGHT.............................
WARNING LIGHT.................................
READING LIGHT......................................
SIDE TURN SIGNAL - 9200/9400/9900..................
32 CANDLEPOWER.........................
1 CANDLEPOWER..........................
2 WATTS............................
21 CANDLEPOWER.........................
21 CANDLEPOWER.........................
100 WATTS..............................
32/3 CANDLEPOWER.......................
65/35 WATTS............................
3 CANDLEPOWER..........................
0.5 CANDLEPOWER........................
1 CANDLEPOWER..........................
0.5 CANDLEPOWER........................
15 CANDLEPOWER.........................
1156
1455
VDO-600 802
1142
1142
4921-1
3157
6053
168
37
161
37
1003
3157
SLEEPER
DOME LIGHT......................................... 15 WATTS............................... F15T8-CW
FRONT TURN SIGNAL
9200/9400/9900 INCANDESCENT
SPEEDOMETER....................................... 161
9200/9400/9900.....................................
HEATER AND AIR CONDITIONER CONTROLS................
SPOTLIGHT..........................................
STOP-TAIL-TURN SIGNAL..............................
1 CANDLEPOWER..........................
30 WATTS...............................
32/3 CANDLEPOWER.......................
4405
1157
LUGGAGE COMPARTMENT LIGHT..........................
READING LIGHT......................................
12 CANDLEPOWER.........................
12 CANDLEPOWER.........................
211-2
912
EXTERIOR MIRROR LIGHT.............................. 2 CANDLEPOWER.......................... 1895
HIGH/LOW B EAM............................... 65/35 WATTS............................ H5054
HALOGEN (OPTIONAL)
CLEARANCE/IDENTIFICATION LIGHTS - SMALL............
CLEARANCE/IDENTIFICATION LIGHTS - LARGE............
2 CANDLEPOWER..........................
4 CANDLEPOWER..........................
194
904
TACHOMETER......................................... 1 CANDLEPOWER.......................... 161
TURN SIGNAL INDICATOR............................. 0.5 CANDLEPOWER........................ 37
WORK LIGHT......................................... 35 WATTS............................... 4411
32/3 CANDLEPOWER.......................
OVERHEAD CABINET LIGHT.............................
TV/VCR & MICROWAVE CABINET LIGHT...................
12 CANDLEPOWER.........................
12 CANDLEPOWER......................... 211-2
211-2
Figure 7 Lamp Bulb Chart
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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
CHANGE
RELEASE NO.
NAME
ELECTRICAL CIRCUIT DIAGRAM
DATE
DATE REV
NAVISTAR INTERNATIONALTRANSPORTATION CORP.
SHEET
THIS PRINT IS PROVIDED ONA RESTRICTEDBASISAND
IS NOT TOBE USEDIN ANYWAY DETRIMENTAL TO THE
INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.
DRAWN
PART NO.
CHK REFERENCE
CHAPTER 212V POWER DISTRIBUTION - START FEED
CHAPTER 2
12FEB99 AE08-52502 1
5000/9100/9200/9400/9900U00EDL2
P50317A
B1 BAT
STUD
IS
GND
OFF
I
S
OFF
I
A
S
AI
OFF
S
AI
OFF
S
B
A
KEY
SWITCH
(40)
14FB
8RD
14C
10RD
15
12RD
F7-A
25A
PUSH
BUTTON
START
SWITCH
(41)
17A
14PK
17
14PK
17
14PK
START
FEED
ADAPTER
(509)
17B
14PK
STARTMAGNETICSWITCH
(CH3
,PG1-5
)
17B
16PK
(2)
W/PUSH
BUTTON
START
W/KEY
SWITCH
START
17
14PK
44
18GY
44A
16GY
FROM DRL
PARK BRAKE
SWITCH
(CH 11,PG 7)
Figure 8 Start Feed
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
9
2.2. ACCESSORY, P. 2
CHANGE
RELEASE NO.
NAME
ELECTRICAL CIRCUIT DIAGRAM
DATE
DATE REV
NAVISTAR INTERNATIONALTRANSPORTATION CORP.
SHEET
THIS PRINT IS PROVIDED ONA RESTRICTEDBASISAND
IS NOT TOBE USEDIN ANYWAY DETRIMENTAL TO THE
INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.
DRAWN
PART NO.
