Electrical.circt.diag.Re 2000 2004

7/27/2019 Electrical.circt.diag.Re 2000 2004

http://slidepdf.com/reader/full/electricalcirctdiagre-2000-2004 1/180

SERVICE MANUAL

SERVICE MANUAL SECTION

3000FE, 3000RE Models Built August 1, 2000 to February 29, 2004 —

ELECTRICAL CIRCUIT DIAGRAMS

Model: 3000 FEStart Date: 08/01/2000 End Date: 02/29/2004

Model: 3000 REStart Date: 08/01/2000 End Date: 02/29/2004

s08208Y, Formerly CTS-5216W

03/27/2000

s08208Y

Copyright© 03/27/2000 Navistar, Inc.





3000FE, 3000RE Models Built August 1, 2000 to February 29, 2004 — ELECTRICAL

CIRCUIT DIAGRAMS

i

Table of Contents

1. ELECTRICAL CIRCUIT DIAGRAMS — 3000FE..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1

1.1. INSTRUCTIONS AND CHARTS, (CHAPTER 1)........................................................1

Circu it Diag ram Ins tru ct ion s, p . 1 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Circu it Diag ram Ins tru ct ion s, p . 2 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Sc hematic Sy mb ols , p . 3.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Sc hematic Sy mb ols , p . 4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

International Circuit Number Identific a tio n , p . 5 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

International Circuit Number Identific a tio n , p . 6 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

International Circuit Number Identification: Engine Control Module, p. 7.. .. .. ... .. .. .. .. .7

1.2. POWER DISTRIBUTION (CHAPTER 2)..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...8

B a tte ry , p . 1 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Gr ou nd , p . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Ig nit io n — Key Sw itc h, p. 3 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101.3. CAB ACCESSORIES (CHAPTER 3)... ... ... .... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .11

Ho rn , p . 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1.4. ENGINE SYSTEMS (CHAPTER 4)...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .12

Am met er (Shu nt ), p. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Ch arg in g Sy stem, p . 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

C ra n k in g S y s te m, p . 3 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

C ra n k in g S y s te m, p . 4 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

R a d ia to r S h u tte rs , p . 5 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

E th e r S ta rt, p . 6 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

1.5. GA UGES (CHA PTER 5).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Fu el L ev el Gau ge, p. 1 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Speedometer, Tachometer, Voltmeter, Engine Oil Pressure, Water Temperature, p. 2.. .19

Transmission Temperature Gauge, p. 3..........................................................20

1.6. WARNING LIGHTS (CHAPTER 6)......................................................................21

Low Oil Pressure/High Water Temp/Low Coolant L evel/Brake Warning (Ai r) Ligh ts/Alarm,

p . 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Low Oil Pressure/High Water Temperature/Low Coolant Level/Brake Warning (Hyd.)

L ig h ts a n d A la rm, p . 2 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Diagnostic/Programming Connector and Self-Test Switch and Warning Light Systems,

p . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Parking Brake and Trans. Warning Lights, p. 4..... .... .... ... ... .... ... ... ... .... ... ... .... ...24

1.7. CHASSIS ACCESSORIES (CHAPTER 7)... ... ... .... .... ... ... ... ... ... ... .... ... ... ... ... .... ... ... .25

Heated Fuel Filter/Water in Fuel, p. 1.............................................................25

Ai r Dry er/Dr ain Valve, p. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

B o dy B u ilder C on nec tio ns , p . 3.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27B rak e Sy stem Hy d rau l ic , p. 4 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Stoplight Switch (With Air Brake), p. 5...........................................................29

An ti lo ck Br akes (4–Chan nel ) Wit h CEC I6 and Ai r Br akes , p. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

An ti lo ck Br akes (4–Chan nel ) Wit h AT, MT, Wit h TEC III Al li so n Trans., p. 7...............31

Al li so n AT/MT Au to mat ic Trans mi ss io n Sys tem , p. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Al li so n Wit h TEC III Trans mi ss io n Wit h CEC I6 HEUI, p. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Al li so n Wit h TEC III Trans mi ss io n Wit h CEC I6 HEUI (Con t.), p . 10. . . . . . . . . . . . . . . . . . . . . . . . .34

Al li so n Wit h TEC III Au to mat ic Trans mi ss io n, p. 11.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Al li so n Wit h TEC III Au to mat ic Trans mi ss io n — J-1939, p. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

s08208Y



ii 3000FE, 3000RE Models Built August 1, 2000 to February 29, 2004 — ELECTRICAL

CIRCUIT DIAGRAMS

Al li so n Wit h TEC III Au to mat ic Trans mi ss io n (Elect ro ni c) Spar e In pu t/Ou tp ut s, p. 13. . .37

Al li so n Wit h TEC III Au to mat ic Trans mi ss io n (Elec tr on ic ) Spar e Inp ut /Out pu ts (Con t.), p.

1 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

An ti lo ck Br ake Sys tem — Hyd rau li c, p. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

An ti lo ck Br ake Sys tem — Hyd rau li c (Con t.), p. 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

An ti lo ck Br akes (4–Chan nel ) W/CEC I6 and W/Ai r Br akes W/Al li so n 2000 Xms n, p.1 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Al li so n 2000 (LCT) Trans mi ss io n W/CEC I6 HEUI, p. 18.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Al li so n 2000 (LCT) Trans mi ss io n W/CEC I6 HEUI, p. 19.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Al li so n 2000 (LCT) Trans mi ss io n J-1939, p. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Al li so n 2000 (LCT) Trans mi ss io n (Elec tr on ic ) Spar e Inp ut /Out pu ts , p. 21. . . . . . . . . . . . . . . . .45

1.8. LIGHT SYSTEMS (CHAPTER 8)........................................................................46

Back-Up Light System N/Electronic Transmissions, p. 1.....................................46

Day time Ru nn in g L ig hts (USA ), p . 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Headlight System With Douglas Turn Signal Switch (Tilt Column), p. 3... .. .. .. .. .. .. .. ..48

P a n e l L ig h ts , p . 4 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Tu rn Sign al Sy stem, p . 5.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

