2 CASE ADT Electricr04 PDF

ELECTRICAL
25 & 30 TON ARTICULATED DUMP TRUCKS

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CASE 325 & 330
ARTICULATED
DUMP TRUCKS

Electrical
ELECTRICAL

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CNH America LLC 2004
700 STATE STREET
RACINE, WI 53404 U.S.A. Printed in U.S.A.
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Table of Contents

Test Equipment ...................................................................................................5

Test Procedures..................................................................................................8

Legends and Symbols ......................................................................................14

Relay and Fuse Identification and Location ...................................................17

Electrical Legend ..............................................................................................23

Power control and Distribution, Batteries, Alternator, Key Switch ..............26

Headlights, High Beam, Low Beam, Clearance, & Fog Light Circuits..........30

Hazard and Directional Lights Circuits ...........................................................34

Indicator Lamps, Dash Panel ...........................................................................35

Mirror-Hood-AC, Mirror Alignment Motors & Heating, AC Circuit ................40

TV Monitor and Gauges....................................................................................42

Working Lights and Windshield Wipers..........................................................44

Differential Lock Switch Circuit .......................................................................44

Body Unloading Hoist and Transmission Kick Down Circuits......................46

Parking Brake Circuit........................................................................................46

Ejector Circuit (Optional)..................................................................................46

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PAGE LEFT
INTENTIONALLY
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Electrical Test Equipment

Electrical Testing
The most important aspect of troubleshooting todays sophisticated electrical and/or
electronic systems is the test results. A service technician must have confidence in his
testing equipment to get accurate readings.

The days of checking a system with a test light are past. Electronic
equipment runs on very low amperage, and a test light can draw enough amperage to
burn out a circuit in a control box.

Todays electronics will run on variable voltages. Just because the machine has 24-
volt batteries does not mean the system is running on 24 volts. Most machines will
have 24, 12, 8 and 5-volt circuits. With different voltages being used, a test light will be
useless. The only way to test a circuit is with an electronic voltmeter and an
ohmmeter.

The Electronic Voltmeter should be used to do all electrical testing and trouble
shooting. Remember that the circuit must be fully connected and operated to
get proper test results. You should be looking for voltage drops to determine
where the problem is. You must also be aware of how the system functions. If
the system shuts down after automatically detecting a fault, you cannot test the
circuit for proper system voltage.

An Ohmmeter should be used when a voltmeter cannot be used for some
reason. The ohmmeter should only be used when checking components or
circuits that have a specified resistance. An example would be a solenoid that
may have a specified resistance of 7 to 9 ohms; an ohmmeter is the proper tool
to be used.
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Listed below is an abbreviated list of electrical tools that can be purchased locally or
through the OTC tool catalog.

Piercing Clips may be used to test for voltage in the harness with out
damaging the wires.

An example would be:
Piercing Clips Fluke 1TC26
Alligator Clips Fluke 1TC21
Leads 1TC08
Digital Volt/Ohm Meter;
An example would be a Fluke 23

Replacement Probes

Fundamentals of Testing an Electrical System

Before any testing is done to the electrical system in question, the service
technician must fully understand how the entire system (electrical and hydraulic)
functions normally. In many instances, the operation of the system may only
need to be explained to the operator, or a simple adjustment made to the system
for it to function properly. Referencing the appropriate operators manual will
generally resolve these types of problems.

When searching for the cause of an electrical problem, it is desirable to obtain all
of the symptoms of the problem from the operator. A few pertinent questions
asked of the operator may give you valuable clues as to the cause of the problem.
While questioning the operator, a chance remark may well reveal the cause of the
problem to an alert service technician. Operate the equipment to see if you can
duplicate the problem.

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Utilize the easiest and simplest tests first to try to identify the problem. When it
has been determined that a problem does exist with the electrical system, the
service technician must understand the fundamentals of electricity.

Understanding the properties of voltage, current and resistance is a must. The
service technician has to be equipped with the proper testing equipment to
resolve the problem. Use of the digital multimeter is strongly recommended.
However, just having the equipment is not enough, the service technician must
understand and utilize the functions and features of the digital multimeter!

Once the problem has been identified, correct repair procedures must be followed
to insure that the problem does not reoccur. Use of the Electrical Connector and
Terminal Repair Kit, is strongly recommended. The kit is equipped with the
necessary tools and connectors for proper repairs as well as information on how
to utilize the repair tools in the kit.

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Test Procedures
Visual Inspection
Carefully inspect the complete wiring harness for damage. Check for loose or
broken wires. Make sure the connector terminals are fully seated and locked in
the connector. Insure that the terminals are clean and not damaged. Use of
Lectra Clean, is recommended, and Silicone Compound Dielectric Grease, can be
used for lubricant and corrosion protection.

Testing For Open Circuits
An open circuit is defined as a place in a circuit that is separated and does not
permit a path for electrical current to flow. This could be a disconnected
connector or a broken wire. Because the circuit is open, the circuit resistance,
when measured with a Digital Multimeter, will indicate infinite resistance (OL or
Open Lead).

Test for continuity through each wire using a digital multimeter. Use wire colors or
connector pin identification numbers to identify the wires at each end of the
harness. If the harness is long and both ends cannot be reached, connect two
pins together at one connector with a jumper wire. Test for continuity through the
wires at the other connector. Repeat this process by moving the jumper wire as
needed until all wires are checked.

Finding an Open Circuit
Using a digital multimeter set to the ohms () scale, connect one probe to each
end of the broken wire. Move along the length of the harness, flexing the harness
by hand, while watching the Multimeter. Any change on the ohmmeter indicates
the damaged area has been located.

If the damage cannot be located, find the approximate middle of the harness
length. Carefully cut the outer jacket of the harness to reach the wire to be tested.
Insert a needle or pin through the wire insulation and connect the meter to the
needle or pin. Test for continuity between the middle and the end of the wire. If
there is continuity, move to another test point farther down the wire and test
again. When no continuity is obtained, the break in the circuit will be between the
last points tested which will permit the exact location to be determined.

If the cable is strapped down, it will be necessary to add a length of wire to one
probe of the ohmmeter to lengthen the meter leads.
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Opens

A
________________
A

B
________________
B

C
________________
C

D
________________
D

E
_______ ______
E

F
________________
F

G
_______ ______
G

H
________________
H
I
_________________
I

J
______ ______
J

K
_________________
K

L
_________________
L

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Testing For Short Circuits

A short circuit is defined as an unintended, low resistance current path. This
means that the current is taking a shorter path than was intended in the original
circuit. This could be a result of two or more wires rubbing together (copper to
copper) or a wire rubbing the system ground (copper to iron). This results in the
shorted circuit having resistance much smaller than specifications as shown on
the next page.

Disconnect the harness at both ends. Use a digital multimeter set to the ohms
scale, test for continuity between the wires. To accomplish this, at one of the
harness connectors, test for continuity between pins as follows:

1-grd 2-grd 3-grd 4-grd
1-2 2-3 3-4 4-5
1-3 2-4 3-5 4-6
1-4 2-5 3-6 4-7
1-5 2-6 3-7 4-8
etc. etc. etc. etc.

By progressively moving through the pin count, no combination of two conductors
is missed. Continuity should not be found between any wires or the ground
unless shown on the wiring schematic. If continuity IS found, the wires are
shorted together.