CHK REFERENCE
12FEB99
12V POWER DISTRIBUTION - ACCESSORY
CHAPTER 2CHAPTER 2CHAPTER 2
AE08-52502 2
5000/9100/9200/9400/9900U00EDL2
P50317A
(426)
B1 BAT
STUD
IS
GND
OFF
I
S
OFF
I
A
S
AI
OFF
S
AI
OFF
S
B
A
KEY SWITCH
(40)
14FB
8RD
14C
10RD
F7-A
25A
86
16LT GN
F5-B
15A12M
12LT BL
12
12LTB
L
A1
ACCESSORY
ADAPTER
(499)
12AC
12LT BL
12-GH
16WH
TO 4C
CONTROL RELAY
12AD
10LTBL
A3
ACCESSORY
ADAPTER
(501)
12P
12LTBL
FOGLIGHTSFUSE
12W
12LTBL
RIGHTELECTRICWINDOW
RELAY
ACCESSORY
ADAPTER
RELAY
(145)
86
16LT GNTO RADIO
(CH 8,PG 13)
*
(CH11
,PG8)
(CH8
,PG3)
30
87
A 85
86
87
12A
12LTB
L
ELECTRICWIPERINTERMITTENT
REL
AY
(CH8,PG6)
12F
12LTBL
12F12LT BL
86E16LT GN
86E16LT GN
(428)
TO CB RADIO
(CH 8,PG 12)
* FUSE AND RELAY
LOCATIONS VARY -
CHECK INSIDE POWER
DISTRIBUTION CENTERFOR ACTUAL LOCATION.
14BJ
10RD
F6-C
30A
ONWER/OPERATORSPARESWITCH
W/FUSE
(CH8
,PG14)
12S
12LTBL
15
12RD
14AJ
10RD
D
E
(CH 12,PG 1)
Figure 9 Accessory
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10 5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
2.3. BATTERY, B1, P. 3
CHANGE
RELEASE NO.
NAME
ELECTRICAL CIRCUIT DIAGRAM
DATE
DATE REV
NAVISTAR INTERNATIONALTRANSPORTATION CORP.
SHEET
THIS PRINT IS PROVIDED ONA RESTRICTEDBASISAND
IS NOT TOBE USEDIN ANYWAY DETRIMENTAL TO THE
INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.
DRAWN
PART NO.
CHK REFERENCE
12FEB99
12V POWER DISTRIBUTION - BATTERY
AE08-52502 3
5000/9100/9200/9400/9900U00EDL2
P50317A
CHAPTER 2
B1 BAT
STUD
14FB
8RD
14C
10RD
15
12RD
14R
10RD
14S
12RD
55
12OR
70E
10OR
85
16GY
57H
12OR
14F
10RD
14L
10RD
14AM
10RD
88B
16LT GN
F7-A 25A
F2-C 30A
F2-D 20A
F7-D 30A
F5-C 15A
F7-C 15A
14AN
10RD
B2 BAT
STUD
14AD
16RD
14BD
14RD
TO KEY SWITCH
TO IGNITION RELAY
TO STOP LIGHT RELAY
TO HORN RELAY
TO RADIO BATTERY
FEED
TO RIGHT TURN RELAY
TO ABS RELAY
TO AIR DRYER FUSE
TO RIGHT ELECTRIC WINDOW FUSE
TO FLASHER
14V
10RD
14A
2RD
FROM STARTER
MAGNETIC
SWITCH
(CH 3,PG 1-5)
FUSE LOCATIONS VARY -
CHECK INSIDE POWER
DISTRIBUTION CENTER
FOR ACTUAL LOCATION.
*
(CH 2,PG 2)
(CH 11,PG 14)
(CH 11,PG 14)
(CH 11,PG 14)
(CH 2,PG 10)
(CH 8,PG 7)
(CH 8,PG 13)
(CH 9,PG 2)
(CH 8,PG 3)
((CH 9, PG 1)
06BK B
M
S
(CH 3,PG 1-5)
B1 BAT
STUD
B2 BAT
STUD
14AL
10RDTO ELECTRIC WIPER
INTERMITTENT RELAY
82K
16GY
(CH 8,PG 6)
14J
16RD
14G
18RDTO SPEEDOMETER/
TACHOMETER MODULE(CH 6,PG 3,5,6,8,10
CH 7,PG 2-5
CH 9,PG 10)
TO LEFT TURN RELAY56H
12OR
F7-B 15A
(CH 11,PG 14)
14BC
14RDTO CATERPILLAR RUN RELAY FUSE
(CH 4,PG 3)
F4-D 15A
STARTER
MAGNETIC
SWITCH
CRANKING
MOTOR
SOLENOID
BATTERIES
COPPER
BUS BAR
N/3+1 BAT
(CH 8,PG 2)
TO A3 ACC ADAPTER RELAY14AJ
10RD
TO DRL MODULE (USA)(CH 11,PG 7)
14A
02RD
150A
MEGA FUSE
FROM
ALTERNATOR
14
02RD
2
04RD
FUSIBLE LINKS
14A
02RD
BA
TYPE I ONLY
14CP
10RD
(CH 9,PG 8,9)
94AH
10GYTO TRAILER ABS RELAY
F10-A 30A
66A
14YL
39A
16GY
F9-A 15A
F9-C 15A
14BL
14RD
B1 BAT
ADAPTER
(497)
14W
6RD
14K
8RD
Figure 10 Battery, B1
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
11
2.4. BATTERY, B2, P. 4
