FREEDOM™ MEDIUM DUTY TRUCKS ELECTRICAL SYSTEM SERVICE MANUALa PLEASE LET US KNOW! Your comments and suggestions will help us improve this manual! Please complete and mail this form or FAX your comments to: (610) 709-3800. Manual: Publication Number: Vehicle Model: Model Year: Do you find procedures properly organized and easy to follow? (1 Yes CINo If not, please explain: Manual page numbers: Are there any important procedures or other information presently not in this manual that you would like to see included? 1 Yes CNo If yes, please describe: Did you find any errors in the procedures or illustrations? O Yes ONo If yes, what pages? Please explain: Please include a copy of each page in question and mark your comments and suggestions. Name: Phone: ( ) . Company: a Address: City: State: Zip: Position Title: Thank You For Your Assistance Mack Trucks, Inc. (ATTENTION: RTS STAFF, 683) DO NOT STAPLE — USE TRANSPARENT TAPEFOLDALONGTHSLINE + _DONOTSTAPLE + _USE TRANSPARENT TAPE No POSTAGE NECESSARY TF MAILED INTHE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO, 1602 ALLENTOWN, PA POSTAGE WILL BE PAID BY ADDRESSEE SERVICE PUBLICATIONS (RTS), 683 MACK TRUCKS INC WORLD HEADQUARTERS: PO BOX M ALLENTOWN PA 18105-9972 FOLD ALONG THISLINE> ELECTRICAL SYSTEM SERVICE MANUAL FREEDOM™ MEDIUM DUTY TRUCKS OCTOBER 2002 ©MACK TRUCKS, INC. 2002 (REVISED — SUPERSEDES ISSUE DATED MAY 2001) Mv8-101ATTENTION The information in this manual is not all inclusive and cannot take into account all unique situations. Note that some illustrations are typical and may not reflect the exact arrangement of every component installed on a specific chassis. The information, specifications, and illustrations in this publication are based on information that was current at the time of publication. No part of this publication may be reproduced, stored in a retrieval system, or be transmitted in any form by any means including (but not limited to) electronic, mechanical, photocopying, recording, or otherwise without prior written permission of Mack Trucks, Inc.ing TABLE OF CONTENTS TABLE OF CONTENTSINTRODUCTION COMPONENT LOCATOR ... ‘SCHEMATIC DIAGRAMS SAFETY INFORMATION Advisory Labels Service Procedures and Tool Usage. CONVERSION CHART «2.05... 000+ VEHICLE ELECTRICAL .......... : Vehicle Locator Map for Electrical Components. Pinpointing of Electcal Components Pinpointing Example... . GheHonpeoned How to Read the Electrical Diagrarn 1... Pre-Equipment ee Connector Unit... PINPOINTING OF ELECTRICAL COMPONENTS Layout of Engine Components........ Layout of Front Frame Components Layout of Rear Frame Components... Layout of In-Cab Components ... FUSES/CIRCUIT BREAKERSIRELAYS . Connection Unit (Fuses and Relays Box) ... Fuses/Relays Away from Connection Unit... CONNECTION UNIT (FUSES AND RELAYS BOX): . internal Diagram... . Connector Pin Locations {Connection Unit) Wires — Connector Links (Connection Unit) peeseoonosed Bulkhead Connector Panel (Connector Pinning) ............+ ELECTRICAL WIRING HARNESSES . oe Top Ledge Wiring Hamesses Roof Wiring Hamness ...... Front End Wiring Harness... Door Wiring Harnesses Dashboard Wiring Hamess ..... Stalk Switch Wiring Hames and Radio Remote Control rl Wing Hamess - Engine Wiring Hamess a Front Frame Wiring Hamesses Rear Frame Wiring Hamess Bumper Wiring Hames . ELECTRICAL SCHEMATIC DIAGRAMS. Key to Diagrams... Plate 1 — "CAN" Communication Network without Allison Transmission . . Plate 2— “CAN" Communication Network with Alison Transmission . Plate 3— “CAN” Communication Network with Allison Transmission Plate 5 — Power Supply/Starting . cee 5 Plate 6 — Power Supply . Plata 7 — Electronic Theft Protection Systern . Plate @—Englne Airinake Prehesting ...... Plate 9— Starting . Plate 10 — Fuel Preheater Plate 11 — Interior Lighting and Signalling. -TABLE OF CONTENTS Plate 12 — Lighting ...... Plate 13 — Daytime Running Lamps (OAL) Plate 14 — Signalling . Plate 15 — Signalling Plate 16 — Diagnostics Connectors Plate 17 — Doors Locking ..... Plate 18 — Electric Window Litt Motors Plate 19 — Electric Detrosting Rearview Plate 20 — Cab Interior Lighting . Plate 21 — Windshield Wiper _ Plate 22 — Cigar Lighter/12-Volt Socket/Radio ... Piate 23 —Retarder Control . Plate 24 — Air Conditioning . . Plate 25 — Principal Display . Plate 26 — Principal Display . Plate 27 — Brake Pad Wear : Plate 28 — ABS Electronic Control Unit Plate 29 — Automatic Transmission Plate 30 — Automatic Transmission Plate 31 — Automatic Transmission Plate 82 — Automatic Transmission toe Plate 33 — Vehicle Electronic Control Unit (VECU) .. Plate 84 — Engine Electronic Control Unit (EECU) . Plate 35 — Available Power Supplies Plate a6 — Avatabe Power Supplies «... Wire Sizes ..... : INDEX& NOTES& INTRODUCTION INTRODUCTION Page 1INTRODUCTION SAFETY INFORMATION Advisory Labels Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibilty of improper service methods which may damage. - the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of procedural importance and provide suggestions for ease of repair. The following definitions indicate the Use of these advisory labels as they appear throughout the manual: Activities associated with Danger indicate that death or serious personal injury may result from failing to heed the advisory. Serious personal injury may be equated to career-ending injury. ‘Activities associated witn Warning indicate that personal injury may result ry. In this case, personal injury is not equated to sults in possible change in quality of life. ACAUTION Activities associated with Caution indicate that product damage may result from falling to heed the advisory. Caution is not used for personal injury. NOTE A procedure, practice, of condition that is essential to emphasize. SERVICE HINT Ahhelpful suggestion that will make it quicker and/or easier to perform a procedure, possibly reducing service cost. Page 2> INTRODUCTION Service Procedures and Tool Usage Anyone using a service procedure or toa! not recommended in this manual must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects. Individuals deviating in any manner from the instructions provided assume all risks of consequential personal injury or damage to equipment involved, Also note that particular service procedures may require the use of a special tool(s) designed for a specific purpose. These special tools must be used in the manner described, whenever specified in the instructions. : the driver's seat, pl transmission in neutral, be sure that parking brakes are set, and disengage the clutch. 2. Before working on a vehicle, place the transmission in neutral, set the parking brakes, and block the wheels. 3. Before towing the vehicle, place the transmission in neutral and lift the rear wheels off the ground, or disconnect the driveline to avoid damage to the transmission during towing. Engine-driven components such as Power Take-Off (PTO) units, fans and fan belts, driveshafts and other related rotating assemblies, can be very dangerous. Do not work on or service engine-driven components unless the engine is shut down. Always keep body parts and loose clothing out of range of these powerful components to prevent serious personal injury. Be aware of PTO engagement or nonengagement status. Always disengage the PTO when not in use. REMEMBER, SAFETY. . .IS NO ACCIDENT! Pages> INTRODUCTION Mack Trucks, Inc. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recognizing potentially hazardous situations and taking necessary precautions. Performing service procedures correctly is critical to technician safety and safe, reliable vehicle operation. The following list of general shop safety practices can help technicians avoid potentially hazardous situations and reduce the risk of personal injury. DO NOT perform any services, maintenance procedures or lubrications until this manual has been read and understood. * Perform all service work on a flat, level surface. Block wheels to prevent vehicle from rolling. * DO NOT wear loose-fitting or tom clothing. Remove any jewelry before servicing vehicle. © ALWAYS wear safety glasses and protective shoes. Avoid injury by being aware of sharp comers and jagged edges. Page 4 Use hoists or jacks to lift or move heavy objects. NEVER run engine Indoors unless exhaust fumes are adequately vented to the outside. Be aware of hot surfaces. Allow engine to cool sufficiently before performing any service or tests in the vicinity of the engine. Keep work area clean and orderly. Clean up any spilled oil, grease, fuel, hydraulic fluid, etc. Only use tools that are in good condition, and always use accurately calibrated torque wrenches to tighten all fasteners to specified torques. In instances where procedures require the use of special tools which are designed for a specific purpose, use only in the manner described in the instructions. Do not store natural gas powered vehicles Indoors for an extended period of time (overnight) without first removing the fuel. Never smoke around a natural gas powered vehicle.CONVERSION CHART INTRODUCTION Conversion Units Length Calculations Inches (a) to Milietors (ry 25.40 inches (in) Centimeters om) 2540 Feet) ‘ Centimeters (em) 3048 Feet ) ‘ Meters (a) 03046 Yards (yd) te Genteters (em) mae ‘Yards (yd) to ~__| Metars (m) 09144 Miles ‘ icfomatars (en) +600 Milineters (mm) ‘ inches (np 0.08887 Centimeters (em) © Inches (n) 0.3807 entimeters (em) © Feet f) 0.0888 Centimeters (em) © Yards (vd) 0.0109 Meters), ‘ Feet 3281 Meters () ® Yards (yd) +094 iKometers (an) [te ‘Mes oeet4 ‘rea Calculations Square inches (sq) © Square Miliaters (eqn) waz Square Inches (647) © ‘Square Centimeters (sen) 6.482 Square Feet Ga) to | Square Centimeters (sa-om) 3290 Square Feet (64-8) oy Square Meters (64-m) i) Square Yards 29-¥a) to | Square Motors (sq-m) acer ‘Square Mies (sq-iles) Dy Square Klomotos (sk) 2.500 ‘Square Nilimetors(6q-nm) D Square inches (earn) 0.00185 ‘Square Centimeters feq-am) oO Square ches (earn) 0.165 Square Centimeios (6q-a) oD Square Fest 6a) 0.001076 ‘Square Meters (sq-m) to ‘Square Feet (sq-ft) 10.76 ‘Square Meters (6a-m) to Square Yards (39-y2) 1496 “Square Kilometers (0e-k) oD Square Miles (sq-iles) 03861 Volume Calculations {bie nches (eurin) © Gubie Gantimoters (Cue) 16.287 ‘Cuble nches (cu ‘ Tiers 0.01699 ‘Quans (at [ites 09464 Gallons (gal io Liters (0) 37664 ‘able Yards (Ora) to __| Gabi Metors (unm 07646 ‘Ciible Centimeters (eum) to Cubic inches (an) o.06t02 ters © Cube inches (un) 61.024 Lies 0) © ‘Quarts (@) 10867 Uiers (0) © Gallons (ga) 02642 Cubic Motors (eum) © Guile Yards (ond) 1308 Page 5INTRODUCTION Conversion Unite Mutiply By: Weight Calculations ‘Ounces (02) 0 Grams (5) 28.5714 Pounds (b) Ielograms (9) 0.4596 Pounds (8) ‘Shor Tons (US tons) (0.0008 Paunds (6) . Metic Tons () (0.00045 Short Tons (US tons) Pounds (b) 2000 Short Tons (US tone) a Klograms (9) 207.18886 Short Tons (US tons) D Mate Tons onorie Grams (@) o ‘Ounces (oz) 0.085 iKlograms (kg) o Pounds () 2205 iKlograms (kg) 6 Short Tons (US tons) o0TT02 iKlograms (kg) © Metio Tons () 0.001 Metre Tors () ‘ Pounds (B) 2205 Metre Tors () ie ‘Shor Tone (US tons) 11028 Meri Tons () © Kilogram (kg) 1000 Foree Calculations ‘Ounces Fore (ez) e Newtons (8) 2780 Pounds Force (6) o Newtons (N) aa48 Pounds Fore (2) ‘e iKllograms Force (el) 0.86 iKlograms Fores (3) Pounds Force (6) 2.2088 iKlograms Foree (gi) e Newions (N) 9.807 Newtons (N) e ‘Kilograme Force (al) 0.10196 Newtons (N) ‘Ounces Force (oz) 3597 Newtons (N) io Pounds Force (i) 0.2248 “Torque Calculations Pound inches (b-n) e Newion Meters (Nem) 0.11208 Pound Feet (b-) © ‘Newton Meters (Nem) 3858 Pound Feet (b-R) © iKlograms Force per Mater (gia) 0.10825 Newion Meters (Nem) © Pound Inches (bn) east Newon Meters (Nem) © Pound Foot (bf) 07876 Newton Meters (Nem) © Klograms Force per Meter (kgm) | 0.10197 Klograms Force pet Meter kam) te Pound Feet (bf) 7288 ilograms Fores per Meter af) te Newton Meters (Nem) 3.807 Radiator Specific Heat Dissipation Calculations Bish Thormal Unit per Hour (@TUM) | to ‘Klowalt per Degree Gelsus KWI'O) | 0.000898 Kowatt per Degree Celsius (RW?°0) | to Bish Thermal Unt per Hour (@TUMA) | 8414.43 Temperature Calculations Degrees Fahrenheit (°F) to | Degrees Celsius (°C) (°F2) 0.556 Degrees Gelsius (0) ‘ Degrees Fahvenhelt (F) (18x) +32 PagesINTRODUCTION Conversion Unite Multiply By: Preseure Calculations ‘Atmospheres (atm) to Bars (bar) 4.01825 ‘Atmospheres (atm) 6 Kiopascals (kPa) 101.925 Bars (bar) “Atmospheres (atm) 0.98692 Bars (bar) to Kilopascals (kPa) 100 Bar ban) co Pounds per Square Inch (pa) 145087 Inches of Mercury (in Ha) to | Kilopascats KPa) 3877 Inches of Water (in HO) 6 Kilopascals (KPa) 02491 Pounds per Square Inch (psi) 6 Kiiopascals (KPa) 6.895 Pounds per Square inch (psi) Bar bar) 0.06895 Kilopascals (kPa) ‘Atmospheres (atm) 0.00887 Kilopascals (kPa) to Inches of Mercury (in Ho) 0.29612 Kllopascals (kPa) 6 Inches of Water (in H,0) 0145 Kilopascals (KPa) to Pounds per Square Inch (ps) 0.145 Power Calculations Horsepower (hp) to Kilowatts (kW) 0.74627 Kilowatts (kW) cy Horsepower (hp) 134 Fuel Performance Calculations Miles per Gallon (mile/gal) © Kilometers per Liter (K/L) 04251 Kilometers per Liter (kL) Mies per Gallon (ile/gal) 2.362 Velocity Calculations Milles per Hour (mile/h) to Kilometers per Hour (kmh) 1608 ‘Kilometers per Hour mht) cy Miles per Hour (miler) oat Volume Flow Calculations (Cubic Feet per Minute (cumin) to Liters per Minute (Uimin) 28.92 Liters par Minute (Uminy to Cubic Feet per Minute (cu-fUmin) 0.08581 Pago 7& NOTES Pages> COMPONENT LOCATOR COMPONENT LOCATOR Pages> COMPONENT LOCATOR VEHICLE ELECTRICAL Vehicle Locator Map for Electrical Components The vehicle is broken down into several zones each designated by an iten number. 7208 « Heightwise breakdown Widthwise breakdown Reserved for the cab, four zones designated bya Three zones designated by a capital letter. smal eter A: RH side and RH sidemember B: central part C: LH side and LH sidememberCOMPONENT LOCATOR Lengthwise breakdown Nine zones designated by a number. Zone 4 includes: — onthe chassis, the bumper and the appliances it supports — on the cab, the front end elements with access through the front grille Example’ ‘At: RH bumper (headlamps) 3: LH front roadwheels (ABS sensor) 2b: LH fascia panel A3c: passenger seat Pinpointing of Electrical Components The Key to Diagrams (in SCHEMATIC DIAGRAMS) situates each on-vehicle electrical component (on chassis, in cab and on major unit) as follows, Each component may be pinpointed: — Location on the vehicle by reference to the Vehicle Locator Map (see figure under “Vehicle Locator Map for Electrical Components” on page 10). — Inthe electrical diagrams by reference to the specified plate(s). Pinpointing Example 2101 — Battery No. 1 2101: Component reference Battery No. 1: key to component (Cédt Pinpointing of component on the Vehicle Locator Map (see figure under “Vehicle Locator Map for Electrical Components” on page 10). 04/05: Pinpointing of component in electrical diagram (see plate 5). This localization method aiso applies for fuses, relays and diodes, How to Read the Electrical Diagram The diagram consists of several plates numbered in the bottom right-hand comer. ‘wire connecting components located in different plates includes a connection address. Example: 20 = see plate 20 4618 = Driver's overhiead lamp Connectors: The connectors are identified by a figure indicating the number of ways and by one or several letters indicating the color. BLACK BROWN RED ORANGE YELLOW GREEN BLUE PURPLE GRAY WHITE Pre-Equipment Circuits represented with dotted lines indicate a connection solution or an optional assembly. Connector Unit ‘The connector unit provides the electrical link. between chassis and cab. Each face of the connector unit is detailed in the Body Installer’s Guide, MV1-001. Page 11COMPONENT LOCATOR PINPOINTING OF ELECTRICAL COMPONENTS Layout of Engine Components ENGINE RIGHT SIDE — Engine Component Locations Figure 1 Page 12COMPONENT LOCATOR ENGINE COMPONENT IDENTIFICATION Component 2211 — Starter 2311 — Alternator 2414 — Proheating relay No. 1 2452 — Preheating resistor No. 1 ‘2453 —Preheating resistor No. 2 "7962 — Coolant temperature sensor "7368 — Oil pressure sensor 8261 — Engine speed sensor 8275 — Engine ol level sensor {9200 — Boost air pressure and temperature sensor ‘9202 — Engine master ECU (ECU) ‘9204 — EGR solenoid valve ‘9208 — Fuel high pressure sensor 9212 — High pressure pump, solenoid valve cylinder 2 9213 ~ High pressure pump, solenoid valve cylinder 1 {9220 — Unit injector No. 1 Incorporating solenoid valve £9221 — Unit injector No. 2 incorporating solenoid valve {9222 — Unit injector No. 8 incorporating solenoid valve {9223 — Unit injector No. + incorporating solenoid valve 19224 — Unit injector No. § incorporating solenoid valve {9225 — Unt injector No, 6 incorporating solencid valve 9230 — Camshaft speed sensor Plate (0) (05) (08) (08) (08) ey oy oy (34) (34) 34) (4) (4) 4) wy 4) 34) 64) oy (a) oy my Page 13,COMPONENT LOCATOR Layout of Front Frame Components FOR CLARITY Figure 2— Front Frame Component Locations Page 14COMPONENT LOCATOR FRONT FRAME COMPONENTS IDENTIFICATION Component 1100 — Fuses 2165 — Master switch 2266 — Engine stop control 2400 — Fue! iter clogging switch 2416 — Preheating relay No. 2 2422 — Fuel preheater relay 2428 — Fuel preheater 2449 — Ar dryer 2464 — Fuel preheater thermal switch 8211 —RH front flashing lamp 3212 — LH front flashing lamp 17462 —Fuel level transmitter 8014 — ABS LH front modulator valve 8015 — ABS RH front modulator valve {8081 — ABS LH front wheel speed sensor {8082 — ABS RH front wheel speed sensor {8100 — LH front brake pads wear switch sensor 8104 — Front ar pressure sensor £8105 — Rear air pressure sensor £8108 — RH front brake pads wear switch sensor £8150 — Exhaust brake solenoid valve 18165 — Rear brakes air pressure switch '8166 — Front brakes air pressure ewitch 8178 — Parking brake indicator air pressure switch 9202 — Engine master ECU (EECU) 9210 — VECUIEECU ECU power supply relay 8) (22) (28) en (es) (es) (27) (34) es) (es) (83) (ovz/es/s4) (33) Page 15& COMPONENT LOCATOR Layout of Rear Frame Components Figure 3 — Rear Frame Component Locations Page 16COMPONENT LOCATOR REAR FRAME COMPONENTS IDENTIFICATION Component 16825 — Reverse warning buzzer 8016 — ABS LH rear modulator valve 8017 — ABS RH rear modulator valve (8064 — ABS RH rear wheel speed sensor {8109 — LH rear brake pads wear switch sensor 8159 — RH rear brake pads wear switch sensor 8964 — Inter-anle diforential lock switch Plat (15) (8) (28) (28) (7) en (25) peo& COMPONENT LOCATOR Layout of In-Cab Components Figure 4— In-Cab Component Locations Page 18COMPONENT LOCATOR {N-CAB COMPONENTS IDENTIFICATION Component £2209 — Star inhibit relay 3506 — Signal flasher 4901 — Door lock control box. '5266 — Accelerator pedal position sensor {6123 — High beam headlight warning lamp 6167 — Stalk eit —Antithett Side lamps — Headlight and dipped headlight —Homidiection indiator fight — Windshield wiperiwasher ~ Cruise control 6316 — Reverse light relay 7411 ~Fuel level gauge 7519 ~ Diagnosis connector (MACK) ‘7520 — Diagnostics connector No. 2 (ALLISON) 7614 — Principal display 18000 — ABS ECU 8011 — ABS safety waming iamp 8129 — Air pressure alert warning lamp 6141 — Front ar pressure gauge 8142 — Air pressure indicator roar circuit £8160 — Stop lamp switch 15318 — Intey-axt ciferential lock waming lamp 18499 — Neutral rolay 19201 — Vehicle master ECU (VECU) Plate (09) (14) (7) (33) (28) (or (07) (1) (12) (14) (a 3) (13) 5) corte) (arte) (011020325726) (01/28) (26) 3) (25) 5) (18) (25) (29) (0102/03/39) Page 19& COMPONENT LOCATOR FUSES/CIRCUIT BREAKERS/RELAYS Connection Unit (Fuses and Relays Box) [| EBREN | Jo GHOWRRESRE ABGARNRG = FARR BND a atta san Sven dain ||] autigon nae a | aaa wnbow ee eaten Il axe ‘i oa Aseeaea lg Bs a Bay ||| ser. (25) = ait eH hamhSS LEFT REAR By Macebonn aera] ||"E" | |, R23E sa) a sigh. | | oMoG (25a) ;—t 028088 Figure § — Connection Unit Fuse and Relay Locations Page 20COMPONENT LOCATOR FUSES. ‘TABLE OF FUSES ON CONNECTION UNIT ‘Assignment Item Amp. Pate Start relay FI 10 06 Roverse lights relay FI to 06 Stop lights rolay A 10 06 LH suivaling defrosting rearview mirror AY 10 05 RH swiveling deftosting rearview mirror Ft 10 06 ‘Windshield wiper speed controler Ft 10 08 ‘Windshield wiper disabling relay A 10 08 (Clutch snitch A 10 29131 ‘Automatic transmission power supply 2 10 29% Ar dryer heater F3 10 10 Clearance lamps Fa 10 1" FH side/parking lights FS 10 1" RH marker lights FS 10 1" LH side(parking lights FS 10 1" LH marker lights FS 10 " Dashboard instruments lighting FS 10 " ‘Switch ighting F5 10 tt Bodybuilder equipment control No. 1 Ft 10 35 Badybuilder equipment control No. 2 Ft 10 35 Bodybuilder equipment for lights available power supply F12 10 35 Exhaust brake Ft 10 23 ‘ABS-ASR ECU Fe 10 08 Dashboard warning lights and instruments power supply Fie 10 06 ‘Stop lights switch Fie 10 06 Dashboard warning lights power supply Fie to 06 Cab interior power connecting pin FI 20 22 Heater motor Fie 20 24 Signal flasher F20 1 4 Far lights relay F20 18 4 Flashing direction indicator tights relay F20 18 4 Hazard lights control F290 18 4 ‘Avaliable power supply 12V Fat 10/15 35 Driver's overhead light F238 10 20 Passengers overhead light F29 10 20 Bottom bunk overhead light F23 10 20 “Top bunk overhead light F23 10 20 Step fight F23 10 20 Vehicle Control Unit memory supply F25 5 05 Horn F286. 10 4 Page 21COMPONENT LOCATOR ‘Assignment stem Amp. Plate ‘Stop lights For 10 18 ‘ABS-ASR unit control power supply F28 18 28 Heater motor F2a % 24 Radio F90 20 2 (Cigar tighter F309 20 PA ‘+2ev0lt socket Fat 10 2 Diagnostics connector Fa 10 18 Radio tuner memory power supply F4 5 08 Stop lights signal for Vehicle Control Unit Fat 0 8 ‘Automatic tranemiaston power supply aa 10 2031 ‘Automatic transmission unit control Fag 10 29'a1 UH electric door lock Fas 10 7 RH electric door lock Fas 10 7 Door lock control box Fas, 10 7 Reverse lamp(s) Fas. 10 1 Reverse buzzer Fag, 10 18 Vehicle Control Unit power supply Fs7 10 33 peallable Pe 10 ‘Available FxA 10 ‘Available FXS: 10 CIRCUIT BREAKERS ‘TABLE OF CIRCUIT BREAKERS ‘Assignment tem Amp. Plate LH window regulator motor but 20 18 RH window regulator motor but 20 18 Low beam headlights relay pve 20 2 LH low beam headlight pu 20 12 FH low beam headlight paz 20 12 Windshield wiper motor Dus 20 at ‘Windshield washer pump Dus 20 at FH high beam headlight Dus 20 2 LH high beam headtight Dus 20 12 RELAYS ‘TABLE OF RELAYS ON CONNECTION UNIT Assignment fem, Amp. Plate ‘Atir ignition power supply relay No. + Ri 50 8 Windshield wiper disabling relay Ra 25 at ‘Comfort accessories relay Re 40 22 Low beam Headlights relay Ri 25 12 Page 22COMPONENT LOCATOR Assignment tem Amp. Plate High beam headlights relay Ria 25 12 ‘Stop lights relay Ria 25 18 ‘ABS signal relay RIB 25 33 Windshield wiper speed controler relay Res 25 2 Start relay 33 50 9 Window regulator motors and air dtyer relay Rat 50 10 RH rear lights Reo 25 “ RH front and RH side flashing lamps. Ret 25 4 LH roar lights Re2 25 4 LH front and LH side flashing lamps Res 25 4 Door lock relay Rut 25 17 Door unlock relay Ru 25 7 Avaliable power supplies relay (bodybuilder equipment) Rxt 25 36 Page 23> COMPONENT LOCATOR Fuses/Relays Away from Connection Unit FUSES ‘TABLE OF FUSES AWAY FROM CONNECTION UNIT Assignment ‘tom Amp. Plate Engine Control Unit power supply Fat 25 34 Engine Control Unit power supply Foe 10 34 Fuel fter preheater control Fos 50 10 ' f She C TonclAnT = Figure 6 — Fuses Away from Connection Unit Page 24& COMPONENT LOCATOR RELAYS ‘TABLE OF RELAYS AWAY FROM CONNECTION UNIT ‘Assignment ftom Amp. Plate Vehicle Control Unit and Engine Control Unit power supply relay og 50 3 Noutral relay Rat 25 29 Starter inhibit relay Rez 25 09 Reverse lights relay Roa 25 18 Fuel preheater relay Res 60 10 reheating relay No. 1 Roe 170 os reheating relay No. 2 Rov 25 08 = = ‘COVER REMOVED = lana FOR CLARITY 028110 Figure 7 — Relays Away from Connection Unit Page 25COMPONENT LOCATOR CONNECTION UNIT (FUSES AND RELAYS BOX) Internal Diagram RELAY IDENTIFICATION TABLE Item signment Plate RI 2196 — After ignition power supply relay No. 1 BFR2 cy {5820 — Windshield wiper disabling relay BFR2 RS. 4136 — Comfort accessories relay BFR Rit 6119 — Low beam headlights relay BFR Ri2 6121 — High beam headights relay BFRA Ris 9512 — Stop lights relay BFR2 Rie (8424 — ABS signal relay BFAS a5 {5901 — Windshield wiper speed controller relay BFR2 a3 2212 — Start relay BFRS Rat 2450 — Window regulators and alr dryer relay BFR2 80 3502 — RH rear lights BFR Ret 3603 — RH front and RH side flashing lamps erg a2 3504 — LH rear lights BFR Res 3505 — LH front and LH side flashing lamps BFR Rut 5838 — Door unlock relay BFRE RL 15700 — Door lock relay BFRE RXi 21113 — Bodybuilder equipment avallable power supply relay BFRI FUSE IDENTIFICATION TABLE Item Plate tem Plate em Plate FI BFR2 F209 BFRS Fs BFR F2 BFR2 Fat BFR Fo BFRS Fs BFR F23 BFR Fat BFR2 Fe BFRS F258 BFR Faa BFRA FS BFRE F268 ras a5, BFR Fit BFR Fer BFR2 Fas BFRI Fe BRE F28 BFRA F67 BFRG Fie BFR2 F29 BFR FXa FRA FZ BFRI Fa BFRI x4 BFRI Fig BFR2 Fat BFRI FXS BFRI Fig BFR CIRCUIT BREAKER IDENTIFICATION TABLE tem Plate Nem Plate Item Plate. Disst BFR2 pis BFR DIss3 BFRI bisa BFR2 Page 26> COMPONENT LOCATOR PLATE BFRO1 a 2: | ces 18) ces + co | cw 9p 8 ces fe t {J eg ee ty) p= ca | cx at | (BFR POWER FRO SUPPLY RFROH one RELAY Figure 8 — Plate BFROT Page 27& COMPONENT LOCATOR PLATE BFRO2 (BFROM a S022 ‘DRYER RELAY SI nequtaron [2000 Be MOTOR ANDAR + ual cw AFTER IGNITION POWER SUPPLY 2 MELA HO.T +s rtp =| ceo | (286) 73 WINDSHIELD WIPER SPEED Fp) ‘CONTROLLER RELA WINDSHIELD wiPER DISABLE RELAY 5320 Cc mrs so A aut wa = Y uy x ee ee 352] Ft STOP LIGHTS RELAY ROS —a tls 45: cw —8) co FROZ 7020190 Figure 9 — Plate BFRG2 Page 28& COMPONENT LOCATOR PLATE BFRO3 2 | ane —=— lal ceo 3502] i RH FRONT AND [3603] RH SIDE FLASHING LAMPS LH REAR 3508) LianTs ea Yt ie : 18 ces et Bi = ea SEH See tne ia! pat LAMPS +8 ce [BFRO3| ‘roee14D Figure 10— Plate BFROS Page 20isn) PLATE BFROS COMPONENT LOCATOR (BFROM neon El HIGH BEAM HEADLIGHTS RELAY Page 30 Figure 11 — Plate BFRO4ds COMPONENT LOCATOR PLATE BFROS BFRON ' mn oy 222 START oe RELAY HL 8 ate a se tu ie [BROS] ro2e10> Figure 12 — Plate BFROS Page 31Dies) PLATE BFRO6 COMPONENT LOCATOR Door Lock RELAY DOOR UNLOCK RELAY ABS SIGNAL RELAY 3 Ss ie i ei tl cw + —_ jor Rav 3 om Rea : ces + cea B42 Yh 3 658; ce ie Lj cot Page 32 Figure 13 — Plate BFROS> COMPONENT LOCATOR Connector Pin Locations (Connection Unit) - 8 oO fe} eee Figure 14 — Rear View of FuseRelay Box Page 33COMPONENT LOCATOR FACE A CONNECTORS Number Assignment Color Number of ways. 0180 Dashboard wiring harnoss White Ea ret Dashboard wiring hamoss Yellow 8 0182 Dashboard wiring harness Red 8 183 Dashboard wiring harness Brown 2 Cres, Dashboard wiring harness Gray 2 cr9t Dashboard wiring hamess Yellow 8 C192 Dashboard wiring hamess Rod 8 Cres Dashboard wiring hamess Red 8 195 Dashboard wiring hamess Brown 8 ci96 Dashboard wiring hamess Gray 8 c197 Dashboard witing hamess white 8 Page 34COMPONENT LOCATOR [ai] 608 imi] 298 i]s 908 o10—+[a1 225 -+[1 202 [64 pa]e—ei8 pa] 205 pa] 966 652+ |a2 273 -9|p2 208 ~»|B2 a(x] e—s10 mail 12 = faale 204 le 70» [aa 90° ase 2 260 —s|ea}Aile 2! + an] - 2—»|B5 As 62: co Peleg 24-085) ase 0 aa ae S|? 