Finding A Short Circuit

Connect the Ohm meter probes to the wires in the harness that are shorted to
each other. Move along the harness flexing the harness by hand while watching
the Digital Multimeter. Any change in the meter indicates that the damaged area
has been located. Carefully cut the outer jacket of the harness to repair the
shorted wires.

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Short

1________________________ 1
2________________________ 2
3________________________ 3
4________________________ 4
5________________________ 5
6________________________ 6
7________________________ 7
8________________________ 8
9________________________ 9
10______________________ 10
11______________________ 11
12______________________ 12

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Testing For High Resistance

A high resistance circuit is defined as an unintended resistance to current flow.
This means that the circuit must overcome more resistance than normally found in
the circuit. Corroded connectors or wires, or a wire in the circuit that is nearly
pinched in half could cause this condition. This may cause the circuit to work
erratically or not at all. If the circuit is tested while disconnected from the load, the
circuit may or may not indicate the proper resistance and/or voltage level. A high
resistance circuit can generally only be tested when the circuit is under a load (i.e.
solenoid activated, control module resetting, etc.). To properly test for a high
resistance circuit, the digital multimeter (set to the voltage scale) has to be
installed into the completed circuit and operated. If a high resistance circuit is
present, the voltage recorded when operating the circuit will be lower than
specifications.

Finding A High Resistance Circuit

A digital multimeter is used (set to the volts scale) to test for a high resistance
circuit. The digital multimeter is placed in the circuit so that it becomes a parallel
path for the circuit. The completed circuit voltage (as shown on the multimeter) is
then checked between segments of the circuit. The problem area has been
located when the voltage changes noticeably on a segment being checked. As
an example, refer to the next page, the DVM indicates circuit voltage for three of
the segments of .01 volt indicating low resistance. The fourth segment of the
circuit indicates .20 volts, indicating higher resistance. The original circuit is using
the DVM to indicate the higher circuit resistance in the fourth segment.

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COLOR CODES

The wiring system has been split into ten main functions, associated with ten
cable colors. A four-digit number identifies each function.

The first digit of the number indicates the basic function and color of the cable.
The next three digits indicate the specific wire on the machine.

CODE COLOR FUNCTION
1111 Light Blue Optical and audible signals
2222 White Illumination by headlights
3333 Yellow Parking lights/side position lights
4444 Gray Internal Lighting
5555 Orange Optical signals, engine operation and measuring
instruments
6666 Violet Optical signals
7777 Red Main power not excluded by the ignition switch
8888 Green Switch key operated supply
9999 Pink Electrically operated mechanical components
0000 Brown Ground

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Number 1 Ground (-) (31)
Number 2 Battery power (24V+) (30)
Number 3 Power when the key switch is in the on or start position (15).
Number 4 Power with the key switch in the on position from relay E3 (15/A, off during
engine cranking).
Number 5 Power when the key switch is in the on or start position from fuse F18 (15).

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Relay numbers and Fuse identification and location

The 25 & 30 ton articulated trucks have one main electrical distribution center,
which allows access to relays and fuses. The main electrical distribution center is
located in the right front access panel in the cab, all of the fuses and relays for the
truck are there. The schematics and pictures on the next pages list the name,
location, and function of each relay and fuse.

Note that some of the fuses and relays are optional and are not installed on all of
the trucks.

When replacing relays, it is important to order the same part number for the new
relay as the old relay. Failure to do so may result in a short in the circuit, which
could result in electrical damage to the wiring harness.

There are three different types of relays used on these trucks. They all fit in the
same socket.

There are two diode blocks, (D1 & D2) that also fit in the same type socket, dont
interchange them.

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Relay and Fuse Locations

INTERCONNECTION CONTROL UNIT

ICU

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INTERCONNECTION CONTROL UNIT

ICU

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White Fuse Block Black Fuse B lock

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FUSE IDENTIFICATION TABLE

Fuse Use Amp. Fuse Use Amp. Fuse Use Amp
1 Position lights-
instr. cluster
7.5 13 Instruments-
CCTV
5 31 LH side wiper 7.5
2 Position lights-
warning lights
7.5 14 Warning Lights 3 32 RH side wiper 7.5
3 High beams-
Low beam
3 15 Wind shield
wiper
7.5 33 Park brake-
Body cont.
7.5
4 LH low beam 7.5 16 Hazard Lights 10 34 24/12 converter 10
5 RH low beam 7.5 17 Turn signal
lights
7.5 35 Power socket
12 -volt
7.5
6 LH high beam 7.5 18 Stop light,
Reverse light,
Fuel Solenoid,
Monitor
7.5 36 Hood Raising
Pump
10
7 RH high beam 7.5 19 Seat-Low
temp. solenoid
7.5 41 Transmission
controller
7.5
8 Front Work
lamps (75W x 4)
20 20 Speedometer 3 42 Emergency
Steering
7.5
9 Rear fog light 5 21 Cigarette
lighter
Ceiling lamps
10 43 6x6- Jake
brake
10
10 Not used 7.5 22 Rotating or
Flashing Light
7.5 44 Transmission
controller
7.5
11 Horn 10 23 Air conditioner 10 45 Differential lock 7.5
12 Mirror-Hood-
High beam flash
7.5 24 Fan Control 20 46 Not used 7.5

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RELAY IDENTIFICATION TABLE

Type Relay Use Type Relay Use
E1 Not used S E18 K2 relay in rev.
N E2 Headlight S E19 Emergency steering
N E3 Switched
power
S E20 K1 relay
Neutral start
N E4 Flasher S E21 Jake brake A
S E5 Park brake S E22 Jake brake B
N E6 Stop light S E23 Park brake (idle)
S E7 Not used S E24 Transfer
E8 Not used S E25 Emergency safety
pump
X E9 Wiper S E26 Jake brake A retarder
S E10 High and low
beam
S E27 LH side window wiper
N E11 Work Lights S E28 RH side window wiper
N E12 Horn S E29 Hourmeter
S E13 Not used S E30 Side window washer
S E14A Ejector (opt) S E31 Climate control
E14B Not used S E32 Telecamera
E15 Not used S E33 Hood lift
S E17 Body hoist
and gear shift
Z D1 Emergency steering
pump safety pump
buzzer
Z D2 Park brake
Light
T T1 Heater

