International Trucks Manual (EN)

ELECTRICAL CIRCUIT DIAGRAM MANUAL 0000002529 Electrical Circuit Diagrams - TerraStar ® Revision 5 EPA 10 - US, Canada, Mexico February 2015 ELECTRICAL CIRCUIT DIAGRAM MANUAL Electrical Circuit Diagrams TerraStar ® Navistar, Inc. 2701 Navistar Drive, Lisle, IL 60532 USA © 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

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Table of Contents

TABLE OF CONTENTS TABLE OF CONTENTS 2. INSTRUCTIONS AND CHARTS (CHAPTER 2)................................................................ 1 2.1. ABBREVIATIONS, P. 1..................................................................................... 1 2.2. ACRONYMS, P. 2.......................................................................................... 2 2.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3............................................................. 3 2.4. CIRCUIT NUMBER IDENTIFICATION AND COLOR, P. 4............................................. 4 2.5. CIRCUIT NUMBER IDENTIFICATION AND COLOR (CONT.), P. 5.................................. 5 2.6.

CIRCUIT NUMBER IDENTIFICATION AND COLOR (CONT.), P. 6.................................. 6 2.7. LAMP BULB CHART, P. 7................................................................................. 7 2.8. RELAY FUNCTION AND WIRING DIAGRAM, P. 8..................................................... 8 2.9. SCHEMATIC SYMBOL CHART, P. 9..................................................................... 9 2.10. SCHEMATIC SYMBOL CHART (CONT.), P. 10....................................................... 10 2.11. SCHEMATIC SYMBOL CHART (CONT.), P. 11........................................................ 11 2.12. SCHEMATIC SYMBOL CHART (CONT.), P.

12....................................................... 12 3. 12 VOLT POWER DISTRIBUTION, GROUNDS, DATA BUS AND ELECTRICAL SYSTEM CONTROLLER (CHAPTER 3).................................................................................. 13 3.1. BATTERY FEED, DUAL, P. 1............................................................................ 13 3.2. IGNITION FEED – STANDARD, THEFT DETERRENT, REMOTE START / STOP, P. 2.......... 14 3.3. J708 DATA LINK – PUBLIC EFFECTS, P. 3........................................................... 15 3.4. J1708 DATA LINK – PRIVATE WITH POWER WINDOW AND LOCK, P. 4........................ 16 3.5. J1939 DATA LINK, P.

5................................................................................... 17 3.6. GROUND – IP, P. 6....................................................................................... 18 3.7. ZERO VOLT REFERENCE, P. 7........................................................................ 19 3.8. BATTERY FEED, SINGLE, P. 8......................................................................... 20 3.9. J1939 DATA LINK – V8 ENGINE, P. 9.................................................................. 21 3.10. J1939 DATA LINK – V8 ENGINE WITH ALLISON WTEC, P. 9A.................................... 22 3.11. J1939 DATA LINK – V8 ENGINE WITH ALLISON LCT WITH IN-CAB TCM, P.

9B............... 23 3.12. ACCESSORY FEED, P. 10.............................................................................. 24 3.13. J1939 DATA LINK – WITH OPTIONS, P. 11........................................................... 25 3.14. IGNITION FEED – RELAY 1, P. 12...................................................................... 26 3.15. INTENTIONALLY LEFT BLANK, P. 13.................................................................. 27 3.16. IGNITION FEED – RELAY 3, P. 14...................................................................... 28 3.17. BATTERY FEED, DUAL, P. 15.......................................................................... 29 3.18.

BATTERY FEED, DUAL (CONT.), P. 16................................................................ 30 3.19. BATTERY FEED, SINGLE, P. 17........................................................................ 31 3.20. INTENTIONALLY LEFT BLANK, P. 18.................................................................. 32 3.21. GROUND – SEAT AND SEAT BELT SENSOR, P. 19................................................ 33 3.22. GROUND – IP, P. 20...................................................................................... 34 3.23. GROUND – IP (CONT.), P. 21........................................................................... 35 3.24. GROUND – IP (CONT.), P.

22........................................................................... 36 3.25. GROUND – CHASSIS, P. 23............................................................................ 37 3.26. GROUND – IP, P. 24...................................................................................... 38 3.27. GROUND – IP (CONT.), P. 25........................................................................... 39 3.28. GROUND – CHASSIS, P. 26............................................................................ 40 3.29. INTENTIONALLY LEFT BLANK, P. 27.................................................................. 41 3.30. GROUND – TRAILER SOCKET AND FUEL PUMP, P.