5 3 [8] 85 abel 2* — +B 24—ofe a7|+—2079 Se aT] «925 az|«—28 22-+[67 507 oer 213-67] |AB}e—311 |Ag|<— 501 jag|¢— 119 c21—e|p0 501 |p) 110 -+]e0}S fas|e—e2s oped po] 119 se 509 —s[p0) 119 -+[p0) ioje—e2 of 68 gle 119 ar—oler 08+ 22a wife 47 viet fe 9075 a7-olen 63-614 229 -»/ar sc lenile—sze cans = aha 0028 a 76: + oles vaje-a7 gfe 2100 vf 22 C180 C181 C182 2 [esse 1 afi 4 [e208 2)e2t 2)e2 3 [+208 @ fe-szs cies cies cist Je-s03 le-27 Je-273 J<-s29 Je-270 Je-i28 J+-2009 Je-s2s C192 C193 ‘roeatga Figure 15 — Pin Assignments Page 35& COMPONENT LOCATOR C196 C196 C197 Figure 16 — Pin Assignment Page 36COMPONENT LOCATOR Wires — Connector Links (Connection Unit) Connectors Wire No. Wire Section (mm) "Terminal Number ‘0028 08 Bia Tai i 08 Att 184 1 08 7 1 1 2 6 197 2 Os A 180 2 7 cy 180 2 7 2 185 2 08 7 185 7% 3 a 181 2 Os 2 183 2 06 aig 182 2 08 Bia 182 2 1 7 198 2 06 6 198 23 06 aa 181 24 05 76 182 2 06 aT, 12 2 1 Be 182 4 06 Be 182 at oy Be a 182 22 oy 87 180 38 06 7 180 34 06 3 188 34 08 7 198 34 05 8 196 a 08 Ais 180 [37 05 Bit 180 37 06 Bia 180 a 2 ait 180 a 1 Bio 180 | 8 2 8 185, 7] @ 06 AiO 180 Cy 08 a9 181 8 oy ‘a0 181 68 2 B10 181 38 08 Bit 181 119 1 Aa 182 119. 1 79 182 119 1 AiO 182 Page 37COMPONENT LOCATOR Connectors Wire No. Wire Section (mm) Terminal Number 7 38 Be 1a 9 oi 59 182 138 os 6 18 201 2 7m a2 202 1 [et 12 204 i 7% 132 208 2 Be 12 21a 7 BIO 1 214 08 a 18 228 7 Bt 12 285 08 A 181 25 7 ne ‘8 235 7 ai 18 288 H aS 12 288 7 Be 12 285 2 3 1% 270 2 $ 192 270 7 7 192 27a 0 3 wet 27a 08 3 192 28 06 5 197 278 08 3 12 278 a8 4 182 278 08 2 188 28 08 3 196 204 1 2 11 204 7 é eH 204 05 7 ‘34 304 1 5 191 304 1 3 tt 310 1 a 10 at 1 Aa 100 a8 2 1 vat 368 08 me 10 368 08 at 12 386 2 a 12 382 2 3 187 a0 08 8 180 wa 06 B4 11 are 05 3 197 wa o8 3 81 Page 38COMPONENT LOCATOR Connectors Wire No. Wire Section (mm) ‘Terminal Number #6 1 7 197 co 2 7 196 co 1 6 196 | 484 1 2 196 01 2 * 781 50r 2 Ba 181 503, 08 2 182 507, 2 57 181 509 2 Be 181 523 2 Az 720 523 08 3s 193 528 08 4 139 606 1 a 180 ot8 2 Re 180 618 05 Ey 780 eat 05 7 180 eat 2 88 180 625 08 5 181 625 oy cg tet 625 08 a7 18 025 1 Bs 18 025 08 56 181 632 1 2 191 652 06 Ba 180 1060 06 a 187 2008 06 3 182 | 008 06 ort @ 182 [2086 2 a 196 2079 1 a7 180 2089 08 2 193 2100 06 as 181 4801 06 4 196 4302 06 4 197 8068 2 7 195 8075 08 att 182 ort 2 2 185 Page 39COMPONENT LOCATOR Bulkhead Connector Panel (Connector Pinning) Figure 17 — Connector Panel 1 Pin Locations BULKHEAD CONNECTOR PANEL 1 (CONNECTOR INTERFACE) Number of Number Assignment Color ways 160 Front signallinglighting Yellow 8 ret LH front wiring harness White 16 c162 Stanter Gray 2 crea Power unit Gray a cr64 Bodybuilder equipment Brown 8 ores: Engine Electronic Control Unit (ECU) Purple 8 ores. ear witing hamess Yellow 25 cre7 Windshield wash pump Gray 4 170 RH front wiring hamess Brown 16 e401 Bodybuilder equipment Bue 16 (0505 ‘Automatic transmission (ALLISON) Red 16 0506 ‘Speed change control of transmission (ALLISON) Green 16 Page 40> COMPONENT LOCATOR Figure 18 — Connector Panel 1 Location Figure 19 — Connector Panel 2 Connector Locations: Page 41a> COMPONENT LOCATOR BULKHEAD CONNECTOR PANEL 2 (CONNECTOR INTERFACE) Number of Number Assignment Color ways o1s2 Stop lights switch Yotlow 4 c154 Doors and front end equipment Rod 8 crs Windshield wiper motor Yellow 8 7o2saa Figure 20 — Connector Panel 2 Location Page 42COMPONENT LOCATOR e250 z]48 i Tf es Je ara Jette om cise cies ea 2 Jeo Joa fee aia jo 304 'B7|+- 8068 ra-afae 8 0-+[p0 85 e599 c160 C162 | sao se sor ae as aial| "ALLISON" oe 2 |e-63 ae a Bt }e—34 tobe +-o08 je-24 [pa]<—0013 corer 8 core As] 2000 anol sas C163 s29—+[A5 ciet a IAS Ta] e—88 ra a coer» sile-2206 2010 | 822 ooss—[At — cots ots e285 }e— 651 je-1 oe em os Figure 21 — Connector Pin Locations (C152, C154, C155, C160-165, C505) Page 43COMPONENT LOCATOR fx las 7 9 | 19 Bo [pa|<~552 551 -» [a8 C167 B7|<- 547 solr EA sor 528 -+| [p5|4~598 535+] sae mat : 83 }<— 868 a7—>[a9 si fBi]e-372 BBE BEE C166 C170) "ALLISON" es oore—o[aal ele re B7| B7|<—0075, B6|<—1 [ee |«~2073 B5|<—2074 Je 1044 |<-2001 m1 2087—+| 8088—| 8085-»| 2208-»| B5|<—08 Bale—24 ERE ale — rast | | co vera J+ 1026 or i wre =[8[BF[alalzle £ CaOT C506 008258 Figure 22 — Connector Pin Locations (166-0167, C170, C401, C506) Page 44& COMPONENT LOCATOR ELECTRICAL WIRING HARNESSES Top Ledge Wiring Harnesses TOP LEDGE WIRING HARNESS — “LUXURY” Figure 23 — Top Ledge Wiring Harness — “Luxury” Page 45COMPONENT LOCATOR CONNECTOR ASSIGNMENTS Top ledge wiring harness — “Luxury’ Connector Assignment co ‘9690 — Clearance lamps cz 9690 — Clearance lamps e129 4618 — Driver's overhead light e130 4625 — Passenger's overhead light c1s2 4202 — Ratio (speakers) e133 4202 — Radio (speakers) 288 4221 — PH speaker 289 4214 — LH speaker e339 4228 — Cab identification lamps e340 4228 — Cab identification lamps com 4228 — Cab identification lamps azo “Link with dashboard wiring hamess 430 “Link with cab identification lamps wiring hamess Page 46& COMPONENT LOCATOR CONNECTOR TERMINAL IDENTIFICATION 119 4 OG a a} + of a ! we 1 [ae50 1 [550 1 [are ci C2 i298 444 451 119 + erat aay apa 1 + = or fer] erp a a ald l [aeae 1 [4202 L [azoz C130) cig2 or38 no lar tle ass lass ale ass T + 4 faa] CT azia3)| mea Ea C288 C280 C338 aye le Aye le tot tage od m4 1 [3637 [3037 1 [oj C340 Cait caas roasera Figure 2¢— Connector Terminal identification Page 47as COMPONENT LOCATOR Figure 25 — Connector Terminal Identification Page 48& COMPONENT LOCATOR TOP LEDGE WIRING HARNESS — “STANDARD” Figure 25 — Top Ledge Wiring Harness — “Standard” Page 49COMPONENT LOCATOR CONNECTOR ASSIGNMENTS Top ledge wiring harness — “Standard” Connector ‘Assignment co 3830 —- Clearance lamps 2 ‘9690 — Clearance lamps e128 4618 — Driver's overhead light 132 4202 — Ratio (apeatars) 133 4202 — Radio (speakers) 288 4221 —RH speaker 289 4214 —LH speaker e339 4228 — Cab identification lamps e340 4228 — Cab identification lamps cat 4228 —- Cab identiiction lamps caz9 *Link with dashboard wiring harness 430 “Link with cab identification lamps wiring hamess Page 50& COMPONENT LOCATOR CONNECTOR TERMINAL IDENTIFICATION 19 Tels “Te 235+} 1 t 4 «= } 1 (36307 1 [as50 L. [are or C2 C28 44 451 44 a aE (Me aer teifor} or ferp orl at tt 7 ia 47 0 202 147 1 [azo 1 [a2ox : [azar 132 oes 288) Aino ayes feast cir ale aes af mt 1 [azra] [ 1 [337° L [36377] 289) C338 C540 aye e + Tf wet 1 [3637 1 Ce 1. | Cait C430 CAB 28208 Figure 27 — Connector Terminal Identification — “Standard” Page §1> COMPONENT LOCATOR Roof Wiring Harness rope Figure 28 — Rost Wiring Harness CONNECTOR ASSIGNMENTS Roof wiring harness Connector Assignment 1 Links with dashboard wiring harness 2 4625. nger's overhead light 3 4618 — Diver's overhead light Page 52& COMPONENT LOCATOR CONNECTOR TERMINAL IDENTIFICATION 235 | ] z 4625 A676 Ct C2 ca Figure 29 — Connector Terminal Identification Page 53a> COMPONENT LOCATOR Front End Wiring Harness sos 00 t ’ _— ost i ete |) hi or aaa] © 6 7 a Figure 30 — Front End Wiring Harness CONNECTOR ASSIGNMENTS Front end wiring harness Connector Assignment c108 4568 — Externai temporature sonsor 300 “Link with passenger's door wiing harness e301 “Link with ctver’s door wiring hamess es03 “Link with dashboard wiring hamess 504 “Link with dashboard wiring hamess Page 54& COMPONENT LOCATOR CONNECTOR TERMINAL IDENTIFICATION 709 >| - 4566 C198 48 e265, (C503 300 C301 Figure 31 — Connector Terminal Identification Page 55> COMPONENT LOCATOR Door Wiring Harnesses DRIVER’S DOOR WIRING HARNESS 168 167 26s c2ra 7008980 Figure 32 — Driver's Door Wiring Harness Page 56COMPONENT LOCATOR CONNECTOR ASSIGNMENTS Driver's door wiring harness Connector Assignment rsa 4361 — LH window regulator contro! e187 4368 — RH window regulator control (driver's side) 158 4311 — LH window regulator mstor e160 4161 — External rearview mirrors swiveling control 249 *Link with front end wiring harness 265 4850 — Driver's stop light cat 4122 — LH swiveling defrosting rearview mirror 278 4048 — LH side electic door lock Page 57& COMPONENT LOCATOR CONNECTOR TERMINAL IDENTIFICATION m1 a la 49 le 470 a0] 40 | 1 25> le aoe le 40a (4365, [aoae] (1. [ast Cier C276 Cis arsteteiet [sie ase 119! |+2as azole re 428 a0 —+[le le Je 295, co [azar C163 C160 Cees hon C349 aa Figure 38 — Connector Terminal Identification Page 58COMPONENT LOCATOR PASSENGER'S DOOR WIRING HARNESS care C158COMPONENT LOCATOR CONNECTOR ASSIGNMENTS Passenger's door wiring harness Connector Assignment c1s7 4962 — PH window regulator control 158 4912 — RH window regulator motor e249 “Link with front end wiring harness, 285 4851 — Passongor's step light e271 4128 — RH sufvaling defrosting rearview mirror 278 4047 — RH side electric door lock Page 60a> CONNECTOR TERMINAL IDENTIFICATION COMPONENT LOCATOR 498 —| 469 | 1 625 | e-1 1 |< 469 le 497 J+ 4968 le 497 119 >| }— 235A, 4362 4312 C187 C158 4s 14 80> 428 > 422 | 263+ J 432 J+ 428 J 430 4123 4047 C249 c27t C278 Figure 34 — Connector Terminal