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

S08316

Copyright © 11/03/2006 International Truck and Engine Corporation

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	i
After — ELECTRICAL CIRCUIT DIAGRAMS

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 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 BATTERY SYSTEM, 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 AND CRANKING SYSTEM (CHAPTER 3)..............................................19 3.1. W/CAT AND CUMMINS ENGINES, P. 1................................................................19 3.2. W/OVERCRANK PROTECTION W/CAT AND CUMMINS ENGINES, P. 2.........................20 3.3. W/I6 HEUI ENGINE, P. 3..................................................................................21 3.4. W/OVERCRANK PROTECTION W/I6 HEUI, P. 4.....................................................22 3.5. W/CAT AND CUMMINS ENGINES AND W/1GA CHARGING CIRCUIT, 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. CATERPILLAR C10, C11, C12, C13, C15, AND C16 ENGINE CONTROLS, P. 3.................26 4.4. CUMMINS ISM, ISX CRUISE CONTROL, P. 4.........................................................27 4.5. CUMMINS ISM, ISX ENGINE BRAKE, P. 5............................................................28 4.6. CUMMINS ISM , ISX — ENGINE CONTROLS, P. 6...................................................29 4.7. CUMMINS AHD AND ISM – ENGINE CONTROLS, 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 KYSOR ENGINE FAN WITH I6 HEUI ENGINES W/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. SPEEDOMETER GAUGE — TACHOMETER GAUGE, P. 8.........................................47 6.9. TRANSMISSION OIL TEMPERATURE GAUGE, P. 9.................................................48 6.10. VOLTMETER GAUGE, P. 10............................................................................49 6.11. ETHER START, P. 11....................................................................................50 6.12. MANIFOLD PRESSURE GAUGE, 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) WARNING LIGHT 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 AND LEFT, P. 4......................................................63 8.5. DEFROSTER FAN(S), P. 5...............................................................................64 8.6. ELECTRIC WINDSHIELD WIPERS WITH INTERMITTENT WIPE AND WASH, P. 6.............65 8.7. HORN, P. 7.................................................................................................66 8.8. MIRROR LIGHTS AND HEATED MIRRORS, P. 8.....................................................67 8.9. RIGHT MOTORIZED MIRROR, P. 9.....................................................................68 8.10. DUAL AXIS MOTORIZED MIRRORS, P. 10..........................................................69 8.11. POWER SOURCE (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 RELAY IV, 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	iii
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 — BACK OF 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 CONNECTION, 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 COBRA SHIFTER, 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

10. SLEEPER LIGHTING AND 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. AUXILIARY 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. LUGGAGE COMPARTMENT LIGHTS, P. 6.........................................................115 10.7. POWER SOURCE, P. 7................................................................................116 10.8. REFRIGERATOR WIRING, 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. SHORE POWER WIRING (08WET) NOT WITH INVERTER, P. 12.............................121 10.13. SHORE POWER 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 SWITCH AND 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, READING AND COURTESY LIGHTS N/SKYRISE, P. 5...........................127 11.6. CAB DOME, READING AND 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 END EFFECTS, P. 8................................................	130
	11.9. HEADLIGHT SWITCH AND DIMMER SWITCH WIRING, P. 9....................................	131
	11.10. HEADLIGHTS, P. 10..................................................................................132
	11.11. PANEL LIGHTS, 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 AND HAZARD SIGNAL LIGHTS WITH FLASHER, P. 14................	136
	11.15. WORK LIGHT W/SLEEPER, P. 15..................................................................	137

12. HEATER AND AIR CONDITIONER (CHAPTER 12)...........................................................138 12.1. AIR CONDITIONER — 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. AUX HEATER, P. 7.....................................................................................144 12.8. APU SYSTEM: DISTRIBUTION BOX, P. 8..........................................................145 12.9. APU SYSTEM: 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 GAUGE CLUSTER (CONNECTOR 420), P. 6..............................................153 13.7. RIGHT GAUGE CLUSTER — GAUGE INFORMATION, P. 7.....................................154 13.8. RIGHT GAUGE CLUSTER — TERMINAL INFORMATION, P. 8.................................155 13.9. SPEEDOMETER/TACHOMETER MODULE — TERMINAL INFORMATION, P. 9. . .. . .. . .. . ..156 13.10. SPEEDOMETER/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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5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	v
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 J4, 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 AND CIRCUIT BREAKER LOCATION (CONT.), P. 2.......................................240 14.3. RELAY LOCATION, P. 3...............................................................................241 14.4. PRO SLEEPER FUSE INDEX, P. 4...................................................................242