1.9. ELECTRONIC CONTROLS (CHAPTER 9).... ... ... ... ... ... .... ... ... ... .... ... ... ... ... ... .... .... ..51ECM Power and Ground System With I6 HEUI/CEC, p. 1.....................................51

Ac cel erat or, BA P and ATS Sy st ems , p. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Cruise Control and Electronic Hand Throttle System, p. 3...................................53

1.10. CONNECTOR COMPOSITES (CHAPTER 10).......................................................54

Junction Points — J1, J2, J3, J5, J6, J7, J8, J10..... ... ... .. ... ... ... ... ... ... ... ... ... ... ... .54

Fu s e B lo c k Co n nec tio ns ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Fu s e B lo c k Co n nec tio ns ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Connector Composites (2), (2A), (5)..............................................................57

Connector Composites (7), (8), (9), (10), (11), (12).... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..58

Connector Composites (13), (15), (15A)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .59

Connector Composites (16), (20), (22), (23), (26), (27), (30), (31).. .. .. .. .. .. .. .. .. .. .. .. .. .. .60

Connector Composites (32), (37), (38), (39), (40), (41).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .61

Connector Composites (41F), (44), (44M), (45), (46), (51), (64), (76).. .. .. .. .. .. .. .. .. .. .. .. .62Connector Composites (80), (81), (82), (83)...... ... .... ... ... ... ... ... .... .... .... ... ... ... ... ..63

Connector Composites (84), (85), (86), (87), (88).. ... .. .. ... .. .. ... .. .. .. ... .. .. ... .. .. ... .. .. ..64

Connector Composites (89), (90), (91), (92), (93), (94), (165), (168).. .. .. .. .. .. .. .. .. .. .. .. ..65

Connector Composit es (168), (169), (170), (194), (209), (218), (224), (258).. . . . . .. .. . . . . . . .66

Connector Composites (261), (279), (283), (284)................................................67

Connector Composites (288), (289), (290), (291), (292), (293), (295), (297), (303F),

(304). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Connector Composites (323), (329), (335), (336), (337), (340), (344).........................69

Connector Composites (350), (351), (352), (353), (354), (372).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .70

Connector Composites (373), (374), (379)..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..71

Connector Composites (382), (384), (387M), (388F), (389M), (391).. .. .. .. .. .. .. .. . .. .. .. .. .72

Connector Composites (392), (396), (404), (406), (420), (422).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .73

Connector Composites (426), (426/A), (428), (438), (450), (451).. .. .. .. .. .. .. .. .. .. .. .. .. .. ..74Connector Composites (463), (466), (499), (523)................................................75

Connector Composit es (569), (571), (571A), (572), (572A), (574), (575), (615).. . . . . . . . . . . .76



Connector Composites (832), (836), (1002), (1133), (3084)....................................79

Connector Composit es (3024), (3025), (3026), (3027), (3028), (3029), (3030).. .. .. .. .. .. .. .80

Connector Composites (3031), (3032), (3036), (3043).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..81

Connector Composites (3044), (3047), (3055), (3084), (3084A), (3084B), (3084D,

(3 0 8 4 E ).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

s08208Y




CIRCUIT DIAGRAMS

iii

L am p B ul b Ch ar t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Fu se/Circu it B reak er Ch art. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

2. ELECTRICAL CIRCUIT DIAGRAMS — 3000RE...... ... ... .... ... ... ... ... .... .... ... ... ... .... ... ... .... .... ...85

2.1. INSTRUCTIONS AND CHARTS (CHAPTER 1).......................................................85

International Circuit Identific ation C hart, p . 1 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85International Circuit Identific ation C hart, p . 2 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Circu it D iag ram In struc tio ns , p . 3.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Circu it D iag ram In struc tio ns , p . 4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

S c h e ma tic S y mb o ls , p . 5 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Relay Pinout, Function Data, and Sealed Relay, p. 6..........................................90

2.2. 12 VOLT POWER DISTRIBUTION (CHAPTER 2).. .. ... .. .. .. .. .. ... .. .. .. .. ... ... .. .. .. .. ... .. ... .. .91

Battery/Alternator With T 444E, p. 1..............................................................91

B attery /A ltern ator With I6, p . 2.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

K ey Sw it ch , p . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

2.3. CAB ACCESSORIES (CHAPTER 3)... ... ... ... .... .... ... ... ... ... ... ... .... .... ... ... ... ... .... ... ...94

Am met er, p. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Ho rn , p . 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95Turn Signals, International Turn Signal Switch (Stationary Column), p. 3.................96

Turn Signals, Douglas Turn Signal Switch (Tilt Column), p. 4...............................97

2.4. ENGINE SYSTEMS (CHAPTER 4)...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .98

Charging System (12V) Delco 100, 130, 145 Amp and L/N 105, 130, 145, 180 Amp, p.

1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .98

Cranking System (12V), Optional Starter Overcrank Protection With T 444E, p. 2.......99

Cranking System (12V), Optional Starter Overcrank Protection With I6, p. 3.. .. .. .. .. ..100

Ether Start With I6, p. 4 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Schwitzer Fan With Electric Solenoid Control With T 444E or With I6, p. 5.............. 102

2.5. GA UGES (CHA PTER 5 ).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Fu el L ev el Gau ge, p . 1.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Speedometer, Tachometer, Voltm eter, Engine Oil Pressure, Water Temperature, p.

2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104Transmission Oil Temperature Gauge, p. 3.... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...105

2.6. WARNING LIGHTS (CHAPTER 6)...... ... ... ... ... ... ... ... ... .... ... ... ... ... ... ... ... ... .... ... ... .106

Low Oil Pressure/High Water Temp/Low Coolant Level/Brake Warning (Air) Lights and

Al arm s, p. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Low Oil Pressure/High Water Temperature/Low Coolant Level/Brake Warning (Hyd.)

L ig h ts a n d A la rms , p . 2 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Diagnostic/Programming Connector and Self-Test Switch and Warning Light System, p.

