International 5500, 5600i, 5900i, 9200i, 9400i Service Manual
...
SERVICE MANUAL
SERVICE MANUAL SECTION
5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005
to February 28, 2007 — ELECTRICAL CIRCUIT DIAGRAMS
Model: 5500i
Start Date: 12/01/2005 End Date: 02/28/2007
Model: 5600i
Start Date: 12/01/2005 End Date: 02/28/2007
Model: 5900i
Start Date: 12/01/2005 End Date: 02/28/2007
Model: 9200i
Start Date: 12/01/2005 End Date: 02/28/2007
Model: 9400i
Start Date: 12/01/2005 End Date: 02/28/2007
Model: 9900i
Start Date: 12/01/2005 End Date: 02/28/2007
S08316
11/03/2006
08316
Copyright©11/03/2006 International Truck and Engine Corporation
S
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
Table of Contents
1. INSTRUCTIONS AND CHARTS (CHAPTER 1).....................................................................1
1.1. CIRC UIT IDENTIFICATION CHART, P. 1................................................................1
1.2. CIRC UIT 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 AND 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, P. 3.............................................................................................10
2.4. BATTERY, B2, P. 4........................................................................................11
2.5. BATTERY, B2 (CONT.),P. 5..............................................................................12
2.6. 3+1 BATTERYSYSTEM,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. PANELLIGHTS ADAPTER COMPOSITE, P. 11.....................................................18
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3. 12 VOLT CHARGING AND CRA NKING SYSTEM (CHAPTER 3).............................. ................19
3.1. W/CAT AND CUMMINS ENGINES, P. 1................................................................19
3.2. W/OVERCRANK PROTECTION W/CAT AND CUMMINS ENGINES, P. 2.........................20
3.3. W/I6 HEUIENGINE,P. 3..................................................................................21
3.4. W/OVERCRANK PROTECTION W/I6 HEUI, P. 4.....................................................22
3.5. W/CAT AND CUMMINS ENGINES AND W/1GA CHARGINGCIRCUIT, P. 5......................23
4. ENGINE SYSTEMS (CHAPTER 4)..................................................................................24
4.1. CATERPILLAR C10, C11, C12, C13, C15, AND C16 CRUISE CONTROL, P. 1...................24
4.2. CATERPILLAR C10, C11, C12, C13, C15, AND C16 ENGINE BRAKE, P. 2......................25
4.3. CATERPILLARC10, C11,C12,C13, C15, ANDC16ENGINE CONTROLS, P. 3.................26
4.4. CUMMINS ISM,ISX CRUISE CONTROL, P. 4.........................................................27
4.5. CUM MINS ISM, ISX ENGINE BRAKE, P. 5............................................................28
4.6. CUMMINS ISM , ISX — ENGINE CONTROLS, P. 6...................................................29
4.7. CUMMINS AHD AND ISM – ENGINECONTROLS, P. 7.............................................30
4.8. I6 HEUI — CRUISE CONTROL, P. 8....................................................................31
4.9. I6 HEUI — ENGINE BRAKE,P. 9.......................................................................32
4.10. I6 HEUI —ENGINE CONTROLS, P. 10...............................................................33
4.11. I6 HEUI — MODULE POWER AND GROUND SYSTEM, P. 11....................................34
4.12. I6 HEUI — ACCELERATOR, BAP, AMBIENT AIR TEMP SENSOR SYSTEM, P. 12............35
4.13. I6 HEUI — SURGE TANK AND EXHAUST BRAKE SOLENOID, P. 13...........................36
5. FANS (CHAPTER 5)..................................................................................................37
5.1. HORTON AND KYSOR ENGINE FAN WITH CAT C10, C11, C12, C13, C15 AND C16 W/ AND
N/ A/C, W/ AND N/ MANUAL FAN OVERRIDE SWITCH, P. 1.................................... ...37
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ii 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 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..............................................................38
5.3. HORTON AND KYSORENGINE FAN WITH I6 HEUIENGINESW/SHUTTER, P. 3..............39
6. GAUGES AND SYSTEMS (CHAPTER 6)............................................... ...........................40
6.1. 4X2 REAR AXLE OIL TEMPERATURE GAUGE, P. 1................................................40
6.2. 6X4 AXLE FORWARD-REAR AND REAR-REAR TEMPERATURE GAUGE, P. 2................41
6.3. ENGINE OIL PRESSURE GAUGE, P. 3................................................................42
6.4. ENGINE OIL TEMPERATURE GAUGE, P.4...........................................................43
6.5. ENGINE WATER TEMPERATURE GAUGE, P. 5......................................................44
6.6. FUEL LEVEL GAUGE,P. 6..............................................................................45
6.7. PYROMETER GAUGE,P. 7..............................................................................46
6.8. SPEEDOME TER GAUGE — TACHOMETER GAUGE, P. 8.................... .....................47
6.9. TRANSMISSION OILTEMPERATURE GAUGE,P. 9.................................................48
6.10. VOLTMETER GAUGE, P. 10............................................................................49
6.11. ETHERSTART, P. 11....................................................................................50
6.12. MANIFOLD PRESSUREGAUGE, P. 12..............................................................51
7. WARNING LIGHTS (CHAPTER 7)..................................................................................52
7.1. AIR SUSPENSION RELEASE WARNING LIGHT, P. 1...............................................52
7.2. ENGINE OIL PRESSURE WARNING LIGHT, P. 2........ ................ ................ .............53
7.3. ENGINE WATER TEMPERATURE WARNING LIGHT, P. 3..........................................54
7.4. LOW AIR PRESSURE WARNING LIGHT,P. 4........................................................55
7.5. LOW FUEL LEVEL WARNING LIGHT, P. 5............................................................56
7.6. POWER DIVIDER LOCK (PDL) WARNINGLIGHT AND BUZZER,P. 6...........................57
7.7. DIFFERENTIAL LOCK WARN LIGHT — 4X2, P. 7.......... .........................................58
7.8. DIFFERENTIAL LOCK WARN LIGHT — 6X4, P. 8.......... .........................................59
8. CAB ACCESSORIES (CHAPTER 8)...............................................................................60
8.1. CIGAR LIGHTER, P. 1....................................................................................60
8.2. CLOCK, P. 2................................................................................................61
8.3. ELECTRIC WINDOW —RIGHT,P. 3...................................................................62
8.4. ELECTRIC WINDOW —RIGHT ANDLEFT, P. 4......................................................63
8.5. DEFROSTER FAN(S),P. 5...............................................................................64
8.6. ELEC TRIC WINDSHIELD W IPERS WITH INTERMITTENT WIPE AND WASH, P. 6.............65
8.7. HORN, P. 7.................................................................................................66
8.8. MIRROR LIGHTS ANDHEATEDMIRRORS, P. 8.....................................................67
8.9. RIGHT MOTORIZEDMIRROR,P. 9.....................................................................68
8.10. DUAL AXIS MOTORIZED MIRRORS, P. 10..........................................................69
8.11. POWER SO URCE (CB), P. 11..........................................................................70
8.12. RADIO-CB ACCOMMODATION PACKAGE, P. 12..................................................71
8.13. RADIO-CAB, SPEAKERS, P. 13.......................................................................72
8.14. OWNER/OPERATOR SPARE SWITCH,P. 14........................................................73
8.15. ELECTRIC LOCK —RIGHT AND LEFT, P. 15.......................................................74
8.16. INTERVISION DISPLAY, P. 16..........................................................................75
8.17. EATON VORAD — COLLISION AVOIDANCE, P. 17................................................76
8.18. EATON VORAD — COLLISION AVOIDANCE, P. 18................................................77
8.19. TEMPERATURE/COMPASS DISPLAY, P. 19.........................................................78
8.20. ROAD RELAYIV, P. 20..................................................................................79
8.21. HEATED SEAT —DRIVER,P. 21......................................................................80
8.22. HEATED SEAT —PASSENGER, P. 22...............................................................81
9. CHASSIS ACCESSORIES (CHAPTER 9).........................................................................82
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5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
