International Trucks Electrical Manual (EN)

ELECTRICAL CIRCUIT DIAGRAM MANUAL 0000002441 Electrical Circuit Diagrams - PayStar ® 5900 Revision 8 EPA 10 - US, Canada, Mexico April 2016 Electrical Circuit Diagrams PayStar ® 5900 Engine Family: MaxxForce ® 11/13, 15L, N13 or ISX15 Engines with SCR Navistar, Inc. 2701 Navistar Drive, Lisle, IL 60532 USA © 2016 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

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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 GUIDE, 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 (CHAPTER 3)............................................................ 13 3.1. BATTERY FEED WITH ENGINE BRAKE, P. 1........................................................ 13 3.2. BATTERY FEED WITH ENGINE BRAKE WITH 500K BAUD RATE, P. 1A........................ 14 3.3. BATTERY FEED WITH ENGINE BRAKE (CONT.), P. 2.............................................. 15 3.4. BATTERY FEED WITH ENGINE BRAKE WITH 500K BAUD RATE (CONT.), P. 2A.............. 16 3.5. BATTERY FEED WITH ENGINE BRAKE (CONT.), P. 3.............................................. 17 3.6.

BATTERY FEED WITH ENGINE BRAKE WITH 500K BAUD RATE (CONT.), P. 3A.............. 18 3.7. BATTERY FEED WITHOUT ENGINE BRAKE, P. 4................................................... 19 3.8. BATTERY FEED WITHOUT ENGINE BRAKE WITH 500K BAUD RATE, P. 4A................... 20 3.9. BATTERY FEED WITHOUT ENGINE BRAKE, P. 5................................................... 21 3.10. BATTERY FEED WITHOUT ENGINE BRAKE WITH 500K BAUD RATE (CONT.), P. 5A........ 22 3.11. IGNITION FEED, P. 6..................................................................................... 23 3.12. IGNITION FEED WITH 500K BAUD RATE, P. 6A..................................................... 24 3.13.

IGNITION FEED (CONT.), P. 7.......................................................................... 25 3.14. IGNITION FEED WITH 500K BAUD RATE (CONT.), P. 7A.......................................... 26 3.15. POWER FEED, P. 8...................................................................................... 27 3.16. ACCESSORY FEED, P. 9................................................................................ 28 3.17. ACCESSORY FEED WITH 500K BAUD RATE, P. 9A................................................ 29 3.18. J1939 DATA LINK WITH IBB ENGINE, P. 10.......................................................... 30 3.19. J1939 DATA LINK WITH IBB ENGINE (CONT.), P.

11................................................ 31 3.20. J1939 DATA LINK WITH IBB ENGINE (CONT.), P. 11A.............................................. 32 3.21. DIAGNOSTIC DATA LINK, P. 12........................................................................ 33 3.22. GROUND, P. 13........................................................................................... 34 3.23. GROUND (CONT.), P. 14................................................................................. 35 3.24. GROUND (CONT.), P. 15................................................................................. 36 3.25. GROUND (CONT.), P.

16................................................................................. 37 3.26. GROUND CHASSIS, P. 16A............................................................................. 38 3.27. ZERO VOLT REFERENCE, P. 17....................................................................... 39 3.28. PANEL LIGHT ADAPTER, P. 18........................................................................ 40 3.29. ECA POWER, P. 19....................................................................................... 41 3.30. J1939 DATA LINK WITH 15L ISX 2013, P. 20......................................................... 42 3.31. CAB J1939 DATA LINK WITH 11 / 13L IBB SCR, P.

21.............................................. 43 3.32. ECM SWITCH GND SPLICE, P. 22..................................................................... 44 3.33. ECM SWITCH GND SPLICE 2, P. 23................................................................... 45 3.34. 250K J1939 CAB DATA LINK WITH 500K REGULATORY UPDATE, P. 24........................ 46 3.35. J1939 DATA LINK WITH 500K BAUD RATE (CONT.), P. 25......................................... 47 i

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TABLE OF CONTENTS TABLE OF CONTENTS (CONT.) 4. CAB ACCESSORIES (CHAPTER 4)........................................................................... 48 4.1. CIGAR LIGHTER, P. 1.................................................................................... 48 4.2. ELECTRIC WINDOW – RIGHT AND LEFT, P. 2...................................................... 49 4.3. ELECTRIC WINDOW – RIGHT, P. 3.................................................................... 50 4.4. DEFROSTER FAN(S), P. 4.............................................................................. 51 4.5. HORN, P. 5................................................................................................ 52 4.6.