3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Wait-to-Start, Parking Brake and Trans. Warning Lights, p. 4.. .. .. .. .. .. .. .. .. .. .. .. .. .. ..109

2.7. CHASSIS ACCESSORIES (CHAPTER 7)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...110

Ai r Dry er (AD-9) Wit h Ai r Br akes , p. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110

Au to mat ic Trans mi ss io n — Al li so n Mech ani cal , p. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

An ti lo ck Br akes (4–Chan nel ) — Ai r, p. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 An ti lo ck Br akes (4–Chan nel ) — Ai r (Con t.), p. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Al li so n WTEC Trans mi ss io n, p. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Al li so n WTEC Trans mi ss io n (Con t.), p. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115




Al li so n WTEC Trans mi ss io n (Con t.), p. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Transmission Retarder Controls With I6 — Allison WTEC Trans., p. 11..................120

Transmission Retarder Controls With I6 — Allison WTEC Trans. (Cont.), p. 12.. . . . . . .121

s08208Y



iv 3000FE, 3000RE Models Built August 1, 2000 to February 29, 2004 — ELECTRICAL

CIRCUIT DIAGRAMS

D ra in V a lv e , p . 1 3 ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122

Fu el Fi l ter Wirin g S ys tem, p . 14... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

Brake System (Hyd.) With T 444E, p. 15... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..124

An ti lo ck Br ake Sys tem — Hyd rau li c, p. 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

An ti lo ck Br ake Sys tem — Hyd rau li c (Con t.), p. 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

An ti lo ck Br akes (4–Chan nel ) W/Ai r Br akes W/Al li so n 2000 Xms n, p. 18. . . . . . . . . . . . . . . . .127 Al li so n 2000 (LCT) Trans mi ss io n, p. 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

Al li so n 2000 (LCT) Trans mi ss io n, p. 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

Al li so n 2000 (LCT) Trans mi ss io n J-1939, p. 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

Al li so n 2000 (LCT) Trans mi ss io n (Elec tr on ic ) Spar e Inp ut /Out pu ts , p. 22. . . . . . . . . . . . . . .131

2.8. LIGHT SYSTEMS (CHAPTER 8)...... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... .... ...132

B ac k-Up L igh t Sy s tem, p. 1 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

Headlight System With Douglas Turn Signal Switch (Tilt Column), p. 2.................. 133

Headlight System With International Turn Signal Switch (Stationary Column), p. 3. . .134

Daytime Running Lights With Douglas or International Turn Signal Switch, p. 4... .. ..135

Stoplight Switch With Air Brakes, p. 5..........................................................136

P a n e l L ig h ts , p . 6 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

2.9. ELECTRONIC ENGINES (CHAPTER 9)..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...138ECM Power and Ground System, p. 1...........................................................138

Ac cel erat or, BA P and ATS Sy st ems , p. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Cruise Control and Electronic Hand Throttle System, p. 3..................................140

Co ntrol B ox Sy stem, p . 4.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Co ntrol B o x Sy stem (Co nt.), p . 5 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

2.10. CONNECTOR COMPOSITES (CHAPTER 10)......................................................143

F u s e B lo c k C o n n e c tio n s ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Fu s e B lo c k C on n ec tio ns (Co nt.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144

Fu s e/Circu it B reak er Ch art. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

Connector Composites (1A), (1B), (1C), (1XM), (2).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..146

Connector Composites (2A), (2F)................................................................147

Co nn ec to r C o mp os ite (3).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Connector Composites (4), (6), (7), (8), (9), (11), (12).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .149Connector Composites (13), (16), (20), (21), (22), (23), (25)..................................150

Connector Composites (32), (37), (42), (43), (47), (64), (69), (74)... .. .. .. .. .. .. .. .. .. .. .. .. .151

Connector Composites (75), (78), (79), (80), (82), (86).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..152

Connector Composites (88), (89), (90), (91), (94), (100)... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .153

Connector Composites (101), (165), (169), (170), (187), (196).. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .154

Connector Composites (197), (198), (209), (211)..............................................155

Connector Composites (218), (226), (258), (279), (283), (284), (288).. .. .. .. . .. .. .. .. .. .. ..156

Connect or Compo sit es (289), (290), (291), (292), (293), (295), (297), (303), (304F). . . . . .157

Connector Composites (304M), (337), (340), (344), (345), (350), (351), (352), (353)......158

Connector Composites (354), (372), (373), (374), (375), (376), (377).. .. .. .. . .. .. .. .. .. .. ..159

Connector Composites (379), (382), (384)...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...160

Connect or Compo sit es (385), (387M), (389M), (391), (392), (396), (400), (401), (403). . . .161

Connector Composites (412), (420), (426, 426M, 426F), (437), (445), (450), (451)........ 162Connector Composites (458), (463), (465), (466), (499), (500), (523).. .. .. .. . .. .. .. .. .. .. ..163

Connector Composit es (569), (571), (571A), (572), (572A), (574), (575), (615).. . . . .. . . . ..164

Connector Composites (632), (633), (634)...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...165

Connector Composites (635), (636), (637), (639), (640).... .. ... ... ... ... .. .. ... ... .. .. ... ... .166

Connector Composit es (643), (644/644M), (646), (647), (665), (763), (832). .. . . .. .. . . .. . . .167

Connect or Compo sit es (836), (918), (919), (922), (922A), (923), (924), (925), (925A), (926),

(926A ), (1000), (1001).. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

Connect or Compo sit es (1133), (3024), (3025), (3026), (3027), (3028), (3029), (3030). . . .169

Connector Composites (3031), (3032), (3043), (3047), (3084)...............................170

s08208Y




CIRCUIT DIAGRAMS

v

Lamp Bulb Chart and Body Builder Information..............................................171