INTERNATIONAL TRUCK AND ENGINE CORPORATION
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
12V POWER DISTRIBUTION - BATTERY
12FEB99 AE08-52502 04
5000/9100/9200/9400/9900U00EDL2
P50317A
CHAPTER 2
P52739ESEB//ADDED 14BW A
RMVD 14N, ADDED 14AX. 55093FBJKP 4MAR02
14BW6RD
14X10RD
7510LT GN
F1-A 30A
77T14LT GN
F1-B 10A
TO A/C CONTROL RELAY14Z
10RD
14H6RD
14B10RD
6810BN
5018YL
14D10RD
50A18YL
5114YL
F3-C 30A
F3-D 10A
F8-A 10A
F8-B 25A
TO CAB & TRAILER TAIL RELAY
TO HEADLIGHT SWITCH
TO HEADLIGHT SWITCH
58D12BN
14E10RD
F3-A 20A
TO TRAILER MARKER RELAY
7012OR
F3-B 20A
TO HEADLIGHT RELAY
TO STOP LIGHT SWITCH
(CH 12,PG 2)
(CH 12,PG 1)
(CH 11,PG 2)
(CH 11,PG 2)
(CH 11,PG 9)
(CH 11,PG 9)
(CH 11,PG 9)
(CH 11,PG 14)
14M
10RDXXX
XXX
14T10RD
65A14OR
6318DK BL
F6-A 20A
F6-B 10A
F2-A 15A
F2-B 10A
14AX18RD
B2BATTERYADAPTER
(498)
TO OWNER/OPERATOR OPTION
TO OWNER/OPERATOR OPTION
TO WORK LIGHT
TO REFRIGERATOR FUSE
TO DOME & COURTESY LIGHTS
14AH
10RD
84
14LT GNTO CAB CIGAR LIGHTER
EXTRA FUSES PROVIDEDFOR OWNER/OPERATOR
CONNECTION
**
**
**
(CH 11,PG 15)
(CH 8,PG 1)
(CH 11,PG 5)
(CH 10,PG 8)
86K14LT GN
(CH 8,PG 11)
14AA14RD TO POWER SOURCE
F5-D 20A
63P16DK BL
14Y14RD
F1-D 15ATO SPOTLIGHT & READINGLIGHTS (CH 11,PG 5,13)
B2BATTERY
STUD
14AR10RD
F10-A 30A *14AS10RD TO OWNER/OPERATOR SPARE
SWITCH W/FUSE (CH 8,PG 14)
FUSE LOCATIONS VARY -CHECK INSIDE POWERDISTRIBUTION CENTER
FOR ACTUAL LOCATION.
*
(CH 12,PG 2)
TO HEATER CONTROL RELAY75A14LT GN
F1-C20A
BA
BA
TO HIGH SPEED RELAY
TYPE 1 ONLY
TYPE 1 ONLY
97DL14VT (CH 4,PG 3,6,10,14)
TO DATA LINK
14W
6RD
Figure 11 Battery, B2
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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
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
12FEB99
12V POWER DISTRIBUTION - BATTERY
AE08-52502 05
5000/9100/9200/9400/9900U00EDL2
P50317A
CHAPTER 2
55093FAADDED O/H CABINET LTS TO
F10-D & AUX CIR FAN PG WAS 1, F8-D WAS CH 10, PG 3,5.
J KP 4MAR 02
FUSE LOCATIONS VARY -CHECK INSIDE POWERDISTRIBUTION CENTER
FOR ACTUAL LOCATION.
*
TO SLEEPER POWER SOURCE
F10-C 20A14AW10RD
14AK6RD
*14AY12RD
(CH 10,PG 7)
TO AUX BUNK BLOWER RELAY
F10-B 15A*
(CH 12,PG 3)
F10-A 30A14AU10RD
75AW10LT GN TO SLEEPER BLOWER RELAYS
(CH 12,PG 3)
*
F8-D 20A
14AP14RD
63AA14DK BL TO SLEEPER LIGHTS/LUGGAGE
COMPARTMENT LIGHTS(CH 10,PG 4,6)
B2BATTERY
STUD
14AV10RD
14AX10RD TO AUX CIRCULATION FAN
*
(CH 10,PG 1-3)
F10-D 30A
75AX14LT GN
TO TV/VCR WIRING(CH 10,PG 9)
TO OVERHEAD CABINET LIGHTS(CH 10,PG 10)
Figure 12 Battery, B2 (cont.)
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
13
2.6. 3+1 BATTERY SYSTEM (DEEP CYCLE BATTERY B2 BATTERY), P. 6
12V POWER DISTRIBUTION - 3 + 1 BATTERY SYSTEM
CHANGE
RELEASE NO.
NAME
ELECTRICAL CIRCUIT DIAGRAM
DATE
DATE REV
NAVISTAR INTERNATIONALTRANSPORTATION CORP.
SHEET
THIS PRINT IS PROVIDED ONA RESTRICTEDBASISAND
IS NOT TOBE USEDIN ANYWAY DETRIMENTAL TO THE
INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.
DRAWN
PART NO.