9.1. AIR DRYER, P. 1...........................................................................................82
9.2. ABS/ATC (BENDIX), P. 2.................................................................................83
9.3. ABS/ATC (BENDIX) (CONT.),P. 3.......................................................................84
9.4. ABS/ATC (BENDIX) (CONT.),P. 4.......................................................................85
9.5. ABS/ATC (WABCO), P. 5.................................................................................86
9.6. ABS/ATC (WABCO) (CONT.), P. 6......................................................................87
9.7. ABS/ATC (WABCO) (CONT.), P. 7......................................................................88
9.8. TRAILER CONNECTION —BACKOF SLEEPER MOUNTED W/TRACTOR ABS, P. 8.........89
9.9. TRAILER CONNECTION W/FOUR WHEEL TRAILER — FRAME MOUNTED, P. 9.......... ....90
9.10. TWO SPEED AXLE WIRING, P. 10....................................................................91
9.11. TRUCK BODY CON NECTION, P. 11..................................................................92
9.12. TRAILER CONNECTION N/SLEEPER — BACK OF CAB MOUNTED, P. 12....................93
9.13. TRAILER CONNECTION W/FOUR WHEEL TRAILER — FRAME MOUNTED W/5000, P.
13.............................................................................................................94
9.14. MERITOR G SERIES TRANSMISSION, P. 14........................................................95
9.15. EATON AUTOSHIFT TRANSMISSION — CAB WIRING, P. 15....................................96
9.16. EATON AUTOSHIFT TRANSMISSION — TRANSMISSION WIRING, P. 16.....................97
9.17. EATON LIGHTNING TRANSMISSION — TRANSMISSION WIRING, P. 17......................98
9.18. EATON ULTRASHIFT/DM2 —TRANSMISSION WIRING, P. 18...................................99
9.19. EATON ULTRASHIFT/DM2 —TRANSMISSION WIRING (CONT.),P. 19.......................100
9.20. EATON ULTRASHIFT/DM2 AND COBRASHIFTER, P. 20.......................................101
9.21. ABS6/ATC BENDIX AIR, P. 21........................................................................102
9.22. ABS6/ATC BENDIX AIR, P. 22........................................................................103
9.23. ABS6/ATC BENDIX AIR, P. 23........................................................................104
9.24. ABS6 ADVANCE ECU, W/BENDIX RSP, P. 24.....................................................105
9.25. EATON AUTOSHIFT 3, P. 25..........................................................................106
9.26. EATON AUTOSHIFT 3, P. 26..........................................................................107
9.27. EATON AUTOSHIFT 3 W/PUSH BUTTON SHIFTER, P. 27.......................................108
9.28. EATON AUTOSHIFT 3 W/COBRA SHIFTER, P. 28................................................109
iii
10. SLEEPER LIGHTINGAND ACCESSORIES(CHAPTER 10).................................................110
10.1. AUXILIARY CIRCULATION FAN (LOW ROOF), P. 1........................... ...................110
10.2. AUXILIARY CIRCULATION FAN (HIGH ROOF), P. 2..............................................111
10.3. AU XILIARY CIRCULATION FAN (SKYRISE), P. 3.................................................112
10.4. BUNK FLUORESCENT AND READING LIGHTS, P. 4............................................113
10.5. BUNK SPEAKERS, P. 5...............................................................................114
10.6. LUGGAGECOMPARTMENT LIGHTS, P. 6.........................................................115
10.7. POWER SOURCE, P. 7................................................................................116
10.8. REFRIGERATORWIRING, P. 8.......................................................................117
10.9. TV/VCR WIRING,P. 9..................................................................................118
10.10. OVERHEAD CABINETS, ACCENT LIGHTS, P. 10...............................................119
10.11. OPTIONAL SLEEPER MOUNTED RADIO CONTROLS, P. 11..................................120
10.12. SHOREPOWER WIRING(08WET)NOT WITHINVERTER, P. 12.............................121
10.13. SHOREPOWER WIRING(08WET)WITH INVERTER (08WES),P. 13........................122
11. LIGHT SYSTEMS (CHAPTER 11)................. ................................ ...............................123
11.1. BACK-UP LIGHTS, P. 1......................... .......................................................123
11.2. CAB AND TRAILER LIGHTS SWITCHAND RELAYS WIRING,P. 2............................124
11.3. CAB CLEARANCE AND IDENTIFICATION LIGHTS, P. 3.........................................125
11.4. WORK LIGHT N/SLEEPER, P. 4................. ................ ................ ................ .....126
11.5. CAB DOME,READINGAND COURTESY LIGHTS N/SKYRISE, P. 5...........................127
11.6. CAB DOME,READINGAND COURTESY LIGHTS W/SKYRISE,P. 6........................ ..128
11.7. DAYTIME RUNNING LIGHTS (DRL) — USA, P. 7.................................................129
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iv 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
11.8. FOGLIGHTS — CAB/FRONT ENDEFFECTS, P. 8................................................130
11.9. HEADLIGHT SWITCHAND DIMMER SWITCH WIRING, P. 9....................................131
11.10. HEADLIGHTS, P. 10..................................................................................132
11.11. PANELLIGHTS,P. 11................................................................................133
11.12. PARK/TURN/SIDE MARKER LIGHTS — WITH DRL, P. 12....................... ..............134
11.13. SPOTLIGHT, P. 13....................................................................................135
11.14. STOP, TAIL, TURN ANDHAZARD SIGNAL LIGHTS WITH FLASHER, P.14................136
11.15. WORKLIGHT W/SLEEPER, P. 15..................................................................137
12. HEATER ANDAIR CONDITIONER(CHAPTER 12)...........................................................138
12.1. AIRCONDITIONER — CAB, P. 1....................................................................138
12.2. HEATER — CAB, P. 2..................................................................................139
12.3. HEATER — BUNK AUXILIARY BLOWER, P. 3....................................................140
12.4. HEATER — BUNK W/STANDARD TEMPERATURE CONTROL, P. 4...........................141
12.5. HEATER — BUNK W/THERMOSTAT TEMPERATURE CONTROL, P. 5.......................142
12.6. LOWERED HEATER BOX,P. 6.......................................................................143
12.7. AUXHEATER, P. 7.....................................................................................144
12.8. APUSYSTEM:DISTRIBUTION BOX, P. 8..........................................................145
12.9. APUSYSTEM:DISTRIBUTION BOX, P. 9..........................................................146
12.10. APU SYSTEM, P. 10..................................................................................147
13. CONNECTOR COMPOSITES (CHAPTER 13).................................................................148
13.1. LEFT GAUGE CLUSTER (CONNECTOR 423), P. 1...............................................148
13.2. LEFT GAUGE CLUSTER (CONNECTOR 424), P. 2...............................................149
13.3. LEFT GAUGE CLUSTER —GAUGE INFORMATION, P. 3.......................................150
13.4. LEFT GAUGE CLUSTER —TERMINAL INFORMATION, P. 4...................................151
13.5. LEFT GAUGE CLUSTER —TERMINAL INFORMATION, P. 5...................................152
13.6. RIGHT GAUGECLUSTER(CONNECTOR 420), P. 6..............................................153
13.7. RIGHT GAUGECLUSTER— GAUGE INFORMATION,P. 7.....................................154
13.8. RIGHT GAUGECLUSTER— TERMINAL INFORMATION, P. 8........................... ......155
13.9. SPEEDOME T ER/TACHOMETER MODULE — TERMINAL INFORMATION, P. 9.............156
13.10. S PE EDOMETER/TACHOMETER MODULE — TERMINAL INFORMATION, P. 10...........157
13.11. CONNECTOR COMPOSITES (1), (2), (3), P. 11...................................................158
13.12. CONNECTOR COMPOSITES(4), (9), (11), (15), (20), (27), P. 12...............................159
13.13. CONNECTOR COMPOSITES (40), (41),(42), (43), (48),(65),P. 13.......... ................ ..160
13.14. CONNECTOR COMPOSITES (66), (71),(72), (76), (77),(94),P. 14.......... ................ ..161
13.15. CONNECTOR COMPOSITES (100), (100A), (105), (111), (112), (113), (115), P. 15..........162
13.16. CONNECTOR COMPOSITES(116), (117), (118), (127A), (128), P. 16.........................163
13.17. CONNECTOR COMPOSITES (137), (141), (142), (143), (144), (145), (146), (147), (148), P.
17...........................................................................................................164