International System Acronyms and Descriptions..... ... ... ... ... ... ... ... ... ... ... ... ... ..172

s08208Y



vi 3000FE, 3000RE Models Built August 1, 2000 to February 29, 2004 — ELECTRICAL

CIRCUIT DIAGRAMS

s08208Y




CIRCUIT DIAGRAMS

1

1. ELECTRICAL CIRCUIT DIAGRAMS — 3000FE

1.1. INSTRUCTIONS AND CHARTS, (CHAPTER 1)

Circuit Diagram Instructions, p. 1

Figure 1 Circuit Diagram Instructions, Page 1

s08208Y



2 3000FE, 3000RE Models Built August 1, 2000 to February 29, 2004 — ELECTRICAL

CIRCUIT DIAGRAMS


Figure 2 Circuit Diagram Instructions, Page 2

s08208Y




CIRCUIT DIAGRAMS

3

Schematic Symbols, p. 3

Figure 3 Schematic Symbols

s08208Y




CIRCUIT DIAGRAMS



s08208Y




CIRCUIT DIAGRAMS

5

International Circuit Number Identification, p. 5

Figure 5 International Circuit Number Identification

s08208Y




CIRCUIT DIAGRAMS

International Circuit Number Identification, p. 6

Figure 6 International Circuit Number Identification

s08208Y




CIRCUIT DIAGRAMS

7

International Circuit Number Identification: Engine Control Module, p. 7

Figure 7 International Circuit Number Identification: Engine Control Module

s08208Y




CIRCUIT DIAGRAMS

1.2. POWER DISTRIBUTION (CHAPTER 2)

Battery, p. 1

Figure 8 Battery

s08208Y




CIRCUIT DIAGRAMS

9

Ground, p. 2

Figure 9 Ground

s08208Y




CIRCUIT DIAGRAMS

Ignition — Key Switch, p. 3

Figure 10 Ignition — Key Switch

s08208Y




CIRCUIT DIAGRAMS

11

1.3. CAB ACCESSORIES (CHAPTER 3)

Horn, p. 1

Figure 11 Horn

s08208Y




CIRCUIT DIAGRAMS

1.4. ENGINE SYSTEMS (CHAPTER 4)

Am met er (Shu nt ), p. 1

Figure 12 Ammeter (Shunt)

s08208Y




CIRCUIT DIAGRAMS

13

Charging System, p. 2

Figure 13 Charging System

s08208Y




CIRCUIT DIAGRAMS

Cranking System, p. 3

Figure 14 Cranking System

s08208Y




CIRCUIT DIAGRAMS

15

Cranking System, p. 4

Figure 15 Cranking System

s08208Y




CIRCUIT DIAGRAMS

Radiator Shutters, p. 5

Figure 16 Radiator Shutters

s08208Y




CIRCUIT DIAGRAMS

17

Ether Start, p. 6

Figure 17 Ether Start

s08208Y




CIRCUIT DIAGRAMS

1.5. GAUGES (CHAPTER 5)

Fuel Level Gauge, p. 1

Figure 18 Fuel Level Gauge

s08208Y




CIRCUIT DIAGRAMS

19

Speedometer, Tachometer, Voltmeter, Engine Oil Pressure, Water Temperature, p. 2

Figure 19 Speedometer, Tachometer, Voltm eter, Engine Oil Pressure, Water Temperature

s08208Y




CIRCUIT DIAGRAMS

Transmission Temperature Gauge, p. 3

Figure 20 Transmission Temperature Gauge

s08208Y




CIRCUIT DIAGRAMS

21

1.6. WARNING L IGHTS (CHAPTER 6)

Low Oil Pressure/High Water Temp/Low Coolant Level/Brake Warning (Air) Lights/Alarm, p. 1

Figure 21 Low Oil Pressure/High Water Temp/Low Coolant Level/Brake Warning (Air ) Lights/Alarm

s08208Y




CIRCUIT DIAGRAMS

Low Oil Pressure/High Water Temperature/Low Coolant Level/Brake Warning (Hyd.) Lights and

Al arm , p. 2

Figure 22 Low Oil Pressure/High Water Temperature/Low Coolant Level/Brake Warnin g (Hyd.) Lig hts

and Alarm

s08208Y




CIRCUIT DIAGRAMS

23

Diagnostic/Programming Connector and Self-Test Switch and Warning Light Systems, p. 3

Figure 23 Diagnostic/Programming Connector and Self-Test Switch and Warning Ligh t Systems

s08208Y




CIRCUIT DIAGRAMS

Parking Br ake and Trans. Warning Lights, p. 4

Figure 24 Parking Brake and Trans. Warning Lights

s08208Y




CIRCUIT DIAGRAMS

25

1.7. CHASSIS ACCESSORIES (CHAPTER 7)

Heated Fuel Filter/Water in Fuel, p. 1

Figure 25 Heated Fuel Filter/Water in Fuel

s08208Y




CIRCUIT DIAGRAMS

Ai r Dry er/Dr ain Valve, p. 2

Figure 26 Air Dryer/Drain Valve

s08208Y




CIRCUIT DIAGRAMS

27

Body Builder Connections, p. 3

Figure 27 Body Builder Connections

s08208Y




CIRCUIT DIAGRAMS

Brake System Hydraulic, p. 4

Figure 28 Brake System Hydraulic

s08208Y




CIRCUIT DIAGRAMS

29

Stoplight Switch (With Air Brake), p. 5

Figure 29 Stoplight Switch (With Air Brake)

s08208Y




CIRCUIT DIAGRAMS

An ti lo ck Br akes (4–Chan nel ) Wit h CEC I6 and Ai r Br akes , p. 6

Figure 30 Antilock Brakes (4–Channel) With CEC I6 and Air Brakes

s08208Y




CIRCUIT DIAGRAMS

31

An ti lo ck Br akes (4–Chan nel ) Wit h AT, MT, Wit h TEC III Al li so n Trans ., p. 7

Figure 31 Antil ock B rakes (4–Channel) With AT, MT, With TEC III Allison Trans.

s08208Y




CIRCUIT DIAGRAMS

Al li so n AT/MT Au to mat ic Trans mi ss io n Sys tem , p. 8

Figure 32 Allison AT/MT Automatic Transmission System

s08208Y




CIRCUIT DIAGRAMS

33

Al li so n Wit h TEC III Trans mi ss io n Wit h CEC I6 HEUI, p. 9

Figure 33 Alli son With TEC III Transmiss ion With CEC I6 HEUI

s08208Y




CIRCUIT DIAGRAMS

Al li so n Wit h TEC III Trans mi ss io n Wit h CEC I6 HEUI (Con t.), p. 10

Figure 34 Allis on With TEC III Transmissi on With CEC I6 HEUI (Cont.)