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5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	1
After — ELECTRICAL CIRCUIT DIAGRAMS

1.INSTRUCTIONS AND CHARTS (CHAPTER 1)

1.1.CIRCUIT IDENTIFICATION CHART, P. 1

INTERNATIONAL TRUCK AND ENGINE CORPORATIONELECTRICAL CIRCUIT DIAGRAMCHAPTER 1

	THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND								NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR
	IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE
	INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.
		CIRCUIT			DESCRIPTION - COLOR					CIRCUIT				DESCRIPTION - COLOR
		NUMBER								NUMBER
		1		GENERATOR - FIELD - LIGHT BLUE						37		FUEL PUMP - TAN
		2		GENERATOR - CHARGE - RED						38		HEATED SEAT - LIGHT GREEN
		3								39		AIR DRYER - GRAY
		4								40		LOW AIR PRESSURE WARNING - GRAY
		5								41		OUTSIDE AIR TEMP/COMPASS - TAN
		6								42		FRONT AXLE - GRAY
		7			ALTERNATOR - RESISTANCE - RED					43		POWER DIVIDER LOCK (PDL) - GRAY
		8								44		PARK BRAKE WARNING - GRAY
		9								45		ANTI-THEFT WARNING - LIGHT GREEN
		10								46		POWER TAKE-OFF WARNING - GRAY
		11			GROUND - WHITE					47		SPEEDOMETER - GRAY
		12			ACCESSORY FEED - LIGHT BLUE					48		TACHOMETER - GRAY
		13			IGNITION FEED - PINK					49		DIFFERENTIAL LOCK - GRAY
		14			BATTERY FEED - RED					50		LIGHT SWITCH FEED - YELLOW
		15			KEY SWITCH FEED - RED					51		DIMMER SWITCH - YELLOW
		16								52		HEADLIGHT - HIGH BEAM - YELLOW
		17			STARTER CONTROL - PINK					53		HEADLIGHT - LOW BEAM - YELLOW
		18			GLOW PLUG/PRE-HEATER - PINK					54		PARKING/MARKER LIGHTS - BROWN
		19			ENGINE SHUT-OFF - GRAY					55		TURN SIGNAL - ORANGE
		20								56		TURN SIGNAL LIGHTS - LEFT - ORANGE
		21			ETHER START - TAN					57		TURN SIGNAL LIGHTS - RIGHT - ORANGE
		22								58		CLEARANCE AND IDENTIFICATION LIGHTS - BROWN
		23			ENGINE COOLING - TAN					59
		24			ENGINE BRAKE GRAY					60		HAZZARD LIGHTS - ORANGE
		25			PYROMETER - TAN					61		AIR SUSPENSION - GRAY
		26			AMMETER - TAN					62		PANEL LIGHTS - DARK BLUE
		27			VOLTMETER - TAN					63		COURTESY AND DOME LIGHTS - DARK BLUE
		28			INSTRUMENT FEED - TAN					64		AUXILIARY LIGHTS - YELLOW
		29			ENGINE WATER TEMPERATURE - TAN					65		5TH WHEEL/WORK LIGHT - ORANGE
		30			ENGINE OIL TEMPERATURE - TAN					66		DAYTIME RUNNING LIGHTS - YELLOW
		31			TRANSMISSION OIL TEMPERATURE - TAN					67
		32			AXLE OIL TEMPERATURE - TAN					68		TAIL LIGHTS - BROWN
		33			ENGINE OIL LEVEL - TAN					69		LICENSE PLATE LIGHT - BROWN
		34			WATER LEVEL - TAN					70		STOP LIGHTS - ORANGE
		35			ENGINE OIL PRESSURE - TAN					71		BACK-UP LIGHTS - ORANGE
		36			FUEL LEVEL - TAN					72		TRAILER AUXILIARY - ORANGE
	CHK	DATE			CHANGE		REV	REFERENCE	DRAWN			NAME
	JKP	4MAR02			ADDED DESC AT 38 & 41.		A	55093F	RROEPKE		INSTRUCTIONS AND CHARTS FOR ALL MODELS
									RELEASE NO.		DATE		PART NO.		SHEET
									P52600M		29JUL98			AE08-52011	01
Figure 1			Circuit Identification Chart, page 1

