International CF500, CF600 Wiring Diagram

CF 500, CF 600 Circuit Diagrams
Table of Contents 1-1
Table of Contents 1-1..............................................
Introduction 3-1..................................................
Symbols 4-1.....................................................
Connector Repair Procedures 5-1....................................
Wiring Harness Overview 9-1.......................................
Fuse and Relay Information 11-1......................................
Charging System 12-1.............................................
Power Distribution 13-1............................................
Module Communications Network 14-1...............................
Starting System 20-1..............................................
Electronic Engine Controls 23-1.....................................
Transmission Controls 29-1.........................................
Speed Control 31-1...............................................
Vehicle Dynamic Systems 42-1......................................
Horn/Cigar Lighter 44-1...........................................
Fuel Tank Selector 49-1............................................
Manual Climate Control System 54-1.................................
Instrument Cluster 60-1............................................
Cluster and Panel Illumination 71-1..................................
Front Wipers and Washers 81-1......................................
Headlamps 85-1..................................................
Fog Lamps 86-1..................................................
Interior Lamps 89-1...............................................
Turn Signal/Stop/Hazard Lamps 90-1.................................
Parking, Rear and License Lamps 92-1................................
Reversing Lamps 93-1.............................................
Trailer Adapter 95-1...............................................
Daytime Running Lamps 97-1.......................................
Power Windows 100-1.............................................
Power Door Locks 110-1............................................
Remote Keyless Entry and Alarm 117-1................................
Audio System 130-1..............................................
Customer Access 140-1............................................
Component Testing 149-1..........................................
Connector Views 150-1............................................
Component Location Views 151-1...................................
Component Location Charts 152-1...................................
Vehicle Repair Location Charts 160-1.................................
NOTE: The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. International Truck and Engine Corporation reserves the right to change specifications or design without notice and without incurring any obligation.
S08311
p
3-1
Introduction
Note
All wiring connections between components are shown exactly as they exist in the vehicles. It is important to realize, however, that no attempt has been made on the schematic to represent components and wiring as they physically appear on the vehicle. For example, a 4-foot length of wire is treated no differently in a schematic from one which is only a few inches long. Furthermore, to aid in understanding electrical (electronic) operation, wiring inside complicated components has been simplified.
Complete Circuit Operation
Each circuit is shown completely and independently in one cell. Other components which are connected to the circuit may not be shown unless they influence the circuit operation.
Current Flow (1)
Each cell normally starts with the component that powers the circuit, such as a fuse or the ignition switch. Current flow is shown from the power source at the top of the page to ground at the bottom of the page. In order to concentrate on the essential parts, power supply and ground connections are sometimes simplified by a dashed line in the schematics. A full representation of the power supply of a fuse or the power distribution from a f use to various components is given in cell 13 “Power Distribution”. Full representation of the ground connections are shown in cell 10 “Grounds”.
Switch Positions (2)
Hot in run
F2.6 5A
C270a31
LB/BK1405
See page 13−8
11 C220a
1
4
VT939
15
VT939
7
2
Central Junc­tion Box (CJB) (14A067)
13−4
12
16
C220a
DG603
C1019
27
DG603
15
1
6
Instrument cluster (10849)
1) Traction control
12) ABS
62−3
4
3
8
LG/YE530
S200
LG/YE530
G104
5
Data Link Con­nector (DLC) (14489)
2
See page 14−3
S157
TN/OG914
3
SCP + SCP
11 C135
C25110 See page 14−3
S156
PK/LB915
ABS control module (2C219)
151−5
7
Within the schematic, all switches, sensors and relays are shown “at rest” (as i f the Ignition Switch were OFF).
Splices (3)
A dashed line indicates that the splice is not shown completely. A reference is given to the page where the splice appears in full. It is also listed in the Index.
p
Component Referencing (4)
Each component on a schematic has a reference to the component location view or the page where it is shown completely. It is located to the right of each component.
Component Names, Notes and Base Part Numbers (5)
Component names are placed on the r ight hand side of each component. Any notes that describe switch positions or operating conditions follow the name. Descriptions of the internals of the component are also included here. The page where the component appears in full is listed in the Index. The base part number for a component is listed in parentheses next to or under a component. These part numbers will appear any place the component name appears i n the publication.