s08208Y




CIRCUIT DIAGRAMS

35

Al li so n Wit h TEC III Au to mat ic Trans mi ss io n, p. 11

Figure 35 Allison With TEC III Automatic Transmission

s08208Y




CIRCUIT DIAGRAMS

Al li so n Wit h TEC III Au to mat ic Trans mi ss io n — J-1939, p. 12

Figure 36 Allison With TEC III Automatic Transmission — J-1939

s08208Y




CIRCUIT DIAGRAMS

37

Al li so n Wit h TEC III Au to mat ic Trans mi ss io n (Elect ro ni c) Spar e Inp ut /Out pu ts , p. 13

Figure 37 Allison With TEC III Automatic Transmission (Electronic) Spare Input/Outputs

s08208Y




CIRCUIT DIAGRAMS

Al li so n Wit h TEC III Au to mat ic Trans mi ss io n (Elec tr on ic ) Spar e Inp ut /Out pu ts (Con t.), p. 14

Figure 38 Allison With TEC III Automatic Transmission (Electronic) Spare Input/Outputs (Cont.)

s08208Y




CIRCUIT DIAGRAMS

39

An ti lo ck Br ake Sys tem — Hyd rau li c, p. 15

Figure 39 Antilock Brake System — Hydraulic

s08208Y






CIRCUIT DIAGRAMS

41

An ti lo ck Br akes (4–Chan nel ) W/CEC I6 and W/Ai r Br akes W/Al li so n 2000 Xms n, p. 17

Figure 41 Antil ock Br akes (4–Channel) W/CEC I6 and W/Air Brakes W/Allison 2000 Xmsn

s08208Y




CIRCUIT DIAGRAMS

Al li so n 2000 (LCT) Trans mi ss io n W/CEC I6 HEUI, p. 18

Figure 42 Alli son 2000 (LCT) Transmiss ion W/CEC I6 HEUI

s08208Y




CIRCUIT DIAGRAMS

43

Al li so n 2000 (LCT) Trans mi ss io n W/CEC I6 HEUI, p. 19

Figure 43 Allis on 2000 (LCT) Transmissi on W/CEC I6 HEUI

s08208Y




CIRCUIT DIAGRAMS

Al li so n 2000 (LCT) Trans mi ss io n J-1939, p. 20

Figure 44 Allis on 2000 (LCT) Transmiss ion J-1939

s08208Y




CIRCUIT DIAGRAMS

45

Al li so n 2000 (LCT) Trans mi ss io n (Elec tr on ic ) Spar e Inp ut /Out pu ts , p. 21

Figure 45 Alli son 2000 (LCT) Transmissi on (Electroni c) Spare Input/Outputs

s08208Y




CIRCUIT DIAGRAMS

1.8. LIGHT SYSTEMS (CHAPTER 8)

Back-Up Light System N/Electronic Transmissions, p. 1

Figure 46 Back-Up Light System N/Electronic Transmissions

s08208Y




CIRCUIT DIAGRAMS

47

Daytime Running Lights (USA), p. 2

Figure 47 Daytime Running Lights (USA)

s08208Y




CIRCUIT DIAGRAMS

Headlight System With Douglas Turn Signal Switch (Tilt Column), p. 3

Figure 48 Headlight System With Douglas Turn Signal Switch (Tilt Column)

s08208Y




CIRCUIT DIAGRAMS

49

Panel Lights, p. 4

Figure 49 Panel Lights

s08208Y




CIRCUIT DIAGRAMS

Turn Signal System, p. 5

Figure 50 Turn Signal System

s08208Y




CIRCUIT DIAGRAMS

51

1.9. ELECTRONIC CONTROLS (CHAPTER 9)

ECM Power and Ground System With I6 HEUI/CEC, p. 1

Figure 51 ECM Power and Ground System With I6 HEUI/CEC

s08208Y




CIRCUIT DIAGRAMS

Ac cel erato r, BA P and ATS Sys tem s, p. 2

Figure 52 Accelerator, BAP and ATS Systems

s08208Y




CIRCUIT DIAGRAMS

53

Cruise Control and Electronic Hand Throttle System, p. 3

Figure 53 Cruise Control and Electronic Hand Throttle System

s08208Y




CIRCUIT DIAGRAMS

1.10. CONNECTOR COMPOSITES (CHAPTER 10)

Junction Points — J1, J2, J3, J5, J6, J7, J8, J10

Figure 54 Junction Points — J1, J2, J3, J5, J6, J7, J8, J10

s08208Y




CIRCUIT DIAGRAMS

55

Fuse Block Connections

Figure 55 Fuse Block Connections

s08208Y




CIRCUIT DIAGRAMS



s08208Y




CIRCUIT DIAGRAMS

57

Connector Composites (2), (2A), (5)

Figure 57 Connector Composites (2), (2A), (5)

s08208Y




CIRCUIT DIAGRAMS

Connector Composites (7), (8), (9), (10), (11), (12)

Figure 58 Connector Comp osites (7), (8), (9), (10), (11), (12)

s08208Y




CIRCUIT DIAGRAMS

59

Connector Composit es (13), (15), (15A)

Figure 59 Connector Composit es (13), (15), (15A)

s08208Y




CIRCUIT DIAGRAMS

Connector Composites (16), (20), (22), (23), (26), (27), (30), (31)

Figur e 60 Connect or Com pos ites (16), (20), (22), (23), (26), (27), (30), (31)

s08208Y




CIRCUIT DIAGRAMS

61


Figure 61 Connector Composit es (32), (37), (38), (39), (40), (41)

s08208Y




CIRCUIT DIAGRAMS

Connector Composites (41F), (44), (44M), (45), (46), (51), (64), (76)

Figur e 62 Connect or Com pos ites (41F), (44), (44M), (45), (46), (51), (64), (76)

s08208Y




CIRCUIT DIAGRAMS

63

Connector Composites (80), (81), (82), (83)

Figure 63 Connector Composi tes (80), (81), (82), (83)

s08208Y




CIRCUIT DIAGRAMS

Connector Composites (84), (85), (86), (87), (88)