28........................................... 42 4. CAB ACCESSORIES (CHAPTER 4)........................................................................... 43 4.1. CIGAR LIGHTER AND POWER FEED, P. 1........................................................... 43 4.2. CIGAR LIGHTER AND POWER FEED (CONT.), P. 2................................................ 44 4.3. COMPASS DISPLAY, P. 3................................................................................ 45 i

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TABLE OF CONTENTS TABLE OF CONTENTS (CONT.) 4.4. FRONT DOOR WINDOWS AND LOCKS (POWER), P. 4............................................ 46 4.5. FRONT DOOR WINDOWS AND LOCKS (POWER) FOR CREW, P. 5............................. 47 4.6. HORN – ELECTRIC AND AIR, P. 6..................................................................... 48 4.7. MIRRORS (HEATED, LIGHTED & POWER), P. 7.................................................... 49 4.8. 2 – WAY RADIO, P. 8..................................................................................... 50 4.9. INTENTIONALLY LEFT BLANK, P. 9................................................................... 51 4.10. SELF CONTAINED AIR SEAT, P.

10.................................................................... 52 4.11. RADIO (ENTERTAINMENT) SPEAKERS – WITH 16 WAY CONNECTOR, P. 11................. 53 4.12. RADIO (ENTERTAINMENT) SPEAKERS – WITH 12 WAY CONNECTOR, P. 11A............... 54 4.13. RADIO (ENTERTAINMENT), SPEAKERS – WITH 16 WAY CONNECTOR (CONT.), P. 12...... 55 4.14. INTENTIONALLY LEFT BLANK, P. 13.................................................................. 56 4.15. INTENTIONALLY LEFT BLANK, P. 14.................................................................. 57 4.16. INTENTIONALLY LEFT BLANK, P. 15.................................................................. 58 4.17. INTENTIONALLY LEFT BLANK, P.

16.................................................................. 59 4.18. ROOF AUX LOAD, P. 17................................................................................. 60 4.19. INTENTIONALLY LEFT BLANK, P. 18.................................................................. 61 4.20. INTENTIONALLY LEFT BLANK, P. 19.................................................................. 62 4.21. INTENTIONALLY LEFT BLANK, P. 20.................................................................. 63 4.22. MIRRORS (HEATED, LIGHTED & POWER) , P. 21.................................................. 64 4.23. CB POWER RADIO, P.

22............................................................................... 65 4.24. BACK-UP CAMERA, P. 23............................................................................... 66 4.25. HEATED SEATS, P. 24................................................................................... 67 4.26. SWITCH PACK OPTIONAL GAUGE PACK, P. 25.................................................... 68 4.27. WINDSHIELD WIPER, P. 26............................................................................. 69 4.28. SEAT BELT AND SEAT SENSOR, P. 27............................................................... 70 4.29. SEAT BELT AND SEAT SENSOR (CONT.), P.

28..................................................... 71 4.30. SEAT BELT AND SEAT SENSOR (CONT.), P. 29..................................................... 72 4.31. SEAT BELT AND SEAT SENSOR (CONT.), P. 30..................................................... 73 5. 12V CHARGING AND CRANKING SYSTEM (CHAPTER 5)................................................ 74 5.1. STARTING AND CRANKING ENGINE WITH ALLISON TRANSMISSION, P. 1................... 74 5.2. ROCKER START, P. 2.................................................................................... 75 6. FANS AND ENGINE ACCESSORIES (CHAPTER 6)........................................................ 76 6.1. FAN WIRING – V8 ENGINE, P.

1....................................................................... 76 6.2. SNOW VALVE, P. 2....................................................................................... 77 7. ELECTRONIC ENGINES (CHAPTER 7)....................................................................... 78 7.1. ELECTRONIC ENGINE CONTROLS – V8 ENGINE, P. 1............................................ 78 7.2. ELECTRONIC ENGINE CONTROLS – V8 ENGINE (CONT.), P. 2................................. 79 7.3. ELECTRONIC ENGINE CONTROLS – V8 ENGINE (CONT.), P. 3................................. 80 7.4. ELECTRONIC ENGINE CONTROLS – V8 ENGINE (CONT.), P. 3................................. 81 7.5.

ELECTRONIC ENGINE CONTROLS – V8 ENGINE (CONT.), P. 4................................. 82 7.6. ELECTRONIC ENGINE CONTROLS – V8 ENGINE CRUISE CONTROLS, P. 5.................. 83 8. GAUGES WITH AND WITHOUT INTERNAL WARNING LIGHT (CHAPTER 8).......................... 84 8.1. BRAKE SWITCH AND PARK BRAKE SWITCH, P. 1................................................. 84 8.2. GAUGES AND WARNING LIGHTS – AMMETER, P. 2............................................... 85 8.3. INTENTIONALLY LEFT BLANK, P. 3................................................................... 86 8.4. AIR PRESSURE INPUT CIRCUIT, P. 4................................................................. 87 8.5.