Internal Name and Function Identification Numbers (6)
Some components on each page have internal symbols with an identification number l ocated to the right. You can identify the internal symbol or function by finding the corresponding number under the component name.
Introduction
3-2
Circuit Function Identifiers (7)
Some components without internal schematics use symbols or text to describe the function of a circuit in a system.
p
3-3
Introduction
Fuse and Relay Information
Cell 11 “Fuse and Relay Information” contains a view of the fuse-/relay box in which all fuses and relays are identified.
Fuse and Relay Numbering and Naming
Fuse and relay numbering and naming follow the indication of the fuse panel cover. In addition, a prefix precedes the fuse number to facilitate finding the fuse in the Component Location Charts, e.g. “F1.” precedes Power Distribution Center fuses, and “F2.” precedes Central Junction Box fuses.
Power Distribution
Cell 13 “Power Distribution” shows the current feed circuit. The current path is shown from the battery to the ignition switch and to all fuses. It also shows the circuits protected by each fuse. The circuit is traced from the fuse to the component. All details (wires, splices, connectors) between the fuse and t he first component are shown.
F1.12
F1.13
F1.14
F1.15
F1.1
F1.2
F1.3
F1.4
57 BK
F1.24
Battery
G1002
S130
Fusible Link A
1) 12 gauge
2) gray
S131
F1.20
10A
F1.21
20A
F1.23
Power Distributi on Center (PDC)
F1.2
20A
DB/OG
Power Distributio nCenter (PDC)
Instrument cluster
60−1
Hot at all times Hot at all times
F1.1
30A
RD RD
932
C1041 C1021 C220
Headlamp, right
85−1
932
Headlamp, left
85−1
196
711
Introduction
p
3-4
Ground Distribution
Cell 10 “Grounds” contains the schematics that show the complete details for each ground connection or main ground splice. This is useful in diagnosing a problem affecting several components at once (poor ground connection or ground splice). All details (wires, splices, connectors) between the ground point and the components are shown. These ground connection details are shown here in order to keep the individual cell schematics as uncluttered as possible.
Headlamp, right (13008)
85−2
C1041 C162 C152
21 1
BK BK57 57BK57
Side lamp , left front (13411)
92−1
22
BK
57
Fog lamp, right front (15200)
86−1
Headlamp, left (13008)
85−2
C1021C1127
BK57
S102
BK BK
57 57
2
Fog lamp, front left (15200)
86−1
Side lamp, right front (13411)
92−1
C1126
G100
151−3
p
3-5
Introduction
Component and Connector Information
Cell 152 “Component Location Charts” helps the user find where the various items depicted on the schematic can physically be found on the vehicle. A brief written description of the location is given, along with a reference t o the component location views. Cell 151 “Component Location Views” show the components and their connecting wires as they can be found on the vehicle. Cell 150 “Connector Views” show the views of the pins and/or cavities of all connectors. The pin and cavity sides are shown separately as if the connector were disconnected. The color of the connector housing is indicated next to the connector number when available. The harness causal number is located above the component name and below the connector number or above the connector face itself. Wiring harness designations are listed in cell 152 “Component Location Charts”. Circuit function charts are located below each connector.
C150
(BK)
12A581
Wheel speed sen­sor, left front (2C205)
Pin Circuit Circuit Function
1 522 (TN/BK) Wheel speed sensor, left front (2C205)
2 521 (TN/OG) Wheel speed sensor, left front (2C205) +
2
FEMALE
1
C1033
(BK)
(1)
(2) 1102 (YE/LG)
12B637
42
31
FEMALE
14B102
2
1
MALE
(3) 359 (GY/RD)
(4)
4
3
p
WARNINGS
!
D Always wear safety glasses for eye protection.
D Use safety stands whenever a procedure requires being under a
vehicle.
D Be sure that the Ignition Switch is always in the OFF position, unless
otherwise required by the procedure.
D Set the parking brake when working on any vehicle. An automatic
transmission should be in PARK. A manual transmission should be in NEUTRAL.
D Operate the engine only in a well-ventilated area to avoid danger of
carbon monoxide.