13.18. CONNECTOR COMPOSITES(149), (150), (151), (152), (161), (162),P. 18...................165
13.19. CONNECTOR COMPOSITES(165), (166), (167), (170), (171), (180),P. 19...................166
13.20. CONNECTOR COMPOSITE (190), P. 20...........................................................167
13.21. CONNECTOR COMPOSITES (196), (199), (200), (201), (209), (211), (214), (216), P. 21....168
13.22. CONNECTOR COMPOSITES(217), (218), (220), (221), P. 22..................................169
13.23. CONNECTOR COMPOSITES(227), (228), (229), P. 23..........................................170
13.24. CONNECTOR COMPOSITES(230), (231), (236), (241), P. 24..................................171
13.25. CONNECTOR COMPOSITES(243), (244), (249), (250), (251), P. 25........... ...............172
13.26. CONNECTOR COMPOSITES(252), (260), (267), P. 26..........................................173
13.27. CONNECTOR COMPOSITES(268), (273), (275), (278), (282), (289),P. 27...................174
13.28. CONNECTOR COMPOSITES(290), (291), (292), (293), (294), (296),P. 28...................175
13.29. CONNECTOR COMPOSITES (298), (299), (311), (312), (313), (315, 316), P. 29.............176
13.30. CONNECTOR COMPOSITES(316), (318), (320), (321), (322), (323),P. 30...................177
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316
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
13.31. CONNECTOR COMPOSITES (325), (345), (350), (351), (352), (353), (354), P. 31...........178
13.32. CONNECTOR COMPOSITES (355), (360),(363), (379), (393), (396), P. 32...................179
13.33. CONNECTOR COMPOSITES (400), (402),(403), (404), (406), (409), P. 33...................180
13.34. CONNECTOR COMPOSITES (417), (420),(421), P. 34..........................................181
13.35. CONNECTOR COMPOSITES (422), (423),(424), (425), (426), P. 35................ ..........182
13.36. CONNECTOR COMPOSITES (427), (428),(429), (430), P. 36..................................183
13.37. CONNECTOR COMPOSITES (433), (434),(435), P. 37..........................................184
13.38. CONNECTOR COMPOSITES (436), (437),(440), (441), (442), P. 38................ ..........185
13.39. CONNECTOR COMPOSITES (453), (454),P. 39.................................................186
13.40. CONNECTOR COMPOSITES (455), (456),(460), (462), P. 40..................................187
13.41. CONNECTOR COMPOSITES (462), (463),P. 41.................................................188
13.42. CONNECTOR COMPOSITES (463), P. 42.........................................................189
13.43. CONNECTOR COMPOSITES (464), P. 43.........................................................190
13.44. CONNECTOR COMPOSITES (464), (465), (466), (468), (470), (1000), P. 44.................191
13.45. CONNECTOR COMPOSITES (474), (480),(481), (482), (483), (489), P. 45...................192
13.46. CONNECTOR COMPOSITES (491), (492), (494), (495), (497), (498), (499), (501), P. 46.. .193
13.47. CONNECTOR COMPOSITES (502), (503),(504), (506), P. 47..................................194
13.48. CONNECTOR COMPOSITES (509), (511), (512), (513), (514), (515),P. 48...................195
13.49. CONNECTOR COMPOSITES (517), (520), (521), (522), (523), (524), (525), (526), P. 49.. .196
13.50. CONNECTOR COMPOSITES (528), (529), (530), (531), (550), (560), (562), (574), P. 50.. .197
13.51. CONNECTOR COMPOSITES (575), (576),(577), (578), (579), (582), P. 51...................198
13.52. CONNECTOR COMPOSITES (584), (585),(587), P. 52..........................................199
13.53. CONNECTOR COMPOSITES (592), (592F), (593),(594), (600), P. 53.........................200
13.54. CONNECTOR COMPOSITES (603), (604), (605), (606), (607), (610), (611), P. 54...........201
13.55. CONNECTOR COMPOSITES (612), (613),(640), (642), (643), (659), P. 55...................202
13.56. CONNECTOR COMPOSITES (662), (675),(676), (690), P. 56..................................203
13.57. CONNECTOR COMPOSITES (720), (753),(755), (766), (767), (768), P. 57...................204
13.58. CONNECTOR COMPOSITES (769), (770), (771), (774), (775), (776), (777), (778), (789), P.
58...........................................................................................................205
13.59. CONNECTOR COMPOSITES (791), (823), (851), (854), (884), (885), (887), P. 59...........206
13.60. CONNECTOR COMPOSITES (904), (905),(906), P. 60..........................................207
13.61. CONNECTOR COMPOSITES (907), (909), (912), (913), (914), (915), (916), (918), P. 61.. .208
13.62. CONNECTOR COMPOSITES (922), (923),(925), P. 62..........................................209
13.63. CONNECTOR COMPOSITES (926), (930),(935), (936), (937), P. 63................ ..........210
13.64. CONNECTOR COMPOSITES (938), (939), (940), (941), (942), P. 64..........................211
13.65. CONNECTOR COMPOSITES (955), (956), (962), (963), (992), (993), (994), P. 65...........212
13.66. CONNECTOR COMPOSITES (995–999), (1000), (1033), (1034),P. 66........................213
13.67. CONNECTOR COMPOSITES (1039), (1040), (1041), (1042), (1043), (1044), P. 67..........214
13.68. CONNECTOR COMPOSITES (1045), (1046), (1047), (1048),P. 68............................215
13.69. CONNECTOR COMPOSITES (1049), (1050), (1051), P. 69.....................................216
