New Holland W270C W300C Wheel Loader Service Manual (84547255A_A4) NH W270C W300C - PDF Download by www.heydownloads.com

SERVICE MANUAL Wheel Loader W270C W300C

Print No. 84547255A

W270C W300C Wheel Loader 84547255A

Use for Service Manual

W270C - W300C Wheel Loader Service Manual 84547255A

Table of Contents Description General

Section No. Tab 1

Section Index - General Standard Torque Specifications

1001

Fluids and Lubricants

1002

Metric Conversion Chart

1003 Tab 2

Engines Section Index - Engines Engine and Radiator Removal and Installation

2000

Stall Tests

2002

After Cooler

2003

For Engine Repair, See the Engine Service Manual 84394558 Fuel System

Tab 3

Section Index - Fuel System For Fuel System Repair, See the Engine Service Manual 84394558 SCR System

3002

Electrical

Tab 4

Section Index - Electrical Removal and Installation of Starter and Alternator

4001

Electrical Specifications and Troubleshooting

4002

Batteries

4003

Jump post option

4003a

Instrument Cluster

4005

Rear view Camera and Monitor

4006

Steering

Tab 5

Section Index - Steering Removal and Installation of Steering Components

5001

Steering Specifications, Pressure Checks, and Troubleshooting

5002

Steering Cylinders

5005

Center Pivot

5006

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

W270C - W300C Wheel Loader Service Manual 84547255A

Table of Contents Description

Section No.

Auxiliary Steering Motor and Pump

5008

Joystick Steering System (JSS) (Optional)

5009

Power Train

Tab 6

Section Index - Power Train Removal and Installation of Power Train Components

6001

Transmission Specifications, Pressure Checks, and Troubleshooting

6002

Transmission

6003

Front Axle

6004

Rear Axle

6004

Drive Shafts, Center Bearing, and Universal Joints

6005

Wheels and Tires

6006

Transmission Control Valve

6007

Brakes

Tab 7

Section Index - Brakes Removal and Installation of Brake Components

7001

Hydraulic Brake Troubleshooting

7002

Brake Pump

7003

Brake Accumulators

7004

Parking Brake

7008

Hydraulics

Tab 8

Section Index - Hydraulics Removal and Installation of Hydraulic Components

8001

Hydraulic Specifications, Troubleshooting, and Pressure Checks

8002

Cleaning the Hydraulic System

8003

Hydraulic Pump

8004

Loader Control Valve

8005

Cylinders

8006

Ride Control Accumulator

8013

Ride Control Valve

8014

W270C - W300C Wheel Loader Service Manual 84547255A

Table of Contents Description Mounted Equipment

Section No. Tab 9

Section Index - Mounted Equipment Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a Refrigerant

9002

Air Conditioner System Service

9003

Removal and Installation of Air Conditioning and Heater Components

9004

Loader

9006

Rollover Protective Structure (ROPS) Cab Structural Frame (CSF)

9007

Cab Glass Installation

9010

Electrical Schematic Foldouts and Hydraulic Schematic Foldout

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

In Rear Pocket

SECTION INDEX

GENERAL Section Title

Section Number

Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002 Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

1001 Section 1001 GENERAL TORQUE SPECIFICATIONS

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

1001-2

TABLE OF CONTENTS TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84547255A

Issued 11-11

3 4 5 6

Printed in E.C.

1001-3

TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 5 Bolts, Nuts, and Studs

Grade 8 Bolts, Nuts, and Studs

PoundInches

Newton metres

1/4 inch

144 to 180

16 to 20

5/16 inch

288 to 348

33 to 39

3/8 inch

540 to 648

61 to 73

Size

PoundInches

Newton metres

Size

PoundFeet

Newton metres

1/4 inch

108 to 132

12 to 15

7/16 inch

70 to 84

95 to 114

5/16 inch

204 to 252

23 to 28

1/2 inch

110 to 132

149 to 179

3/8 inch

420 to 504

48 to 57

9/16 inch

160 to 192

217 to 260

5/8 inch

220 to 264

298 to 358

Size

PoundFeet

Newton metres

3/4 inch

380 to 456

515 to 618

7/16 inch

54 to 64

73 to 87

7/8 inch

600 to 720

814 to 976

1/2 inch

80 to 96

109 to 130

1.0 inch

900 to 1080

1220 to 1465

9/16 inch

110 to 132

149 to 179

1-1/8 inch

1280 to 1440

1736 to 1953

5/8 inch

150 to 180

203 to 244

1-1/4 inch

1820 to 2000

2468 to 2712

3/4 inch

270 to 324

366 to 439

1-3/8 inch

2380 to 2720

3227 to 3688

7/8 inch

400 to 480

542 to 651

1-1/2 inch

3160 to 3560

4285 to 4827

1.0 inch

580 to 696

787 to 944

1-1/8 inch

800 to 880

1085 to 1193

1-1/4 inch

1120 to 1240

1519 to 1681

1-3/8 inch

1460 to 1680

1980 to 2278

1-1/2 inch

1940 to 2200

2631 to 2983

Size

84547255A

NOTE: Use thick nuts with Grade 8 bolts.

Issued 11-11

Printed in E.C.

1001-4

TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following torques when specifications are not given. These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.

Grade 8.8 Bolts, Nuts, and Studs 8.8

Size

PoundInches

Grade 10.9 Bolts, Nuts, and Studs 10.9

Size

PoundInches

Newton metres

36 to 48

4 to 5

84 to 96

9 to 11

132 to 156

15 to 18

324 to 384

37 to 43

PoundFeet

Newton metres

24 to 36

3 to 4

Size

60 to 72

7 to 8

M10

54 to 64

73 to 87

96 to 108

11 to 12

M12

93 to 112

125 to 150

228 to 276

26 to 31

M14

149 to 179

200 to 245

M10

456 to 540

52 to 61

M16

230 to 280

310 to 380

M20

450 to 540

610 to 730

Newton metres

M24

780 to 940

1050 to 1275

Size

PoundFeet

M30

1470 to 1770

2000 to 2400

M12

66 to 79

90 to 107

M36

2580 to 3090

3500 to 4200

M14

106 to 127

144 to 172

M16

160 to 200

217 to 271

M20

320 to 380

434 to 515

M24

500 to 600

675 to 815

M30

920 to 1100

1250 to 1500

M36

1600 to 1950

2175 to 2600

84547255A

Grade 12.9 Bolts, Nuts, and Studs 12.9

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

Issued 11-11

Printed in E.C.

1001-5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS 37 Degree Flare Fitting

Straight Threads with O-ring

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

Tube OD Hose ID

Thread Size

PoundInches

Newton metres

1/4 inch 6.4 mm

7/16-20

72 to 144

8 to 16

1/4 inch 6.4 mm

7/16-20

144 to 228

16 to 26

5/16 inch 7.9 mm

1/2-20

96 to 192

11 to 22

5/16 inch 7.9 mm

1/2-20

192 to 300

22 to 34

3/8 inch 9.5 mm

9/16-18

120 to 300

14 to 34

3/8 inch 9.5 mm

9/16-18

300 to 480

34 to 54

1/2 inch 12.7 mm

3/4-16

180 to 504

20 to 57

1/2 inch 12.7 mm

3/4-16

540 to 804

57 to 91

5/8 inch 15.9 mm

7/8-14

300 to 696

34 to 79 Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

Tube OD Hose ID

Thread Size

PoundFeet

Newton metres

5/8 inch 15.9 mm

7/8-14

58 to 92

79 to 124

3/4 inch 19.0 mm

1-1/16-12

40 to 80

54 to 108

3/4 inch 19.0 mm

1-1/16-12

80 to 128

108 to 174

7/8 inch 22.2 mm

1-3/16-12

60 to 100

81 to 135

7/8 inch 22.2 mm

1-3/16-12

100 to 160

136 to 216

1.0 inch 25.4 mm

1-5/16-12

75 to 117

102 to 158

1.0 inch 25.4 mm

1-5/16-12

117 to 187

159 to 253

1-1/4 inch 31.8 mm

1-5/8-12

125 to 165

169 to 223

1-1/4 inch 31.8 mm

1-5/8-12

165 to 264

224 to 357

1-1/2 inch 38.1 mm

1-7/8-12

210 to 250

285 to 338

1-1/2 inch 38.1 mm

1-7/8-12

250 to 400

339 to 542

Split Flange Mounting Bolts PoundInches

Newton metres

5/16-18

180 to 240

20 to 27

3/8-16

240 to 300

27 to 34

7/16-14

420 to 540

47 to 61

Size

PoundFeet

Newton metres

1/2-13

55 to 65

74 to 88

5/8-11

140 to 150

190 to 203

Size

84547255A

Issued 11-11

Printed in E.C.

1001-6

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS O-ring Boss End Fitting or Lock Nut

O-ring Face Seal End Nom. SAE Dash Size

Tube OD

Thread Size

PoundInches

Newton metres

Thread Size

PoundInches

Newton metres

-4

1/4 inch 6.4 mm

9/16-18

120 to 144

14 to 16

7/16-20

204 to 240

23 to 27

-6

3/8 inch 9.5 mm

11/16-16

216 to 240

24 to 27

9/16-18

300 to 360

34 to 41

-8

1/2 inch 12.7 mm

13/16-16

384 to 480

43 to 54

3/4-16

540 to 600

61 to 68

Thread Size

PoundFeet

Newton metres

7/8-14

60 to 65

81 to 88

1-1/16-12

85 to 90

115 to 122

-10

Nom. SAE Dash Size

5/8 inch 15.9 mm

Tube OD

1-14

552 to 672

62 to 76

Thread Size

PoundFeet

Newton metres

1-3/16-12

95 to 100

129 to 136

-12

3/4 inch 19.0 mm

1-3/16-12

65 to 80

90 to 110

1-5/16-12

115 to 125

156 to 169

-14

7/8 inch 22.2 mm

1-3/16-12

65 to 80

90 to 110

1-5/8-12

150 to 160

203 to 217

-16

1.0 inch 25.4 mm

1-7/16-12

92 to 105

125 to 140

1-7/8-12

190 to 200

258 to 271

-20

1-1/4 inch 31.8 mm

1-11/16-12

125 to 140

170 to 190

-24

1-1/2 inch 38.1 mm

2-12

150 to 180

200 to 254

84547255A

Issued 11-11

Printed in E.C.

1002

Section 1002 FLUIDS AND LUBRICANTS

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

1002-2

TABLE OF CONTENTS CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYDRAULIC OIL TEMPERATURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84547255A

Issued 11-11

3 5 5 5

Printed in E.C.

1002-3

CAPACITIES AND LUBRICANTS W270C CAPACITIES AND SPECIFICATIONS Engine Type of oil

AMBRA Mastergold HSP (SAE 15W-40)

Capacity (with filter change)

28.5 l (30.1 US qt)

Cooling system System capacity

56.8 l (60.0 US qt)

Fuel system System capacity

473.0 l (125.0 US gal)

Hydraulic system Type of fluid

AMBRA Hydrosystem 46 HV

Total system capacity

250.0 l (66.0 US gal)

Reservoir capacity

134.0 l (35.4 US gal)

Transmission Type of oil

AMBRA Supergold (SAE 10W-30)

Service capacity - with filter change

45.4 l (48 US qt)

Type of oil

AMBRA TRX Transaxle Fluid

Front axle STD

42 l (44 US qt)

Rear axle STD

42 l (44 US qt)

Front axle HD

62 l (65.5 US qt)

Rear axle HD

65.7 l (69.4 US qt)

Axles

Tank Urea (AD Blue) Type of fluid

Fluid Diesel exhaust (Spec ES-B5001)

Capacity

91 l (96 US qt)

84547255A

Issued 11-11

Printed in E.C.

1002-4 W300C Capacities and Specifications Engine Type of oil

AMBRA Mastergold HSP (SAE 15W-40)

Capacity (with filter change)

28.5 l (30.1 US qt)

Cooling system System capacity

56.8 l (60.0 US qt)

Fuel system System capacity

473.0 l (125.0 US gal)

Hydraulic system Type of fluid

AMBRA Hydrosystem 46 HV

Total system capacity

250.0 l (66.0 US gal)

Reservoir capacity

134.0 l (35.4 US gal)

Transmission Type of oil

AMBRA Supergold (SAE 10W-30)

Service capacity - with filter change

45.4 l (48 US qt)

Type of oil

AMBRA TRX Transaxle Fluid

Front axle STD

64.0 l (67.6 US qt)

Rear axle STD

64.0 l (67.6 US qt)

Front axle HD

62 l (65.5 US qt)

Rear axle HD

65.7 l (69.4 US qt)

Axles

Tank Urea (AD Blue) Type of fluid

Fluid Diesel exhaust (Spec ES-B5001)

Capacity

91 l (96 US qt)

84547255A

Issued 11-11

Printed in E.C.

1002-5

HYDRAULIC OIL TEMPERATURE CHART

LEEN11T0128EA

TRANSMISSION OIL TEMPERATURE CHART

LEEN11T0127EA

ENGINE OIL TEMPERATURE CHART

LEEN11T0126FA

84547255A

Issued 11-11

Printed in E.C.

1002-6

Coolant solution

Fuel storage

Put only ethylene-glycol coolant solution in the cooling system. Use good quality ethylene-glycol that has a high boiling point with no additives to prevent l e a k a g e . D o n o t u se n o n - a p p r o v e d a n t i - r u s t additives. Anti-rust additives and ethylene-glycol can mix and work against each other, reducing anti-corrosion protection, forming deposits in the cooling system, and causing damage to the cooling system and radiator. Contact your dealer who can supply you with the suitable coolant solution.

Prolonged storage of fuel can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be traced to the presence of water in the fuel.

Anti-freeze/Anti-corrosion Use anti-freeze in all seasons to protect the cooling system from corrosion and risk of freezing. For areas where the ambient temperature is over -36 째C (-32.8 째F) use a blend of 50 % ethylene-glycol based anti-freeze. For areas where the temperature is below -36 째C (-32.8 째F)- it is advisable to use a blend of 40 % water and 60 % anti-freeze.

Fuel Use diesel fuel suitable for the ambient temperature conditions ( ASTM D975). Use fuel which is to ASTM (American Society for Testing and Materials) D975 standard (North America). In Europa, fuel must comply with Specification Standard EN 590 or ITS EQUIVALENT. Use grade No. 2 fuel. The use of other types of fuel can result in a loss of power of the engine and may cause high fuel consumption. In very low ambient temperatures, use a mixture of fuels No. 1 and No. 2 as necessary. Consult your fuel supplier for appropriate fuel supply. If the temperature falls below the fuel cloud point (point at which wax begins to form) the wax crystals will cause power loss or will prevent the engine from starting. In cold weather, fill the fuel tank at the end of the day's work in order to prevent the formation of condensation.

The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off water and impurities regularly.

Hydraulic fluid Ambra Hydrosystem 46 HV Ultra hydraulic fluid is specifically designed for high pressure applications and for New Holland hydraulic systems. Your New Holland Dealer can provide hydraulic fluid to fulfill different climate/temperature conditions. Refer to the charts at the beginning of this section.

Transmission component oil Extreme pressure oil should be used for enclosed transmission components. Choose an oil that is manufactured for your climate/temperature conditions such as Ambra Supergold SAE 10W-30. See charts at the beginning of this section.

Grease The type of grease to use depends on ambient temperature such as: Ambra GR 75 MD.

Environment Before you service this machine and dispose of oil, fluids, and lubricants, obey environmental regulations. Do not drain oil or fluids on to the ground or into containers that leak. Check with your local environmental, recycling center or your dealer for correct disposal information.

Engine oil Ambra Mastergold engine oil is recommended for your engine. This oil insures correct lubrication of your engine in all working conditions. See charts at the beginning of this section to choose the correct oil for climate/temperatures. If Ambra Mastergold engine oil cannot be obtained, use only oil of the API SERVICE CI-4 category. NOTE: Do not put any Performance Additive or other additive in the sump. Oil change intervals shown in this manual are based on tests carried out utilizing New Holland lubricants. LEEN11T0129AA

84547255A

Issued 11-11

Printed in E.C.

1003

Section 1003 METRIC CONVERSION CHART

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

1003-2

TABLE OF CONTENTS CONVERSION FACTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Metric to U.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 U.S. to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84547255A

Issued 11-11

Printed in E.C.

1003-3

CONVERSION FACTORS Metric to U.S. MULTIPLY

TO OBTAIN

Area:

sq. meter hectare

10.763 91 2.471 05

square foot acre

Force:

newton newton

3.596 942 0.224 809

ounce force pound force

Length:

millimeter meter kilometer

0.039 370 3.280 840 0.621 371

inch foot mile

Mass:

kilogram

2.204 622

pound

Mass/Area:

kilogram/hectare

0.000 466

ton/acre

Mass/Energy:

gr/kW/hr.

0.001 644

lbs/hp/hr.

Mass/Volume:

kg/cubic meter

1.685 555

lb/cubic yd.

Power:

kilowatt

1.341 02

horsepower

Pressure:

kilopascal bar

0.145 038 14.50385

lb/sq. inch lb/sq. inch

Temperature:

degree C

1.8 x C +32

degree F

Torque:

newton meter newton meter

8.850 748 0.737 562

lb/inch lb/foot

Velocity:

kilometer/hr.

0.621 371

miles/hr.

Volume:

cubic centimeter cubic meter cubic meter milliliter litre litre litre litre

0.061 024 35.314 66 1.307 950 0.033 814 1.056 814 0.879 877 0.264 172 0.219 969

cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US liquid) gallon (Imperial)

Volume/Time:

litre/min. litre/min.

0.264 172 0.219 969

gallon/min. (US liquid) gallon/min. (Imperial)

84547255A

Issued 11-11

Printed in E.C.

1003-4

U.S. to Metric MULTIPLY

TO OBTAIN

Area:

square foot acre

0.092 903 0.404 686

square meter hectare

Force:

ounce force pound force

0.278 014 4.448 222

newton newton

Length:

inch foot mile

25.4 * 0.304 8 * 1.609 344 *

millimeter meter kilometer

Mass:

pound ounce

0.453 592 28.35

kilogram gram

Mass/Area:

ton/acre

2241 702

kilogram/hectare

Mass/Energy:

lb/hp/hr

608.277 4

gr/kW/hr

Mass/Volume:

lb/cubic yd.

0.593 276

kg/cubic meter

Power:

horsepower

0.745 700

kilowatt

Pressure:

lbs/sq. in. lbs/sq. in. lbs/sq. in.

6.894 757 0.069 0.070 303

kilopascal bar kg/sq. cm

Temperature:

degree F

1.8 F - 32

degree C

Torque:

pound/inch pound/foot

0.112 985 1.355 818

newton meter newton meter

Velocity:

miles/hr.

1.609 344 *

kilometer/hr.

Volume:

cubic inch cubic foot cubic yard ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US) gallons (Imperial)

16.387 06 0.028 317 0.764.555 29.573 53 0.946 353 1.136 523 3.785 412 4.546 092

cubic centimeter cubic meter cubic meter milliliter litre litre litre litre

Volume/Time:

gallon/min.

3.785 412

litre/min.

* = exact

84547255A

Issued 11-11

Printed in E.C.

SECTION INDEX

ENGINES Section Title

Section Number

Engine and Radiator Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2000 Stall Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2002 After Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2003

FOR ENGINE REPAIR, SEE THE ENGINE SERVICE MANUAL 84394558

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

Section 2000

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

2000

ENGINE AND RADIATOR REMOVAL AND INSTALLATION

2000-2

TABLE OF CONTENTS Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84547255A

Issued 11-11

3 3 12 21 21 22

Printed in E.C.

2000-3

ENGINE Removal

STEP 8

NOTE: Put caps on the fittings and plugs in the hoses to prevent foreign material from entering the system when disconnecting fuel lines or hydraulic hoses.

STEP 1

W270R613

Put the master disconnect switch (1) in the off position. W270R612

Park the machine on a level surface and lower the bucket to the ground. Put the articulation lock (1) in the locked position.

STEP 2 Key in the run position, engine off, place the pilot control switch in the normal operation position.

STEP 9 Drain the engine radiator coolant.

STEP 10 Drain the engine oil.

STEP 11

STEP 3 Move the loader hydraulic control handle to the raise and lower position in order to release any hydraulic pressure in the lift circuit.

STEP 4 Move the loader control handle in and out of the tilt position several times, this will relieve any pressure in the pilot accumulator.

STEP 5 Release the pressure in the ride control accumulator with the bleeder valve in the ride control valve.

STEP 6 Depress the brake pedal several times to discharge brake accumulators.

W270R614

Loosen the hose clamp (1) on the air box snorkel under the air inlet hood.

STEP 7 Slowly loosen the filler cap on the hydraulic oil tank to release air pressure.

84547255A

Issued 11-11

Printed in E.C.

2000-4

STEP 12

STEP 14

W270R615

W270R617

Remove the mounting bolts on the exhaust stack hood. Attach lifting equipment to the exhaust stack. Remove the exhaust stack hood (1).

Disconnect the deaeration tank overflow hose (2). Remove the P-clamps (1) that secure the overflow hose to the wall and brackets. Position the overflow hose away from the engine and engine wall.

STEP 13 STEP 15

W270R616

Remove the SCR line support bracket (1).

W270R618

Remove the left bracket (1) and right bracket (2).

84547255A

Issued 11-11

Printed in E.C.

2000-5

STEP 16

STEP 18

W270R651

Remove the hydraulic oil lines (1).

W270R620

Remove the oil dipstick P-clamp (3) . Pull the oil dipstick tube (1) through the wall. Label and disconnect the hood lift strut electrical connector (2).

STEP 17

STEP 19

W270R619

Remove the after air cooler tube (1) . Remove the bulkheads (2). W270R621

Remove the before air coller tube (1). Remove the upper radiator tube (2).

84547255A

Issued 11-11

Printed in E.C.

2000-6

STEP 20

STEP 22

W270R622

Label and disconnect the humidity sensor electrical connector (1). Remove the turbo inlet tube (2). Label and disconnect the air filter restriction sensor electrical connector (3).

W270R624

Remove the lower, right panel (1) on the engine wall.

STEP 23

STEP 21

W270R625

Remove the air box assembly. W270R623

Remove the wire harness P-clamp (1). Loosen the hose clamp on the air box snorkel (2). Disconnect the air box snorkel (3).

STEP 24

W270R626

Remove the lower radiator tube (1) . 84547255A

Issued 11-11

Printed in E.C.

2000-7

STEP 25

STEP 27

W270R627

W270R629

Attach lifting equipment to the engine wall. Remove the engine wallâ&#x20AC;&#x2122;s hold-down bolts. Lift and remove the engine wall.

Disconnect the SCR coolant solenoid heater hose (1).

STEP 28 STEP 26

W270R630 W270R628

Remove the turbo exhaust tube (1).

84547255A

Remove two bolts (2), washers (3), and nuts (4). Remove the air box snorkel (1) .

Issued 11-11

Printed in E.C.

2000-8

STEP 29

STEP 31

W270R631

W270R633

Disconnect the inlet and outlet heater core heater hoses (1).

Disconnect the following from the crank case ventilation/fuel filter bracket assembly: ●

STEP 30

● ● ● ● ● ● ● ●

Fuel pump electrical connector; Water sensor electrical connector; Ground wire; Wire harness P-clamp; Crank case filter inlet hose; Crank case filter outlet hose; Crank case filter oil return hose; Fuel pump inlet tube; Fuel pump outlet tube.

STEP 32 Remove the crank case ventilation/fuel filter bracket assembly.

STEP 33 W270R632

Disconnect the starter battery cables (1) and starter switch wire (2).

W270R634

Label and disconnect the engine control module electrical connector (1). 84547255A

Issued 11-11

Printed in E.C.

2000-9

STEP 34

STEP 36

W270R635

Disconnect the fuel return line (1). Disconnect the battery positive wire (2) on the air grid heater.

W270R637

Remove the engine serpentine belt (1).

STEP 37 STEP 35

W270R638

W270R636

Disconnect the engine ground wires (1). Remove the wire harness P-clamp (2).

84547255A

Label and disconnect the A/C compressor electrical connector (1). Label and disconnect the A/C pressure switch electrical connector (4). Remove the alternator power wire (3). Label and disconnect the bulk electrical connector (5). Remove the A/C compressor (2). Position the A/C compressor (2) away from the engine.

Issued 11-11

Printed in E.C.

2000-10

STEP 38

STEP 40

W270R641

Remove the wire harness P-clamps (1).

Attach lifting equipment to the engine. Support the engine.

STEP 39

STEP 41

W270R639

W270R640

Remove the engine oil drain tube (1).

84547255A

W270R642

Remove the hydraulic oil return tube P-clamp (1). Position the hydraulic oil return tube away from the converter housing cover plate.

Issued 11-11

Printed in E.C.

2000-11

STEP 42

STEP 45

W270R646 W270R643

Remove the converter housing cover plate (1).

Remove the front engine mounts (1) and engine mount plate (2).

STEP 43

STEP 46

W270R644

W270R647

Remove the flex plate bolts (1).

Remove the bell housing bolts (1).

STEP 44

STEP 47

W270R645

Remove the harmonic balancer (1). 84547255A

W270R641

Remove the engine. Issued 11-11

Printed in E.C.

2000-12

Install

STEP 50

STEP 48

W270R649

W270R641

Carefully lower the engine into the chassis.

STEP 49

Install the engine mount plate (5) and the engine mount brackets (1), but do not tighten the bolts to a torque value. Tighten the engine bracket upper bolts (2) to a torque of 171 - 231 N·m (126 - 170 lb ft). Tighten the engine bracket lower bolts (3) to a torque of 69 - 80 N·m (51 - 59 lb ft). Tighten the engine mount plate bolts (4) to a torque of 386 - 434 N·m (285 - 320 lb ft). Tighten the engine bracket-to-engine mount plate bolts (6) to a torque of 397 - 447 N·m (293 - 330 lb ft).

STEP 51

W270R647

Install the bell housing bolts (1). Tighten the bell housing bolts (1) to a torque of 54 - 60 N·m (40 - 44 lb ft).

W270R650

Install the harmonic balancer (1). Tighten the harmonic balancer bolts (2) to a torque of 115 N·m (85 lb ft).

84547255A

Issued 11-11

Printed in E.C.

2000-13

STEP 52

STEP 54

W270R644

W270R631

Install the flex plate bolts (1). Tighten the flex plate bolts (1) to a torque of 33 - 41 NÂˇm (24 - 30 lb ft).

Connect the inlet and outlet heater core heater hoses (1).

STEP 53

STEP 55

W270R642 W270R643

Apply DOW 732 RTV SILICONE CLEAR to the converter housing cover plate (1). Install the converter housing cover plate (1).

84547255A

Reposition the hydraulic oil return tube. Install the hydraulic oil return tube P-clamp (1).

Issued 11-11

Printed in E.C.

2000-14

STEP 56

STEP 58

W270R630

Install the air box snorkel (1). Install two bolts (2), washers (3), and nuts (4).

W270R628

Install the turbo exhaust tube (1).

STEP 59 STEP 57

W270R641 W270R629

Remove lifting equipment from the engine.

Connect the SCR coolant solenoid heater hose (1).

STEP 60

W270R627

Install the engine wall. 84547255A

Issued 11-11

Printed in E.C.

2000-15

STEP 61

STEP 63

W270R626

Install the lower radiator tube (1).

W270R623

Install the wire harness P-clamp (1). Connect the air box snorkel (3). Tighten the hose clamp on the air box snorkel (2).

STEP 62

STEP 64

W270R625

Install the air box. W270R624

Install the lower, right panel (1) on the engine wall.

84547255A

Issued 11-11

Printed in E.C.

2000-16

STEP 65

STEP 67

W270R622

Install the turbo intlet tube (2). Connect the humidity sensor electrical connector (1). Connect the air filter restriction sensor electrical connector (3).

W270R640

Install the engine oil drain tube (1).

STEP 68

STEP 66

W270R639 W270R621

Install the upper radiator tube (2). Install the before air cooler tube (1).

Install the wire harness P-clamps (1).

STEP 69

W270R637

Install the engine serpentine belt (1). 84547255A

Issued 11-11

Printed in E.C.

2000-17

STEP 70

STEP 72

W270R638

Install the A/C compressor (2). Connect the A/C compressor electrical connector (1). Connect the A/C pressure switch electrical connector (4). Connect the alternator power wire (3). Connect the bulk electrical connector (5).

W270R635

Connect the fuel return line (1). Connect the battery positive wire (2) on the air grid heater.

STEP 73

STEP 71

W270R636

Connect the engine ground wires (1). Install the wire harness P-clamp (2).

W270R634

Connect the engine control module electrical connector (1).

STEP 74 Install the crank case ventilation/fuel filter bracket assembly.

84547255A

Issued 11-11

Printed in E.C.

2000-18

STEP 75

STEP 77

W270R633

W270R620

Connect the following on the crank case ventilation/ fuel filter bracket assembly:

Connect the hood lift strut electrical connector (2). Slip the oil dipstick tube (1) through the engine wall. Install the dipstick tube P-clamp (3).

● ● ● ● ● ● ● ● ●

Fuel pump electrical connector Water sensor electrical connector Ground wire Wire harness P-clamp Crankcase filter inlet hose Crankcase filter outlet hose Crankcase filter oil return hose Fuel pump inlet tube Fuel pump outlet tube

STEP 78

STEP 76

W270R619

Install the bulkheads (2). Install the after air cooler tube (1).

W270R632

Connect the starter battery cables (1) and starter switch wire (2).

84547255A

Issued 11-11

Printed in E.C.

2000-19

STEP 79

STEP 82

W270R651

W270R616

Install the hydraulic lines (1).

Install the SCR line support bracket (1).

STEP 80

STEP 83

W270R618

Install the left bracket (1) and right bracket (2).

STEP 81

W270R615

Lower the exhaust stack hood (1) in front of the engine wall and onto the left bracket, right bracket, and hydraulic oil tank. Install the exhaust stack hood mounting bolts.

W270R652

Install the P-clamps (2) and overflow tube (1) to the engine wall, left bracket, and deaeration tank (3). 84547255A

Issued 11-11

Printed in E.C.

2000-20

STEP 84

W270R614

Attach the air box snorkel to the air inlet hood. Tighten the air box snorkel hose clamp (1).

STEP 85 Check and adjust all fluid levels.

84547255A

Issued 11-11

Printed in E.C.

2000-21

RADIATOR Removal

STEP 5

STEP 1 Park the machine on a level surface and lower the bucket to the ground. stop the engine and apply the parking brake.

STEP 2 Raise the engine hood.

STEP 3 Place the master disconnect switch in the OFF position.

STEP 4 W270R606

Disconnect the top hose and install a plug in the hose and a cap on the fitting.

STEP 6

W270R571

W270R608

Put a 30 liter (8 gallon) container below radiator drain. Remove radiator cap then remove cap and drain coolant into container. Install cap after coolant has drained. Install radiator cap.

Disconnect the hose from the bottom of the oil cooler. Install a plug in the hose and a cap on the fitting.

84547255A

Issued 11-11

Printed in E.C.

2000-22

STEP 7

STEP 9 4

4 3

2 1 W270R608 W270R607

Loosen and remove the bolt (1) and washer (2), the nut (3), washer (4) and bolt (5) that fasten the oil cooler to the cooling frame. Remove radiator from machine.

Connect the lower hose to the oil cooler to cooling frame.

STEP 10

Insallation STEP 8 4

4 3

W270R606

Connect the hose to the top of the oil cooler.

2 1 W270R607

Place the oil cooler in position in the cooling frame. Install and tighten the two mounting bolts (5), washer (4) and nuts (3), the washers (2) and bolts (1).

84547255A

Issued 11-11

Printed in E.C.

2000-23

STEP 11

STEP 13 Put master disconnect switch in ON position.

STEP 14 Start engine and run the engine at low idle. Run the engine at operating temperature for approximately five minutes to completely mix the Ethylene Glycol and water. When the coola nt is a t ope ratin g temperature, stop the engine. When engine has cooled, check the coolant level at the reservoir. WARNING: Hot coolant can spray out if radiator cap is removed. To remove radiator cap: Let system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast removal of radiator cap.

STEP 15 Put articulation lock in OPERATING position.

W270R571

Check that coolant drain cap is tight.

STEP 12 Fill engine coolant system with a solution of 50% Ethylene Glycol and 50% water. Cooling system capacity is 30 liter (8 gallon). Install the radiator cap. Fill the coolant reservoir up to the FULL mark on the reservoir.

84547255A

Issued 11-11

Printed in E.C.

2000-24

NOTES

84547255A

Issued 11-11

Printed in E.C.

2002

Section 2002 STALL TEST

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

2002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stall Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT CLUSTER DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PROCEDURE TO HEAT THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER MODE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORMING STALL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 1 - Torque Converter and Hydraulic Stall Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding the Results of Test No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 2 - Torque Converter Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding the Results of Test No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 3 - Hydraulic Stall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Understanding the Results of Test No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84547255A

Issued 11-11

3 3 3 3 5 5 5 6 7 7 7 7 7 8 8

Printed in E.C.

2002-3

SPECIFICATIONS ENGINE W/4 Speed Trans. (W270C-W300C) A. Idle RPM

870-930

Alternate Low Idle

570-630

Alternate Accelerated Idle

1170-1230

B. Maximum No Load RPM

2187Âą25

C. Converter Stall

1st gear 1970 - 2nd/4th gear 2075

D. Hydraulic Stall

1885-2195

E. Converter & Hydraulic Stall

1665

Note: Hydraulic Stall and Converter & Hydraulic Stall RPM values are read while the lift arms are rising with the bucket held rolled back and the engine at WOT in max power mode.

STALL TESTS During these tests the engine runs at full throttle and works against the torque converter, the hydraulic system, or both the torque converter and the hydraulic system. The results of these tests will show if the cause of poor performance is one or more of the following: (1) engine, (2) torque converter or transmission, and (3) hydraulic system.

INSTRUMENT CLUSTER DISPLAYS 1. With the engine running, press the up or down key and scroll through the information screens and trip screens. The following sequence is using the down key only. NOTE: Pressing the escape key will return the LCD back to the normal driving screen.

W230R435

3. Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPMâ&#x20AC;&#x2122;s, speed, fuel level, and the Urea level.

BD06F188

2. From the driving screen push the down arrow, as shown.

84547255A

Issued 11-11

Printed in E.C.

2002-4

W230R436

W230R438

4. Info 2 will be displayed next. The Info 2 screen will display coolant temperature, turbocharger air temperature, engine oil temperature in either Fahrenheit or Celsius, and the Urea level.

7. Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour.

W230R437

5. Push the down button again and the Info 3 screen. This screen displays the temperature in Fahrenheit or Celsius of the transmission oil, hydraulic oil, sump oil, and the Urea level.

Info Voltage Air Turbo DefTemp DefLvl

W230R439

8. By continuing to scroll down, the fifth screen will display the Trip 2 screen. Trip 1 and Trip 2 screens can be reset independently. The previous screen can be accessed by using the up arrow key.

4 V 24.2 Â°C 42 Â°C 32 % 24 W230M171

6. Push the down key again to display the info 4 screen. This screen display the voltage level, turbocharger air temperature, Urea temperature and Urea level.

84547255A

Issued 11-11

Printed in E.C.

2002-5

PROCEDURE TO HEAT THE OIL Torque Converter

Hydraulic System

1. Sit in the seat.

1. Apply the parking brake.

2. Start the engine and run the engine at low idle.

2. Start the engine and run at full throttle.

3. To measure the oil temperature with the instrument cluster:

A. Press the up or down arrow key.

B. Stop at the info screen with the temperatures that need to be monitored.

B. Stop at the info screen with the temperatures that need to be monitored are on.

4. Place the declutch switch in the OFF position. 5. Place the automatic switch in the manual mode position. Push down and hold the brake pedal for the remainder of this procedure. 6. Release the parking brake.

4. Hold the bucket control lever in the ROLLBACK position and hold the lift control lever in the FLOAT position. 5. Continue this procedure until the temperature of the hydraulic oil is 54° to 57°C (129° to 134°F).

7. Move the transmission control lever to Forward and turn the transmission control lever to 3rd gear. 8. Increase the engine speed to full throttle and run the engine at this speed for 30 seconds. 9. Decrease the engine speed to low idle and move the transmission control lever to the Neutral position for 15 seconds. 10. Repeat steps 7, 8, and 9 until the temperature of the torque converter oil is 82° to 104°C (180° to 220°F).

84547255A

Issued 11-11

Printed in E.C.

2002-6

POWER MODE SELECTION 1. After the oil temperatures have been raised to operating temperatures the power mode must be set to “Auto”.

3. Use down arrow to scroll through the menu’s. 4. High light Power Mode and press the enter key. 5. Power Mode Menu

W230R440

2. Press and hold the confirmation “enter” button for two seconds to arrive at the above service screen.

W230R441

A. Max - Maximum power possible B. Standard - Standard operation C. Auto - Will cycle between Max and Standard D. Eco - Limited power for economy 6. High light Auto mode and press the enter key. 7. Press the escape key to return to the normal driving screen.

84547255A

Issued 11-11

Printed in E.C.

2002-7

PERFORMING STALL TESTS Test No. 1 - Torque Converter and Hydraulic Stall Together 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Press the brake pedal, release the park brake, shift into Forward.

Test No. 2 - Torque Converter Stall 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Press the brake pedal, release the park brake, shift into Forward. 4. Run the engine at low idle.

4. Run engine at low idle. Push the clutch cutout switch to OFF. Put the transmission in manual mode. Push down and hold the brake pedal for the remainder of this procedure.

6. Turn the transmission control lever to third gear.

5. Turn the transmission control lever to third gear.

7. Increase the engine speed to full throttle.

6. Increase the engine speed to full throttle.

8. Check the engine speed.

7. Hold the bucket control lever in the ROLLBACK position and raise the lift arms. The stall speed must be read while the lift arms are in motion.

9. Decrease the engine speed to low idle.

8. Check the engine speed.

5. Push down and hold the brake pedal for the remainder of this test.

10. Place the transmission in neutral and apply the parking brake. 11. Stop the engine.

9. Release the bucket control lever. 10. Decrease the engine speed to low idle. 11. Lower the bucket to the ground, place the transmission in neutral and apply the parking brake. 12. Stop the engine.

Understanding the Results of Test No. 1 1. If the engine speed was as specified, the engine, torque converter, transmission and hydraulic system are probably good.

Understanding the Results of Test No. 2 1. If the engine speed was as specified, the engine, torque converter and transmission are probably good. 2. If the engine speed was more than specified, the problem can be in the torque converter or the transmission. See Section 6002 for troubleshooting information. 3. If the engine speed was less than specified, do Test No. 3.

2. If the engine speed was not as specified, do Test No. 2 and 3.

84547255A

Issued 11-11

Printed in E.C.

2002-8

Test No. 3 - Hydraulic Stall 1. Sit in the seat. 2. Start the engine and run the engine at low idle. 3. Increase the engine speed to full throttle. 4. Hold the bucket control lever in the ROLLBACK position and raise the lift arms. The stall speed must be read while the lift arms are in motion. 5. Check the engine speed. 6. Release the bucket control lever.

Understanding the Results of Test No. 3 1. If the engine speed was as specified, the engine and hydraulic system are good. 2. If the engine speed was more or less than specified the main relieef setting may be too low or too high. See Section 8002 for troubleshooting information. 3. If the engine speed was less than specified in all tests, the engine is probably the cause.

7. Decrease the engine speed to low idle. 8. Lower the bucket to the ground. 9. Stop the engine.

84547255A

Issued 11-11

Printed in E.C.

2003

Section 2003 AFTER COOLER

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

2003-2

TABLE OF CONTENTS TROUBLESHOOTING AFTER COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AFTERCOOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84547255A

Issued 11-11

3 4 4 6 6

Printed in E.C.

2003-3

TROUBLESHOOTING AFTER COOLER STEP 1

STEP 6

Park machine on level ground, lower the bucket. Put transmission in neutral, apply the parking brake. Turn off engine.

STEP 2 Raise hood. Install â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port.

STEP 3 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. If the pressure difference is greater than 60 mbar (0.87 psi), inspect cooler components for damaged or missing parts.

W230R429

Inspect the after cooler outlet flex hose for leaks or holes and insure that the clamps are tight.

STEP 7

STEP 4

W270R602 W270R601

Inspect the turbocharger flex hose for leaks or holes and insure that the clamps are tight.

Inspect the intake manifold flex hose for leaks or holes and insure that the clamps are tight.

STEP 8

STEP 5

W270R603 BD03A115

Inspect the after cooler inlet flex hose for leaks or holes and insure that the clamps are tight.

84547255A

Visually inspect top of after cooler for damage or leaks NOTE: If the leak source has not been located, remove and test the after cooler.

Issued 11-11

Printed in E.C.

2003-4

AFTERCOOLER REMOVAL Removal

STEP 5

STEP 1 Park the machine on a level surface and lower the bucket to the floor. Stop the engine and apply the parking brake.

STEP 2 Raise the hood and place the master disconnect switch in the OFF position. NOTE: Radiator drain is located under the rear chassis behind the rear axle. W270R602

Drain of coolant from engine cooling system.

Loosen clamps and remove Intake hose.

STEP 3

STEP 6

W270R601

Loosen clamps and remove turbocharger outlet components.

W230R429

Loosen clamps and remove air cooler outlet hose.

STEP 4

BD03A115

Loosen clamps and remove air cooler inlet hose.

84547255A

Issued 11-11

Printed in E.C.

2003-5

STEP 7 1

3 W270R604

Remove the two nuts (1), washer (2) and U-bolt (3) of the plate of the after cooler mounting frame.

STEP 8 1

1 3

2 4

W270R605

Remove four bolts (1), washers (2) and springs (3) of the after cooler mounting frame (4). Remove air cooler from frame.

84547255A

Issued 11-11

Printed in E.C.

2003-6

Leak Test

Installation STEP 1 1

1 3

BS03B028

Check the core for leaks by closing off the outlet tube and attaching regulated air pressure 550kPa (80psi) to the inlet tube. Submerge the cooler in water and watch for air leakage. NOTE: If leakage is detected replace the after cooler.

W270R605

Install after cooler in its frame (4). Install four mounting washers (2), springs (3) and bolts (1).

STEP 2 1

3 W270R604

Install U-bolt (3), washers (2) and nuts (1) of the plate of the after cooler mounting frame.

84547255A

Issued 11-11

Printed in E.C.

2003-7

STEP 3

STEP 6

W270R601

Install air cooler inlet hose. Tighten clamps at turbocharger outlet.

STEP 4

W230R429

Tighten clamps at air cooler outlet.

STEP 7 Refill the cooling system.

STEP 8 Install â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; fitting in waste gate valve hose. Attach pressure gauge. Install another pressure gauge into the intake manifold port.

STEP 9 Have assistant start engine and run at 2000 r/min (rpm). Record pressure readings for both gauges. confirm that the pressure difference is less than 60 Bar (0.87 psi). BD03A115

Tighten clamps at air cooler inlet.

STEP 5

W270R602

Install air cooler outlet hose and tighten clamps at engine intake.

84547255A

Issued 11-11

Printed in E.C.

2003-8

NOTES

84547255A

Issued 11-11

Printed in E.C.

SECTION INDEX

FUEL SYSTEM Section Title

Section Number

SCR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3002

FOR FUEL SYSTEM REPAIR, SEE THE ENGINE SERVICE MANUAL 84394558

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

3002

Section 3002 SCR SYSTEM

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

3002-2

TABLE OF CONTENTS Selective catalytic reduction (SCR) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Storage, handling and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SCR System Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Upstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Upstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Downstream Exhaust Temperature Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Downstream Exhaust Temperature Sensor Reinstall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 NOx Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 NOx Sensor Reinstall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Intake Temperature/Humidity Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DEF/ADBLUE Heater Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DEF/ADBLUE DNOx Supply Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 DEF/Adblue Dosing Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 DEF/AdBlue Supply Tank Level and Temperature Sensor Pickup and Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DEF/adblue supply filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Removal Supply Tank Filler Neck Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Installation Supply Tank Filler Neck Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Removal Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Installation Supply Line Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Installation DNOx Supply Module Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Air Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Primary/Secondary Fillter Element Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Primary/Secondary Element Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

84547255A

Issued 11-11

Printed in E.C.