Identification cee> COMPONENT LOCATOR Dashboard Wiring Harness DASHBOARD WIRING HARNESS C120 te Figure 35 — Dashboard Wiring Harness Page 62ds COMPONENT LOCATOR DASHBOARD WIRING HARNESS Diag Socket (C120) C154 152 ——4 | eo Figure 36 — Dashboard Wiring Harness Page 63> COMPONENT LOCATOR DASHBOARD WIRING HARNESS Figure 37 — Dashboard Wiring Hames: Page 64> COMPONENT LOCATOR DASHBOARD WIRING HARNESS cis2 C185 cis : cite omfg Sh 7 crs Hy j cree ) i C197 cis ci8t SIDE OF FUSE PANEL BRACKET en Figure 38 — Dashboard Wiring Harness: Page 65COMPONENT LOCATOR CONNECTOR ASSIGNMENTS. Dashboard wiring harness 100 101 cons 120 e121 12 128 125 126 127 0130 c1st e132 e133 e134 e136 137 e138 139 152 154 e155, e160 cist e162 16s 164 cre 166 167 e170 e180 erst e182 e183 c18s, e191 e192 e193 Connector Assignment ‘7614 — Instrument cluster ‘7614 — Instrument cluster *Link with stalk control wiring harness 7519 — Diagnostics connector (MACK) 2261 — Steering lock and stating control “Link with stalk contro witing harness 1119 — Dashboard lighting dimming rheostat 4111 — Cigar lighter “Link with under steering control wiring hamess 4421 — Blower motor 44001 — Door lock control box 8161 — Hazard lights control 21120 — Bodybuilder equipment control No. 2 4163 — Delrosting rearview mitror contr 21101 — Bodybuilder equipment control No. 4 8362 — Power take-off control 7825 — Diagnostics contro! £8059 — Electric or hydraulc retarder control 9214 — Shut down override control “Link with front end wiring hamess “Link with front end wiring harness “Link with front end wiring hamess 1229—Chassis-cab connection unit 1229 —Chassis-cab connection unit 41229 —Chassis-cab connection unit 41229—Chassis-cab connection unit 41229—Chassis-cab connection unit 1229 —Chassie-cab connection unit 1229 —Chassic-cab connection unit 1229 —Chassis-cab connection unit 1229 —Chassis-cab connection unit BFR — Box Fuses Relay BFA — Box Fuses Relay BFA — Box Fuses Relay BFR — Box Fuses Relay BFR — Box Fuses Relay BFR — Box Fuses Relay BFA — Box Fuses Relay BFA —Box Fuses Relay Page 66COMPONENT LOCATOR Connector ignment 0195 ‘BFR — Box Fuses Relay C196 BFR — Box Fuses Relay c197 BFR — Box Fuses Relay 209 19201 — Vehicle master Electronic Control Unit (VECU) e210 19201 — Vehicle master Electronic Control Unit (VECU) e212 19201 — Vehicle master Electronic Control Unit (VECU) e216 “Link with roof wiring harness 220 “Link with speed change control of ALLISON $2000 transmission 269 (0108 — Cab interior power connecting pin e272 £2208 — Start inhibit olay 274 8000 — ABS Electronio Control Unit 27s 8000 — ABS Electronic Control Unit ca24 5266 — Throttle position sensor a2 8160 — Stop lights switch 401 1228 —Chassis-cab connection unit cae “Link with top ledge wiring harness cas2 ‘3506 — Signal ight flasher case “Link with 12-volt socket e502 6316 — Reverse lights rolay e503 8439 — Neutral relay e504 7820 — Diagnostics connector No. 2 (ALLISON) e505 1228 —Chassis-cab connection unit 506 1228 —Chassis-cab connection unit 507 “Link with speed change control of ALLISON MD3060 transmission 508 “Link with speed change control of ALLISON MD3060 transmission 4078 4078 — LH door switch 4079 4079 — RH (passenger's) door switch Page 67CONNECTOR TERMINAL IDENTIFICATION 7 Js0 ‘351+ I! a je: BD ee | - 8087—>| 119->| [3]fte] |+-31 62+ 2. Mes 000-1 aa| Falfi7] Joo | | a0 867—>| 5002» [5 re) 37 oo12—>| Fai} J—25 wa—>| co12—>| [7 [20] |-as1 1 [x rR—-| 0013—>| [8 |[21] |+-oo11 C116 ne coxa) [ea no 2+ fa] -co1e - 2 Aiea) loo11+| a) \\+-251 12126) looto- @) | es [13][26) '2073-+| COX jet 1 [76ers 1 [reis 1 [7515 C100 C101 C120 . Jeoosr | | oo-ertPa eos | je-22 +501 1) Ts |+-205 +504 eas—>l[e] et ae +310 i 1 [Bear 1 [Ce 1 oie oa ore oie a TS __ confor eele a «(O01 5002—+| |s-045 28-»| [5 fae GU) or tes 028-| ha aso oon = 1 fant) [ 1 [* [ 1 [aaat C126 C126 C127 eaekoa Figure 39 — Connector Terminal Identification Page 68COMPONENT LOCATOR J—119 Je-as01 EoT an eas [ 3 e206 e25s—+ [5 | +608 1 [e[sleot [= |+-e083 pr feat [7 |+-0083 soliote}est t[o [a ]+-8088 Je22 1 [a00r “1 [316T 1 Fal C180 cist C182 zo 7 aaa cass Ts |e-273 625—+[-+] 3 |e 606 I= 608 ete |e4 a fs |eos2 opr fens a [7 |ees2 |—z208 iofetele4 so[o Te Joes 1 163 1 [2tt0T l [e362 | C183 Cis C136 essay eas E41 ess Pte see [+ fe fe—28 «fa Jez e [sas e fs lest ets ni 2 [7 e555 [7 }+-2008 min 1+fols ets cs 1 [7525 1 [305s 1 [sai C187 C138 C138 709 269 sas-efe 2] a) a 4 |e-e25 of 273 436; 119 as] fecema| [eum [® 1 [re Cis2 C184 C185 oabtan Figure 40 — Connector Terminal IdentificationCOMPONENT LOCATOR falco —ai] 295 xi] — 366 o1a— 25» 202 -+| Sthra|—sie Stipa 208 Pipa] 4 366 052—» a2 273» |p 208 ~»|B2 raale—a10 Shale 12 [Ail 204 a] ea] a3 ee oe Sis|aa 260 eee} 2" 370+) - - [ 7 S71 BAT 625, [A5|<— 263 ee a8 TT Os 2B oy a1-»[6 o —+las| }A7|¢— 2079 eal laa | <-625 Az! «— 24 32—»|B7| 507 —»/B7 213 {87 | faa|—311 "aa 501 ale 119 ca1-+|b0 501 >| 119 -o|p0) 5 j-621 a[e— 63 aoe 119 509 119 | Ce aed [Bee 19 989 ato a7 68+ br 212 oa | a7 tie 1 i] 8075 | afar 83+] 229 -»|511 yah as a}e~ 0023, 2 z 7B fax be a|—a7 a[<— 2100 sa 22 BFR [arr [BFR C180 cist c1a2 |—s04 2|+21 +2 +204 ja s74 BFA BER BER | cies Ci8s, cist J-—s03 273 J-270 J+-2009 273 J—s29 J-i23 Js011 Je-s23 48 BFA BFR FA C192 C193, C195 — Figure 41 — Connector Terminal Identification Page 70COMPONENT LOCATOR 33) 2086. 273 652 260 508 506 bore st+[a [rats a Ere tos 463: 272 4 \\Sal 6 |e-o28 EATS toa a oe 1 BFR 1 [BFR C 1 9207 C196 C197 C209 2070" e000 a : ae 16y,17f[18 16 aie bores He ets occas Het o011 ti lw ofr leon Tap o|eve | |i trate nootetste Crate eyte fecce sts Thtts 17 te cole di Cc l ‘8207 1 [9207 1 ad CHE a8 20 %, 0 7 Ca Pelee a7s—>{f] 5 [2||<-1056 joort—+| 40 41"| 12 ass 7 Tate le 7 t a. ds ds L [ote _[2208 1 [8000 C269 C272 C274 a7 58 551}552) 48778 ssosHetittie|so| | o-[@@]-or Sat to] 11 [12 ]-645 022 | 6)@) 7 oe corsa pete sie @ Hts fportssst ded, 1 [8000 1 [5266 1 [8160 C275 C324 C325 Figure 42 — Connector Terminal Identification Page 71& COMPONENT LOCATOR o aso] 7-2 202-+] ra) 304—»| a7 alee 007» a 2000+] male) a7 a7] feels S085 AST a5 «05 P08 Teal e264 1 fevaea|| & eee] [3506 oaa2 MT aa|<-o47 C429 ASTp2|<-045 es Ae rayf< 1026 + a oy a i) ‘2000—+| [EE soot [f] EI 1018 t aia s031—+| t 1 [ea3s) C50s 1044+] eos 0073-+| 2073 0071+] [9072 0089-+} ee 1 [x l [% C508 ‘C220 vroassra Figure 43 — Connector Terminal Identificationés COMPONENT LOCATOR "ALLISON" "ALLISON" fae t of fpe]-<—0013 Be iad Oo1s—* Ao Tp7| 40012 *Ta7|e—2068 012+ [a7 2000 72-0|A7 sas 270+ [Ae 5031 80+ A so 1 ae so AST e—12 a erase 201 C4078 At Tag] <—08 Ser | Aa Tag] «8040 Ala O42 [e883 on87— A Fi] 2206 7h ear |e 36 oo65—*[ ila BoA 1b ihe 1 1229 1228] [ 1 4078 (C505 ‘508 4079 02840 Figure 44 — Connector Terminal Identification Page 73dé COMPONENT LOCATOR Stalk Switch Wiring Harness and Radio Remote Control Wiring Harness Figure 45 — Stalk Switch Wiring Harness and Radio Remote Control Wiring Harness Page 74COMPONENT LOCATOR CONNECTOR ASSIGNMENTS Under steering control wiring harness Connector Assignment a 6167 — Lighting switch: Main and dipped beam headlights Sloaranco and deiteaton cb his 2 66167 — Lighting switch: Direction indicator ca 6167 — Front air pressure transmitter c “Link with dashboard wiring harness. cs “Link with dashboard wiring harness. cs 6167 — Windshield and cruise control 7 £2220 — Transponder ignition key Radio remote control wiring harness Connector Assignment e334 4202 —Radio 335 *Link with under steering wiring harness Page 75COMPONENT LOCATOR CONNECTOR TERMINAL IDENTIFICATION J<—047 310 J+ 028 3 —>| es 22 2-4 <2 |< 0057 2-| 2 «22 313 -4| | 370 2 |e 22 8 J_— 045 6167 G167, _ [6167 C1 C2 ca 508» 1 +310 le 63 52 +504 2 js 048 pata «501 +33 je-0010 506 <-0087 +370 22 = = 1 6167 ca cs ce 019 —>| Je 0020 0017 —>| | oo18 hope 0015 >| Je cote le 0020 |< 0017 1 2220 4202 1 * C7 C334 (c336 abc, Figure 46 — Connector Terminal identification Page 76& COMPONENT LOCATOR Engine Wiring Harness ENGINE RIGHT SIDE Figure 47 — Engine Wiring Harness Page 77COMPONENT LOCATOR CONNECTOR ASSIGNMENTS Engine wiring harne: Connector Assignment co £8275 — Engine ol evel sensor 2 7962 — Coolant temperature sensor ca £8200 — Boost ar pressure and temperature sensor cs 7968 — Oli pressure sensor ce 8261 — Engine speed sensor cr 9208 — Fuel high pressure sensor ce 9212 — High pressure pump, solenoid valve cylinder No. 2 co 9213 — High pressure pump, solenoid valve cylinder No. 1 10 {9230 — Camshatt speed sensor on “Link with front rear wiring harness ce 9204 — EGR solenoid valve 1a {9220 — Unit pump No. 1 Incorporating solenoid valve ow {9221 — Unit pump No. 2 incorporating solenoid valve os {9222 — Unit pump No. 3 incorporating solenoid valve 18 19223 — Unit pump No. 4 incorporating solenoid valve co ‘9224 — Unit pump No. 5 incorporating solenoid valve 18 {9225 — Unit pump No. 6 Incorporating solenold vave 2414 — Preheating relay No. 1 ‘9202 — Vehicle master ECU (VECU) gg Page 7a& COMPONENT LOCATOR CONNECTOR TERMINAL IDENTIFICATION || R ig a . 