Figure 64 Connector Compo sites (84), (85), (86), (87), (88)

s08208Y




CIRCUIT DIAGRAMS

65



s08208Y




CIRCUIT DIAGRAMS

Connect or Compo sit es (168), (169), (170), (194), (209), (218), (224), (258)


s08208Y




CIRCUIT DIAGRAMS

67


Figure 67 Connector Compo sites (261), (279), (283), (284)

s08208Y




CIRCUIT DIAGRAMS

Connector Composites (288), (289), (290), (291), (292), (293), (295), (297), (303F), (304)

Figur e 68 Connect or Compo sit es (288), (289), (290), (291), (292), (293), (295), (297), (303F), (304)

s08208Y




CIRCUIT DIAGRAMS

69

Connect or Compo sit es (323), (329), (335), (336), (337), (340), (344)

Figur e 69 Connect or Com pos ites (323), (329), (335), (336), (337), (340), (344)

s08208Y




CIRCUIT DIAGRAMS


Figur e 70 Connect or Com pos ites (350), (351), (352), (353), (354), (372)

s08208Y




CIRCUIT DIAGRAMS

71

Connector Composites (373), (374), (379)

Figure 71 Connector Composi tes (373), (374), (379)

s08208Y




CIRCUIT DIAGRAMS

Connect or Compo sit es (382), (384), (387M), (388F), (389M), (391)

Figur e 72 Connect or Com posi tes (382), (384), (387M), (388F), (389M), (391)

s08208Y




CIRCUIT DIAGRAMS

73


Figur e 73 Connect or Comp osi tes (392), (396), (404), (406), (420), (422)

s08208Y




CIRCUIT DIAGRAMS

Connector Composites (426), (426/A), (428), (438), (450), (451)

Figur e 74 Connect or Comp osi tes (426), (426/A), (428), (438), (450), (451)

s08208Y




CIRCUIT DIAGRAMS

75



s08208Y




CIRCUIT DIAGRAMS

Connect or Compo sit es (569), (571), (571A), (572), (572A), (574), (575), (615)

Figur e 76 Connect or Com posi tes (569), (571), (571A), (572), (572A), (574), (575), (615)

s08208Y




CIRCUIT DIAGRAMS

77



s08208Y






CIRCUIT DIAGRAMS

79


Figur e 79 Connect or Comp osi tes (832), (836), (1002), (1133), (3084)

s08208Y




CIRCUIT DIAGRAMS


Figur e 80 Connect or Compo sit es (3024), (3025), (3026), (3027), (3028), (3029), (3030)

s08208Y




CIRCUIT DIAGRAMS

81



s08208Y




CIRCUIT DIAGRAMS

Connector Composites (3044), (3047), (3055), (3084), (3084A), (3084B), (3084D, (3084E)

Figur e 82 Connect or Compo sit es (3044), (3047), (3055), (3084), (3084A), (3084B), (3084D, (3084E)

s08208Y




CIRCUIT DIAGRAMS

83

Lamp Bulb Chart

Figure 83 Lamp Bulb Chart

s08208Y




CIRCUIT DIAGRAMS

Fuse/Circuit Breaker Chart

Figure 84 Fuse/Circuit Breaker Chart

s08208Y




CIRCUIT DIAGRAMS

85

2. ELECTRICAL CIRCUIT DIAGRAMS — 3000RE

2.1. INSTRUCTIONS AND CHARTS (CHAPTER 1)

International Circuit Identification Chart, p. 1

Figure 85 International Circuit Identification Chart

s08208Y




CIRCUIT DIAGRAMS

International Circuit Identification Chart, p. 2

Figure 86 International Circuit Identification Chart

s08208Y




CIRCUIT DIAGRAMS

87


Figure 87 Circuit Diagram Instructions

s08208Y




CIRCUIT DIAGRAMS


Figure 88 Circuit Diagram Instructions

s08208Y




CIRCUIT DIAGRAMS

89



s08208Y




CIRCUIT DIAGRAMS

Relay Pinout, Function Data, and Sealed Relay, p. 6

Figure 90 Relay Pinout, Function Data, and Sealed Relay

s08208Y




CIRCUIT DIAGRAMS

91

2.2. 12 VOLT POWER DISTRIBUTION (CHAPTER 2)

Battery/Alternator With T 444E, p. 1

Figure 91 Battery/Alternator With T 444E

s08208Y




CIRCUIT DIAGRAMS

Battery/Alternator With I6, p. 2

Figure 92 Battery/Alternator With I6

s08208Y




CIRCUIT DIAGRAMS

93

Key Switch, p. 3

Figure 93 Key Switch

s08208Y




CIRCUIT DIAGRAMS

2.3. CAB ACCESSORIES (CHAPTER 3)

Am met er, p. 1

Figure 94 Ammeter

s08208Y




CIRCUIT DIAGRAMS

95

Horn, p. 2

Figure 95 Horn

s08208Y




CIRCUIT DIAGRAMS

Turn Signals, International Turn Signal Switch (Stationary Column), p. 3

Figure 96 Turn Signals, International Turn Signal Switch (Stationary Column)

s08208Y




CIRCUIT DIAGRAMS

97

Turn Signals, Douglas Turn Signal Switch (Tilt Column), p. 4

Figure 97 Turn Signals, Douglas Turn Signal Switch (Tilt Column)

s08208Y




CIRCUIT DIAGRAMS

2.4. ENGINE SYSTEMS (CHAPTER 4)

Charging System (12V) Delco 100, 130, 145 Amp and L/N 105, 130, 145, 180 Amp, p. 1