8900116885

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ELECTRICAL LEGEND
100 INTERCONNECTION CONTROL UNIT (ICU) 130 RIGHT TURN INDICATOR CIRCUIT
101 BATTERIES 130a RIGHT FRONT TURN INDICATOR LAMP
102 STARTER 130b RIGHT REAR TURN INDICATOR LAMP
103 ALTERNATOR 131 LEFT SIDE TURN INDICATOR LAMP
104A STARTER RELAY 132 RIGHT SIDE TURN INDICATOR LAMP
104B BRAKE PUMP UNLOADING VALVE 133 ENGINE LOW TEMP. SWITCH
105 EMERG. STEERING PUMP (325) 134 ENGINE PRE-START HEATER
106 EMERG. STRG PUMP RELAY (325) 135 ENGINE HEATER TIMER RELAY T1
107 MASTER SWITCH 136 OPERATORS SEAT 24 VOLT CONNECTOR
108 ENGINE HEATER LOW TEMP. RELAY 137 EMERG. STEERING PUMP VALVE (30 TON)
109 KEY SWITCH 138 MASTER DISCONNECT RELAY (OPT)
110 HOUR METER RELAY E29 139 MASTER DISC. RELAY SWITCH (OPT)
111 EXTERNAL LIGHT SWITCH 140 FUEL SHUT-OFF SOLENOID (30 TON)
112 FLASHER SWITCH 141 FUEL SHUT-OFF SOLENOID (25 TON)
113 HIGH AND LOW BEAM SWITCH 200 WARNING LAMPS PANEL
114 LEFT CLEARANCE LIGHTS 201 WARNING LAMPS PANEL
114/A FRONT LH CLEARANCE LIGHT 202 WARNING LAMPS PANEL
114/B SIDE LH CLEARANCE LIGHT 203 AIR CLNR RESTRICTION SWITCH N.O.
114/C REAR LH CLEARANCE LIGHT 204 PARK BRAKE PRESSURE N.C.
115 RIGHT CLEARANCE LIGHTS 205 TRANS. DIFF-LOCK INDIC. SWITCH N.O.
115/A FRONT RH CLEARANCE LIGHT 206 REAR AXLE DIFF-LOCK SWITCH N.O.
115/B SIDE RH CLEARANCE LIGHT 207 ACCUM. LOW BRAKE PRESSURE
115/C REAR RH CLEARANCE LIGHT 208 BRAKE OIL FILTER SWITCH N.O.
116 LH LOW BEAM 209 LAMP TEST SWITCH
117 RH LOW BEAM 210 ROTATING BEACON SWITCH
118 LH HIGH BEAM 211 ROTATING BEACON LAMP
119 RH HIGH BEAM 212 HEATED MIRROR SWITCH (OPT)
120 REAR FOG LIGHT SWITCH 213 LH HEATED MIRROR (OPT)
121 REAR FOG LIGHT LAMP 214 RH HEATED MIRROR (OPT)
122 BACK-UP LIGHT LAMP 215 MIRROR MOTOR SWITCH (OPT)
123 BACK-UP ALARM HORN 216 LH MIRROR MOTOR (OPT)
124 BRAKE LIGHT SWITCH 217 RH MIRROR MOTOR (OPT)
125 BRAKE LIGHTS 218 HOOD RAISING RELAY E33
126 HAZARD LIGHT SWITCH 219 HOOD OPENING BUTTON CHASSIS
127 TURN SIGNAL SWITCH 220 CLIMATE CONTROL
128 FLASHER MODULE 221 AIR CONDITION PRESSURE SWITCH N.O.
129 LEFT TURN INDICATOR CIRCUIT 222 BODY RAISED SWITCH N.C. - HELD OPEN
129a LEFT FRONT TURN INDUCATOR LAMP 223 AIR CONDITIONING COMPRESSOR
129b LEFT REAR TURN INDICATOR LAMP 224 CIGARETTE LIGHTER (24V)
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PAGE LEFT INTENTIONALLY BLANK
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ELECTRICAL LEGEND
225 LH CEILING LIGHT SWITCH 410 EMERGENCY STEERING PRES. SWITCH
226 RH CEILING LIGHT SWITCH 411 CAB WARNING BUZZER
301 SPEEDOMETER 412 24/12V CONVERTER
302 TACHOMETER 413 SOCKET 12V
303 ENGINE WATER TEMP. GAUGE 414 SOCKET 12V
304 FUEL LEVEL GAUGE 416 BODY RAISING CONTROL SWITCH
305 FUEL LEVEL SENDER 417 EJECTOR SWITCH (IF EQUIPPED)
306 ENGINE OIL PRESSURE GAUGE 418 BODY RAISING/LOWERING SOLENOID
307 TRANS. OIL TEMPERATURE GAUGE 419 EJECTOR SOLENOID (IF EQUIPPED)
308 TRANSMISSION TEMPERATURE SENSOR 420 BODY RAISED LIMIT SWITCH (OPT.)
309 ~ 421 BODY LOWERING TIMER (OPT)
310 TV MONITOR, REAR VIEW DEVICE 422 PARK BRAKE SWITCH
311 WINDSHIELD WIPER/WASHER SWITCH 423 PARK BRAKE SOLENOID VALVE
312 WINDSHIELD WIPER MOTOR 424 RADIO
313 WINDSHIELD WASHER PUMP 425 LEFT RADIO SPEAKER
314 SIDE WINDOWS WIPER SWITCH 426 RIGHT RADIO SPEAKER
315 LH SIDE WINDOW WIPER MOTOR 427 CB RADIO (OPT)
316 RH SIDE WINDOW WIPER MOTOR 428 ZF TRANS. DIF-LOCK INTERFACE
317 SIDE WINDOWS WASHER SWITCH 429 JAKE BRAKE/RETARDER INTERFACE (330)
318 SIDE WINDOWS WASHER PUMP 500 ZF TRANSMISSION CONTROLLER EST37
319 HORN SWITCH 501 DIAGNOSTIC CONNECTOR
320 HORN 502 TRANSMISSION SHIFTER CONNECTOR
321 HOURMETER 503 CAN. DATA BUS CONNECTOR
322 ENGINE TEMPERATURE LIGHT SWITCH 504 ZF TRANSMISSION DISPLAY
322 ENGINE TEMP GAUGE SENDING UNIT 505 31 PIN EST 37 CONNECTOR
323 ENGINE OIL PRESSURE LIGHT SWITCH 506 7 PIN EST 37 CONNECTOR
324 ENGINE OIL PRESSURE INDI. SENDER 507 22 PIN EST 37 CONNECTOR
325 FRONT WORK LIGHT SWITCH 508 ENGINE SPEED SENSOR (TRANSMISSION)
326 FRONT WORK LIGHTS 509 TURBINE SPEED SENSOR (TRANSMISSION)
327 TACHOMETER SENDER 510 GEAR TRAIN SENSOR (TRANSMISSION)
328 TACHOMETER SIGNAL FILTER (330) 511 TRANSMISSION RETARDER TEMP. SENSOR
400 JAKE BRAKE/RETARDER SWITCH (330) 512 TRANS. FILTER RESTRICTION SWITCH
401 RETARDER SWITCH (330 OPT) 513 TRANSMISSION CONTROL VALVE CONNECT
402 DIFFERENTIAL LOCK SWITCH 514 TRANSMISSION OUT-PUT SPEED SENSOR
403 TRANSMISSION KICK DOWN SWITCH 515 TRANSMISSION DIFF-LOCK SOLENOID
404 INTERMED. AXLE DIFF-LOCK SOLENOID 516 RETARDER SOLENOID VALVE
406 JAKE BRAKE ENGINE SENSOR 517 ENGINE LOAD SENSOR
408 JAKE BRAKE "A" SOLENOID (330) 518 CONVERTER LOCK UP CLUTCH SOLENOID
409 JAKE BRAKE "B" SOLENOID (330)
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POWER CONTROL AND DISTRIBUTION

General (Batteries, Master Switch, Key Switch, Starter & Emergency
Steering Pump)

The starting circuits consist of two 12-volt batteries 101 connected in series. The
negative post of one battery is grounded to the engine block.

Power from the positive post of the other battery is routed through the Battery
master switch 107 and on to the starter relay 104A. Power is also supplied to the
alternator 103, starter motor 102, emergency steering Pump Relay 106 (E8) and
the key switch 109.

Alternator: 103

The positive post of the alternator (B+), is connected to the battery master switch
107. The negative post (B-), is connected to the chassis. The alternator exciter
post (D+), is fed back through the Alternator charge warning light and the Hour
Meter Relay E29.