MIRROR LIGHTS AND HEATED MIRRORS, P. 6.................................................... 53 4.7. LEFT AND RIGHT MOTORIZED MIRRORS, P. 7..................................................... 54 4.8. DUAL AXIS MOTORIZED MIRRORS, P. 8............................................................. 55 4.9. POWER SOURCE (CB), P. 9............................................................................ 56 4.10. RADIO - CB ACCOMMODATION PACKAGE, P. 10.................................................. 57 4.11. RADIO – CAB SPEAKERS, P. 11....................................................................... 58 4.12. ELECTRIC LOCK – RIGHT AND LEFT, P.

12......................................................... 59 4.13. TEMPERATURE / COMPASS DISPLAY, P. 13........................................................ 60 4.14. ROAD RELAY IV, P. 14................................................................................... 61 4.15. HEATED SEAT – DRIVER, P. 15........................................................................ 62 4.16. HEATED SEAT – PASSENGER, P. 16................................................................. 63 4.17. ELECTRIC WINDSHIELD WIPER WITH INTERMITTENT WIPE AND WASH, P. 17............. 64 4.18. DEF GAUGE, P. 18....................................................................................... 65 4.19.

HEWITT MOTION SENSOR, P. 19..................................................................... 66 5. CHARGING AND CRANKING (CHAPTER 5)................................................................. 67 5.1. STARTER INTERLOCK WITH IBB ENGINES, P. 1................................................... 67 5.2. STARTER INTERLOCK WITH IBB ENGINES WITH 500K BAUD RATE, P. 1A................... 68 5.3. STARTER INTERLOCK WITH IBB ENGINES, P. 2................................................... 69 5.4. STARTER INTERLOCK WITH IBB ENGINES, P. 2A................................................. 70 6.

FANS WIRING (CHAPTER 6)................................................................................... 71 6.1. FAN WIRING – IBB ENGINE, P. 1...................................................................... 71 6.2. FAN WIRING – IBB ENGINE (CONT.), P. 1A.......................................................... 72 6.3. FAN WIRING – IBB ENGINE (CONT.), P. 2............................................................ 73 7. ENGINE SYSTEMS (CHAPTER 7)............................................................................. 74 7.1. ELECTRONIC ENGINE CONTROLS (2010 IBB ENGINE), P. 1..................................... 74 7.2. ELECTRONIC ENGINE CONTROLS (2010 IBB ENGINE) (CONT.), P.

2.......................... 75 7.3. ELECTRONIC ENGINE CONTROLS (2010 IBB ENGINE) (CONT.), P. 3.......................... 76 7.4. ELECTRONIC ENGINE CONTROLS (2010 IBB ENGINE) (CONT.), P. 3A........................ 77 7.5. ELECTRONIC ENGINE CONTROLS (2010 IBB ENGINE) (CONT.), P. 4.......................... 78 7.6. FAN DRIVE PROTECTION JUMPER, P. 4A........................................................... 79 7.7. ELECTRONIC ENGINE CONTROLS (2010 IBB ENGINE) (CONT.), P. 5.......................... 80 7.8. ELECTRONIC ENGINE CONTROLS (2010 IBB ENGINE) (CONT.), P. 6.......................... 81 7.9. ELECTRONIC ENGINE CONTROLS (2010 IBB ENGINE) (CONT.), P. 7.......................... 82 7.10.

ELECTRONIC ENGINE CONTROLS (2010 IBB ENGINE) (CONT.), P. 8.......................... 83 7.11. AFTERTREATMENT CONTROL, P. 9.................................................................. 84 7.12. SART MODULE, P. 9A................................................................................... 85 7.13. AFTERTREATMENT CONTROL (CONT.), P. 10...................................................... 86 7.14. AFTERTREATMENT CONTROL WITH 500K BAUD RATE, P. 10A................................. 87 7.15. AFTERTREATMENT CONTROL WITH 500K BAUD RATE (CONT.), P. 10B...................... 88 7.16. ELECTRONIC ENGINE CONTROLS (15L ENG) ISX 2013, P. 11................................... 89 7.17.