1 =m | | oS = son fH || a [EH | ofS 1 [ear [ 1 [ears 1 [3330 a oo tio 3) [e202 |<—t088 2s 1 Ce 1 iE cit o2 oasste Figure 48 — Connector Terminal Identification Page 70COMPONENT LOCATOR Oo 0 o Oo o oO Po fet fl mo ts me 1 [s2a0 1 [oat 1 TEE cis cia cis Oo Oo o Oo o Oo t t t t t t 14208 1m at 6 or 3223 l [eer l [e225 cié ci7 C18 = faa cor oOo ota = 81 + ot 023 loos 058252 oro loos aro 04 + 002 —087 | 078 oo1-»| |= 055 coos 1 [zara no |.—as0 a WK |= 2064 2008 08 aig lars 257 l—170 290 226 |—174 294 zof Ef ler se E41 : [a2] s Figure 49 — Connector Terminal IdentificationCOMPONENT LOCATOR Front Frame Wiring Harnesses 2 | ‘COVER REMOVED C14 is C16 ‘OR CLARI Figure 60 — Front Frame Wiring Harness Page 81COMPONENT LOCATOR CONNECTOR ASSIGNMENTS Left front frame wiring harness Connector Assignment ce “Link with dashboard wiring harness 2 “Link with dashboard witing harness c 2266 — Engine stop contre (cab tited) cs 18100 — LH front brake pads wear switch sensor cs 8014 — ABS LH front modulator valve 7 {8061 — ABS LH front sensor co 3212 — LH front ashing lamp cio, ‘2400 — Fuel fiter clogging switch en 8165 — Rear brakes alr pressure switch cr {8104 — Front air pressure sensor c13 £8166 — Front brakes air pressure switch cu £8178 — Parking brake indicator alr pressure switch cs, £8105 — Rear air pressure sonsor e168 9202 — Vehicle master ECU (VECU) ar *Link with engine wiring harness cw 8150 — Exhaust brake solenoid valve cre 2449 — Air dryer 20 “Link with preheating fuel wiring hares cat 2416 — Preheating ray No. 2 oz 9210 — VECU/EECU ECU power supply relay 23 1100 — Engine Electronic Control Unt fuse No. 1 24 1100 — Engine Electronic Control Unit fuse No. 2 25 2422 — Fuel preheater relay Right front frame wiring harness Connector Assignment cat “Link with dashboard wiring hamess 32 “Link with alr conditioned wiring hamess 3a £8108 — RH front brake pads wear switch sensor cat 8015 — ABS FH front modulator valve 36 8062 — ABS FH font censor 36 ‘8211 — RH front signal lamp 38 7462 — Fuel level transmitter Page 62COMPONENT LOCATOR CONNECTOR TERMINAL IDENTIFICATION cvs | sre—o| ae oore 22 on \e-25- | | 802s: oot2—>| ae a a7 cose lar 546 —>|A6| eae as|e—s09 510s co [x [e266 Ba|+—201 a a poet B3|¢~ 8040 Alea 71-ofaa| pias oo 510 040+) |-se7 e|| Ox 1 [= 1 [5100 [aera] cr cs cs 1 eas e540 o 1 fa0et] [—1 [are [2400 C7 co C10 a [3765] 1 [aTor} S166. Cit Cz Cs eee Figure 61 — Connector Terminal Identification Page 83& COMPONENT LOCATOR 8072| cia Ce. cre l-e02s ae [2493] Je-0013 ce = on FE cS [ez0r| [1 -_ re = = ti 8 . ® OU C1 Cy Z|] SO tr ! 1 iT 1 9270 1 fitoe ae = = rotessa Figure 62 — Connector Terminal Identification Page 84a> COMPONENT LOCATOR . wa ; ti CG ob doe {aa 2204 rar 87] on wo co Gieo} (7. [2A2z) | cso—olash 29-857 C24 C25 BA) <— 409 B : m2 Se ak en =e va Ql. =) C1 [x 1 [aioe L pe) C32) C33, C31 l 8015 l [e062" 1 [x 1 (sat) [ 1 [7a6z C36 C38 02856 Figure 53 — Connector Terminal Identification Page 85& COMPONENT LOCATOR Rear Frame Wiring Harness Figure 54— Rear Frame Wiring Harness Page 86COMPONENT LOCATOR CONNECTOR ASSIGNMENTS Rear frame wiring harness Connector ‘Assignment ce 3364 — Inter-axle differential lock switch cz £8109 — LH rear brake pads wear switch sensor cs 8016 — ABS LH rear modulator valve Cy 8063 — ABS LH rear sensor cs 8158 — RH rear brake pads wear switch sensor cs. 8017 -- ABS RH rear modulator valvo 7 8064 — ABS RH roar sensor co “Link with dashboard wiring hamess co 8718 — RH rear lights 10 8719 — LH rear lights en 6825 — Reverse warning buzzer Page 67> COMPONENT LOCATOR CONNECTOR TERMINAL IDENTIFICATION 2081} lt 1 [es6a 1 [e109 1 [wore a cz 3 sos» am 1 8063, 1 [arse 1 [aor a os. 6. 308 inn! oe fart 4 7 sie —+/ 847 b frame + £ +608 nO co 30er} [3778 | oF cB cs t|(Te)j 008 [= 1 [aris l [esas cio ci esto Figure 65 — Connector Terminal Identification Page 88& COMPONENT LOCATOR Bumper Wiring Harness Figure 56 — Bumper Wiring Harness CONNECTOR ASSIGNMENTS Bumper wiring harness Connector Assignment co 6124— Headlight, low-beamvhigh-beam and signal light (oh) 2 6124 — Headlight, low-beamvhigh-boam and signal light (ft) cs 8212 — Side marker light (oft) ca “Link with dashboard wiring hamess cs 8211 — Side marker ight (ight) CF 6125 — Headlight, low-beamhigh-boam and signal light right) o 66125 — Headlight, low-beamhigh-beam and signal light (right) cs. 3411 —Hom&> COMPONENT LOCATOR CONNECTOR TERMINAL IDENTIFICATION 68 et I + 1+|(7 12 }}—304 co alee lt 1 6124 6124 8212 Ci C2 C3 =. 68 ra o 1 pe t es le 34 2] 35 e2i| e365 tet |e-304 no x 3211 6125 ca cs cé || 34 a4 1 6125, oat C7 cB Figure §7 — Connector Terminal Identificationes SCHEMATIC DIAGRAMS SCHEMATIC DIAGRAMS Page a1SCHEMATIC DIAGRAMS ELECTRICAL SCHEMATIC DIAGRAMS Key to Diagrams Locator Map (see “Vehicle Locator Map for Electrical Components" on Key to Diagrams Plate No. age 10) Tos Shunt @, eb (0108 —Cab interior power connecting pin 2) Bab 0172 — Diodes (a) Re 1100— Fuse 1119— Dashboard lighing dimming rheostat a 2 1229 — Chassis-cab connection unt (owearearasre6) | Azo 1701 — Circuit breaker 201 — Battery No.1 3) Cae 2102 — Battery No.2 (05) ota 2133— 12 volt secket 2) Bob 2165 — Master switch cy ona 72196 — After ignition power supply relay No.1 8) aac £2200 — Anti-theft electronic box 7”) [c2a 2209 — Stan inhi relay (8) cy 22H — Starter (©) 38 2212 — Staring olay (©) Ae 2218 — Transponder antenn om “Teea 2220 — Transponder ignition key o Cae 2261 — Steering lock and starting control cr) 2p 2266 — Engine stop control (ea tted) oH oad 2311 — Atemator (05) Bee 2400-— Fuel iter dogging switch (4) oad 2at4— Preheating relay No.1 (08) oad 2416 — Preheating relay No.2 (08) cad 72422 — Fuel preheater relay (19) nb 2423 — Fuel prohoater (9) Bee 2442 — Immersion heater (9) Bee, 2449 Air dryer (9) cad 2450 — Air dyer relay (9) Ree 2462 — Preteating resistor No. 1 (08) Bee, £2459 — Preheatng resistor No. 2 (02) Bec 2464 — Fuel proheator thormal suiich (9) Be B12 — Lot shor waring ight (2) om | 5113 — ight tasher warring FoRt 25) Ca ‘3161 — Hazard lights contol a) Be [/2217 — RH font signal lamp 4) faa Page 92SCHEMATIC DIAGRAMS Map tor Electrical Components" on Key to Diagrams Plate No. age 10) 3212 — LH font signal amp 7 cd 3213 — RH side signal lamp (14) ASd 3214 — LH side signal lamp (14) 3d 3411 — Hom (14) Cb £3502 — Stop lights and right rear signal light aay a) Ae £3508 — Fight signal ight clay 4) Ae £3506 — Stop lights and let rear signal ight relay 4) Ae ‘3505 — Left signal light relay (ay ne 3506— Signal ight fasher (4) Ae 3512— Stop This relay (8) ab | 3630 — Clearance lamps 1) Baa 3637 — Cab idenifcation lamps (a) Ba 3716—LH conival marker lamp (i) 5a 717 — RH central marker lamp () Ad S718 RH rear ights (4) oo 3719— LH rea ghts (a4) ced 4001 — Door lock contol box (7 Aa 4047 — RH side electric door lock (7) Aab 4048 — LH side electric door lock a7 3b 4078 — LH door switch (20) C2 4079 — RH door ewitch (20) Re 4111 — Cigar lighter (22) Bab “4122— LH swiveling derosting rearview mirror 7) 2a “H23— RH swiveling defrosting rearview miror (9) Rea “4196 — Comfort accessories relay 2) Re “4161 — External rearview mirrors swiveling control (9) 02 “4163 — Datrosting rearview mirror control (9) Ea [a202— Rado @) 2a 2210— Antenna @ Ba 4214 — LH speaker (22) Ca 4221 — RH speaker (22) Ada 4311 — LH window regulator motor (ie) C20 “4812 — RH window regulator motor (a) 26 461 — LH window regulator control (a) 2b 4962 — RH window regulator control (a) 2 4365 — RH window regulator contol (rivers side) (9) 2b 21 — Blower motor cy 32 “4479 — Liab ventilation contol @) Bee “4512 — Air condoning compressor 4) B20 Page 03SCHEMATIC DIAGRAMS Locator Map (o6e “Vehicle Locator Map for Electrical Components” on Key to Diagrams Plate No. age 10) 74500 — External temperature sensor B Be 4617 — Top bunk overhead ight (29) Cia {4618 — Driver's overhead light (29) Ba 4619— Bunk inerior ight (20) Cia {4625 — Passengers overhead ight (20) Baa “4650 — Drivers stoplight (20) Gee 4651 — Passenger's step light (20) A2c 5266 — Throttle position sensor (33) C20 15907 — Windshield wiper contol relay ei) Ae 5311 — Windshield wiper motor (ea) Bio 5814 — Windshield washor pump (2) Cte 15320 — Windshield wipor disabling relay (ei) ae £5639 — Door unlock rlay (7) Re '5700 — Door lock relay (7) Ae 6101 — Daytime running lamp relay (13) “Age {6119 — Low beam headlight relay (2) ‘ee 6121 — High beam headlight olay (2) Re 16123— High beam headlight waring lamp (2) ‘Gab {6124— Left side lamp and headlight (ay cid {6125 — Fight side lamp and headlight ana) ata 6132 — Low beam headlight warning lamp (26) Cb 6167 — Stalk switch (01) ‘C2b — Anti-theft (07) C2b- = Side lamps (ny 2b — Headlight and dipped headlight (12) cab — Homndiaction indicator light ia ceo = Windshield wipertwindshiold washor we Se — Cruise contol ‘att — Reverse ight) (3) ‘ABIO8A 6316 — Reverse lights relay (15) | A2b 6325 — Reverse warning buzzer (18) BEd oo 7362 — Coolant temperature sensor (4) Bac 7368 — Oil pressure sonsor (4) B36 7411 — Fuel level gauge (25) C2b ‘7462 — Fuel level transmitter (25) ASA 7519 — Diagnostics connector (MACK) (01/16) Cac 7520-— Diagnestios connector No. 2 (ALLISON) (oar) ab 7525 — Diagnostics control (28) Bab 7614 — Instrument dustor (owanaesies) | Cab 8000 — ABS ECU (01/28) ‘A2b 8011 — ABS eafly warning lamp 8) (2b Page 94SCHEMATIC DIAGRAMS Tocator Map (o00 “Vehite Locetor Map for Elect Components” on Key to Diagrams Plate No. Page 10) ‘8014 — ABS LH front modulator valve (28) 3d ‘8015 — ABS RH front modulator valve (28) “Asa 8016 — ABS LH rear modulator valve (28) | BramBed [8017 — ABS AH rear modulator valve ) B7abed 8050 — Elecite or hydric retardercorvl 3) ab 8061 — ABS LH front wheel speed sensor @) ced ‘8062 — ABS RH front wheel speed sensor (28) Aad ‘8063 — ABS LH rear wheel speed sensor (28) craiced 3064 — ABS AH rear wheel speed sensor 28) ‘ATahed {100 — LH tonl brake pads woar switch sensor @ oad 8104 — Front ar pressure sensor i) cad 9105 — Rear air pressure sensor @ Cad {108 — AH Fron brake pads wea’ switch sensor a md 18100 — LH rearbrako pads wear avitch sensor @ orarcea 1123 — Air pressure alent warring lamp @) om 13198 — Brakes ar pressure gauge i) cab 3141 — Front ar pressure gauge 5) C2 18142 — Air pressure indlcator rear creut i) a 1150 — Exhaust brake solenoid valve o) cad 18159 — RH rear brake pads wear such sensor @ ATaiaBa '160— Stop lghs sich 5) ATaiaBa 165 — Roar brakes air pressure Wich i) cad 3166 — Front brakes ar pressure switch i) cea 8178 — Parking brake indicator ar pressure owich @ oad 8261 — Engine speed sensor (34) Bac | ‘8275 — Engine oll level sensor 84) Bad 8318 — Iner-ao dferontl ook waring lamp 25) cab 8362 — Power take-of control =) Bee 8364 — Iner-anadfferantal lock eich ) B7dbed 8424 — Range change waring lamp 3 2 8439 — Neutral relay (29) Bad 18472 — Reverse gear switch 8) a4 9404 — Gear selacor (0) B25 18602 — Automatic transmission EOU (Ca0aRaaOST) | Ab 9544 — Gitch such ©) Bac {675 — Electron coir] automate Wanemiasion valve body (2182) Bae {576 — Turbine speed sensor automat tanemisson (2032) Bae {9677 — Speed sensor automalisransmission (ears) Bee {678 — Oil pressure sensor automatic transmission (222) Bae Page 95SCHEMATIC DIAGRAMS Locator Map (se8 “Vehicle Locator Map for Electrical Components” on Key to Diagrams Plate No. age 10) ‘8679 — Automatic tranemission sump olf lavel sensor @ BAe "8680 — Aulomalic transmission sump oil temperature sensor (28/82) B40 ‘8681 — Neutral Start BackUp awitch (32) Bac ‘9200 — Boost ar pressure and temperature sensor (4) B30 ‘9201 — Vehicle master ECU (VECU, (0102/03/89) BSc 19202 — Engine master ECU (EECU) (010200734) 836 ‘9204 — EGA solenoid (34) Be 9008 — Fuel high pressure sensor a) Be ‘9210 — VEGUIEEGU EGU power supply relay &) cad ‘9212 — High pressure pump, solenoid valve oylinder 2 (4) Be | 2213— High pressure pump, solenoid valve cylinder 1 a Bo ‘214 — Shu down overide contol (3) 82 '9220— Unit injector No. + incorporating solenoid valve (4) Bae {9221 — Unit injector No. 2 incorporating solenoid valve 4) Be '9222.— Unit injector No. 8 incorporating solenoid valve 4) Bae {9223 — Uni injector No. 4 incorporating solenoid vale 4) Bae {9224 — Unitinjector No. 5 incorporating solenoid valve @) Bae {9225 — Unit injector No. 6 Incorporating solenoid valve oH BSc ‘9230 — Camshaft speed sensor 4) Bae 2251 — Engin fywheo! speed sensor (2882733) Bo 2HT01 — Bodybuilder equipment control No.1 8) 21113— Bodybuildor equipment available power supply relay (35) | 21120 — Bodybuilder equipment controt No. 2 (35) 45144 — level ar conditioning pressure contr (24) Page 96& SCHEMATIC DIAGRAMS Plate 1 — “CAN” Communication Network without Allison Transmission (5169) 764] [3204 ANTLTHEFT ‘SYSTEM INSTRUMENT ‘CLUSTER, om ECU (MACK) Bs as CONNECTION UNIT pop & 8 o 5 EECU (9202) Figure 68 — “CAN” Communication Network without Allison Transmission Page 97> SCHEMATIC DIAGRAMS Plate 2— “CAN” Communication Network with Allison Transmission RUMENT USTER CHASSIS-CAB [az33] CONNECTION “== unin 7 3 2 AUTOMATIC ‘TRANSMISSION ECU Figure 89 —— “GAN” Communication Network with Allison Transmission Page 98SCHEMATIC DIAGRAMS Plate 3 — “CAN” Communication Network with Allison Transmission (5203) VECU (MACK) 20 26 Bt Be Diaanosric coNNecron NO (ALLISON) cHassis-caB CONNESHON ONT FERS | ——— DIAGNOSTIC CONNECTOR LOCATION: PAEMOVE THE FUSERELAY PANEL COVER FROM THE LOWER PASSENGER 2 Ste oast. avo w + REMOVE THE LOWER DASH PANEL ON PASSENGER SDE. + REMOVE THE TWO SCREWS RETANING THE UPPCR COVER ON THE PASSENGER SID SF" - THe atuson pacnosnic ponTis BEHIND THE UPPER COVER. eEcu a ‘AUTOMATIC ‘TRANSMISSION ECU (5602| 9202] ress — “CAN” Communication Network with Allison Transmission Page 99Pris SCHEMATIC DIAGRAMS Plate 5 — Power Supply/Starting [23%] 100 AND 120A ALTERNATOR BATTERY NO.1 (OPTION) [2i04 MASTER ‘SWITCH al [2402] BATTERY NO. 2 2s starrer (3) < ANT THEFT vecu| INTERIOR rr O4 rene.ar() am IGNITION KEY ‘SWITCH 2 I — CAB GROUND INSTRUMENT CLUSTER, (@ KEYLESS REMOTE CONTROL CS) DISTRIBUTION Figure 61 — Power Supply/Starting Page 100& SCHEMATIC DIAGRAMS Plate 6 — Power Supply 96 AFTER IGNITION POWER SUPPLY RELAY NO. 1 [> G) starrer T> ()eackur ReLay INTERMITTENT p> @Mipenneuay MIRROR [> Obenesren [> (=) BACKUP LIGHTS “E> (a) vecu [> (@)ReTaRDER INSTRUMENT > @)aisren * © (@) aes POWER @ B——Of > Gi FUEL HEATER vecu(@) neLay mi @ 2——Z} > (®)xvac a » —— 3 = —l> @raoo 4400) 8 rasan Figure 62 — Power Supply Page 101& SCHEMATIC DIAGRAMS Plate 7 — Electronic Theft Protection System ANTLTHEFT ELECTRONIC BOK rmavsronoen CHIP IGNITION KEY oo INSTRUMENT CLUSTER [2220] (© Biagnostic cy CONNECTOR a INSTRUMENT CLUSTER a @)ecunss @)vees G@)eeeu ‘TRANSPONDER 2249) aNTENNA STEERING LOCK AND 2264] staRTING CONTROL $467) ANTHTHEFT EC ©Qrevswnenon @ rower Figure 63 — Electronic Theft Protection System Page 102& SCHEMATIC DIAGRAMS Plate 8 — Engine Air Intake Preheating PREHEATING RELAY NO.2 EEcU Low. ‘SIDE 2 iba 26m i ess +f PREHEATING RELAY NO. alle 7 PREHEATING (zon) [2682] pesisronno.2 PREHEATING RESISTOR NO.1 Figure 64— Preheating Page 103,d> SCHEMATIC DIAGRAMS Plate 9 — Starting ‘STARTER FOR MANUAL TRANSMISSION STARTER (2a44] a | | cunt | swiren O@ eel } [2292] StaRTING RELAY rr 2203) START INHIBIT @ atusson 2060 ALLISON SERIES 2000 owen OO @veou @® ave START INHIBIT RELAY ‘STARTER FOR AUTOMATIC TRANSMISSION 728s Figure 65 — Starting Page 104& SCHEMATIC DIAGRAMS Plate 10 — Fuel Preheater RELAY Rt ‘SWITCH 2564 FUEL REHEATER 2623 IMMERSION HEATER all cr —_—— sone oC [zee] Os NSE Figure 66 — Fuel Pret Page 105& SCHEMATIC DIAGRAMS Plate 11 — Interior Lighting and Signalling © iemese* [aie] wise [2797] manner vane (274) re nean uoHs 749] neanvcars (B)aaanvanren (& nme (@)assemren 08s Figure 67 — Interior Lighting and Signalling Page 106& SCHEMATIC DIAGRAMS Plate 12 — Lighting SYSTEM SYSTEM ANTL-THEFT ANTLTHEFT 7704 CIRCUIT BREAKER i Low BEAM —1 HEADLIGHT HEADLIGHT RELAY ciRcuT BREAKER @on (eieleean” [eras] er Low LOW BEAM HEADLIGHT WARNING LAMP. ieee Gaa5)RH HIGH 6125)pcam Dome e265 Figure 68 — Lighting Page 107dé SCHEMATIC DIAGRAMS Plate 13 — Daytime Running Lamps (DRL) oz cRcUT, BREAKER ae 7 : i » | + ert | 6104 oe lore Low BEAM Figure 69 — Daytime Running Lamps (DRL)dé SCHEMATIC DIAGRAMS Plate 14 — Signalling crioNAL inecrionA wnotearon eet ‘STOP LIGHTS HAZARD LIGHTS ‘CONTROL ucHTING DIMMER © signa Lens og contmon S85) ae SIGNAL LIGHT > (9502) ReLay 7 STOP LIGHTS | a RIGHT REAR] (oa ‘ iE ee & [9505] RELAY "Tog terTsicnay (oan RIGHT SIGNAL += LGHT RELAY ieee 29) SIGNAL LIGHT 2%] LIGHT RELAY INSTRUMENT CLUSTER RH SIDE SIGNAL LAMP. RH FRONT. SIGNAL LAMP LH REAR LGHT INSTRUMENT CLUSTER, LH FRONT. SIGNAL LAMP LH SIDE SIGNAL LAMP INSTRUMENT CLUSTER, o20e Figure 70 — Signalling Page 109& SCHEMATIC DIAGRAMS Plate 15 — ‘STOP LIGHTS RELAY ‘swiTcH (en72| REVERSE cn 63%] LGHT(S) 2000 = 2 oe sag) REVERSE WARNING key ean SWITCH 23 BUZZER FUSE ON : REVERSE oe noir Sy (6844) antes) 00) av (ateg FUSE 4 (H TaNTION nse __y_ 7 —__ REVERSE aes A [6825] WARNING 6346) BUZZER Lights RELAY ® vecu Figure 71 — Signalling Page 110> SCHEMATIC DIAGRAMS Plate 16 — Diagnostics Connectors DIAGNOSTIC CONNECTOR (MACK) 7549) ) INSTRUMENT CLUSTER INSTRUMENT CLUSTER. )eounss @veou @eecu ANTLTHEFT SYSTEM ‘TRANSMISSION ‘AuTomaric. (MD 3060) AUTOMATIC TRANSMISSION eee Figure 72 — Diagnostics Connectors Page 111> SCHEMATIC DIAGRAMS Plate 17 — Doors Locking DooR Lock RELAY S700 INTERIOR © ‘LIGHT — | RH SIDE | ELECTRIC m1 DOOR LOCK ; fe} Ia DOOR Lock key fe 5087) control [4004 fH ad. oo Ft LH SIDE Ic] Ie] ELECTRIC i] DOOR Lock $048 wrenon OPT TOUT DOOR CMT) untoex RELAY 5638) Figure 73 — Door Locking Page 112& SCHEMATIC DIAGRAMS Plate 18 — Electric Window Lift Motors LH WINDOW LIFT CONTROL 5364 RHEOSTAT —_ © LH WINDOW LET MOTOR 57 RHWINDOW LIFT CONTROL (ORIVER'S SIDE) RH WINDOW (FT MOTOR 5342] RH WINDOW LIFT CONTROL, swan cincurr 70 BREAKER DISTRIBUTION © ey Figure 74 — Electric Window Lift Motors: Page 119,> SCHEMATIC DIAGRAMS Plate 19 — Electric Defrosting Rearview Mirror aneostar®) > DEFROSTING REAR VIEW MIRROR CONTROL, 63] 22-1, RESISTOR eia2 LH SWIVELLING DEFROSTING. FEAR VIEW MIRROR MOTOR (ai68 EXTERNAL REAR VIEW MIRRORS. SWIVELLING ‘CONTROL RESISTOR AH SWIVELLING DEFROSTING REAR VIEW MIRROR MOTOR oases Page 114 Figure 75 — Electric Detrosting Rearview Mirroras SCHEMATIC DIAGRAMS Plate 20— Cab Interior Lighting INSTRUMENT