Key Switch 109 (Off Position)

The key switch 109 has three-positions, off, on and start. Power is supplied to the
ignition switch from the batteries through the battery cut off switch 107. In the off
position no power is supplied through the ignition switch.

Key Switch 109 (On Position)

When the key switch 109 is turned to the first position clockwise, power flows from
terminal 15/A of the key switch to the E3 relay coil, which turns it on. The E3
relay then supplies power by wire 15/A to fuses F12, F15, F24, F31 and F32, and
to terminal 8 of the headlight switch 111.

Power from terminal 15 of the key switch flows by wire 15 to fuses F13, F14, F17,
F18, F19, F22 and F23, and to terminal 4 of the headlight switch 111.

Key Switch 109 (Start Position)

When the key switch 109 is turned to the start position and the shift lever is in the
neutral position, 24 volt power is sent through the key switch to K1 relay E20, the
gearbox-in-neutral relay. Power continues on to activate the brake pump
unloading solenoid valve 104, and to energize the starter relay 104, which cranks
the engine. The circuits previously discussed from terminal 15 of the key switch
109, also remain active in the start position.

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Number 1 GROUND
Number 2 BATTERY POWER (+)
Number 3 POWER WITH KEY IN RUN/START POSITION (15)
Number 4 POWER WITH KEY IN RUN POSITION FROM RELAY
E3 (15/A)
Number 5 POWER WITH KEY IN ON/ START POSITION FROM
FUSE 18
100 FUSE AND RELAY BOARD
101 BATTERIES 109 KEY SWITCH
102 STARTER 133 LOW TEMP. BUTTON
103 ALTERNATOR 134 LOW TEMP. HEATER
105 EMERGENCY STEERING PUMP
107 MASTER SWITCH
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POWER CONTROL AND DISTRIBUTION

Brake Pump Unloading Solenoid Valve: 104B

The brake pump unloading solenoid valve 104B is energized every time the key
switch is in the start position and the transmission shift lever 502 is in neutral, to
release the brake pump back-pressure for easier starting.

Cold temperature Start Relay: T1

The cold engine temperature start relay T1 is supplied with power from fuse F19,
with the key switch in the on or start position.

The low temperature start push button 133 is supplied power through the normally
closed contacts of the hourmeter relay E29, from fuse F19, with the key switch
109 in the on or start position, and the alternator 103 not charging.

When the low temperature start push button 133, is pressed, power is sent to
energize the engine heater relay T1. The power going through the relay supplies
the power to the low temperature start relay 108. When this relay is energized,
battery power is able to flow to the heater.

Neutral start relay: E20

The neutral start relay E20 (Page 46 & 47), is activated by a signal that is sent
from the transmission shift selection lever 502. This relay is active only when the
shift selection lever is in the neutral position.

Engine run/stop solenoid: 140 or 141

On the 8.3-liter engine, there are 3 wires plugged into the engine stop solenoid,
(141). Pink wire 9903 is powered whenever the key switch is in the run or start
position, from fuse F18. This is the holding coil wire.

Green wire 8888 is powered only when the key switch is in the start position,
green wire 8888* is powered through the neutral start relay number E20,
(page 49). This is the pull-in coil wire.

The other wire is a ground wire, connected to the chassis.

On the M11 engine, solenoid 140, there is the pink wire 9903, powered whenever
the key switch is in the run or start position, from fuse F18. It must be powered for
the engine to run.

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Number 1 GROUND
Number 4 POWER WITH KEY IN RUN POSITION FROM RELAY
E3 (15/A)
Number 5 POWER WITH KEY IN ON/ START POSITION FROM
FUSE 18
100 FUSE AND RELAY BOARD
101 BATTERIES 109 KEY SWITCH
102 STARTER 133 LOW TEMP. BUTTON
103 ALTERNATOR 134 LOW TEMP. HEATER
105 EMERGENCY STEERING PUMP
107 MASTER SWITCH
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Lighting

The headlight switch 111 is a THREE-position toggle switch. The following table
illustrates the THREE positions.

Off Position (A)

Power is fed into the headlight switch 111 from three sources: The first power
supply comes directly from the battery101, through the Battery Switch 107 to
terminal 2 of the headlight switch 111, yellow wire 3333.

The second power source comes directly from the key switch 109 when it is in run
or start position to terminal 4, green wire 8887.

The third source comes from relay number E3 when the key switch is in the run
position to terminal 8, white wire 2235. When the headlight switch is in the off
position, power stops at all three points.

Second Position (B)

When the headlight switch 111 is pressed to the number two position, power flows
from terminal number 2, through the switch and out terminal number 3 of the
headlight light switch, yellow wire 3380, powering fuses F1 and F2, and on to the
4 clearance lights 114 & 115 on the front and rear of the main frame.

Third Position (C)

When the headlight light switch 111 is pressed to the number 3 position, power
flows from terminal 4, powered from the key switch in the run or start position, out
terminal 3 of the light switch, yellow wire 3380. This powers fuses F1 and F2
flowing on to the 4 clearance lights 114 & 115 on the front and rear of the main
frame.

Power from terminal number 8, coming from the key switch in the run position
flows out terminal number 6, to fuses F3 and F9. Power from fuse F3 energizes
relay E2 and on to terminal 3 of the headlight low/high beam switch 113. With the
E2 relay energized, battery power is able to flow to relay E10 contacts. With relay
E10 not energized (low beam position), this power flows through relay E10 NC
contacts to fuses F4 and F5, powering the low beam headlights.

With the low beam/high beam switch 113, in the high beam, closed position, relay
E10 will be energized, sending power from relay E2, out to fuses F6, F7 and F10,
turning on the headlight high beams.

At the same time that the headlights are on, power from fuse F9 is sent to
terminal 2 of the fog lamp switch 120, when the switch is turned on, this power
flows out terminal 3 to the rear red fog light 121.
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111 LIGHT SWITCH 119 R-H HIGH BEAM
112 HIGH BEAM FLASHER SWITCH 120 REAR FOG LIGHT SWITCH
113 HIGH AND LOW BEAM SWITCH 121 REAR FOG LIGHT LAMP
114 A/B/C LEFT SIDE AND MARKER LIGHTS 122 REVERSE LIGHT LAMP
115 A/B/C RIGHT SIDE AND MARKER LIGHTS 123 REVERSE ALARM HORN
116 L-H LOW BEAM 124 BRAKE LIGHT SWITCH
117 R-H LOW BEAM 125 BRAKE LIGHTS
118 L H HIGH BEAM
Number 1 GROUND
Number 4 POWER WITH KEY IN RUN POSITION FROM RELAY E3 (15/A)
Number 5 POWER WITH KEY IN ON/ START POSITION FROM FUSE 18

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Lighting

HIGH BEAM FLASH RELAY: E4

The E4 relay is powered from fuse F12, any time the key switch is in the run
position. When the High Beam Flasher Control 112 is squeezed, a ground path is
made to energize relay E4, which sends battery power out to fuses F6, F7 and
F10, turning on the high beam headlights as long as the control is squeezed.

BACK UP LIGHT 122 AND REVERSE ALARM 123

Relay E18 is powered from fuse F18 when the key switch is in the run or start
position. When the Transmission Selector Lever 502, is shifted to reverse, relay
E18 is energized, sending this power to the back up light 122 and the reverse
alarm 123. Additional lighting for backing up can be had in the US by replacing
the Red Fog light lens with a clear lens and switching it on when backing.