13.70. CONNECTOR COMPOSITES (1053), (1054), (1056), (1057),P. 70............................217
13.71. CONNECTOR COMPOSITES (1058), (1059), (1060), (1084), (1085), (1086), (1088), (1090F),
P. 71........................................................................................................218
13.72. CONNECTOR COMPOSITES (1090M), (1091),(1093), (1094), (1095), P. 72.................219
13.73. CONNECTOR COMPOSITES (1097), (1098), (1099), (1108), P. 73..... .......................220
13.74. CONNECTOR COMPOSITES (1110), (1112), (1113), (1125), (1126), P. 74.................. ..221
13.75. CONNECTOR COMPOSITES (1127), (1128),(1130), (1135), P. 75.............................222
13.76. CONNECTOR COMPOSITES (1137), (1138),(1139), (1140), (1141), P. 76....................223
13.77. CONNECTOR COMPOSITES (1155), (1156),(1157), (1158), (1159), (1170), P. 77...........224
13.78. CONNECTOR COMPOSITES (1171), (1188), (1189), AND JUNCTION POINTS J7 AND J 4, P.
78...........................................................................................................225
13.79. CONNECTOR COMPOSITES (1190), (1193), (1194), (1195), (1223), (1224), (1225), P.
79...........................................................................................................226
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vi 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
13.80. CONNECTOR COMPOSITES (1227), (1229), (1239A, B, C), (1239), (1240), P. 80..........227
13.81. CONNECTOR COMPOSITES (1241), (1243), (1244), (1258), (1260), (1261), P. 81..........228
13.82. CONNECTOR COMPOSITES(1262), (1263), (1264), (1265), (1279), P. 82.................. .229
13.83. LEFT BLANK INTENTIONALLY, P. 83.............................................................230
13.84. CONNECTOR COMPOSITE (1285), P. 84.........................................................231
13.85. CONNECTOR COMPOSITES(1286), (1287), (1288), (1289), (1290), P. 85.................. .232
13.86. CONNECTOR COMPOSITES(1304), (1305), (1306), (1307), (1308), (1309M), P. 86........233
13.87. CONNECTOR COMPOSITES (1310), (1311), (1312), (1313), (1315), (1316OL), (1316PL), P.
87...........................................................................................................234
13.88. CONNECTOR COMPOSITES (1321), (1322), (1323), (1324), (1327), (1328), P. 88..........235
13.89. CONNECTOR COMPOSITES(1331), (1332), P. 89..............................................236
13.90. CONNECTOR COMPOSITES(1348), (1349), P. 90..............................................237
13.91. CONNECTOR COMPOSITES(1360), (1361), (5710L), P. 91....................................238
14. POWER DISTRIBUTION LAYOUT (CHAPTER 14)............................................................239
14.1. POWER DISTRIBUTION CENTER, FUSE AND CIRCUIT BREAKER LOCATION, P. 1......239
14.2. FUSE ANDCIRCUIT BREAKER LOCATION (CONT.), P. 2.......................................240
14.3. RELAY LOCATION, P. 3...............................................................................241
14.4. PROSLEEPERFUSEINDEX, P. 4...................................................................242
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316
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
1. INSTRUCTIONS AND CHARTS (CHAPTER 1)
1.1. CIRCUIT IDENTIFICATION CHART, P. 1
1
INTERNATIONAL TRUCK AND ENGINE CORPORATION
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.
CIRCUIT
NUMBER
1
GENERATOR - CHARGE - RED
2
3
4
5
6
ALTERNATOR - RESISTANCE - RED
7
8
9
10
GROUND - WHITE
11
ACCESSORY FEED - LIGHT BLUE
12
IGNITION FEED - PINK
13
BATTERY FEED - RED
14
KEY SWITCH FEED - RED
15
16
17
STARTER CONTROL - PINK
18
GLOW PLUG/PRE-HEATER - PINK
ENGINE SHUT-OFF - GRAY
19
20
21
ETHER START - TAN
22
ENGINE COOLING - TAN
23
ENGINE BRAKE GRAY
24
PYROMETER - TAN
25
AMMETER - TAN
26
VOLTMETER - TAN
27
INSTRUMENT FEED - TAN
28
ENGINE WATER TEMPERATURE - TAN
29
ENGINE OIL TEMPERATURE - TAN
30
TRANSMIS SION OIL TEMPERATURE - TAN
31
AXLE OIL TEMPERATURE - TAN
32
33
ENGINE OIL LEVEL - TAN
WATER LEVEL - TAN
34
ENGINE OIL PRESSURE - TAN
35
FUEL LEVEL - TAN
36
DESCRIPTION - COLOR
ELECTRICAL CIRCUIT DIAGRAM
CHAPTER 1
NAVISTAR CIRCUIT NUMBER ID EN TIFICATION & COLOR
CIRCUIT
NUMBER
FUEL PUMP - TA NGENERATOR - FIE L D - LI G H T BL U E
37
HEATED SEAT - LIGHT GREEN
38
AIR DRYER - GRAY
39
40
LOW AIR PRESSURE WARNING - GRAY
OUTSIDE AIR TEMP/COMPASS - TAN
41
42
FRONT AXLE - GRAY
43
POWER DIVIDER LOCK (PDL) - GRAY
44
PARK BRAKE WAR NI NG - GR AY
45
ANTI-THEFT WARNING - LIGHT GREEN
46
POWER TAKE-OFF WARNING - GRAY
47
SPEEDOMETER - GRAY
48
TACHOMETER - GRAY
DIFFERENTIAL LOCK - GRAY
49
LIGHT SWITCH FEED - YELLOW
50
DIMMER SWITCH - YELLOW
51
HEADLIGHT - HIGH BEAM - YELLOW
52
HEADLIGHT - LOW BEAM - YELLOW
53
54
PARKING/MARKER LIGHTS - BROWN
TURN SIGNAL - ORANGE
55
TURN SIGNAL LIGHTS - LEFT - ORANGE
56
TURN SIGNAL LIGHTS - RIGHT - ORANGE
57
CLEARANCE AND IDENTIFICATION LIGHTS - BROWN
58
59
HAZZARD LIGHT S - OR AN GE
60
AIR SUSPENSION - GRAY
61
62
PANEL LIGHTS - DARK BLUE
63
COURTESY AND DOME LIGHTS - DARK BLUE
64
AUXILIARY LIGHTS - YELLOW
65
5TH WHEEL/WORK LIGHT - ORANGE
66
DAYTIME RUNNING LIGHTS - YELLOW
67
68
TAIL LIGHTS - BROWN
69
LICENSE PLATE LIGHT - BROWN
STOP LIGHTS - ORANGE
70
BACK-UP LIGHTS - ORANGE
71
TRAILER AUXILIARY - ORANGE
72
DESCRIPTION - COLOR
CHK
DATE REFERENCEREV
JKP 4MAR02
ADDED DESC AT 38 & 41.