ELECTRONIC ENGINE CONTROLS (15L ENG) ISX 2013 (CONT.), P. 12........................ 90 7.18. 15L ENG & CRUISE CONTROL – ISX 2013, P. 13................................................... 91 ii

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TABLE OF CONTENTS TABLE OF CONTENTS (CONT.) 7.19. ELECTRONIC ENGINE CONTROLS (IBB ENGINE) – SCR EFFECTS, P. 14.................... 92 7.20. ELECTRONIC ENGINE CONTROLS (IBB ENGINE) – SCR EFFECTS (CONT.), P. 15.......... 93 7.21. ELECTRONIC ENGINE CONTROLS (IBB ENGINE) – SCR EFFECTS (CONT.), P. 16.......... 94 7.22. ELECTRONIC ENGINE CONTROLS (IBB ENGINE) – SCR EFFECTS (CONT.), P. 17.......... 95 7.23. 11L / 13L IBB ENG CRUISE CONTROL – SCR EFFECTS, P. 18................................... 96 7.24. ISX 2013 DEF & AFTERTREATMENT (15L), P. 19................................................... 97 7.25. ISX 2013 DEF & AFTERTREATMENT (15L) (CONT.), P. 20.........................................

98 7.26. ISX 2013 DEF & AFTERTREATMENT (15L) (CONT.), P. 21......................................... 99 7.27. ISX 2013 DEF & AFTERTREATMENT (15L) (CONT.), P. 22....................................... 100 7.28. ISX 2013 DEF & AFTERTREATMENT (15L) (CONT.), P. 23....................................... 101 7.29. DEF & AFTERTREATMENT (IBB SCR ENG), P. 24................................................. 102 7.30. DEF & AFTERTREATMENT (IBB SCR ENG) (CONT.), P. 25...................................... 103 7.31. 15L ISX & IBB SCR ENG THROTTLE POSITION, P. 26........................................... 104 7.32. DEF & AFTERTREATMENT (SCR ENGINE), P. 27.................................................

105 7.33. DEF & AFTERTREATMENT (SCR ENGINE) (CONT.), P. 27A..................................... 106 7.34. DEF & AFTERTREATMENT (SCR ENGINE) (CONT.), P. 28....................................... 107 7.35. DEF & AFTERTREATMENT (SCR ENGINE) (CONT.), P. 29....................................... 108 8. GAUGES AND WARNING LIGHTS (CHAPTER 8)......................................................... 109 8.1. LOW FUEL LEVEL WARNING, LOW AIR PRESSURE WARNING LIGHTS, P. 1............... 109 8.2. ENGINE OIL PRESSURE, ENGINE WATER TEMPERATURE WARNING LIGHTS, ENGINE AMBIENT AIR TEMP, P. 2................................................................... 110 8.3.

POWER DIVIDER LOCK (PDL) WARNING LIGHT AND BUZZER, IBB WAIT TO START LIGHT, P. 3................................................................................................ 111 8.4. AIR SUSPENSION RELEASE WARNING LIGHT, P. 4.............................................. 112 8.5. TRANSMISSION OIL TEMPERATURE GAUGE, AXLE FORWARD-REAR AND REAR-REAR TEMPERATURE GAUGE, P. 5........................................................ 113 8.6. MANIFOLD PRESSURE GAUGE, P. 6................................................................ 114 8.7. PYROMETER GAUGE, P. 7............................................................................ 115 8.8. VOLTMETER AND FUEL LEVEL GAUGE, P.

8...................................................... 116 8.9. ENGINE WATER TEMPERATURE, ENGINE OIL PRESSURE, SPEEDOMETER AND TACHOMETER GAUGE, P. 9.......................................................................... 117 8.10. ETHER START, P. 10.................................................................................... 118 8.11. RED STOP LAMP BUZZER SYSTEM, P. 11......................................................... 119 9. LIGHTING SYSTEM (CHAPTER 9)........................................................................... 120 9.1. BACKUP LIGHTS, P. 1.................................................................................. 120 9.2.

CAB AND TRAILER LIGHT SWITCH AND RELAY, P. 2............................................ 121 9.3. CAB CLEARANCE LIGHTS, P. 3...................................................................... 122 9.4. WORK LIGHT WITHOUT SLEEPER, P. 4............................................................ 123 9.5. CAB DOME, READING AND COURTESY LIGHTS, P. 5........................................... 124 9.6. DAYTIME RUNNING LIGHTS, P. 6.................................................................... 125 9.7. FOG LIGHTS, P. 7....................................................................................... 126 9.8. HEADLIGHT SWITCH AND DIMMER SWITCH, P.

8............................................... 127 9.9. HEADLIGHTS, P. 9...................................................................................... 128 9.10. HEADLIGHTS (CONT.), P. 9A.......................................................................... 129 9.11. PANEL LIGHTS, P. 10.................................................................................. 130 9.12. PARK / TURN / SIDE MARKER LIGHTS WITH AUXILIARY HEADLIGHTS, P. 11.............. 131 9.13. STOP, TAIL, TURN AND HAZARD SIGNAL LIGHTS WITH FLASHER, P. 12.................... 132 9.14. BEACON LIGHT, P. 13.................................................................................. 133 iii

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