BRAKE LIGHTS 125

The brake light switch 124, and the brake light relay E6, are supplied with power
when the key switch is in the run or start position through fuse F18. When brake
light switch 124 closes by brake pressure, power flows to the brake light relay E6.
When this relay is energized, it sends power to the brake lights 125.

The brake light pressure switch is located on the treadle valve of the 25 ton truck,
and on the manifold on the back of the cab on the 30 ton truck.

ELECTRICAL

33

Number 1 GROUND
111 LIGHT SWITCH 118 L-H HIGH BEAM
112 HIGH BEAM FLASHER SWITCH 119 R-H HIGH BEAM
113 HIGH AND LOW BEAM SWITCH 120 REAR FOG LIGHT SWITCH
114 A/B/C LEFT SIDE AND MARKER LIGHTS 121 REAR FOG LIGHT LAMP
115 A/B/C RIGHT SIDE AND MARKER LIGHTS 122 & 123 REVERSE LIGHT/HORN
116 L-H LOW BEAM 124 BRAKE LIGHT SWITCH
117 R-H LOW BEAM 125 BRAKE LIGHTS
ELECTRICAL

34

LIGHT CIRCUIT

CONTROL OF TURN SIGNAL AND HAZARD LIGHTS

Off position

Fuse F17 sends power to the hazard light switch 126 terminal 8, whenever the
key switch is in the on or start position. With the hazard switch in the off position,
this power is sent to terminal 2 of the flasher module 128. Since terminal 1 of the
flasher module is connected to terminal 2A of the turn signal directional control
switch 127, and terminal 5 of the hazard light switch, it is ready for which ever
choice the operator makes. The flasher module will not send power out terminal
numbers 4 or 12, no lights will be turned on.

HAZARD LIGHTS

On position

Battery power from fuse F16 enters the hazard light switch 126, at terminal 2, with
the switch in the on position, this power is sent to terminal 2 of the flasher module
128, which is mounted behind the dash panel. Also, with the switch in the on
position, terminal 1 of the flasher module is connected to terminals 8 and 13 of the
flasher module 128, through the hazard light switch terminals 1, 3 and 5.
Therefore the flasher module will send power out terminals 4, and 12, to flash the
left and right, front and rear directional lights.

Turn signals

The turn signal control 127 connects terminal number 1 of the flasher module 128
to either terminal 8 or 13, depending on whether a right or left turn. At this time
the flasher module will send power out terminal 4, or terminal 12, to flash the
appropriate lights, left or right, front and rear.

ELECTRICAL

35

INDICATOR LAMPS

Number 1 GROUND
126 HAZARD SWITCH 130 RIGHT TURN INDICATOR LAMPS
127 TURN SIGNAL SWITCH 131 LEFT SIDE TURN INDICATOR LAMPS
128 FLASHER MODULE 132 RIGHT SIDE TURN INDICATOR LAMPS
129 LEFT TURN INDICATOR LAMPS
ELECTRICAL

36

The indicator lights are shown in three blocks of ten lights apiece. Blocks number
200, 201 & 202. Not all lights are used in each of the blocks.

Block 200

Number 1 Engine cold start heating indicator light:
Powered from the heater relay T1 when the heat coils are on. It has a constant
path to ground.

Number 2 Engine air filter restriction indicator light:
Powered from fuse F14 when the key switch is in the run or start position. It
receives a path to ground through the vacuum operated switch 203, when the air
filter needs to be serviced. This light is also connected to the lamp test button
209, pressing the test button will complete a ground path and illuminate the light.

Number 3 Alternator indicator light:
receives a path to ground through the D+ terminal of the alternator, number 103.

Number 4 High beam indicator light:
Powered from fuse F6 when the headlights are on high beam. It has a constant
path to ground.

Number 5 Clearance lights indicator light:
Powered from fuse F2 when the clearance lights are on. It has a constant path to
ground. The clearance lights can be turned on without the key switch being on.

Number 6 & Number 7 Direction indicators & Hazard lights indicator light:
Only one lamp, Number 6 is used to indicate both Directional and Hazard lights
on condition. The lamp is powered from terminal 6 of the flasher module 128. It
has a constant path to ground.
ELECTRICAL

37

200 WARNING LAMPS
203 AIR CLEANER RESTRICTION. SWITCH
Number 1 GROUND Number 4 POWER WITH KEY IN RUN POSITION FROM RELAY E3 (15/A)
Number 2 BATTERY POWER (+) Number 5 POWER WITH KEY IN ON OR START POSITION FROM FUSE 18
Number 3 POWER WITH KEY IN RUN OR START POSITION (15)

ELECTRICAL

38
INDICATOR LAMPS

Number 8 Park brake indicator light:
receives a ground from the park brake switch 422, when the switch is in the on
position. This light is also hooked to the lamp test button 209, pressing the test
button will complete a ground path and illuminate this light.

Numbers 9 and 10 Front and Rear brake pressure indicator lights:
Powered from fuse F14 when the key switch is in the run or start position. Brake
system low pressure light receives a ground from the accumulator pressure
switch 207, when the brake system pressure is low. This light is also hooked to
the lamp test button 209, pressing the test button will complete a ground path and
illuminate the light.

Number 11 Low engine oil pressure indicator light:
receives a ground from the engine oil pressure switch 323 when engine oil
pressure is low.

Number 12 Differential lock indicator light:
receives a ground from the differential lock switch 205 when the differential lock is
in the on position. This light is also hooked to the lamp test button 209, pressing
the test button will complete a ground path and illuminate this light.

Number 13 Body raised indicator light:
receives a ground from the body-raised switch 222, when the body is in the raised
position. This light is also hooked to the lamp test button 209, pressing the test
button will complete a ground path and illuminate this light.

LAMP TEST BUTTON: 209
When this button is pressed, a ground path is made to the following indicator
lights turning them on:
Air cleaner restriction, high beams, clearance lights, brake pressure, park brake,
differential lock and body up.

ELECTRICAL

39

201 WARNING LAMPS 209 DASH LAMP TEST BUTTON
202 WARNING LAMPS 222 BODY RAISED SWITCH
206 REAR DIFF LOCK SWITCH
207 ACCUMULATOR BRAKE PRESSURE SWITCH
208 BRAKE OIL FILTER SWITCH
Number 1 GROUND Number 4 POWER WITH KEY IN RUN POSITION FROM RELAY E3 (15/A)
Number 2 BATTERY POWER (+) Number 5 POWER WITH KEY IN ON OR START POSITION FROM FUSE 18
Number 3 POWER WITH KEY IN RUN OR START POSITION (15)
ELECTRICAL

40

Rotating light:

Fuse F22 sends power to the rotating light switch 210 when the key switch is in
the run or start position. When the switch is turned on, the power travels to the
rotating light 211. This light has a constant ground.

Mirrors:

With the key switch in the run position, power from fuse F12 flows to the mirror
heat switch 212, and to the mirror control switch 215. With the heat switch turned
on, power flows to heat the mirrors, 213 and 214.

When the remote control mirror adjustment switch 215 is moved, power will flow
to the mirror motors 216 or 217.

Hood raise or lower:

With the key switch in the run position, power from fuse F12 travels to the hood
relay, number E33. When the hood opening/closing button number 218 is
pressed a ground path is made to energize relay number E33. This allows power
from fuse number F36 to flow to hood pump motor number 219.

Cigarette lighter: 224

The cigarette lighter receives battery power from fuse F21 all the time.