CHANGE
55093F
A
DRAWN
RROEPKE
RELEASE NO.
P52600M
Figure 1 Circuit Identification Chart, page 1
NAME
INSTRUCTIONS AND CHARTS FOR ALL MODELS
DATE
29JUL98
S08
PART NO.
AE08-52011
316
SHEET
01
2 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
1.2. CIRCUIT IDENTIFICATION C HART, P. 2
INTERNATIONAL TRUCK AND ENGINE CORPORATION
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.
CIRCUIT
NUMBER
COLLISION AVOIDANCE SYSTEM - LIGHT BLUE
73
74
HEATER BLOWER MOTOR - LIGHT GREEN
75
76
AUXILIARY FAN - LIGHT GREEN
AIR CONDITIONER - LIGHT GREEN
77
MIRRORS - HEATED * MOTORIZED - LIGHT GREEN
78
SEAT BELTS - LIGHT GREEN
79
80
POWER DOOR LOCKS - LIGHT GREEN
81
82
WINDSHIELD WIPERS - GRAY
POWER WINDOW - LIGHT GREEN
83
CIGAR LIGHTER - LIGHT GREEN
84
HORN - ELECTRIC - GRAY
85
RADIO - ENTERTAINMENT - LIGHT GREEN
86
NOTE:
*
NOT ALL CIRCUITS MAY BE USED.
COLORS ABOVE ARE NEW STD COLORS
FOR MAJOR HARNESSES.
DESCRIPTION - COLOR
ELECTRICAL CIRCUIT DIAGRAM
NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR
CIRCUIT
NUMBER
WINDSHIELD WASHER - GRAY
87
CLOCK/HOURMETER - LIGHT GREEN
88
89
90
HYDRAULIC BRAKE PUMP - GRAY
INTERCOMMUNICATIONS - VIOLET
91
92
TRANSMISSION (ELECTRONIC) - TAN
AXLE SHIFT CONTROL - TAN
93
94
ANTILOCK BRAKES - GRAY
95
EXHAUST EMI S SI ON - TA N
96
SNOW PLOW LIGHTS - YELLOW
CRUISE CONT ROL AND ELECTRONIC ENGINE - VIOLET
97
DATA LINK AND DI AG N OS T I C S - BL AC K
98
THROTTLE POSITION SENSOR - VIOLET
99
DESCRIPTION - COLOR
CHAPTER 1
CHK
DATE REFERENCEREV
10DEC01
JKP 4MAR02
GSC2 ADDED CIR 73 DESC
ADDED SEAT BELTS.
CHANGE
A
P53583SJPM
B
55093F
DRAWN
RROEPKE
RELEASE NO.
P52600M 29JUL98
Figure 2 Circuit Identification Chart, page 2
NAME
INSTRUCTIONS AND CHARTS FOR ALL MODELS
DATE
PART NO.
AE08-52011
316
S08
SHEET
02
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
1.3. CIRCUIT DIAGRAM INSTRU CTION S, P. 3
3
Figure 3 Circuit Diagram Instructions, page 3
S08
316
4 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
1.4. CIRCUIT DIAGRAM INSTRUCTIONS, P. 4
Figure 4 Circuit Diagram Instructions, page 4
S08
316
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
1.5. SCHEMATIC SYMBOLS, P. 5
5
Figure 5 Schematic Symbols
S08
316
6 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
1.6. RELAY PINOUT, FUNCTION DATA AND SEALED RELAY, P. 6
Figure 6 Relay Pinout, Function Data and Sealed Relay
316
S08
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
1.7. LAMP BULB CHART, P. 7
7
INTERNATIONAL TRUCK AND ENGINE CORPORATION
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.
ELECTRICAL CIRCUIT DIAGRAM
LAMP BULB CHART
BULB APPLICATION WATTS OR CANDLEPOWER TRADE NUMBER
AIR RESTRICTION GAUGE..............................
BACK-UP LIGHTS.....................................
CIGAR LIGHTER......................................
CLOCK - ANALOG.....................................
CLEARANCE/IDENTIFICATION LIGHTS - SMALL............
CLEARANCE/IDENTIFICATION LIGHTS - LARGE............
COURTESY LIGHT.....................................
DOME LIGHT............................... .... ... ...
EXTERIOR MIRROR LIGHT.............................. 2 CANDLEPOWER..........................
FOG LIGHT................................ ... .... ...
FRONT TURN SIGNAL
9200/9400/9900......................... ............
HEADLIGHTS
9200/9400/9900 INCANDESCENT
HIGH/LOW BEAMS..............................
HALOGEN (OPTIONAL)
HIGH/LOW BEAM............................... 65/35 WATTS......................... ...
HEATER AND AIR CONDITIONER CONTROLS................
HIGH BEAM INDICATOR...............................
INSTRUMENT CLUS TE R
ILLUMINATION LIGHT.............................
WARNING LIGHT.................................
READING LIGHT.................................. ....
SIDE TURN SIGNAL - 9200/9400/9900..................
SPEEDOMETER.......................................
SPOTLIGHT..........................................
STOP-TAIL-TURN SIGNAL..............................
TACHOMETER................................ ... ...... 1 CANDLEPOWER..........................
TURN SIGNAL INDICATOR............................. 0.5 CANDLEPOWER........................
WORK LIGHT................................ ... .... .. 35 WATTS.................. .... ... ......
2 CANDLEPOWER..........................
32 CANDLEPOWER.........................
1 CANDLEPOWER..........................
2 WATTS............................
2 CANDLEPOWER..........................
4 CANDLEPOWER..........................
21 CANDLEPOWER.........................
21 CANDLEPOWER.........................
100 WATTS.......................... ....
32/3 CANDLEPOWER.......................
65/35 WATTS......................... ...
3 CANDLEPOWER..........................
0.5 CANDLEPOWER........................
1 CANDLEPOWER..........................
0.5 CANDLEPOWER........................
15 CANDLEPOWER.........................
32/3 CANDLEPOWER.......................
1 CANDLEPOWER..........................
30 WATTS...............................
32/3 CANDLEPOWER.......................
CHAPTER 1
57
1156
1455
VDO-600 802
194
904
1142
1142
1895
4921-1
3157
6053
H5054
168
37
161
37
1003
3157
161
4405
1157
161
37
4411
DOME LIGHT............................... .... ...... 15 WATTS............................. .. F15T8-CW
LUGGAGE COMPARTMENT LIGHT..........................
READING LIGHT.................................. ....
OVERHEAD CABINET LIGHT.............................
TV/VCR & MICROWAVE CABINET LIGHT...................
CHK
DATE REFERENCEREV
JKP 4MAR02
ADDED & EDITED SLPR ITEMS
CHANGE
Figure 7 Lamp Bulb Chart
SLEEPER
12 CANDLEPOWER.........................
12 CANDLEPOWER.........................
12 CANDLEPOWER.........................
12 CANDLEPOWER.........................
DRAWN
55093F
A
RROEPKE
RELEASE NO.