CHK REFERENCE
12FEB99 AE08-52502 6
5000/9100/9200/9400/9900U00EDL2
P50317A
CHAPTER 2
ALTERNATOR
BG
7V
ISOLATED
BATTERY
MAGNETIC
SWITCH
R
7
16RD
7
16RD
11H
14WH
+ + + +
1ST 2ND 3RD
1/0BK
DEEP CYCLE
BATTERY
----
POWER
DISTRIBUTION
CENTER
GND STUD
14-F
L
10RUST
14A
6RD
14AB
6RD
B1
B2
GND
STUD
14A
2RD
11-G
G
10WH
11-G
8WH
4/0BK
TO
CRANKING
MOTOR
SOLENOID
(CH 3,PG 1-5)
7
16RD
1/0RD
14A
6RD
FROM
MEGA
FUSE
(CH 3,PG 1-5)
(RIGHT
DASH
PANEL)
Figure 13 3+1 Battery System (Deep Cycle Battery B2 Battery)
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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
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
U00EDL2
12V POWER DISTRIBUTION - GROUND ADAPTER COMPOSITE
07AE08-52502P50317A
CHAPTER 2
12FEB99
5000/9100/9200/9400/9900REVISED 11-GBC &
11-GBD. ADDED 38-G & 38-GB.
A 55093FJKP 4MAR02
*NOTE - A GROUND ADAPTER AS REFERRED TO IN THIS MANUAL IS ANINTERNALLY BUSSED CONNECTOR USED TO CONNECT & DISTRIBUTEGROUND CIRCUITS TO VARIOUS POINTS IN THE VEHICLE.
11-GA12WH
11-GC10WH
11-GX18WH
RIGHT MOTORIZED MIRROR
GROUNDADAPTER
(453)
GROUNDADAPTER
(456)
11-GE12WH
11-GAW14WH
13-GAD18WH
94-G16WH
11-GAC14WH
AIR DRYER RELAY
ABS RELAYS
FOG LIGHT RELAY & SWITCH
GROUNDADAPTER
(455)
11-GY10WH
11-GBC12WH
11-GAV18WH
AUXILIARY BUNK BLOWER RELAY& SLEEPER OPTIONS
CLOCK
GROUNDADAPTER
(454)
11-GB8WH
11-GD8WH
11-GI10WH
11-G8WH
GNDSTUD
25-G18WH PYROMETER CONTROL MODULE
(CH 8,PG 9)
(CH 9,PG 1)
(CH 9,PG 2,5)
(CH 11,PG 8)
(CH 12,PG 3 ; CH 10,PG 6-10)
(CH 8,PG 2CH 11,PG 11)
(CH 6,PG 7)
(LEFTDASH
PANEL)
(RIGHTDASH
PANEL)
11-GA
6WH
TOENGGND
(CH 3,PG 1-4)
GNDSTUD
RIGHT WINDOW SWITCH & RELAY(CH 8,PG 3)
G1
G4
G3
G2
11-GAD
18WH
SLEEPER OPTIONS(CH 10,PG 1-4)
11-GBD12WH
ABS TRAILER RELAY13-GCP
14WH
11-GAE18WH
(CH 8,PG 8)
RIGHT POWER MIRROR
(CH 9,PG 8)11-GZ18WH LEFT POWER MIRROR
(CH 8,PG 8)
11-GT18WH
62-GL18WH
62-GN18WH
62-GK18WH
62-GJ18WH
11-GR14WH
62-GQ18WH
62-GR18WH
DATA LINK 6-WAY(CH 4,PG 3,6,10,14)
CRUISE ON/OFF SWITCH(CH 4,PG 1,4,8)
CRUISE SET/RESUME SWITCH(CH 4,PG 1,4,8)
ENG BRAKE ON/OFF(CH 4,PG 2,5,9)
ENG BRAKE SELECT
INC/DEC IDLE DIAG(CH 4,PG 10,14)
DIAG ON/OFF(CH 4,PG 14)
(CH 4,PG 2,5,9)
CUMMINS & DET.
CUMMINS ONLY
DEIS. ONLY
38-G18WH DRIVER HEATED SEAT
(CH 8,PG 21)
38-GB18WH PASSENGER HEATED SEAT
(CH 8,PG 22)
Figure 14 Ground Adapter Composite
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
15
2.8. GROUND STUD COMPOSITE, P. 8
CHANGE
RELEASE NO.
NAME
ELECTRICAL CIRCUIT DIAGRAM
DATE
DATE REV
NAVISTAR INTERNATIONALTRANSPORTATION CORP.
SHEET
THIS PRINT IS PROVIDED ONA RESTRICTEDBASISAND
IS NOT TOBE USEDIN ANYWAY DETRIMENTAL TO THE
INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.
DRAWN
PART NO.