Internal lighting: 225 and 226
The inside lights receive battery power from fuse F21 all the time. When the
switch is closed it sends power to internal lights 225 or 226.

Air-condition:

With the key switch in the run or start position, power from fuse F24 is sent to the
climate control switch 220, when this switch is closed, power will flow to the
climate control relay, E31. When the air-conditioner switch number 220 is turned
on, a ground path is made to energize relay E31, sending power from fuse F23 to
the air-conditioner clutch, 223.
ELECTRICAL

41

210 ROTATING LAMP SWITCH 221 A-C SWITCH
211 ROTATING LAMP 215 MIRROR MOTOR SWITCH 223 A-C COMPRESSOR
212 HEATED MIRROR SWITCH 216 L-H MIRROR MOTOR
213 L-H HEATED MIRROR 217 R-H MIRROR MOTOR
214 R-H HEATED MIRROR 220 CLIMATE CONTROL
Number 1 ground Number 4 power with key in run position from relay E3 (15/A)
Number 2 battery power (+) Number 5 power with key in on or start position from fuse 18
Number 3 power with key in run or start position (15)
ELECTRICAL

42
TV monitor: 310
With the key switch in the run or start position, power from fuse F13 is sent to the
TV relay E32, sending power to the TV monitor, 310, whenever the shift selector
lever is in the reverse position, to power the monitor.

Speedometer: 301
The speedometer receives power from fuse F20 all the time and power from fuse
F13 whenever the key switch is in the run or start position. It also receives a
speed signal from pin 36 of the ZF transmission controller.

Tachometer: 302
The tachometer receives power from fuse F13 whenever the key switch is in the
run or start position. It also receives a signal from the engine RPM Sender, 327.
Module 328 is a noise suppression device.

Engine coolant temperature gauge and warning light 303
The engine coolant temperature gauge receives power from fuse F13 when the
key switch is in the run or start position. It also receives a signal from the engine
coolant temperature-sending unit, number 322.

The engine coolant warning light receives power from fuse F13 and a ground from
the sending unit 322.

Fuel level gauge: 304
The fuel level gauge receives power from fuse F13 when the key switch is in the
run or start position, and a signal from the fuel level-sending unit 305.

Engine oil pressure gauge: 306
The engine oil pressure gauge receives power from fuse F13 when the key switch
is in the run or start position, and a signal from the engine oil pressure-sending
unit 324.

Engine oil pressure light:
The engine oil pressure light receives power from fuse F13 when the key switch is
in the run or start position, and a signal from the engine oil pressure switch 323.

Transmission oil temperature gauge: 307
The transmission oil temperature gauge receives power from fuse F13 when the
key switch is in the run or start position, and a signal from the transmission oil
temperature-sending unit 308.

Hour meter: 321
The hour meter receives power from the hour meter relay E29, which is turned on
by power from the D+ terminal of the alternator 103.
ELECTRICAL

43

224.CIGARETTE LIGHTER 24 VOLT 313.WINDSHIELD WASHER PUMP
225.L-H ADJ. CEILING LIGHT 314.SIDE WINDOWS WIPER BUTTON
225.L-H CEILING LIGHT SWITCH 315.L-H SIDE WINDOW WIPER MOTOR
226.R-H ADJ. CEILING LIGHT 316.R-H SIDE WINDOW WIPER MOTOR
226.R-H CEILING LIGHT SWITCH 317.SIDE WINDOWS WASHER SWITCH
301.SPEEDOMETER 318.SIDE WINDOWS WIPER WASHER PUMP
302.TACHOMETER 319.HORN SWITCH
303.ENGINE WATER TEMP.GAUGE 320.HORN
304.FUEL LEVEL GAUGE 321.HOURMETER
305.FUEL LEVEL SENDER 322.ENGINE TEMP LIGHT SWITCH
306.ENGINE OIL PRESSURE GAUGE 322.ENGINE TEMP. GAUGE SENDER
307.TRAN. OIL TEMP. GAUGE 323.ENGINE OIL PRESSURE LIGHT SWITCH
311.WINDSHIELD WASHER SWITCH 324.ENGINE OIL PRESSURE INDICATOR SENDER
311.WINDSHIELD WIPER SWITCH 327.TACHOMETER SENDER
312.WINDSHIELD WIPER

Number 1.GROUND
Number 2.BATTERY POWER (+)
Number 3.POWER WITH KEY IN RUN OR START POSITION (15)
Number 4.POWER WITH KEY IN RUN POSITION FROM RELAY E3 (15/A)
Number 5 POWER WITH KEY IN ON OR START POSITION FROM FUSE 18
ELECTRICAL

44
Work Lights switch: 325

With the external light switch 111 in the Headlight on position, power from fuse F1
enters the Work light switch 325 at terminal 2. With the switch in the on position
this power energizes the work light relay E11, sending power from fuse F8 to the
work lights 326, located on the top front of the cab.

Windshield wiper / washer switch: 311
The windshield wiper switch receives power from fuse F15 when the key switch is
in the run position. When switch 311 is closed, power flows to the windshield
wiper motor 312.

When the windshield washer switch 311 is pressed, power flows to the windshield
washer pump, 313, and to the windshield wiper through the timed relay E9.

Side window wiper switch: 314
The switch receives power from fuse F31 when the key switch is in the run or start
position. When the switch is closed, power flows to energize relay E27, sending
power from fuse F31 to the left hand wiper motor 315, and also relay E28 which
sends power from fuse F32 to the right hand wiper motor, 316.

Side window washer switch: 317
The switch receives power from fuse F32 when the key switch is in the run or start
position. When the switch is closed, power flows to energize relay E27, sending
power from fuse F31 to the left hand wiper motor 315, and relay E28, sending
power from fuse F32 to the right hand wiper motor 316. In addition, power from
fuse F32 is sent to the window washer pump 318, which sends washer fluid to
both side windows. The switch also energizes relay E30 to keep the side window
wipers from parking until the switch is released.

Horn: 320
Battery power from fuse F11 is sent to the horn switch 319, and to the horn relay
E12. When the horn switch 319 is pressed, power from fuse F11 energizes relay
E12, sending power from fuse F11 to blow the horn.
ELECTRICAL

45

224.CIGARETTE LIGHTER 313.WINDSHIELD WASHER PUMP
225.L-H ADJ. CEILING LIGHT 314.SIDE WINDOW WIPER BUTTON
225.L-H CEILING LIGHT SWITCH 315.L-H SIDE WINDOW WIPER
226.R-H ADJ. CEILING LIGHT 316.R-H SIDE WINDOW WIPER
226.R-H CEILING LIGHT SWITCH 317.SIDE WINDOW WASHER BUTTON
301.SPEEDOMETER 318.SIDE WINDOW WIPER WASHER PUMP
302.TACHOMETER 319.HORN SWITCH
303.ENGINE COOLANT TEMP.GAUGE 320.HORN
304 .FUEL LEVEL GAUGE 321.HOURMETER
305.FUEL LEVEL SENDER 322.ENGINE TEMP LIGHT SWITCH
306.ENGINE OIL GAUGE 322.ENGINE TEMP. GAUGE SENDER
307.TRAN. OIL TEMP. GAUGE 323.ENGINE OIL PRESSURE SWITCH
311.WINDSHIELD WASHER SWITCH 324.ENGINE OIL PRESSURE SENDER
311.WINDSHIELD WIPER SWITCH 327.TACHOMETER SENDER
312.WINDSHIELD WIPER

ELECTRICAL

46
Park Brake Release Switch: 422

Power from fuse F33 when the key switch is in the run or start position sends
power to the park brake relay E5. When the park brake switch 422 is closed, a
ground path is made energizing relay E5, sending power from fuse F33 to the two
park brake solenoids 423. This action turns the park brake off by hydraulic
pressure to the caliper pistons.