3002-3 SELECTIVE CATALYTIC REDUCTION (SCR) SYSTEM Your machine is equipped with additional components to comply with national and local exhaust emissions requirements. The main components of the SCR system include the SCR catalyst, the Diesel Exhaust Fluid (DEF) /AdBlue (27), injection unit (7), the DEF/AdBlue tank (1), and the DEF/AdBlue electronic control unit (26). During combustion, harmful Nitrogen Oxide (NOx) molecules are formed in the exhaust. By injecting a DEF/AdBlue solution into the exhaust prior to a catalyst, the NOx can be converted to harmless elemental Nitrogen and water. This happens when the NOx olecules react inside the catalyst with the heat generated by the engine and the ammonia in the DEF/AdBlue solution. Storage, handling, and transport NOTE: Storage temperatures above 30 °C (86 °F) greatly reduce the shelf life of DEF/AdBlue. DEF/AdBlue has a typical shelf life of 6-12 months. In order for DEF/AdBlue to remain in a useable condition, storage requirements need to be met. ●

Store between -11 °C (12 °F) and 30 °C (86 °F).

●

Use only an approved DEF/AdBlue container. Contact your dealer to obtain proper storage container(s).

●

Keep container tightly closed.

●

Keep container in a cool, well-ventilated area.

●

Keep away from heat and direct sunlight.

●

Your machine is equipped with an internal tank heater to thaw frozen DEF/AdBlue. Your machine will still function until the DEF/AdBlue begins to flow. The SCR system will then function normally.

●

No additives are required.

NOTE: Contaminated DEF/AdBlue performance of your machine.

can

affect

the

Shelf life Constant ambient storage temperature Minimum shelf life Less than or equal to 10 °C (50 °F) 36 months Less than or equal to 25 °C (77 °F) ¹ 18 months Less than or equal to 30 °C (86 °F) 12 months Less than or equal to 35 °C (95 °F) 6 months Greater than 35 °C (95 °F) -² ¹ To prevent decomposition of DEF/AdBlue, prolonged transportation or storage above 25 °C (77 °F) should be avoided. ² Significant loss of shelf life: check every batch before use. See your New Holland dealer for more information on testing. Disposal ●

Dispose of DEF/AdBlue and any filter accumulations in accordance with all applicable Federal, State, and local laws governing waste disposal.

Do not heat DEF/AdBlue for long periods of time at temperatures above 30 °C (86 °F). This causes the solution to decompose, which very slowly decreases the expected shelf life. NOTE: Do not use an anti-gelling or freeze point improver in your DEF/AdBlue. The 32.5 % solution is specifically designed to provide the optimum NOx reduction properties. Any further blending or adjusting of the DEF/AdBlue mixture will lessen its ability to perform correctly and may cause damage to the SCR components. Handling and supply of additives, if any. ●

Personal Protective Equipment (PPE) is not required under normal conditions. If splashing is likely, wear eye protection. For prolonged or repeated contact, impervious gloves are recommended.

84547255A

Issued 11-11

Printed in E.C.

3002-4 COMPONENT LOCATION ILLUSTRATION SCR SYSTEM (table 1) 1. Tank - 90 liter (24 gallon) 2. Bracket tank 3. Cap 4. Hose 5. Clamp 6. Clamp 7. Module DNOX2 UREA dosing 8. Bracket module 9. Filler neck 10.Screw 11.Bolt 15.Hose UREA fill 16.Washer 17.Bracket sensor mount 19.Nut 20.Bracket DEF support 21.Hose 22.Screw - torque 7 ± 0.5 Nm (5 ± 0.36 lb-ft) 23.Muffler 24.Rear chassis 25.Clamp 27.Solution aqueous UREA (Ad Blue) A1.White connection A2.Black connection A3.Blue connection A4.White connection

84547255A

Issued 11-11

Printed in E.C.

3002-5

19 25 21 11

16 16 19

5 A3

A4 23 4 3 A

19 16 11 10 16

16 11 24

16 19

1 27 11 2

W270R093

84547255A

Issued 11-11

Printed in E.C.

3002-6

32 42 28 34 28 33

26 34 28

36 37 38 33 28 35

28 29

W270R094

84547255A

Issued 11-11

Printed in E.C.

3002-7 COMPONENT LOCATION ILLUSTRATION SCR SYSTEM (table 2) 26.Electronic control unit DNOX2 UREA 28.Washer 29.Bolt - torque 24 ± 4 Nm (17.7 ± 3 lb-ft) 30.Valve, heater 31.Bolt - torque 18 ± 2 Nm (13 ± 1.5 lb-ft) 32.Clamp 33.Bolt 34.Nut 35.Clamp 36.Fitting 37.Clamp 38.Hose 39.Clamp 40.Clamp 41.Sleeve protective heat 42.Clamp 43.Engine cap

84547255A

Issued 11-11

Printed in E.C.

3002-8

SCR SYSTEM SENSORS Upstream Exhaust Temperature Sensor Removal

STEP 3

NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.

2 1

STEP 1

W270R097

Locate exhaust temperature sensor (1) on exhaust system before the catalyst (2).

STEP 4 W270R095

Raise the hood using controls located behind the access cover.

STEP 2

W270R098

Loosen hex nut on sensor.

W270R096

Turn master electric switch to the â&#x20AC;&#x153;offâ&#x20AC;? position.

84547255A

Issued 11-11

Printed in E.C.

3002-9

Upstream Exhaust Temperature Sensor Reinstall

STEP 5

STEP 1

W270R099

Remove temperature sensor from exhaust system.

STEP 6

W270R099

Install temperature sensor into exhaust pipe.

STEP 2

W270R100

Remove wire ties securing wire harness to support brackets. Unplug sensor from machine wiring harness and remove it.

W270R098

Secure sensor into exhaust pipe. Sensor torque 40 to 50 Nm (30 to 36 lb ft.). Reconnect sensor to wire harness and secure harness to support brackets using new wire ties.

84547255A

Issued 11-11

Printed in E.C.

3002-10

STEP 3

STEP 2

W270R096

Turn master electric switch to “on” position. Clear any fault code. Start engine and check to see if problem has been corrected.

W270R096

Turn master electric switch to the “off” position.

STEP 3

Downstream Exhaust Temperature Sensor Removal NOTE: Emission sensor in the exhaust system and on the vehicle may be damaged by vibrations from use of impact wrenches or hammers during service work. Avoid using these tools servicing components close to the sensor. Remove the sensors with care if use of these tools cannot be avoided.

2 1

STEP 1

W270R101

Locate the exhaust temperature sensor (1) on exhaust system after catalyst (2).

STEP 4

W270R095

Raise the hood using controls located behind the access panel.

W270R102

Loosen hex nut and remove sensor from exhaust system. 84547255A

Issued 11-11

Printed in E.C.

3002-11

Downstream Exhaust Temperature Sensor Reinstall

STEP 5

STEP 1

W270R659

Loosen hex nut and remove P-clamp securing sensor wiring harness to catalyst mounting support bracket. Remove any wire ties securing wiring harness to machine.

STEP 6

W270R102

Install temperature sensor into exhaust system. Secure sensor by tightening hex nut. Sensor torque 40 to 50 Nm (30 to 36 lb ft.).

STEP 2

W270R660

Disconnect sensor from wiring harness.

STEP 7

W270R661

Install hex nut and P-clamp holding sensor wiring harness to catalyst mounting support bracket.

W270R100

Remove sensor and wiring harness as one component from machine. 84547255A

Issued 11-11

Printed in E.C.

3002-12

NOx Sensor Removal

STEP 3

STEP 1

W270R662

Reconnect sensor to machine wiring harness.

STEP 4

W270R095

Raise the hood using controls located behind the access cover.

STEP 2

W270R096

Turn master electric switch to “on” position. Clear any fault code. Start engine and check to see if problem has been corrected.

W270R096

Turn master electric switch to the “off” position.

84547255A

Issued 11-11

Printed in E.C.

3002-13

STEP 3

STEP 5 1

W270R103

Locate NOx sensor (1) on exhaust system down stream of catalyst (2).

W270R104

Loosen hex nut on NOx sensor.

STEP 6

STEP 4

W270R105 W270R663

Loosen hex nut and remove P-clamp (1) holding sensor wiring harness to catalyst mounting support bracket (2).

Remove NOx sensor from exhaust system.

STEP 7

W270R106

Locate NOx sensor module (1) on the backside of the SCR catalyst mounting support bracket (2). 84547255A

Issued 11-11

Printed in E.C.

3002-14

NOx Sensor Reinstall

STEP 8

STEP 1

W270R664

Disconnect NOx sensor module from machine wiring harness.

STEP 9

W270R105

Install NOx sensor into exhaust system.

STEP 2

W270R107

Remove hex bolts securing NOx sensor module to mounting support bracket and remove module.

STEP 10 W270R104

Secure NOx sensor with hex nut. Sensor torque 40 to 60 Nm (30 to 44 lb ft.)

W270R665

Remove wire ties securing NOx sensor wiring harness to machine and remove sensor.

84547255A

Issued 11-11

Printed in E.C.

3002-15

STEP 3

STEP 5 2 1

W270R107

W270R667

Install NOx sensor module and secure it to mounting support bracket using hex bolts. NOx sensor module torque 10.5 to 14.5 Nm (8 to 10.5 lb ft.).

Secure NOx sensor wire harness with P-clip (1) to catalyst mounting support bracket (2) using hex bolts. Secure wire harness with wire ties where appropriate.

STEP 4

STEP 6

W270R096 W270R666

Reconnect machine wiring harness to NOx sensor module.

84547255A

Turn master electric switch to â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault code. Start engine and check to see if problem has been corrected.

Issued 11-11

Printed in E.C.

3002-16

INTAKE TEMPERATURE/HUMIDITY SENSOR Removal

STEP 3

STEP 1

W270R108

Locate the intake temperature/humidity sensor on air intake pipe between the air filter housing and turbocharger.

STEP 4 W270R095

Raise the engine compartment hood using controls located behind the access cover.

STEP 2

W270R109

Disconnect wiring harness plug.

W270R096

Turn the master electric switch to the â&#x20AC;&#x153;offâ&#x20AC;? position.

84547255A

Issued 11-11

Printed in E.C.

3002-17

Installation

STEP 5

STEP 1

W270R110

Remove hex bolts.

STEP 6

W270R111

Remove plug covering hole in intake pipe. Insert sensor.

STEP 2

W270R111

Remove sensor. NOTE: Cover hole in the intake pipe to prevent debris from entering the system.

W270R110

Secure sensor with hex bolts. Maximum tightening torque: 17 Nm (12.5 lb ft).

84547255A

Issued 11-11

Printed in E.C.

3002-18

STEP 3

W270R109

Reconnect wiring harness plug.

STEP 4

W270R096

Turn master electric switch â&#x20AC;&#x153;onâ&#x20AC;?. Clear any fault code. Start machine and confirm that problem has been corrected.

84547255A

Issued 11-11

Printed in E.C.

3002-19

DEF/ADBLUE HEATER CONTROL VALVE Removal

STEP 3

STEP 1

W270R095

Raise the hood using controls located behind the access cover. W270R571

STEP 2

Place a suitable container below radiator drain located behind access cover. Remove radiator cap. Remove drain cap and drain engine coolant. Install tank drain plug and radiator cap after coolant has drained. NOTE: Use compressed air and water to clean debris from around drain plug area prior to draining the system.

STEP 4

W270R096

Turn master electric switch to the â&#x20AC;&#x153;offâ&#x20AC;? position.

W270R668

Locate DEF/AdBlue Heater Control valve next to the DNOx Supply Module on the left hand side of the engine.

84547255A

Issued 11-11

Printed in E.C.

3002-20

STEP 5

STEP 7

W270R669

W270R671

Disconnect the machine wiring harness from the DEF/AdBlue heater control valve.

Remove hex bolts securing heater control valve to mounting support bracket.

STEP 6

STEP 8

W270R670

Using a small flat blade screw driver, pull up on the fitting retaining clip and disconnect the coolant inlet/outlet lines from the heater control valve.

84547255A

W270R672

Remove heater control valve from machine.

Issued 11-11

Printed in E.C.

3002-21

Installation

STEP 3

STEP 1

W270R0962

W270R673

Turn master electric switch to the â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault code. Start the machine and check for engine coolant leaks. Confirm that problem has been corrected.

Position DEF/AdBlue heater control valve on the mounting support bracket and secure it with hex bolts.

STEP 2

W270R674

Reconnect coolant inlet/outlet lines and wiring harness. Refill engine cooling system.

84547255A

Issued 11-11

Printed in E.C.

3002-22

DEF/ADBLUE DNOX SUPPLY MODULE Removal

STEP 3

STEP 1

W270R095

W270R112

Raise the hood using controls located behind the access cover.

On the left hand side of engine mark supply and return line connection locations for reference during reassembly.

STEP 2 STEP 4

W270R096

Turn the master electric switch to the â&#x20AC;&#x153;offâ&#x20AC;? position. W270R113

From the bottom of the module disconnect DEF/AdBlue supply and return lines from underneath DNOx supply module. NOTE: To disconnect fittings, squirt water into the fitting connection to lubricate the O-ring. Squeeze the locking tabs together while slightly pushing the fitting ends together and then pulling them apart. If the fitting will not release, but is free to rotate, the O-ring is likely stuck and additional water should be used. NOTE: Use compressed air and water to clean debris from supply and return line connections.

84547255A

Issued 11-11

Printed in E.C.

3002-23

Installation

STEP 5

STEP 1 2

W270R114

Remove hex bolts securing the DNOx supply module to the mounting support bracket.

STEP 6

W270R676

Position the DNOx supply module on its mounting support bracket. Connect wiring harness to back of supply module. Be sure the lever (1) is fully engaged and the plug (2) is fully seated.

STEP 2

W270R675

Partially remove DNOx supply module from its mounting support bracket to gain access to the wiring harness (1). Open the lever (2) and disconnect wiring harness from DNOx supply module. Remove DNOx supply module from the machine.

84547255A

W270R114

Fit the DNOx supply module into mounting support bracket and secure with hex bolts. Bolts torque 24 Âą 4 Nm (17.7 Âą l Lb ft).

Issued 11-11

Printed in E.C.

3002-24

STEP 3

STEP 4

W270R113

Reconnect supply and return lines underneath DNOx control module. To connect, push the two fitting ends together until an audible snap is heard. NOTE: Test fitting connections to be sure they are secure. Match supply and return markings to ensure correct connections are made.

W270R112

Check wire harness and supply lines for proper positioning. NOTE: Make sure wire harness and supply lines do not contact anything that would cause damage.

STEP 5

W270R096

Turn master switch to â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault codes. Start engine. Check for fluid leaks at connections. Confirm problem has been corrected. Close engine compartment hood.

84547255A

Issued 11-11

Printed in E.C.

3002-25

DEF/ADBLUE DOSING INJECTOR Removal

STEP 3

STEP 1

W270R116

Clean dirt and debris from around engine air intake pipe connections and DEF/AdBlue dosing injector.

STEP 4

W270R095

Raise the hood using controls located behind the access cover.

STEP 2

W270R115

NOTE: The dosing injector (1) is located in the exhaust system upstream from the SCR catalyst and downstream of the turbocharger. W270R096

Turn master electric switch â&#x20AC;&#x153;offâ&#x20AC;?.

84547255A

Issued 11-11

Printed in E.C.

3002-26

STEP 5 1

STEP 7 2

W270R658

W270R678

Remove fuel pipe emissions (1) for easier access to dosing injector (2).

Mark location of DEF/AdBlue supply and return lines for reference dur ing reassembly. Remove DEF/AdBlue supply and return lines. Cap lines to prevent debris from entering the system.

NOTE: Mark location and routing of coolant lines for reference during reassembly.

NOTE: To separate connections, squirt water into fittings to lubricate O-rings. Squeeze fitting locking tabs slightly and push fitting together then pull it apart. If fitting will not release, but is free to rotate, the O-ring is likely stuck and additional water should be applied.

STEP 6

STEP 8

W270R677

Disconnect dosing injector wiring harness.

W270R679

Remove bolts securing dosing injector into mixing pipe.

84547255A

Issued 11-11

Printed in E.C.

3002-27

Installation

STEP 9

STEP 1

W270R680

Remove dosing injector. Cover opening to prevent debris from entering exhaust system.

STEP 10

W270R682

Remove cover from exhaust system and install dosing injector. NOTE: Use markings made during disassembly to determined proper positioning.

STEP 2 W270R681

Inspect dosing injector and service or replace as recommended.

W270R683

Secure dosing injector to exhaust pipe. Torque screws to 7 +/- 0.5 Nm (62 +/- 4 lb in.).

84547255A

Issued 11-11

Printed in E.C.

3002-28

STEP 3

STEP 5

W270R684

Connect DEF/AdBlue supply and return lines and wiring harness to dosing injector. NOTE: Use marks made during disassembly to determine proper positioning.

W270R096

Turn master electric switch to â&#x20AC;&#x153;onâ&#x20AC;?. Clear any fault code. Start machine. Check for leaks at DEF/AdBlue, exhaust and intake system connections. Confirm problem has been corrected.

STEP 4

W270R685

Secure fuel pipe emissions.

84547255A

Issued 11-11

Printed in E.C.

3002-29

DEF/ADBLUE SUPPLY TANK LEVEL AND TEMPERATURE SENSOR PICKUP AND HEATER Removal

STEP 3

STEP 1

W270R095

Raise the hood using controls located behind the access cover.

STEP 2

W270R118

Open the frame (1) of the engine cooling system.

W270R096

Turn master electric switch “off”.

84547255A

Issued 11-11

Printed in E.C.

3002-30

STEP 4

STEP 6

W270R119

Place a suitable container below DEF/AdBlue supply tank drain plug. Remove filler neck cap from supply tank. Loosen drain plug and drain DEF/AdBlue. Install drain plug and access cover after DEF/AdBlue has drained. W270R571

STEP 7

Place a suitable container below radiator drain located beneath the access cover at rear left hand side of machine. Remove radiator cap. Remove drain cap. Drain coolant. Install tank drain plug and radiator cap after coolant has drained. NOTE: Use compressed air and water to clean debris from around drain plug area.

STEP 5

W270R125

Remove bolts securing filler neck screen assembly. NOTE: Place a plug in filler neck hole to prevent loose screws from entering the supply tank.

W270R117

Loosen hex bolts and remove access cover below supply tank to gain access to the drain. NOTE: Use compressed air and water, to clean debris from around drain plug area.

84547255A

Issued 11-11

Printed in E.C.

3002-31

STEP 8

STEP 10

W270R686

W270R126

Remove filler neck/screen assembly and O-ring from supply tank by pulling upward while twisting assembly left and right.

STEP 9

Unplug wiring harness. Disconnect engine coolant lines and DEF/AdBlue lines by pushing coupling together, squeezing tabs and then pulling connection apart. Pull wire and hose harness up and off to the side out of the way. NOTE: Plug all lines to prevent debris from entering the system.

STEP 11

W270R120

Remove rubber boot cover (1) from liquid level/temp sensor sending unit wires, DEF/AdBlue and engine coolant supply lines. Mark wire and hose connection positions. NOTE: Use compressed air and water to clean debris from top of DEF/AdBlue supply tank around liquid level/temp sensor sending unit area.

84547255A

W270R687

Mark location of pickup unit within tank before removal. Twist DEF/AdBlue level temperature sensor unit counter clockwise to loosen it from tank.

Issued 11-11

Printed in E.C.

3002-32

Installation

STEP 12

STEP 1 3

W270R122 W270R121

Lift DEF/AdBlue level/temp sensor unit out of tank. NOTE: Cover tank opening to prevent debris from entering it.

STEP 13 3

Install DEF/AdBlue supply tank into the fuel tank cradle and secure it using hex bolts (1) and upper support mounting bracket. Fix the tank urea through the belts (2). Connect the hose urea fill with the clamp (3).

STEP 2 2

W270R122

Remove hex bolts (1) from mounting support bracket above tank, remove belts fuel tank (2) and loosen hose clamp urea fill (3). Lift tank urea up and out of its cradle from the fuel tank.

W270R121

Lower DEF/AdBlue level temp sensor and pick-up unit into tank.

84547255A

Issued 11-11

Printed in E.C.

3002-33

STEP 3

STEP 6

W270R688

Use reference marks from disassembly procedure to position DEF/AdBlue level temp sensor and pick-up unit. Secure by turning it clockwise.

STEP 4

W270R690

Reinstall the O-ring onto the DEF/AdBlue supply tank with the radius surface facing upward. NOTE: Lubricate O-ring with petroleum jelly.

STEP 7

W270R689

Remove plugs from all lines. Reconnect DEF/AdBlue supply/return and purge lines, engine coolant supply/return lines and liquid level gage sensor wiring harness. To connect, push connections together all the way, and then pull back to lock.

W270R691

Reinstall filler neck assembly onto supply tank.

STEP 5

W270R120

Replace rubber boot protective cover (1).

84547255A

Issued 11-11

Printed in E.C.

3002-34

STEP 8

W270R692

Secure filler neck assembly using Torx bolts. Refill DEF/AdBlue storage tank and engine cooling system.

STEP 9

W270R096

Turn master electric power switch to â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault codes. Start machine and check for DEF/AdBlue and coolant leaks. Confirm that the problem has been corrected.

84547255A

Issued 11-11

Printed in E.C.

3002-35

DEF/ADBLUE SUPPLY FILTERS Removal Supply Tank Filler Neck Screen

STEP 3

STEP 1

W270R096

Turn off master electric switch to the “off” position. W270R123

STEP 4

Locate the DEF/AdBlue supply tank on the left hand side of the machine beneath an access cover.

STEP 2

W270R124

W270R095

Raise the hood using controls located behind the access cover.

84547255A

Open access cover and remove filler cap from filler neck of supply tank. NOTE: Use compressed air and water, to clean debris from around filler cap/neck area.

Issued 11-11

Printed in E.C.

3002-36

STEP 5

STEP 7

W270R693 W270R125

Remove bolts securing filler cap/neck screen assembly. NOTE: Place a stopper into filler neck hole to prevent loose screws and debris from entering supply tank.

STEP 6

Remove plug from filler neck. Rinse screen with water to remove accumulated debris. Reinstall plug into filler hole. NOTE: If the screen is damaged replace it. To replace, remove bolts and separate filler neck from screen. Attach new screen to filler neck and secure with bolts.

Installation Supply Neck Screen

Tank

Filler

STEP 1

W270R126

Remove filler cap/neck screen assembly and O-ring. Pull upwards while twisting assembly left and right. NOTE: Cap opening of supply tank to prevent debris from entering tank.

W270R127

Reinstall O-ring (1) with radius surface facing upward. NOTE: Lubricate O-ring with petroleum jelly.

84547255A

Issued 11-11

Printed in E.C.

3002-37

Removal Supply Line Screen

STEP 2

STEP 1

W270R126

Reinstall filler cap/neck screen assembly.

W270R128

DEF/AdBlue supply line screen is located under the engine hood on the left side of engine at rear of machine.

STEP 3

STEP 2

W270R125

Secure assembly with bolts and remove stopper from filler neck hole. Reinstall supply tank filler neck cap.

STEP 4

W270R095

Raise the hood using controls located behind the access cover.

STEP 3

W270R096

Close side cover concealing supply tank. Turn master electric switch to “on” position. Lower engine compartment hood. 84547255A

W270R096

Turn master electric switch to “off” position. Issued 11-11

Printed in E.C.

3002-38

STEP 4

STEP 6

1 W270R130

W270R129

Locate supply line filter screen housing within supply line between supply tank (1) and DNOx supply module (2) mounted on left hand side of engine. NOTE: Use compressed air and water to clean debris from around screen assembly.

Remove filter screen from housing with needle nose pliers. Rinse filter screen with water to remove accumulated debris. NOTE: If filter screen is damaged, replace it.

Installation Supply Line Screen STEP 1

STEP 5

W270R130 W270R694

To open fitting, push fitting together, squeeze locking tabs slightly, and then pull apart.

Install filter screen into supply line filter housing.

STEP 2

NOTE: Squirt water into fitting connection to lubricate O-ring. If fitting will not release, but is free to rotate, O-ring is likely stuck and additional water should be used to free connection. NOTE: Use a suitable container to catch any fluid discharged during hose and filter disassembly.

W270R695

Reconnect supply line coupling.

84547255A

Issued 11-11

Printed in E.C.

3002-39

STEP 3

STEP 2

W270R096

W270R095

Turn master electric switch to “on” position. Clear any fault codes. Start engine and check connections for leaks. Confirm problem has been corrected.

Raise the hood using controls located behind the access cover.

Removal DNOx Supply Module Filter

STEP 3

STEP 1

W270R096

Turn master electric switch to the “off” position.

STEP 4 W270R128

The DEF/AdBlue Supply filter is located inside the DNOx supply module under the hood on the left side of the engine at the rear of the machine.

2 W270R131

Locate the DNOx supply module (1). The filter element assembly (2) is located on the underside of the module. NOTE: Clean dirt and debris from filter element housing using compressed air and water. 84547255A

Issued 11-11

Printed in E.C.

3002-40

STEP 5

STEP 7

W270R696

W270R698

Squirt water into fitting connections to lubricate O-rings. Disconnect fittings by pushing them together. Then squeeze locking tabs and pull fitting down and off.

Remove filter element (1) from housing (2) by turing it counter clockwise. Discard filter element following local environmental and waste regulations.

NOTE: If the fitting will not release, but is free to rotate, the O-ring is likely stuck and lubrication of the O-ring should be repeated.

Installation DNOx Supply Module Filter STEP 1

STEP 6

W270R699 W270R697

Remove the DEF/AdBlue filter element assembly from DNOx supply module by turning it counter clockwise. Pull straight down and away from module. NOTE: Use a suitable container to catch any fluid discharged during disassembly.

84547255A

Lubricate filter element O-ring (1) on housing side. Lubricate housing O-ring (2). Install filter element on housing by turing it clockwise. NOTE: Lubricate O-ring with petroleum jelly. NOTE: Hand tighten filter only.

Issued 11-11

Printed in E.C.

3002-41

STEP 2

STEP 5

W270R700

Lubricate filter element O-ring on control module side. NOTE: Lubricate O-ring with petroleum jelly.

W270R096

Turn master electric switch to â&#x20AC;&#x153;onâ&#x20AC;? position. Clear any fault codes. Start engine and check connections for leaks. Confirm problem has been corrected.

STEP 3

W270R697

Insert filter housing assembly into DNOx supply module and turn clockwise to tighten. NOTE: Hand tighten filter only.

STEP 4

W270R701

Reinstall DEF/AdBlue supply line. Push connection together and then pull back to make sure it is secure.

84547255A

Issued 11-11

Printed in E.C.

3002-42

AIR FILTRATION Primary/Secondary Fillter Element Disassembly

STEP 3

STEP 1 1

W270R133

Release all clips securing air filter element housing cover.

STEP 4

W270R702

Raise engine compartment hood using controls located behind access cover (1). Airfilter housing/element (2) is located in main engine compartment on right hand side of engine. W270R134

STEP 2

Remove cover from air filter element housing.

STEP 5

W270R096

Turn master electric switch â&#x20AC;&#x153;offâ&#x20AC;?. W270R135

Remove primary filter element by lifting up on handle.

84547255A

Issued 11-11

Printed in E.C.

3002-43

STEP 6

STEP 2

W270R136

W270R135

Remove secondary filter element from right side of housing. Remove debris from inside filter element housing before installing new filter elements.

Install new primary filter element by sliding it down into housing.

NOTE: Do not clean the seconday filter element. It must be replaced if damaged or clogged.

NOTE: Make sure primary and secondary filter elements form an effective seal.

STEP 3

Primary/Secondary Element Reassembly STEP 1

W270R134

Install housing cover.

W270R136

Install new secondary filter element by inserting it into positioning slot. NOTE: Make sure filter element is firmly seated into housing.

84547255A

Issued 11-11

Printed in E.C.

3002-44

STEP 4

W270R133

Lock clips to secure filter housing cover. NOTE: If cover does not fit properly, recheck filter element installation. Cover will be difficult to install if filter elements are not properly installed.

STEP 5

W270R096

Turn master electric power switch â&#x20AC;&#x153;onâ&#x20AC;?. Clear any fault codes. Start machine and confirm problem has been corrected.

84547255A

Issued 11-11

Printed in E.C.

SECTION INDEX

ELECTRICAL Section Title

Section Number

Removal and Installation of Starter and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4001 Electrical Specifications and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4002 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003 Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4003a Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4005 Rear view Camera and Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4006

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

4001 Section 4001 REMOVAL AND INSTALLATION OF STARTER AND ALTERNATOR

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

4001-2

TABLE OF CONTENTS STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84547255A

Issued 11-11

3 3 4 5 5 6 7

Printed in E.C.

4001-3

STARTER Removal

STEP 4

STEP 1 Park machine on a level surface and lower bucket to ground.

STEP 2

BD06F135

Remove the ground strap from the starter, remove the starter mounting bolts, remove the stater.

2 W270R587

1. HOOD SWITCH 2. MASTER DISCONNECT

Raise the engine compartment with lifting motor. Place the master disconnect switch in the OFF position.

STEP 3

BD06F134

Place identification tags on the positive cables and remove the positive cables from the starter.

84547255A

Issued 11-11

Printed in E.C.

4001-4

Installation

STEP 7

STEP 5

1 2

BD06F134

Install and tighten the wires on the starter solenoid. Remove and discard tags.

STEP 8 BC05G047

1. STUDS 2. NUTS

Place the master disconnect switch in the ON position. Lower the engine compartment with lifting motor.

Apply Loctite 747 primer to studs and holes, apply 2 drops of Loctite 271 to each hole and stud. Immediately install and torque studs to 19 to 29 Nm (14 to 21 pound-feet). Allow adhesive to cure for 20 minutes before installing starter.

STEP 6

1 2 BD06F135

Position the starter on the machine, attach the ground cable to the bottom mounting stud (2) and install the nut, attach the ground strap and wire to the outer stud (1) and install the nut, install the lower nut. Torque the three nuts to 40 to 48 Nm (29 to 35 pound-feet).

84547255A

Issued 11-11

Printed in E.C.

4001-5

ALTERNATOR Removal

STEP 4

STEP 1 Park machine on a level surface and lower bucket to ground.

STEP 2

W270R589

Use a wrench to move the belt tensioner to loosen the tension on the belt. Remove the belt.

STEP 5 W270R587

1. HOOD SWITCH 2. MASTER DISCONNECT

Raise the engine compartment with lifting motor. Place the master disconnect switch in the OFF position.

STEP 3

W270R590

Remove mounting bolts for alternator, remove alternator. W270R588

Disconnect wires from the alternator.

84547255A

Issued 11-11

Printed in E.C.

4001-6

Installation

STEP 8

STEP 6

W270R588

Connect wires to the alternator, place rubber boot over positive post.

STEP 9

W270R590

Place alternator onto engine, install mounting bolts for alternator and tighten.

STEP 7 1

2 W270R587

1. HOOD SWITCH 2. MASTER DISCONNECT

Place the master disconnect switch in the ON position. Lower the engine compartment with lifting motor.

W270R589

Use a wrench to move the belt tensioner, install the belt. NOTE: Belt routing instructions are on belt cover.

84547255A

Issued 11-11

Printed in E.C.

4001-7

BELT INSTALLATION

W270R591

84547255A

Issued 11-11

Printed in E.C.

4001-8

NOTES

84547255A

Issued 11-11

Printed in E.C.

4002

Section 4002 ELECTRICAL SPECIFICATIONS AND TROUBLESHOOTING

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

4002-2

TABLE OF CONTENTS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ELECTRICAL WIRE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

84547255A

Issued 11-11

Printed in E.C.

4002-3

SPECIFICATIONS Electrical System ............................................................Two 12 volt batteries connected in series, negative ground System Voltage .............................................................................................................................................. 24 volts Batteries Group Size ..........................................................................................................................................................31 Reserve Capacity ................................................................................................................................ 170 minutes Cold Cranking Capacity At -17qC (0qF) for 60 Seconds At 6.0 Volts.................................................700 amperes Load of Capacity (Load) Test .............................................................................................................400 amperes Alternator ..................................................................................................................................... 24 volt, 65 amperes Voltage Regulator............................................................................................................. Solid State, Not Adjustable Starter................................................................................................................................ 24 volt, Solenoid Actuated Bucket Control Valve (Joystick) Detent Electromagnets Resistance at 20qC (68qF) (Nominal) ................ 68.2 ohms Bucket Control Valve (Single Axis) Detent Electromagnets Resistance at 20qC (68qF) (Nominal) ............ 305 ohms Fuel Level Sender .............................................................................................................................. 33 to 240 ohms Coolant, Torque Converter, and Hydraulic Temperature Sender 20qC (68qF) ......................................... 3521 ohms Transmission Filter Restriction Switch with 510 ohms Internal Resistor (Normally Open) Closing Set point ............................................................................................................................ 2.8 Bar (40 psi) Hydraulic Filter Restriction Switch (Normally Open) Closing Set point .............................................. 2.8 Bar (40 psi) Air Filter Restriction Switch (Normally Open) Closing Set point ................................. -6.4 kPa (Gauge) (-0.928 psig) A/C Trinary Pressure Switch (Closed With Normal System Pressure) Opens With Pressure ............................................................................ Above 28.5 ± 2.5 bar (413.3 ± 36,25 psi) Below 2.5 ± 0.25 bar (36.25 ± 3.6 psi) Brake Declutch Pressure Switch (Normally Closed) Opening Set point............................................ 24 Bar (350 psi) Brake Warning Pressure Switch (Normally Closed) Opening Set point ................. 106 to 115 bar (1530 to 1670 psi) Brake Redundant Pressure Switches (Normally Open) Closing Set point 55 to 69 bar decreasing (800 to 1000 psi) Brake Lamp Pressure Switch (Normally Open) Closing Set point........................ 5 to 6 bar increasing (75 to 85 psi) Secondary Steering Pressure Switch (Form C) Closing Set point ..................................................... 2.4 Bar (35 psi) Fuel Filters Heater Resistance At 20qC (68qF) (Nominal)............................................................................ 1.9 ohms Parking Brake Solenoid DC Resistance At 20qC (68qF) (Nominal) ........................................................... 40.3 ohms Pilot Pressure Solenoid (Joystick) DC Resistance At 20qC (68qF) (Nominal) ........................................... 29.9 ohms Pilot Pressure Solenoid (Single Axis) DC Resistance At 20qC (68qF) (Nominal) ...................................... 27.4 ohms Ride Control Solenoid DC Resistance At 20qC (68qF) (Nominal) .............................................................. 22.7 ohms Pin Engage Solenoid DC Resistance At 20qC (68qF) (Nominal) ............................................................... 28.8 ohms Secondary Steering Solenoid DC Resistance At 20qC (68qF) (Nominal) .................................................. 39.3 ohms Fan Reversing Solenoid DC Resistance At 20qC (68qF) (Nominal)........................................................... 39.3 ohms Fan PWM Solenoid DC Resistance At 20qC (68qF) (Nominal) ...................................................................xx.x ohms Rollback Pressure Switch (Normally Closed) Opening Set point ....................................................... 6.2 Bar (90 psi) Fuel Temperature Sensor At 20qC (68qF) (Nominal) ................................................................................ 2500 ohms Grid Heater .................................................................................................................................................. 500 ohms Engine Control Unit ............................................................................................... Electronic Diesel Control (EDC 7) Analog Throttle ................................................................................. Idle Validation Switch Closes At 0.775V ± 0.1V Throttle Position Potentiometer ................................................................................................. 5V Reference ± 0.2V Low Idle Position .............................................................................................................................. 0.4V ± 0.025V High Idle Position ................................................................................................................................. 4.0V ± 0.1V

84547255A

Issued 11-11

Printed in E.C.

4002-4

ELECTRICAL WIRE IDENTIFICATION Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

W0 8 GXL TWIST

JUMP1, JSS LOAD SENSE

JUMP2, JSS LOAD SENSE

BK0 8 GXL TWIST

JUMP1, JSS LOAD SENSE

JUMP2, JSS LOAD SENSE

Alternator D+

Lg 1.0 SXL

AD, Alternator D+

ENG, Engine Cab

Battery sensing

R 1.0 SXL

ALT_5, Alternator D+

AB_5, Alternator B+

EDC Relay CNTL

OR 0.8 GXL

EDC7, Engine controller

SPL_EDC4, Ultrasonic

Doser valve B+

R 0.8 GXL

DNOX2, NOX Controller

DEFDM, Doser metering VLV

Work Lights Switched Fused Pwr R 2.0 GXL

SPL-WL, Ultrasonic

ECC, ELect CNTR C

Brake Lt Control Power

T 1.0 SXL

BTM_C, CAB Bottom bulkhd

PBL, Brake Light Press Switch

Back Lt Power

DU1.0 GXL

D-OR, Diode OR

SPL-BCK-LGT, Spl Back Lgt Pwr

Fan Reverse LSD

W 0.8 TXL

AIC-1, Adv Instr Clust 1

ECB, Electrical Center B

Fan Control PWM

W 0.8 TXL

CAB-E, Cab Engine

AIC-1, Adv Instr Clust 1

Pin Engage Sol Pwr

W 1.0 SXL

FRONT, Cab Front Chassis

YPE, Pin Engage Option

Ride Control Sol Pwr

W 1.0 SXL

PRBF, Rollback Press Sw

YRC, Ride Control Option

Horn Power

Or 1.0 SXL

FRONT, Cab Front Chassis

HN1, Horn Power

460

Fan speed sensor signal

Y 1.0 GXL

FSS, Fan_speed_sens

ENG, Engine-CAB1

016B

Pedal Sensor Grnd

DU 0.8 GXL

BTM_C, CAB BOTTOM BULKHD

BPP, Pedal position

017A

Fan speed sensor GND

BK 1.0 GXL

GND_ENG7, Tranny, cool temp

FSS, Fan_speed_sens

OD_C DIAG2 GRND

BK 0.8 GXL

DIA_2, Diagnostic

GND_CAB_SPL, CAB GRND SPLICE

OE_A Exht temp up GND

BK 0.8 GXL

UTS, Upstream temp sense

DNOX2, NOX Controller

0 29

RTT/Float Ground

Bk 0.8 GXL

SFL, Return To Travel Sw

SPL-BCK-LT-GD2, Spl Back Lgt Gnd

0 AA

Proximity Switch Grnd

Bk 1.0 SXL

PXH, Height Control RTT

SPL-A2, Ultrasonic

0 AB

Proximity Switch Grnd

Bk 1.0 SXL

SPL-A2, Ultrasonic

GND-FC, Ground A

0 AC

Proximity Switch Grnd

Bk 1.0 SXL

PXF, RTD

SPL-A2, Ultrasonic

0 AD

Ride Control Ground

Bk 1.0 SXL

YRC, Ride Control Option

SPL-A1, Ultrasonic

0 AE

Pin Engage Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

YPE, Pin Engage Jumper

0 AF

Horn Ground

Bk 1.0 SXL

HN2, Horn Ground

SPL-A1, Ultrasonic

84547255A

Issued 11-11

Printed in E.C.

4002-5

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

0 AG

Front Chassis Ground

Bk 2.0 SXL

SPL-A1, Ultrasonic

GND-FC, Ground A

0 AH

RH Front Lights Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

LRF, Lights RH

0 AJ

LH Front Lights Ground

Bk 1.0 SXL

SPL-A1, Ultrasonic

LLF, Lights LH

0 AK

Park Brake/Warning Ground

Bk 1.0 SXL

SPL-A4, Ultrasonic

BTM_E, CAB BOTTOM

0 AL

Brake Warning Press Sw Gnd

Bk 1.0 SXL

PBW, Brake Warn Press Sw

SPL-A4, Ultrasonic

0 AM

RTD Grnd

Bk 1.0 SXL

PXM, RTD

PXT, RTD

0 AN

Park Brake Solenoid Ground

Bk 1.0 SXL

YPB, Park Brake Solenoid

SPL-A4, Ultrasonic

0 AP

Front To Rear Chassis Ground

Bk 5.0 SXL

GND-S1, Ground A

GND-S2, Ground A

0_AS

GRND, Joystick

BK 1.0 GXL

JSS_FRM, JSS Frame to cab

SPL_JSS_17, Ultrasonic

0_AT

GRND, JSS VLV

BK 1.0 GXL

JSS_Valve, JSS HYD Valve

SPL_JSS_17, Ultrasonic

0_AU

GRND, Pilot dump

BK 1.0 GXL

SPL_JSS_17, Ultrasonic

JSS_PIL_Dump, JSS Pilot dump

0_AV

GRND

BK 1.0 GXL

SPL_JSS_17, Ultrasonic

GND_JSS, Ground_A

BK 1.0 SXL

YPE1, PIN Engage jumper

YPE2, PIN_Engage_OPT

0_AW PIN Engage GND 0B

Front Washer Ground

Bk 1.0 SXL

FWW, Front Washer

SPL_ENG, ULTRASONIC

0 B1

Back Light Ground

Bk 0.8 GXL

SPC, Pilot Control Switch

SPL-PED-BL-GD, Spl Bk Lgt Grnd 6 Pck

0 B2

Back Light Ground

Bk 0.8 GXL

SFL, Return To Travel Switch

SPL-BCK-LT-GD2, Spl Bk Lgt Grnd

0 B3

Back Light Ground

Bk 0.8 GXL

SHC, Height Control Switch

SPL-BCK-LT-GD2, Spl Bk Lgt Grnd

0 B4

Back Light Ground

Bk 0.8 GXL

SRTD, Detent Switch

SPL-BCK-LT-GD2, Spl Bk Lgt Grnd

0 B5

Back Light Ground

Bk 0.8 GXL

SPE, Pin Engage Switch

SPL-BCK-LT-GD2, Spl Bk Lgt Grnd

0 B6

Cab2 Ground

Bk 1.0 GXL

SPL_BCK_LT_GD, SPL BACK LGHT GD

SPL-BCK-LT-GD2, Spl Bk Lgt Grnd

0 B7

Back Light Ground

Bk 0.8 GXL

SFC, Fan Control Switch

SPL-BCK-LT-GD2, Spl Bk Lgt Grnd

0 B8

Front Wiper Motor Ground

Bk 0.8 GXL

GND_CAB2, GROUND_A

FWMG, Wiper Ground

0 B10 Hood Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Grnd 6 Pck

GND-CAB2, Ground A

0 B11 Back Light Ground

Bk 0.8 GXL

SPL-BCK-LT-GD2, Spl Bk Lgt Grnd

SPL-PED-BL-GD, Spl Bk Lgt Grnd 6 Pck

84547255A

Issued 11-11

Printed in E.C.

4002-6

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

0 B12 Hood Down Relay Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Grnd 6 Pck

ECC, Elect Cntrc

0 B13 Back Light Ground

Bk 1.0 GXL

SPL-BCK-LT-GD, Spl Bk Lght Grnd

SPL_WL1, ULTRASONIC

0 B14 Back Light Ground

Bk 0.8 GXL

SWL, Work Lights Switch

SPL-BCK-LT-GD, Spl Bk Lght Grnd

0 B15 Back Light Ground

Bk 0.8 GXL

SBE, Beacon Switch

SPL-BCK-LT-GD, Spl Bk Lght Grnd

0 B16 Hood Down Control Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Grnd 6 Pck

ECC, ELECT CNTR C

0 B17 Back Light Ground

Bk 0.8 GXL

STA, Trans Auto Switch

SPL-BCK-LT-GD, Spl Bk Lght Grnd

0 B18 Back Light Ground

Bk 0.8 GXL

SDC, Declutch Switch

SPL-BCK-LT-GD, Spl Bk Lght Grnd

0 B19 Back Light Ground

Bk 0.8 GXL

SDR, Driving Lights Switch

SPL-BCK-LT-GD, Spl Bk Lght Grnd

0 B20 Back Light Ground

Bk 0.8 GXL

SRC, Ride Control Switch

SPL-BCK-LT-GD2, Spl Bk ghLt Grnd

0 B21 Back Light Ground

Bk 0.8 GXL

SBU, Backup Alarm Disc Sw

SPL-BCK-LT-GD, Spl Bk Lght Grnd

0 B22 Hood Up Relay Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Gnd 6 Pck

ECC, ELECT CNTR C

0 B23 Back Light Ground

Bk 0.8 GXL

SRWP, Rear Wiper Switch

SPL-BCK-LT-GD, Spl Bk Lght Grnd

0 B24 Back Light Ground

Bk 0.8 GXL

SHZ, Hazard Switch

SPL-PED-BL-GD, Spl Bk Lght Grnd 6 Pck

0 B25 Hood Up Control Ground

Bk 1.0 GXL

SPL-HOOD-GRND, Hood Gnd 6 Pck

ECC, ELECT CNTR C

0 B26 Buzzer/Switch Pad Ground

Bk 0.8 GXL

SPL-BUZ, Ultrasonic

GND_CAB2, Ground_A

0 B27 Buzzer Ground

Bk 0.8 GXL

SPL-BUZ, Ultrasonic

BUZ, AIC Buzzer

0 B28 Switch Pad Ground

Bk 0.8 TXL

SW-PD, Switch Pad

SPL-BUZ, Ultrasonic

0 B29 RTT/Float Ground

Bk 0.8 GXL

SPB, Parking Brake Switch

SPL-PED-BL-GD, Spl Bk Lgt Grnd 6 Pck

0_B31 SDA GND

BK 0.8 GXL

SPL_BCK_LT_GD2, SPL_Back LGT GRND

SDA, Diff lock switch

0_B32 Back light GND

BK 0.8 GXL

SRP, Work lights SW

SPL_BCK_LT_GD, SPL Back lght GD

Bk 5.0 SXL.