Figure 98 Charging System (12V) Delco 100, 130, 145 Amp and L/N 105, 130, 145, 180 Amp

s08208Y




CIRCUIT DIAGRAMS

99

Cranking System (12V), Optional Starter Overcrank Protection With T 444E, p. 2

Figure 99 Cranking System (12V), Optional Starter Overcrank Protection With T 444E

s08208Y




CIRCUIT DIAGRAMS

Cranking System (12V), Optional Starter Overcrank Protection With I6, p. 3

Figure 100 Cranking System (12V), Optional Starter Overcrank Protecti on With I6

s08208Y




CIRCUIT DIAGRAMS

101

Ether Start With I6, p. 4

Figure 101 Ether Start With I6

s08208Y




CIRCUIT DIAGRAMS

Schwitzer Fan With Electric Solenoid Control With T 444E or With I6, p. 5

Figure 102 Schwitzer Fan With Electric Solenoid Control With T 444E or With I6

s08208Y




CIRCUIT DIAGRAMS

103

2.5. GAUGES (CHAPTER 5)

Fuel Level Gauge, p. 1

Figure 103 Fuel Level Gauge

s08208Y




CIRCUIT DIAGRAMS

Speedometer, Tachometer, Voltmeter, Engine Oil Pressure, Water Temperature, p. 2

Figure 104 Speedometer, Tachometer, Voltm eter, Engine Oil Pressure, Water Temperature

s08208Y




CIRCUIT DIAGRAMS

105

Transmission Oil Temperature Gauge, p. 3

Figure 105 Transmissi on Oil Temperature Gauge

s08208Y




CIRCUIT DIAGRAMS

2.6. WARNING L IGHTS (CHAPTER 6)

Low Oil Pressure/High Water Temp/Low Coolant Level/Brake Warning (Air) Lights and Alarms, p. 1

Figure 106 Low Oil Pressure/High Water Temp/Low Coolant Level/Brake Warning (Air) Ligh ts/Alarms

s08208Y




CIRCUIT DIAGRAMS

107

Low Oil Pressure/High Water Temperature/Low Coolant Level/Brake Warning (Hyd.) Lights and

Al arm s, p. 2

Figure 107 Low Oil Pressure/High Water Temperature/Low Coolant Level/Brake Warning (Hyd.)

Lights and Alarms

s08208Y




CIRCUIT DIAGRAMS

Diagnostic/Programming Connector and Self-Test Switch and Warning Light System, p. 3

Figure 108 Diagnostic/Programmi ng Connector and Self-Test Switc h and Warning Light System

s08208Y




CIRCUIT DIAGRAMS

109

Wait-to-Start, Parking Brake and Trans. Warning Lights, p. 4

Figure 109 Wait-to-Start, Parking Brake and Trans. Warning Lights

s08208Y




CIRCUIT DIAGRAMS

2.7. CHASSIS ACCESSORIES (CHAPTER 7)

Ai r Dry er (AD-9) Wit h Ai r Br akes , p. 1

Figure 110 Air Dryer (AD-9) With Air Brakes

s08208Y




CIRCUIT DIAGRAMS

111

Au to mat ic Trans mi ss io n — Al li so n Mech ani cal , p. 2

Figure 111 Automatic Transmission — Allison Mechanical

s08208Y




CIRCUIT DIAGRAMS

An ti lo ck Br akes (4–Chan nel ) — Ai r, p. 3

Figure 112 Antilock Brakes (4–Channel) — Air

s08208Y






CIRCUIT DIAGRAMS

Al li so n WTEC Trans mi ss io n, p. 5

Figure 114 Allison WTEC Transmission

s08208Y




CIRCUIT DIAGRAMS

115

Al li so n WTEC Trans mi ss io n (Con t.), p. 6

Figure 115 Allison WTEC Transmission (Cont.)

s08208Y




CIRCUIT DIAGRAMS



s08208Y




CIRCUIT DIAGRAMS

117



s08208Y




CIRCUIT DIAGRAMS



s08208Y




CIRCUIT DIAGRAMS

119



s08208Y




CIRCUIT DIAGRAMS

Transmission Retarder Controls With I6 — Allison WTEC Trans., p. 11

Figure 120 Transmission Retarder Controls With I6 — Allison WTEC Trans.

s08208Y




CIRCUIT DIAGRAMS

121

Transmission Retarder Controls With I6 — Allison WTEC Trans. (Cont.), p. 12

Figure 121 Transmiss ion Retarder Controls With I6 — Allison WTEC Trans. (Cont.)

s08208Y




CIRCUIT DIAGRAMS

Drain Valve, p. 13

Figure 122 Drain Valve

s08208Y




CIRCUIT DIAGRAMS

123

Fuel Filter Wiring System, p. 14

Figure 123 Fuel Filter Wiring System

s08208Y




CIRCUIT DIAGRAMS

Brake System (Hyd.) With T 444E, p. 15

Figure 124 Brake System (Hyd.) With T 444E

s08208Y




CIRCUIT DIAGRAMS

125

An ti lo ck Br ake Sys tem — Hyd rau li c, p. 16

Figure 125 Antilock Brake System — Hydraulic

s08208Y




CIRCUIT DIAGRAMS

An ti lo ck Br ake Sys tem — Hyd rau li c (Con t.), p. 17

Figure 126 Antilock Brake System — Hydraulic (Cont.)

s08208Y




CIRCUIT DIAGRAMS

127

An ti lo ck Br akes (4–Chan nel ) W/Ai r Br akes W/Al li so n 2000 Xms n, p. 18

Figure 127 Antil ock Brakes (4–Channel) W/Air Brakes W/Alli son 2000 Xmsn

s08208Y




CIRCUIT DIAGRAMS

Al li so n 2000 (LCT) Trans mi ss io n, p. 19

Figure 128 Allison 2000 (LCT) Transmission

s08208Y




CIRCUIT DIAGRAMS

129

Al li so n 2000 (LCT) Trans mi ss io n, p. 20

Figure 129 Allison 2000 (LCT) Transmission

s08208Y




CIRCUIT DIAGRAMS

Al li so n 2000 (LCT) Trans mi ss io n J-1939, p. 21

Figure 130 Alli son 2000 (LCT) Transmiss ion J-1939

s08208Y




CIRCUIT DIAGRAMS

131

Al li so n 2000 (LCT) Trans mi ss io n (Elec tr on ic ) Spar e Inp ut /Out pu ts , p. 22