CHK REFERENCE
GROUND STUD COMPOSITE
12FEB99 AE08-52502 8
5000/9100/9200/9400/9900U00EDL2
P50317A
CHAPTER 2
RIGHT TURN RELAY57-G
18WH
11-GB
8WH
11-G
8WH
(CH 11,PG 14)
75-G
10WHHEATER CONN #1
(CH 12,PG 2)
GND
STUD
(RIGHT
DASH
PANEL)
11-G
A6WH
TO
ENG
GND
(CH 3,PG 1-5)
11-GG
10WH
FUSE BLOCK
ASSY GND
56-G
18WHLEFT TURN RELAY
(CH 11,PG 14)
70-G
18WHSTOP LIGHT RELAY
(CH 11,PG 14)
58-G
18WHTRAILER TAIL RELAY
(CH 11,PG 2)
(CH 11,PG 2)
TRAILER MARKER RELAY
77-G
18WH AIR CONDITIONING RELAY(CH 12,PG 1)
13-GT
18WHHEATER CONTROL RELAY
58-GA
18WH
(CH 12,PG 2)
(CH 11,PG 9)
50-GB
18WH HEADLIGHT RELAY
75-GC
18WHMED SPEED RELAY
(CH 12,PG 2)
75-GB
18WHHIGH SPEED RELAY
(CH 12,PG 2)
13-GA
18WHIGNITION RELAY
(CH 2,PG 20)
57-GA
16WHRIGHT SIDE TURN LIGHT
(CH 11,PG 12)
11-GAB
16WHDOME,READING,CLEARANCE & ID LIGHTS
(CH 11,PG 3-6)
38-G
18WHAIR SUSPENSION RELEASE SWITCH
(CH 7,PG 1)
43-G
18WHPDL SWITCH
(CH 7,PG 6)
11-GC
10WHG4 GND ADAPTER
(CH 2,PG 7)
(CH 2,PG 7)
G1 GND ADAPTER11-GA
12WH
(CH 12,PG 2)
HVAC CONTROL75-GL
18WH
(CH 12,PG 2)
AIR DIST75-GM
18WH
(CH 12,PG 2)
RECIRC75-GK
18WH
(CH 9,PG 14)
MERITOR G XMSN14WH
Figure 15 Ground Stud Composite
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16 5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
2.9. GROUND STUD COMPOSITE, P. 9
CHANGE
RELEASE NO.
NAME
ELECTRICAL CIRCUIT DIAGRAM
DATE
DATE REV
NAVISTAR INTERNATIONALTRANSPORTATION CORP.
SHEET
THIS PRINT IS PROVIDED ONA RESTRICTEDBASISAND
IS NOT TOBE USEDIN ANYWAY DETRIMENTAL TO THE
INTEREST OF THE NAVISTAR INTERNATIONAL TRANSPORTATION CORP.
DRAWN
PART NO.
CHK REFERENCE
12FEB99
GROUND STUD COMPOSITE
AE08-52502 9
5000/9100/9200/9400/9900U00EDL2
P50317A
CHAPTER 2
GND
STUD(LEFT
DASH
PANEL)
11-GD
8WH
52-GE
12WHHEADLIGHTS
(CH 11,PG 9)
RIGHT SIDE CLUSTER(CH 6,PG 1,2,9)
11-GJ
18WH
11-GF
10WH
77-GS
18WHA/C CONTROL RELAY
(CH 12,PG 1)
82-GB
16WHWASH/WIPE INTERMITTENT SWITCH
(CH 8,PG 6)
82-GC
16WH WIPER MOTOR(CH 8,PG 6)
11-GM
18WHLEFT SIDE CLUSTER
(CH 6,PG 4)
11-GL
18WHSPEEDO/TACH MODULE
(CH 6,PG 3,5,6,8,10
CH 7,PG 2-5
CH 9,PG 10)
11-GQ
16WH
62-GC
18WHLEFT GAUGE CLUSTER PANEL LIGHTS
(CH 11,PG 11)
62-GD
18WHSPEEDO/TACH MODULE PANEL LIGHTS
(CH 11,PG 11,14)
62-GB
18WHRIGHT GAUGE CLUSTER PANEL LIGHTS
(CH 11,PG 11)
11-GY
10WH
TO AUX POWER
11-GN
10WH(CH 9,PG 9 ; CH 12,PG 4,5)
TO GROUND TERMINAL (B-PILLAR)
(CH 2,PG 7)
TO G2 GROUND ADAPTER
86-GK
14WH(CH 8,PG 11)
11-GI
10WH
G3 GND ADAPTER(CH 2,PG 7)
CIGAR LIGHTER(CH 8,PG 1)
LOW AIR SWITCH 1(CH 7,PG 4)
LOW AIR SWITCH 2(CH 7,PG 4)
LT SIDE TURN LGT(CH 11,PG 12)
11-GE
12WH
84-G
16WH
11-GK
16WH
40-GA
16WH
40-GB
16WH
56-GA
16WH
11-GS
16WH
11-GP
12WH
62-GW
18WH
62-GAR
16WH
66-G
14WH
62-GAS
18WH
CAB/TRAILER LGT SWITCH
PANEL LGT SWITCH
CAB/TRAILER LGT SWITCH
L4 PANEL GND ADAPTER(CH 2,PG 11)
(CH 2,PG 11 ; CH 11,PG 11)
(CH 11,PG 2)
(CH 11,PG 2)
PANEL LGT SWITCH(CH 2,PG 11; CH 11,PG 11)
DRL PARK BRAKE
SWITCH
44-GB
16WH
DRL MODULE
(CH 11,PG 7)
(CH 11,PG 7)
66-GA
14WH
Figure 16 Ground Stud Composite
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
17
2.10. IGNITION, P. 10
INTERNATIONAL TRUCK AND ENGINE CORPORATION
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
12FEB99
12V POWER DISTRIBUTION - IGNITION
AE08-52502 10
5000/9100/9200/9400/9900U00EDL2
P50317A
CHAPTER 2
2 SPEED AXLE SW WAS GOING B 55093F
TO CH 11, PG 10. ADDED 13EF & 13EG AT (495).