GND-PDST, Ground A

GND-PDST2, Ground A

0 BAC EDC7 Ground

Bk 2.0 SXL

SPL-EDC1, Ultrasonic

GND-ENG2 Dedicated, WIF, EDC

0 BAE EDC7 Sender Ground

Bk 1.0 GXL

RECT, Engine Coolant Temp

GND-ENG7Grnd Trans. Clnt

0 BAG Hood Grounds (EURO)

Bk 1.0 SXL

GND-ENG4, Rear Lighting

E-HD, Trans Hood

0 BA

Pedestal Gnd Strap

84547255A

Issued 11-11

Printed in E.C.

4002-7

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

0 BAG Hood Grounds (NA) N

Bk 1.0 SXL

ENG-H, Engine to Hood

GND-ENG4, Rear Lighting

0 BAR WIF Body Ground

Bk 1.0 SXL

GND-WIF, Gnd WIF Ring Term

GND-ENG6, Dedicated

0_BAT Crank request GND

BK 1.0 SXL

ENG, Engine-CAB1

GND_ENG2 Dedicated, WIF, EDC

0_BAU EVGT_2 GND

BK 1.0 TXL

Turbo, ENG DASH_Turbo

GND_ENG2 Dedicated, WIF, EDC

Bk 1.0 SXL

YFR, Fan Reverse Sol Opt

SPL-FAN, Ultrasonic

0_BBA Joystick ground

BK 0.8 GXL

SPL_JSS_1, Ultrasonic

SJS, Joystick_control_SW

0_BBB Joystick ground

BK 0.8 GXL

SJS, Joystick_control_SW

SPL_JSS_1, Ultrasonic

0_BBC Joystick ground

BK 0.8 GXL

GND_CAB_SPL2, SPL Back lght GD

SPL_JSS_1, Ultrasonic

0_BBD Joystick ground

BK 0.8 GXL

JSS_Cab, JSS Cab

SPL_JSS_1, Ultrasonic

0_BBE Joystick ground

BK 0.8 GXL

SJS, Joystick_control_SW

SPL_JSS_1, Ultrasonic

0_BBF DNOX2 Module GND

BK 2.0 SXL

SPL_DCUG, Ultrasonic

GND, ENG7 GRND, Trans Clnt

0_BBR Ground

BK 1.0 SXL

ENG_B, Cab bottom

GND_ENG3, SPLC_PK, WSHR MTR

0_BC

EDC7 GND

BK 1.0 GXL

SPL_EDC1, Ultrasonic

EDC7, Engine controller

0 BD

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BE

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BF

EDC7 Grnd

Bk 1.0 GXL

SPL-EDC1, Ultrasonic

EDC7, Engine Controller

0 BG

AIC Power Ground

Bk 0.8 GXL

ENG, Engine Cab 1

GND-ENG6, Dedicated

0 BH

AIC Power Ground Red

Bk 0.8 GXL

ENG, Engine Cab 1

GND-ENG6, Dedicated

0 BJ

AIC Sensor Ground

Bk 0.8 GXL

ENG, Engine Cab 1

GND-ENG6, Dedicated

0 BK

Tele Ground

Bk1 0 SXL

ENG, Engine Cab 1

GND, ENG7, Grnd Trans Clnt

0 BL

Rear Washer Ground

Bk 1.0 SXL

RWW, Rear Washer

SPL_ENG, Ultrasonic

0 BM

Engine Splice Grounds

Bk 1.0 SXL

SPL_ENG, Ultrasonic

GND-ENG3, SPLC-PK, Washer Motor

0 BP

WIF Sensor Ground

Bk 1.0 GXL

GND-ENG2 Dedicated, WIF, EDC

WIF, Water In Fuel Sensor

0 BQ

Fan Speed PWM Sol Grd

Bk 1.0 SXL

YFN, Fan PWM Solenoid

SPL-FAN, Ultrasonic

0 BR

RH Rear Light Ground (EURO)

Bk 1.0 SXL

LRR-E, RH Rear Comb Lamp

GND-ENG4, Rear Lighting

Bk 1.0 SXL

LLR-N, LH Rear Comb Lamp

SPL-J1, Ultrasonic

0 BB

Fan Reverse Solenoid Ground

0 BR N LH Rear Light Ground (NA) 84547255A

Issued 11-11

Printed in E.C.

4002-8

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

2.0 mm 5.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

To Connector

Wire

Circuit

0 BS

Fan Control Ground

Bk 1.0 SXL

SPL-FAN, Ultrasonic

SPL_ENG, Ultrasonic

0 BT

LH Rear Light Ground (EURO)

Bk 1.0 SXL

LLR-E, LH Rear Comb Lamp

GND-ENG4, Rear Lighting

Bk 1.0 SXL

LRR-N, RH Rear Comb Lamp

SPL-J1, Ultrasonic

0 BT N RH Rear Light Ground (NA)

Connector

K = Pink U = Blue Y = Yellow

Cavity

Connector

Cavity

0 BU

Fuel Level Sender Ground

Bk 1.0 SXL

RFLG, Fuel Send Ground

GND-ENG7, Grnd Trans Clnt

0 BV

Grid Heater Control Grnd

Bk 0.8 TXL

GHC, Grid Heater Relay

EDC7, Engine Controller

0 BW

Water Separator Htr Ground

Bk 2.0 SXL

GND-ENG1, Start, FFH, WSH

WSH, Water Separator Heater

0 BX

Fuel Filter Heater Ground

Bk 2.0 SXL

FFH, Fuel Filter Heater

GND_ENG1, STRT, FFH, WAT_SEP_HTR

0 BY

Air Filter Restriction Sw Grd

Y 1.0 GXL

SPL_ENG, Ultrasonic

PAF, Air Filter Restriction Sw

0 BZ

Fuel level sender GND

Bk 1.0 SXL

RFL_23, Fuel_level_send

GND_ENG7, Grnd Trans Clnt

0 CA

Sec. Steering Signal Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

SPL_SEC, Ultrasonic

0 CB

Sec. Steering Signal Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

SPL_SEC, Ultrasonic

0 CC

Sec. Steering Press Sw Ground

Bk 1.0 SXL

PSS, Sec. Steer Press Switch

SPL_SEC, Ultrasonic

0 CD

Sec. Steering Splice Ground

Bk 1.0 SXL

SPL_SEC, Ultrasonic

GND_SSMOD, SEC STR Chasis GND

0 CE

Sec. Steering Chassis Ground

Bk 1.0 SXL

SSM, Sec. Steering Mod

GND-SSMOD, Sec. Str Chas Gnd

0 CF

Sec. Steering Sol Ground

Bk 1.0 SXL

YSS, Sec. Strg Sol

SPL_SEC, Ultrasonic

0_CG SEC STR Flyback GND

BK 1.0 SXL

245F, SEC_STR_Flyback

SSD, SEC_STR_Diode

0_CH

SEC STR Flyback GND

BK 1.0 SXL

245F, SEC_STR_Flyback

SSD, SEC_STR_Diode

0 DA

AIC Chassis Ground

Bk 0.8 TXL

GND-PDST1, Ground A

AIC-2, Advanced Inst Cluster 2

0 DAP Back Light Ground

S 0.8 GXL

STE, Trans Enable Switch

SPL-BCK-LT-GD, Splice Back Light Ground

0 DAV TECM Diagnostic Ground

Bk 0.8 GXL

108F, Diagnostic connector

GND-CAB3D, Ground A

0 DB

AIC Power Ground Red

Bk 0.8 TXL

CAB-E, Cab Engine

AIC-2, And Instr Cluster 2

0 DD

Work Lights GRND

BK 2.0 GXL

SPL_WL1, Ultrasonic

GND, Cab 1, Ground A

0 DE

Neutral Start Relay Control Grd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back Light Ground

ECB, Elect Center B

0 DF

Crank Request Relay Control Ground

Bk 0.8 GXL

Cab_E, Cab-Engine

ECB, Elect Center B

0 DG

Cab Splice Grounds

Bk 1.0 GXL

GND-CAB-SPL, Cab Grd Spl

GND-CAB3, Ground C

0 DH

Diagnostic Connector Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

DIA, Diagnostic

84547255A

Issued 11-11

Printed in E.C.

4002-9

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

K = Pink U = Blue Y = Yellow

To Connector

Connector

Cavity

Connector

Cavity

0 DJ

AC Relay Control Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

ECD, Elect Center D

B10

0 DK

Seat Compressor Motor Ground

Bk 1.0 GXL

GND-CAB-SPL, Cab Grd Spl

SC, Seat Comp Motor

0 DM

Speed Sensor Grounds

Bk 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

0 DN

Output Speed Sensor Ground

Bk 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

0 DP

DIAG TECM Ground

Bk 0.8 TXL

GND-CAB3D, Ground A

TECM, Trans

0 DQ

DIAG TECM Ground

Bk 0.8 TXL

GND-CAB3D, Ground A

TECM, Trans

0 DR

Roof Splice Grounds

Bk 1.0 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB1, Ground A

0 DS

Roof Splice Grounds

Bk 1.0 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB1, Ground A

0 DT

Front Wiper/Washer Sw Grd

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SFWW, Front Wiper/Washer

0 DU

Pilot Pressure Sol Grd

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

YPP, Pilot Press Sol

0 DV

Cigar Lighter Ground

Bk 3.0 SXL

CL, Cigar Lighter

GND-CAB3, Ground C

0 DW

AIC Power Ground

Bk 0.8 TXL

CAB-E, Cab Engine

AIC-1, Adv Instr Cluster 1

0 DX

AIC Sensor Ground

Bk 0.8 TXL

CAB-E, Cab Engine

AIC-1, Adv Instr Cluster 1

0 DY

Roof Splice GNDS

BK 1.0 GXL

SPL_WL1, Ultrasonic

Cab_RF, Cab to Roof Connection

0_DZ

Work Lights GRND

BK 2.0 GXL

Cab_RF, Cab to Roof Conn.

SPL_WL1, Ultrasonic

0 EA

PWR Relay GND

BK0_8-GXL

ECB, Elect CNTR B

SPL_SD3, Ultrasonic

0 EB

Ignition Relay Control Ground

Bk 0.8 GXL

SPL_SD3, Ultrasonic

PRM-C1, PRM Signal

0 EC

ACC Relay Control Ground

Bk 0.8 GXL

SPL_SD3, Ultrasonic

PRM-B1, PRM Signal

0 ED

HVAC Grounds

Bk 3.0 SXL

HVAC2, HVAC2

GND-CAB4, Ground C

0 EE

DIODE Suppression Grounds

Bk 0.8 GXL

GND-CAB-SPL, Cab Grnd Spl

140M, DIODE Module

0 EF

Brake Lights Relay Ctrl Grnd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back Light Ground

ECD, ELEC CNTR D

0 EG

Flasher Module Ground

Bk 0.8 GXL

FLSHR, Flasher Module

GND-CAB-SPL2, Spl Back Light Ground

0 EH

Flasher Module Ground

Bk 0.8 GXL

FLSHR, Flasher Module

GND-CAB-SPL2, Spl Back Light Ground

0 EJ

Power Converter Ground

Bk 1.0 GXL

CNV, 24V to 12V Pwr Convert

GND-CAB4, Ground C

0 EK

AUX Power Outlet 1 Grnd

Bk 1.0 GXL

PO1, Power Outlet

GND-CAB5, Ground C

0 EL

AUX Power Outlet 2 Grnd

Bk 1.0 GXL

PO2, Power Outlet

GND-CAB5, Ground C

0 EM

Radio Ground

Bk 0.8 GXL

CAB-RF, Cab to Roof Conn.

GND-CAB-SPL, Cab Grnd Spl

84547255A

Issued 11-11

Printed in E.C.

4002-10

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

0 EN

Radio Ground

Bk 0.8 GXL

ROOF, Roof to Cab Conn.

RAD, Radio Power

0 EP

Horn Switch Ground

Bk 0.8 GXL

GND-CAB-SPL, Cab Grd Spl

SRHSTLK, RH Stalk Switch

0 EQ

Splice Pack GND-CAB-SPL2 Grnd

Bk 0.8 GXL

GND-CAB-SPL2, Spl Back Light Ground

GND-CAB6, Start, FFH, Water Sep Htr

0 ER

Power Converter Grnd

Bk 1.0 GXL

CNV, 24V to 12V Pwr Conv

GND-CAB4, Ground C

0 ES

Grid Heater Ground

Bk 19.0 SXL

GH-1, Grid Heater

GND-GH1, STRT, FFH, Water Sep Htr

0 ET

Power Relat GND

BK 0.8 GXL

ECB, ELECT CNTR B

SPL_SD1, Ultrasonic

0 EU

PWR Converter RLY CTRL GND BK 0.8 GXL

SPL_SD3. Ultrasonic

PRM_A2, PRM Signal

0 EV

IGN Latch GND

BK 0.8 GXL

ECB, ELECT CNTR B

SPL_SD1, Ultrasonic

0 EW

Power Relay GND

BK 0.8 GXL

GND_Cab_SPL2, SPL Back Light GD

ECB, ELECT CNTR B

0 EY

Power Relay GND

BK 0.8 GXL

SPL_SD1, Ultrasonic

ECD, ELEC CNTR D

0 EZ

Power Relay Control

W 0.8 GXL

ECD, ELEC CNTR D

AIC_1, ADV Instr Cluster 1

BK2 0 SXL

GND CB Ground, on Cooling Box

GND GL, Ground, Rear Grill

0G 0 GB

Starter Relay Control Ground

Bk 1.0 SXL

SRC-1, Relay

GND-ENG1, STRT, FFH, Water Sep Htr

0 HD

Speed Sensor Grounds

Bk 1.0 SXL

TRANS, Cab Transmission

SPL-H2, Ultrasonic

0 HE

Output Speed Sensor Grnd

Bk 1.0 SXL

TRANS, Cab Transmission

OSS, Out Speed Sensor

0 HF

Engine Speed Sensor Grnd

Bk 0.8 GXL Twist

ESS, Engine Speed Sensor

SPL-H2, Ultrasonic

0 HG

Inter Speed Sensor Grnd

Bk 0.8 GXL Twist

ISS, Inter Speed Sensor

SPL-H2, Ultrasonic

0 HH

Turbine Speed Sensor Grnd

Bk 0.8 GXL Twist

TSS, Turbine Speed Sensor

SPL-H2, Ultrasonic

0 HL

Redundant Brake Switch Grnd

Bk 1.0 SXL

PRB2, Redundant Brake Sw

GND_Trans, Ground_Trans

0 HM

Redundant Brake Switch Grnd

Bk 1.0 SXL

PRB1, Redundant Brake Sw

GND_Trans, Ground_Trans

0 HR

HYD FLTR SW GRND

BK 1.0 SXL

PHF9, HYD_FLTR_RES_SW

GND_Trans, Ground_Trans

0 HW

Hot Ground

Bk 1.0 SXL

HOT, Hydraulic Oil Temp Send

GND_Trans, Ground_Trans

Start Lockout RLY GND

BK 0.8 GXL

ECC, ELECT CNTR C

GND_CAB_SPL2, SPL Back LGHT GD

0 JA

Hood Grounds (EURO)

Bk 1.0 SXL

HD-E, Hood Trans

SPL-J1, Ultrasonic

84547255A

Issued 11-11

Printed in E.C.

4002-11

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

2.0 mm 5.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

0 JA N Hood Grounds (NA)

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

Bk 1.0 SXL

HD-N, Hood to Engine

SPL-J1, Ultrasonic

0 JB

Backup Alarm Grnd

Bk 1.0 SXL

BU1, Backup Alarm Grnd

SPL-J1, Ultrasonic

0 JC

License Plate Light Grnd

Bk 1.0 SXL

LPL, Lic Plate Light

SPL-J1, Ultrasonic

Camera GND

BK 0.8 GXL

GND_Cab_SPL2, SPL Back Light GD

MON, Camera/Monitor

0 KA

IGN PWR Control GND

BK0_8-GXL

ECD, ELEC CNTR D

AA3

GND_Cab_SPL2, SPL Back Light GD

Telematics GRND

BK 1.0 GXL

CAB-E, Cab Engine

TEL, Telematics

0 LB

DNOX2 Module GND

BK 1.0 GXL

DNOX2, NOX Controller

SPL_DCUG, Ultrasonic

0 LC

DNOX2 Module GND

BK 1.0 GXL

SPL_DCUG, Ultrasonic

DNOX2, NOX Controller

0 LD

Heat Load Vlv Sol

BK1 0 SXL

YLV, Heated Valve Opt.

SPL, FAN, Ultrasonic

0 LE

Heat Load Vlv Sol

BK1 0 SXL

YLV2, Heated Valve Opt.

YLV3, Heated Valve OPT

0 MA

Rear Wiper Motor Grnd

Bk 1.0 GXL

SPL-ROOF, Spl Rood Grnd

RWMG, Rear Wiper Motor Grnd

0 MB

Dome Light Grnd

Bk 0.8 GXL

LDM3, Dome Light Grnd

SPL-ROOF, Spl Rood Grnd

0 MC

Beacon Light Grnd

Bk 1.0 GXL

LBEGRD, Light Beacon Grnd

SPL-ROOF, Spl Rood Grnd

0 ME

LH Rear Work Light Grnd

Bk 1.0 GXL

LLRW, LH Rear Work Light

SPL_WR, Ultrasonic

0 MF

RH Rear Work Light Grnd

Bk 1.0 GXL

LRRW, RH Rear Work Light

SPL_WR, Ultrasonic

0 MG

RH Front Work Light GND

Bk 1.0 GXL

LRFS, Front_WK_LT_OPT

SPL_WRK2, Ultrasonic

0 MH

Rear Work Light GND

Bk 1.0 GXL

ROOF, Roof to Cab Conn.

SPL_WR, Ultrasonic

0 MJ

RH Front Work Light Grnd

Bk 1.0 GXL

LRFW, RH Front Work Light

SPL_WR, Ultrasonic

0 MK

Roof Grounds

Bk 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-ROOF, Spl Rood Grnd

0 ML

RH Front Work Light GND

Bk 1.0 GXL

SPL_WRK2, Ultrasonic

LRFR, Front_WK_LT_OPT

0 MN

Roof Grounds

Bk 1.0 GXL

ROOF, Roof to Cab Conn.

SPL-ROOF, Spl Rood Grnd

0 MP

RH Front Work Light GND

Bk 1.0 GXL

SPL_WRK2, Ultrasonic

LRFO, Front_WK_LT_OPT

0 MU

LH Front Work Light Grnd

Bk 1.0 GXL

LLFW, LH Front Work Light

SPL_WK, Ultrasonic

0 MV

RH Front Work Light GND

Bk 2.0 SXL

SPL_WK, Ultrasonic

ROOF, Roof to Cab Connector

0 NA

Hood Grounds (EU)

Bk 1.0 SXL

HD 9, Hood to ENG

SPL, B1

0 NB

Master Disconnect Grnd

Bk 62.0 SGR

DC2, Discon Black Grnd

B3, Starter Battery

0 NC

Battery Disconnect

Bk 62.0 SGR

BT4, Discon Black Grnd

STTR GRN, Grid HTR Fuse

0 ND

SSM Ground

Bk 62.0 SGR

242F, Chassis Grnd Sec. Strg Motor

GND-SSCHAS, SSM Ground Cable

0 NE

Hood Grounds (EU)

Bk 1.0 SXL

SPL, B1

LLR 9, LH Rear Comb. LT

84547255A

Issued 11-11

Printed in E.C.

4002-12

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

2.0 mm 5.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

To Connector

Wire

Circuit

0 NF

Hood Grounds (EU)

Bk 1.0 SXL

SPL, B1

LRR 9, RH Rear Comb. LT

0 NG

Hood Grounds (EU)

Bk 1.0 SXL

SPL, B1

SPL_J1, Ultrasonic

0 PA

Left Speaker Grnd

Bk 0.8 GXL

LSPK, Left Speaker

SPK, Speaker

0 PB

Right Speaker Grnd

Bk 0.8 GXL

RSPK, Right Speaker

SPK, Speaker

0 RD

Ride Control GND

Bk 1.0 SXL

YRC_J, Ride Cntrl_Jumper

YRC_J2, Ride_Control_opt

0 SC

GRND, Joystick

Bk 0.8 GXL

JSS_Arm, JSS Armrest to Cab

PVRES, JSS Joystick

0 SD

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

Cab_Arm, Cab to Armrest

0 SE

GRND

Bk 0.8 TXL

SPL_JSS_10, Ultrasonic

CAN_MOD_2, JSS CAN MOD

0 SF

GRND

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

Cab_FRM, Cab to JSS Frame

0 SG

COMMON

Bk 0.8 GXL

SPL_JSS_10, Ultrasonic

Arm_pos, Arm position

0 SH

GRND, CAN MOD

Bk 0.8 GXL

JSS_Arm, JSS Armrest to Cab

SPL_JSS_10, Ultrasonic

0 SJ

GRND, CAN MOD

Bk 0.8 GXL

SPL_JSS_9, Ultrasonic

Cab_Arm, Cab to Armrest

0 SK

GRND, CAN MOD

Bk 0.8 GXL

Cab_Arm_FRM, Cab to Arm to FRM

SPL_JSS_9, Ultrasonic

0 SL

GROUND

Bk 0.8 GXL

JSS_RLY, Relay K2

87A

SPL_JSS_9, Ultrasonic

0 SM

GRND, Joystick

Bk 0.8 GXL

JSS_CNT, JSS Controller

SPL_JSS_20, Ultrasonic

0 SN

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_20, Ultrasonic

JSS_CNT, JSS Controller

0 SP

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

R1, Resistor

0 SR

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_14, Ultrasonic

JSS_CNT, JSS Controller

0 SS

GRND, Joystick

Bk 0.8 GXL

JSS_197F, Main_Cab_FNR

FNR_RLY, Relay K2

87A

0 ST

GRND, Joystick

Bk 0.8 GXL

FNR_RLY, Relay K2

SPL_JSS_9, Ultrasonic

0 SU

GRND, Joystick

Bk 0.8 GXL

SPL_JSS_20, Ultrasonic

SPL_JSS_9, Ultrasonic

DEF Sensor GND

Bk 0.8 GXL

UBJ, DEF Level Temp

DNOX2, NOX Controller

0 TA

DEF Sensor GND

LU 0.8 GXL

UBJM, DEF Level Temp

DTLTS, DEF_Tank Level Temp Sensor

EXHT Temp DWN GND

BK 0.8 SXL

DNOX2, NOX Controller

DTS, Downstream Temp Sens

0 VA

Heated Mirrors GND

Bk 1.0 SXL

MH, Heated Mirrors

GND, CAB SPL, CAB GRND SPLICE

0 VB

Heated Mirrors GND

Bk 1.0 GXL

SPL1, Ultrasonic

MH C, Heated Mirrors

0 VC

Heated Mirrors GND

Bk 1.0 GXL

TRLY, Timer Relay

SPL1, Ultrasonic

84547255A

Connector

K = Pink U = Blue Y = Yellow

Cavity

87A

Connector

Issued 11-11

Cavity

CS0

Printed in E.C.

4002-13

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

2.0 mm 5.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

To Connector

Wire

Circuit

0 VD

Heated Mirrors GND

Bk 1.0 GXL

SPL1, Ultrasonic

MHS, Trans. Enable SW

0 VE

Heated Mirrors GND

Bk 1.0 GXL

SPL1, Ultrasonic

MHS, Trans. Enable SW

0 VH

Heated Mirrors GND

Bk 1.0 GXL

SPL1, Ultrasonic

MH L, Mirror HTR

0 VJ

Heated Mirrors GND

Bk 1.0 GXL

SPL1, Ultrasonic

MH R, Mirror HTR

12ACC Ignition Switch ACC Power

W 0.8 GXL

S-KEY, Ignition Switch

SPL-ACC, Ultrasonic

12ACC ACC PRM control Power B

W 0.8 GXL

SPL-ACC, Ultrasonic

PRM-B1, PRM Signal

12ACC Power Converter PRM Control C Power

W 0.8 GXL

SPL-ACC, Ultrasonic

PRM-A2, PRM Signal

12V Pwr To Outlet 1

Or 1.0 GXL

PO1, Power Outlet

ECB, Elect Center B

AA1

12V A 12V Pwr To Outlet 2

Or 1.0 GXL

PO2, Power Outlet

ECB, Elect Center B

AA2

12V B 12V Fused Pwr to Radio

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

ECB Elect Center B

AA9

12V C 12V Switched Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-12V, Ultrasonic

12V D Plug 1 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECB, Elect Center B

12V E Plug 2 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECB, Elect Center B

12V F Radio 12V Switched Power

Or 1.0 GXL

SPL-12V, Ultrasonic

ECB, Elect Center B

12V G 2 Way Radio 12V Switched Pwr

Or 1.0 GXL

SPL-12V, Ultrasonic

ECB, Elect Center B

A10

12V H 12V Fused Power to Radio

Or 0.8 GXL

ROOF, Roof to Cab Conn.

SPL-RAD, Ultrasonic

12V

Connector

K = Pink U = Blue Y = Yellow

Cavity

Connector

Cavity

12V HA

12V Fused Power to Radio

Or 0.8 GXL

SPL-RAD, Ultrasonic

RAD, Radio Power

12V HB

12V Fused Power to Radio

Or 0.8 GXL

SPL-RAD, Ultrasonic

RAD, Radio Power

13A

EVGT Relay

OR 0.8 TXL

EVGT_4, EVGT

EDC7, ENGINE Controller

13B

EVGT Relay PWR

OR 1.0 GXL

Turbo, ENG DASH_Turbo

EVGT_4, EVGT

13C

Fuel Shutoff Fused Power

Or 1.0 SXL

DC3, Fuel Solenoid Disc

DISC, Disconnect Engine

13C A Fuel Shutoff Fused Power

Or 1.0 SXL

ENG-D, Disc Harness

ENG, Engine Cab 1

13C B Fuel Shutoff Fused Power

Or 1.0 SXL

CAB-E, Cab Engine

ECA, Elect Center A

Or 1.0 GXL

S-KEY, Ignition Switch

SPL_SD2, Ultrasonic

13K A IGN PWR Control B+

W 0.8 GXL

SPL_SD2, Ultrasonic

ECD, Elect Center D

AA4

13K B IGN PWR Latch B+

W 0.8 GXL

ECB, ELECT CNTR B

SPL_SD2, Ultrasonic

13K C Ignition Switch Pwr

Or 1.0 GXL

SPL_SD2, Ultrasonic

PRM_C1, PRM Signal

Or 1.0 SXL

DC4, Fuel Sol Disconnect

DISC, Disconnect Engine

13K

13M

Ignition Switch Pwr

Fuel Shutoff Fused Power

84547255A

Issued 11-11

Printed in E.C.

4002-14

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

13M A Fuel Shutoff Fused Power

Or 0.8 TXL

SPL, 13M, Ultrasonic

EDC7, Engine Controller

13M B WIF IGN PWR

Or 1.0 SXL

ENG D, Disc Harness

SPL, 13M, Ultrasonic

13M C WIF Sensor Fused PWR

Or 1.0 GXL

SPL, 13M, Ultrasonic

WIF, Water in Fuel Sensor

14_5

Alternator D+

LG 1.0 SXL

ALT_5, Alternator D+

ENG, Engine-Cab1

14 A

Alternator D+

LG 0.8 GXL

SPL_ALT, Ultrasonic

215F, Alternator Resistor

14 AB Alternator D+

LG 0.8 GXL

SPL_ALT, Ultrasonic

Cab_E, Cab-Engine

14 AC Altenator Running

LG 0.8 GXL

SPL_ALT, Ultrasonic

TEL, Telematics

16R C FNR reverse Signal

LU 0.8 GXL

JSS_197M, FNR-Main_Cab

RVS_Diode, Diode Assy

17P A Switch Pad Power From AIC Pwr Or 0.8 TXL

SW-PD, Switch Pad

SPL_SW_PD, Ultrasonic

17P B SW PAD PWR FR0M AIC PWR

OR 0.8 TXL

SPL_SW_PD, Ultrasonic

AIC_1, ADV INSTR Cluster 1

17P C B+, CAN Module

OR 0.8 GXL

SPL_SW_PD, Ultrasonic

JSS_Cab, JSS Cab

17P D B+, CAN Module

OR 0.8 GXL

SPL_JSS_18, Ultrasonic

Cab_Arm, Cab to Armrest

17P E B+, CAN Module

BK 0.8 TXL

JSS_Arm, JSS Armrest to Cab

CAN_MOD_2, JSS CAN MOD

17P F B+, JSS Controller

OR 0.8 GXL

SPL_JSS_18, Ultrasonic

JSS_CNT, JSS Controller

17P G B+, Joystick

OR 0.8 GXL

SPL_JSS_18, Ultrasonic

Cab_Arm_FRM, Cab to Arm to FRM

LH High Beam Fused Power

OR 2.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18B A LH High Beam Fused Power

OR 2.0 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

RH High Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

18C A RH High Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

LH Low Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18D A LH Low Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

RH Low Beam Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

18E A RH Low Beam Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECB, Elect Center B

LH Position/Tail Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

18F A LH Position/Tail Fused Power

Or 0.8 GXL

CABE2, CAB TO ENG2 BULKHD

SPL-POS-L, Ultrasonic

LH Position/Tail Fused Power

Or 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

18F B LH Position/Tail Fused Power

Or 1.0 SXL

ENG2, ENG BULKHD 2

LLR-E, LH Rear Comb Light

LH Position/Tail Fused Power

Or 1.0 SXL

HD-N, Hood to Engine

LLR-N LH Rear Combination Light

18F C LH Position/Tail Fused Power

Or 1.0 GXL

SPL-POS-L, Ultrasonic

ECB, Electric Center B

18B

18C

18D

18E

18F

18F AN

18F BN

84547255A

Issued 11-11

AA3 3 AA4 2 AA6 2 AA5

AA7 Printed in E.C.

4002-15

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

2.0 mm 5.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

18F E LH Position/Tail Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

SPL-POS-L, Ultrasonic

18F F LH Position/Tail Fused Power

Or 1.0 SXL

HD 9, Hood to ENG

LLR 9, LH Rear Comb. LT

RH Position/Tail Fused Power

Or 1.0 GXL

SPL-POS-R, Ultrasonic

ECB, Elect Center B

18G A RH Position/Tail Fused Power

Or 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

RH Position/Tail Fused Power

Or 1.0 SXL

SPL-POS-NA, Ultrasonic

LRR-N, RH Rear Combination Light

18G D Licence Plate Light Fused Pwr

Or 1.0 SXL

SPL-POS, Ultrasonic

E-HD, Trans Hood

18G E Licence Plate Light Fused Pwr

Or 0.8 GXL

HD-E, Hood Trans

LPL, Licence Plate Light

Licence Plate Light Fused Pwr

Or 1.0 SXL

LPL, Licence Plate Light

SPL-POS-NA, Ultrasonic

18G F RH Position/Tail Fused Power

Or 0.8 GXL

CABE2, CAB TO ENG2 BULKHD

SPL-POS-R, Ultrasonic

18G G RH Position/Tail Fused Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

SPL-POS-R, Ultrasonic

18G H RH Position/Tail Fused Power

Or 1.0 SXL

ENG2, ENG BULKHD 2

SPL-POS, Ultrasonic

RH Position/Tail Fused Power

Or 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

18G J RH Position/Tail Fused Power

Or 1.0 SXL

LRR-E, RH Rear Combination Light

SPL-POS, Ultrasonic

RH Position/Tail Fused Power

Or 1.0 SXL

HD-N, Hood to Engine

SPL-POS-NA, Ultrasonic

18G K RH Position/Tail Fused Power

Or 1.0 SXL

HD-9, Hood to Engine

SPL-P9

18G L LIC Plate LT Fused Power

Or 1.0 SXL

SPL-P9

LPL, LIC Plate Light

18G M RH Position/Tail Fused Power

Or 1.0 SXL

SPL-P9

LRR-9, RH Rear Comb. LT

18J B EDC7 Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J C EDC7 Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J D EDC7 Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J E EDC7 Fused Power

Or 1.0 GXL

SPL-EDC2, Ultrasonic

EDC7, Engine Controller

18J F

OR 3.0 GXL

PRM_D1, PRM OUTPUT

SPL-EDC2, Ultrasonic

18K A Diagnostic Fused PWR

OR 0.8 GXL

SPL_PK1, Splice 3-4Way

ECC, Elect Cntr C

18K B Diagnostic Fused B+

OR 0.8 GXL

SPL_PK1, Splice 3-4Way

DIA_2, Diagnostic

18K D Diagnostic Fused B+

OR 0.8 GXL

SPL_PK1, Splice 3-4Way

DIA, Diagnostic

Blower Motor Fused Power

Or 3.0 GXL

SPL-BLWR, Ultrasonic

ECA, Elect Center A

18N A Blower Motor Fused Power

Or 0.8 GXL

SPL-BLWR, Ultrasonic

HVAC1, HVAC1

18G

18G CN

18G EN

18G HN

18G JN

18N

EDC7 Fused Power

84547255A

Issued 11-11

AA8

2 Printed in E.C.

4002-16

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

18N B Blower Motor Fused Power

Or 3.0 GXL

SPL-BLWR, Ultrasonic

HVAC2, HVAC2

18S A B+, JSS Fused

OR 0.8 GXL

SPL_JSS_3, Ultrasonic

ECA, ELECT CNTR A

18S B B+, JSS Fused

OR 0.8 GXL

SPL_JSS_3, Ultrasonic

SJS, Joystick_Control_SW

18S C B+, JSS Fused

OR 0.8 GXL

JSS_Cab, JSS Cab

SPL_JSS_3, Ultrasonic

18S D B+, JSS Fused

OR 0.8 GXL

Cab_FRM, Cab to JSS Frame

Cab_Arm_FRM, Cab to Arm to FRM

18S E B+, JSS Fused

OR 1.0 SXL

JSS_PIL_PR, JSS Pilot Pressure

JSS_FRM, JSS Frame to Cab

OR 0.8 GXL

ECA, ELECT CNTR A

A10

Cabe2, Cab to ENG2 BULKHD

18T A DNOX2 SW B+

OR 1.0 SXL

ENG2, ENG BULKHD 2

DNOX2, NOX Controller

18U A DCU B+ N0N Disconnectd

OR 5.0 GXL

PRM A1, PERM Output

SPL TEL, Ultrasonic

18U B DCU B+ N0N Disconnectd

OR 3.0 GXL

ENG2, ENG BULKHD 2

DNOX2, NOX Controller

18U C DCU B+ N0N Disconnectd

OR 3.0 GXL

Cabe2, Cab to ENG2 BULKHD

SPL TEL, Ultrasonic

18U D DCU B+ N0N Disconnectd

OR 3.0 GXL

DNOX2, NOX Controller

ENG2, ENG BULKHD 2

18U E DCU B+ N0N Disconnectd

OR 3.0 GXL

CABE2, CAB to ENG2 Bulkhd

SPL TEL, Ultrasonic

18U F Telematics FSD ND PWR

OR 0.8 GXL

SPL TEL, Ultrasonic

TEL, Telematics

Heated Mirror PWR

OR 1.0 GXL

MH, Heated Mirror

ECA, ELECT CNTR A

18V A Heated Mirror PWR

OR 1.0 GXL

SPL2, Ultrasonic

MH-C, Heated Mirror

18V B Heated Mirror PWR

OR 1.0 GXL

TRLY, Timer Relay

SPL2, Ultrasonic

18V C Heated Mirror PWR

OR 1.0 GXL

MHS, Trans Enable SW

SPL2, Ultrasonic

TRANS, Cab Transmission

OSS, Out Speed Sensor

18T

18V

19A

DNOX SW B+

Output Speed Sensor Fused Pwr Or 1.0 SXL

19A A Brake Declutch Sw Fused Pwr

Or 1.0 SXL

Trans, Transmission-Cab

PBD, Dec. Pressure Switch

19A B FNR Switched Fused Power

Or 0.8 GXL

197M, FNR Main Cab

SPL-FNR, Ultrasonic

19A C FNR Switched Fused Power

Or 0.8 GXL

197F, Main Cab FNR

SPL-TRNS-PWR, Trans Pwr

19A D Trans Enable Switch Fused Pwr

Or 0.8 GXL

STE, Trans Enable Switch

SPL-D15, Ultrasonic

19A E AIC Fused PWR

Or 0.8 GXL

STE, Trans Enable Switch

SPL-D15, Ultrasonic

19A F Trans Enable Switch Fused Pwr

Or 0.8 GXL

SPL-TRNS-PWR, Trans Pwr

SPL-D15, Ultrasonic

19A G FNR Sw Fused Power

Or 0.8 GXL

SPL-FNR, Ultrasonic

SFNR, FNR Switch

19A H Trans Shifter Fused Power

Or 0.8 GXL

TS1, Transmission Shifter

SPL-TRNS-PWR, Trans Pwr

19A K TECM Fused Power

Or 0.8 TXL

SPL-TRANS-PWR, Trans Pwr

TECM, Trans

84547255A

Issued 11-11

Printed in E.C.

4002-17

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

19A L Park Brake Switched Fused Pwr

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

SPB, Parking Brake Switch

SPL-PBS, Ultrasonic

19A M Output Speed Sensor Fused Pwr Or 0.8 TXL

CAB-T, Cab Transmission

SPL-TRNS-PWR, Trans Power

19A N Trans Fused Power

Or 1.0 GXL

SPL-TRANS-PWR, Trans Pwr

ECA, Elect Center A

19A P Backup Alarm Relay

OR1_0-GXL

ECD, ELEC CNTR D

SPL_TRNS_PWR, TRANS_PWR

19A Q Trans/Auto Switch Fused Power

Or 0.8 GXL

STA, Trans Auto Switch

SPL-TRANS-PWR, Trans Pwr

19A R Declutch Switch Fused Power

Or 0.8 GXL

SDC, Declutch Switch

SPL-TRANS-PWR, Trans Pwr

19A T Brake Declutch Switch Fused Power

Or 0.8 GXL

CAB-T, Cab Transmission

SPL-TRANS-PWR, Trans Pwr

19A U Trans Dick Down Switch Fused Power

Or 0.8 GXL

SPL-FNR, Ultrasonic

20M, Trans Kick Down

19A V FNR Switch Fused Power

Or 0.8 GXL

SFNR, FNR Switch

SPL-FNR, Ultrasonic

19A W Diagnostic Conn. Fused Power

Or 0.8 GXL

108F, Diagnostic Connector

SPL-TRANS-PWR, Trans Pwr

Turn Signal Fused Power

Or 0.8 GXL

SRHSTLK, RH Stalk Switch

49a

ECA, Elect Center A

19B A FNR Switch Fused Power

W 0.8 GXL

FNR_RLY, Relay K2

JSS_197M, FNR-Main Cab

19B B FNR Switch Fused Power

OR 0.8 GXL

Cab FNR, Main Cab FNR

FNR_RLY, Relay K2

19B C FNR Switch Fused Power

OR 0.8 GXL

Arm FNR, FNR-Main Cab

SPL_AJ, Ultrasonic

19B D FNR Switch Fused Power

OR 0.8 GXL

21M, Trans_Kick-Down

SPL_AJ, Ultrasonic

19B E FNR Switch Fused Power

OR 0.8 GXL

SAJ, FNR Switch

SPL_AJ, Ultrasonic

19B F FNR Switch Fused Power

OR 0.8 GXL

SAJ, FNR Switch

SPL_AJ, Ultrasonic

19C A Pilot Ctrl Rly Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

ECA, Elect Center A

19C B Pilot Ctrl Rly Fused Pwr

Or 1.0 GXL

SPL-D24, Ultrasonic

ECD, Elect Center D

19C C Pilot Ctrl Rly Fused Pwr

Or 0.8 GXL

SPL-D24, Ultrasonic

ECD, Elect Center D

19C D Ride Control SW Fused Pwr

Or 1.0 GXL

SRC, Ride Control Switch

SPL-D24, Ultrasonic

19C E Pilot Control SW Fused Pwr

OR 0.8 GXL

TEL, Telematics

SPL_D24, Ultrasonic

19C F Pilot Control SW Fused Pwr

OR 0.8 GXL

SPC, Pilot Control Switch

SPL_D24, Ultrasonic

19D A Parking Brake Relay Fused Pwr

Or 1.0 GXL

SPL-PBS, Ultrasonic

ECA, Elect Center A

19D B Parking Brake Relay Fused Pwr

Or 0.8 GXL

SPL-PBS, Ultrasonic

ECB, Elect Center B

19D C Parking Brake Relay Fused Pwr

Or 1.0 GXL

SPL-PBS, Ultrasonic

ECB, Elect Center B

19E A AIC Wake Up Ignition

Or 0.8 TXL

SPL_AP, Ultrasonic

ECA, Elect Center A

19B

Or 0.8 GXL

AA10

19H

Backup Alarm B+

OR 1.0 GXL

ECD, ELEC CNTR D

A10

ECA, Elect Center A

19J

Front Wiper Fused Pwr

Or 0.8 GXL

SPL-FW, Ultrasonic

ECA, Elect Center A

84547255A

Issued 11-11

Printed in E.C.

4002-18

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

19J A Front Wiper Motor Fused Pwr

Or 0.8 GXL

SPL-FW, Ultrasonic

FWM, Front Wiper Motor

19J B Front Wip Wash Sw Fused Pwr

Or 0.8 GXL

SFWW, Front Wiper/Washer

SPL-PK3, Splice 3-4 Way

19J C Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

SPL-FW, Ultrasonic

19J D Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

ECD, Elect Center D

19J E Front Wiper Relay Fused Power

Or 0.8 GXL

SPL-FW, Ultrasonic

ECD, Elect Center D

Or 0.8 GXL

SPL-PK3, Splice 3-4 Way

ECD, Elect Center D

Or 0.8 GXL

SPL-FW, Ultrasonic

K-WCO, Wiper Cutout

Or 1.0 GXL

SPL-RWW, Ultrasonic

ECA, Elect Center A

19K A Rear Wiper Sw Fused Pwr

Or 1.0 GXL

SRWP, Rear Wiper Sw

SPL-RWW, Ultrasonic

19K B Rear Wip Wash Fused Pwr

Or 0.8 GXL

SRWP, Rear Wiper Sw

SPL-RWW, Ultrasonic

19K C Rear Wiper Motor Fused Pwr

Or 1.0 GXL

CAB-RF, Cab to Roof Connect

SPL-RWW, Ultrasonic

19K D Rear Wiper Motor Fused Pwr

Or 1.0 SXL

ROOF, Roof to Cab Connect

RWM, rear Wiper Motor

Pwr Converter Fused Power

Or 3.0 GXL

PRM-A1, PRM Output

SPL-CNV, Ultrasonic

19L A Pwr Converter Fused Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-CNV, Ultrasonic

19L B Pwr Converter Fused Power

Or 2.0 GXL

CNV, 24V to 12V Pwr Conver

SPL-CNV, Ultrasonic

Sec. Steering Accessory Fused Pwr

Or 0.8 GXL

CAB-T, Cab Transmission

ECA, Elect Center A

19M A Sec. Steering Accessory Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19M C Sec. Steering Accessory Fused Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Mod Trans

19J F

Front Wiper Relay LS Control Fused Power

19J G Wiper Cutout Relay Fused Pwr 19K

19L

19M

Rear Wiper Fused Pwr

19N

Seat Compressor Fused Pwr

Or 1.0 GXL

SC, Seat Compressor Motor

ECA, Elect Center A

19P

Pin Engage/Fan Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECA, Elect Center A

19P A Pin Engage Sw Fused Pwr

Or 0.8 GXL

SPE, Pin Engage Sw

SPL-PIN, Spl Back Lgt Pwr

19P C Fan Rev Sw Fused Pwr

Or 0.8 GXL

SFC, Fan Control Switch

SPL-PIN, Spl Back Lgt Pwr

19P D Fan Rev Relay Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECB, Elect Center B

19P E Fan Rev Relay Fused Pwr

Or 0.8 GXL

SPL-PIN, Spl Back Lgt Pwr

ECB, Elect Center B

19R

Sec. Steering Ign Fused Pwr

Or 0.8 GXL

DM, Diode OR

SPL-2 Ultrasonic

19RR

Sec. Steering Ign Fused Pwr

Or 0.8 GXL

DM, Diode OR

ECA, Elect Center A

19R A Sec. Steering Ign Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

84547255A

Issued 11-11

Printed in E.C.