Unloading the body control switch: 416

Power is available at fuse F33 whenever the key switch is in the run or start
position. The power is sent to the unloading control switch 416 by wire 8840.
Pulling back on this switch will send power to the unloading solenoid 418 to raise
the body. Pushing forward on the switch will lower the body. Number 421 is a
jumper connector in place of an optional timer, for lowering the body without
holding the switch in the lower position.

Possible Future Ejector control switch option: 417

Power is available at fuse F33 when the key switch is in the run or start position.
The power is sent to the ejector control switch 417. Moving this switch will send
power to the ejector solenoid 419 to extend or retract the ejector cylinder

12 Volt supply: 412

The 24V/12V converter 412 is supplied 24 volts from fuse F34 and sends 12 volts
through fuse F35 to the 12 volt supply socket.

ELECTRICAL

47
ELECTRICAL

48

Transmission Electronic Control Unit (T.E.C.U.)

Body Hoist Relay: E17
When the truck body raises to dump the load, Body Raised Switch number 222,
closes, this provides the ground for relay E17. The relay receives its powered
from fuse F41 when the key switch is in the run or start position. When the relay
is energized, the normally open contacts close, this condition sends power from
fuse F41 through pin 5 of connector 507 to pin 66 of the T.E.C.U. The purpose is
to keep the transmission from shifting higher than second gear with the body
raised.

Reverse Alarm Relay: E18
Power from fuse F41 is sent to the reverse relay E18 when the key switch is in the
run or start position. A ground is supplied through pin 3 of connector 507 and Pin
7 of the T.E.C.U. connector when the shift selector handle is in reverse.
Energizing this relay sends power to the reverse alarm, back up light and TV
Monitor.

Neutral Start Relay: E20
To energize the neutral start relay, power from fuse F41 is sent to the shift
assembly on wire 900, through pin 1 of connector 507. When the shift assembly
is in neutral, power goes out pin 2 of connector number 507 to the neutral start
relay E20.

Park Brake Relay: E23
When the park brake pressure is low (brake on condition), the park brake
pressure switch 204, closes, this provides the ground for Park Brake Indicator
light and Park Brake Relay E23. The relay receives its power from fuse F41.
When Relay E23 closes, it provides a path from Fuse F41 through wire 444
through pin 17 of connector 507 to the T.E.C.M. pin number 44. Power on wire
444 puts the transmission in neutral.

Kick Down Switch: 403
The kick down switch button 403 is powered from fuse F41 when the key switch is
in the run or start position. When this button is pressed, power flows through pin
7 of connector number 507 to the T.E.C.U pin 29. As long as the button is
pressed by the accelerator petal, the transmission will not Up-Shift. It is important
to have the throttle linkage adjusted properly for full High Idle before pressing the
button.

ELECTRICAL

49
ELECTRICAL

50
Differential Switch: 402
The differential switch number 402 is powered from fuse F45, with the switch in the off
position, no power exits the switch.

With the switch in the second position, power exits the switch to power the
Intermediate Axle differential lock solenoid 404, and locks the differential between the
two rear axles.

With the switch in the third position, power exits the switch to power the Intermediate
Axle differential lock solenoid and also sends power to relay E24. When the relay E24
is energized, there is a signal to the transmission to lock the differential between the
front axle and the rear driveline. The transmission controller EST 37 number 500 also
receives a signal by wire number 430 through pin 8 of connector 507, and on to power
pin 30 of the T.E.C.U.

ELECTRICAL

51

ELECTRICAL

52

Front Differential lock Solenoid: 515
The front differential lock solenoid 515 receives power and ground connections from
the T.E.C.U. pins 8 and 11
ELECTRICAL

53
RELAY IDENTIFICATION TABLE
Type Relay Use Page Type Relay Use Page
E1 Not used S E18 K2 relay in rev. 32,48
N E2 Headlight 30 S E19 Emergency
steering
49
N E3 Switched power 15,26
30
S E20 K1 relay
Neutral start
26,28
48
N E4 Flasher 32 S E21 Jake brake A 49
S E5 Park brake 46 S E22 Jake brake B 49
N E6 Stop light 32 S E23 Park brake (idle) 48
S E7 Not used S E24 Transfer 50
E8 Emergency
Steering Pump
26 S E25 Emergency safety
pump warning
49
X E9 Wiper-Washer
Timer
44 S E26 Jake brake A
retarder
49
S E10 High and low
beam
30 S E27 LH side window
wiper
44
N E11 Work Lights 44 S E28 RH side window
wiper
44
N E12 Horn 44 S E29 Hourmeter 26,28
42
S E13 Not used
(Option)
47 S E30 Side window
washer & wiper
44
S E14A Ejector (opt) 47 S E31 Climate control 40
E14B Not used S E32 Telecamera 42
E15 Not used S E33 Hood lift 40
S E17 Body hoist and
gear shift
48 N E34 Battery Relay
Option
27
Z D1 Emergency
steering pump
safety pump
buzzer
49 S E35 Battery Relay Light
(Option)
39
Z D2 Park brake
Light
38 T T1 Engine Cold Start
Heater
28

ELECTRICAL

54
ELECTRICAL LEGEND INDEX
No. Description Page Numbers
100 INTERCONNECTION CONTROL UNIT (ICU) 16-27-29
101 BATTERIES 26-27-29 30
102 STARTER 26-27-29
103 ALTERNATOR 26-27-28-29-36-42
104A STARTER RELAY 16-26
104B BRAKE PUMP UNLOADING VALVE 28
105 EMERG. STEERING PUMP (325) 27-29
106 EMERG. STRG PUMP RELAY (325) 26
107 MASTER SWITCH 26-27-29-30
108 ENGINE HEATER LOW TEMP. RELAY 28
109 KEY SWITCH 26-27-28-29-30
110 HOUR METER RELAY E29 26-28-42
111 EXTERNAL LIGHT SWITCH 26-30-31-33-44
112 FLASHER SWITCH 31-32-33
113 HIGH AND LOW BEAM SWITCH 30-31-33
114 LEFT CLEARANCE LIGHTS 30-31-33
114/A FRONT LH CLEARANCE LIGHT 30
114/B SIDE LH CLEARANCE LIGHT 30
114/C REAR LH CLEARANCE LIGHT 30
115 RIGHT CLEARANCE LIGHTS 30-31-33
115/A FRONT RH CLEARANCE LIGHT 30
115/B SIDE RH CLEARANCE LIGHT 30
115/C REAR RH CLEARANCE LIGHT 30
116 LH LOW BEAM 30-31-33
117 RH LOW BEAM 30-31-33
118 LH HIGH BEAM 30-31-33
119 RH HIGH BEAM 30-31-33
120 REAR FOG LIGHT SWITCH 30-31-33
121 REAR FOG LIGHT LAMP 30-31-33
122 BACK-UP LIGHT LAMP 31-32-33
123 BACK-UP ALARM HORN 31-32-33
124 BRAKE LIGHT SWITCH 31-32-33
125 BRAKE LIGHTS 31-32-33
126 HAZARD LIGHT SWITCH 34-35
127 TURN SIGNAL SWITCH 34-35
128 FLASHER MODULE 34-35
129 LEFT TURN INDICATOR CIRCUIT 34-35
129a LEFT FRONT TURN INDUCATOR LAMP 34-35
129b LEFT REAR TURN INDICATOR LAMP 34-35
130 RIGHT TURN INDICATOR CIRCUIT 34-35
ELECTRICAL