D Keep away from moving parts, especially the fan and belts, when the
engine is running.
D To prevent serious burns, avoid contact with hot metal parts such as
the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.
D Do not allow flame or sparks near the battery. Gases are always pres-
ent in and around the battery cell. An explosion could occur.
D Do not smoke when working on a vehicle.
D To avoid injury, always remove rings, watches, loose hanging jewelry
and avoid wearing loose clothing.
Introduction
3-6
Symbols4-1
Distributed splice
Crossed wiring without connection
Splice
Removable connection
Ground
Connector
Female connector
Male connector
Entire component Resistor
Part of a component
Potentiometer (pressure or temperature)
Component case directly at­tached to metal part of vehicle (ground)
Component with screw terminals
Connector attached to component
Connector attached to com­ponent lead (pigtail)
Potentiometer (outside in­fluence)
Battery
Fuse
Circuit breaker
Twisted pair
Positive Temperature Coef­ficient (PTC)
Heating element, Con­ductor loop
Symbols 4
-2
Ignition coil assembly
Solenoid controlled valve or clutch solenoid
Light emitting diode (LED)
Capacitor
Variable capacitor
Coil
Hall sensor
Air bag sliding contact (14A664)
Diode, current flows in direction of arrow
Transistor
Bifilament lamp
Gauges
Antenna
Permanent magnet, onespeedmotor
Permanent magnet, twospeedmotor
Shield
Horn or speaker
Fusible link
Warning
!
Piezoelectric sensor
Lamp
Rotational sensor
Symbols4-3
Wire colors
BK
Black
BN Brown
BU Blue
DB Dark blue
DG Dark green
GN Green
GY Gray
LB Light blue
LG Light green
NA Natural
OG Orange
PK Pink
RD Red
SR Silver
TN Tan
VT Violet
WH White
YE Yellow
VREF
Reference volt­age
PWR
VBATT VPWR SCP + SCP
Switched power
signal signal Signal return
Joint connector
Battery voltage Switched or
+
module voltage
SIG RTN
Standard Cor­porate Proto­col (SCP) data +
Standard Corpo­rate Protocol (SCP) data
ground
C1201
GY/RD359
C2003
ISO
Data bus ISO 9141 (Kline)
Groundsignal Signal return Switched
jumper
C2004
GY/RD359
C1202
Symbols 4
-4
Hot in Start or Run
910 GY/BK
53 C240
Circuit number
Pin number
F1.18 15A
See page 13-1
PK329
4 C100
57
BK
G100
Power Distribution
Center (PDC) (14A003)
Other circuits which share fuse 18, but are not shown, can be referenced in Power Distribution
Wire insulation is one color
Connector reference number for component location chart
Ground numbered for reference to component location chart
1 C125
57 BK
See page 10-1
G100
29−1 Transmission Controls
Windshield wiper
motor (17508)
Other circuits which are also grounded at G100, but are not shown, can be referenced in Grounds
GN/WH329
Wire insulation is one color with another color stripe (green with white)
Reference to another cell where circuit is shown completely
359
359
3
GY/RD
GY/RD
Shorting bar
PK329
4 C103
Two connections (pins) in the same connector
Dashed line indi­cates terminals for the same con­nector
A choice bracket shows wiring differ­ences between mod­els, countries or op­tions
A
See page 46−2
See page 46−1
A
Cut wires referenced be­tween pages. Arrows show current flow from power to ground.