S08316

2	5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
	After — ELECTRICAL CIRCUIT DIAGRAMS

1.2. CIRCUIT IDENTIFICATION CHART, P. 2

INTERNATIONAL TRUCK AND ENGINE CORPORATIONELECTRICAL CIRCUIT DIAGRAM CHAPTER 1
THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND
IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE						NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR
INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.
		CIRCUIT	DESCRIPTION - COLOR		CIRCUIT	DESCRIPTION - COLOR
		NUMBER			NUMBER
	73		COLLISION AVOIDANCE SYSTEM - LIGHT BLUE		87	WINDSHIELD WASHER - GRAY
		74			88	CLOCK/HOURMETER - LIGHT GREEN
		75	HEATER BLOWER MOTOR - LIGHT GREEN		89
	76		AUXILIARY FAN - LIGHT GREEN		90	HYDRAULIC BRAKE PUMP - GRAY
		77	AIR CONDITIONER - LIGHT GREEN		91	INTERCOMMUNICATIONS - VIOLET
	78		MIRRORS - HEATED * MOTORIZED - LIGHT GREEN		92	TRANSMISSION (ELECTRONIC) - TAN
	79		SEAT BELTS - LIGHT GREEN		93	AXLE SHIFT CONTROL - TAN
	80				94	ANTILOCK BRAKES - GRAY
	81		POWER DOOR LOCKS - LIGHT GREEN		95	EXHAUST EMISSION - TAN
		82	WINDSHIELD WIPERS - GRAY		96	SNOW PLOW LIGHTS - YELLOW
	83		POWER WINDOW - LIGHT GREEN		97	CRUISE CONTROL AND ELECTRONIC ENGINE - VIOLET
		84	CIGAR LIGHTER - LIGHT GREEN		98	DATA LINK AND DIAGNOSTICS - BLACK
		85	HORN - ELECTRIC - GRAY		99	THROTTLE POSITION SENSOR - VIOLET
86			RADIO - ENTERTAINMENT - LIGHT GREEN

*NOTE:

NOT ALL CIRCUITS MAY BE USED.

COLORS ABOVE ARE NEW STD COLORS

FOR MAJOR HARNESSES.

CHK	DATE	CHANGE	REV	REFERENCE	DRAWN	NAME
JPM	10DEC01	GSC2 ADDED CIR 73 DESC	A	P53583S	RROEPKE	INSTRUCTIONS AND CHARTS FOR ALL MODELS
					RELEASE NO.	DATE	PART NO.	SHEET
JKP	4MAR02	ADDED SEAT BELTS.	B	55093F	P52600M	29JUL98	AE08-52011	02

Figure 2 Circuit Identification Chart, page 2

S08316

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	3
After — ELECTRICAL CIRCUIT DIAGRAMS

1.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3

Figure 3 Circuit Diagram Instructions, page 3

S08316

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

S08316

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	5
After — ELECTRICAL CIRCUIT DIAGRAMS

1.5. SCHEMATIC SYMBOLS, P. 5

Figure 5 Schematic Symbols

S08316

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

S08316

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and

7

After — ELECTRICAL CIRCUIT DIAGRAMS

1.7. LAMP BULB CHART, P. 7

INTERNATIONAL TRUCK AND ENGINE CORPORATIONELECTRICAL CIRCUIT DIAGRAM

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

CHAPTER 1

LAMP BULB CHART

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE

INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

BULB APPLICATION

WATTS OR CANDLEPOWER

TRADE NUMBER

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

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

57

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

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

1156

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

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

1455

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

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

VDO-600 802

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

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

194

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

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

904

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

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

1142

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

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

1142

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

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

1895

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

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

4921-1

FRONT TURN SIGNAL

9200/9400/9900.....................................