55
130a RIGHT FRONT TURN INDICATOR LAMP 34-35
130b RIGHT REAR TURN INDICATOR LAMP 34-35
131 LEFT SIDE TURN INDICATOR LAMP 34-35
132 RIGHT SIDE TURN INDICATOR LAMP 34-35
133 ENGINE LOW TEMP. SWITCH 27-28-29
134 ENGINE PRE-START HEATER 27-29
135 ENGINE HEATER TIMER RELAY T1 28
136 OPERATORS SEAT 24 VOLT
CONNECTOR
27
137 EMERG. STEERING PUMP VALVE (30 TON) 27
138 MASTER DISCONNECT RELAY (OPT) 27
139 MASTER DISC. RELAY SWITCH (OPT) 27
140 FUEL SHUT-OFF SOLENOID (30 TON) 28
141 FUEL SHUT-OFF SOLENOID (25 TON) 28
200 WARNING LAMPS PANEL 36-37
203 AIR CLNR RESTRICTION SWITCH N.O. 36-37
204 PARK BRAKE PRESSURE N.C. 48
205 TRANS. DIFF-LOCK INDIC. SWITCH N.O. 38
206 REAR AXLE DIFF-LOCK SWITCH N.O. 39
207 ACCUM. LOW BRAKE PRESSURE 38-39
208 BRAKE OIL FILTER SWITCH N.O. 39
209 LAMP TEST SWITCH 36-38-39
210 ROTATING BEACON SWITCH 40-41
211 ROTATING BEACON LAMP 40-41
212 HEATED MIRROR SWITCH (OPT) 40-41
213 LH HEATED MIRROR (OPT) 40-41
214 RH HEATED MIRROR (OPT) 40-41
215 MIRROR MOTOR SWITCH (OPT) 40-41
216 LH MIRROR MOTOR (OPT) 40-41
217 RH MIRROR MOTOR (OPT) 40-41
218 HOOD RAISING RELAY E33 40
219 HOOD OPENING BUTTON CHASSIS 40
220 CLIMATE CONTROL 40-41
221 AIR CONDITION PRESSURE SWITCH N.O. 40-41
222 BODY RAISED SWITCH N.C. - HELD OPEN 38-39-48
223 AIR CONDITIONING COMPRESSOR 40-41
224 CIGARETTE LIGHTER (24V) 40-41
225 LH CEILING LIGHT SWITCH 40-41
226 RH CEILING LIGHT SWITCH 40-41
301 SPEEDOMETER 42-43
ELECTRICAL

56
302 TACHOMETER 42-43
303 ENGINE WATER TEMP. GAUGE 42-43
304 FUEL LEVEL GAUGE 42-43
305 FUEL LEVEL SENDER 42-43
306 ENGINE OIL PRESSURE GAUGE 42-43
307 TRANS. OIL TEMPERATURE GAUGE 42-43
308 TRANSMISSION TEMPERATURE SENSOR 42
309 ~ -
310 TV MONITOR, REAR VIEW DEVICE 42
311 WINDSHIELD WIPER/WASHER SWITCH 44-45
312 WINDSHIELD WIPER MOTOR 44-45
313 WINDSHIELD WASHER PUMP 44-45
314 SIDE WINDOWS WIPER SWITCH 44-45
315 LH SIDE WINDOW WIPER MOTOR 44-45
316 RH SIDE WINDOW WIPER MOTOR 44-45
317 SIDE WINDOWS WASHER SWITCH 44-45
318 SIDE WINDOWS WASHER PUMP 44-45
319 HORN SWITCH 44-45
320 HORN 44-45
321 HOURMETER 42-43
322 ENGINE TEMPERATURE LIGHT SWITCH 42-43
322 ENGINE TEMP GAUGE SENDING UNIT 42-43
323 ENGINE OIL PRESSURE LIGHT SWITCH 38-42-43
324 ENGINE OIL PRESSURE INDI. SENDER 42-43
325 FRONT WORK LIGHT SWITCH 44
326 FRONT WORK LIGHTS 44
327 TACHOMETER SENDER 42-43
328 TACHOMETER SIGNAL FILTER (330) 42-43
400 JAKE BRAKE/RETARDER SWITCH (330) 49
401 RETARDER SWITCH (330 OPT) 49
402 DIFFERENTIAL LOCK SWITCH 50
403 TRANSMISSION KICK DOWN SWITCH 48
404 INTERMED. AXLE DIFF-LOCK SOLENOID 50
406 JAKE BRAKE ENGINE SENSOR 49
408 JAKE BRAKE "A" SOLENOID (330) 49
409 JAKE BRAKE "B" SOLENOID (330) 49
410 EMERGENCY STEERING PRES. SWITCH 49
411 CAB WARNING BUZZER 49
412 24/12V CONVERTER 46
413 SOCKET 12V 46
414 SOCKET 12V 46
416 BODY RAISING CONTROL SWITCH 46
ELECTRICAL

57
417 EJECTOR SWITCH (IF EQUIPPED) 46
418 BODY RAISING/LOWERING SOLENOID 46
419 EJECTOR SOLENOID (IF EQUIPPED) 46
420 BODY RAISED LIMIT SWITCH (OPT.) 46
421 BODY LOWERING TIMER (OPT) 46
422 PARK BRAKE SWITCH 38-46
423 PARK BRAKE SOLENOID VALVE 46
424 RADIO 47
425 LEFT RADIO SPEAKER 47
426 RIGHT RADIO SPEAKER 47
427 CB RADIO (OPT) 47
428 ZF TRANS. DIF-LOCK INTERFACE -
429 JAKE BRAKE/RETARDER INTERFACE
(330)
-
500 ZF TRANSMISSION CONTROLLER EST37 50
501 DIAGNOSTIC CONNECTOR 59
502 TRANSMISSION SHIFTER CONNECTOR 28-32-59
503 CAN. DATA BUS CONNECTOR 59
504 ZF TRANSMISSION DISPLAY 59
505 31 PIN EST 37 CONNECTOR 59
506 7 PIN EST 37 CONNECTOR 59
507 22 PIN EST 37 CONNECTOR 48-50-59
508 ENGINE SPEED SENSOR
(TRANSMISSION)
59
509 TURBINE SPEED SENSOR
(TRANSMISSION)
59
510 GEAR TRAIN SENSOR (TRANSMISSION) 59
511 TRANSMISSION RETARDER TEMP.
SENSOR
59
512 TRANS. FILTER RESTRICTION SWITCH 59
513 TRANSMISSION CONTROL VALVE
CONNECT
59
514 TRANSMISSION OUT-PUT SPEED SENSOR 59
515 TRANSMISSION DIFF-LOCK SOLENOID 52-59
516 RETARDER SOLENOID VALVE 59
517 ENGINE LOAD SENSOR 59
518 CONVERTER LOCK UP CLUTCH
SOLENOID
59

ELECTRICAL

58

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ELECTRICAL

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