F1.3 10A
Busbar
F1.14 10A
Symbols4-5
Indicates incomplete internal bussing
Name of com-
Ignition switch
(11572)
3
C3003
12
0) Off
0
1) Acc
12
2) Run
3) Start
Switches that move to­gether
Reference number indicates
12
switch position
Dashed line shows a mechani­cal connection between switches
Normally open contact When coil is energized, switch is activated
ponent
Details about component or operation
Component con­nector number
nonserviceable components
Hot in Start or Run
Fuel pump relay
DG/YE238
LB/OG238
16
18
33
BK57
4
19
57
LB/RD19
C17517
C175
BK
C2012
Engine
Control Module (ECM)
(12A650)
Hotatalltimes
F2.23
3A
720
RD/YE
C2205
6
C2204
See page 13−1
S100
LB/RD19
C1351
C1352
BK57
Fuse conditionRelays shown without a connector number are
Central Junction
Box (CJB)
Instrument cluster
6) Illumination
ABS control
module (2C219)
Name of component
Details about component or operation
Reference number for internal component name
Referencetopagewhere circuit is shown complete
Component connector number
Base service part number
Dashed line indicates termi­nals for the same connector
Wire insulation is one color
One pole, two posi­tion switch
12
G102
Ground numbered for refer­ence to component location chart
S101
See page
10−1
G101
Splice numbered for refer­ence in component location chart
Other circuits which are also grounded at G100, butarenotshown,canbe found using the reference
The first digit of every connector, ground, and splice number used in this publication references its location within the vehicle.
The chart below describes the different sec­tions of the vehicle, and lists the number associated with each.
Symbols 4
-6
Number
100199 10001999
200299 20002999
300399 30003999
400499 40004999
500599 left front door
600699 right front door
700799 left rear door
800899 right rear door
900999 A, B, C pillars Above door trim panel and
Location
front fascia, hood, front fenders, front axle, En­gine compartment, Powertrain (including: axle/ differential/transmission/exhaust system)
Instrument Panel and Center Stack Console, Steering wheel assembly, front kick panels, cowl panel (body side)
From instrument panel to rear seat, A, B, C pillars below door trim panel, center console
behind rear seats, to rear bumper; Truck bed, Tailgate, Liftgate, Rear fenders
headliner
Connector Repair Procedures5-1
Troubleshooting wiring harness and connector hidden concerns
The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration.
NOTE: Several components, such as the ECM, utilize gold plated terminals in t heir connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal.
Terminal not properly seated
1 = Locked terminal 2 = Male half 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Unlocked terminal (Hidden by wire seal) 7 = Seal
Check for unlocked terminals by pulling each wire at the e nd of the connector.
Connector Repair Procedures 5-2
Defective insulation stripping
1 = Proper crimp 2 = Insulation not removed 3 = Wire strands missing 4 = Intermittent signals through pierced insulation
Partially mated connectors
1 = Seal 2 = Displaced tab 3 = Female half 4 = Seal 5 = Intermittent contact 6 = Male half 7 = Intermittent contact
Lock may be displaced into an unlocked position; pull on the connector to verify the lock.
Connector Repair Procedures5-3
Deformed (enlarged) female terminals
1= Enlarged 2= Normal
Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating terminal (Location A) from the service kit and feel for a loose fit.
Electrical s hort inside the harness
1 = Solder coated wire to ground 2 = Harness protective tape 3 = Intermittent short
Solder coated wire pierced through the insulation of another circuit
4 = Grounding foil
Connector Repair Procedures 5-4
Electrical short within the harness
Splicetaperemoved
1 = Intermittent short
Splice covered
2 = Wire strand 3 = Splice tape 4 = Harness tape
Broken wire strands in harness
1 = Wiring harness tape 2 = Wiring strand 3 = Broken strands intermittent signal 4 = Circuit insulation
Remove the tape and flex/feel each circuit for a reduction in diameter at break.
Connector Repair Procedures5-5
Recommended splicing method Solder (For 16 AWG and Smaller Diameter Wire Only)
1. Disconnect battery ground cable.
2. Strip wires to appropriate length.
3. Install heat shrink tubing.
4. Twist wires together.
5. Solder wires together.
NOTE: Use rosin core mildly-activated (RMA) solder. Do not use acid core solder.
7. Evenly position heat shrink tubing over wire repair.
NOTE: Overlap tubing on both wires.
8. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of heat shrink tubing.
9. Reconnect battery ground cable.
6. Bend wire 1 back in a straight line.
NOTE: Wait for solder to cool before moving wires.
Connector Repair Procedures 5-6
Recommended splicing method Crimp (For 1022 AWG Diameter Wire to Like Wire Diameter)
1. Disconnect battery ground cable.
2. Remove proper amount of
insulation from each wire end, taking care not to nick or cut wire strands.