J KP 4MAR 02
B1 BATSTUD
I1IGNITIONADAPTER
(494)
IS
GND
OFF
I
S
OFF
I
AS
AIOFF
S
AI
OFF
S
B
A
14C10RD
15
12RD
F7-A25A
13
12PK
F4-C10A
13H12PK
F4-A10A
13B12PK
13V
16PK
TOBACK-UPLIGHTS
30
87 A
87
86
85
13A12PK
13AH
14PK
13Z
12PK
13AB
14PK
13W
14PK
13L
12PK
AIRDRYERRELA
Y
2SPEEDAXLESWITCH
PYROMETERFUSE
ABSIGNITIONRELAY
ETHERSTARTFUSE
EC
M
28C
18TN
28D
18TN
28A
18TN
28B
18TN
LEFTGAUGECLUSTER
LEFTGAUGECLUSTER
SPEEDO/TACHCLUSTER
RIGHTGAUGECLUSTER
IGNITIONRELAY
(462-R1)
14R10RD
14S12RD
F2-C30A
(CH4,PG3,6,14
CH6,PG4
CH7,PG2
CH11,PG4,15)
(CH6,PG1,2,9
CH7.PG1,4-8
CH9,PG2,5
CH11,PG7)
(CH4,PG3,6,10,14)
(CH6,PG3,5,6,8,10
CH7,PG2-5
CH9,PG10)
(CH6,PG11)
(CH9,PG2,6)
(CH6,PG7)
(CH4,PG3,7,10,15)
(CH9,PG10)
(CH9,PG1)
(CH 11,PG 1)
13F
12PK
(CH7,PG6)
PDLB
UZZER
13X
18PK
13U
12PK
(CH12,PG
2)
HVACCONTROLF
EE
D
14K
8RD
KEYSWITCH
(40)(CH 12,PG 2)
13-GA
18WH
IGN-DRLFE
ED
(CH
11,PG7)
TOHIGH SPEED
RELAY(462-R2)
13BN
12PK
13J
12PK
71
18OR
TO MOTORIZEDAND HEATED
MIRRORS
(CH 8,PG 8)
13P12PK1
3BL
14PK
93
14TN
I2IGNITIONADAPTER
(495)
AUXBUNKBLOWERRELAY
(CH12,PG3)
13AT
18PK
AUXBUNKBLOWERRELAY
(CH12,PG3)
13AT
18PK
ABSTRAILERRELAY
(CH9,PG8)
13CP
14PK
14FB
8RD
13Y
14PK
MERITORGXMSNFUSE
(CH9,PG14)
13BM
16PK
ENGINEFAN
(CH5,PG1)
DRIVERHEATEDSEAT
(CH8,PG21)
13EF
18PK
PASSENGERHEATEDSEAT
(CH8,PG22)
13EG
18PK
Figure 17 Ignition
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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
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
CHAPTER 2
12FEB99
12V POWER DISTRIBUTION - PANEL LIGHTS ADAPTER
COMPOSITE
P50317A
U00EDL2 5000/9100/9200/9400/9900
AE08-52502 11A 55093FADDED CIR 62X & 86-GKJKP 4MAR02
11-GF10WH
GNDSTUD
62-GC18WH
62-GB18WH
62-GD
18WH
L4PANEL
LTS GNDADAPTER
(506)
LEFT SIDE CLUSTER
RIGHT SIDE CLUSTER
SPEEDO/TACH MODULE
(CH 11,PG 11)
(CH 11,PG 11)
(CH 11,PG 11)
PANELLIGHT
SWITCH(425)
AC
B
D
F
L1PANEL
LTS FEEDADAPTER
(503)
(LEFTDASH
PANEL)
11-GD8WH
62-GAS18WH
62-GAR16WH
HEADLIGHT SWITCH
TRAILER LIGHTS SWITCH(CH 11,PG 9)
(CH 11,PG 2)
11-GK16WH
11-GT18WH CRUISE/DIAGNOSTIC/ENG
BRAKE SWITCHES
62-GAY18WH ETHER START SWITCH
(CH 6,PG 11)
11-GP
12WH
62-GW
18WH
11-GS
16WH
(CH 11,PG 11)
62B18DK BL
SPEEDO/TACH MODULE
62C18DK BL LEFT SIDE CLUSTER
WIPER SWITCH(CH 8,PG 6)
(CH 11,PG 11)
62D18DK BL
62AG
16DK BL
RIGHT SIDE CLUSTER(CH 11,PG 11)
62T16DK BL CIGAR LIGHTER LIGHT
(CH 11,PG 11)
62W
16DKBL
62W
16DKBL
62A
16DKBL
62
A
16DK
BL
62
16D
KBL
(CH 11,PG 11)
HEADLIGHT SWITCH
62AP16DK BL DOME LIGHT SWITCH
TRAILER LIGHTS SWITCH(CH 11,PG 2)
(CH 11,PG 9)
62AS16DK BL
62AR16DK BL