4002-19

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

19R C Sec. Steering Ign Fused Pwr

Or 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Mod Trans

19R D Alternator Resistor Fused Pwr

Or 0.8 GXL

SPL-2, Ultrasonic

216F, Alternator Resistor

19R E Sec. Steering Ign Fused Pwr

Or 0.8 GXL

SPL-2, Ultrasonic

CAB-T, Cab Transmission

19S1

Sec. Steering Pwr

Or 3.0 GXL

PRMB L2, B+ Power

SPL, 19S, Ultrasonic

19S2

Sec. Steering Fused Pwr

Or 1.0 GXL

SPL, 19S, Ultrasonic

CAB-T, Cab Transmission

19S1 E Sec. Steering Fused Pwr

Or 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Module Opt

19S1 X Sec. Steering Fused Pwr

R 1.0 SXL

SSM, Sec. Steering Module

SS-TR, Sec. Steering Module Trans

19S B AIC Delay Fused Power

Or 0.8 GXL

SPL-DLY3, Ultrasonic

ECC, Elect Center C

19S C AIC Delay Fused Power

Or 0.8 TXL

SPL-DLY3, Ultrasonic

AIC-2, Advanced Instr Cluster 2

19S D AIC Delay Fused Power

Or 0.8 TXL

SPL-DLY3, Ultrasonic

AIC-2, Advanced Instr Cluster 2

19S E AIC Batt B+

OR 0.8 GXL

SPL_AP, Ultrasonic

AIC_1, Advanced Instr Cluster 1

19S F AIC Batt B+

OR 0.8 GXL

SPL_AP, Ultrasonic

AIC-2, Advanced Instr Cluster 2

19T A Fused Batt. Power

Or 0.8 TXL

TECM, Trans

SPL_D17, Ultrasonic

19T B Fused Batt. Power

OR 0.8 TXL

TECM, Trans

SPL_D17, Ultrasonic

19T C Fused Batt. Power

OR 0.8 TXL

SPL_D17, Ultrasonic

ECC, Elect Center C

A10

Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Elect Center C

19U A Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Elect Center C

19U B Beacon Dome Lt Fused Pwr

Or 1.0 GXL

SPL-LT, Ultrasonic

ECC, Elect Center C

19U C Dome Lt Fused Pwr

Or 0.8 GXL

ROOF, Roof to Cab Connection

LDM1, Dome Light B+

19U D Dome Lt Fused Pwr

Or 0.8 GXL

CAB-RF, Cab to Roof Connection

SPL-LT, Ultrasonic

19U E Horn Relay Fused Power

Or 0.8 GXL

SPL-HRN, Ultrasonic

ECC, Elect Cntr C

19U F Door Sw Fused Power

Or 0.8 GXL

ROOF, Roof to Cab Connection

DS, Door Switch

19U G Door Sw Fused Power

Or 0.8 GXL

CAB-RF, Cab to Roof Connection

SPL-LT, Ultrasonic

19U H Beacon Switch Fused Power

Or 1.0 GXL

SBE, Beacon Switch

SPL-LT, Ultrasonic

19U

19W

Cigar Lighter Fused Power

Or 3.0 GXL

CL, Cigar Lighter

ECA, Elect Cntr A

19Y

Hood control Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Elect Cntr C

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Elect Cntr C

19Y A Hood Up Relay Fused Power

84547255A

Issued 11-11

Printed in E.C.

4002-20

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

19Y B Hood Down Relay Fused Power

Or 1.0 GXL

SPL-HOOD, Ultrasonic

ECC, Elect Cntr C

19Y C Hood Switch Fused Power

Or 1.0 GXL

Cabe2, Cab to ENG2 BULKHD

SPL-HOOD, Ultrasonic

19Y D Hood Switch Fused Power

Or 1.0 GXL

ENG2, ENG BULKHD 2

HD, Hood Switch

Driving Lights Sw Fused Power

Or 1.0 GXL

SPL_DR, Ultrasoic

ECC, Elect Cntr C

19Z A Driving Lights Sw Fused Power

Or 1.0 GXL

SDR, Driving Lights Sw

SPL_DR, Ultrasoic

19Z B Driving Lights Sw Fused Power

Or 1.0 GXL

SDR, Driving Lights Sw

SPL_DR, Ultrasoic

19Z C High Beam Flash Fused Power

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56d

SPL_DR, Ultrasoic

Cab CB Protected Power

R 19.0 SXL

P C3, B+ PWR FRM PRMD

CBPW, Cab Power

1CB A Cab CB Protected Power

R 19.0 SXL

P-A3, B+ Power

CAB-PW, Cab Power

19Z

1CB

1DM

Time Delay/Ign Sw Fused Pwr

R 1.0 GXL

S_KEY, Ignition Switch

ECC, Elect Cntr C

1 AA

Brake Lt Sw Pwr

R 1.0 SXL

BTM_C, Cab Bottom BULKHD

PBL, Brake Light Press Switch

EVGT Relay Power

R 1.0 GXL

EVGT 3, EVGT Fuse

EVGT 4, EVGT

1 BA

Alternator B+

R 13.0 SXL

AB+, Alternator B+

B2 Starter Power

1 BB

Starter Solenoid Pwr

R 8.0 SXL

193 Starter Relay

194 Starter Signal

1 BE

Grid Htr Pwr

R 19.0 SXL

115 Grid Htr Pwr

GH, Grid Htr

1 BF

Alternator B+

R 13.0 SXL

AB 5, Alternator B+

B6, Starter Power

1 BG

B+ PWR PRMC

R19_0-SXL

B5, Starter Pwr Stud

P C1, B+ Pwr frm prmd

ECC Bat Power

R 8.0 GXL

P-A1, B+ Power

L1-ECC, ECC Battery Power

1 DR

Brake Light Switch Power

R 1.0 GXL

Cab B, Cab BTM Bulkhead

SPL-FLSHR-PWR, Ultrasonic

1 DU

Flasher Module Pwr

R 1.0 GXL

FLSHR, Flasher Module

SPL-FLSHR-PWR, Ultrasonic

1 DV

Brake Lights/Flasher Bat Pwr

R 2.0 GXL

SPL-FLSHR-PWR, Ultrasonic

ECC, Elect Cntr C

1 DW

Brake Lt Relay Bat Pwr

R 1.0 GXL

SPL-FLSHR-PWR, Ultrasonic

ECD, Elect Cntr D

Grid heater Fuse Bat Power

R 19.0 SXL

P-C2, B+ Power from PRMD

GHF1, Grid Heater Fuse

1 GA

Filter Htr Pwr

R 3.0 SXL

PRM-D1, PRM Output

SPL-HTR, Ultrasonic

1 GB

Fuel Filter Htr Pwr

R 2.0 SXL

SPL-HTR, Ultrasonic

FFH, Fuel Filter Heater

1 GC

Water Sep Htr Pwr

R 2.0 SXL

SPL-HTR, Ultrasonic

WSH, Water Separator Heater

1 KA

Hazard Switch Pwr

R 1.0 GXL

SHZ, Hazard Switch

SPL-FLSHR-PWR, Ultrasonic

1 NA

Battery Crossover

R 62.0 SGR

BT3, Starter Battery

BT2, Disconnect Battery

1 NB

Battery Starter

R 62.0 SGR

BT1, Battery Starter

DC1, Disconnect Battery

84547255A

Issued 11-11

Printed in E.C.

4002-21

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

1 NC

B+ Power PRMC

R 19.0 SXL

B1, Starter Power Stud

P-C1, B+ Power From PRMD

1 ND

SSM Power

R 62.0 SGR

244F Starter Sec. Strg Mtr

B4, Starter Power

1 NE

Battery Starter

R 62.0 SGR

B7, Starter Battery

BT1, Battery Starter

1 NF

SSM Pwr

R 62.0 SGR

B8, Starter Power

244F, Starter-Sec Strg Mtr

1 NG

Power Non Disconnected

R 8.0 SXL

BT1, Battery Starter

PW-B, Cab Power

1 NH

Power Non Disconnected

R 8.0 SXL

SPL 1N, Ultrasonic

PW-E, Cab Power

1 NJ

Power Non Disconnected

R 3.0 SXL

ENG2, ENG BULKHD 2

SPL 1N, Ultrasonic

1 NK

Power Non Disconnected

R 3.0 SXL

ENG2, ENG BULKHD 2

SPL 1N, Ultrasonic

1 NL

Power Non Disconnected

R 3.0 GXL

CABE2, Cab to ENG2 BULKHD

P A2, B+ Power

1 NM

Power Non Disconnected

R 3.0 GXL

CABE2, Cab to ENG2 BULKHD

P A2, B+ Power

EVGT 3 Pwr

R 1.0 SXL

P C6, B+ Pwr Frm prmd

EVGT 3, EVGT Fuse

Grid Heater Fused Power

R 19.0 SXL

GHF3, Grid heater Fuse

GHF4, Grid Heater

Starter Relay Battery Power

R 8.0 SXL

P-C4, B+, Power From PRMD

195, Starter Relay Power

20G A EDC7 ISO-K Interface

W 0.8 TXL

ENG, Engine Cab 1

EDC7, Engine Controller

20G B EDC7 ISO-K Interface

W 0.8 GXL

CAB-E, Cab Engine

DIA, Diagnostic

Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center B

21C A Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center B

21C B Neutral Start Relay Output

W 0.8 GXL

SPL-CR, Ultrasonic

ECB, Elect Center D

Starter Relay Signal

W 1.0 SXL

SRC-1, Relay

ENG, Engine Cab 1

21D A Starter Relay Signal

W 0.8 GXL

Cab E, Cab-Engine

ECB, Elect Center D

AA5

Key Switch Crank

W 0.8 GXL

ECC, Elect Cntr C

ECB, Elect Center B

21E A Key Switch Crank

W 0.8 TXL

ENG, Engine Cab 1

EDC7, Engine Controller

21E B Key Switch Crank

W 0.8 GXL

Cab E, Cab-Engine

ECC, Elect Cntr C

C10

EDC7 Digital Ground

W 0.8 GXL

CAB-E, Cab Engine

ECB, Elect Center B

21F A EDC7 Digital Ground

W 0.8 GXL

ENG, Engine Cab 1

SPL-EDC3, Ultrasonic

21F B EDC7 Digital Ground

W 0.8 TXL

SPL-EDC3, Ultrasonic

EDC7, Engine Controller

21F C EDC7 Digital Ground

W 0.8 TXL

ENG_B, Cab Bottom

SPL-EDC3, Ultrasonic

21F D EDC7 Digital Ground

W 0.8 TXL

RTHP, Throttle Pedal

BTM E, Cab Bottom

W 0.8 GXL

CAB-E, Cab Engine

ECB, Elect Center D

AA6

21C

21D

21E

21F

21G

EDC7 Crank Control relay

84547255A

Issued 11-11

Printed in E.C.

4002-22

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

21G A EDC7 Crank Control relay

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

W 0.8 TXL

ENG, Engine Cab 1

EDC7, Engine Controller

Crank control relay LSD

W 0.8 GXL

CAB-E, Cab Engine

ECD, Elect Center D

21H A Crank control relay LSD

W 0.8 TXL

ENG, Engine Cab 1

EDC7, Engine Controller

TEL, Telematics

21H

21J

Restart Prevent

W 0.8 GXL

ECC, Elect Cntr C

21K

Ign Sw Start Signal

W 0.8 GXL

S-KEY, Ignition Switch

SPL-CRK, Ultrasonic

21K A Ign Sw Start Signal

W 0.8 TXL

SPL-CRK, Ultrasonic

AIC-2, Adv Instrument Cluster 2

21K B Ign Sw Start Signal

W 0.8 GXL

SPL-CRK, Ultrasonic

ECB, Elect Center B

22A

Declutch SW

DU 0.8 TXL

SDC, Declutch Switch

TECM, Trans

22B

Pedal Sensor +5V

K 0.8 TXL

Cab_B, Cab BTM BULKHEAD

TECM, Trans

22C

Pedal Pos Signal

Y 0.8 TXL

TECM, Trans

Cab B, Cab BTM BULKHEAD

22D

Pedal Sensor Grnd

LU 0.8 TXL

Cab_B, Cab BTM BULKHEAD

TECM, Trans

22E

Pedal Sensor +5V

K 0.8 TXL

BTM_C, Cab Bottom BULKHD

BPP, Pedal Position

22F

Pedal Pos Signal

Y 0.8 GXL

BTM_C, Cab Bottom BULKHD

BPP, Pedal Position

22G

Pedal Sensor Grnd

LU 0.8 GXL

BTM_C, Cab Bottom BULKHD

BPP, Pedal Position

23A A DNOX2 Module B+

N 0.8 TXL

NOXS, NOX Sensor

ENG2, ENG BULKHD 2

23B A NOX Sensor B+

OR 0.8 GXL

CabE2, Cab to ENG2 BULKHD

ECD, Elec Cntr D

23B B NOX Sensor B+

N 0.8 GXL

CabE2, Cab to ENG2 BULKHD

ECD, Elec Cntr D

AA7

23B C NOX Relay Gnd

BK 0.8 GXL

ECD, Elec Cntr D

GND Cab_SPL, Cab Grnd Splice

23B D NOX Relay, B+

OR 0.8 GXL

CabE2, Cab to ENG2 BULKHD

ECD, Elec cntr D

23B E NOX Sensor B+

OR 1.0 GXL

SPL EDC2, Ultrasonic

ENG2, ENG BULKHD 2

23B F NOX Relay B+

OR 1.0 SXL

SPL EDC4, Ultrasonic

ENG2, ENG BULKHD 2

23D D NOX Sensor Gnd

BK 0.8 TXL

NOXS, NOX Sensor

GND ENG2 Dedicated, WIF, EDC

23J B DNOX2 K-Line

W 0.8 GXL

Cab E, Cab-Engine

DIA 2, Diagnostic

23K A Temp/Humd B+

K 0.8 TXL

HTS, HMDTY And AMB Temp

EDC7, Engine Controller

23K B Temp/Humd Temp

Y 0.8 GXL

HTS, HMDTY And AMB Temp

EDC7, Engine Controller

23K C Temp/Humd Humd

Y 0.8 GXL

HTS, HMDTY And AMB Temp

EDC7, Engine Controller

23K E Temp/Humd Gnd

LU 0.8 GXL

EDC7, Engine Controller

HTS, HMDTY And Amb Temp

Throttle Signal

W 0.8 TXL

ENG B, Cab Bottom

EDC7, Engine Controller

24B A Throttle Signal

W 0.8 TXL

RTHP, Throttle Pedal

BTM E, Cab Bottom

24B

84547255A

Issued 11-11

E AA8

Printed in E.C.

4002-23

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire 24L

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

W 0.8 TXL

ENG B, Cab Bottom

EDC7, Engine Controller

W 0.8 TXL

RTHP, Throttle Pedal

BTM_E, Cab Bottom

Throttle Grnd

W 0.8 TXL

ENG B, Cab Bottom

EDC7, Engine Controller

24R A Throttle Grnd

W 0.8 TXL

RTHP, Throttle Pedal

BTM E, Cab Bottom

Throttle Supply

W 0.8 TXL

ENG B, Cab Bottom

EDC7, Engine Controller

24S A Throttle Supply

W 0.8 TXL

RTHP, Throttle Pedal

BTM E, Cab Bottom

24T B TC Lockup Sol Gnd

LU 1.0 SXL

YLS, TC Lockup Valve

Trans, Transmission-Cab

255E

Pedal Sensor +5V

K 0.8 TXL

BTM-C, Cab Bottom Bulkhd

BPP, Pedal Position

25A

Eng Speed Sig

LU 0.8 GXL Twist

TRANS, Cab Transmission

ESS, Engine speed Sensor

25A A Eng Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Int Speed Sig

LU 0.8 GXL Twist

TRANS, Cab Transmission

ISS, Int Speed Sensor

25B A Int Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Turbine Speed Sig

LU 0.8 GXL Twist

TRANS, Cab Transmission

TSS, Turbine Speed Sensor

25C A Turbine Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Output Speed Sig

LU 1.0 SXL

TRANS, Cab Transmission

OSS, Output Speed Sensor

25D A Output Speed Sig

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Low Idle Sw

24L A Low Idle Switch 24R

24S

25B

25C

25D

25F

Forward Signal

LU 0.8 TXL

TS1, Transmission Shifter

TECM, Trans

25G

Brake Declutch Switch Ctrl

LU 1.0 SXL

Trans, Transmission-Cab

PBD, Declutch Pressure Switch

25G A Brake Declutch Switch Ctrl

LU 0.8 GXL

Cab T, Cab-Transmission

SPL-DC, Ultrasonic

25G B Brake Declutch Switch Ctrl

LU 0.8 GXL

SDC, Declutch Switch

SPL-DC, Ultrasonic

25G C Brake Declutch Switch Ctrl

LU 0.8 TXL

SPL-DC, Ultrasonic

TECM, Trans

25H

Trans Auto Signal

LU 0.8 TXL

STA, Trans Auto Switch

TECM, Trans

25J

Trans Sol Valve Y6

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25J A Trans Sol Valve Y6

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Trans Sol Valve Y1

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25K 9 Trans Sol Valve Y2

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25K A Trans Sol Valve Y1

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

25K

25L

Trans Sol Valve Y2

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25L 9

Trans Sol Valve Y1

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

84547255A

Issued 11-11

Printed in E.C.

4002-24

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

25L A Trans Sol Valve Y2

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

25M

Trans Sol Valve Y3

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25M A Trans Sol Valve Y3

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Trans Sol Valve Y4

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25N A Trans Sol Valve Y4

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Trans Sol Valve Y5

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

25P A Trans Sol Valve Y5

LU 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

LU 0.8 TXL

TS1, Transmission Shifter

TECM, Trans

25R A TC Lockup Sol Power

LU 0.8 TXL

TECM, Transmission

Cab T, Cab-Transmission

25R B TC Lockup Sol Power

LU 1.0 SXL

YLS, TC Lockup Valve

Trans, Transmission-Cab

Output Sw Power VPS1

LU 0.8 TXL

TRANS, Cab Transmission

TRC, Transmission Control

25S A Output Sw Power VPS1

LU 0.8 TXL

CAB-T, Cab Transmission

SPL D12, Ultrasonic

25S B Output Sw Power VPS1

LU 0.8 TXL

SPL D12 Ultrasonic

TECM, Trans

25S C Output Sw Power VPS1

LU 0.8 TXL

SPL D12 Ultrasonic

TECM, Trans

LU 0.8 GXL

SPL-NEU, Ultrasonic

ECB, Elect Center B

25T A TC Lockup Sol Gnd

W 0.8 TXL

SPL_D19, Ultrasonic

Cab T, Cab-Transmission

25T B Neutral Signal

LU 0.8 GXL

TS1, Transmission Shifter

SPL-NEU, Ultrasonic

25T C Neutral Signal

LU 0.8 TXL

SPL-NEU, Ultrasonic

TECM, Trans

25W

3rd And 4th Gear Signal

LU 0.8 TXL

TS2, Transmission Shifter

TECM, Trans

25Y

Trans Kick Down Signal

LU 0.8 GXL

TS2, Transmission Shifter

SPL D11, Ultrasonic

25Y A Trans Kick Down Signal

LU 0.8 TXL

SPL D11, Ultrasonic

TECM, Trans

25Y B Trans Kick Down Signal

LU 0.8 GXL

197F, Main Cab FNR

SPL D11, Ultrasonic

25Y C Trans Kick Down Signal

LU 0.8 GXL

20M, Trans Kick Down

197M, FNR Main Cab

25Y D Trans Kick Down Signal

LU 0.8 GXL

KD_Diode, Diode Assy

JSS 197M, FNR Main Cab

25Y E Trans Kick Down Signal

LU 0.8 GXL

Cab Fnr, Main Cab Fnr

KD Diode, Diode Assy

25Y F Trans Kick Down Signal

LU 0.8 GXL

KD Diode, Diode Assy

JSS 197F, Main Cab FNR

25Y G Trans Kick Down Signal

LU 0.8 GXL

21M, Trans Kick-Down

Arm FNR, FNR-Main Cab

LU 0.8 TXL

TS2, Transmission Shifter

TECM, Trans

26E A Trans Enable Signal

LU 0.8 TXL

STE, Trans Enable Switch

TECM, Trans

26F A FNR Forward Signal

LU 0.8 GXL

197M, FNR Main Cab

SFNR, FNR Switch

26F B FNR Forward Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

25N

25P

25R

25S

25T

25Z

Reverse Signal

Neutral Signal

1st And 4th Gear Signal

84547255A

Issued 11-11

Printed in E.C.

4002-25

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

26F C FNR Forward Signal

LU 0.8 GXL

FWD Diode, Diode Assy

JSS 197M, FNR-Main Cab

26F D FNR Forward Signal

LU 0.8 GXL

JSS 197F, Main Cab FNR

FWD Diode, Diode Assy

26F E FNR Forward Signal

LU 0.8 GXL

Cab FNR, Main Cab FNR

FWD Diode, Diode Assy

26F F FNR Forward Signal

LU 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR Main Cab

26J

FNR Switch Jumper

LU 0.8 GXL

SFNR, FNR Switch

26K

FNR Switch Jumper

LU 0.8 GXL

SAJ, FNR Switch

26N A FNR Neutral Signal

LU 0.8 GXL

SFNR, FNR Switch

197M, FNR Main Cab

26N B FNR Neutral Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

26N C FNR Neutral Signal

LU 0.8 GXL

JSS 197M, FNR-Main Cab

Ntrl Diode, Diode Assy

26N D FNR Neutral Signal

LU 0.8 GXL

JSS 197F, Main Cab FNR

Ntrl Diode, Diode Assy

26N E FNR Neutral Signal

LU 0.8 GXL

Ntrl Diode, Diode Assy

Cab FNR, Main Cab FNR

26N F FNR Neutral Signal

LU 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR-Main Cab

26R A FNR Reverse Signal

LU 0.8 GXL

SFNR, FNR Switch

197M, FNR Main Cab

26R B FNR Reverse Signal

LU 0.8 TXL

197F, Main Cab FNR

TECM, Trans

26R D FNR Reverse Signal

LU 0.8 GXL

JSS 197F, Main Cab FNR

RVS Diode, Diode Assy

26R E FNR Reverse Signal

LU 0.8 GXL

Cab FNR, Main Cab FNR

RVS Diode, Diode Assy

26R F FNR Reverse Signal

LU 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR-Main Cab

28F

Fuel Filter Htrs Relay Control

W 0.8 TXL

PRM-D2,PRM Signal

EDC7, Engine Controller

28G

Grid Heater Source Dr.

W 1.0 GXL

GHC, Grid Htr Relay

EDC7, Engine Controller

31A

EVGT Relay B+

OR 0.8 GXL

EVGT 4, EVGT

SPL EDC4, Ultrasonic

31B

Filter Heater Control

OR 0.8 GXL

PRM D2, PRM Signal

SPL EDC4, Ultrasonic

31F

Air Filter Rest Sw Signal

Y 1.0 SXL

ENG, Engine Cab 1

PAF, Air Filter Rest Sw

31F A Air Filter Rest Sw Signal

Y 0.8 TXL

CAB-E, Cab Engine

SW-PD, Switch Pad

31H

Hyd Filter Rest Sw Signal

Y 1.0 SXL

TRANS, Cab Transmission

PHF, Hyd Oil Filter Rest Sw

31H9

Hyd Filter Rest Sw 9

Y 1.0 SXL

Trans, Transmission Cab

PHF9, Hyd Oil Filter Rest Sw

Y 0.8 GXL

SW-PD, Switch Pad

CAB-T, Cab Transmission

31H A Hyd Filter Rest Sw Signal 31L

Pilot Control Switch High

Y 0.8 TXL

SPC, Pilot Control Switch

AIC-2, Advance Instr Cluster 2

32F

Trans Filter Maint Sw

Y 1.0 SXL

TRANS, Cab Transmission

FM, Filter Maint Sw

32F A Trans Filter Maint Sw

Y 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

32J A Trans Enable Indiction

Y 0.8 GXL

SFNR, FNR Switch

197M FNR Main Cab

32J C Trans Enable Indiction

Y 0.8 GXL

STE, Trans Enable Switch

SPL-D16, Ultrasonic

84547255A

Issued 11-11

Printed in E.C.

4002-26

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

32J D Trans Enable Indiction

Y 0.8 TXL

SPL-D16, Ultrasonic

TECM, Trans

32J E Trans Enable Indiction

Y 0.8 GXL

197F, Main Cab FNR

SPL-D16, Ultrasonic

32J F

Trans Enable Indiction

Y 0.8 GXL

SPL JSS_21, Ultrasonic

JSS 197M, FNR Main Cab

32J G Trans Enable Indiction

Y 0.8 GXL

JSS 197F, Main Cab FNR

SPL JSS_21, Ultrasonic

32J H Trans Enable Indiction

Y 0.8 GXL

Cab FNR, Main Cab FNR

SPL JSS_21, Ultrasonic

32J J

Trans Enable Indiction

Y 0.8 GXL

SAJ, FNR Switch

Arm FNR, FNR Main Cab

33P

Brake Warning Press Low

Y 1.0 SXL

BTM_C, Cab Bottom BULKHD

PBW, Brake Warning Press Sw

33P A Brake Warning Press Low

Y 0.8 TXL

Cab B, Cab BTM BULKHEAD

AIC-2, Advance Instr Cluster 2

Redundant Brake Accumulator Pressure Low

Y 0.8 TXL

CAB-T, Cab Transmission

AIC-2, Advance Instr Cluster 2

33R A Redundant Brake Accumulator Pressure Low

Y 1.0 SXL

TRANS, Cab Transmission

SPL-RD, Ultrasonic

33R B Redundant Brake Accumulator Pressure Low

Y 1.0 SXL

SPL-RD, Ultrasonic

PRB2, Redundant Brake Switch

33R C Redundant Brake Accumulator Pressure Low

Y 1.0 SXL

SPL-RD, Ultrasonic

PRB1, Redundant Brake Switch

Y 0.8 TXL

SPB, Parking Brake Switch

AIC-2, Advance Instr Cluster 2

34A A Diff Lock SW B+

OR 0.8 GXL

SDA, Diff Lock Switch

SPL PBS, Ultrasonic

34A B Diff Lock SW SIG B+

OR 0.8 GXL

SDM, Diff Lock Switch

SPL PBS, Ultrasonic

34A C Diff Lock Sol B+

W 0.8 TXL

SPL D19, Ultrasonic

Cab T, CAB Transmission

34A D Diff Lock Sol B+

OR 1.0 SXL

Trans, Transmission Cab

YDL, Diff Lock Solenoid

34A E Diff Lock Sol B+

OR 1.0 SXL

YDL 1, Diff Lock Solenoid

YDL 2, Diff Lock Solenoid

33R

33U

Parking Brake Switch

34B

Diff Lock SW SIG

LU 0.8 TXL

SDA, Diff Lock Switch

TECM, Trans

34C

Diff Lock Sol GND

LU 0.8 TXL

Cab T, Cab Transmission

TECM, Trans

34C A Diff Lock Sol GND

LU 1.0 SXL

Trans, Transmission Cab

YDL, Diff Lock Solenoid

34C D Diff Lock Sol GND

LU 1.0 SXL

YDL 1, Diff Lock Solenoid

YDL 2, Diff Lock Solenoid

LU 0.8 TXL

TECM, Trans

SDM, Diff Lock Switch

35A 9 BKUP ALM RLY OUT

BK 1.0 SXL

HD-9, Hood to ENG

BU2, Backup Alarm

35A A Backup Alarm

Y 0.8 GXL

ECD, Elec Cntr D

AA9

SPL 35A, Ultrasonic

35A B Backup Alarm Disable Switch

Y 0.8 GXL

SBU, Backup Alarm Dis Sw

SPL 35A, Ultrasonic

35A C Backup Alarm Relay Out

Y 0.8 GXL

Cabe2, Cab to ENG2 BULKHD

SPL 35A, Ultrasonic

34D

Diff Lock SW SIG

84547255A

Issued 11-11

Printed in E.C.

4002-27

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

35A D Backup Alarm Relay Out

Y 0.8 GXL

209M, Backup Alarm Dis Jump

SPL 35A, Ultrasonic

35A E Backup Alarm Relay Out

Y 0.8 SXL

209F, Backup Alarm Dis Jump

SPL-D8-C1, Ultrasonic

35A F Backup Alarm Relay Out

Y 0.8 SXL

Cabe2, Cab to ENG2 BULKHD

SPL-D8-C1, Ultrasonic

35A G Backup Alarm Relay Out

Y 1.0 SXL

ENG2, ENG BULKHD 2

E-HD, Trans Hood

Backup Alarm Relay Out

Y 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

35A H Backup Alarm Relay Out

Y 1.0 SXL

HD-E, Hood Trans

BU2, Backup Alarm

Y 1.0 SXL

HD-N, Hood to Engine

BU2, Backup Alarm

35A J Revers Light

K 1.0 SXL

ENG2, ENG BULKHD 2

SPL-A1A, Ultrasonic

35A K Revers Light

K 1.0 SXL

SPL-A1A, Ultrasonic

LRR-E, RH rear Comb Light

35A L Revers Light

K 1.0 SXL

SPL-A1A, Ultrasonic

LLR-E, LH rear Comb Light

35A M Reverse Signal

Y 0.8 GXL

MON, Camera/Monitor

SPL 35A, Ultrasonic

35A N Revers Light

K 1.0 SXL

SPL, REV

LLR-9, LH Rear Comb Light

35A O Revers Light

K 1.0 SXL

HD-9, Hood to ENG

SPL, REV

35A P Revers Light

K 1.0 SXL

SPL, REV

LRR-9, RH Rear Comb Light

35A R Backup Alarm Relay Out

Y 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

35A GN

35A HN

Backup Alarm Relay Out

35B

AIC Buzzer HSD

W 0.8 TXL

BUZ, AIC Buzzer

AIC-1, Advance Instr Cluster 1

35C

Backup Alarm Relay Control

Y 0.8 GXL

ECD, Elec Cntr D

TECM, Trans

Y 0.8 GXL

SBU, Backup Alarm Dis Sw

SPL-D8-C1, Ultrasonic

35R C Backup Alarm Sw 35W

Water In Fuel Indicator

W 0.8 TXL

WIF, Water In Fuel Sensor

EDC7, Engine Controller

35X

Sec. Str Low Press Sig

Y 0.8 TXL

CAB-T, Cab Transmission

AIC-2, Advance Instr Cluster 2

35X A Sec. Str Low Press Sig

Y 1.0 SXL

SPL-C3, Ultrasonic

PSS, Sec. Steering Press Sw

35X B Sec. Str Low Press Sig

Y 1.0 SXL

TRANS, Cab Transmission

TR-SS, Sec. Steering Mod Option

35X C Sec. Str Low Press Sig

Y 1.0 SXL

SPL-C3, Ultrasonic

SS-TR, SS Module Trans

35X D Sec. Str Low Press Sig

Y 1.0 SXL

SSM, Sec. Steering Module

SPL-C3, Ultrasonic

Radiator Cool Temp Signal

P 1.0 GXL

ENG, Engine Cab 1

RECT, Engine Coolant Temp

36C A Radiator Cool Temp Signal

P 0.8 TXL

CAB-E, Cab Engine

AIC-1, Advance Instr Cluster 1

Fuel Level Analog

P 1.0 SXL

ENG, Engine Cab 1

RFL, Fuel Sender

36F A Fuel Level Analog

P 0.8 TXL

CAB-E, Cab Engine

AIC-1, Advance Instr Cluster 1

36C

36F

84547255A

Issued 11-11

Printed in E.C.

4002-28

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

Torque Conv Output Temp Signal

P 1.0 SXL

TRANS, Cab Transmission

TCOT, TCO Sender

36G A Torque Conv Output Temp Signal

P 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

P 1.0 SXL

TRANS, Cab Transmission

HOT, Hydraulic Oil Temp Sender

P 0.8 TXL

CAB-T, Cab Transmission

AIC-1, Advance Instr Cluster 1

Fuel Level Analog

P 1.0 SXL

ENG, Engine Cab1

RFL 23, Fuel Level Sender

36R A Trans Temps/Filter Return

P 1.0 SXL

TRANS, Cab Transmission

SPL H1, Ultrasonic

36R B Trans Filter Maint Sw Return

P 1.0 SXL

SPL H1, Ultrasonic

FM, Filter Maint Switch

36R C Valve Body Temp Return

P 0.8 TXL

SPL H1, Ultrasonic

TRC, Trans Control

36R D TCO Temp Return

P 1.0 SXL

SPL H1, Ultrasonic

TCOT, TCO Sender

36R E Trans Temps/Filter Return

P 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

Valve Body Temp Sig

P 0.8 TXL

TRANS, Cab Transmission

TRC, Trans Control

36T A Valve Body Temp Sig

P 0.8 TXL

CAB-T, Cab Transmission

TECM, Trans

37D A Diagnostic Signal

P 0.8 TXL

108F, Diagnostic Connector

TECM, Trans

36G

36H

Hydraulic Oil Temp Signal

36H A Hydraulic Oil Temp 36J

36T

37E

Diagnostic Signal Switched

P 0.8 TXL

108F, Diagnostic Connector

TECM, Trans

38A

Doser Valve GND

LU 0.8 GXL

DNOX2, NOX Controller

DEFDM, Doser Metering Valve

38B

Def Level Sig

Y 0.8 GXL

UBJ, Def Level Temp

DNOX2, NOX Controller

38B A Def Level Sig

Y 0.8 GXL

UBJM, Def Level Temp

DTLTS, Def Tank Level Temp Sensor

38C

Tank Heat GND

LU 0.8 TXL

DNOX2, NOX Controller

THV, Tank Heater Control Valve

38D

Tank Heat B+

OR 0.8 TXL

DNOX2, NOX Controller

THV, Tank Heater Control Valve

38E

Exht Temp DWN B+

Y 0.8 GXL

DNOX2, NOX Controller

DTS, Downstream Temp Sens

38F

Exht up Signal

Y 0.8 GXL

UTS, Upstream Temp Sense

DNOX2, NOX Controller

38G

Def Temp Sig

Y 0.8 GXL

UBJ, Def Level Temp

DNOX2, NOX Controller

38G A Def Temp Sig

Y 0.8 GXL

UBJM, Def Level Temp

DTLTS, Def Tank Level Temp Sensor

38H

DNOX2 K-line

W 0.8 TXL

DNOX2, NOX Controller

ENG, Engine-Cab1

401B

Pedal Pos Signal

Y 0.8 GXL

BTM_C, Cab Bottom BULKHD

BPP, Pedal Position

41H A High Beam Pwr

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56a

SPL HB, Ultrasonic

41H B High Beam LH Pwr

Or 0.8 GXL

SPL HB, Ultrasonic

ECB, Elect Center B

41H C High Beam RH Pwr

Or 0.8 GXL

SPL HB, Ultrasonic

ECB, Elect Center B

84547255A

Issued 11-11

Printed in E.C.

4002-29

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

41H D High Beam Pwr

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

Or 0.8 TXL

SW-PD, Switch Pad

SPL HB, Ultrasonic

Or 1.0 GXL

SDR, Driving Lights Switch

SRHSTLK, RH Stalk Switch

41L A Low Beam Power

Or 1.0 GXL

SRHSTLK, RH Stalk Switch

56b

SPL-LB, Ultrasonic

41L B Low Beam RH Power

Or 0.8 GXL

SPL-LB, Ultrasonic

ECB, Elect Center B

41L C Low Beam LH Power

Or 0.8 GXL

SPL-LB, Ultrasonic

ECB, Elect Center B

K 1.0 GXL

SDR, Driving Lights Switch

SPL PR, Ultrasonic

41T A Position Lights RH Switched Pwr K 1.0 GXL

SPL PR, Ultrasonic

ECB, Elect Center B

41T B Position Lights LH Switched Pwr K 1.0 GXL

SPL PR, Ultrasonic

ECB, Elect Center B

41T C Position Lights Switched Pwr

K 1.0 GXL

D-OR, Diode OR

SPL-PR, Ultrasonic

42C A Front Work Lights Fused Pwr

DU 2.0 GXL

CAB-RF, Cab to Roof Conn.

SPL-42C Ultrasonic

42C C Front Work Lights Fused Pwr

DU 2.0 GXL

SPL-42C Ultrasonic

SWL, Work lights SW

42C D Front Work Lights Fused Pwr

DU 1.0 GXL

SPL-42C Ultrasonic

D-OR, Diode OR

42C F Front Work Lights Fused Pwr

DU 2.0 GXL

ROOF, Roof to Cab Conn.

SPL-WRKF, Ultrasonic

42C G RH Front Work Lights Fused Pwr DU 1.0 GXL

SPL-WRKF, Ultrasonic

LRFW, RH Front Work Light

42C H LH Front Work Lights Fused Pwr DU 1.0 GXL

SPL-WRKF, Ultrasonic

LLFW, LH Front Work Light

42R A RH Front Work LTS Fused Pwr

DU 1.0 GXL

LRFS, Front Wk LT Opt

SPL Wrk1, Ultrasonic

42R B RH Front Work LTS Fused Pwr

DU 1.0 GXL

SPL Wrk1, Ultrasonic

LRFR, Front Wk LT Opt

42R C Rear Work Lights Fused Pwr

DU 2.0 GXL

CAB-RF, Cab to Roof Conn.

SWL, Work lights SW

42R F Rear Work Lights Fused Pwr

DU 2.0 GXL

ROOF, Roof to Cab Conn.

SPL-WRKR, Ultrasonic

42R G RH Rear Work Lt Fused Pwr

DU 1.0 GXL

SPL-WRKR, Ultrasonic

LRRW, RH Rear Work Light

42R H LH Rear Work Lt Fused Pwr

DU 1.0 GXL

SPL-WRKR, Ultrasonic

LLRW, LH Rear Work Light

42R K RH Front Work LTS Fused Pwr

DU 1.0 GXL

SPL WRK1, Ultrasonic

LRFO, Front Wk LT Opt

41J

41T

Driving Light Power

Position Lights Switched Pwr

42 A

Work Lights Fused Power

R 2.0 GXL

SWL, Work Lights Switch

SPL-WL, Ultrasonic

42 B

Work Lights Fused Power

R 1.0 GXL

SWL, Work Lights Switch

SPL-WL, Ultrasonic

43S A Door Open Signal

W 0.8 GXL

CAB-RF, Cab to Roof Conn.

AIC 2, ADV Instr Cluster 2

43S B Door Open Signal

W 0.8 GXL

ROOF, Roof to Cab Conn.

DS, Door Switch

43 A

Dome Light Auto Mode

DU 0.8 TXL

CAB-RF, Cab to Roof Conn.

AIC-1, Adv Instrument Cluster 1

43 B

Dome Light Auto Mode

DU 0.8 GXL

ROOF, Roof to Cab Conn.

LDM2, Dome Light Auto

44A A Brake Light Relay Out

T 0.8 GXL

Cabe2, Cab to ENG2 BULKHD

ECD, Elec Cntr D

AA1

44A D Brake Light Relay Out

T 1.0 SXL

ENG2, ENG BULKHD 2

SPL-B8, Ultrasonic

84547255A

Issued 11-11

Printed in E.C.

4002-30

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

2.0 mm 5.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification Wire 44A DN

Circuit

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

Brake Light Relay Out

T 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

44A E Brake Light Relay Out

T 1.0 SXL

LLR-E, LH Rear Comb Light

SPL-B8, Ultrasonic

Brake Light Relay Out

T 1.0 SXL

HD-N, Hood to Engine

SPL-J2-N, Ultrasonic

44A F Brake Light Relay Out

T 1.0 SXL

LRR-E, RH Rear Comb Light

SPL-B8, Ultrasonic

44A EN

44A FN

Brake Light Relay Out

T 1.0 SXL

LLR, LH Rear Comb Light

SPL-J2-N, Ultrasonic

44A GN

Brake Light Relay Out

T 1.0 SXL

LRR, RH Rear Comb Light

SPL-J2-N, Ultrasonic

44A J Brake Light Relay Out

T 1.0 SXL

HD-9, Hood to Engine

SPL, L1

44A K Brake Light Relay Out

T 1.0 SXL

SPL, L1

LRR-9, RH Rear Comb. LT

44A L Brake Light Relay Out

T 1.0 SXL

SPL, L1

LRR-9, LH Rear Comb. LT

44 A

T 0.8 GXL

Cab_B, Cab BTM BULKHEAD

ECD, Elec Cntr D

45A A Left Turn Switch Power

N 0.8 GXL

FLSHR, Flasher Module

SRHSTLK, RH Stalk Switch

45B A Right Turn Switch Power

N 0.8 GXL

FLSHR, Flasher Module

SRHSTLK, RH Stalk Switch

Brake Light Control Power

AA2

45H

Hazard Switch Power

N 0.8 GXL

FLSHR, Flasher Module

SHZ, Hazard Switch

45L

Left Turn Signal

N 1.0 SXL

FRONT, Cab Front Chassis

LLF, Lights LH

45L A Left Turn Signal

N 1.0 SXL

ENG2, ENG BULKHD 2

LLR-E, LH Rear Comb Light

45L AN Left Turn Signal

N 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

45L B Left Turn Signal

N 0.8 GXL

Cabe2, Cab to ENG2 BULKHD

SPL-PK3, Splice 3-4 Way

45L BN Left Turn Signal

N 1.0 SXL

HD-N, Hood to Engine

LLR, LH Rear Comb Light

45L C Left Turn Signal

N 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PK3, Splice 3-4 Way

45L D Left Turn Signal

N 0.8 GXL

FLSHR, Flasher Module

SPL-PK3, Splice 3-4 Way

45L E Left Turn Signal

N 0.8 TXL

SPL-PK3, Splice 3-4 Way

AIC-2, Adv Instrument Cluster 2

45L N Left Turn Signal

N 1.0 SXL

HD-9, Hood to Engine

LLR-9, LH Rear Comb. LT

45N A Flasher OPP Side Control

N 0.8 GXL

FLSHR, Flasher Module

64F, Flasher Connector

45N B Flasher OPP Side Control

N 0.8 GXL

FLSHR, Flasher Module

64M, Flasher Connector

Right Turn Signal

N 1.0 SXL

FRONT, Cab Front Chassis

LRF, Lights RH

45R 9 Right Turn Signal

N 1.0 SXL

HD-9, Hood to Engine

LRR-9, RH Rear Comb. LT

45R A Right Turn Signal

N 1.0 SXL

ENG2, ENG BULKHD 2

LRR-E, RH Rear Comb Light

45R

84547255A

Issued 11-11

Printed in E.C.

4002-31

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire 45R AN

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

Right Turn Signal

N 1.0 SXL

ENG2, ENG BULKHD 2

ENG-H, Engine to Hood

45R B Right Turn Signal

N 0.8 GXL

Cabe2, Cab to ENG2 BULKHD

SPL-PK3, Splice 3-4 Way

Right Turn Signal

N 1.0 SXL

HD-N, Hood to Engine

LRR, RH Rear Comb Light

45R C Right Turn Signal

N 0.8 TXL

SPL-PK3, Splice 3-4 Way

AIC-2, Adv Instrument Cluster 2

45R D Right Turn Signal

N 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PK3, Splice 3-4 Way

45R E Right Turn Signal

N 0.8 GXL

FLSHR, Flasher Module

SPL-PK3, Splice 3-4 Way

460 A

Y 0.8 TXL

CAB-E, CAB-Engine

AIC-2, Adv Instrument Cluster 2

45R BN

46 C

Beacon Switched Power

K 1.0 GXL

CAB-RF, Cab to Roof Conn.

SBE, Beacon Switch

46 D

Beacon Switched Power

K 1.0 GXL

ROOF, Roof to Cab Conn.

LBEPWR, Light Beacon power

49A

Back Light Power

S 0.8 GXL

HVAC1, HVAC1

SPL-BCK-LGT, Spl Back Lgt Pwr

49S

Back Light Power

S 0.8 GXL

STA, Trans Auto Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 A

Back Light Power

S 0.8 GXL

SWL, Work Lights Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 B

Back Light Power

S 0.8 GXL

SBE, Beacon Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 C

Back Light Power

S 0.8 GXL

SRWP, Rear Wiper Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 D

Back Light Power

S 0.8 GXL

SHZ, Hazard SWitch

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

49 E

Back Light Power

S 0.8 GXL

SPL-BCK-LGT2, Spl Back Lgt Pwr

SPL-BCK-LGT, Spl Back Lgt Pwr

49 F

Back Light Power

S 0.8 GXL

SPE, Pin Engage Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 G

Back Light Power

S 0.8 GXL

SRC, Ride control Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 H

Back Light Power

S 0.8 GXL

STE, Trans Enable Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 J

Back Light Power

S 0.8 GXL

SRTD, Detent Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 K

Back Light Power

S 0.8 GXL

SFL, Return to Travel Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 L

Back Light Power

S 0.8 GXL

SBU, Back Up Alarm Dis Sw

SPL-BCK-LGT, Spl Back Lgt Pwr

49 M

Back Light Power

S 0.8 GXL

SHC, Height Control Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 N

Back Light Power

S 0.8 GXL

SPC, Pilot Control Switch

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

84547255A

Issued 11-11

Printed in E.C.

4002-32

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

49 P

Back Light Power

S 0.8 GXL

SDR, Driving Lights Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 Q

Back Light Power

S 0.8 GXL

SFC, Fan Control Switch

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 R

Back Light Power

S 0.8 GXL

SDC, Declutch Switch

SPL-BCK-LGT, Spl Back Lgt Pwr

49 S

Back Light Power

S 0.8 GXL

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

SPL-BCK-LGT2, Spl Back Lgt Pwr

49Y A Back Light Power

S 0.8 TXL

MH, Heated Mirror

SPL-BCK-LGT, Spl Back Lgt Pwr

49Y B Back Light Power

S 0.8 GXL

MHS, Trans Enable SW

MH-C, Heated Mirror

49 T

Back Light Power

S 0.8 GXL

SFWW, Front Wiper/Washer

SPL-BCK-LGT2, Spl Back Lgt Pwr

49 V

Back Light Power

S 0.8 GXL

SPB, Parking Brake Switch

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

49 W

JSS Back Light

S 0.8 GXL

SJS, Joystick Control SW

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

49 X

Back Light AIC

S 0.8 TXL

SW PD, Switch Pad

SPL-PED-BL, Spl Back Lgt Pwr 6 Pck

49 Z

Back Light PWR

S 0.8 GXL

SPL-BCK-LGT2, SPL_Back Lgt Pwr

SDA, Diff Lock Switch

51B A JSS ACT SW

W 0.8 GXL

SPL-JSS 2, Ultrasonic

SJS, Joystick Control SW

51B B JSS ACT SW

W 0.8 GXL

SJS, Joystick Control SW

SPL-JSS 2, Ultrasonic

51B C JSS ACT SW

W 0.8 GXL

JSS Cab, JSS Cab

SPL-JSS 2, Ultrasonic

51B D JSS ACT SW

W 0.8 GXL

Cab Arm FRM, Cab to Arm to FRM

SPL-JSS 7, Ultrasonic

51B E B+, JSS

W 0.8 GXL

JSS-RLY, Relay K2

SPL-JSS 7, Ultrasonic

51B G B+, JSS

W 0.8 GXL

SPL-JSS 7, Ultrasonic

JSS RLY, Relay K2

51B H JSS ACT SW

W 0.8 GXL

SPL-JSS 7, Ultrasonic

Cab Arm, Cab to Armrest

51B J JSS ACT SW

BK 0.8 TXL

JSS arm, JSS Armrest to Cab

CAN MOD_2, JSS CAN MOD

51B K JSS Power

W 0.8 GXL

FNR Rly, relay K2

SPL JSS_4, Ultrasonic

51C A JSS ACT BTN

Y 0.8 GXL

JSS Cab, JSS Cab

SJS, Joystick Control SW

51C B JSS ACT BTN

Y 0.8 GXL

Cab Arm FRM, Cab to Arm to FRM

JSS CNT, JSS Controller

51D A GRND, Relay Ctrl

BK 0.8 GXL

JSS Cab, JSS Cab

AIC 1, ADV Instr Cluster 1

51D B GRND, Relay Ctrl

BK 0.8 GXL

Cab Arm FRM, Cab to Arm to FRM

JSS RLY, Relay K2

84547255A

Issued 11-11

Printed in E.C.

4002-33

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

51E A Armrest Lower

OR 0.8 GXL

JSS CNT, JSS Controller

Cab Arm, Cab to Armrest

51E B Armrest Lower

OR 0.8 GXL

JSS Arm, JSS Armrest to Cab

Arm Pos, Arm Position

51F A LS Press SW SIG

G 1.0 GXL

JSS LS, JSS Load Sense

JSS FRM, JSS Frame to Cab

51F B LS Press SW

G 0.8 GXL

Cab FRM, Cab to JSS Frame

JSS CNT, JSS Controller

51F C LS Press SW SIG

G 1.0 GXL

JSS FRM, JSS Frame to Cab

JSS LS2, JSS Load Sense

51H B Joystick Signal

Y 0.8 GXL

JSS CNT, JSS Controller

Cab Arm, Cab to Armrest

51H C Joystick Signal

Y 0.8 GXL

JSS Arm, JSS Armrest to Cab

PVRES, JSS Joystick

51J A Valve Alarm

P 0.8 GXL

SPL JSS_11, Ultrasonic

Cab FRM, Cab to JSS frame

51J B Valve Alarm

P 0.8 GXL

JSS CNT, JSS Controller

SPL JSS 11, Ultrasonic

51J C JSS Alarm

P 1.0 GXL

JSS Valve, JSS HYD Valve

JSS FRM, JSS Frame to Cab

51J D Valve Alarm

P 0.8 GXL

SPL JSS 11, Ultrasonic

R1, Resistor

51K B Pilot Press SW

G 0.8 GXL

Cab FRM, Cab to JSS Frame

JSS CNT, JSS Controller

51K C Pilot Press SW SIG

G 1.0 GXL

JSS PIL PR, JSS Pilot Pressure

JSS FRM, JSS Frame to Cab

Joystick Signal

Y 1.0 GXL

JSS Valve, JSS HYD Valve

JSS FRM, JSS Frame to Cab

51L A Joystick Signal

Y 0.8 GXL

JSS CNT, JSS Controller

CAB FRM, Cab to JSS Frame

51NC

BK 0.8 TXL

PVRES, JSS Joystick

CAN MOD 2, JSS CAN MOD

51NO NC Neutral SW

Y 0.8 GXL

JSS Arm, JSS Armrest to Cab

PVRES, JSS Joystick

51NO NC Neutral SW A

P 0.8 GXL

Cab Arm, Cab to Armrest

JSS CNT, JSS Controller

51PW JSS Power H

W 1.0 SXL

SPL JSS_16, Ultrasonic

JSS FRM, JSS Frame to Cab

51PW JSS Power J

W 1.0 SXL

JSS LS, JSS Load Sense

SPL JSS 16, Ultrasonic

51PW JSS Power K

W 1.0 SXL

SPL JSS 16, Ultrasonic

JSS Pil Dump, JSS Pilot Dump

51 PW JSS Power L

W 1.0 GXL

SPL JSS 16, Ultrasonic

JSS LS2, JSS Load Sense

51PW JSS Power M

W 0.8 GXL

SPL JSS 6, Ultrasonic

Cab Arm FRM, Cab to Arm to FRM

51PW JSS Power N

W 0.8 GXL

JSS Cab, JSS Cab

SJS, Joystick_Control SW

51PW JSS Power P

W 0.8 GXL

JSS Rly, Relay K2

SPL JSS 4, Ultrasonic

51L

NC Neutral SW

84547255A

Issued 11-11

CS0

Printed in E.C.

4002-34

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

51PW JSS Power Q

W 0.8 GXL

JSS Cnt, JSS Controller

SP JSS 4, Ultrasonic

51PW JSS Power R

W 0.8 GXL

SPL JSS 6, Ultrasonic

Cab Arm, Cab to Armrest

51PW JSS Power S

W 0.8 GXL

SPL JSS 13, Ultrasonic

JSS Arm, JSS Armrest to Cab

51PW JSS Power T

W 0.8 GXL

SPL JSS 6, Ultrasonic

Cab Frm, Cab to JSS Frame

51PW JSS Power U

BK 0.8 TXL

SPL JSS 13, Ultrasonic

Can Mod 2, JSS Can mod

51PW JSS Power V

W 0.8 GXL

SPL JSS 13, Ultrasonic

PVRES, JSS Joystick

51PW JSS Power W

W 0.8 GXL

SPL JSS 6, Ultrasonic

SPL JSS 4, Ultrasonic

51P A Sec. Str High Press

W 1.0 SXL

SSM, Sec. Steer Module

PSS, Sec. Str Pres Switch

Armrest Raise

BK 0.8 TXL

Arm Pos, Arm Position

CAN MOD 2, JSS CAN MOD

51S A JSS Okay Pwr

W 0.8 GXL

JSS Cnt, JSS Controller

SPL JSS 5, Ultrasonic

51S B JSS Okay Pwr

W 0.8 GXL

Cab Arm, Cab to Armrest

SPL JSS 5, Ultrasonic

51S C JSS Okay Pwr

W 0.8 GXL

SPL JSS 15, Ultrasonic

JSS Arm, JSS Armrest to Cab

51S D JSS Okay Pwr

BK 0.8 TXL

CAN MOD_2, JSS CAN MOD

SPL JSS 15, Ultrasonic

51S E JSS Okay Pwr

W 0.8 GXL

PVRES, JSS Joystick

SPL JSS 15, Ultrasonic

51S F JSS Okay Pwr

W 0.8 GXL

Cab Frm, Cab to JSS Frame

SPL JSS 5, Ultrasonic

51S J JSS Okay Pwr

W 1.0 SXL

JSS Valve, JSS HYD Valve

JSS Frm, JSS Frame to Cab

51 A

Sec. Str Motor Control

W 1.0 SXL

SSM, Sec. Steer Module

SPL-SS, Ultrasonic

51 B

Sec. Str Motor Control

W 1.0 SXL

SPL-SS, Ultrasonic

SSS, SS Mag Switch

51 C

Sec. Strg Sol Control

W 1.0 SXL

SPL-SS, Ultrasonic

YSS, Sec. Steering Solenoid

51 D

Sec. Str Flyback

W 1.0 SXL

SSS, SS MAG Switch

SSD, Sec. Steering Diode

52AU

Fan Reverse Auto

W 0.8 TXL

SFC, Fan Control Switch

AIC-2, Adv Instrument Cluster 2

52A A Fan Reverse Relay Out

W 1.0 GXL

CAB-E, Cab Engine

ECB, Elect Center B

52A B Fan Reverse Relay Out

W 1.0 SXL

ENG, Engine Cab 1

YFR, Fan Rev Solenoid Option

51R

D8 1

52C

Parking Brake Solenoid LSD

W 0.8 TXL

AIC-1, Adv Instrument Cluster 1

ECB, Elect Center B

52J

Fan Control Switch Jumper

W 0.8 GXL

SFC, Fan Control Switch

52M

Fan Reverse Manual

W 0.8 TXL

SFC, Fan Control Switch

AIC-2, Adv Instrument Cluster 2

84547255A

Issued 11-11

B10

Printed in E.C.

4002-35

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire 52P

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

K = Pink U = Blue Y = Yellow

To Connector

Connector

Cavity

Connector

Cavity

Parking Brk Relay Out

W 1.0 SXL

BTM_C, CAB Bottom BULKHD

YPB, Park Brake Solenoid

52P A Parking Brk Relay Out

W 0.8 GXL

Cab_B, Cab BTM BULKHEAD

SPL-PTM, Ultrasonic

52P B Parking Brk Relay Out

W 0.8 GXL

SPL-PTM, Ultrasonic

ECB, Elect Center B

D10

53A

RTD Switch Power

W 0.8 GXL

SRTD, Detent Switch

EM, RTD Height Control RTT

53B

RTD ControlSignal

W 1.0 SXL

FRONT, Cab Front Chassis

PXF, RTD

53B A RTD Control Signal

W 1.0 SXL

PXM, RTD

PXT, RTD

53B B RTD Control Signal

W 0.8 GXL

EM, RTD Height Control RTT

CAB-F, Cab Front Chassis

53C A Pilot Control Solenoid LSD

W 0.8 TXL

AIC-1, Adv Instrument Cluster 1

ECD, Elect Center D

53P A Pilot Control Relay Out

W 0.8 GXL

SPL-D25, Ultrasonic

YPP, Pilot Pressure Solenoid

53P B Pilot Control Relay Out

W 0.8 GXL

SFL, Return to Travel Switch

SPL-D25, Ultrasonic

53P C Pilot Control Relay Out

W 1.0 GXL

SPL-D25, Ultrasonic

ECD, Elect Center D

53P D Pilot Control Relay Out

W 0.8 GXL

SHC, Height Control Switch

SPL-D25, Ultrasonic

53P E Pilot Control Relay Out

W 0.8 GXL

SRTD, Detent Switch

SPL-D25, Ultrasonic

53P F Pilot Control Relay Out

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-D25, Ultrasonic

53P G Pilot Control Relay Out

W 1.0 SXL

FRONT, Cab Front Chassis

SPL-A3, Ultrasonic

53P H Pilot Control Relay Out

W 1.0 SXL

SPL-A3, Ultrasonic

PXF, RTD

53P I

Pilot Control Relay Out

W 1.0 SXL

PXM, RTD

PXT, RTD

53P J Pilot Control Relay Out

W 1.0 SXL

SPL-A3, Ultrasonic

PXH, Height Control RTT

54A

Height Control Switch Power

W 0.8 GXL

SHC, Height Control Switch

EM, RTD Height Control RTT

54B

Height RTT Control Signal

W 1.0 SXL

FRONT, Cab Front Chassis

PXH, Height Control RTT

54B A Height RTT Control Signal

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-D1, Ultrasonic

54B B Height RTT Control Signal

W 0.8 GXL

EM, RTD Height Control RTT

SPL-D1, Ultrasonic

54B C Height RTT Control Signal

W 0.8 GXL

SFL, Return to Travel Switch

SPL-D1, Ultrasonic

55A A RTT Float Sw Power

W 0.8 GXL

EM, RTD Height Control RTT

SPL-RTT, Ultrasonic

55A B RTT Float Sw Power

W 0.8 GXL

SFL, Return to Travel Switch

SPL-RTT, Ultrasonic

55A C RTT Float Sw Power

W 0.8 GXL

SFL, Return to Travel Switch

SPL-RTT, Ultrasonic

55B

RTT Float Switch Control

W 0.8 GXL

SFL, Return to Travel Switch

EM, RTD Height Control RTT

56 A

Fan Control PWM

W 1.0 SXL

ENG, Engine Cab 1

YFN, Fan PWM Solenoid

57 A

Pin Engage Sol Pwr

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-PINE, Ultrasonic

57 B

Pin Engage Sol Pwr

W 0.8 GXL

SPE, Pin Engage Switch

SPL-PINE, Ultrasonic

84547255A

Issued 11-11

Printed in E.C.

4002-36

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

2.0 mm 5.0 mm

DU = Dark Blue W = White Or = Orange

Wire Identification

S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector

Wire

Circuit

Cavity

Connector

Cavity

57 C

Pin Engage Sol Pwr

W 0.8 TXL

SPL-PINE, Ultrasonic

AIC-2, Adv Instrument Cluster 2

57 D

Pin Engage Sol Pwr

W 1.0 SXL

YPE1, Pin Engage Jumper

YPE2, Pin Engage Opt

58C

Ride Control Switch Jumper

W 0.8 GXL

SRC, Ride Control Switch

58H A Pwr VPS2

W 0.8 TXL

TECM, Trans

SPL D19, Ultrasonic

58H B Power VPSL

W 0.8 TXL

SPL D19, Ultrasonic

TECM, Trans

58H C Power

W 0.8 GXL

ECD, Elec Cntr D

SPL D19, Ultrasonic

58L

Ride Control Relay LSD

Bk 0.8 TXL

TECM, Trans

ECD, Elect Center D

58T

Ride Control Relay Sw Pwr

W 0.8 GXL

SRC, Ride Control Switch

ECD, Elect Center D

58 A

Ride Control Sol Pwr

W 1.0 SXL

202M, Rollback Jumper

58 B

Ride Control Sol Pwr

W 1.0 SXL

FRONT, Cab Front Chassis

PRBF, Rollback Pressure Switch

58 C

Ride Control Sol Pwr

W 0.8 GXL

CAB-F, Cab Front Chassis

SPL-D26, Ultrasonic

58 D

Ride Control Sol Pwr

W 0.8 GXL

140M, Diode Module

SPL-D26, Ultrasonic

58 E

Ride Control Sol Pwr

W 0.8 GXL

SPL-D26, Ultrasonic

ECD, Elect Center D

58 F

Ride Control Sol Pwr

W 0.8 GXL

SRC, Ride Control Switch

SPL-D26, Ultrasonic

58 G

Ride Control Sol Pwr

W 1.0 SXL

YRC, Ride Control Opt

Front, Frnt Chas-Cab

58 H

Ride Control Signal

W 1.0 SXL

YRC J, Ride Control Jumper

YRC J2, Ride Control Opt

59D

Hood Relay Control Down

W 1.0 GXL

Cabe2, Cab to ENG2 BULKHD

ECC, Elect Cntr C

59D A Hood Relay Control Down

W 1.0 SXL

ENG2, ENG BULKHD 2

HD, Hood Switch

Hood Relay Control Up

W 1.0 GXL

Cabe2, Cab to ENG2 BULKHD

ECC, Elect Cntr C

59U A Hood Relay Control Up

W 1.0 SXL

ENG2, ENG BULKHD 2

HD, Hood Switch

Hood Down Relay Out

W 1.0 GXL

Cabe2, Cab to ENG2 BULKHD

ECC, Elect Cntr C

60D A Hood Down Relay Out

W 1.0 SXL

ENG2, ENG BULKHD 2

HDM, Hood Lift Motor

Hood Up Relay Out

W 1.0 GXL

Cabe2, Cab to ENG2 BULKHD

ECC, Elect Cntr C

60U A Hood Up Relay Out

W 1.0 SXL

ENG2, ENG BULKHD 2

HDM, Hood Lift Motor

W 1.0 SXL

ENG, Engine Cab 1

SPL ACP, Ultrasonic

61A B Trinary Press Sw Input

W 0.8 GXL

CAB-E, Cab Engine

SPL AC, Ultrasonic

61A C AC Switch Input

W 1.0 SXL

SPL ACP, Ultrasonic

ENG B, Cab Bottom

61A D AC Switch Input

W 1.0 SXL

SPL ACP, Ultrasonic

PRH, AC High Press SW

61A E AC Switch Input

W 1.0 SXL

PRL, AC Low Press SW

BTM E, Cab Bottom

61A F Trinary Press SW Input

W 0.8 GXL

HVAC1, HVAC1

SPL AC, Ultrasonic

61A G Trinary Press SW Input

W 0.8 GXL

SPL AC, Ultrasonic

ECD, Elec Cntr D

59U

60D

60U

61A

AC Press Sw Input

84547255A

Issued 11-11

Printed in E.C.

4002-37

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

61B A AC Signal

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

W 0.8 GXL

AIC 2, ADV Instr Cluster 2

HVAC1, HVAC1

AC Relay Out

Or 0.8 GXL

CAB-E, Cab Engine

ECD, Elect Center D

61C A AC Relay Out

Or 1.0 SXL

ENG, Engine Cab 1

ACT, AC Comp Clutch

Heat Load Valve Solenoid

Or 0.8 TXL

CAB-E, Cab Engine

AIC-1, ADV Instrument Cluster 1

61H A Heat Load Valve Solenoid

Or 1.0 SXL

YLV, Heated Valve opt.

ENG, Engine Cab 1

61H B Heat Load Valve Solenoid

Or 1.0 SXL

YLV2, Heated Valve opt.

YLV3, Heated Valve opt.

AC Relay Control

W 1.0 SXL

ENG, Engine Cab 1

SPL ACS, Ultrasonic

61R B AC Relay Control

W 0.8 GXL

CAB-E, Cab Engine

ECD, Elect Center D

61R C AC Switch Output

W 1.0 SXL

SPL ACS, Ultrasonic

ENG B, Cab Bottom

61R D AC Switch Output

W 1.0 SXL

SPL ACS, Ultrasonic

PRH, AC High Press SW

61R E AC Switch Output

W 1.0 SXL

PRL, AC Low Press SW

BTM_E, Cab Bottom

61C

61H

61R

4 C10

63C

Front Wiper Park Control

W 0.8 GXL

FWM, Front Wiper Motor

ECD, Elect Center D

63C2

Front Wiper Park Control

W 0.8 GXL

ECD, Elect Center D

63C3

Front Wiper Park Control

W 0.8 GXL

K-WCO, Wiper Cutout

87a

ECD, Elect Center D

63HC

Front Wiper High Speed Rly Ctrl

W 0.8 GXL

SFWW, Front Wiper/Washer

SPL-HC, Ultrasonic

63HC A

Wiper Cutout Relay Control

W 0.8 GXL

SPL-HC, Ultrasonic

K-WCO, Wiper Cutout

63HC B

Front Wiper High Speed Rly Ctrl

W 0.8 GXL

ECD, Elec Cntr D

SPL HC, Ultrasonic

63H A Front Wiper High Speed Rly Out

W 0.8 GXL

FMW, Front Wiper Motor

SPL-WHS, Ultrasonic

63H B Front Wiper High Speed Rly Out

W 0.8 GXL

ECD, Elec Cntr D

SPL WHS, Ultrasonic

63H C Front Wiper High Speed Rly Out

W 0.8 GXL

140M, Diode Module

SPL-WHS, Ultrasonic

63LC

Front Wiper Low Speed Rly Ctrl

W 0.8 GXL

SFWW, Front Wiper/Washer

ECD, Elect Center D

63L A Front Wiper Low Speed Rly Out

W 0.8 GXL

FMW, Front Wiper Motor

SPL-WLS, Ultrasonic

63L B Front Wiper Low Speed Rly Out

W 0.8 GXL

K-WCO, Wiper Cutout

SPL-WLS, Ultrasonic

63L C Front Wiper Low Speed Rly Out

W 0.8 GXL

140M, Diode Module

SPL-WLS, Ultrasonic

63W

Front Washer Pump

W 0.8 GXL

CAB-E, Cab Engine

SFWW, Front Wiper/Washer

63W A Front Washer Pump

W 1.0 SXL

ENG, Engine Cab 1

FWW, Front Washer

64C

Horn Relay Control

Or 0.8 GXL

SRHSTLK, RH Stalk Switch

31b

ECC, Elect Center C

64 A

Horn Power

Or 0.8 GXL

CAB-F, Cab Front Chassis

ECC, Elect Center C

65L

Left Speaker

Or 0.8 GXL

LSPK, Left Speaker

SPK, Speaker

84547255A

Issued 11-11

Printed in E.C.

4002-38

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

65R

Right Speaker

Or 0.8 GXL

RSPK, Right Speaker

SPK, Speaker

66A

RR Camera Pwr

OR 0.8 GXL

Mon, Camera/MOnitor

ECA, Elect Cntr A

67A

Park Brake Signl

OR 0.8 GXL

TEL, Telematics

SPL PTM, Ultrasonic

67B

Start Lockout

OR 0.8 GXL

ECC, Elect Cntr C

SRP, Work Lights SW

68C

Rear Wiper Park Control

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

SRWP, Rear Wiper Switch

68C A Rear Wiper Park Control

Or 1.0 GXL

ROOF, Roof to Cab Conn.

RWM, Rear Wiper Motor

Rear Wiper Switch Power

Or 1.0 GXL

SRWP, Rear Wiper Switch

SPL-3, Ultrasonic

68L A Rear Wiper Switch Power

Or 1.0 GXL

ROOF, Roof to Cab Conn.

RWM, Rear Wiper Motor

68L B Rear Wiper Switch Power

Or 1.0 GXL

CAB-RF, Cab to Roof Conn.

SPL-3, Ultrasonic

68L C Rear Wiper Switch Power

Or 1.0 GXL

140M, Diode Module

SPL-3, Ultrasonic

68W

Rear Washer Pump

W 0.8 GXL

CAB-E, Cab Engine

SRWP, Rear Wiper Switch

68W A Rear Washer Pump

W 1.0 SXL

ENG, Engine Cab 1

RWW, Rear Washer

68L

69F

Heated Mirror Signal

W 1.0 GXL

TRLY, Timer Relay

MHS, Trans Enable SW

69A

Heated Mirror Signal

W 1.0 GXL

SPL3, Ultrasonic

TRLY, Timer Relay

69B

Heated Mirror Signal

W 1.0 GXL

SPL3, Ultrasonic

MHS, Trans Enable SW

69D

Heated Mirror Signal

W 1.0 GXL

SPL3, Ultrasonic

MH-R, Mirror HTR

69E

Heated Mirror Signal

W 1.0 GXL

SPL3, Ultrasonic

MH-R, Mirror HTR

CAN1 CAN HI H

Y 0.8 TXL TWIST

EDC7, Engine Controller

ENG, Engine-Cab1

CAN1 CAN LO L

G 0.8 TXL TWIST

EDC7, Engine Controller

ENG, Engine-Cab1

CANS HA CAN HI, CAN MOD2

Y 0.8 TXL TWIST

JSS Arm, JSS Armrest to Cab

CAN MOD 2, JSS CAN MOD

CANS HB CAN HI, CAN MOD2

Y 0.8 TXL TWIST

Cab Arm FRM, Cab to Arm to FRM

Cab Arm, Cab to Armrest

CANS HD CAN HI, CAN MOD3

Y 0.8 TXL TWIST

Cab Arm FRM, Cab to Arm to FRM

JSS CNT, JSS Controller

CANS CAN LO, CAN MOD2 LA

G 0.8 TXL TWIST

JSS Arm, JSS Armrest to Cab

CAN MOD 2, JSS CAN MOD

CANS CAN LO, CAN MOD2 LB

G 0.8 TXL TWIST

Cab Arm, Cab to Armrest

Cab Arm FRM, Cab to Arm to FRM

CANS CAN HI, CAN MOD3 LD

G 0.8 TXL TWIST

Cab Arm FRM, Cab to Arm to FRM

JSS CNT, JSS Controller

84547255A

Issued 11-11

Printed in E.C.

4002-39

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

CAN H CAN HIGH

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

Y 0.8 TXL TWIST

ENG, ENGINE-CAB1

SPL CAN DH, Ultrasonic

CAN H2

CAN2 HI, TERM

Y 0.8 GXL TWIST

TERM CAN 2, CAN Bulk Head

SPL CAN HV, Ultrasonic

CAN H3

CAN2 HI, Nox

Y 0.8 TXL TWIST

SPL-CAN-HT, Ultrasonic

EDC7, Engine Controller

CAN HA

CAN High

Y 0.8 TXL TWIST

SPL CAN_JS_H1, Ultrasonic

SPL CAN GH, Ultrasonic

CAN HB

CAN High

Y 0.8 TXL TWIST

SPL-CAN-DIAG, Ultrasonic

DIA, Diagnostic

CAN HC

CAN High

Y 0.8 TXL TWIST

SPL-CAN-TRANS, Ultrasonic

SPL-CAN-DIAG, Ultrasonic

CAN HD

CAN High

Y 0.8 TXL TWIST

SPL-CAN-TRANS, Ultrasonic

TECM, Trans

CAN HE

CAN High

Y 0.8 TXL TWIST

SPL-CAN, Ultrasonic

SPL-CAN-TRANS, Ultrasonic

CAN HF

CAN High

Y 0.8 TXL TWIST

SW-PD, Switch Pad

SPL-CAN, Ultrasonic

CAN HG

CAN High

Y 0.8 TXL TWIST

SPL-CAN, Ultrasonic

AIC-1, Adv Instrument Cluster 1

CAN HH

CAN High

Y 0.8 TXL TWIST

SPL CAN TEL, Ultrasonic

TEL, Telematics

CAN HJ

CAN High

Y 0.8 TXL TWIST

SPL CAN TEL, Ultrasonic

SPL CAN JS H2, Ultrasonic

CAN HK

CAN HI, EDC

Y 0.8 TXL TWIST

SPL CAN DH, Ultrasonic

EDC7, Engine Controller

CAN HL

CAN High

Y 0.8 TXL TWIST

SPL CAN TEL, Ultrasonic

SPL CAN DIAG, Ultrasonic

CAN HM

CAN2 HI, EDC

Y 0.8 GXL TWIST

Cab E, Cab-Engine

SPL-CAN-GH, Ultrasonic

CAN HN

CAN High

Y 0.8 TXL TWIST

SPL CAN JS H1, Ultrasonic

SPL CAN JS H2, Ultrasonic

CAN HO

CAN2 HI, DIAG2

Y 0.8 GXL TWIST

SPL CAN GH, Ultrasonic

DIA 2, Diagnostic

CAN HP

CAN HI,CAN MOD2

Y 0.8 GXL TWIST

SPL CAN JS H1, Ultrasonic

JSS Cab, JSS Cab

84547255A

Issued 11-11

Printed in E.C.

4002-40

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

CAN HQ

CAN HI, DNOX2

Y 0.8 GXL TWIST

SPL CAN DH, Ultrasonic

DNOX2, NOX Controller

CAN HR

CAN HI,CAN MOD3

Y 0.8 GXL TWIST

SPL CAN JS H2, Ultrasonic

JSS Cab, JSS Cab

CAN HS

CAN2 HI, NOX

Y 0.8 TXL TWIST

SPL CAN HV, Ultrasonic

EDC7, Engine Controller

CAN HU

CAN2 HI, NOX

Y 0.8 TXL TWIST

SPL CAN HT, Ultrasonic

NOXS, NOX Sensor

CAN HV

CAN2 HI, TERM

Y 0.8 GXL TWIST

SPL CAN HT, Ultrasonic

TERM CAN 2, CAN Bulk Head

CAN HW

CAN 2 HI, EVGT

Y 0.8 TXL TWIST

SPL CAN HV, Ultrasonic

Turbo, Eng DASH Turbo

CAN HZ

CAN 2 HI

Y 0.8 GXL TWIST

SPL CAN HV, Ultrasonic

SPL CAN HT, Ultrasonic

CAN L CAN Low

G 0.8 TXL TWIST

ENG, Engine-Cab1

SPL CAN DL, Ultrasonic

CAN L2

CAN 2 LO, Term

Y 0.8 GXL TWIST

Term CAN 2, CAN Bulk Head

SPL CAN LV, Ultrasonic

CAN L3

CAN L2, Nox

G 0.8 TXL TWIST

SPL-CAN-LT, Ultrasonic

EDC7, Engine Controller

CAN LA

CAN Low

G 0.8 TXL TWIST

SPL CAN JS_L1, Ultrasonic

SPL CAN GL, Ultrasonic

CAN LB

CAN Low

G 0.8 TXL TWIST

SPL-CAN-DIAG-L, Ultrasonic

DIA, Diagnostic

CAN LC

CAN Low

G 0.8 TXL TWIST

SPL-CAN-TRANS-L, Ultrasonic

SPL-CAN-DIAG-L, Ultrasonic

CAN LD

CAN Low

G 0.8 TXL TWIST

TECM, Trans

SPL-CAN-TRANS-L, Ultrasonic

CAN LE

CAN Low

G 0.8 TXL TWIST

SPL-CAN-L, Ultrasonic

SPL-CAN-TRANS-L, Ultrasonic

CAN LF

CAN Low

G 0.8 TXL TWIST

SW-PD, Switch Pad

SPL-CAN-L, Ultrasonic

CAN LG

CAN Low

G 0.8 TXL TWIST

SPL-CAN-L, Ultrasonic

AIC-1, Adv Instrument Cluster 1

CAN LH

CAN Low

G 0.8 TXL TWIST

SPL CAN TEL2, Ultrasonic

SPL CAN JS L2, Ultrasonic

84547255A

Issued 11-11

Printed in E.C.

4002-41

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

CAN LJ

CAN Low, EDC

G 0.8 TXL TWIST

EDC7, Engine Controller

SPL CAN DL, Ultrasonic

CAN LK

CAN Low, DNOX2

G 0.8 GXL TWIST

SPL CAN DL, Ultrasonic

DNOX2, NOX Controller

CAN LL

CAN2 LO, EDC

G 0.8 GXL TWIST

Cab E, Cab-Engine

SPL CAN GL, Ultrasonic

CAN LM

CAN Low

G 0.8 TXL TWIST

SPL CAN TEL2, Ultrasonic

TEL, Telematics

CAN LP

CAN Low,CAN MOD3

G 0.8 GXL TWIST

SPL CAN JS L1, Ultrasonic

JSS Cab, JSS Cab

CAN LQ

CAN LOW

G 0.8 TXL TWIST

SPL CAN JS L1, Ultrasonic

SPL CAN JS L2, Ultrasonic

CAN LR

CAN Low, CAN MOD2

G 0.8 GXL TWIST

SPL CAN JS L2, Ultrasonic

JSS Cab, JSS Cab

CAN LS

CAN2 LO, NOX

G 0.8 TXL TWIST

SPL CAN LV, Ultrasonic

EDC7, Engine Controller

CAN LU

CAN2 LO, NOX

G 0.8 TXL TWIST

NOXS, NOX Sensor

SPL CAN_LT, Ultrasonic

CAN LV

CAN2 LO, Term

G 0.8 GXL TWIST

Term CAN 2, CAN Bulk Head

SPL CAN LT, Ultrasonic

CAN LW

CAN LO, EVGT

G 0.8 TXL TWIST

SPL CAN LV, Ultrasonic

Turbo, ENG DASH Turbo

CAN LX

CAN2 LO, DIAG2

G 0.8 GXL TWIST

SPL CAN GL, Ultrasonic

DIA 2, Diagnostic

CAN LY

CAN Low

G 0.8 TXL TWIST

SP CAN TEL2, Ultrasonic

SPL CAN DIAG L, Ultrasonic

CAN LZ

CAN 2 LO

G 0.8 GXL TWIST

SPL CAN LV, Ultrasonic

SPL CAN LT, Ultrasonic

ECC L1

Beacon/Dome Light L1 ECC

BUSS

L1-ECC, ECC Batt Power

ECC, Elect Cntr C

Trans ECM Power

ECA-BUSS

ECA-L1, B+ Power

cs01

ECA, Elect Center A

Trans ECM Power

ECA-BUSS

ECA, Elect Center A

EMG STR AIC Power

ECA-BUSS

ECA, Elect Center A

Emergency Steer AIC Power

ECA-BUSS

ECA, Elect Center A

Emergency Steer Pltem Dtnts

ECA-BUSS

ECA, Elect Center A

Pltem Dtnts Park Brk Sol

ECA-BUSS

ECA, Elect Center A

84547255A

Issued 11-11

L1-1

Printed in E.C.

4002-42

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

Park Brake Solenoid Horn

ECA-BUSS

ECA, Elect Center A

Fan Reverse Turn Signal

ECA-BUSS

ECA, Elect Center A

Turn Signal Engine Shut Down

ECA-BUSS

ECA, Elect Center A

J10

DNOX SW B+

ECA-BUSS

ECA, Elect Center A

J11

Blower Motor Power

ECA-BUSS

PRMB_L1, B+ Power

cs01

ECA, Elect Center A

J12

Blower Motor Front Wiper Washer

ECA-BUSS

ECA, Elect Center A

J13

Front Wiper Rear Wiper Washer

ECA-BUSS

ECA, Elect Center A

J14

Rear Wiper Washer Backup

ECA-BUSS

ECA, Elect Center A

J15

Backup AC

ECA-BUSS

ECA, Elect Center A

J16

Heated Mirrors

ECA-BUSS

ECA, Elect Center A

J17

Seat Comp EMG Strtr

ECA-BUSS

ECA, Elect Center A

J18

Diagnostic Power

ECA-BUSS

ECA, Elect Center A

ECA-BUSS

ECA, Elect Center A

J19 J2 ECC

Beacon/Dome Lt Work Lights

ECC-BUSS

ECC, Elect Center C

L1-1

ECC, Elect Center C

L1-2

J3 ECC

Work Lights Driving Lights

ECC-BUSS

ECC, Elect Center C

L1-2

ECC, Elect Center C

L1-3

J4 ECC

Driving Lights Brake Lights

ECC-BUSS

ECC, Elect Center C

L1-3

ECC, Elect Center C

L1-4

J5 ECC

Brake Lights Delay Power

ECC-BUSS

ECC, Elect Center C

L1-4

ECC, Elect Center C

L1-5

J6 ECC

Delay Power Horn

ECC-BUSS

ECC, Elect Center C

L1-5

ECC, Elect Center C

L1-6

J7 ECC

Horn HOD Control

ECC-BUSS

ECC, Elect Center C

L1-6

ECC, Elect Center C

L1-7

J9 ECC

ECC-BUSS

ECC, Elect Center C

L1-8

ECC, Elect Center C

L1-9

J10 ECC

BUSS

ECC, Elect Center C

L1-9

ECC, Elect Center C

L1-10

RAD1 Radio Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

RAD2 12V Fused Power to Radio

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

RAD3 12V Fused Power to Radio

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J1, Radio Power

RAD4 Left Speaker Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

84547255A

Issued 11-11

Printed in E.C.

4002-43

Wire Identification Codes

21C Bk - 1.0 Wire Size (mm2) 0.8 mm 1.0 mm Wire Color Wire Name

Bk = Black T = Tan LU = Light Blue

DU = Dark Blue W = White Or = Orange

Wire Identification Wire

Circuit

2.0 mm 5.0 mm S = Gray N = Brown R = Red

LG = Light Green G = Green P = Purple

From Connector Color, Size, and Material

Connector

K = Pink U = Blue Y = Yellow

To Connector Cavity

Connector

Cavity

RAD5 Left Speaker

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD6 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD7 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD8 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD9 Not Used

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD10 Right Speaker Ground

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

RAD11 Right Speaker

W 0.8 GXL

RAD-J3, Radio Jumper

RAD-J2, Speaker

84547255A

Issued 11-11

Printed in E.C.

4002-44

CONNECTORS CONNECTOR AB+, ALTERNATOR B+ CAV 1

WIRE IDENT 1 BA

AIC 1, ADV INSTR CLUSTER 1

CIRCUIT ALTERNATOR B+

CONNECTOR AB5, ALTERNATOR B+ CAV

WIRE IDENT

CIRCUIT

1 BF

ALTERNATOR B+

BATTERY SENSING

CONNECTOR ACT - AIR CONDITIONING COMPRESSOR CLUTCH

87419488

CAV 1

8602417

CAV 1

WIRE IDENT 61C-A

CIRCUIT AC RELAY OUT

AD, ALTERNATOR D+ CAV 1

WIRE IDENT 14

84547255A

CIRCUIT ALTERNATOR D+

WIRE IDENT 19S-E

CIRCUIT AIC BATT B+

36F-A

FUEL LEVEL ANALOG

CAN-HG

CAN HIGH

CAN-LG

CAN LOW

0-DX

AIC SENSOR GND

43-A

DOME LT AUTO MODE

36H-A

HYDRAULIC OIL TEMP

36C-A

RADITAOR COOL TEMP SGNL

0-DW

AIC POWER GND

35B

AIC BUZZER HSD

52C

PARK BRAKE SOL LSD

61H

HEAT LOAD VLV SOL

53C-A

PILOT CTRL SOL LSD

51D-A

GRND, RELAY CTRL

0-EZ

POWER RELAY CONTROL

FAN REVERSER LSD

17P-B

SW PAD PWR FR0M AIC PWR

FAN CONTROL PWM

Issued 11-11

Printed in E.C.

4002-45 ARM FNR, FNR-MAIN CAB

AIC 2, ADV INSTR CLUSTER 2 CAV

WIRE IDENT

CIRCUIT

19B-C

FNR SWITCHED PWR

26F-F

FNR FORWARD SIGNAL

26N-F

FNR NEUTRAL SIGNAL

26R-F

FNR REVERSE SIGNAL

32J-J

FNR LT SIGNAL

25Y-G

TRANS KICKDOWN SIGNAL

ARM POS, ARM POSITION 87410948

CAV 2

WIRE IDENT 43S-A

CIRCUIT DOOR OPEN SGNL

33R

RDNT BRK ACCUM PRESS LOW

33P-A

BRK WARN PRESS LOW

CAV

WIRE IDENT

CIRCUIT

0-SG

COMMON

51R

ARMREST RAISE

51E-B

ARMREST LOWER

33U

PARK BRK SWITCH

52M

FAN REVERSE MAN

52AU

FAN REVERSE AUTO

CAV

45L-E

LEFT TURN SGNL

45R-C

RIGHT TURN SGNL

35X

SEC STR LOW PRESS SGNL

61B-A

AC SIGNAL

19S-D

AIC DELAY FSD PWR

CAV

0-DB

AIC POWER GND RED

57-C

PIN ENGAGE SOL PWR

21K-A

IGN SW START SIGNAL

31L

PILOT CTRL SW HIGH

19S-C

AIC DELAY FSD PWR

19S-F

AIC BATT B+

0-DA

AIC CHASSIS GND

B1, STARTER PWR STUD WIRE IDENT 1-NC

CIRCUIT B+ PWR PRMC

B2, STARTER POWER WIRE IDENT 1-BA

CIRCUIT ALTERNATOR B+

B3, STARTER BATTERY CAV 1

WIRE IDENT 0-NB

CIRCUIT MASTER DISCONNECT GND

B4, STARTER POWER ALT5, ALTERNATOR D+

CAV 1

CAV

WIRE IDENT 30

BATTERY SENSING

14-5

ALTERNATOR D+

BT1, BATTERY STARTER

WIRE IDENT 1-BG

CIRCUIT

CIRCUIT B+ PWR PRMC

B6, STARTER POWER

1-NB

BATTERY STARTER

1-NG

PWR NON DISCNT

CAV

1-NE

BATTERY STARTER

84547255A

SSM PWR

B5, STARTER POWER STUD CAV

WIRE IDENT

1-ND

CIRCUIT

CAV

WIRE IDENT

WIRE IDENT 1-BF

CIRCUIT ALTERNATOR B+

Issued 11-11

Printed in E.C.

4002-46 B7, STARTER BATTERY CAV 1

WIRE IDENT 1-NE

BT4, DISCON-BLCK GRND

CIRCUIT

CAV

BATTERY STARTER

B8, STARTER POWER CAV 1

WIRE IDENT 1-NF

WIRE IDENT 0-NC

CIRCUIT BATTERY DISCONNECT

BTM C, CAB BOTTOM BULKHD

CIRCUIT SSM PWR

BPP, PEDAL POSITION

W230R397

CAV A

W230R395

CAV

WIRE IDENT

CIRCUIT

22G

PEDAL SENSOR GRND

22E

PEDAL SENSOR +5V

22F

PEDAL POS SIGNAL

401B

PEDAL POS SIGNAL

255E

PEDAL SESNOR +5V

016B

PEDAL SENSOR GRND

BT2, DISCONECT BATTERY CAV 1

WIRE IDENT 1-NA

CIRCUIT BATTERY CROSSOVER

WIRE IDENT

CIRCUIT

22G

PEDAL SENSOR GRND

22E

PEDAL SENSOR +5V

22F

PEDAL POS SIGNAL

016B

PEDAL SENSOR SIGNAL

255E

PEDAL SENSOR +5V

401B

PEDAL POS SIGNAL

BRK LT CTRL PWR

1-AA

BRK LT SW PWR

33P

BRK WARNING PRESS LOW

52P

PARK BRK RLY OUT

22D

PEDAL SENSOR GRND

22B

PEDAL SENSOR +5V

22C

PEDAL POS SIGNAL

44-A

BRK LT CTRL PWR

1-DR

BRK LT SW PWR

52P-A

PARK BRK RLY OUT

BT3, STARTER BATTERY CAV 1

WIRE IDENT 1-NA

84547255A

CIRCUIT BATTERY CROSSOVER

Issued 11-11

Printed in E.C.

4002-47 BTM E, CAB BTTOM

CABE2, CAB TO ENG2 BULKHD

225319C1

CAV

WIRE IDENT

CIRCUIT

W230R398

CAV

WIRE IDENT

CIRCUIT

21F-D

EDC7 DIGITAL GND

23B-D

NOX RELAY, B+

0-AK

PARK BRAKE/WARNING GND

18U-C

DCU B+ NON DISCONNECTD

24B-A

THROT SIGNAL

23B-B

NOX SENSOR B+

24R-A

THROT GND

1-NM

PWR NON DISCONNECTD

24S-A

THROT SUPPLY

18U-E

DCU B+ NON DISCONNECTD

24L-A

LOW IDLE SWITCH

23B-A

NOX SENSOR B+

61R-E

AC SWITCH OUTPUT

1-NL

PWR NON DISCONNECTD

61A-E

AC SWITCH INPUT

18T

DNOX SW B+

35A-F

BKUP ALM RLY OUT

35A-C

BKUP ALM RLY OUT

18F-A

LH POSN/TAIL FUSED PWR

18G-F

RH POSN/TAIL FUSED PWR

45R-B

RIGHT TURN SGNL

45L-B

LEFT TURN SGNL

44A-A

BRK LT RLY OUT

BU1, BACKUP ALARM GRND CAV 1

WIRE IDENT 0-JB

CIRCUIT BACKUP ALARM GND

BU2, BACKUP ALARM CAV

WIRE IDENT

CIRCUIT

35A-H

BKUP ALM RLY OUT

35A-HN

BKUP ALM RLY OUT

35A-9

BKUP ALM RLY OUT

19Y-C

HOOD SWITCH FSD PWR

60D

HOOD DOWN RLY OUT

59D

HOOD DOWN RLY CTRL

60U

HOOD UP RLY OUT

59U

HOOD UP RLY CTRL

BUZ, AIC BUZZER CAV

WIRE IDENT

CIRCUIT

35B

AIC BUZZER HSD

0-B27

BUZZER GND

CAB PW, CAB POWER CAV 1

WIRE IDENT 1CB-A

84547255A

CIRCUIT CAB CB PROTECTED PWR

Issued 11-11

Printed in E.C.

4002-48 CAB ARM, CAB TO ARMREST

CAB B, CAB BTM BULKHEAD

225389C1

CAV

WIRE IDENT

CIRCUIT

W230R396

CAV

WIRE IDENT

CIRCUIT

CANS-HB

CAN HI, CAN MOD2

22D

PEDAL SENSOR GRND

0-SJ

GRND, CAN MOD

22B

PEDAL SENSOR +5V

51E-A

ARMREST LOWER

22C

PEDAL POS SIGNAL

17P-D

B+, CAN MOD

44-A

BRK LT CTRL PWR

51B-H

JSS ACT SW

1-DR

BRK LT SW PWR

0-SD

GRND, JOYSTICK

33P-A

BRK WARN PRESS LOW

51PW-R

JSS POWER

52P-A

PARK BRK RLY OUT

51S-B

JSS OKAY PWR

51H-B

JOYSTICK SIGNAL

51NO-A

NO NEUTRAL SW

CANS-LB

CAN LO, CAN MOD2

CAB ARM FRM, CAB TO ARM TO FRM CAV

WIRE IDENT

CIRCUIT

CANS-LB

CAN LO, CAN MOD2

17P-G

B+, JOYSTICK

51D-B

GRND, RELAY CNTL

51B-D

JSS ACT SW

CANS-LD

CAN LO, CAN MOD3

CANS-HD

CAN HI, CAN MOD3

0-SK

GRND, CAN MOD

51PW-M

JSS POWER

51C-B

JSS ACT BTN

18S-D

B+, JSS FUSED

CANS-HB

CAN HI, CAN MOD2

84547255A

CAB FNR, MAIN CAB FNR CAV

WIRE IDENT

CIRCUIT

19B-B

TRANS ENA SW PWR

26F-E

FNR FORWARD SIGNAL

26N-E

FNR NEUTRAL SIGNAL

26R-E

FNR REVERSE SIGNAL

32J-H

TRANS ENABLE LT SIG

25Y-E

NONE

Issued 11-11

Printed in E.C.

4002-49 CAB E, CAB-ENGINE CAV

WIRE IDENT

CIRCUIT

36F-A

FUEL LEVEL ANALOG

61C

AC RELAY OUT

21G

EDC7 CRANK CTRL RLY

21H

CRANK CTRL RLY LSD

36C-A

RADITAOR COOL TEMP SGNL

0-DF

CRANK REQUEST RLY CTRL GND

0-L

TELEMATICS GRND

61H

HEAD LOAD VLV SOL

21F

EDC7 DIGITAL GND

CAN-LL

CAN2 LO, EDC

CAN-HM

CAN2 HI, EDC

21D-A

STARTER RLY SIGNAL

460-A

0-DX

AIC SENSOR GND

23J-B

DNOX2 K-LINE

0-DW

AIC POWER GND

0-DB

AIC POWER GND RED

13C-B

FUEL SHUTOFF FUSED PWR

52A-A

FAN REVERSE RLY OUT

FAN CONTROL PWM

68W

REAR WSHR PUMP

63W

FNT WASHER PUMP

14-AB

ALTERNATOR D+

21E-B

KEY SWITCH CRANK

31F-A

AIR FLTR REST SW SGNL

61R-B

AC RELAY CONTROL

61A-B

TRINARY PRESS SW INPUT

20G-B

EDC7 ISO-K INTERFACE

CAV

WIRE IDENT

CIRCUIT

18C-A

RH HIGH BEAM FUSED PWR

57-A

PIN ENGAGE SOL PWR

58-C

RIDE CTRL SOL PWR

CAB FRM, CAB TO JSS FRAME CAV

WIRE IDENT

CIRCUIT

51F-B

LS PRESS SW

51J-A

VALVE ALARM

51K-B

PILOT PRESS SW

51L-A

JOYSTICK SIGNAL

51S-F

JSS OKAY PWR

0-SF

GRND

51PW-T

JSS POWER

18S-D

B+, JSS FUSED

CAB RF, CAB TO ROOF CONNECTION

388710A1

CAB F, CAB FRONT CHAS CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

0-DZ

WORK LIGHTS GRND

0-DY

ROOF SPLICE GNDS

43-A

DOME LT AUTO MODE

19U-D

DOME LT FSD PWR

46-C

BEACON SW PWR

0-DR

ROOF SPLICE GNDS

0-DS

ROOF SPLICE GNDS FNT WRK LTS FUSE PWR

45L-C

LEFT TURN SGNL

42C-A

45R-D

RIGHT TURN SGNL

19K-C

REAR WPR MOTOR FSD PWR

68C

REAR WPR PARK CTRL

18G-G

RH POSN/TAIL FUSED PWR

18B-A

LH HIGH BEAM FUSED PWR

68L-B

REAR WPR SW PWR

53P-F

PILOT CTRL RLY OUT

0-EM

RADIO GND

18F-E

LH POSN/TAIL FUSED PWR

12V-B

12V FUSED PWR TO RADIO

19U-G

DOOR SW FSD PWR

54B-A

HC-RTT CTRL SGNL

53B-B

RTD CTRL SIGNAL

43S-A

DOOR OPEN SGNL

64-A

HORN POWER

42R-C

REAR WRK LTS FUSE PWR

18D-A

LH LOW BEAM FUSED PWR

18E-A

RH LOW BEAM FUSED PWR

84547255A

Issued 11-11

Printed in E.C.

4002-50 CAB T, CAB TRANSMISSION

CAN MOD 2, JSS CAN MOD

380839A1

CAV

WIRE IDENT

CIRCUIT

33R

RDNT BRK ACCUM PRESS LOW

34A-C

DIFF LOCK SOL B+

19M

SEC STR ACCESSORY FSD PWR

19R-E

SEC STR IGN FSD PWR

36T-A

VALVE BODY TEMP SGNL

35X

SEC STR LOW PRESS SGNL

25A-A

ENG SP SIGNAL

25C-A

TURBINE SP SIGNAL

25B-A

INT SP SIGNAL

25D-A

OUTPUT SP SIGNAL

0-DM

SPEED SENSOR GNDS

36R-E

TRANS TEMPS/FLTR RETURN

36G-A

TCO TEMP SIGNAL

25G-A

BRK DECLUTCH SW CTRL

25R-A

TC LOCKUP SOL POWER

25K-A

TRANS SOL VALVE Y1

25L-A

TRANS SOL VALVE Y2

25M-A

TRANS SOL VALVE Y3

25N-A

TRANS SOL VALVE Y4

25P-A

TRANS SOL VALVE Y5

25J-A

TRANS SOL VALVE Y6

25S-A

OUTPUT SW PWR VPS1

31H-A

HYD FLTR REST SW SGNL

19A-T

BRK DECLUTCH SW FSD PWR

25T-A

TC LOCKUP SOL GND

19S2

SEC STR FSD PWR

34C

DIFF LOCK SOL GND

0-DN

OUTPUT SPEED SENSOR GND

19A-M

OUTPUT SP SNSR FUSED PWR

36H-A

HYDRAULIC OIL TEMP

32F-A

TRANS FLTR MAINT SW

84547255A

87552623

CAV

WIRE IDENT

CIRCUIT

51B-J

JSS ACT SW

51PW-U

JSS POWER

51NC

NC NEUTRAL SW

51S-D

JSS OKAY PWR

51R

ARMREST RAISE

CANS-HA

CAN HI, CAN MOD2

CANS-LA

CAN LO, CAN MOD2

17P-E

B+, CAN MODULE

0-SE

GRND

CBPW, CAB POWER CAV 1

WIRE IDENT 1CB

CIRCUIT CAB CB PROTECTED PWR

CONNECTOR CL - CIGAR LIGHTER

3227856R1

CAV

WIRE IDENT

CIRCUIT

19W

CIGAR LIGHTER FUSED POW

0-DV

CIGAR LIGHTER GROUND

Issued 11-11

Printed in E.C.

4002-51 CONNECTOR DIA - DIAGNOSTIC

CONNECTOR CNV - 24V TO 12V POWER CONVERTER

310057A1 225351C1

CAV

WIRE IDENT

CAV

WIRE IDENT

CIRCUIT A

CIRCUIT DIAGNOSTICS CONNECTOR GND

0-DH

19L-A

POW CONVER. FUSED POW

19L-B

POW CONVER. FUSED POW

18K-D

DIAGNOSTICS FUSED B+

POW CONVERTER GROUND

CAN-HB

CAN HIGH

NOT USED

CAN-LB

CAN LOW

20G-B

EDC7 ISO-K INTERFACE

0-EJ

4 5

12V-C

12V SWITCHED POWER

0-ER

POW CONVERTER GROUND

DIA 2, DIAGNOSTIC DC1, DISCONECT BATTERY CAV 1

WIRE IDENT 1-NB

CIRCUIT BATTERY STARTER

DC2, DISCON BLCK GRND CAV 1

WIRE IDENT 0-NB

CIRCUIT MASTER DISCONNECT GND 310057A1

DC3, FUEL SOL DISCONNECT CAV 1

WIRE IDENT 13C

CIRCUIT FUEL SHUTOFF FUSED PWR

DC4, FUEL SOL DISCONNECT CAV 1

WIRE IDENT 13M

CAV

WIRE IDENT

CIRCUIT

0D-C

DIAG2 GRND

18K-B

DIAG FUSED B+

CAN-HO

CAN2 HI, DIAG2

CAN-LX

CAN2 LO, DIAG2

23J-B

DNOX2 K-LINE

CIRCUIT FUEL SHUTOFF FUSED PWR

DEFDM, DOSER METERING VLV CAV

WIRE IDENT

CIRCUIT

DOSER VALVE B+

38A

DOSER VALVE GND

84547255A

Issued 11-11

Printed in E.C.

4002-52 CONNECTOR DISC - DISCONNECT ENGINE

DNOX2, NOX CONTROLLER CAV

245482C1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

38D

TANK HEAT B+

18U-D

DCU B+ NON DISCONNECTD

18U-B

DCU B+ NON DISCONNECTD

CAN-QH

CAN HI, DNOX2

CAN-LK

CAN LO, DNOX2

38A

DOSER VALVE GND

DOSER VALVE B+

0-LB

DNOX2 MODULE GND

13C

FUEL SHUTOFF FUSED POW

0-LC

DNOX2 MODULE GND

13M

FUEL SHUTOFF FUSED POW

0E-A

EXHT TEMP UP GND

38B

DEF LEVEL SIG

0-T

DEF SENSOR GND

38C

TANK HEAT GND

18T-A

DNOX2 SW B+

0-U

EXHT TEMP DWN GND

38E

EXHT TEMP DWN B+

38F

EXHT UP SIGNAL

38G

DEF TEMP SIG

38H

DNOX2 K-LINE

CONNECTOR DM - DIODE OR

245485C1

CAV

WIRE IDENT 19RR

SEC. STEERING IGNITION FUSED PWR

NOT USED

19R

SEC. STEERING IGNITION FUSED PWR

CONNECTOR DS - DOOR SWITCH

CIRCUIT

245482C1

CAV

84547255A

WIRE IDENT

CIRCUIT

19U-F

DOOR SWITCH FUSED POWER

43S-B

DOOR OPEN SIGNAL

Issued 11-11

Printed in E.C.

4002-53 DTLTS, DEF TANK LEVEL TEMP SENSOR

W230R399

CAV

WIRE IDENT

CIRCUIT

38B-A

DEF LEVEL SIG

0-TA

DEF SENSOR GND

38G-A

DEF TEMP SIG

DTS, DOWNSTREAM TEMP SENS CAV

WIRE IDENT

CIRCUIT

38E

EXHT TEMP DWN B+

0-U

EXHT TEMP DWN GND

CONNECTOR D-OR - DIODE OR

245485C1

CAV

WIRE IDENT

CIRCUIT

42C-D

FRONT WORK LIGHTS FUSED POWER

41T-C

POSITION LIGHTS SWITCHED POWER

BACK LIGHT POWER

84547255A

Issued 11-11

Printed in E.C.

4002-54 EDC7, ENGINE CONTROLLER

CAV

WIRE IDENT

CIRCUIT

CAN1-H

CAN HI

CAN-HK

CAN HI, EDC

28F

FUEL FLTR HTR RLY CTRL

21G-A

EDC7 CRANK CTRL RLY

13M-A

FUEL SHUTOFF FUSED PWR

35W

WIF INDICATOR

24L

LOW IDLE SWITCH

13A

EVGT RELAY

CAN-LS

CAN LO, NOX

CAN-L3

CAN2 LO, NOX

CAN-HS

CAN2 HI, NOX

CAN-H3

CAN2 HI, NOX

23K-A

TEMP/HUMD B+

0-BV

GRID HEATER CTRL GND

24S

THROT SUPPLY

24R

THROT GND

24B

THROT SIGNAL

20G-A

EDC7 ISO-K INTERFACE

ECA L1, B+ POWER CAV cs01

BOSCH-89-POLE

CAV

WIRE IDENT

CIRCUIT TRANS ECM PWR

CONNECTOR EM - HEIGHT CONTROL RTD - RTT

CIRCUIT

18J-C

EDC7 FSD PWR

18J-B

EDC7 FSD PWR

0-BE

EDC7 GND

0-BF

EDC7 GND

18J-D

EDC7 FSD PWR

18J-E

EDC7 FSD PWR

0-BD

EDC7 GND

0-BC

EDC7 GND

28G

GRID HTR SOURCE DR

EDC RELAY CNTL

21H-A

CRANK CTRL RLY LSD

23K-B

TEMP/HUMD TEMP

23K-C

TEMP/HUMD HUMD

23K-E

TEMP/HUMD GND

21F-B

EDC7 DIGITAL GND

21E-A

KEY SWITCH CRANK

CAN-LJ

CAN LO, EDC

CAN1-L

CAN LO

84547255A

WIRE IDENT

225351C1

CAV

WIRE IDENT

CIRCUIT

55A-A

RTT/FLOAT SWITCHED POW.

54A

HEIGHT CONTROL SWITCHED POWER

53A

RTD SWITCHED POWER

53B-B

RTD CONTROL SIGNAL

54B-B

HC-RTT CONTROL SIGNAL

55B

RTT FLOAT SWITCH CONTROL

Issued 11-11

Printed in E.C.

4002-55 ENG B, CAB BOTTOM

ENG, ENGINE CAB1 CAV

WIRE IDENT

CIRCUIT

36F

FUEL LEVEL ANALOG

36J

FUEL LEVEL ANALOG

61C-A

AC RELAY OUT

21G-A

EDC7 CRANK CTRL RLY

21H-A

CRANK CTRL RLY LSD

36C

RADIATOR COOL TEMP SGNL

0-BAT

CRANK REQUEST GND

0-BK

TELE GROUND

61H-A

HEAT LOAD VLV SOL

21F-A

EDC7 DIGITAL GND

CAN-L

CAN LOW

CAN1-L

CAN LO

CAN-H

CAN HIGH

CAN1-H

CAN HI

21D

STRTR RLY SIGNAL

460

FAN SPEED SENSOR SIGNAL

0-BJ

AIC SENSOR GND

225320C1

CAV

WIRE IDENT

CIRCUIT

21F-C

EDC7 DIGITAL GND

0-BBR

GROUND

24B

THROT SIGNAL

24R

THROT GND

24S

THROT SUPPLY

24L

LOW IDLE SWITCH

61R-C

AC SWITCH OUTPUT

61A-C

AC SWITCH INPUT

84547255A

38H

DNOX2 K-LINE

0-BG

AIC POWER GND

0-BH

AIC POWER GND RED

13C-A

FUEL SHUTOFF FUSED PWR

52A-B

FAN REVERSE RLY OUT

56-A

FAN CONTROL PWM

68W-A

REAR WSHR PUMP

63W-A

FNT WASHER PUMP

ALTERNATOR D+

14-5

ALTERNATOR D+

21E-A

KEY SWITCH CRANK

31F

AIR FLTR REST SW SGNL

61R

AC RELAY CONTROL

61A

AC PRESS SW INPUT

20G-A

EDC7 ISO-K INTERFACE

Issued 11-11

Printed in E.C.

4002-56 ECA, ELECT CNTR A

87315248

CAV A1

WIRE IDENT 19A-N

CIRCUIT TRANS FUSE PWR

18S-A

B+, JSS FUSED

19E-A

AIC WAKE UP IGN

19RR

SEC STR IGN FSD PWR

19C-A

PILOT CTRL RLY FSD PWR

19D-A

PARK BRK RLY FSD PWR

19P

PIN ENGAGE/FAN FSD PWR

19B

TURN SIGNAL FSD PWR

13C-B

FUEL SHUTOFF FUSED PWR

A10

18T

DNOX SW B+

18N

BLOWER MOTOR FUSED PWR

19J

FNT WPR FSD PWR

19K

REAR WPR FSD PWR

19H

BACKUP ALARM B+

19N

SEAT CPRSR FSD PWR

19M

SEC STR ACCESSORY FSD PWR

19W

CIGAR LIGHTER FSD PWR

66A

RR CAMERA PWR

TRANS ECM PWR

EMG STR AIC PWR

84547255A

CAV

WIRE IDENT

CIRCUIT

EMG STRG PLT EM DTNTS

PLTEM DTNTS PRK BRK SOL

PRK BRK SOL HRN

FAN RVSR TURN SGNL

TURN SGNL ENG SHTDWN.

J10

DNOX SW B+

J11

BLWR MOTOR PWR

J12

BLWR MTR FRNT WIPR WASH

J13

FRNT WIPR RER WIPR WSH

J14

RER WIPR WSH BACKUP

J15

BKUP A/C

J16

HEATED MIRRORS

J17

SEAT COMP EMG STRTR

J18

DIAGNOSTIC PWR

Issued 11-11

Printed in E.C.

4002-57 ECB, ELECT CNTR B

87312843

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

12V-D

PLUG 1 12V SW PWR

0-DE

NEUT START RLY CTRL GND

12V-E

PLUG 2 12V SW PWR

21F

EDC7 DIGITAL GND

41H-B

HIGH BEAM LH PWR

0-DF

CRANK REQUEST RLY CTRL GND

41H-C

HIGH BEAM RH PWR

41L-C

LOW BEAM RH PWR

41L-B

LOW BEAM LH PWR

41T-B

POSN LIGHTS LH SW PWR

41T-A

POSN LIGHTS RH SW PWR

12V-F

RADIO 12V SW PWR

A10

12V-G

2 WAY RADIO 12V SW PWR

AA1

12V

12V PWR TO OUTLET 1

AA2

12V-A

12V PWR TO OUTLET 2

AA3

18B-A

LH HIGH BEAM FUSED PWR

AA4

18C-A

RH HIGH BEAM FUSED PWR

AA5

18E-A

RH LOW BEAM FUSED PWR

AA6

18D-A

LH LOW BEAM FUSED PWR

AA7

18F-C

LH POSN/TAIL FUSED PWR

AA8

18G

RH POSN/TAIL FUSED PWR

AA9

12V-B

12V FUSED PWR TO RADIO

0-EW

POWER RELAY GND

0-EV

IGN LATCH GND

21K-B

IGN SW START SIGNAL

84547255A

19P-E

FAN REV RLY FSD PWR

FAN REVERSER LSD

19D-C

PARK BRK RLY FSD PWR

B10

52C

PARK BRK SOL LSD

0-EA

PWR RELAY GND

13K-B

IGN PWR LATCH B+

0-ET

POWER RELAT GND

25T

NEUTRAL SIGNAL

21C

NEUTR START RLY OUTPUT

21C-A

NEUTR START RLY OUTPUT

21E

KEY SWITCH CRANK

19P-D

FAN REV RLY FSD PWR

52A-A

FAN REVERSE RLY OUT

19D-B

PARK BRAKE RLY FSD PWR

D10

52P-B

PARK BRK RLY OUT

Issued 11-11

Printed in E.C.

4002-58 ECD, ELECT CNTR D

87312843

CAV

WIRE IDENT

CIRCUIT

0-EF

BRK LTS RLY CTRL GND

1-DW

BRAKE LT RLY BAT PWR

0-EZ

POWER RELAY CONTROL

0-EY

POWER RELAY GND

21H

CRANK CTRL RLY LSD

21C-B

NEUT START RLY OUTPUT

23B-C

NOX RELAY GND

23B-A

NOX SENSOR B+

35C

BACK UP ALRM CNTL

A10

19H

BACK ALARM B+

AA1

44A-A

BRK LT RLY OUT

AA2

44A

BRK LT CTRL PWR

AA3

0-KA

IGN PWR CONTROL GND

AA4

13K-A

IGN PWR CONTROL B+

AA5

21D-A

STRTR RLY SIGNAL

AA6

21G

EDC7 CRANK CTRL RLY

AA7

23B-B

NOX SENSOR B+

AA8

23B-D

NOX RELAY B+

AA9

35A-A

BACKUP ALARM

AA10

19A-P

BACKUP ALARM RELAY

19J-E

FNT WPR RLY FSD PWR

63HC-B

FNT WPR RLY HS

84547255A

CAV

WIRE IDENT

CIRCUIT

63C3

FNT WPR PARK CTRL

63LC

FNT WPR LS RLY CTRL

19C-B

PILOT CTRL RLY FSD PWR

53C-A

PILOT CTRL RLY SOL LSD

58T

RIDE CTRL RLY SW PWR

58L

RIDE CTRL RLY LSD

61A-G

TRINARY PRESS SW INPUT

B10

0-DJ

AC RELAY CONTROL GND

63C2

FNT WPR PARK CTRL

63C

FNT WPR PARK CTRL

C10

61C

AC RELAY OUT

19J-D

FNT WPR RLY FSD PWR

63H-B

FNT WPR RLY HS

19J-F

FNT WPR RLY LS CTRL FSD PWR

63-C2

FNT WPR PARK CTRL

19C-C

PILOT CTRL RLY FSD PWR

53P-C

PILOT CTRL RLY OUT

58H-C

POWER

58-E

RIDE CTRL SOL PWR

61R-B

AC RELAY CONTROL

Issued 11-11

Printed in E.C.

4002-59 ECC, ELECT CNTR C

87315249

CAV

WIRE IDENT

CIRCUIT

CAV D2

WIRE IDENT 19Y-A

CIRCUIT HOOD UP RLY FSD PWR

19U-B

BEACON DOME LT FSD PWR

WORK LIGHTS SW FSD PWR

59D

HOOD DOWN RLY CTRL

19Y-B

HOOD DOWN RLY FSD PWR

19Z

DRIVING LTS SW FSD PWR

1-DV

BRK LTS/FLASHER BAT PWR

19U-E

HORN RLY FSD PWR

1DM

TIME DELAY/IGN SW FSD PWR

64-A

HORN POWER

19U

HORN RLY FSD PWR

21J

RESTART PREVENT

67B

START LOCKOUT

19Y

HOOD CTRL FSD PWR

D10

19S-B

AIC DELAY FSD PWR

L1-1

ECC-L1

BEACON/DOME LT LI ECC

18K-A

DIAGNOSTIC FUSED PWR

L1-1

J2-ECC

BEACON/DOME LT WORK LTS

A10

19T-C

FUSED BATT PWR

L1-2

J3-ECC

WORK LTS DRIVING LTS

J2-ECC

BEACON/DOME LT WORK LTS

60U

HOOD UP RLY OUT

L1-2

0-B25

HOOD UP CONTROL GND

L1-3

J4-ECC

DRIVING LTS BRK LTS

60D

HOOD DOWN RLY OUT

L1-3

J3-ECC

WORK LTS DRIVING LTS

0-B16

HOOD DOWN CONTROL GND

L1-4

J5-ECC

BRK LTS DLY PWR

J4-ECC

DRIVING LTS BRK LTS

19U-A

HORN RLY FSD PWR

L1-4

64C

HORN RLY CTRL

L1-5

J6-ECC

DLY PWR HRN

21E

KEY SWITCH CRANK

L1-5

J5-ECC

BRK LTS DLY PWR

B10

0-J

START LOCKOUT RLY GND

L1-6

J7-ECC

HRN HOD CTRL

J6-ECC

DLY PWR HRN HRN HOD CTRL

0-B22

HOOD UP RELAY GND

L1-6

0-B12

HOOD DOWN RELAY GND

L1-7

J7-ECC

C10

21E-B

KEY SWITCH CRANK

L1-8

J9-ECC

59U

HOOD UP RLY CTRL

L1-9

J10-ECC

L1-10

J10-ECC

84547255A

Issued 11-11

Printed in E.C.

4002-60 ENG2, ENG BULKHD 2

CONNECTOR ENG-D - DISCONECT HARNESS

245483C1

CAV

WIRE IDENT

CIRCUIT

13C-A

FUEL SHUTOFF FUSED POW

13M-B

WIF IGN PWR

W230R397

CAV

WIRE IDENT

CIRCUIT

23B-F

NOX RELAY B+

18U-D

DCU B+ NON DISCONNECTD

23A-A

DNOX2 MODULE B+

1-NK

PWR NON DISCONNECTD

18U-B

DCU B+ NON DISCONNECTD

23B-E

NOX SENSOR B+

1-NJ

PWR NON DISCONNECTD

18T-A

DNOX2 SW B+

35A-G

BKUP ALM RLY OUT

35A-GN

BKUP ALM RLY OUT

35A-J

REVERSE LT

35A-R

BKUP ALM RLY OUT

18F-AN

LH POSN/TAIL FUSED PWR

18F-B

LH POSN/TAIL FUSED PWR

18G-H

RH POSN/TAIL FUSED PWR

18G-HN

RH POSN/TAIL FUSED PWR

45R-A

RIGHT TURN SGNL

45R-AN

RIGHT TURN SGNL

45L-A

LEFT TURN SGNL

45L-AN

LEFT TURN SGNL

44A-D

BRK LT RLY OUT

44A-DN

CONNECTOR ENG-H - ENGINE TO HOOD

225320C1

CAV

WIRE IDENT

CIRCUIT

0-BAG-N

HOOD GROUND (NA)

44A-DN

BRAKE LIGHT RELAY OUT

45L-AN

LEFT TURN SIGNAL

45R-AN

RIGHT TURN SIGNAL

18G-HN

RH POSITION/TAIL FUSED PWR

18F-AN

LH POSITION/TAIL FUSED PWR

BRK LT RLY OUT

35A-GN

BACKUP ALARM RELAY OUT

19Y-D

HOOD SWITCH FSD PWR

35A-R

BACKUP ALARM RELAY OUT

60D-A

HOOD DOWN RLY OUT

59D-A

HOOD DOWN RLY CTRL

60U-A

HOOD UP RLY OUT

59U-A

HOOD UP RLY CTRL

84547255A

Issued 11-11

Printed in E.C.

4002-61 CONNECTOR E-HD - TRANSMISSION HOOD

CONNECTOR FLSHR - FLASHER MODULE

245485C1

CAV

WIRE IDENT

CIRCUIT

225389C1

18G-D

LIC PLATE LIGHT FUSED PWR

35A-G

BACKUP ALARM RELAY OUT

0-BAG

HOOD GROUND (EURO)

CONNECTOR ESS - ENGINE SPEED SENSOR

CAV

1 2

WIRE IDENT

1-DU

FLASHER MODULE POWER

45N-A

FLASHER OPT. SIDE CONTR.

0-EH

FLASHER MODULE GROUND

0-EG

FLASHER MODULE GROUND

NOT USED

45R-E

RIGHT TURN SIGNAL

45L-D

LEFT TURN SIGNAL

45A-A

LEFT TURN SWITCH POWER

45B-A

RIGHT TURN SWITCH POWER

45H

HAZARD SWITCH POWER

45N-B

FLASHER OPT. SIDE CONT.

CONNECTOR FM - FILTER MAINTENANCE SWITCH

CIRCUIT

25A

ENGINE SPEED SIGNAL

0-HF

ENGINE SPEED SENSOR GROUND

CIRCUIT

291718A1

CAV

WIRE IDENT

CONNECTOR FFH - FULE FILTER HEATER

371614A1

CAV

WIRE IDENT

CIRCUIT

32F

TRANS FILTER MAINT SW

36R-B

TRANS FM SWITCH RETURN

182069A1

CAV

WIRE IDENT

CIRCUIT

1-GB

FUEL FILTER HEATER PWR

0-BX

FUEL FILTER HEATER GROUND

84547255A

Issued 11-11

Printed in E.C.

4002-62 FNR RLY, RELAY K2 CAV

WIRE IDENT

CONNECTOR FWM - FRONT WIPER MOTOR

CIRCUIT

19B-A

FNR SW FUSED PWR

0-ST

GRND, JOYSTICK

51B-K

JSS POWER

19B-B

TRANS ENA SW PWR

87A

0-SS

TRANS ENA SW PWR

FRONT, FRNT CHAS-CAB 245715C1

CAV

WIRE IDENT

CIRCUIT

45L

LEFT TURN SGNL

45R

RIGHT TURN SGNL

18G-A

RH POSN/TAIL FUSED PWR

18B

LH HIGH BEAM FUSED PWR

53P-G

PILOT CTRL RLY OUT

18F

LH POSN/TAIL FUSED PWR

54B

HC-RTT CTRL SGNL

53B

RTD CTRL SIGNAL

HORN POWER

18D

LH LOW BEAM FUSED PWR

18E

RH LOW BEAM FUSED PWR

18C

RH HIGH BEAM FUSED PWR

PIN ENGAGE SOL PWR

58-B

RIDE CONTROL SOL PWR

58-G

RIDE CONTROL SOL PWR

CAV

WIRE IDENT

CIRCUIT

63H-A

FRONT WIPER HIGH SPEED RLY OUT

63L-A

FRONT WIPER LOW SPEED RLY OUT

19J-A

FRONT WIPER MOTOR FUSED POWER

63C

FRONT WIPER PARK CONTROL

CONNECTOR FWMG - FRONT WIPER MOTOR GROUND

FWD DIODE, DIODE ASSY CAV

WIRE IDENT

CIRCUIT

26F-D

FNR FORWARD SIGNAL

26F-E

FNR FORWARD SIGNAL

26F-C

FNR FORWARD SIGNAL

84547255A

245480C1

CAV A

WIRE IDENT 0-B8

CIRCUIT FRONT WIPER MOTOR GROUND

Issued 11-11

Printed in E.C.

4002-63 CONNECTOR FWW - FRONT WASHER

GHF3, GRID HEATER FUSE CAV 1

WIRE IDENT 1-Y

CIRCUIT GRID HTR FSD PWR

GHF4, GRID HEATER CAV 1

WIRE IDENT 1-Y

GND CAB1 , GROUND A

3227856R1

CAV

WIRE IDENT

CIRCUIT CAV

63W-A

FRONT WASHER PUMP

0-B

FRONT WASHER GROUND

GH, GRID HEATER CAV 1

WIRE IDENT 1-BE

CIRCUIT

0-DD

WORK LIGHTS GRND

0-DR

ROOF SPLICE GNDS

0-DS

ROOF SPLICE GNDS

CIRCUIT

GND CAB2 , GROUND A

GRID HTR PWR

GH 1, GRID HEATER

WIRE IDENT

CAV

CIRCUIT GRID HTR FSD PWR

WIRE IDENT 0-ES

CIRCUIT

WIRE IDENT

CIRCUIT

0-B8

FRONT WIPER MOTOR GND

0-B10

HOOD GND

0-B26

BUZZER/SW PAD GND

GRID HTR GND

GND CAB3 , GROUND C CONNECTOR GHC - GRID HEATER RELAY

CAV

WIRE IDENT

CIRCUIT

0-DG

CAB SPLICE GNDS

0-DV

CIGAR LIGHTER GND

GND CAB3D , GROUND A CAV

3227856R1

CAV

WIRE IDENT 28G

GRID HTR SOURCE DR

0-BV

GRID HTR CONT GND

0-DP

DIAG TECM GND

0-DQ

DIAG TECM GND

0-DAV

TECM DIAGNOSTIC GND

GND CAB4 , GROUND C CAV

GHF1, GRID HEATER FUSE

WIRE IDENT 1-E

84547255A

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

0-ED

HVAC GNDS

0-EJ

POWER CONVERTER GND

0-ER

POWER CONVERTER GND

GRID HTR FUSE BAT PWR

Issued 11-11

Printed in E.C.

4002-64 GND CAB5 , GROUND C CAV

WIRE IDENT

GND CAB SPL2, SPL BACK LGHT GD

CIRCUIT

0-EK

AUX POWER OUTLET 1 GND

0-EL

AUX POWER OUTLET 2 GND

GND CAB6, STRT, FFH, WAT SEP HTR CAV 1

WIRE IDENT

CIRCUIT SPLICE PACK GND CAB SPL2 GND

0-EQ

87324393

EVGT3, EVGT FUSE CAV

WIRE IDENT

CAV

CIRCUIT

WIRE IDENT

CIRCUIT

0-J

START LOCKOUT RLY GND

0-KA

IGN PWR CONTROL GND

1-T

EVGT 3 PWR

1-B

EVGT RELAY PWR

0-K

CAMERA GND

0-EW

POWER RELAY GND

0-BBC

JOYSTICK GROUND

0-DE

NEUT START RLY CTRL GND

0-EQ

SPLICE PACK GND CAB SPL2 GND

0-EH

FLASHER MODULE GND

0-EG

FLASHER MODULE GND

0-EF

BRK LTS RLY CTRL GND

CONNECTOR GND-CAB-SPL - CAB GROUND SPLICE

GND ENG1 , STRT, FFH, WAT SEP HTR CAV

87324393

CAV

WIRE IDENT 0-EE

DIODE SUPPRESSION GROUNDS

0-EM

RADIO GROUND

0-EP

HORN SWITCH GROUND

0D-C

DIAG2 GROUND

23B-C

NOX RELAY GROUND

0-DG

CAB SPLICE GROUNDS

0-DT

FRNT WIP/WASHER SW GND

0-DK

SEAT COMPR MOTOR GND

0-VA

HEATED MIRRORS GND

0-DJ

AC RELAY CONTROL GRND

0-DU

PILOT PRESS SOLEN GND

0-DH

DIAGNOSTIC CONNECTOR GROUND

84547255A

CIRCUIT

0-BW

WATER SEP HEATER GND

0-BX

FUEL FILTER HEATER GND

0-GB

STARTER RLY CTRL GND

CIRCUIT

WIRE IDENT

GND ENG2 , DEDICATED WIF, EDC CAV

WIRE IDENT

CIRCUIT

0-BP

WIF SENSOR GND

0-BAT

CRANK REQUEST GND

0-BAC

EDC7 GND

0-BAU

EVGT_2 GND

23D-D

NOX SENSOR GND

Issued 11-11

Printed in E.C.

4002-65 GND FC , GROUND A

GND ENG3 , SPLC PK, WSHR MTR CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

0-BM

ENGINE SPLICE GNDS

0-AG

FRONT CHASSIS GND

0-BBR

GROUND

0-AB

PROX SW GND

GND GH1, STRT, FFH, WAT SEP HTR

GND ENG4 , REAR LIGHTING CAV

WIRE IDENT

CIRCUIT

0-BAG

HOOD GROUNDS (EURO)

0-BAG-N

HOOD GROUNDS (NA)

0-BT

LH REAR LIGHT GND (EURO)

0-BR

RH REAR LIGHT GND (EURO)

CAV 1

CAV

WIRE IDENT

0-ES

CIRCUIT GRID HTR GND

GND JSS , GROUND A

EVGT4, EVGT

WIRE IDENT

WIRE IDENT 0-AV

CIRCUIT

CIRCUIT GRND

GND PDST , GROUND A

13B

EVGT RELAY PWR

31A

EVGT RELAY B+

CAV

13A

EVGT RELAY

1-B

EVGT RELAY PWR

WIRE IDENT 0-BA

CIRCUIT PEDESTAL GND STRAP

GND PDST1 , GROUND A FSS, FAN SPEED SENS CAV CAV

WIRE IDENT

CIRCUIT

460

FAN SPEED SENSOR SIGNAL

017A

FAN SPEED SENSOR GND

GND ENG6 , DEDICATED

WIRE IDENT

0-DA

CIRCUIT AIC CHASSIS GND

GND PDST2 , GROUND A CAV 1

CAV

WIRE IDENT

WIRE IDENT 0-BA

CIRCUIT PEDESTAL GND STRAP

CIRCUIT

0-BG

AIC POWER GND

0-BH

AIC POWER GND RED

0-BJ

AIC SENSOR GND

0-BAR

WIF BODY GRND

GND S1 , GROUND A CAV 1

WIRE IDENT

CIRCUIT FRONT TO REAR CHASSIS GND

0-AP

GND ENG7 , GRND TRANS CLNT GND S2 , GROUND A CAV

WIRE IDENT

CIRCUIT

017A

FAN SPEED SENSOR GND

0-BAE

EDC7 SENDER GND

0-BBF

DNOX2 MODULE GND

0-BK

TELE GROUND

0-BU

FUEL LEVEL SENDER GND

0-BZ

FUEL LEVEL SENDER GND

84547255A

CAV 1

WIRE IDENT 0-AP

CIRCUIT FRONT TO REAR CHASSIS GND

Issued 11-11

Printed in E.C.

4002-66 GND SSCHAS, SSM GROUND CABLE CAV 1

WIRE IDENT 0-ND

CONNECTOR HD-E - HOOD HARNESS TO TRANSMISSION HARNESS

CIRCUIT SSM GROUND

GND SSMOD, SEC STR CHASIS GND CAV

WIRE IDENT

CIRCUIT

0-CE

SEC STEERING CHASSIS GND

0-CD

SEC STEERING SPLICE GND

245484C1

CAV

GND WIF, GRND WIF RING TERM CAV 1

WIRE IDENT 0-BAR

CIRCUIT WIF BODY GRND

WIRE IDENT

CIRCUIT

18G-E

LICENSE PLATE LIGHT FUSED PWR

35A-H

BACKUP ALARM RELAY OUT

0-JA

HOOD GROUND (EURO)

HDM, HOOD LIFT MOTOR

GND TRANS, GROUND TRANS CAV

WIRE IDENT

CAV

CIRCUIT

0-HW

HOT GROUND

0-HR

HYD FLTR SW GRND

0-HL

RED BRAKE SW GND

0-HM

RED BRAKE SW GND

WIRE IDENT

CIRCUIT

60U-A

HOOD UP RLY OUT

60D-A

HOOD DOWN RLY OUT

CONNECTOR HD - HOOD SWITCH

245485C1

CAV

WIRE IDENT

CIRCUIT

59D-A

HOOD RELAY CONT DOWN

19Y-D

HOOD SWITCH FUSED PWR

59U-A

HOOD RELAY CONTROL UP

84547255A

Issued 11-11

Printed in E.C.

4002-67 CONNECTOR HD-N - HOOD TO ENGINE

HTS, HMDTY AND AMB TEMP CAV

WIRE IDENT

CIRCUIT

23K-A

TEMP/HUMD B+

23K-B

TEMP/HUMD TEMP

23K-C

TEMP/HUMD HUMD

23K-E

TEMP/HUMD GND

HVAC1, HVAC1 CAV 1 225319C1

CAV 1

WIRE IDENT 0-JA-N

WIRE IDENT 61A-F

TRINARY PRESS SW INPUT

18N-A

BLOWER MOTOR FUSED PWR

49A

BACK LIGHT POWER

61B-A

AC SIGNAL

CIRCUIT HOOD GROUNDS (NA)

44A-EN

BRAKE LIGHT RELAY OUT

45L-BN

LEFT TURN SIGNAL

45R-BN

RIGHT TURN SIGNAL

CIRCUIT

CONNECTOR HVAC2 - HVAC2

18G-JN

RH POSITION/TAIL FUSED PWR

18F-BN

LH POSITION/TAIL FUSED PWR

35A-HN

BACKUP ALARM RELAY OUT

HN1, HORN PWR CAV 1

WIRE IDENT 64

CIRCUIT HORN POWER

HN2, HORN GRND CAV 1

WIRE IDENT 0-AF

87552622

CIRCUIT CAV

HORN GND

WIRE IDENT

CIRCUIT

18N-B

BLOWER MOTOR FUS PWR

0-ED

HVAC GROUNDS

CONNECTOR HOT - HYDRAULIC OIL TEMPERATURE SENDER

194788A1

CAV

WIRE IDENT

CIRCUIT

36H

HYDR. OIL TEMP SIGNAL

0-HW

HYDR. OIL TEMP GROUND

84547255A

Issued 11-11

Printed in E.C.

4002-68 CONNECTOR ISS - INT-SPEED-SENSOR

JSS CAB

225389C1

291718A1

CAV

WIRE IDENT

CAV

CIRCUIT

WIRE IDENT

CIRCUIT

25B

INT SPEED SIGNAL

CANS-LP

CAN LOW,CAN MOD3

0-HG

INT SPEED SENSOR GROUND

17P-C

B+, CAN MOD

51D-A

GRND, RELAY CTRL

51B-C

JSS ACT SW

CAN-LR

CAN LOW, CAN MOD2

CAN-HR

CAN HI,CAN MOD3

0-BBD

JOYSTICK GROUND

51PW-N

JSS POWER

51C-A

JSS ACT BTN

18S-C

B+, JSS FUSED

CAN-HP

CAN HI,CAN MOD2

JSS ARM, JSS ARMREST TO CAB

JSS CONTROLLER CAV 1

WIRE IDENT

CANS-HD

CIRCUIT CAN HI, CAN MOD3

CANS-LD

CAN LO, CAN MOD3

17P-F

B+, JSS CONTROLLER

51H-B

JOYSTICK SIGNAL

51S-A

JSS OKAY PWR

CIRCUIT

51E-A

ARMREST LOWER

51L-A

JOYSTICK SIGNAL

W230R400

CAV

WIRE IDENT

CANS-HA

CAN HI, CAN MOD2

0-SH

GRND, CAN MOD

51K-B

PILOT PRESS SW

51E-B

ARMREST LOWER

51PW-Q

JSS POWER

17P-E

B+, CAN MODULE

0-SM

GRND, JOYSTICK

0-SN

GRND, JOYSTICK

51B-J

JSS ACT SW

0-SC

GRND, JOYSTICK

51J-B

VALVE ALARM

51PW-S

JSS POWER

51C-B

JSS ACT BTN

51S-C

JSS OKAY PWR

51NO-A

NO NEUTRAL SW

0-SR

GRND, JOYSTICK

51F-B

LS PRESS SW

51H-C

JOYSTICK SIGNAL

51NO

NO NEUTRAL SW

CANS-LA

CAN LO, CAN MOD2

84547255A

Issued 11-11

Printed in E.C.

4002-69 JSS PILOT PRESSURE

JSS FRAME TO CAB CAV

WIRE IDENT

CIRCUIT

51F-A

LS PRESS SW SIG

51F-C

LS PRESS SW SIG

51J-C

JSS ALARM

51K-C

PILOT PRESS SW SIG

51L

JOYSTICK SIGNAL

51S-J

JSS OKAY PWR

0-AS

GRND, JOYSTICK

51PW-H

JSS POWER

CAV

18S-E

B+, JSS FUSED

18S-E

B+, JSS FUSED

51K-C

PILOT PRESS SW SIG

245483C1

WIRE IDENT

CIRCUIT

JSS LOAD SENSE RLY, RELAY K2

245483C1

CAV

WIRE IDENT

CIRCUIT

51PW-J

JSS POWER

51F-A

LS PRESS SW SIG

245731C1

CAV

JSS PILOT DUMP CAV

WIRE IDENT

CIRCUIT

51PW-K

JSS POWER

0-AU

GRND, PILOT DUMP

84547255A

WIRE IDENT

CIRCUIT

51PW-P

JSS POWER

51D-B

GRND, RELAY CNTL

51B-E

B+, JSS

51B-G

B+, JSS

87A

0-SL

GROUND

Issued 11-11

Printed in E.C.

4002-70 JSS 197F, MAIN CAB FNR

JSS VALVE, JSS HYD VALVE

225350C1

CAV

WIRE IDENT

239451A1

CIRCUIT

0-SS

GRND, JOYSTICK

26F-D

FNR FORWARD SIGNAL

CAV

26N-D

FNR NEUT SIGNAL

26R-D

FNR REVERSE SIGNAL

32J-G

TRANS ENABLE INDICTION

25Y-F

TRANS KICK DOWN SIGNAL

WIRE IDENT

CIRCUIT

51L

JOYSTICK SIGNAL

51J-C

JSS ALARM

0-AT

GRND, JSS VLV

51S-J

JSS OKAY PWR

KD DIODE, DIODE ASSY JSS 197M, FNR-MAIN CAB

245485C1

CAV A 225351C1

CAV

WIRE IDENT

CIRCUIT

19B-A

FNR SW FUSED PWR

26F-C

FNR FORWARD SIGNAL

26N-C

FNR NEUT SIGNAL

16R-C

FNR REVERSE SIGNAL

32J-F

TRANS ENABLE INDICTION

25Y-D

TRANS KICK DOWN SIGNAL

84547255A

WIRE IDENT 25Y-F

CIRCUIT TRANS KICK DOWN SIGNAL

25Y-E

TRANS KICK DOWN SIGNAL

25Y-D

TRANS KICK DOWN SIGNAL

KWCO, WIPER CUT OUT CAV

WIRE IDENT

CIRCUIT

63L-B

FNT WPR LS RLY OUT

63HC-A

WPR CUT OUT RLY CTRL

19J-G

WPR CUT OUT RLY FSD PWR

87A

63C3

FNT WPR PARK CTRL

Issued 11-11

Printed in E.C.

4002-71 LDM3, DOME LIGHT GND

LLR, LH REAR COMB. LT CAV

WIRE IDENT

CIRCUIT

0BR-N

LH REAR LIGHT GND (NA)

44A-FN

BRK LT RLY OUT

18F-BN

LH POSN/TAIL FUSED PWR

45L-BN

LEFT TURN SGNL

CAV 1

WIRE IDENT 0-MB

CIRCUIT DOME LIGHT GND

LLF, LIGHTS LH

LLR, RH REAR COMB. LT CAV

WIRE IDENT

CIRCUIT

0BT-N

RH REAR LIGHT GND (NA)

44A-GN

BRK LT RLY OUT

18G-CN

RH POSN/TAIL FUSED PWR

45R-BN

RIGHT TURN SGNL 225351C1

L1 ECC, ECC BATT PWR CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT

0-AJ

LH FRONT LIGHTS GND

18D

LH LOW BEAM FUSED PWR

18B

LH HIGH BEAM FUSED PWR

1-C

ECC BAT PWR

ECC-L1

BEACON/DOME LT LI ECC

18F

LH POSN/TAIL FUSED PWR

45L

LEFT TURN SGNL

LBEGRD, LIGHT BEACON GRND CONNECTOR LLFW - LH FRONT WORK LAMP CAV 1

WIRE IDENT 0-MC

CIRCUIT BEACON LIGHT GND

LBEPWR, LIGHT BEACON PWR CAV 1

WIRE IDENT 46-D

CIRCUIT BEACON SW PWR 245483C1

LDM1, DOME LIGHT B+ CAV 1

WIRE IDENT 19U-C

CIRCUIT DOME LT FSD PWR

CAV

WIRE IDENT

CIRCUIT

42C-H

LH FRONT WORK LTS FUSE PWR

0-MU

LH FRONT WORK LIGHT GND

LDM2, DOME LIGHT AUTO CAV 1

WIRE IDENT 43-B

84547255A

CIRCUIT DOME LT AUTO MODE

Issued 11-11

Printed in E.C.

4002-72 CONNECTOR LLRW- LH REAR WORK LAMP

CONNECTOR LPL - LICENSE PLATE LAMP

245483C1

CAV

WIRE IDENT

CIRCUIT

245482C1

CAV

42R-H

LH REAR WORK LTS FUS PWR

0-ME

LH REAR WORK LIGHT GRND

CONNECTOR LLR-E - LH REAR COMBINATION LAMP

WIRE IDENT

CIRCUIT

18G-E

LICENSE PLATE LAMP FUSED PWR

18G-EN

LICENSE PLATE LAMP FUSED PWR

18G-L

LICENSE PLATE LAMP FUSED PWR

0-JC

LICENSE PLATE LAMP GRND

CONNECTOR LRF - RH FRONT COMBINATION LAMP

225351C1

CAV

WIRE IDENT

CIRCUIT

44A-E

BRAKE LIGHT RELAY OUT

45L-A

LEFT TURN SIGNAL

18F-B

LEFT POSN/TAIL FUSED POWER

35A-L

REVERSE LT

CAV

LH REAR LIGHT GROUND (EURO)

0-AH

RH FRONT LIGHTS GROUND

18E

RH LOW BEAM FUSED PWR

NOT USED

18C

RH HIGH BEAM FUSED PWR

18G-A

RH POSIT/TAIL FUSED PWR

45R

RIGHT TURN SIGNAL

0-BT

225351C1

84547255A

WIRE IDENT

CIRCUIT

NOT USED

Issued 11-11

Printed in E.C.

4002-73 CONNECTOR LRFO - FRONT WORK LAMP OPT

CONNECTOR LRFW - RH FRONT WORK LAMP

245483C1

CAV

WIRE IDENT

CIRCUIT

245483C1

CAV

42R-K

RH FRONT WORK LAMP FUSED PWR

0-MP

RH FRNT WORK LAMP GRND

CONNECTOR LRFR - FRONT WORK LAMP OPT

WIRE IDENT

CIRCUIT

42C-G

RH FRONT WORK LAMP FUSED PWR

0-MJ

RH FRONT WORK LAMP GRND

CONNECTOR LRRW- RH REAR WORK LAMP

245483C1 245483C1

CAV

WIRE IDENT

CIRCUIT

CAV

42R-B

RH FRONT WORK LAMP FUSED PWR

0-ML

RH FRNT WORK LAMP GRND

WIRE IDENT

CIRCUIT

42R-G

RH REAR WORK LAMP FUSED PWR

0-MF

RH REAR WORK LAMP GRND

CONNECTOR LRFS- FRONT WORK LAMP OPT

245483C1

CAV

WIRE IDENT

CIRCUIT

42R-A

RH FRONT WORK LAMP FUSED PWR

0-MG

RH FRONT WORK LAMP GRND

84547255A

Issued 11-11

Printed in E.C.

4002-74 CONNECTOR LRR-E - RH REAR COMBINATION LAMP

NOXS, NOX SENSOR CAV

WIRE IDENT

CIRCUIT

23A-A

DNOX2 MODULE B+

23D-D

NOX SENSOR GND

CAN-LU

CAN2 LO, NOX

CAN-HU

CAN2 HI, NOX

NTRL DIODE, DIODE ASSY 225351C1

CAV

WIRE IDENT

CIRCUIT

44A-F

45R-A

RIGHT TURN SIGNAL

18G-J

RIGHT POSITION/TAIL FUSED PWR

35A-K

REVERSE LAMP

0-BR

RH REAR LIGHT GND (EURO)

BRAKE LIGHT RELAY OUT

245485C1

CAV

NOT USED

CONNECTOR LSPK - LEFT SPEAKER

WIRE IDENT 26N-D

CIRCUIT FNR NEUT SIGNAL

26N-E

FNR NEUT SIGNAL

26N-C

FNR NEUT SIGNAL

CONNECTOR OSS - OUTPUT SPEED SENSOR

195552A1

CAV

WIRE IDENT

CIRCUIT

65L

LEFT SPEAKER

0-PA

LEFT SPEAKER GROUND

MON, CAMERA/MONITOR

291719A1

CAV CAV

WIRE IDENT

CIRCUIT

66A

RR CAMERA PWR

0-K

CAMERA GND

35A-M

REVERSE SIGNAL

84547255A

WIRE IDENT

CIRCUIT

0-HE

OUTPUT SPEED GROUND

25D

OUTPUT SPEED SIGNAL

19A

OUTPUT SPEED SENSOR FUSED PWR

Issued 11-11

Printed in E.C.

4002-75 CONNECTOR PAF - AIR FILTER RESTRICTION SWITCH

CONNECTOR PBL - BRAKE LAMP PRESSURE SWITCH

222136A1 291718A1

CAV

WIRE IDENT

CAV

CIRCUIT

31F

AIR FILTER RESTRICTION SWITCH SIGNAL

0-BY

AIR FILTER RESTRICTION SWITCH GRND

WIRE IDENT

CIRCUIT

1-AA

BRAKE LAMP SWITCH PWR

BRAKE LAMP CONTR PWR

CONNECTOR PBW - BRAKE PRESSURE WARNING SWITCH P A1, B+ POWER CAV 1

WIRE IDENT 1-C

CIRCUIT ECC BAT PWR

P A3, B+ POWER CAV 1

WIRE IDENT 1CB-A

CIRCUIT CAB CB PROTECTED PWR

225316C1

CAV

CONNECTOR PBD - BRAKE DECLUTCH PRESSURE SWITCH

WIRE IDENT

CIRCUIT

33P

LOW BRAKE PRESS WARNING

0-AL

BRAKE PRESS WARN SW GROUND

P C1, B+ PWR FRM PRMD CAV

WIRE IDENT

CIRCUIT

1-BG

B+ PWR PRMC

1-NC

B+ PWR PRMC

245482C1

CAV

WIRE IDENT

CIRCUIT

19A-A

BRAKE DECLUTCH SW FUSED PWR

25G

BRAKE DECLUTCH SWITCH CONTROL

84547255A

P C2, B+ PWR FRM PRMD CAV 1

WIRE IDENT 1-E

CIRCUIT GRID HTR FUSE BAT PWR

Issued 11-11

Printed in E.C.

4002-76 P C3, B+ PWR FRM PRMD CAV 1

WIRE IDENT 1CB

CONNECTOR PO2 - POWER OUTLET

CIRCUIT CAB CB PROTECTED PWR

P C4, B+ PWR FRM PRMD CAV 1

WIRE IDENT 1-Z

CIRCUIT STRTR RLY BAT PWR

P C6, B+ PWR FRM PRMD CAV 1

WIRE IDENT 1-T

CIRCUIT

12176446

EVGT3 POWER

CAV A

12V-A

PHF, HYD OIL FILT RES SW

WIRE IDENT 31H

CIRCUIT 12V PWR TO OUTLET 2 NOT USED

C CAV

WIRE IDENT

0-EL

AUX POWER OUTLET 2 GND

CIRCUIT HYD FLTR REST SW SGNL

PRH, AC HIGH PRESS SW

PHF9, HYD FLTR RES SW CAV

WIRE IDENT

CIRCUIT

0-HR

HYD FLTR SW GRND

31-H9

HYD FLTR RST SW 9

CONNECTOR PO1 - POWER OUTLET

245483C1

CAV

WIRE IDENT

CIRCUIT

61A-D

AC SWITCH INPUT

61R-D

AC SWITCH OUTPUT

CONNECTOR PRB1 - REDUNDANT BRAKE SWITCH

12176446

CAV A

WIRE IDENT 12V

B C

CIRCUIT 12V PWR TO OUTLET 1 NOT USED

0-EK

245483C1

AUX POWER OUTLET 1 GND CAV

84547255A

WIRE IDENT

CIRCUIT

33R-C

RDNT BRAKE ACCUMULATOR PRESS LOW

0-HM

RED BRAKE SW GROUND Issued 11-11

Printed in E.C.

4002-77 CONNECTOR PRB2 - REDUNDANT BRAKE SWITCH

PRM A2, PRM SIGNAL CAV

WIRE IDENT

CIRCUIT

12ACC-C

PWR CONVERTER PRM CTRL PWR

0-EU

PWR CONVERTER RLY CTRL GND

CONNECTOR PRM-B1 - PRM SIGNAL 245483C1

CAV

WIRE IDENT

CIRCUIT

33R-B

RDNT BRAKE ACCUMULATOR PRESS LOW

0-HL

RED BRAKE SW GROUND

CONNECTOR PRBF - ROLLBACK PRESSURE SWITCH 256340A1

CAV

WIRE IDENT

CIRCUIT

12ACC-B

ACC PRM CONTROL POWER

0-EC

ACC RELAY CONTROL GND

PRM C1, PRM SIGNAL 245483C1

CAV A B

WIRE IDENT 58 58-B

CAV

CIRCUIT

WIRE IDENT

CIRCUIT

RIDE CONTR SOLENOID PWR

13K-C

IGNITION SWITCH POWER

RIDE CONTR SOLENOID PWR

0-EB

IGNITION RELAY CTRL GND

PRM D1, PRM OUTPUT

PRM A1, PRM OUTPUT CAV

WIRE IDENT

CIRCUIT

18J-F

EDC7 FSD PWR

1-GA

FLTR HTR PWR

PRM D2, PRM SIGNAL 409084A1

CAV

WIRE IDENT

CIRCUIT

18U-A

DCU B+ NON DISCONNECTD

19L

PWR CONVERTER FSD PWR

84547255A

CAV

WIRE IDENT

CIRCUIT

28F

FUEL FLTR HTR RLY CTRL

31B

FILTER HEATER CONTROL

Issued 11-11

Printed in E.C.

4002-78 PRMB L1, B+ POWER CAV

WIRE IDENT

CS01

J11

CONNECTOR PXF - RTD

CIRCUIT BLWR MOTOR PWR

PRMB L2, B+ POWER CAV 1

WIRE IDENT 19S1

CIRCUIT SEC STRG PWR 245485C1

CAV

PVRES, JSS JOYSTICK CAV

WIRE IDENT

CIRCUIT

51S-E

JSS OKAY PWR

51PW-V

JSS POWER

51H-C

JOYSTICK SIGNAL

51NO

NO NEUTRAL SW

0-SC

GRND, JOYSTICK

51NC

NC NEUTRAL SW

WIRE IDENT

CIRCUIT

53B

RTD CTRL SIGNAL

0-AC

PROXIMITY SWITCH GROUND

53P-H

PILOT CONTROL RELAY OUT

CONNECTOR PXH - HEIGHT CONTROL RTT

CONNECTOR PSS - SECONDARY STEERING PRESSURE SWITCH

245485C1

CAV A

WIRE IDENT 54B

HC-RTT CTRL SIGNAL

0-AA

PROXIMITY SWITCH GROUND

53P-J

PILOT CONTROL RELAY OUT

245485C1

CAV

WIRE IDENT

CONNECTOR PXM - RTD

CIRCUIT

51P-A

SECONDARY STEER HIGH PRESSURE

0-CC

SEC. STEER PRESS SWITCH GROUND

35X-A

SECONDARY STEER LOW PRESS SIG

CIRCUIT

245485C1

CAV

84547255A

WIRE IDENT

CIRCUIT

53B-A

RTD CONTROL SIGNAL

0-AM

RTD GROUND

53P-I

PILOT CONTROL RELAY OUT

Issued 11-11

Printed in E.C.

4002-79 CONNECTOR PXT - RTD

CONNECTOR RAD-J1 - RADIO POWER

245485C1

CAV

WIRE IDENT

CIRCUIT

53B-A

RTD CONTROL SIGNAL

0-AM

RTD GROUND

CAV

53P-I

PILOT CONTROL RELAY OUT

NOT USED

292497A1

R1, RESISTOR

4 CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

RAD3

CIRCUIT

12V FUSED PWR TO RADIO NOT USED

CS0

0-SP

GRND, JOYSTICK

CS0

51J-D

VALVE ALARM

RAD2

12V FUSED PWR TO RADIO

RAD1

RADIO GROUND

NOT USED

CONNECTOR RAD - RADIO POWER CONNECTOR RAD-J2 - SPEAKER

292495A1

CAV

WIRE IDENT

CIRCUIT

292501A1

NOT USED

CAV

NOT USED

RAD11

RIGHT SPEAKER

NOT USED

RAD10

RIGHT SPEAKER GROUND

12V FUSED PWR TO RADIO

RAD9

NOT USED

RAD8

NOT USED

RAD7

NOT USED

3 4

12V-HB

WIRE IDENT

CIRCUIT

12V-HA

12V FUSED PWR TO RADIO

RAD6

NOT USED

0-EN

RADIO GROUND

RAD5

LEFT SPEAKER

RAD4

LEFT SPEAKER GROUND

84547255A

Issued 11-11

Printed in E.C.

4002-80 CONNECTOR RAD-J3 - RADIO JUMPER

RFLG, FUEL SEND GRND CAV 1

WIRE IDENT 0-BU

CIRCUIT FUEL LEVEL SENDER GND

RFL.23, FUEL LEVEL SEND 411311A1

CAV

WIRE IDENT

CIRCUIT

RAD10

RIGHT SPEAKER GROUND

RAD8

NOT USED

RAD4

LEFT SPEAKER GROUND

RAD6

NOT USED

RAD1

RADIO GROUND

CAV

WIRE IDENT

CIRCUIT

36J

FUEL LEVEL ANALOG

0-BZ

FUEL LEVEL SENDER GND

ROOF, ROOF TO CAB CONNECTION

NOT USED

RAD3

12V FUSED PWR TO RADIO

RAD11

RIGHT SPEAKER

RAD9

NOT USED

RAD5

LEFT SPEAKER

RAD7

NOT USED

RAD2

12V FUSED POWER TO RADIO

0-MV

RH FRONT WORK LIGHT GND

NOT USED

0-MH

REAR WORK LIGHT GND

NOT USED

43-B

DOME LT AUTO MODE

19U-C

DOME LT FSD PWR

46-D

BEACON SW PWR

0-MN

ROOF GROUNDS

0-MK

ROOF GROUNDS

42C-F

FNT WRK LTS FUSE PWR

19K-D

REAR WPR MOTOR FSD PWR

68C-A

REAR WPR PARK CTRL

68L-A

REAR WPR SW PWR

0-EN

RADIO GND

12V-H

12V FUSED PWR TO RADIO

19U-F

DOOR SW FSD PWR

43S-B

DOOR OPEN SGNL

42R-F

REAR WRK LTS FUSE PWR

388708A1

CAV

CONNECTOR RECT - ENGINE COOLANT TEMPERATURE

WIRE IDENT

CIRCUIT

194788A1

CAV

WIRE IDENT

CIRCUIT

36C

RADIATOR COOLANT TEMP SIGNAL

0-BAE

EDC7 SENDER GROUND

RFL, FUEL SENDER CAV 1

WIRE IDENT 36F

84547255A

CIRCUIT FUEL LEVEL ANALOG

Issued 11-11

Printed in E.C.

4002-81 CONNECTOR RWM - REAR WIPER MOTOR

CONNECTOR RSPK - RIGHT SPEAKER

195552A1

CAV

WIRE IDENT

CIRCUIT

65R

RIGHT SPEAKER

0-PB

RIGHT SPEAKER GROUND

245715C1

CAV

WIRE IDENT

CONNECTOR RTHP - THROTTLE PEDAL

CIRCUIT NOT USED

68L-A

REAR WIPER SWITCH PWR

19K-D

REAR WIPER MOTR FUS PWR

68C-A

REAR WIPER PARK CONTROL

CONNECTOR RWMG - REAR WIPER MOTOR GROUND

225351C1

CAV 1

WIRE IDENT 21F-D

CIRCUIT EDC7 DIGITAL GROUND

NOT USED

24B-A

4 4

24R-A

THROTTLE SIGNAL

245480C1

NOT USED

CAV

THROTTLE POS. SENS GND

WIRE IDENT 0-MA

CIRCUIT REAR WIPER MOTOR GRND

NOT USED

24S-A

THROTTLE SUPPLY

24L-A

LOW IDLE SWITCH

CONNECTOR RWW - REAR WASHER

RVS DIODE, DIODE ASSY CAV

WIRE IDENT

CIRCUIT

26R-D

FNR REVERSE SIGNAL

26R-E

FNR REVERSE SIGNAL

16R-C

FNR REVERSE SIGNAL

3227856R1

CAV

84547255A

WIRE IDENT

CIRCUIT

68W-A

REAR WASHER PUMP

0-BL

REAR WASHER GROUND Issued 11-11

Printed in E.C.

4002-82 SAJ, FNR SWITCH CAV

WIRE IDENT

CONNECTOR SBU - BACKUP ALARM DISABLE SWITCH

CIRCUIT

26R-F

FNR REVERSE SIGNAL

26K

FNR SWITCH JUMPER

26N-F

FNR NEUT SIGNAL

19B-E

FNR SW FUSED PWR

26F-F

FNR FORWARD SIGNAL

32J-J

TRANS ENABLE INDICTION

19B-F

FNR SW FUSED PWR

25Y-F 382391A1

CAV

CONNECTOR SBE - BEACON SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

35R-C

BACKUP ALARM SWITCH

35A-B

BACKUP ALARM DISABLE SW

NOT USED

0-B21

BACK LIGHT GROUND

49-L

BACK LIGHT POWER

NOT USED

CIRCUIT NOT USED

19U-H

BEACON SWITCH FUS PWR

46-C

BEACON SWITCHED POWER

NOT USED

WIRE IDENT

CONNECTOR SC - SEAT COMPRESSOR MOTOR

NOT USED

0-B15

BACK LIGHT GROUND

49-B

BACK LIGHT POWER

NOT USED

245482C1

CAV

WIRE IDENT

CIRCUIT

19N

SEAT COMPRESSOR FUSED PWR

0-DK

SEAT COMPRESSOR MOTOR GROUND

SDA, DIFF LOCK SWITCH CAV 2

84547255A

WIRE IDENT

CIRCUIT

34A-A

DIFF LOCK SW B+

34B

DIFF LOCK SW SIG

0-B31

SDA GND

49-Z

BACK LIGHT PWR Issued 11-11

Printed in E.C.

4002-83 CONNECTOR SDC - DECLUTCH SWITCH

CONNECTOR SDR - DRIVING LIGHTS SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

382391A1

CAV

WIRE IDENT

CIRCUIT

25G-B

BRAKE DECLUTCH SWITCH CONTROL

19A-R

DECLUTCH SW FUSED PWR

19Z-A

DRIVING LIGHTS SW FUSED PWR

22A

41T

POSITION LIGHTS SW PWR

DECLUTCH SW

NOT USED

19Z-B

DRIVING LIGHTS SWITCH FUSED POWER DRIVING LIGHTS POWER

0-B18

BACK LIGHT GROUND

41J

49-R

BACK LIGHT POWER

0-B19

BACK LIGHT GROUND

NOT USED

49-P

BACK LIGHT POWER

NOT USED

SDM, DIFF LOCK SWITCH CAV

WIRE IDENT

CIRCUIT

34D

DIFF LOCK SW SIG

34A-B

DIFF LOCK SW SIG B+

84547255A

Issued 11-11

Printed in E.C.

4002-84 CONNECTOR SFC - FAN CONTROL SWITCH

CONNECTOR SFNR - FNR SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

382391A1

CAV

WIRE IDENT

CIRCUIT

NOT USED

26R-A

FNR REVERSE SIGNAL

52J

FAN CONTROL SW JUMPER

26J

FNR SWITCH JUMPER

52-AU

FAN REVERSE AUTO

26N-A

FNR NEUTRAL SIGNAL

52J

FAN CONTROL SW JUMPER

26J

FNR SWITCH JUMPER

19P-C

FAN REVERSE SWITCH FUSED PWR

19A-V

FNR SWITCH FUSED POWER

26F-A

FNR FORWARD SIGNAL

52M

FAN REVERSE MANUAL

32J-A

TRANS ENABLE INDICATION

0-B7

BACK LIGHT GROUND

19A-G

49-Q

BACK LIGHT POWER

NOT USED

FNR SWITCH FUSED POWER

NOT USED

CONNECTOR SFWW - FRONT WIPER AND WASHER SWITCH

CONNECTOR SFL - RETURN-TO-TRAVEL SWITCH

87345132

382391A1

CAV

WIRE IDENT

CIRCUIT

55A-B

RTT/FLOAT SWITCH POWER

53P-B

PILOT CONTROL RELAY OUT

55A-C

RTT/FLOAT SWITCH POWER

0-29

RTT/FLOAT GROUND

55B

RTT FLOAT SW CONTROL

54B-C

HC-RTT CONTROL SIGNAL

0-B2

BACK LIGHT GROUND

49-K

BACK LIGHT POWER

NOT USED

84547255A

CAV

WIRE IDENT

CIRCUIT NOT USED

0-DT

FRONT WIPER/WASHER SW GND

63LC

FRNT WIP LS RELAY CONTR

19J-B

INT WIP/WAS SW FUSED PWR

4 5

NOT USED

63W

FRONT WASHER PUMP

49-T

BACK LIGHT POWER

63HC

FRONT WIPER HS RELAY CONTROL

NOT USED Issued 11-11

Printed in E.C.

4002-85 CONNECTOR SHC - HEIGHT CONTROL SWITCH

SJS, JOYSTICK CONTROL SW CAV

382391A1

CAV

WIRE IDENT

1 2

CIRCUIT

18S-B

B+, JSS FUSED

51B-A

JSS ACT SW

0-BBA

JOYSTICK GROUND

51C-A

JSS ACT BTN

51B-B

JSS ACT SW

0-BBB

JOYSTICK GROUND

49-W

JSS BACKLIGHT

0-BBE

JOYSTICK GROUND

51PW-N

JSS POWER

NOT USED 53P-D

PILOT CONTROL RELAY OUT

NOT USED

S KEY, IGNITION SWITCH CAV

CIRCUIT TIME DELAY/IGN SW FSD PWR

1DM

BACK LIGHT GROUND

21K

IGN SW START SIGNAL

13K

IGNITION SWITCH POWER

12ACC

IGNITION SW ACC POWER

54A

HC CONTROL SW PWR

0-B3

BACK LIGHT POWER

NOT USED

49-M

WIRE IDENT

CONNECTOR SPB - PARKING BRAKE SWITCH CONNECTOR SHZ - HAZARD SWITCH

382391A1 382391A1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT NOT USED

NOT USED

19A-L

PARK BRK SW FUSED PWR

33U

PARK BRAKE SWITCH

1-KA

HAZARD SWITCH POWER

45H

HAZARD SWITCH POWER

NOT USED

0-B29

RTT/FLOAT GROUND

BACK LIGHT GROUND

49-V

BACK LIGHT POWER

NOT USED

7 8

0-B24 49-D

84547255A

Issued 11-11

Printed in E.C.

4002-86 CONNECTOR SPC - PILOT CONTROL SWITCH

CONNECTOR SPK - SPEAKER

382391A1

CAV

WIRE IDENT

292494A1

CIRCUIT NOT USED

CAV

65R

WIRE IDENT

RIGHT SPEAKER

CIRCUIT

0-PB

RIGHT SPEAKER GROUND

19C-F

PILOT CONTROL SW FUSED PWR

31L

PILOT CONTROL SW HIGH

NOT USED

NOT USED NOT USED

NOT USED

0-B1

BACK LIGHT GROUND

65L

LEFT SPEAKER

49-N

BACK LIGHT POWER

0-PA

LEFT SPEAKER GROUND

NOT USED

SPL ACP, ULTRASONIC

CONNECTOR SPE - PIN ENGAGE SWITCH

CAV

WIRE IDENT

CIRCUIT

61A-C

AC SWITCH INPUT

61A-D

AC SWITCH INPUT

61A

AC PRESS SW INPUT

SPL ACS, ULTRASONIC CAV

382391A1

CAV

WIRE IDENT

CIRCUIT

61R-C

AC SWITCH OUTPUT

61R-D

AC SWITCH OUTPUT

61R

AC RELAY CONTROL

CIRCUIT

57-B

PIN ENGAGE SOL PWR

19P-A

PIN ENGAGE SW FUS PWR

NOT USED

0-B5

BACK LIGHT GROUND

49-F

BACK LIGHT POWER

84547255A

WIRE IDENT

SPL AJ, ULTRASONIC CAV

WIRE IDENT

CIRCUIT

19B-C

FNR SW FUSED PWR

19B-D

FNR SW FUSED PWR

19B-E

FNR SW FUSED PWR

19B-F

FNR SW FUSED PWR

Issued 11-11

Printed in E.C.

4002-87 CONNECTOR SPL-BCK-LGT - SPLICE BACK LIGHT GRND

CAV

WIRE IDENT

CIRCUIT

0-B4

BACK LIGHT GND

0-B5

BACK LIGHT GND

0-B6

CAB 2 GND

NOT USED

0-B20

BACK LIGHT GND

0-B29

RTT/FLOAT GND

0-B11

BACK LIGHT GND

0-B7

BACK LIGHT GND

SPL BCK LGT, SPLICE BACK LGHT PWR 87324393

CAV

WIRE IDENT

CIRCUIT

0-B13

BACK LIGHT GND

0-B14

BACK LIGHT GND

0-B15

BACK LIGHT GND

0-B6

CAB 2 GND

0-B17

BACK LIGHT GND

0-B18

BACK LIGHT GND

0-B19

BACK LIGHT GND NOT USED

0-B21

BACK LIGHT GND

0-DAP

BACK LIGHT GND

0-B23

BACK LIGHT GND

CAV

0-B32

BACK LIGHT GND

BACK LIGHT POWER

49-C

BACK LIGHT POWER

49-H

BACK LIGHT POWER

49-L

BACK LIGHT POWER

49A

BACK LIGHT POWER

49-P

BACK LIGHT POWER

49-R

BACK LIGHT POWER

49S

BACK LIGHT POWER

87324393

CONNECTOR SPL-BCK-LGT2 - SPLICE BACK LIGHT GRND

WIRE IDENT

CIRCUIT

49-E

BACK LIGHT POWER

49-B

BACK LIGHT POWER

49-A

BACK LIGHT POWER

87324393

CAV

WIRE IDENT

CIRCUIT

0-B31

SDA GROUND

0-B2

BACK LIGHT GND

0-B3

BACK LIGHT GND

84547255A

Issued 11-11

Printed in E.C.

4002-88 SPL PED BL, SPL BACK LGT PWR 6 PCK

CONNECTOR SPL-PED-BL-GD - SPL BACK LIGHT POWER 6 PACK

87324391

CAV A

WIRE IDENT 49-W

87324391

CIRCUIT JSS BACKLIGHT

CAV

0-B9

WIRE IDENT NOT USED

CIRCUIT

49-N

BACK LIGHT POWER

49-D

BACK LIGHT POWER

0-B1

BACK LIGHT GROUND

49-X

BACK LIGHT AIC

0-B24

BACK LIGHT GROUND

49-V

BACK LIGHT POWER

0-B30

NOT USED

BACK LIGHT POWER

0-B29

RTT/FLOAT GROUND

0-B11

BACK LIGHT GROUND

49-S

CONNECTOR SPL-HOOD-GND - HOOD GROUND 6 PACK

CONNECTOR SPL-PIN - SPL BACK LIGHT POWER 6 PACK

87324391

CAV

WIRE IDENT

87324391

CIRCUIT

0-B12

HOOD DOWN RELAY GRND

CAV

WIRE IDENT

CIRCUIT

0-B16

HOOD DOWN CONTR GRND

19P-A

PIN ENGAGE SW FUSED PWR

19P

PIN ENGAGE/FAN FUS PWR

19P-C

RAN REVERSE SW FUS PWR

0-B22

HOOD UP RELAY GROUND

0-B25

HOOD UP CONTR GRND

0-B10

HOOD GROUND

NOT USED

19P-D

FAN REV RELAY FUS PWR

19P-E

FAN REV RELAY FUS PWR

84547255A

NOT USED

Issued 11-11

Printed in E.C.

4002-89 SPL PK1, SPLICE 3-4 WAY

CONNECTOR SPL-PK3 - SPLICE 3 - 4 WAY

87324462

CAV

WIRE IDENT

CIRCUIT

87324462

CAV

WIRE IDENT

CIRCUIT

18K-D

DIAG FUSED B+

45L-E

LEFT TURN SIGNAL

18K-A

DIAGNOSTIC FUSED PWR

45L-D

LEFT TURN SIGNAL

18K-B

DIAG FUSED B+

45L-C

LEFT TURN SIGNAL

45L-B

LEFT TURN SIGNAL

45R-C

RIGHT TURN SIGNAL

45R-E

RIGHT TURN SIGNAL

45R-D

RIGHT TURN SIGNAL

45R-B

RIGHT TURN SIGNAL

19J-B

FRONT WIPER/WASHER SW FUSED PWR

19J-C

FRONT WIPER RLY FUSED POWER

19J-D

FRONT WIPER RELAY FUSED POWER

19J-F

FRONT WIPER RLY LS CTRL FUSED POWER

SPL BCK LGT2, SPL BACK LGT PWR

87324462

CAV A

WIRE IDENT

SPL ROOF, SPLICE ROOF GROUND

CIRCUIT

49-E

BACK LIGHT POWER

CAV

49Y-A

BACK LIGHT POWER

49-J

BACK LIGHT POWER

0-MB

DOME LIGHT GND

49-M

BACK LIGHT POWER

0-MA

REAR WIPER MOTOR GND

49-K

BACK LIGHT POWER

0-MN

ROOF GROUNDS

49-F

BACK LIGHT POWER

0-MK

ROOF GROUNDS

49-Q

BACK LIGHT POWER

49-Z

BACK LIGHT POWER

49-T

BACK LIGHT POWER

49-G

BACK LIGHT POWER

49-S

BACK LIGHT POWER

84547255A

WIRE IDENT 0-MC

CIRCUIT BEACON LIGHT GND

Issued 11-11

Printed in E.C.

4002-90 CONNECTOR SPL-TRNS-PWR - TRANSMISSION POWER

CONNECTOR SRC - RIDE CONTROL SWITCH

382391A1

CAV

WIRE IDENT

1 87324393

CAV

WIRE IDENT

CIRCUIT

19A-N

TRANS FUSED POWER

19A-F

TRANS ENABLE SWITCH FUSED PWR

CIRCUIT NOT USED

19C-D

RIDE CTRL SW FUSED PWR

58C

RIDE CTRL SWITCH JUMPER

58T

RIDE CTRL RELAY SW PWR

58C

RIDE CTRL SWITCH JUMPER

58-F

RIDE CTRL SOLENOID PWR

19A-Q

TRANS/AUTO SWITCH FUSED PWR

6 7

0-B20

BACK LIGHT GROUND

19A-T

BRAKE DECLUTCH SW FUSED PWR

49-G

BACK LIGHT POWER

19A-W

DIAGN CONN. FUSED PWR

19A-C

FNR SWITCH FUSED PWR

19A-P

BACKUP ALARM RLY

19A-R

DECLUTCH SW FUSED PWR

19A-K

TECM FUSED PWR

19A-M

OUTPUT SPEED SENSOR FUSED PWR

L M

NOT USED

CONNECTOR SRC-1 - STARTER RELAY

NOT USED 19A-H

TRANS SHIFTER FUSED PWR

225316C1

CAV

84547255A

WIRE IDENT

CIRCUIT

21D

STARTER RELAY SIGNAL

0-GB

STARTER RELAY CONTROL GROUND

Issued 11-11

Printed in E.C.

4002-91 CONNECTOR SRHSTLK - RH STALK SWITCH

CONNECTOR SRWP - REAR WIPER SWITCH

382391A1

CAV

WIRE IDENT

CIRCUIT

68C

REAR WIPER PARK CONTROL

68L

REAR WIPER SW PWR

19K-A

REAR WIPER SW FUSED PWR

87318288

CAV

WIRE IDENT

CIRCUIT

31b

64C

HORN RELAY CONTROL

49a

19B

TURN SIGNAL FUSED POWER

56a

41H-A

HIGH BEAM POWER

56b

41L-A

LOW BEAM POWER

56d

19Z-C

HIGH BEAM FLASH FUS PWR

0-EP

HORN SWITCH GROUND

41J

DRIVE LIGHTS POWER

45A-A

LEFT TURN SWITCH POWER

45B-A

RIGHT TURN SWITCH POWER

NOT USED

19K-B

REAR WIPER SW FUSED PWR

68W

REAR WASHER PUMP

0-B23

BACK LIGHT GROUND

49-C

BACK LIGHT POWER

NOT USED

SSD, SEC STR DIODE CONNECTOR SRTD - DETENT SWITCH

245485C1

CAV 382391A1

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

0-CH

SEC STR FLYBACK GND

0-CG

SEC STR FLYBACK GND

51-D

SEC STR FLYBACK

NOT USED

53P-E

PILOT CONTROL RELAY OUT

53A

RTD SWITCHED POWER

NOT USED

0-B4

49-J

BACK LIGHT GROUND BACK LIGHT POWER

NOT USED

84547255A

Issued 11-11

Printed in E.C.

4002-92 CONNECTOR SS-TR - SS-MOD-TRANS

CONNECTOR SSM - SECONDARY STEERING MODULE

245489C1

CAV

225389C1

CAV

WIRE IDENT

CIRCUIT

19R-C

SEC. STEERING IGNITION FUSED PWR

51-A

SECOND STEER MOTOR CONTR

19S1-X

SECONDY STEER FUS PWR

0-CE

SECONDY STEER CHASSIS GRND

NOT USED

19M-C

SECONDARY STEER ACC FUSED PWR

35X-D

SECOND STEER LOW PRESS SIG

51P-A

SECONDARY STEER HIGH PRESS

WIRE IDENT

CIRCUIT

19M-C

19R-C

SEC. STR IGNIT FUS PWR

35X-C

SEC. STR LOW PRESS SIGNAL

C D

SEC. STR ACCESS FUS PWR

NOT USED

19S1-X

SEC. STR FUSED POWER NOT USED

CONNECTOR STA - TRANSMISSION AUTO SWITCH

NOT USED

0-CA

SECONDARY STEER SIGNAL GRND

0-CB

SECONDARY STEER SIGNAL GRND

SSS, SS MAG SWITCH CAV

WIRE IDENT

382391A1

CAV

WIRE IDENT

CIRCUIT NOT USED

19A-Q

TRANS AUTO SW FUS PWR

25H

TRANS AUTO SIGNAL

NOT USED

CIRCUIT

NOT USED NOT USED

51-D

SEC STR FLYBACK

51-B

SEC STR MOTOR CTRL

0-B17

BACK LIGHT GROUND

49S

BACK LIGHT POWER

84547255A

NOT USED

Issued 11-11

Printed in E.C.

4002-93 CONNECTOR STE - TRANSMISSION ENABLE SWITCH

CONNECTOR SWL - WORK LIGHTS SWITCH

382391A1 382391A1

CAV

WIRE IDENT

CIRCUIT

CAV

WIRE IDENT

CIRCUIT NOT USED

NOT USED

42-A

WORK LIGHTS FUSED PWR

42C-C

FR WORK LIGHTS FUSE PWR

19A-D

TRANS ENABLE SW FUSED POWER

26E-A

TRANS ENABLE SIGNAL

NOT USED

0-DAP

BACK LIGHT GROUND

49-H

BACK LIGHT POWER

32J-C

TRANS ENABLE INDICTION

19A-E

AIC FUSED PWR

NOT USED

42-B

WORK LIGHTS FUS PWR

42RC

RE WORK LIGHTS FUSE PWR

0-B14

BACK LIGHT GROUND

49-A

BACK LIGHT POWER

NOT USED

STTR GRN, GRID HTR FUSE CAV 1

WIRE IDENT 0-NC

84547255A

CIRCUIT BATTERY DISCONNECT

Issued 11-11

Printed in E.C.

4002-94 CONNECTOR SW-PD - SWITCH PAD

CONNECTOR TCOT - TORQUE CONVERTER OUTPUT SENDER

291718A1 87552623

CAV 1

WIRE IDENT 41H-D

2 3

CIRCUIT HIGH BEAM POWER NOT USED

49-X

BACK LIGHT AIC

31H-A

HYDRAULIC FILTER REST SW SIGNAL

31F-A

AIR FILTER REST SWITCH SIGNAL

CAV

WIRE IDENT

CIRCUIT

36G

TCO TEMPERATURE SIGNAL

36R-D

TCO TEMPERATURE RETURN

NOT USED

CAN-HF

CAN HIGH

CAN-LF

CAN LOW

17P-A

SWITCH PAD PWR FROM AIC PWR

0-B28

SWITCH PAD GROUND

84547255A

Issued 11-11

Printed in E.C.

4002-95 TECM, TRANS

CAV

411398A1

CAV 1

WIRE IDENT 0-DP

CIRCUIT DIAG TECM GND

WIRE IDENT

CIRCUIT

26F-B

FNR FORWARD SIGNAL

22A

DECLUTCH SW

25Y-A

TRANS KICK DOWN SIGNAL

19T-A

FUSED BATT PWR

22D

PEDAL SENSOR GRND

CAN-HD

CAN HIGH

CAN-LD

CAN LOW

25H

TRANS AUTO SIGNAL

26R-B

FNR REVERSE SIGNAL

26E-A

TRANS ENABLE SIGNAL

25M-A

TRANS SOL VALVE Y3

34B

DIFF LOCK SW SIG

22B

PEDAL SENSOR +5V

22C

PEDAL POS SIGNAL

36T-A

VALVE BODY TEMP SGNL

25C-A

TURBINE SP SIGNAL

25B-A

INT SP SIGNAL

25F

FORWARD SIGNAL

26N-B

FNR NEUT SIGNAL

19A-K

TECM FUSED PWR

36R-E

TRANS TEMPS/FLTR RETURN

36G-A

TCO TEMP SIGNAL

25R-A

TC LOCKUP SOL POWER

25J-A

TRANS SOL VALVE Y6

58H-B

POWER VPSL

25N-A

TRANS SOL VALVE Y4

25K-A

TRANS SOL VALVE Y1

58L

RIDE CTRL RLY LSD

34D

DIFF LOCK SW SIG

25D-A

OUTPUT SP SIGNAL

25Z

1ST AND 4TH GEAR SIGNAL

0-DQ

DIAG TECM GND

0-DM

SPEED SENSOR GNDS

0-DN

OUTPUT SPEED SENSOR GND

25R

REVERSE SIGNAL

32J-D

TRANS ENABLE INDICTION

25W

3RD AND 4TH GEAR SIGNAL

35C

BACK UP ALRM CNTL

25G-C

BRK DECLUTCH SW CTRL

58H-A

POWER VPS2

25T-C

NEUTRAL SIGNAL

19T-B

FUSED BATT PWR

25P-A

TRANS SOL VALVE Y5

25L-A

TRANS SOL VALVE Y2

34C

DIFF LOCK SOL GND

25S-B

OUTPUT SW PWR VPS1

25S-C

OUTPUT SW PWR VPS1

37D-A

DIAGNOSTIC SGNL

32F-A

TRANS FLTR MAINT SW

37E

DIAGN SGNL SWITCHED

25A-A

ENG SP SIGNAL

84547255A

Issued 11-11

Printed in E.C.