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

3157

HEADLIGHTS

9200/9400/9900 INCANDESCENT

HIGH/LOW BEAMS..............................

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

6053

HALOGEN (OPTIONAL)

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

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

H5054

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

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

168

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

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

37

INSTRUMENT CLUSTER

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

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

161

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

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

37

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

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

1003

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

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

3157

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

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

161

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

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

4405

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

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

1157

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

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

161

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

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

37

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

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

4411

SLEEPER

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

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

F15T8-CW

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

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

211-2

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

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

912

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

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

211-2

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

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

211-2

CHK	DATE	CHANGE	REV	REFERENCE	DRAWN	NAME
JKP	4MAR02	ADDED & EDITED SLPR ITEMS	A	55093F	RROEPKE	INSTRUCTIONS AND CHARTS FOR ALL MODELS
					RELEASE NO.	DATE	PART NO.	SHEET
					P52600M	29JUL98	AE08-52011	07

Figure 7 Lamp Bulb Chart

S08316

8	5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
	After — ELECTRICAL CIRCUIT DIAGRAMS

2.12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (CHAPTER 2)

2.1.START FEED, P. 1

Figure 8 Start Feed

S08316

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	9
After — ELECTRICAL CIRCUIT DIAGRAMS

2.2. ACCESSORY, P. 2

Figure 9 Accessory

S08316

10	5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
	After — ELECTRICAL CIRCUIT DIAGRAMS

2.3. BATTERY, P. 3

Figure 10 Battery, B1

S08316

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	11
After — ELECTRICAL CIRCUIT DIAGRAMS

2.4. BATTERY, B2, P. 4

INTERNATIONAL TRUCK AND ENGINE CORPORATIONELECTRICAL CIRCUIT DIAGRAM CHAPTER 2

THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND

IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE 12V POWER DISTRIBUTION - BATTERY

INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

		14AR	F10-A 30A *		14AS
						TO OWNER/OPERATOR SPARE
		10RD			10RD
						SWITCH W/FUSE		(CH 8,PG 14)
		F8-A 10A	A	B	TYPE 1 ONLY
		14D			50A	TO HEADLIGHT SWITCH
		10RD			18YL
						(CH 11,PG 9)
B2		F8-B 25A	A	B	TYPE 1 ONLY
BATTERY					51	TO HEADLIGHT RELAY
STUD					14YL
						(CH 11,PG 9)
		14AA				86K	TO POWER SOURCE
		14RD				14LT GN
			F5-D 20A				(CH 8,PG 11)
14BW
						97DL	TO DATA LINK
6RD
			F3-C 30A			14VT	(CH 4,PG 3,6,10,14)
		14B			68	TO CAB & TRAILER TAIL RELAY
		10RD			10BN
			F3-D 10A			(CH 11,PG 2)
					50	TO HEADLIGHT SWITCH
14W					18YL
						(CH 11,PG 9)
6RD
			F3-A 20A
		14E			58D	TO TRAILER MARKER RELAY
		10RD			12BN
			F3-B 20A			(CH 11,PG 2)
					70	TO STOP LIGHT SWITCH
					12OR
						(CH 11,PG 14)
		14M		F6-A 20A
14AH	10RD				XXX	TO OWNER/OPERATOR OPTION
		10RD
				F6-B 10A
					XXX	TO OWNER/OPERATOR OPTION
				F2-A 15A
		14T			65A	TO WORK LIGHT
		10RD			14OR
						(CH 11,PG 15)

		84	TO CAB CIGAR LIGHTER
B2		14LT GN
		F2-B 10A	(CH 8,PG 1)
BATTERY
		63	TO DOME & COURTESY LIGHTS
ADAPTER		18DK BL
			(CH 11,PG 5)
(498)		14AX	TO REFRIGERATOR FUSE
		18RD
			(CH 10,PG 8)
14H	14Y	63P	TO SPOTLIGHT & READING
6RD	14RD	16DK BL
	F1-D 15A		LIGHTS	(CH 11,PG 5,13)
	14X	75	TO HIGH SPEED RELAY
	10RD	10LT GN
	F1-A 30A			(CH 12,PG 2)
	14Z	F1-B 10A
		77T	TO A/C CONTROL RELAY
	10RD	14LT GN
			(CH 12,PG 1)
		75A	TO HEATER CONTROL RELAY
		14LT GN
		F1-C	(CH 12,PG 2)
		20A	*	FUSE LOCATIONS VARY -
** EXTRA FUSES PROVIDED				CHECK INSIDE POWER
FOR OWNER/OPERATOR				DISTRIBUTION CENTER
CONNECTION				FOR ACTUAL LOCATION.

**

**

CHK	DATE	CHANGE	REV	REFERENCE	DRAWN	NAME
		SEB//ADDED 14BW	A	P52739E	U00EDL2	5000/9100/9200/9400/9900
					RELEASE NO.	DATE	PART NO.	SHEET
JKP	4MAR02	RMVD 14N, ADDED 14AX.	B	55093F	P50317A	12FEB99	AE08-52502	04

Figure 11 Battery, B2

S08316

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 CORPORATIONELECTRICAL CIRCUIT DIAGRAM
		THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND	CHAPTER 2
			12V POWER DISTRIBUTION - BATTERY
		IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE
		INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

	*	F10-D 30A	TO OVERHEAD CABINET LIGHTS
			(CH 10,PG 10)
	14AV	14AX	TO AUX CIRCULATION FAN
	10RD	10RD
B2			(CH 10,PG 1-3)
			TO TV/VCR WIRING
BATTERY
STUD		* F10-C 20A	(CH 10,PG 9)
14AK	14AW	14AY	TO SLEEPER POWER SOURCE
6RD	10RD	12RD
		* F10-B 15A	(CH 10,PG 7)
		75AX	TO AUX BUNK BLOWER RELAY
		14LT GN
		* F10-A 30A	(CH 12,PG 3)
	14AU	75AW	TO SLEEPER BLOWER RELAYS
	10RD	10LT GN
			(CH 12,PG 3)
		F8-D 20A
	14AP	63AA	TO SLEEPER LIGHTS/LUGGAGE
	14RD	14DK BL

COMPARTMENT LIGHTS

(CH 10,PG 4,6)

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

CHK	DATE	CHANGE	REV	REFERENCE	DRAWN	NAME
JKP	4MAR02	ADDED O/H CABINET LTS TO	A	55093F	U00EDL2	5000/9100/9200/9400/9900
					RELEASE NO.	DATE	PART NO.	SHEET
F10-D &	AUX CIR FAN PG	WAS 1, F8-D WAS CH 10, PG 3,5.			P50317A	12FEB99	AE08-52502	05

Figure 12 Battery, B2 (cont.)

S08316

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	13
After — ELECTRICAL CIRCUIT DIAGRAMS

2.6. 3+1 BATTERY SYSTEM, P. 6

Figure 13 3+1 Battery System

S08316

(CH 11,PG 8)

(CH 9,PG 2,5)

(CH 9,PG 1)

(CH 8,PG 3)

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 CORPORATIONELECTRICAL CIRCUIT DIAGRAM
THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND									CHAPTER 2
					12V POWER DISTRIBUTION - GROUND ADAPTER COMPOSITE
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)
GA-11	6WH					11-GR	DATA LINK 6-WAY
						14WH
						62-GJ		(CH 4,PG 3,6,10,14)
			G1			18WH	CRUISE ON/OFF SWITCH
	GND	(RIGHT				62-GK		(CH 4,PG 1,4,8)
			GROUND				CRUISE SET/RESUME SWITCH
		DASH
	STUD					18WH
		PANEL)	ADAPTER			62-GN		(CH 4,PG 1,4,8)
					11-GT		ENG BRAKE ON/OFF
			(453)
						18WH
					18WH
	11-G		11-GA			62-GL		(CH 4,PG 2,5,9)
							ENG BRAKE SELECT
		8WH	12WH
						18WH
								(CH 4,PG 2,5,9)
			G4			62-GQ	CUMMINS & DET.		INC/DEC IDLE DIAG
						18WH	DEIS. ONLY
			GROUND			62-GR	CUMMINS ONLY		(CH 4,PG 10,14)
									DIAG ON/OFF
			ADAPTER			18WH
									(CH 4,PG 14)
			(456)		11-GAE	RIGHT POWER MIRROR
				11-GX	18WH
	11-GB		11-GC				(CH 8,PG 8)
				18WH	13-GCP
		8WH	10WH			ABS TRAILER RELAY
					14WH
					11-GZ		(CH 9,PG 8)
						LEFT POWER MIRROR
					18WH
								(CH 8,PG 8)
					11-GAD	RIGHT MOTORIZED MIRROR
					18WH
							(CH 8,PG 9)