P52600M
NAME
INSTRUCTIONS AND CHARTS FOR ALL MODELS
DATE
29JUL98
S08
PART NO.
AE08-52011
316
211-2
912
211-2
211-2
SHEET
07
8 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
2. 12 VOLT POWER DISTRIBUTIO N CIRCUIT DIAGRAMS (CHAPTER 2)
2.1. START FEED, P. 1
Figure 8 Start Feed
S08
316
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
2.2. ACCESSORY, P. 2
9
After — ELECTRICAL CIRCUIT DIAGRAMS
Figure 9 Accessory
S08
316
10 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
2.3. BATTERY, P. 3
Figure 1 0 Battery, B1
S08
316
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
2.4. BATTERY, B2, P. 4
11
After — ELECTRICAL CIRCUIT DIAGRAMS
INTERNATIONAL TRUCK AND ENGINE CORPORATION
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.
F10-A 30A *
14AR
10RD
14RD
14D
10RD
14AA
14RD
14B
10RD
14E
10RD
10RD
10RD
14Y
14M
14T
A
A
F5-D 20A
F3-C 30A
F3-D 10A
F3-A 20A
F3-B 20A
F6-A 20A
F6-B 10A
F2-A 15A
F2-B 10A
F1-D 15A
F1-A 30A
B2
BATTERY
STUD
14BW
6RD
B2
BATTERY
ADAPTER
(498)
14H
6RD
F8-A 10A
F8-B 25A
14W
6RD
14AH
10RD
14X
10RD
ELECTRICAL CIRCUIT DIAGRAM
CHAPTER 2
12V POWER DISTRIBUTION - BATTERY
14AS
10RD
B
TYPE 1 ONLY
50A
18YL
B
TYPE 1 ONLY
51
14YL
68
10BN
50
18YL
58D
12BN
70
12OR
XXX
XXX
65A
14OR
84
14LT GN
63
18DK BL
14AX
18RD
63P
16DK BL
75
10LT GN
TO OWNER/OPERATOR SPARE
SWITCH W/FUSE
TO HEADLIGHT SWITCH
(CH 11,PG 9)
TO HEADLIGHT RELAY
(CH 11,PG 9)
86K
14LT GN
97DL
14VT
TO CAB & TRAILER TAIL RELAY
TO HEADLIGHT SWITCH
TO TRAILER MARK ER RELAY
TO STOP LIGHT SWITCH
(CH 11,PG 2)
(CH 11,PG 9)
(CH 11,PG 2)
(CH 11,PG 14)
TO DATA LINK
(CH 4,PG 3,6,10,14)
(CH 8,PG 14)
TO POWER SOURCE
(CH 8,PG 11)
TO OWNER/ OPE R A T OR OPTION
TO OWNER/ OPE R A T OR OPTION
TO WORK LIGHT
(CH 11,PG 15)
TO CAB CIGAR LIGHTER
(CH 8,PG 1)
TO DOME & COURTESY LIGHTS
(CH 11,PG 5)
TO REFRIGERATOR FUSE
(CH 10,PG 8)
TO SPOTLIGHT & READING
LIGHTS
TO HIGH SPEED RELAY
(CH 11,PG 5,13)
(CH 12,PG 2)
**
**
EXTRA FUSES PROVIDED
**
FOR OWNER/OPERATOR
CHK
JKP 4MAR02
CONNECTION
DATE REFERENCEREV
RMVD 14N, ADDED 14AX.
CHANGE
Figure 11 Battery, B2
A
B
10RD
F1-B 10A
14Z
F1-C
20A
P52739ESEB//ADDED 14BW
55093F
14LT GN
14LT GN
DRAWN
U00EDL2
RELEASE NO.
P50317A
77T
75A
NAME
5000/9100/9200/9400/9900
DATE
12FEB99
316
S08
TO A/C CONTROL RE LA Y
(CH 12,PG 1)
TO HEATER CONTROL RELAY
(CH 12,PG 2)
FUSE LOCATIONS VARY -
*
CHECK INSIDE POWER
DISTRIBUTION CENTER
FOR ACTUAL LOCATION.
PART NO.
AE08-52502
SHEET
04
12 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
2.5. BATTERY, B2 (CONT.), P. 5
INTERNATIONAL TRUCK AND ENGINE CORPORATION
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.
F10-D 30A
*
14AV
B2
BATTERY
STUD
14AK
6RD
10RD
14AW
10RD
14AU
10RD
14AP
14RD
F10-C 20A
*
F10-B 15A
*
*
F8-D 20A
ELECTRICAL CIRCUIT DIAGRAM
12V POWER DISTRIBUTION - BATT ER Y
TO OVERHEAD CABINET LIGHTS
14AX
10RD
14AY
12RD
75AX
14LT GN
F10-A 30A
75AW
10LT GN
63AA
14DK BL
(CH 10,PG 10)
TO AUX CIRCULATION FAN
(CH 10,PG 1-3)
TO TV/VCR WIRING
(CH 10,PG 9)
TO SLEEPER POWER SOURCE
(CH 10,PG 7)
TO AUX BUNK BLOWER RELAY
TO SLEEPER BLOWER RELAYS
TO SLEEPER LIGHTS/LUGGAGE
(CH 12,PG 3)
COMPARTMENT LIGHTS
CHAPTER 2
(CH 12,PG 3)
(CH 10,PG 4,6)
FUSE LOCATIONS VARY -
*
CHECK INSIDE POWER
DISTRIBUTION CENTER
CHK
JKP 4MAR02
F10-D & AUX CIR FAN PG WAS 1, F8-D WAS CH 10, PG 3,5.
FOR ACTUAL LOCATION.
DATE REFERENCEREV
ADDED O/H CABINET LTS TO
CHANGE
Figure 12 Battery, B2 (cont.)
DRAWN
55093FA
U00EDL2
RELEASE NO.
P50317A
NAME
5000/9100/9200/9400/9900
DATE
12FEB99
S08
PART NO.
316
AE08-52502
SHEET
05
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
2.6. 3+1 BATTERY SYSTEM, P. 6
13
Figure 13 3+1 Battery System
S08
316
14 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
2.7. GROUND ADAPTER COMPOSITE, P. 7
INTERNATIONAL TRUCK AND ENGINE CORPORATION
THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND
IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE
INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.
TO
ENG
GND
(CH 3,PG 1-4)
6WH
11-GA
GND
STUD
11-G
8WH
11-GB
8WH
(RIGHT
DASH
PANEL)
G1
GROUND
ADAPTER
(453)
11-GA
12WH
G4
GROUND
ADAPTER
(456)
11-GC
10WH
11-GX
18WH
11-GAD
18WH
ELECTRICAL CIRCUIT DIAGRAM
CHAPTER 2
12V POWER DISTRIBUTION - GROUND ADAPTER COMPOSITE
11-GR
62-GJ
62-GK
11-GAE
18WH
13-GCP
14WH
11-GZ
18WH
62-GN
62-GL
62-GQ
62-GR
11-GT
18WH
RIGHT MOTORIZED MIRROR
DATA LINK 6-WAY
14WH
18WH
18WH
18WH
18WH
18WH
18WH
RIGHT POWER MIRROR
ABS TRAILER RELAY
LEFT POWER MIRROR
(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
(CH 4,PG 2,5,9)
CUMMINS & DET.