3. Install heat shrink tubing.
4. Select appropriate wire splice for the wires to be spliced.
5. Install the wire ends into the splice,
making sure the ends of the wires
are fully inserted.
6. Using the proper crimping tool for
the splice, hand crimp the wires and
splice.
7. Gently tug on the wires to be sure
they are secure.
8. Electrically check the circuit for
continuity through the splice.
9. Evenly position supplied heat shrink tubing over wire repair.
10. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing.
11. Reconnect battery ground cable.
Wiring Harness Overview9-1
9
1
4
2
5
3
7
6
8
Connector
Grommet
Wiring Harness Overview 9
DescriptionPart NumberItem
-2
1
2
3
4
5
6
7
8
9
14335 Wiring harness Interior illumination
9D930 Wiring harness Fuel charge
12B637 Wiring harness Engine control sensor
12A581 Wiring harness Main
14401 Wiring harness Instrument panel
14405 Wiring harness Rear Chassis
14A005 Wiring harness Floor
14631 Wiring harness driver door
14630 Wiring harness passenger door
G100
Grounds10 -1
57
B
57
See page 10−2
A
BK
C1041
BK
Headlamp, right
(13008)
85−2
C137
BK
1
57
Windshield
washer pump motor (17618)
81−1
Function selec-
tor switch as­sembly
C294a
BK
(19B888)
54−2
12
57
57
See page 10−3
B
A
BK
57
Pusher fan relay
54−4
C2346
2
BK
57
C
57
Cigar lighter,
front (15055)
44−1
C2031
BK
57
C2333
BK
C202a
BK
Door lock timer
110 −1
C202b
516
BK
57
S202
57
Multifunction switch
811, 851, 92−1
57
C2047
5
BK
S203
BK
Indicator flasher
relay (13350)
90−1
BK
57
G100
15112
Grounds 10
-2
Auxiliary relay box 1
113, 151−9
2
Power window relay
100−1
C2218
BK
Speed control
On/Off switch
31−2
C2178
BK
S204
Ashtray illumi-
nation lamp
71−1
C294c
C2246
B
BK
57
Ashtray illumi-
nation lamp
71−1
C2014
B
BK
57
9
57
Hazard flasher
switch
90−1
C2039
BK
2
BK
57
Function selec-
tor switch as­sembly
(19B888)
54−1
C2177
G
BK
57
86
57
Speed control
Set/Resume switch
31−2
57
57
A
See page 10−1
BK
Grounds10 -3
3
Roof marker
lamp, left
92−2
C970
BK
Roof marker
lamp, left cen­ter
92−2
C971
3
BK
57
57
Parking brake
switch (15A851)
60−2
C306
A
Safety belt
buckle switch
BK
57
57
(10B924)
60−2
C323
3
BK
57
57
A
57
F
Floor shifter
29−4
C3245
57
BK
S300
BK
C300
BK
3
Roof marker
lamp, center
92−2
C972
BK
3
Roof marker
lamp, right
92−2
C974
BK
S900
BK
Roof marker
lamp, right cen­ter
92−2
C973
3
BK
57
57
57
1
57
B
See page 10−1
C210
BK
G101
Grounds 10
-4
ends in harness
BK
57
C1043
3
B
57
Park/turn lamp,
right front (13411)
90−4
Brake fluid level
switch (2L414)
60−2
C124
BK
Master window
adjust switch
100−1
C504
3
BK
C211
1
BK
Run/Accessory
relay
60−3
Function selec-
tor switch as­sembly
(19B888)
C294b
A
57
54−1
BK
S206
C552
6
BK
BK
BK
Door lock actua-
tor, left front
110 −1
S207
57
57
C2312
2
Speed control
On/Off switch
31−2
C2178
7
BK
57
Fog lamp, right
front (15200)
86−1
C162
2
C152
2
B
57
Fog lamp, left
front (15200)
86−1