HEATER CONTROL PANEL LIGHT(CH 11,PG 11)
62P16DK BL
62S
16DKBL
62AQ16DK BL CLOCK
(CH 8,PG 3)
62AL16DK BL
(CH 11,PG 11)
(CH 11,PG 8)
RIGHT WINDOW SWITCH
FOG LIGHT SWITCH62AN
16DK BL
62M
16DKBL
(CH 4,PG 1,2,4-6,8-10,12-14)
62AV16DK BL
ETHER START SWITCH(CH 8,PG 9)
62AY16DK BL
62AW16DK BL
CRUISE/DIAGNOSTIC/ENGBRAKE SWITCHES
RT MOTO MIRRORS SW
L2PANEL
LTS FEEDADAPTER
(504)
62AE
16DKBL
62AB16DK BL GAUGE PANEL LIGHT
(CH 11,PG 11)
62-GAB18WH GAUGE PANEL LIGHT
(CH 11,PG 11)
62-GH18WH SPARE SWITCH N/FUSE
(CH 8,PG 14)
11-GAL18WH SPARE SWITCH W/FUSE
(CH 8,PG 14)
62H16DK BL SPARE SWITCH N/FUSE
(CH 8,PG 14)
62U16DK BL SPARE SWITCH W/FUSE
(CH 8,PG 14)
(CH 4,PG 1,2,4-6,8-10,12-14)
62BP16DK BL
BUNK CONTROL PNL SWITCH(CH 10,PG 3,8,9)
62M16DK BL
ENGINE FAN OVERRIDE SWITCH(CH 5,PG 3,4)
(CH 6,PG 11)
REFRIGERATOR SWITCH(CH 10,PG 6)
62X16DK BL
REFRIGERATOR SWITCH(CH 10,PG 6)
86-GK18WH
Figure 18 Panel Lights Adapter Composite
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
19
3. 12 VOLT CHARGING & CRANKING SYSTEM (CHAPTER 3)
3.1. W/CAT AND CUMMINS ENGINES, P. 1
INTERNATIONAL TRUCK AND ENGINE CORPORATION
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
26JUL01
CHARGING AND CRANKING (12V)
W/CAT AND CUMMINS ENGINES
AE08-54038 01
5000/9200/9400/9900U00CJB5
54719V
CHAPTER 3
S
M
B
+
17C
08PK
B
M
S
- -
BATTERIES
STARTERMAGNETICSWITCH
CRANKING
MOTORSOLENOID
2/O BK
11-GS02BK
FRAMEGROUND
ENGINEGROUND
11-GA06WH
CABJ4 GROUND
2-G04WH
4/0 BK
+- -
4/0 BK
(2) 12GA, BLFUSIBLE LINKS
06
BK
06BK
4/0 BK
06
BK
06BK
+- -
+- -
06
BK
06BK 0
1BK
FRAMEGROUND
4/ 0
BK
17B
16PK
(2)
17B
14PK
CRANKING MOTOR
FROM SENSORGROUND SPLICE
(CH 3,PG 2CH 5,PG 2CH 6,PG 4,9CH 12,PG 1)
11-GU12WH
B
G
B1BATTERY
STUD
STARTFEED
ADAPTER(509)
1402RD
204RD
1402RD
204RD
2-G
04WH
14A
02RD
14A
02RD
150AMEGAFUSE
ALTERNATOR
11-G12WH
TO ECMPOWERCONN
W/CAT(CH 4,PG 2)
14B
12RD
14A
12RD
TO ECMPOWERCONN
(CH 4,PG 2,7)
15A
15A
14D
12RD
14C
12RD
11-G
12WH
FROM ECMGROUND
W/ISX,ISM(CH 4,PG 7)
Figure 19 W/Cat and Cummins Engines
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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
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
26JUL01
12V CRANKING SYSTEM W/OVERCRANK PROTECTIONW/CAT AND CUMMINS
AE08-54038 02
5000/9200/9400/9900U00CJB5
54719V
CHAPTER 3
S
M
B
17C
8PK
B
M
S
STARTERMAGNETICSWITCH
CRANKINGMOTORSOLENOID
TO ALTERNATOR(CH 3,PG 1)
17D
18PK
17D
18PK
FL 12BL
FL
12BL
17-G18WH
17-G
18WH
11-GU
12WH
CRANKINGMOTOR
FOR REMAINDER OFCRANK MOTOR SOLENOIDAND CRANK MOTOR WIRINGSEE CHARGING & CRANKINGSECTION.