G3

GND	(LEFT	GROUND	11-GAW
			14WH
	DASH	ADAPTER
STUD PANEL)			13-GAD
		(455)	18WH
11-GD		11-GE	94-G
8WH		12WH	16WH
			11-GAC
			14WH
			38-G
			18WH
			38-GB
		G2	18WH
		GROUND	11-GBC
		ADAPTER
			12WH
		(454)
11-GI		11-GY	11-GAV
10WH		10WH	18WH
			25-G
			18WH
			11-GBD
			12WH

RIGHT WINDOW SWITCH & RELAY AIR DRYER RELAY

ABS RELAYS

FOG LIGHT RELAY & SWITCH

DRIVER HEATED SEAT

(CH 8,PG 21)

PASSENGER HEATED SEAT

(CH 8,PG 22)

AUXILIARY BUNK BLOWER RELAY

& SLEEPER OPTIONS

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

CLOCK (CH 8,PG 2

CH 11,PG 11)

PYROMETER CONTROL MODULE

(CH 6,PG 7)

SLEEPER OPTIONS

(CH 10,PG 1-4)

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

CHK	DATE	CHANGE	REV	REFERENCE	DRAWN	NAME
JKP	4MAR02	REVISED 11-GBC &	A	55093F	U00EDL2	5000/9100/9200/9400/9900
					RELEASE NO.	DATE	PART NO.	SHEET
11-GBD.	ADDED 38-	G & 38-GB.			P50317A	12FEB99	AE08-52502	07

Figure 14 Ground Adapter Composite

S08316

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	15
After — ELECTRICAL CIRCUIT DIAGRAMS

2.8. GROUND STUD COMPOSITE, P. 8

Figure 15 Ground Stud Composite

S08316

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

S08316

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	17
After — ELECTRICAL CIRCUIT DIAGRAMS

2.10. IGNITION, P. 10

Figure 17 Ignition

S08316

(CH 8,PG 14)

(CH 8,PG 14)

18		5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
			After — ELECTRICAL CIRCUIT DIAGRAMS
2.11. PANEL LIGHTS ADAPTER COMPOSITE, P. 11
		INTERNATIONAL TRUCK AND ENGINE CORPORATIONELECTRICAL CIRCUIT DIAGRAM
		THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND		CHAPTER 2
				12V POWER DISTRIBUTION - PANEL LIGHTS ADAPTER
		IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE
				COMPOSITE
		INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

62T 16DK BL

62AG 16DK BL

62D 18DK BL

62C

18DK BL

62B

18DK BL

	62S 16DK BL	62P
		16DK BL
62W 16DKBL	62A BL16DK	62AR
		16DK BL
		16DK BL
		62AS
		16DK BL
		62AP

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

(CH 11, PG 11)

	62W 16DK BL				62A 16DK BL
			62 16DK BL

	PANEL	D	A
	LIGHT		C
	SWITCH	F	B
	(425)

62-GW 18WH

11-GS 16WH

62M 16DK BL

		16DKBL	L1
	62AE		PANEL
			LTS FEED

ADAPTER (503)

L2

PANEL LTS FEED ADAPTER

(504)

L4

PANEL

LTS GND ADAPTER (506)

11-GP 12WH

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

GAUGE PANEL LIGHT

(CH 11,PG 11)

FOG LIGHT SWITCH

(CH 11,PG 8)

RIGHT WINDOW SWITCH

(CH 8,PG 3)

CLOCK (CH 11,PG 11)