4002-96 TERM CAN 2, CAN BULK HEAD

TRANS, TRANSMISSION-CAB

380838A1

CAV

87315267

CAV

WIRE IDENT

CIRCUIT

WIRE IDENT

CIRCUIT

33R-A

RDNT BRK ACC PRESS LOW

34C-A

DIFF LOCK SOL GND

19M-A

SEC STR ACCESS FSD PWR

19R-A

SEC STR IGN FSD PWR

36T

VALVE BODY TEMP SGNL

CAN-L2

CAN 2 LO, TERM

35X-B

SEC STR LOW PRESS SGNL

CAN-LV

CAN2 LO, TERM

25A

ENG SP SIGNAL

CAN-H2

CAN2 HI, TERM

25C

TURBINE SP SIGNAL

CAN-HV

CAN2 HI, TERM

25B

INT SP SIGNAL

25D

OUTPUT SP SIGNAL

0-HD

SPEED SENSOR GNDS

36R-A

TRANS TEMPS/FLTR RETURN

36G

TCO TEMP SIGNAL

25G

BRK DECLUTCH SW CTRL

25R-B

TC LOCKUP SOL POWER

25K

TRANS SOL VALVE Y1

25K-9

TRANS SOL VALVE Y2

25L-9

TRANS SOL VALVE Y1

25L

TRANS SOL VALVE Y2

25M

TRANS SOL VALVE Y3

25N

TRANS SOL VALVE Y4

25P

TRANS SOL VALVE Y5

THV, TANK HEATER CONTROL VALVE

371614A1

CAV

WIRE IDENT

CIRCUIT

38C

TANK HEAT GND

38D

TANK HEAT B+

84547255A

25J

TRANS SOL VALVE Y6

25S

OUTPUT SW PWR VPS1

31H

HYD FLTR REST SW SGNL

31H9

HYD FLTR REST SW9

19A-A

BRAKE DECLUTCH SW FSD PWR

24T-B

TC LOCKUP SOL GND

19S1-E

SEC STR FSD PWR

34A-D

DIFF LOCK SOL B+

0-HE

OUTPUT SPEED SENS GND

19A

OUTPUT SP SENS FSD PWR

36H

HYDRAULIC OIL TEMP

32F

TRANS FLTR MAINT SW

Issued 11-11

Printed in E.C.

4002-97 CONNECTOR TRC - TRANSMISSION CONTROL

CONNECTOR TR-SS - SEC-STR-MOD-OPT

245488C1 371566A1

CAV

WIRE IDENT

CIRCUIT

CAV

SEC. STEER ACC FUS PWR

19R-A

SEC. STEERING IGNITION FUSED PWR

TRANS SOLENOID VALVE Y2

35X-B

25K

TRANS SOLENOID VALVE Y1

25L-9

TRANS SOLENOID VALVE Y1

25K-9

25L

TRANS SOLENOID VALVE Y2

25M

TRANS SOLENOID VALVE Y3

25N

TRANS SOLENOID VALVE Y4

25P

TRANS SOLENOID VALVE Y5

25J

TRANS SOLENOID VALVE Y6

25S

OUTPUT SW POWER VPS1

36T

VALVE BODY TEMP SIGNAL

36R-C

VALVE BODY TEMP RETURN

NOT USED

SEC STR LOW PRESS SGNL NOT USED

19S1-E

SEC. STEER FUSED PWR NOT USED

CONNECTOR TS1 - TRANSMISSION SHIFTER

245486C1

CAV

84547255A

CIRCUIT

19M-A

WIRE IDENT

CIRCUIT

19A-H

TRANS SHIFTER FUSED PWR

25F

FORWARD SIGNAL

25R

REVERSE SIGNAL

25T-B

NEUTRAL SIGNAL

Issued 11-11

Printed in E.C.

4002-98 CONNECTOR TS2 - TRANSMISSION SHIFTER

UBJ, DEF LEVEL TEMP

245487C1

CAV

WIRE IDENT

CIRCUIT

W230R399

CAV

WIRE IDENT

CIRCUIT

NOT USED

38B

DEF LEVEL SIG

25W

3RD AND 4TH GEAR SIGNAL

0-T

DEF SENSOR GND

25Z

1ST AND 4TH GEAR SIGNAL

38G

DEF TEMP SIG

25Y

TRANSMISSION KICK DOWN SIGNAL

UBJM, DEF LEVEL TEMP CONNECTOR TSS - TURBINE SPEED SENSOR

CAV

WIRE IDENT

CIRCUIT

38B-A

DEF LEVEL SIG

0-TA

DEF SENSOR GND

38G-A

DEF TEMP SIG

UTS, UPSTREAM TEMP SENSE CAV

WIRE IDENT

CIRCUIT

38F

EXHT UP SIGNAL

0E-A

EXHT TEMP UP GND

291718A1

CAV

WIRE IDENT

CIRCUIT

25C

TURBINE SPEED SIGNAL

0-HH

TURBINE SPEED SENS GRND

CONNECTOR WIF - WATER IN FUEL SENSOR

8602416

CAV 1

84547255A

WIRE IDENT 35W

CIRCUIT WIF INDICATOR

0-BP

WIF SENSOR GROUND

13M-C

WIF SENSOR FUSED PWR

Issued 11-11

Printed in E.C.

4002-99 CONNECTOR WSH - WATER SEPARATOR HEATER

CONNECTOR YFN - FNA PWM SOLENOID

256340A1

182069A1

CAV

WIRE IDENT

CAV

CIRCUIT

0-BW

WATER SEPARATOR HEATER GROUND

1-GC

WATER SEPARATOR HEATER POWER

WIRE IDENT

CIRCUIT

56-A

FAN CONTROL PWM

0-BQ

FAN SPEED PWM SOLEN GND

CONNECTOR YFR - FAN REVERSING SOLENOID OPT YDL, DIFF LOCK SOLENOID CAV

WIRE IDENT

CIRCUIT

34A-D

DIFF LOCK SOL B+

34C-A

DIFF LOCK SOL GND

YDL 1, DIFF LOCK SOLENOID 225316C1

CAV

WIRE IDENT

CIRCUIT

52A-B

FAN REVERSING RELAY OUT

0-BB

FAN REVERSING SOLEN GND

YLS, TC LOCKUP VALVE 225315C1

CAV

WIRE IDENT

CIRCUIT

34A-E

DIFF LOCK SOL B+

34C-D

DIFF LOCK SOL GND

CAV

WIRE IDENT

CIRCUIT

25R-B

TC LOCKUP SOL POWER

24T-B

TC LOCKUP SOL GND

YDL 2, DIFF LOCK SOLENOID CAV

WIRE IDENT

CIRCUIT

34A-E

DIFF LOCK SOL B+

34C-D

DIFF LOCK SOL GND

84547255A

Issued 11-11

Printed in E.C.

4002-100 YPE2, PIN ENGAGE OPT

CONNECTOR YPB - PARKING BRAKE SOLENOID

245482C1

CAV 291718A1

CAV

WIRE IDENT

CIRCUIT

52P

PARKING BRAKE RELAY OUT

0-AN

PARK BRAKE SOLEN GND

WIRE IDENT

CIRCUIT

57-D

PIN ENGAGE SOL PWR

0-AW

PIN ENGAGE GND

CONNECTOR YPP - PILOT PRESSURE SOLENOID

CONNECTOR YPE - PIN ENGAGE OPT

245482C1

CAV 245482C1

CAV

WIRE IDENT

CIRCUIT

PIN ENGAGE SOLENOID PWR

0-AE

PIN ENGAGE GROUND

WIRE IDENT

CIRCUIT

53P-A

PILOT CONTROL RELAY OUT

0-DU

PILOT PRESS SOLEN GND

CONNECTOR YRC - RIDE CONTROL OPT YPE1, PIN ENGAGE JUMPER CAV

WIRE IDENT

CIRCUIT

57-D

PIN ENGAGE SOLENOID PWR

0-AW

PIN ENGAGE GROUND

291718A1

CAV

84547255A

WIRE IDENT

CIRCUIT

58-G

RIDE CONTR SOLEN PWR

0-AD

RIDE CONTROL GROUND

Issued 11-11

Printed in E.C.

4002-101 YRC J, RIDE CNTRL JUMPER CAV

WIRE IDENT

21M, TRANS KICK-DOWN

CIRCUIT

58-H

RIDE CONTROL SIGNAL

0-RD

RIDE CONTROL GND

YRC J2, RIDE CONTROL OPT CAV

WIRE IDENT

CIRCUIT

58-H

RIDE CONTROL SIGNAL

0-RD

RIDE CONTROL GND

225316C1

CAV

CONNECTOR YSS - SECONDARY STEERING SOLENOID

WIRE IDENT

CIRCUIT

19B-D

FNR SW FUSED PWR

25Y-G

TRANS KICK DOWN SIGNAL

CONNECTOR 64F - FLASHER CONNECTOR

225316C1

CAV 1 2

WIRE IDENT 51-C 0-CF

CIRCUIT

245481C1

SEC. STEERING SOLENOID CONTROL SEC. STEERING SOLENOID GROUND

CAV 1

WIRE IDENT 45N-A

CIRCUIT FLASHER OPT SIDE CONTR

CONNECTOR 64M - FLASHER CONNECTOR CONNECTOR 20M - TRANSMISSION KICK-DOWN SWITCH

245480C1

225316C1

CAV

WIRE IDENT

CIRCUIT

19A-U

TRANS KICK DOWN SW FSD PWR

25Y-C

TRANS KICK DOWN SIGNAL

84547255A

CAV A

WIRE IDENT 45N-B

CIRCUIT FLASHER OPT SIDE CONTR

Issued 11-11

Printed in E.C.

4002-102 CONNECTOR 108F - DIAGNOSTIC CONNECTOR

193, STARTER RELAY CAV 1

WIRE IDENT 1-BB

CIRCUIT STRTR SOL PWR

194, STARTER SIGNAL CAV 1

291663A1

CAV

WIRE IDENT

19A-W

2 3 4

WIRE IDENT 1-BB

CIRCUIT STRTR SOL PWR

195, STARTER RELAY POWER

CIRCUIT DIAGN CONN. FUSED PWR

CAV

37D-A

DIAGNOSTIC SIGNAL

0-DAV

DIAGNOSTIC TECM GROUND

37E

DIAGNOSTIC SIGNAL SWITCHED

NOT USED

WIRE IDENT 1-Z

CIRCUIT STRTR RLY BAT PWR

CONNECTOR 197F - MAIN CAB FNR

115, GRID HTR PWR CAV 1

WIRE IDENT 1-BE

CIRCUIT GRID HTR PWR

CONNECTOR 140M - DIODE MODULE

225350C1

CAV

WIRE IDENT

CIRCUIT

19A-C

FNR SWITCH FUSED POWER

26F-B

FNR FORWARD SIGNAL

26N-B

FNR NEUTRAL SIGNAL

26R-B

FNR REVERSE SIGNAL

32J-E

TRANS ENABLE INDIC LAMP

25Y-B

TRANS KICK DOWN SIGNAL

245488C1

CAV

WIRE IDENT

CIRCUIT

63H-C

FRONT WIPER HIGH RYL OUT

63L-C

FRONT WIPER LOW RYL OUT

0-EE

DIODE SUPPRESSION GNDS

58-D

RIDE CONTROL SOLENOID PWR

D E F

NOT USED 68L-C

84547255A

REAR WIPER SWITCH PWR

Issued 11-11

Printed in E.C.

4002-103 CONNECTOR 197M - FNR MAIN CAB

CONNECTOR 209F - BACKUP ALARM DISABLE JUMPER

225351C1

CAV

WIRE IDENT

245481C1

CIRCUIT CAV

19A-B

FNR SWITCHED FUSED POWER

26F-A

FNR FORWARD SIGNAL

26N-A

FNR NEUTRAL SIGNAL

26R-A

FNR REVERSE SIGNAL

32J-A

TRANS ENABLE INDIC LAMP

25Y-C

TRANS KICK DOWN SIGNAL

WIRE IDENT 35A-E

CIRCUIT BACKUP ALARM RELAY OUT

CONNECTOR 209M - BACKUP ALARM DISABLE JUMPER

CONNECTOR 202M - ROLLBACK JUMPER

245480C1

CAV A

WIRE IDENT 35A-D

CIRCUIT BACKUP ALARM RELAY OUT NOT USED

245482C1

CAV

WIRE IDENT

CIRCUIT

58-A

RIDE CONTR SOLENOID PWR

58-A

RIDE CONTR SOLENOID PWR

CONNECTOR 215F - ALTERNATOR RESISTOR

199436A1

CAV 1

84547255A

WIRE IDENT 14-A

CIRCUIT ALTERNATOR D+

Issued 11-11

Printed in E.C.

4002-104 CONNECTOR 216F - ALTERNATOR RESISTOR

199436A1

CAV 1

WIRE IDENT 19R-D

CIRCUIT ALTERNATOR RESISTOR FUSED PWR

242F, CHAS GRD SEC STRG MTR CAV 1

WIRE IDENT 0-ND

CIRCUIT SSM GROUND

244F STARTER SEC STRG MTR CAV

WIRE IDENT

CIRCUIT

1-ND

SSM PWR

1-NF

SSM PWR

245F, SEC STR FLYBACK CAV

WIRE IDENT

CIRCUIT

0-CG

SEC STR FLYBACK GND

0-CH

SEC STR FLYBACK GND

84547255A

Issued 11-11

Printed in E.C.

4003

Section 4003 BATTERIES

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

84547255A

4003-2

TABLE OF CONTENTS SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspecting and Cleaning a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacity (Load) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Guide For Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Guide For Batteries Other Than Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARING A DRY CHARGED BATTERY FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84547255A

Issued 11-11

3 3 4 4 4 5 5 5 6 7 7 8 8

Printed in E.C.

4003-3

SAFETY RULES WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-83A

WARNING: Never cause sparks to occur or smoke near batteries that are charging or have been recently charged. 13-8A

WARNING: Disconnect the first when the battery disconnected from the battery.

ground cable cables are

Connect the ground cable last when the battery cables are connected to the battery. 47-55A

WARNING: Some batteries have a ventilation tube. If there is battery acid in the ventilation tube, this battery acid can be released when the battery is turned upside down. If you turn the battery upside down, make sure that the end of the ventilation tube is away from you and away from any other people in the area. Battery acid can cause severe burns.

WARNING: Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: EXTERNAL-Flush with water. INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, and cigarettes away. Ventilate when charging or using in enclosed area. Always shield eyes when working near batteries. Keep out of reach of children. D-47-53A

48-57B

SPECIAL TOOLS

B795328

The CAS10147 tester is used to do the Capacity (Load) Test. This tool is first used on Page 6.

84547255A

Issued 11-11

Printed in E.C.

4003-4

MAINTENANCE Electrolyte Level

Inspecting and Cleaning a Battery

If the battery is a maintenance free battery, check the level of the electrolyte every 1000 hours of operation or six months, whichever occurs first. For all other batteries, check the level of the electrolyte every 250 hours of operation.

If damage causes an electrolyte leak, replace the battery.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part of the decal has been removed for access to the battery caps, it is possible that the words Maintenance Free have been removed from the decal. Check the level of the electrolyte more often during hot weather. The use of a large amount of water by the battery can be caused by high battery temperature or a voltage regulator setting that is too high. Keep the electrolyte level above the top of the plates in the battery at all times to prevent damage to the battery. NOTE: On maintenance free batteries it is necessary to remove the center part of the decal for access to the battery caps. Do not discard the center part of the decal. Install the center part of the decal after the battery caps have been installed.

Inspect the battery at regular intervals for dirt, corrosion, and damage. Electrolyte and dirt on the top of the battery can cause the battery to discharge by making a passage for the current to flow. If the battery must be cleaned, remove the battery from the battery carrier and clean the battery, cable terminals, and the battery carrier. When available, use New Holland Battery Saver and Cleaner according to the instructions on the container. New Holland Battery Saver and Cleaner also helps prevent corrosion. If New Holland Battery Saver and Cleaner is not available, use baking soda and water as a cleaner. DO NOT permit any type of cleaner to enter the cells of the battery. Install the battery in the machine and make sure the fasteners are tight. Apply New Holland Battery Saver and Cleaner or Urethane Seal Coat to the cable terminals to prevent corrosion. See the Parts Counter Catalog. DO NOT apply grease.

If the level of the electrolyte is low, add distilled water or other clean water until the electrolyte is just below the cell opening. Do not add more water than is needed. Too much water can cause bad performance, a short service life, and corrosion around the battery. NOTE: Add water only. DO NOT add electrolyte.

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Issued 11-11

Printed in E.C.

4003-5

BATTERY TEST NOTE: To correctly test a battery, do each part of the battery test until you know the condition of the battery.

Visual Checks 1. Make sure the cable connections are clean and tight. Clean foreign material from the top of the battery. 2. Inspect the battery case, battery posts, and cables for damage. 3. Check the electrolyte level. See Page 4. 4. If you added water to the battery, the battery must be charged for 15 minutes at 15 to 25 amperes to mix the water with the electrolyte.

Specific Gravity Check A hydrometer is used to check the specific gravity (weight) of the electrolyte. The specific gravity is an indication of the level of charge for each cell. Hydrometers are made to show the correct specific gravity when the temperature of the electrolyte is 26.7°C (80°F). When you check the specific gravity, you must know the temperature of the electrolyte. If your hydrometer does not have a thermometer, get a thermometer to check the temperature of the electrolyte. The thermometer must indicate a high temperature of at least 52°C (120°F). 1. Remove enough electrolyte from a cell so that the float is free in the tube. NOTE: If the specific gravity cannot be checked without first adding water to the cell, the battery must be charged for 15 minutes at 15 to 25 amperes to mix the water with the electrolyte. Then check the specific gravity. 2. Read the float. 3. Read the thermometer. If the reading is above 26.7°C (80°F) add specific gravity points to the reading for specific gravity. If the reading is below 26.5°C (80°F) subtract specific gravity points from the reading for specific gravity. See the following illustration and add or subtract specific gravity points as needed.

B790863

1. TEMPERATURE IN F

2. TEMPERATURE IN C

SPECIFIC GRAVITY CHART

4. Make a record of the corrected specific gravity reading for each cell. 5. If the difference between the high reading and the low reading is 0.050 or more, charge the battery and check the specific gravity again. If after charging, the difference is still 0.050 or more, install a new battery. 6. The corrected specific gravity reading shows the level of charge for the cell. The level of charge must be at least 75% in each of the cells. ln maintenance free batteries the level of charge is at least 75% if the corrected specific gravity reading is 1.240 or higher. In all other batteries the level of charge is at least 75% if the corrected specific gravity reading is 1.230 or higher. 7. If the difference between the high reading and the low reading is less than 0.050, and the level of charge is at least 75% in all of the cells, do the Capacity (Load) Test. 8. If the difference between the high reading and the low reading is less than 0.050, but the level of charge is less than 75% in any of the cells, charge the battery and check the specific gravity again. If after charging: A. The level of charge is less than 75% in any of the cells, discard the battery. B. The level of charge is at least 75% in all of the cells, do the Capacity (Load) Test.

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Issued 11-11

Printed in E.C.

4003-6

Capacity (Load) Test This test can be done using a variable load tester such as the Sun Electric VAT -33. Other test equipment can be used. Connect the test equipment according to the instructions of the manufacturer of the equipment. 1. The level of charge of the battery must be at least 75%. Do the Specific Gravity Check in this section. 2. Prepare the tester (Sun Electric VAT-33 shown) for the test. A. Select the voltmeter range that will measure 1 to 18 volts. B. Make sure the load control knob is in the OFF position. C. Select the ammeter range that will measure 0 to 1000 amperes. D. Move the volt lead switch to the NT. position. 3. Connect the tester to the battery as shown.

NOTE: Never apply a load for longer than 15 seconds. After each 15 seconds, turn the load control knob to OFF for at least one minute. 4. Apply a 15 ampere load to the battery for 15 seconds. Wait at least three minutes before applying the load again. 5. Check and make a record of the temperature of the electrolyte. 6. Find the correct load for this test in Specifications in Section 4001. NOTE: The correct load is half of the cold cranking amperes at -17°C (0°F). 7. Turn the load control knob until the ammeter indicates the specified load. Keep the load for 15 seconds and read the voltmeter. Turn the load control knob to OFF. 8. Compare the test reading and the temperature of the electrolyte to the chart below. Temperature of . . . . . . . . . . . . . . . Minimum Voltage electrolyte 21°C (70°F) and above . . . . . . . . . . . . . . . . . . . . 9.6 16°C (60°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 10°C (50°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 4°C (40°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9.3 -1°C (30°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 -7°C (20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9 -12°C (10°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7 -18°C (0°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 A. If the test result is equal to or more than the voltage shown, the battery is in good condition. B. If the test result is less than the voltage shown, discard the battery.

B790499

1. LOAD CONTROL KNOB

84547255A

2. AMMETER CLAMP (TIP OF ARROW AWAY FROM BATTERY)

Issued 11-11

Printed in E.C.

4003-7

CHARGING A BATTERY WARNING: Never try to charge the battery if the electrolyte in the battery is frozen. 47-83

See Specifications in Section 4001 for the reserve capacity of the battery in this machine. The charging rate must be decreased if:

Before you charge the battery, check the level of the electrolyte.

1. Too much gas causes the electrolyte to flow from the cells.

It is difficult to give an exact charging rate because of the following variable conditions: (1) temperature of the electrolyte, (2) level of charge, and (3) condition of the battery. Use the charging guide for the correct charging rate and time.

2. The temperature of the electrolyte rises above 52Â°C (125Â°F). NOTE: For the best charge, use the slow charging rates. The battery is fully charged when, over a three hour

Charging Guide For Maintenance Free Batteries Recommended Rate* and Time for Fully Discharged Battery Battery Capacity - See Reserve Capacity under Specifications

Slow Charge

Fast Charge

10 Hours at 5 Amperes 5 Hours at 10 Amperes

2.5 Hours at 20 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes 7.5 Hours at 10 Amperes

3.75 Hours at 20 Amperes 1.5 Hours at 50 Amperes

Above 125 to 170 Minutes

20 Hours at 5 Amperes 10 Hours at 10 Amperes

5 Hours at 20 Amperes 2 Hours at 50 Amperes

Above 170 to 250 Minutes

30 Hours at 5 Amperes 15 Hours at 10 Amperes

7.5 Hours at 20 Amperes 3 Hours at 50 Amperes

80 Minutes or Less

*initial rate for standard taper charger.

NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If the center part of the decal has been removed to get access to the battery caps, it is possible the words Maintenance Free will have been removed from the decal. Continued on next page

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Charging Guide For Batteries Other Than Maintenance Free Batteries Recommended Rate* and Time for Fully Discharged Battery

Battery Capacity - See Reserve Capacity under Specifications

Slow Charge

Fast Charge

10 Hours at 5 Amperes 5 Hours at 10 Amperes

2.5 Hours at 20 Amperes 1.5 Hours at 30 Amperes

Above 80 to 125 Minutes

15 Hours at 5 Amperes 7.5 Hours at 10 Amperes

3.75 Hours at 20 Amperes 1.5 Hours at 50 Amperes

Above 125 to 170 Minutes

20 Hours at 5 Amperes 10 Hours at 10 Amperes

5 Hours at 20 Amperes 2 Hours at 50 Amperes

Above 170 to 250 Minutes

30 Hours at 5 Amperes 15 Hours at 10 Amperes

7.5 Hours at 20 Amperes 3 Hours at 50 Amperes

Above 250 Minutes

24 Hours at 10 Amperes

6 Hours at 40 Amperes 4 Hours at 60 Amperes

80 Minutes or Less

*initial rate for standard taper charger.

PREPARING A DRY CHARGED BATTERY FOR USE 1. Remove the caps from the battery. 2. Fill each cell to the top of the separators with electrolyte. This will permit the volume of electrolyte to increase when heated by charging the battery. 3. Install the caps on the battery.

5. Charge the battery at 30 amperes until the specific gravity is 1.250 or more an d the temperature of the electrolyte is at least 15.5Â°C (60Â°F). 6. If necessary, fill each cell with electrolyte until the electrolyte is just below split ring at the bottom of the cell opening.

4. Connect a battery charger to the battery.

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4003a

Section 4003a JUMP POST OPTION

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

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4003-2

TABLE OF CONTENTS Jump Post Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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JUMP POST OPTION STEP 1

5. Connect the other end of the negative (-) cable to the negative (-) terminal of the jump post (black). Do not connect it to sheet metal or any rotating part, as damage can result. Do not connect to the negative (-) terminal on the battery. 6. Start the engine. 7. Remove the booster battery negative (-) cable from the jump post and then from the machine being used for starting. Remove the positive (+) cable from the jump post terminal and then from the booster battery. 8. Install the terminal covers.

W270R458

The Jump Post option can be used to provide power to star t the machine if i ts batter ies become discharged. The option can be used to provide power to the machine for the purpose of raising the hood if its batteries have become discharged. The option can be used to start other disabled equipment without accessing the main battery terminals. NOTE: Make sure that the voltage of the booster batteries is the same as that of the machine system (24 volts). The jump post is located on the left hand side of the machine inside the main electrical disconnect compartment. 1. Turn off the ignition and all accessories on the machine(s). Use the jump post to connect the auxiliary battery. 2. Remove the terminal covers and connect one end of the positive (+) cable to the positive (+) terminal on the booster battery. 3. Connect the other end of the positive (+) cable to the positive (+) terminal of the jump post (red). 4. Connect the negative (-) cable to the negative (-) terminal on the booster battery.

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NOTES

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Section 4005

4005

INSTRUMENT CLUSTER

CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia

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4005-2

TABLE OF CONTENTS INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LCD Multi-function Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navigating Through The LCD Multi-function Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering The Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Power Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Language Screen, Measurement Units, and Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MPH/KPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RETRIEVING FAULT CODES AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Printed in E.C.

4005-3

INSTRUMENT CLUSTER 1

BS06H240

1. 2. 3. 4. 5. 6. 7. 8.

LOW BRAKE PRESSURE INDICATOR HIGH BEAM INDICATOR TRANSMISSION OIL TEMPERATURE GAUGE CAUTION MASTER INDICATOR MULTI FUNCTION LCD DISPLAY STOP MASTER INDICATOR HYDRAULIC OIL TEMPERATURE GAUGE WAIT TO START ENGINE PREHEAT

9. 10. 11. 12. 13. 14. 15.

LACK OF AUX STEER PRESSURE (OPTIONAL) PARKING BRAKE INDICATOR RIGHT TURN INDICATOR FUEL LEVEL GAUGE FUEL LEVEL AT MINIMUM ENGINE COOLANT TEMPERATURE GAUGE LEFT TURN INDICATOR

The instrument cluster monitors a number of functions and can be tailored to fit the operatorâ&#x20AC;&#x2122;s preferences The instrument cluster not only monitors machine functions, it warns the operator when caution is needed due to a possible malfunction and when immediate action is needed due to a possible critical malfunction. When the machine is started, the instrument cluster will perform the following self-test:

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4005-4

Self-Test 1. Turn the ignition (key) switch to the ON position. 2. The instrument cluster will automatically check each monitored system. 3. All LEDâ&#x20AC;&#x2122;s (Light Emitting Diodes) will illuminate for 2 - 3 seconds. 4. Four gauges will energize for 2 - 3 seconds. 5. The warning alarm will sound for 2 - 3 seconds.

Power Circuit Test A. Check fuse ECA-F3. If the fuse is bad, replace the fuse and repeat Self-Test. If the fuse is good, go to next step. B. Check wire 19EA for continuity. Repair/replace the wire as required. If continuity is found go to next step. C. Check power relay module A for proper operation, see Section 4002. If the power relay module checks good, go to next step.

6. If there is an open circuit between a sensor and the instrument cluster, the LED will flash and the warning alarm will sound for 5 seconds.

D. Check the ignition switch for proper operation, see Section 4002. If the ignition switch checks good, go to next step.

7. If there were no faults detected during the check, all monitored systems will return to normal operation.

E. Check fuse ECC-F5. If the fuse is bad, replace the fuse.

8. If only some of the LEDs illuminate, replace the instrument cluster. 9. If the LEDs illuminate, but the warning alarm does not sound, see section 4002 and test the alarm circuit. 10. If the warning alarm sounds but the LEDs do not illuminate, if no power is present at buzzer, replace the instrument cluster, if power is present at the buzzer, replace the buzzer. 11. If the warning alarm does not sound and the LEDs do not illuminate on the instrument cluster, do the following steps to test the power circuit:

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4005-5

LCD Multi-function Display

Information will be displayed in different zones on the LCD, as directed by the operator or machine. In most situations the operator or technician will be given specific information to follow if conditions are not correct. 1. In the example, above, the machine hours are displayed. Machine hours will always be displayed briefly, on start up. After, the machine is started, the display will show engine rpm’s. After, beginning travel, the machine will display travel speed, if default settings were not changed by the operator.

W230M139

The LCD Multi-Function Display is located at the center of the modular dashboard. On start up the cluster will flash the instructional lamps.

2. This example, shows that the Transmission Control Lever is in Neutral. The display will show Forward, Neutral, or Reverse, depending on where the Directional Control Lever is positioned. NOTE: Forward and Reverse will blink if the transmission clutches are disconnected. 3. This zone shows the gear numerically (3th).

12 3 4

4. This example shows the current transmission mode that has been selected. A. If the Transmission is operating normally it will display either

7.0 H

A A 11 22

5 4 6

W230R477

LCD MULTI-FUNCTION DISPLAY 4 SPEED

●

A - Automatic

●

M - Manual operation.

B. If the Transmission is not operating normally the display will show ●

C - Substitute Clutch.

●

L - Limp Home.

●

S - Transmission Shutdown.

●

U - TCU Shutdown.

5. This example shows the Power Boost Status.

F N

R 3

7.0 H

12 3 D

A A 11 22

●

MAX - Maximum Power.

●

STD - Normal/Standard mode of Operation.

●

AUTO - Switches automatically Maximum and Standard Power.

●

ECO - Limited Power for fuel efficiency.

between

6. This example will show the Time in either 12 hour or 24 hour.

4 6

W230R476

LCD MULTI-FUNCTION DISPLAY 5 SPEED

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Navigating Through The LCD Multi-function Display Screens

Using The Arrow Keys At any time, during operation or with the key switch on, the operator may scroll through three information screens and two trip screens by using the arrow keys. These five screens are in a circular loop and may be reached by pressing the up or down key. The following sequence is using the down key only.

NOTE: Pressing the escape key will return the LCD back to the normal driving screen.

D BD06F186

Located on the steering column, just to the left of the Park Switch, is the key pad. Use this key pad to move from one screen to another, choose various selections, monitor the machine functions, and retrieve information. All functions can be accessed in the same basic manner. A. Escape key: Use this key to exit and return to the driving screen. Use this key anytime you would like to start over and begin again, plus use to check active, acknowledge errors.

BD06F188

From the driving screen push the down arrow, as shown.

B. Enter key: Use this key to confirm, yes, this is the desired function. C. Up arrow key: Use this key to scroll up to selections. D. Down arrow key: Use this key to scroll down to selections. NOTE: Arrows on the screen will indicate if selections are up or down from the current selection. NOTE: Display units can be changed by the operator.

W230R435

Info 1 is the first information screen using the down arrow from the driving screen. It displays engine RPMâ&#x20AC;&#x2122;s, speed, fuel level, and the Urea level.

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W230R436

W230R438

Info 2 will be displayed next. The Info 2 screen will display coolant temperature, turbocharger air temperature, engine oil temperature in either Fahrenheit or Celsius, and the Urea level.

Press the down button again and the Trip 1 screen will display. The LCD provides two trip computers. These will display since last reset the total time in hours, the total fuel, and the average fuel consumption per hour.

W230R437

Push the down button again and the Info 3 screen. This screen displays the temperature in Fahrenheit or Celsius of the transmission oil, hydraulic oil, sump oil, and the Urea level.

Info Voltage Air Turbo DefTemp DefLvl

W230R439

By continuing to scroll down, the fifth screen will display the Trip 2 screen. Trip 1 and Trip 2 screens can be reset independently. The previous screen can be accessed by using the up arrow key.

4 V 24.2 Â°C 42 Â°C 32 % 24 W230M171

Push the down key again to display the info 4 screen. This screen display the voltage level, turbocharger air temperature, Urea temperature and Urea level.

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Reset The Trip Information

Trip 04May2008,

2 17:42

Time Fuel

Hrs 102.9 L 1000.6

Fuel/hr

L/h

9.1 BD06F172 W230M137

Highlight the trip screen you wish to set.

The trip screen will indicate a reset message. At this screen, press confirm to clear the numbers and reset the trip information. The current date and time will display automatically. The hours, fuel consumption, and fuel used per hour will reset and revert to zero.

Trip 04May2008,

BD06F187

2 17:42

Time Fuel

Hrs 102.9 L 1000.6

Fuel/hr

L/h

9.1

Press the confirm button to reset the trip selection to zero. W230M137

Press the escape key to return to the main driving screen and lock settings into memory. The screen will begin to record time and fuel usage immediately.

84547255A

Issued 11-11

Printed in E.C.

4005-9

Entering The Service Screens After the machine has been started or the key switch has been turned to on the operator or service technican may use this service menu to adjust machine configurations to working conditions, test components, view faults that may have occurred, or select preferences. NOTE: When all the selections have been made they will be stored in memory. If there is an abrupt battery disconnect you may loose all of your selections and need to reprogram the LCD Multi-function display.

W230M141 / BD06F188

Press and hold the confirmation button for two seconds to arrive at the above service screen. Use down arrow to scroll through the menu’s. Items and selections in this menu are: 1. Setting Menu ●

Engine (Auto Idle, Power Mode, Eng Options, Factory Set, Auto Shutdown, Fan Gain)

●

Transmission (Max Gear, Min Gear, ICCO ENABLE)

●

Joystick Steering (Option)

2. Display Menu ●

Options (Engine Snd, Ground Snd)

●

Language (English, Deutsch, Francais, Italiano, Espagnol, Portuguese)

●

Units (Metric, English, Imperial)

●

Clock (24 or 12 Hour Increments)

●

Backlight (Day Disp., Day Led, Night Disp., Night Led)

●

Factory Set (Reset, Display Setting, Confirm Please)

4. Service ●

Calibration (Clutch Calib, Pedal Calib, Park Brake, Fan Test)

●

Change Model

●

Slot Tires

For other submenu see next page. * The tests in the configuration menu should be performed only by a qualified operator or technician, as some tests require the engine to be running at high RPM’s.

3. Diagnostics ●

Show Errors (Red, Yellow, White, Memory) Memory 1/2

●

Reset Errors (Reset, Confirm Please)

●

Cluster S/W (Software Part Number, Software Serial Number, Software ID, Software Version)

●

Transmission (SW, HW, VER, SER)

84547255A

Issued 11-11

Printed in E.C.

84547255A

Transm.

Deflt

WorkIdle

STANDARD AUTO ECO

Low

Accelerated

EngOptions

(Option)

Joyst Steer

JSS_Spd

Fan Auto

Power Mode

(5 Speed)

POWERINCH ON

Min Gear

Max Gear

MAX

Auto Idle

(4 Speed)

Transm.

Joyst. Steer

Off

Factory Set

EngOptions

Min Gear

Power Mode

Transm.

Max Gear

Engine

Auto Idle

Settings

Engine

Ground Spd

Confirm Please

Engine Settings

Reset

Factory Set

Engine Spd

OPT Options

Language

English Imperial

Deutsch Francais Italiano Espagnol Portugue

OFF

(Option)

30 min Protection OFF Interval

Units Metric

English

Language

Factory Set

Backlight

Clock

Units

Auto Shtdwn Economy

Display OPT Options

17NOV10,Hr 1

1067 0.00

SCR Control CAN Msg Engine Timeout

MEMORY 1/2 19605 Warning

WHITE MEMORY

0 0

Show Errors

Ver

Ldr

Backlight Day Disp. Day LED Night Disp. Night LED

1.8.0.0 3.0.2.8

87372814 84340740

Cluster HW P/N SW P/N

12 Hr 12 30 1 1 2011

Clock

RED YELLOW

Format Hour Minute Day Month Year

Settings Display Diagnostics Service

Main Menu

6057 018 121 6009 365 007

Transm.

Confirm Please

Display Settings

Reset

Factory Set

VER 932___tdz_Luc SER 4506JCWFw

SW HW

20 20 5 5

Confirm Please

ClutchCalib

Transm.

Cluster

Show Errors

Diagnostics

Calibration

Issued 11-11

Press Esc To Exit

Turn Key OFF

Now,

Change OK

420

Reset Actual PWM

735 *****

70% Speed

AdjustSpeed

Fan Speed

Engage 3rdManual

PedalCalib

Test at fixed

ParkBrake Test Park Brake

Fixed 70%

Confirm Please

Fan Speed Mode

Switch to Fixed

Fan Test

20.5 Rad

Select Tires TireSize

PedalCalib

Confirm Please

Test Park Brake

ParkBrake

Slct_Tires

Push Pedal Full

Confirm Please

PedalCalib

Fan Test

ParkBrake

PedalCalib

ClutchCalib

Service Calibration

4005-10

W230R478

Printed in E.C.

4005-11 SELECT SCREEN The "Display" selection screen allows time settings to be entered. Highlight "clock" and press the select button. This will allow the time settings to be changed.

W230M142

W230M143

W230M144

The "Diagnostic" selection screen allows the software screens which cannot be modified to be viewed by highlighting "cluster S/W" and pressing the confirmation button.

W230M145

Figure 4

W230M146

Figure 5

W230M147

Figure 6

Figure 1

Figure 2

Figure 3

NOTE: Pressing the escape key will return the LCD back to the normal driving screen. In order to lock the changes into memory, the operator must press the confirm key, then use the escape key to page back to the main screen. Turning the machine off will also lock the settings into memory.

84547255A

Issued 11-11

Printed in E.C.

4005-12 SELECTING POWER MODES The power mode allows the operator to choose the most effective machine power for the current job conditions. Idling can be changed from automatic to a fixed rate. Most commonly Auto is chosen, as the power will automatically increase or decrease between maximum power and standard power while the machine is working. This allows for maximum power if necessary, but will switch to standard mode for economy. Maximum power can be chosen for more severe work conditions. Economy can be chosen for limited power and fuel efficiency. Press and hold the confirm key for two seconds to arrive at the service screen.

W230M141

Figure 9

W230M149

At the screen shown above, highlight the power mode, and press the confirm key to move to the Power Mode Selection Menu.

Figure 7 Figure 10

W230M150

At the Power Mode Menu press the confirm key again to activate the selections. The highlighted section will flash to indicate a new selection can be made. Press the up or down key to select the Power Mode, and then press the confirm key. Use the escape key to return to the main driving screen and to lock the mode selection into memory. Confirming the Selected Mode

W230M148

84547255A

Figure 8

The selected mode will display in zone 3 (bottom) of the Multi-Function Display when power mode is correctly selected.

Issued 11-11

Printed in E.C.

4005-13 OPTIONS AND PREFERENCE SCREENS LANGUAGE SCREEN, MEASUREMENT UNITS, AND CLOCK The LCD screen can be set with language, measurements, and/or clock preferences. Use the arrow keys to scroll to the display menu. Press the confirm key on the correct selection. Press the escape key to return to the main driving screen and lock the selection into memory. Choose the preferences desired: language in English, Spanish, Portuguese, Italian, German, French; measurement units in metric, English, or Imperial; and clock units in 12 or 24 hour cycles. Highlight the preference you wish to change and press the confirm key. The preference will flash and allow you to scroll through the choices. When the correct preference is chosen, press the confirm key, then use the escape key to return to the main driving screen in order to lock the preference into memory.

W230M142

W230M155

84547255A

W230M156

Figure 13

W230M157

Figure 14

W230M158

Figure 15

Figure 11

Figure 12

Issued 11-11

Printed in E.C.

4005-14 CLOCK

DISPLAY MENU

Setting The Hour and Date

The display menu can be used to change the background and brightness of the screen. Use the arrow keys to make your selection from the display menu and press the confirm key until the screen reverts to the main driving screen to lock the selection into memory. The screen display can be changed to suit working conditions. The screen will change to night function illumination when the head lamps are turned on.

From the display screen, choose the clock designation and press the confirm key. Use the arrow keys to show field for time and date by pressing the arrow key. When the correct time and date have been entered by using the up and down arrow keys (up increases the numbers - down decreases the numbers), press the confirm key to lock in correct time. Press the escape key to return to the main driving screen and lock selections into memory.

W230M142

Figure 19

W230M160

Figure 20

Figure 16

W230M143

Figure 17

W230M144

Figure 18

84547255A

W230M159

Issued 11-11

Printed in E.C.

4005-15

Clutch Calibration After warming the oil temperature: 1. Park the machine on a firm level surface. 2. Place the NEUTRAL.

Transmission

Control

Lever

3. Set the Park Brake. 4. With the engine running, at idle, enter the Service Screen Menu and scroll to Service.

W230M175

If, conditions are not correct, an error message will appear and guide the operator or technican. There are six, if conditions not met, screens:

W230M173

Use the confirm and arrow button to scroll to the screen shown above. At this screen push the confirm button again.

●

Not in neutral

●

Park Brake OFF

●

Machine moving

●

Oil temp too low

●

Oil temp too high

●

Engine RPM low

●

Engine RPM high

If conditions are correct the operator or technican will see six calibration screens pass. They will display in this order: ●

Adjust K1

●

Adjust K2

●

Adjust K3

●

Adjust K4

●

Adjust KV

●

Adjust KR

Once the process is completed this screen will direct the operator or technican to shut the engine OFF and then re-start. W230M174

This screen will prompt the operator or technican to confirm or escape.

84547255A

If the process is not completed the operator or technican will be prompted to escape.

Issued 11-11

Printed in E.C.

4005-16

Auto Idle Idling can be changed from automatic to a fixed rate. The fixed idle rate is defined as Standard Idle at 900 RPM. Highlight the auto idle selection by using the arrow keys, then press confirm. When you have chosen the selection, lock the selection into memory by pressing the confirm key.

RPM Engine speed in RPM will show on the display if the engine speed is running up to 550 RPMâ&#x20AC;&#x2122;s, and will disappear if the engine speed is lower than 300 RPM. W230M141

Options Menu

MPH/KPH

Use the arrow keys to choose the menu. Press the confirm key, and the options sub-menu will appear. The options menu will allow the operator to choose options for the fan, idle.

Vehicle speed will show on the display if it is up to 1.0 MPH / 1.5 KPH and will disappear if the vehicle speed is less than 0.6 MPH / 1.0 KPH.

Fan Auto The fan can be set to run at automatic or the fan will run at maximum speed. Automatic is the more common or preferred setting. It will switch between high speed, low speed, or reverse as conditions require depending on actual temperature of the coolant, turbocharger air, transmission oil, and hydraulic oil. The operator can choose fan speed or reversing capabilities. Highlight the fan auto selection by using the arrow keys, then press confirm. When you have chosen the selection, lock the selection into memory by pressing the confirm key.

84547255A

Issued 11-11

Printed in E.C.

4005-17

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Issued 11-11

Printed in E.C.

4005-18

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Printed in E.C.

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