Figure 131 Allis on 2000 (LCT) Transmiss ion (Electroni c) Spare Input/Outputs

s08208Y




CIRCUIT DIAGRAMS

2.8. LIGHT SYSTEMS (CHAPTER 8)

Back-Up Light System, p. 1

Figure 132 Back-Up Light System

s08208Y




CIRCUIT DIAGRAMS

133

Headlight System With Douglas Turn Signal Switch (Tilt Column), p. 2

Figure 133 Headlight System With Douglas Turn Signal Switch (Tilt Column)

s08208Y




CIRCUIT DIAGRAMS

Headlight System With International Turn Signal Switch (Stationary Column), p. 3

Figure 134 Headlight System With International Turn Signal Switch (Stationary Column )

s08208Y




CIRCUIT DIAGRAMS

135

Daytime Running Lights With Douglas or International Turn Signal Switch, p. 4

Figure 135 Daytime Running Lights With Douglas or International Turn Signal Switch

s08208Y




CIRCUIT DIAGRAMS

Stoplight Switch With Air Brakes, p. 5

Figure 136 Stoplight Switch With Air Brakes

s08208Y




CIRCUIT DIAGRAMS

137

Panel Lights, p. 6

Figure 137 Panel Lights

s08208Y




CIRCUIT DIAGRAMS

2.9. ELECTRONIC ENGINES (CHAPTER 9)

ECM Power and Ground System, p. 1

Figure 138 ECM Power and Ground System

s08208Y






CIRCUIT DIAGRAMS

Cruise Control and Electronic Hand Throttle System, p. 3

Figure 140 Cruise Control and Electronic Hand Throttle System

s08208Y




CIRCUIT DIAGRAMS

141

Control Box System, p. 4

Figure 141 Control Box System

s08208Y






CIRCUIT DIAGRAMS

143

2.10. CONNECTOR COMPOSITES (CHAPTER 10)



s08208Y




CIRCUIT DIAGRAMS

Fuse Block Connections (Cont.)

Figure 144 Fuse Block Connections (Cont.)

s08208Y




CIRCUIT DIAGRAMS

145

Fuse/Circuit Breaker Chart

Figure 145 Fuse/Circuit Breaker Chart

s08208Y




CIRCUIT DIAGRAMS

Connector Composites (1A), (1B), (1C), (1XM), (2)

Figure 146 Connector Compo sites (1A), (1B), (1C), (1XM), (2)

s08208Y




CIRCUIT DIAGRAMS

147

Connector Composites (2A), (2F)

Figure 147 Connector Composites (2A), (2F)

s08208Y




CIRCUIT DIAGRAMS

Connector Composite (3)

Figure 148 Connector Composite (3)

s08208Y




CIRCUIT DIAGRAMS

149

Connector Composites (4), (6), (7), (8), (9), (11), (12)

Figure 149 Connector Composites (4), (6), (7), (8), (9), (11), (12)

s08208Y




CIRCUIT DIAGRAMS

Connector Composites (13), (16), (20), (21), (22), (23), (25)

Figur e 150 Connect or Comp osi tes (13), (16), (20), (21), (22), (23), (25)

s08208Y




CIRCUIT DIAGRAMS

151



s08208Y




CIRCUIT DIAGRAMS


Figure 152 Connector Composites (75), (78), (79), (80), (82), (86)

s08208Y




CIRCUIT DIAGRAMS

153


Figure 153 Connector Composites (88), (89), (90), (91), (94), (100)

s08208Y




CIRCUIT DIAGRAMS


Figur e 154 Connect or Com pos ites (101), (165), (169), (170), (187), (196)

s08208Y




CIRCUIT DIAGRAMS

155



s08208Y




CIRCUIT DIAGRAMS



s08208Y




CIRCUIT DIAGRAMS

157

Connect or Compo sit es (289), (290), (291), (292), (293), (295), (297), (303), (304F)

Figur e 157 Connect or Compo sit es (289), (290), (291), (292), (293), (295), (297), (303), (304F)

s08208Y




CIRCUIT DIAGRAMS

Connect or Compo sit es (304M), (337), (340), (344), (345), (350), (351), (352), (353)

Figur e 158 Connect or Compo sit es (304M), (337), (340), (344), (345), (350), (351), (352), (353)

s08208Y




CIRCUIT DIAGRAMS

159



s08208Y




CIRCUIT DIAGRAMS



s08208Y




CIRCUIT DIAGRAMS

161

Connector Composites (385), (387M), (389M), (391), (392), (396), (400), (401), (403)

Figur e 161 Connect or Compo sit es (385), (387M), (389M), (391), (392), (396), (400), (401), (403)

s08208Y




CIRCUIT DIAGRAMS

Connect or Compo sit es (412), (420), (426, 426M, 426F), (437), (445), (450), (451)

Figur e 162 Connect or Compo sit es (412), (420), (426, 426M, 426F), (437), (445), (450), (451)

s08208Y




CIRCUIT DIAGRAMS

163



s08208Y




CIRCUIT DIAGRAMS

Connect or Compo sit es (569), (571), (571A), (572), (572A), (574), (575), (615)

Figur e 164 Connect or Com pos ites (569), (571), (571A), (572), (572A), (574), (575), (615)

s08208Y




CIRCUIT DIAGRAMS

165



s08208Y




CIRCUIT DIAGRAMS


Figure 166 Connector Composit es (635), (636), (637), (639), (640)

s08208Y




CIRCUIT DIAGRAMS

167

Connect or Compo sit es (643), (644/644M), (646), (647), (665), (763), (832)

Figur e 167 Connect or Com pos ites (643), (644/644M), (646), (647), (665), (763), (832)

s08208Y




CIRCUIT DIAGRAMS

Connector Composites (836), (918), (919), (922), (922A), (923), (924), (925), (925A), (926), (926A), (1000),

(1001)

Figur e 168 Connect or Compo sit es (836), (918), (919), (922), (922A), (923), (924), (925), (925A), (926),

(926A), (1000), (1001)

s08208Y






CIRCUIT DIAGRAMS


Figur e 170 Connect or Comp osi tes (3031), (3032), (3043), (3047), (3084)

s08208Y




CIRCUIT DIAGRAMS

171

Lamp Bulb Chart and Body Builder Information

Figure 171 Lamp Bulb Chart and Body Builder Information

s08208Y




CIRCUIT DIAGRAMS

International System Acronyms and Descriptions

Documents

Electrical.circt.diag.Re 2000 2004