IP GAUGES AND WARNING LIGHTS – GAUGE CLUSTER, P. 5.................................. 88 ii

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TABLE OF CONTENTS TABLE OF CONTENTS (CONT.) 8.6. IP / GAUGES, P. 6........................................................................................ 89 8.7. WARNING LIGHTS LIST, P. 7........................................................................... 90 8.8. WARNING LIGHTS CONTROLLING BY ENGINE, TRANSMISSION, ABS CONTROLLER, P. 8...................................................................................... 91 8.9. ENGINE OIL PRESS & TEMP, SPEEDOMETER, TACH, VOLTMETER & WATER TEMP GAUGE CIRCUITS, P. 9................................................................................. 92 8.10. FUEL GAUGE CIRCUITRY (SINGLE TANK AND DUAL TANK), P.

10............................. 93 9. LIGHTS (CHAPTER 9)........................................................................................... 94 9.1. BACK-UP – WITH ALLISON TRANSMISSION, P. 1.................................................. 94 9.2. LIGHT SYSTEM – CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS, P. 2........ 95 9.3. LIGHT SYSTEM CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS (CONT.), P. 3.............................................................................................. 96 9.4. LIGHT SYSTEM, FOG LIGHT, P. 4..................................................................... 97 9.5. HEADLIGHTS, P.

5....................................................................................... 98 9.6. PANEL LIGHTS, P. 6..................................................................................... 99 9.7. INTENTIONALLY LEFT BLANK, P. 7.................................................................. 100 9.8. LIGHT SYSTEM CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS (CONT.), P. 8............................................................................................. 101 9.9. LIGHT SYSTEM CLEARANCE, MARKER, PARK, TAIL, TURN & STOP LIGHTS (CONT.), P. 9............................................................................................. 102 9.10.

AUX HEADLIGHTS, SNOWPLOW LIGHTS, P. 10.................................................. 103 9.11. AUX HEADLIGHTS, SNOWPLOW LIGHTS (CONT.), P. 11........................................ 104 9.12. DOME LIGHT SYSTEM, P. 12......................................................................... 105 9.13. CLEARANCE AND MARKER LIGHT, P. 13.......................................................... 106 10. CHASSIS ACCESSORIES (CHAPTER 10).................................................................. 107 10.1. TRW ABS BRAKES, P. 1............................................................................... 107 10.2. TRW ABS BRAKES (CONT.), P.

2..................................................................... 108 10.3. TRW ABS BRAKES (CONT.), P. 3..................................................................... 109 10.4. BODY BUILDER AND TRAILER – TURN, MARKERS AND STOP , P. 4......................... 110 10.5. BODY BUILDER AND TRAILER – TURN, MARKERS AND STOP (CONT.), P. 5................ 111 10.6. BODY BUILDER ACC FEED WIRING, P. 6.......................................................... 112 10.7. BODY BUILDER CONNECTIONS, P. 7............................................................... 113 10.8. INTENTIONALLY LEFT BLANK, P. 8.................................................................. 114 10.9.

REMOTE POWER MODULE – CAB MOUNTED, P. 9.............................................. 115 10.10. REMOTE POWER MODULE – CAB MOUNTED (CONT.), P. 9A.................................. 116 10.11. FUEL / HEATER RELAY, P. 10......................................................................... 117 10.12. ELECTRIC TRAILER BRAKE, P. 11................................................................... 118 10.13. HOUR METER – PTO, P. 12........................................................................... 119 10.14. AIR DRYER AND HEATED DRAIN VALVE, P. 13................................................... 120 10.15. REMOTE START / STOP, P.

14........................................................................ 121 10.16. INTENTIONALLY LEFT BLANK, P. 15................................................................ 122 10.17. WHEELCHAIR LIFT INTERLOCK, P. 16.............................................................. 123 10.18. WHEELCHAIR LIFT INTERLOCK (CONT.), P. 16A................................................. 124 10.19. AUX INPUTS AND DRIVERS, P. 17................................................................... 125 10.20. AUX AND POWER SOURCE, P. 17A................................................................. 126 10.21. TRANSFER CASE EFFECTS, P.

18.................................................................. 127 10.22. FUEL TRANSFER PUMP, P. 19....................................................................... 128 10.23. TRAILER SOCKET – EOF, P. 20...................................................................... 129 10.24. BODY BUILDER & TRAILER SOCKET – BOC & EOF, P. 21...................................... 130 iii

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