DEIS. ONLY
CUMMINS ONLY
(CH 8,PG 8)
(CH 9,PG 8)
(CH 8,PG 8)
(CH 8,PG 9)
INC/DEC IDLE DIAG
(CH 4,PG 10,14)
DIAG ON/OFF
(CH 4,PG 14)
GND
STUD
11-GD
8WH
(LEFT
DASH
PANEL)
ADAPTER
11-GE
12WH
G3
GROUND
(455)
G2
GROUND
ADAPTER
CHANGE
11-GY
10WH
(454)
A 55093F
11-GI
10WH
*NOTE - A GROUND ADAPTER AS REFE RRED TO IN THIS MANUAL IS AN
INTERNALLY BUSSED CONNECTOR USED TO CONNECT & DISTRIBUTE
GROUND CIRCUITS TO VARIOUS POINTS IN THE VEHICLE.
CHK
DATE REFERENCEREV
JKP 4MAR02
REVISED 11-GBC &
11-GBD. ADDED 38-G & 38-GB.
Figure 14 Ground Adapter Composite
11-GAW
14WH
13-GAD
18WH
94-G
16WH
11-GAC
14WH
38-G
18WH
38-GB
18WH
11-GBC
12WH
11-GAV
18WH
25-G
18WH
11-GBD
12WH
DRAWN
U00EDL2
RELEASE NO.
P50317A
RIGHT WINDOW SWITCH & RELAY
AIR DRYER RELAY
ABS RELAYS
FOG LIGHT RELAY & SWITCH
DRIVER HEATED SEAT
PASSENGER HEATED SEAT
AUXILIARY BUNK BLOWER RELAY
& SLEEPER OPTIONS
CLOCK
PYROMETER CONTROL MODULE
SLEEPER OPTIONS
NAME
5000/9100/9200/9400/9900
DATE
12FEB99
(CH 8,PG 3)
(CH 9,PG 1)
(CH 9,PG 2,5)
(CH 11,PG 8)
(CH 8,PG 21)
(CH 8,PG 22)
(CH 12,PG 3 ; CH 10,PG 6-10)
(CH 8,PG 2
CH 11,PG 11)
(CH 6,PG 7)
(CH 10,PG 1-4)
PART NO.
AE08-52502
SHEET
07
S08
316
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
2.8. GROUND STUD COMPOSITE, P. 8
15
Figure 15 Ground Stud Composite
S08
316
16 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
2.9. GROUND STUD COMPOSITE, P. 9
Figure 16 Ground Stud Composite
S08
316
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
2.10. IGNITION, P. 10
17
After — ELECTRICAL CIRCUIT DIAGRAMS
Figure 17 Ignition
S08
316
18 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
2.11. PANEL LIG HTS ADAPTER CO MPOSITE, P. 11
INTERNATIONAL TRUCK AND ENGINE CORPORATION
THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND
IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE
INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.
62S
16DK BL
62W
16DK BL
62A
16DK BL
62M
16DK BL
L1
PANEL
62AE
LTS FEED
16DK BL
ADAPTER
L2
PANEL
LTS FEED
ADAPTER
(504)
L4
PANEL
LTS GND
ADAPTER
(506)
(503)
11-GP
12WH
PANEL
LIGHT
SWITCH
(425)
62W
D
F
62-GW
(CH 11,
PG 11)
16DK BL
18WH
62A
16DK BL
62
16DK BL
A
C
B
16WH
11-GS
ELECTRICAL CIRCUIT DIAGRAM
12V POWER DISTRIBUTION - PANEL LIGHTS ADAPTER
COMPOSITE
62T
16DK BL
62AG
16DK BL
62D
18DK BL
62C
18DK BL
62B
18DK BL
62P
16DK BL
62AR
16DK BL
62AS
16DK BL
62AP
16DK BL
62AB
16DK BL
62AN
16DK BL
62AL
16DK BL
62AQ
16DK BL
62BP
16DK BL
62M
16DK BL
62AW
16DK BL
62AY
16DK BL
62AV
16DK BL
62U
16DK BL
62H
16DK BL
62X
16DK BL
11-GAL
18WH
62-GH
18WH
62-GAB
18WH
62-GAY
18WH
11-GT
18WH
86-GK
18WH
CIGAR LIGHTER LIGHT
(CH 11,PG 11)
WIPER SWITCH
(CH 8,PG 6)
SPEEDO/TACH MODULE
(CH 11,PG 11)
LEFT SIDE CLUSTER
(CH 11,PG 11)
RIGHT SIDE CLUSTER
(CH 11,PG 11)
HEATER CONTROL PANEL LIGHT
(CH 11,PG 11)
TRAILER LIGHTS SWITCH
(CH 11,PG 2)
HEADLIGHT SWITCH
(CH 11,PG 9)
DOME LIGHT SWITCH
GAUGE PANEL LIGHT
(CH 11,PG 11)
FOG LIGHT SWITCH
(CH 11,PG 8)
RIGHT WINDOW SWITCH
(CH 8,PG 3)
(CH 11,PG 11)
CLOCK
BUNK CONTROL PNL SWITCH
(CH 10,PG 3,8,9)
ENGINE FAN OVERRIDE SWITCH
(CH 5,PG 3,4)
RT MOTO MIRRORS SW
ETHER START SWITCH
CRUISE/DIAGNOSTIC/ENG
BRAKE SWITCHES
(CH 4,PG 1,2,4-6,8-10,12-14)
SPARE SWITCH W/FUSE
(CH 8,PG 14)
SPARE SWITCH N/FUSE
(CH 8,PG 14)
REFRIGERATOR SWITCH
(CH 10,PG 6)
SPARE SWITCH W/FUSE
(CH 8,PG 14)
SPARE SWITCH N/FUSE
(CH 8,PG 14)
GAUGE PANEL LIGHT
(CH 11,PG 11)
ETHER START SWITCH
(CH 6,PG 11)
CRUISE/DIAGNOSTIC/ENG
BRAKE SWITCHES
(CH 4,PG 1,2,4-6,8-10,12-14)
REFRIGERATOR SWITCH
(CH 10,PG 6)
CHAPTER 2
(CH 8,PG 9)
(CH 6,PG 11)
CHANGE
11-GF
10WH
11-GK
16WH
DRAWN
55093FADDED CIR 62X & 86-GK
A
U00EDL2
RELEASE NO.
11-GD
(LEFT
DASH
PANEL)
GND
STUD
CHK
DATE REFERENCEREV
8WH
JKP 4MAR02
P50317A
Figure 18 Panel Lights Adapter Composite
62-GAS
18WH
62-GAR
16WH
62-GC
18WH
62-GB
18WH
62-GD
18WH
NAME
5000/9100/9200/9400/9900
DATE
12FEB99
316
S08
HEADLIGHT SWITCH
(CH 11,PG 9)
TRAILER LIGHTS SWITCH
(CH 11,PG 2)
LEFT SIDE CLUSTER
(CH 11,PG 11)
RIGHT SIDE CLUSTER
(CH 11,PG 11)
SPEEDO/TACH MODULE
(CH 11,PG 11)
PART NO.