Headlamp, left
(13008)
85−2
C1021
BK
57
13
57
57
Park/turn lamp,
left front (13411)
90−4
C1023
3
BK
57
BK
57
BK
57
BK
57
BK
57
S205
BK
57
BK
57
G101
15112
G102, G400
Grounds10 -5
with 137” wheel­base
C1529
B
BK
57
Pusher fan
54−4
BK
57
not used
4
4
57
57
C431
C423
BK
BK
with dual tanks
B
57
BK
57
Fuel sender,
secondary
49−2
C3263
BK
65838485
57
57
BK
BK
S109
License plate
lamp (13550)
92−1
C4046b
1
Fuel sender,
primary
492, 49−3
C3262
B
BK
57
with 137” wheel­base
BK
333
57
62
BK
57
57
B
57
B
Automatic transmission module (7G422)
29−2
C168
BK
Reversing
alarm speaker
93−1
C4015
BK
C422
57
Output Shaft
Speed (OSS) sensor
(7H103)
C193
3
57
29−2
BK
1
Tail lamp, left
90−3
C412
BK
Tail lamp,
right
90−3
C415
1
BK
57
Speed sen-
sor assembly (7M101)
29−2
C143
2
BK
57
BK
57
C421
1
S401
BK
57
C311
9
BK
57
S108
with 137” wheel­base
See page 10−6
C
BK
57
BK
57
G102
15116
G105
Grounds 10
-6
Windshield wip­er relay
81−1
C1491
BK
BK
2
51
Transmission relay
29−1
C1520
BK
D
BK/WH
3027
3
A/C Compres-
sor clutch diode
54−3
C1086
RD/WH
S102
See page 10−7
57
57
E
BK
Fuel heater relay
49−1
C1329
2
BK
57
Horn (13832)
44−1
C131
2
3027
BK
57
3027
1
A/C clutch field
coil (19D798)
54−3
C100
RD/WH
RD/WH
57
See page 10−7
2
Fog lamp relay
86−1
C1007
BK
6
BK/PK
574
574
86
57
Engine Con­trol Module (ECM)
23−1
C175b
7
BK/PK
57
Power Distribu­tion Center (PDC)
111, 15122
S104
BK
57
574
574
C140
41
BK/PK
S105
BK/PK
S101
BK
57
C
See page 10−5
G105
15122
7
BK/PK
574
BK
57
Grounds10 -7
C1450
BK
BK
E
EGR system
module
23−2
C1245d
1
BK
57
Manifold in-
take air heater relay
23−3
57
Injector Driv­er Module (IDM)
23−4
C1174c
BK/WH
3
BK/WH
51
51
21
BK/WH
51
51
BK/WH
See page 10−6
2622
BK/WH
51
S106
BK/WH
51
D
2
57
57
See page 10−6
1
C1084d
BK
Glow plug
relay
23−9
1
57
C1515
BK
C
Boost control
solenoid
23−5
57
C128
BK
S107
Mass Air Flow
(MAF) sensor (12B579)
23−6
G103, G104
Grounds 10
-8
Body builder relay #1
140−1
C1519
2
16
BK
57
G104
15123
530
57
57
BK
Power Distribu­tion Center (PDC)
111, 15122
45
LG/YE
BK
G103
15116
with dual tanks
D
Fuel transfer pump
49−2
C3264
BK
C311
BK
ends in harness
BK
57
S100
ABS control module (2C219)
42−1
C135
BK
57
57
Fuel pump
49−3
C1253
2
BK
57
Fuel heater
49−1
C1076
1
BK
57
23
57
Grounds10 -9
G107, G108, G200
C220b
1
BK
BK
Instrument clus-
ter (10849)
60−2
S200
Daytime Run-
ning Lamps (DRL) module
97−2
C1030
D
BK
57
Battery 2
15118
BK
C
57
premium radio
C1
BK
Audio unit
(18808)
130−1
C290
BK
Battery (10655)
15118
100bC1249b
8
5
57
Engine diagnostic connector
14−1
C2173
A
BK
57
C240
C2188
BK
Audio unit
(18808)
130−1
Cassette
Data Link Connector (DLC) (14489)
14−2
57
BK
14
57
C251
54
BK
57
Remote keyless
entry module (15K602)
117 −1
C272
BK
Door lock timer
117 −2
C2333
5
BK
57
Instrument clus­ter (10849)
60−2
C220b
32
BK
57
BK
57
S201
57
57
G107
BK
G108
BK
57
G200
15112
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