BUNK CONTROL PNL SWITCH

(CH 10,PG 3,8,9)

ENGINE FAN OVERRIDE SWITCH

(CH 5,PG 3,4)

RT MOTO MIRRORS SW

(CH 8,PG 9)

ETHER START SWITCH

(CH 6,PG 11)

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 SPARE SWITCH N/FUSE

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)

11-GD	11-GK
8WH	16WH

(LEFT DASH PANEL)

GND

STUD

11-GF 10WH

62-GAS		HEADLIGHT SWITCH
18WH
62-GAR		(CH 11,PG 9)
16WH		TRAILER LIGHTS SWITCH
		(CH 11,PG 2)
62-GC		LEFT SIDE CLUSTER
18WH
62-GB		(CH 11,PG 11)
		RIGHT SIDE CLUSTER
18WH
62-GD		(CH 11,PG 11)
		SPEEDO/TACH MODULE
18WH
		(CH 11,PG 11)

CHK	DATE	CHANGE	REV	REFERENCE	DRAWN	NAME
JKP	4MAR02	ADDED CIR 62X & 86-GK	A	55093F	U00EDL2	5000/9100/9200/9400/9900
					RELEASE NO.	DATE	PART NO.	SHEET
					P50317A	12FEB99	AE08-52502	11

Figure 18 Panel Lights Adapter Composite

S08316

5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and	19
After — ELECTRICAL CIRCUIT DIAGRAMS

3.12 VOLT CHARGING AND CRANKING SYSTEM (CHAPTER 3)

3.1.W/CAT AND CUMMINS ENGINES, P. 1

INTERNATIONAL TRUCK AND ENGINE CORPORATIONELECTRICAL CIRCUIT DIAGRAMCHAPTER 3

	THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND	CHARGING AND CRANKING (12V)
	IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE	W/CAT AND CUMMINS ENGINES
	INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

B1

START

FEED

BATTERY

ADAPTER

STUD

(509)

17B

14PK

14

14A

02RD

02RD

2

150A

(2)

04RD

ALTERNATOR

MEGA

B

FUSE

BATTERIES

TO ECM

-+

-

11-G

14A

02RD

17B

16PK

G

12WH

POWER

01BK

TO ECM

CONN

POWER

(CH 4,PG 2,7)

06BK

06BK

CONN

G-2 04WH

14D

12RD

14C

12RD

W/CAT

(CH 4,PG 2)

FRAME

14

STARTER

02RD

-+

-

GROUND

MAGNETIC

15A

SWITCH

15A

06BK

06BK

12RD

12RD

17C

08PK

14A

14B

2

04RD

+-

-

(2) 12GA, BL

FUSIBLE LINKS

06BK

06BK

4/0 BK

-+

-

B

S

CRANKING

4/0 BK

MOTOR

4/0 BK

M

SOLENOID

4/0 BK

CRANKING MOTOR

2-G

2/O BK

04WH

11-GA

11-GS

FROM ECM

06WH

02BK

FRAME

11-GU

FROM SENSOR

GROUND

11-G

12WH

GROUND SPLICE

GROUND

12WH

W/ISX,ISM

(CH 3,PG 2

(CH 4,PG 7)

CH 5,PG 2

CAB

ENGINE

CH 6,PG 4,9

CH 12,PG 1)

J4 GROUND

GROUND

CHK

DATE

CHANGE

REV REFERENCE

DRAWN

NAME

U00CJB5

5000/9200/9400/9900

RELEASE NO.

DATE

PART NO.

SHEET

54719V

26JUL01

AE08-54038

01

Figure 19 W/Cat and Cummins Engines

S08316

20		5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
			After — ELECTRICAL CIRCUIT DIAGRAMS
3.2. W/OVERCRANK PROTECTION W/CAT AND CUMMINS ENGINES, P. 2
		INTERNATIONAL TRUCK AND ENGINE CORPORATIONELECTRICAL CIRCUIT DIAGRAM
				CHAPTER 3
		THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND		12V CRANKING SYSTEM W/OVERCRANK PROTECTION
		IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE
				W/CAT AND CUMMINS
		INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