AE08-52502
SHEET
11
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
3. 12 VOLT CHARGING AND CRANKIN G SYSTEM (CHAPTER 3)
3.1. W/CAT AND CUMMINS ENGINES, P. 1
19
INTERNATIONAL TRUCK AND ENGINE CORPORATION
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.
14
02RD
2
04RD
ALTERNATOR
B
BATTERIES
G
(CH 4,PG 2,7)
2-G
04WH
15A
TO ECM
POWER
CONN
14D
12RD
14A
12RD
14C
12RD
15A
14B
12RD
+--
06BK
06BK
+--
06BK
06BK
+
--
FRAME
GROUND
ELECTRICAL CIRCUIT DIAGRAM
CHARGING AND CRANK ING (12V)
W/CAT AND CUMMINS ENG INES
B1
BATTERY
STUD
150A
MEGA
FUSE
11-G
12WH
TO ECM
POWER
01BK
CONN
W/CAT
(CH 4,PG 2)
04RD
14
02RD
2
CHAPTER 3
14A
02RD
14A
02RD
17C
08PK
(2) 12GA, BL
FUSIBLE LINKS
START
FEED
ADAPTER
(509)
17B
14PK
(2)
17B
16PK
STARTER
MAGNETIC
SWITCH
06BK
06BK
4/0 BK
+--
04WH
FROM ECM
GROUND
W/ISX,ISM
(CH 4,PG 7)
CAB
J4 GROUND
CHK
DATE REFERENCEREV
CHANGE
Figure 19 W/Cat and Cummins Engines
2-G
11-GA
06WH
11-G
12WH
DRAWN
U00CJB5
RELEASE NO.
54719V
ENGINE
GROUND
S08
4/0 BK
4/0 BK
4/0 BK
11-GS
02BK
11-GU
12WH
NAME
5000/9200/9400/9900
DATE
26JUL01
PART NO.
316
SMB
BMS
FROM SENSOR
GROUND SPLICE
(CH 3,PG 2
CH 5,PG 2
CH 6,PG 4,9
CH 12,PG 1)
CRANKING
MOTOR
SOLENOID
CRANKING MOTOR
2/O BK
AE08-54038
FRAME
GROUND
SHEET
01
20 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
3.2. W/O VER CRANK PROTECTION W/CAT AND CU MMINS ENGINES, P. 2
INTERNATIONAL TRUCK AND ENGINE CORPORATION
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.
14
TO ALTERNATOR
(CH 3,PG 1)
02RD
04RD
2
ELECTRICAL CIRCUIT DIAGRAM
12V CRANKING SYSTEM W/OVERCRANK PROTECTION
W/CAT AND CUMMINS
K
D
P
7
8
1
1
START
ADAPTER
(509)
17B
14PK
(2)
17B
16PK
STARTER
MAGNETIC
SWITCH
B1
BATTERY
STUD
2
04RD
FL
150A
MEGA
FUSE
14
02RD
12BL
14A
02RD
14A
02RD
17C
8PK
FL
12BL
CHAPTER 3
FEED
SMB
CHK
DATE REFERENCEREV
CHANGE
CRANKING
FOR REMAINDER OF
CRANK MOTOR SOLENOID
AND CRANK MOTOR WIRING
SEE CHARGING & CRANKING
SECTION.
MOTOR
DRAWN
U00CJB5
RELEASE NO.
54719V
BMS
CRANKING
MOTOR
SOLENOID
(275)
17D
18PK
17-G
18WH
NAME
5000/9200/9400/9900
DATE
26JUL01
PART NO.
AE08-54038
Figure 20 W/Overcrank Protection W/Cat and Cummins Engines
K
D
P
7
8
1
1
17-G
18WH
H
U
W
G
-
2
1
1
1
ENGINE
GROUND
SHEET
02
S08
316
5500i, 5600i,5900i, 9200i,9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
3.3. W/I6 HEUI ENGINE, P. 3
21
INTERNATIONAL TRUCK AND ENGINE CORPORATION
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.
BATTERY
2
4RD
40A
14B
10RD
11-G
10WH
-
06BK
-
06BK
-
FRAME
GROUND
01BK
B
ALTERNATOR
G
14A
10RD
BATTERIES
+
06BK
06BK
+
11-GL
06BK
+
ELECTRICAL CIRCUIT DIAGRAM
CHARGING AND CRANKING (12V)
W/I6 HEUI ENGINE
B1
STUD
2
150A
MEGA
FUSE
04RD
14-FL
02RD
TO MODULE
POWER
(CH 4,PG 11)
CHAPTER 3
START
FEED
ADAPTER
(509)
17B
14PK
14A
02RD
2
17B
14A
02RD
16PK
STARTER
MAGNETIC
SWITCH
06BK
+
CHK
DATE REFERENCEREV
CHANGE
Figure 21 W/I6 HEUI Engine
17C
06BK
-
4/0 BK
4/0 BK
4/0 BK
11-GA
DRAWN
U00CJB5
RELEASE NO.
54719V
06WH
NAME
5000/9200/9400/9900
DATE
26JUL01
MAIN
GROUND
08PK
S
B
M
CRANKING MOTOR
PART NO.
AE08-54038
CRANKING
MOTOR
SOLENOID
SHEET
03
S08
316
22 5500i, 5600i, 5900i,9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
3.4. W/OVERCRANK PROTECTION W/I6 HEUI, P. 4
INTERNATIONAL TRUCK AND ENGINE CORPORATION
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.
B1
BATTERY
STUD
2
TO ALTERNATOR
(CH 3,PG 3)
04RD
04RD
2
14
ELECTRICAL CIRCUIT DIAGRAM
12V CRANKING SYSTEM W/OVERCRANK PROTECTION
W/I6 HEUI
START
FEED
ADAPTER
(509)
17B
D
7
1
K
P
8
1
14PK
2
17B
16PK
STARTER
MAGNETIC
SWITCH
(4 TERM)
14A
02RD
150A
MEGA
FUSE
14A
02RD
02RD
17C
8PK
CHAPTER 3
B
S
S
B
M
M
CRANKING
MOTOR
FOR REMAINDER OF
CRANK MOTOR SOLENOID
AND CRANK MOTOR WIRING
SEE CHARGING & CRANKING
SECTION.
CHK
DATE REFERENCEREV
CHANGE
DRAWN
U00CJB5
RELEASE NO.
54719V
Figure 22 W/Overcrank Protection W/I6 HEUI
CRANKING
MOTOR
SOLENOID
275
17D
18PK
17-G
18WH
NAME
5000/9200/9400/9900
DATE
26JUL01
K
D
P
7
8
1
1
18WH
17-G
H
U
W
G
-
4
1
1
1
STARTER MOTOR
GROUND
PART NO.
AE08-54038
SHEET
04
S08
316
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