cLusTea Tpeae) DRIVER'S $648) OVERHEAD LIGHT $078 LH DOOR ‘SWITCH Teeam) PASSENGER'S 6625) OVERHEAD LIGHT INTERIOR UGHT switcH (BY REMOTE, CONTRaL) TOP BUNK OVERHEAD SRM UGHT BUNK INTERIOR ee cht ease Figure 76 — Gab Interior Lighting Page 115ee SCHEMATIC DIAGRAMS Plate 21 — Windshield Wiper HERD Lames 6167) neADUGHT ‘sr Power 5320 crcur “SASLING RELAY 53) sem @Q= ® vecu ‘Whnbshieto ‘WASHER MOTOR Figure 77 —- Windshield Wiper Page 116dé SCHEMATIC DIAGRAMS Plate 22 — Cigar Lighter/12-Volt Socket/Radio COMFORT ACCESSORIES RELAY KEY SWITCH POSITION NO. 1 @® CAB INTERIOR POWER CONNECTING PIN BODY BUILDER cigar INTERFACE LichTER @ tt] INFO RHEOSTAT RADIO 202 LH SPEAKER e258) BH SPEAKER 4224) BATTERY POWER sav socker (ata Figure 78 — Cigar Lighter/12-Volt SocketRadio Page 117a> SCHEMATIC DIAGRAMS Plate 23 — Retarder Control EXHAUST BRAKE 42V IGNITION, ‘SWITCH | 2 ‘SWITCH PARKING UGHTS ELECTRIC OR HYDRAULIC RETARDER ‘CONTROL Figure 79 — Retarder Control Page 118& SCHEMATIC DIAGRAMS Plate 24 — Air Conditioning BLOWER [24] rotor @usrwa LicaB (S679) VENTILATION ‘CONTROL TWO-LEVEL [AIR CONDITIONING PRESSURE CONTROLLER e542] j AIR CONDITIONING | COMPRESSOR __j o26r0 Figure 80 — Air Conditioning Page 119,ee SCHEMATIC DIAGRAMS Plate 25 — Principal Display INSTRUMENT CLUSTER, ph Bete (eH) | FUEL cauae -UEL LEVEL SENSOR aurouanie \ fh ean AR eAMAEEG fret Cop nas | BEAR, enon | (8482) | REAR AIR GAUGE i pare BODY DOME i Cas SWITCH BRAKEWEAR uf 1 INTER-WHEEL 0.5—9- 5 ed 7—O8: - 8964) DIFFERENTIAL INFORMATION $50 tot eg ~ DIFFERENTIAL (2899) | ten-wHeeL Booy BUILDER (= 1) DIFFERENTIAL RCCESSORT ° Cock SwiToH ax) FRONT AIR E) 09 n—as. 1] [8808] pRESSURE SENSOR (8444) |FRONT aR GAUGE ze o0Y Buen SPECIAL eQuPHENT aly} 7a] REAR BRAKES AIR bi Pressune SWITCH Ain PRESSURE ALERT WARNING La eqaq) FRONT BRAKES AIR 8466] pRESSURE SWITCH roast Figure 61 — Principal Display Page 120,a> SCHEMATIC DIAGRAMS Pilate 26 — Principal Display INSTRUMENT CLUSTER [7648] xey swrren on @) s—2——bo j amp tin ED obtln—ar “iz O90 | | aaa] | BIO] ep} so V baasea WARNING | 4 an aurenwavon ©) @) oe a—We rs ts > ally os. ita oP RASHEA) 4 terrum@® Df a—hge a TE Basnen 6 @ oft as vecu(@) DIAGNOSTIC . IL wmere © arf ame—te riage $c as. © wtamert SYSTEM @ past ur @wecam vazano Siren @nowrruew © ABS BLINK /CovE SWITCH DOOR /SwiTcHEs, | ® sso rasrea Figure 82 — Principal Displaydé SCHEMATIC DIAGRAMS Plate 27 — Brake Pad Wear LH FRONT BRAKE PADS WEAR ‘SWITCH SENSOR, LH REAR BRAKE PADS WEAR ‘SWITCH SENSOR 8400) [8109] = BRAKE WEAR, 8 INFORMATION 8108 0159 RH FRONT RH REAR BRAKE PADS WEAR ‘BRAKE PADS WEAR ‘SWITCH SENSOR SWITCH SENSOR 8700 Figure 83 — Brake Pad Weer Page 122a> SCHEMATIC DIAGRAMS Plate 28 — ABS Electro Control Unit KEY switcH on (2) auTomaric. ‘TRANSMISSION Ceo vecu ANTETHEFT, system 2) DlaGNosTic CONNECTOR INSTRUMENT ‘CLUSTER Bots) wm [50%] 0085] [9088] [s082] 6063] (0088) ABS LH REAR MODULATOR VALVE ‘ABS RH REAR MODULATOR. VALVE ‘Ags LH FRONT MODULATOR ‘VALVE |ABS AH FRONT MODULATOR. VALVE JABS LH FRONT ‘SPEED SENSOR |ABS RH FRONT [SPEED SENSOR JABS LH REAR, ISPEED SENSOR |ABS FA REAR [SPEED SENSOR 0874 ‘Figure 64 — ABS Electronic Control Unit Page 123,SCHEMATIC DIAGRAMS Plate 29 — Automatic Transmission aurowane TAANSHISEON ——eyrags eS RELAY 493 ey suren@o} efi ems beara oe OM 00) FUSE T Foret pan mere ae aurowaric ‘99 ode | TRANSMISSION, FUSE i tenosrie a j conneeron | ELECTRON cowTnoL TARNSMSSION runane spec SENSOR ‘AuTOMaTic 2816) TRANeMSsION > @RELAY R38 |ABS INFO LOCKED WHEEL ENGINE FLYWHEEL SPEED SENSOR RANSMISSION OUTPUT SHAFT ‘SPEED SENSOR OIL PRESSURE SENSOR [2870] auTomaric TRANSMISSION TRANSMISSION SUMP On. LEVEL SENSOR TRANSMISSION SUMP OIL TEMPERATURE SENSOR 102678 Figure 65 — Automatic Tranamission rage 124& SCHEMATIC DIAGRAMS Plate 30 — Automatic Transmission [602] AUTOMATIC TRANSMISSION ECU Jomeens 5 AUTOMATIC 5 TRANSMISSION ed 2 a ary yo @Ngrguuen 7 Sowster JeECU Figure 86 — Automatic Transmission Page 125isc SCHEMATIC DIAGRAMS Plate 31 — Automatic Transmission [6606] GEAR SELECTOR AUTOMATIC. ‘TRANSMISSION ECU ey swircn on@) ABs iNFo @ treet i toeKeD as ae Fuse Lo | INSTRUMENT CLUSTER isd remmmncumen®) (2) ait fo coe ezeu(s) a | 00877 Figure 87 — Automatic Transmission Page 126&e SCHEMATIC DIAGRAMS Plate 32 — Automatic Transmission AUTOMATIC TRANSUISSION ECU BE eh pds wanes lal ode, a ne

oe ered OO) eAMAUSTaRAKE (>) > inst ©: ‘Tenpenarune [5585] ‘SENSOR eG STARTERINHIT melayta () eackupucit (2) < monn @) “ma me es 20pv sunneR INTERFACE. = TS |@ nes ercnceo + © sinc 8 anus BnaKe Tifa] nocaron An PRESSURE SWITCH >@ © mineuar SUPPLY RELAY Figure 89 — Vehicle Electronic Control Unit Page 128SCHEMATIC DIAGRAMS Plate 34 — Engine Electronic Control Unit (EECU) (eznalesco ELEC. CONTROL ‘AUTO. TRANS. [8275] VALVE BODY ‘COOLANT TEMP. ‘SENSOR [1862) B008T A 500] PRESSURE AND ‘TEMP. SENSOR ——— OL PRESSURE F7959] ]OQanvewen ANTI-THEFT [ae 7S piscnosne Name e880 3B > (8) BNET a ser FUEL HIGH [5 U,. PRESSURE SENSOR |9208) | @ass un nwecr0R i NO. 8150) Stermovalve vt wecTon S55] | UNIT INJECTOR [9994] i [2b 00) REL FUTER wi (BROOTEYELENE Swrcn UNITINIECTOR raam5] NOS UNIT MJECTOR No.6: UNIT INJECTOR Fo955] Noa ‘SOLENOID NO. 2 [9243 @-w causr see ara, eee Ov exe stor (2266) SG + @) a oii, ee ear so.enow [9208] ‘oaes00 Figure 90 — Engine Electronic Control Unit, Page 129,> SCHEMATIC DIAGRAMS Plate 35 — Available Power Supplies CHASSIS-CAB BODY BUILDER EQUIPMENT BODY BUILDER EQUIPMENT CONTROL No.2 @<|-= 4400] FUSE creas Figure 91 — Available Power Supplies Page 130& SCHEMATIC DIAGRAMS Plate 36 — Available Power Supplies cruise conrnor |, excu) ecu) Booy (*) ua wetee GS) POWER, ‘TAKE-OFF CONTROL, 5362] Bh to cHassis-caB CONNECTION UNIT Figure 62 — Available Power Supplies Page 131& SCHEMATIC DIAGRAMS Wire Sizes Section of electric wires (in mm). lee 7 | 07 | Black | @ 35 | suack | — 75 | stack | som 60 | stacx + we sa | etack (ieee ce | a 6 | eucK | * 0 | WoRY 1 27 | eax | + 5 | Wor j 73 jm x 2 | GREY Arete eras | ¥ ag | orev jy — 1 A 0.35! ORANGE ss a Figure 63 — Wire Sizes Page 132INDEX INDEX Page 133,a> INDEX A L ADVISORY LABELS :-2 LAYOUT OF ENGINE COMPONENTS .....12 LAYOUT OF FRONT FRAME B COMPONENTS ..... 14. BULKHEAD CONNECTOR PANEL LAYOUT OF IN-CAB COMPONENTS 218 (CONNECTOR PINNING) ... LAYOUT OF REAR FRAME BUMPER WIRING HARNESS . COMPONENTS ....... +116 c Pp PINPOINTING EXAMPLE .... eel CORELAYS BOX) (FUSES AND 20,26 PINPOINTING OF ELECTRICAL CONNECTOR PIN LOCATIONS COMPONENTS... oT 12 (CONNECTION UNIT) . PLATE 1 — "CAN" COMMUNICATION CONNECTOR UNIT . NETWORK WITHOUT ALLISON CONVERSION CHART |. TRANSMISSION ... .. seseeees 97 PLATE 2— "CAN" COMMUNICATION io NETWORK WITH ALLISON TRANSMISSION ....... +98 DASHBOARD WIRING HARNESS .... PLATE 3 — "CAN" COMMUNICATION DOOR WIRING HARNESSES .. NETWORK WITH ALLISON TRANSMISSION . oD : PLATE 5 — POWER SUPPLY/ ELECTRICAL SCHEMATIC DIAGRAMS ..... .92 STARTING ...... 100 ELECTRICAL WIRING HARNESSES .......45 PLATE — POWER SUPPLY... stot ENGINE WIRING HARNESS 77 PLATE 7 — ELECTRONIC THEFT F FRONT END WIRING HARNESS . .... FRONT FRAME WIRING HARNESSES FUSES/CIRCUIT BREAKERS/RELAYS FUSES/RELAYS AWAY FROM CONNECTION UNIT «0... 00... 0052-24 H HOW TO READ THE ELECTRICAL DIAGRAM on INTERNAL DIAGRAM pee ort 28) K KEY TO DIAGRAMS ... PROTECTION SYSTEM ............. 102 PLATE 8 — ENGINE AIR INTAKE PREHEATING ....... cee ee 103 PLATE 9— STARTING ..... 2104 PLATE 10 — FUEL PREHEATE! wee 105; PLATE 11 — INTERIOR LIGHTING AND SIGNALLING .... PLATE 12— LIGHTING . PLATE 13 — DAYTIME RUNNING LAMPS (ORL) . PLATE 14 — SIGNALLING « PLATE 15— SIGNALLING ... PLATE 16 — DIAGNOSTICS CONNECTORS .......... PLATE 17— DOORS LOCKING. . PLATE 18 — ELECTRIC WINDOW LIFT MOTORS ...... PLATE 19 — ELECTRIC DEFROSTING REARVIEW MIRROR . i. 106 107 -108 yas 109) +110 a 112 113 24& INDEX PLATE 20 — CAB INTERIOR LIGHTING ...115 PLATE 21 — WINDSHIELO WIPER .......116 PLATE 22 — CIGAR LIGHTER/42-VOLT SOCKET/RADIO .......-0.2-.6.0...417 PLATE 23 — RETARDER CONTROL... 118 PLATE 24 — AIR CONDITIONING .. 119 PLATE 25 — PRINCIPAL DISPLAY . 120 PLATE 26 — PRINCIPAL DISPLAY . 124 PLATE 27 — BRAKE PAD WEAR 122 PLATE 28 — ABS ELECTRONIC CONTROL UNIT... 123 PLATE 29— AUTOMATIC TRANSMISSION .. 124 PLATE 30 — AUTOMATIC. TRANSMISSION «2.2... 26-0005 5 125 PLATE 31 — AUTOMATIC TRANSMISSION ...... 126 PLATE 32 — AUTOMATIC TRANSMISSION «0.2... 20. 00000+ 127 PLATE 33— VEHICLE ELECTRONIC CONTROL UNIT (VECU) . .. vo 128 PLATE 34 — ENGINE ELECTRONIC CONTROL UNIT (EECU)... PLATE 35 — AVAILABLE POWER SUPPLIES ....... pees 180 PLATE 36 — AVAILABLE POWER SUPPLIES ........... PRE-EQUIPMENT ........ REAR FRAME WIRING HARNESS ........86 ROOF WIRING HARNESS ........... s SAFETY INFORMATION .........0005 ‘SERVICE PROCEDURES AND TOOL USAGE ..... eee STALK SWITCH WIRING HARNESS AND RADIO REMOTE CONTROL WIRING HARNESS .......... T TOP LEDGE WIRING HARNESSES: v VEHICLE ELECTRICAL ..... VEHICLE LOCATOR MAP FOR ELECTRICAL COMPONENTS ... w WIRE SIZES ..... 6000 WIRES — CONNECTOR LINKS (CONNECTION UNIT) . = 182 Page 135& NOTES Page 136ELECTRICAL SYSTEM SERVICE MANUAL FREEDOM™ MEDIUM DUTY TRUCKS ‘© MACK TRUCKS, INC. 2002