14

02RD

TO ALTERNATOR

(CH 3,PG 1)			2
			04RD

	B1				START
					FEED
BATTERY					ADAPTER
STUD					(509)
				17B	14PK
		14A	02RD		(2)
	150A
	MEGA
	FUSE
				17B	16PK
		14A	02RD
	14				STARTER
	02RD
					MAGNETIC
	2				SWITCH
04RD
			D71	KP8 1
		17C	8PK
FL	12BL FL	12BL
	B	S	CRANKING			D71 KP81
	M		MOTOR
			SOLENOID

CRANKING

MOTOR

FOR REMAINDER OF

CRANK MOTOR SOLENOID

AND CRANK MOTOR WIRING

SEE CHARGING & CRANKING

SECTION.

(275)

17D

18PK

17-G 18WH

17-G	18WH
UG11	HW 21

ENGINE

GROUND

CHK	DATE	CHANGE	REV	REFERENCE	DRAWN	NAME
					U00CJB5	5000/9200/9400/9900
					RELEASE NO.	DATE	PART NO.	SHEET
					54719V	26JUL01	AE08-54038	02

Figure 20 W/Overcrank Protection W/Cat and Cummins Engines

S08316

	5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and			21
	After — ELECTRICAL CIRCUIT DIAGRAMS
3.3. W/I6 HEUI ENGINE, P. 3
	INTERNATIONAL TRUCK AND ENGINE CORPORATIONELECTRICAL CIRCUIT DIAGRAM
	THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND	CHAPTER 3
		CHARGING AND CRANKING (12V)
	IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE
		W/I6 HEUI ENGINE
	INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

40A

14A

10RD

B

ALTERNATOR

BATTERIES

G

		+	-
	06BK	06BK	06BK
	11-GL	+	-
		06BK	06BK
		+	-
		06BK	06BK
		+	-

B1

BATTERY

STUD

		14A	02RD
2
4RD
14B	TO MODULE	150A
		MEGA
10RD
11-G	POWER	FUSE
	(CH 4,PG 11)
10WH
		14A	02RD
	2	04RD
01BK
		14-FL 02RD
FRAME
GROUND
		17C	08PK

4/0 BK	B	S
4/0 BK
	M

START

FEED

ADAPTER (509)

17B	14PK

2

17B	16PK

STARTER

MAGNETIC

SWITCH

CRANKING

MOTOR

SOLENOID

4/0 BK

CRANKING MOTOR

11-GA

06WH

MAIN

GROUND

CHK

DATE

CHANGE

REV

REFERENCE

DRAWN

NAME

U00CJB5

5000/9200/9400/9900

RELEASE NO.

DATE

PART NO.

SHEET

54719V

26JUL01

AE08-54038

03

Figure 21 W/I6 HEUI Engine

S08316

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 CORPORATIONELECTRICAL CIRCUIT DIAGRAM
		THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND		CHAPTER 3
				12V CRANKING SYSTEM W/OVERCRANK PROTECTION
		IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE
				W/I6 HEUI
		INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.

B1

BATTERY

STUD

			2
TO ALTERNATOR			04RD
(CH 3,PG 3)

2

04RD

14	02RD

START

FEED

ADAPTER (509)

	02RD	17B	14PK
14A

150A

MEGA 2

FUSE

14A

02RD

17B

16PK

STARTER MAGNETIC SWITCH

(4 TERM)

1 18 D7 KP

17C 8PK

CRANKING

MOTOR

FOR REMAINDER OF

CRANK MOTOR SOLENOID

AND CRANK MOTOR WIRING

SEE CHARGING & CRANKING

SECTION.

B S

M

CRANKING

MOTOR

SOLENOID

275

17D

18PK 17-G 18WH

1 18 D7 KP

17-G 18WH

							UGHW4 1 1 1
									STARTER MOTOR
									GROUND
CHK	DATE	CHANGE	REV	REFERENCE	DRAWN	NAME
					U00CJB5	5000/9200/9400/9900
					RELEASE NO.	DATE	PART NO.			SHEET
					54719V	26JUL01			AE08-54038	04

Figure 22 W/Overcrank Protection W/I6 HEUI

S08316