(275)17D18PK
17B
16PK
(2)
17B
14PK
STARTFEED
ADAPTER(509)
ENGINEGROUND
B1BATTERY
STUD
14A
02RD
14A
02RD
150AMEGAFUSE
1402RD
204RD
1402RD
204RD
Figure 20 W/Overcrank Protection W/Cat and Cummins Engines
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
21
3.3. W/I6 HEUI ENGINE, P. 3
INTERNATIONAL TRUCK AND ENGINE CORPORATION
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
54719V
CHARGING AND CRANKING (12V)W/I6 HEUI ENGINE
26JUL01 03
5000/9200/9400/9900U00CJB5
AE08-54038
CHAPTER 3
06BK
2
04RD
B
01BK
STARTFEED
ADAPTER(509)
+
CRANKING MOTOR
B
B1BATTERY
STUD
4/0 BK
06BK
FRAMEGROUND
BATTERIES
24RD
-
+
17B
16PK
14-FL
02RD
S
M
06BK
06BK
14A
02RD
150AMEGAFUSE
17C
08PK
-
STARTERMAGNETICSWITCH
G
4/0 BK
06BK
2
06BK
-
ALTERNATOR
+
17B
14PK
11-GL
4/0 BK
06BK
MAINGROUND
-
CRANKINGMOTORSOLENOID
11-GA06WH
+
14A
02RD
40A14B
10RD
11-G10WH
TO MODULEPOWER
14A10RD
(CH 4,PG 11)
Figure 21 W/I6 HEUI Engine
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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
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
CHAPTER 3
26JUL01 04
5000/9200/9400/9900U00CJB5
54719V
12V CRANKING SYSTEM W/OVERCRANK PROTECTIONW/I6 HEUI
AE08-54038
(CH 3,PG 3)
2
CRANKING
17-G
M
18PK
B1BATTERY
STUD
B
150AMEGA
FUSE
FOR REMAINDER OFCRANK MOTOR SOLENOIDAND CRANK MOTOR WIRINGSEE CHARGING & CRANKINGSECTION.
TO ALTERNATOR
2
16PK
S17D
STARTFEED
ADAPTER(509)
02
RD
14
02
RD
04RD
STARTERMAGNETICSWITCH(4 TERM)
14A
275
18PK
14PK
18PK
17C
14A
17B
11-GU
02
RD
2
S
18WH
04RD
17D
CRANKING
17B
MOTORSOLENOID
MOTOR 17D
14WH
18WH
B
17-G
M
8PK
STARTER MOTORGROUND
Figure 22 W/Overcrank Protection W/I6 HEUI
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5000i, 9200i, 9400i and 9900i Chassis Built November 4, 2002 and After
ELECTRICAL CIRCUIT DIAGRAMS
23
4. ENGINE SYSTEMS (CHAPTER 4)
4.1. CATERPILLAR C10, C12, C15, AND C16 CRUISE CONTROL, P. 1
INTERNATIONAL TRUCK AND ENGINE CORPORATION
NAME
DATE
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.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PARTNO.
DATE REFERENCEREVCHK
26JUL01
CAT C10, C12, C15 & C16 - CRUISE CONTROL
AE08-54039 01
5000/9200/9400/9900U00CJB5
54719V
CHAPTER 4
99
16
VT
ECM (400)
97-GC
18VT
97AE18VT
CRUISESET/
RESUME(436)
97-GB
18VT
97AL
18VT
97AB
18VT
97AA
18VT
97AH
18VT
97AE
18VT
99
18VT 9
9A(8V)
18VT
97-GF18VT
CRUISEON/OFF(435)
(404)
99A(8V)18VT
9918VT
THROTTLEPOSITION
SENSOR
(PEDAL INRELEASED
POSITION)
CLUTCHSWITCH(PEDAL INRELEASED
POSITION)
BK
WH
RD
BRAKESWITCH(141) 18
BK
VEHICLE
SPEEDSENSOR(1099)
18BK
BA
66
97AE
16VT
J
59
97AH
16VT
R
22
97AL
16VT
F
45
97AB
16VT
I
35
97AA
16VT
K
44
99-GA
18VT
7
8
31
2
5
V
97-GA
16VT
97-GA
18VT
(294)
97-GH18VT
62-GK
18WH
62
K
16DKBL
62-GJ
18WH
11-GT
18WH
62AV
16DKBL
62J
16DKBL
PANELLTS FEEDADAPTER
(504)
G4 GROUNDADAPTER
(456)
32334
99A(8V)
16VT
97AK
16
VT
97AJ
16VT
97-G
16VT
FROM
ENGINEBRAKEON/OFFSWITCH
(CH 4,PG 2)
24-G18GY
(190)
25
346
8
7
4
5
6
1
11-GX
18WH
Figure 23 Caterpillar C10, C12, C15 and C16 Cruise Control
s082252a
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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
NAME
DATE
THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND