SERVICE MANUAL
SERVICE MANUAL SECTION
5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005
to February 28, 2007 — ELECTRICAL CIRCUIT DIAGRAMS
Model: 5500i
Start Date: 12/01/2005 End Date: 02/28/2007
Model: 5600i
Start Date: 12/01/2005 End Date: 02/28/2007
Model: 5900i
Start Date: 12/01/2005 End Date: 02/28/2007
Model: 9200i
Start Date: 12/01/2005 End Date: 02/28/2007
Model: 9400i
Start Date: 12/01/2005 End Date: 02/28/2007
Model: 9900i
Start Date: 12/01/2005 End Date: 02/28/2007
S08316
11/03/2006
S08316
Copyright©11/03/2006 International Truck and Engine Corporation
5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
i
Table of Contents
1. INSTRUCTIONS AND CHARTS (CHAPTER 1).....................................................................1
1.1. CIRCUIT IDENTIFICATION CHART, P. 1................................................................1
1.2. CIRCUIT IDENTIFICATION CHART, P. 2................................................................2
1.3. CIRCUIT DIAGRAM INSTRUCTIONS, P. 3..............................................................3
1.4. CIRCUIT DIAGRAM INSTRUCTIONS, P. 4..............................................................4
1.5. SCHEMATIC SYMBOLS, P. 5.............................................................................5
1.6. RELAY PINOUT, FUNCTION DATA AND SEALED RELAY, P. 6.....................................6
1.7. LAMP BULB CHART, P. 7.................................................................................7
2. 12 VOLT POWER DISTRIBUTION CIRCUIT DIAGRAMS (CHAPTER 2).......................................8
2.1. START FEED, P. 1..........................................................................................8
2.2. ACCESSORY, P. 2..........................................................................................9
2.3. BATTERY, P. 3.............................................................................................10
2.4. BATTERY, B2,P. 4........................................................................................11
2.5. BATTERY, B2 (CONT.), P. 5..............................................................................12
2.6. 3+1 BATTERY SYSTEM, P. 6............................................................................13
2.7. GROUND ADAPTER COMPOSITE, P. 7...............................................................14
2.8. GROUND STUD COMPOSITE, P. 8.....................................................................15
2.9. GROUND STUD COMPOSITE, P. 9.....................................................................16
2.10. IGNITION, P. 10..........................................................................................17
2.11. PANEL LIGHTS ADAPTER COMPOSITE, P. 11.....................................................18
3. 12 VOLT CHARGING AND CRANKING SYSTEM (CHAPTER 3)..............................................19
3.1. W/CAT AND CUMMINS ENGINES, P. 1................................................................19
3.2. W/OVERCRANK PROTECTION W/CAT AND CUMMINS ENGINES, P. 2.........................20
3.3. W/I6 HEUI ENGINE, P. 3..................................................................................21
3.4. W/OVERCRANK PROTECTION W/I6 HEUI, P. 4.....................................................22
3.5. W/CAT AND CUMMINS ENGINES AND W/1GA CHARGING CIRCUIT, P. 5......................23
4. ENGINE SYSTEMS (CHAPTER 4)..................................................................................24
4.1. CATERPILLAR C10, C11, C12, C13, C15, AND C16 CRUISE CONTROL, P. 1...................24
4.2. CATERPILLAR C10, C11, C12, C13, C15, AND C16 ENGINE BRAKE, P. 2......................25
4.3. CATERPILLAR C10, C11, C12, C13, C15, AND C16 ENGINE CONTROLS, P. 3.................26
4.4. CUMMINS ISM, ISX CRUISE CONTROL, P. 4.........................................................27
4.5. CUMMINS ISM, ISX ENGINE BRAKE, P. 5............................................................28
4.6. CUMMINS ISM , ISX — ENGINE CONTROLS, P. 6...................................................29
4.7. CUMMINS AHD AND ISM – ENGINE CONTROLS, P. 7.............................................30
4.8. I6 HEUI — CRUISE CONTROL, P. 8....................................................................31
4.9. I6 HEUI — ENGINE BRAKE, P. 9.......................................................................32
4.10. I6 HEUI — ENGINE CONTROLS, P. 10...............................................................33
4.11. I6 HEUI — MODULE POWER AND GROUND SYSTEM, P. 11....................................34
4.12. I6 HEUI — ACCELERATOR, BAP, AMBIENT AIR TEMP SENSOR SYSTEM, P. 12............35
4.13. I6 HEUI — SURGE TANK AND EXHAUST BRAKE SOLENOID, P. 13...........................36
5. FANS (CHAPTER 5)..................................................................................................37
5.1. HORTON AND KYSOR ENGINE FAN WITH CAT C10, C11, C12, C13, C15 AND C16 W/ AND
N/ A/C, W/ AND N/ MANUAL FAN OVERRIDE SWITCH, P. 1.......................................37
S08316
ii 5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
5.2. HORTON AND KYSOR ENGINE FAN WITH CUMMINS ISM, ISX W/ AND N/ A/C, W/ AND N/
MANUAL FAN OVERRIDE SWITCH, P. 2..............................................................38
5.3. HORTON AND KYSOR ENGINE FAN WITH I6 HEUI ENGINES W/SHUTTER, P. 3..............39
6. GAUGES AND SYSTEMS (CHAPTER 6)..........................................................................40
6.1. 4X2 REAR AXLE OIL TEMPERATURE GAUGE, P. 1................................................40
6.2. 6X4 AXLE FORWARD-REAR AND REAR-REAR TEMPERATURE GAUGE, P. 2................41
6.3. ENGINE OIL PRESSURE GAUGE, P. 3................................................................42
6.4. ENGINE OIL TEMPERATURE GAUGE, P. 4...........................................................43
6.5. ENGINE WATER TEMPERATURE GAUGE, P. 5......................................................44
6.6. FUEL LEVEL GAUGE, P. 6..............................................................................45
6.7. PYROMETER GAUGE, P. 7..............................................................................46
6.8. SPEEDOMETER GAUGE — TACHOMETER GAUGE, P. 8.........................................47
6.9. TRANSMISSION OIL TEMPERATURE GAUGE, P. 9.................................................48
6.10. VOLTMETER GAUGE, P. 10............................................................................49
6.11. ETHER START, P. 11....................................................................................50
6.12. MANIFOLD PRESSURE GAUGE, P. 12..............................................................51
7. WARNING LIGHTS (CHAPTER 7)..................................................................................52
7.1. AIR SUSPENSION RELEASE WARNING LIGHT, P. 1...............................................52
7.2. ENGINE OIL PRESSURE WARNING LIGHT, P. 2.....................................................53
7.3. ENGINE WATER TEMPERATURE WARNING LIGHT, P. 3..........................................54
7.4. LOW AIR PRESSURE WARNING LIGHT,P. 4........................................................55
7.5. LOW FUEL LEVEL WARNING LIGHT, P.5............................................................56
7.6. POWER DIVIDER LOCK (PDL) WARNING LIGHT AND BUZZER, P. 6...........................57
7.7. DIFFERENTIAL LOCK WARN LIGHT — 4X2, P. 7...................................................58
7.8. DIFFERENTIAL LOCK WARN LIGHT — 6X4, P. 8...................................................59
8. CAB ACCESSORIES (CHAPTER 8)...............................................................................60
8.1. CIGAR LIGHTER, P. 1....................................................................................60
8.2. CLOCK, P. 2................................................................................................61
8.3. ELECTRIC WINDOW — RIGHT, P. 3...................................................................62
8.4. ELECTRIC WINDOW — RIGHT AND LEFT, P. 4......................................................63
8.5. DEFROSTER FAN(S), P. 5...............................................................................64
8.6. ELECTRIC WINDSHIELD WIPERS WITH INTERMITTENT WIPE AND WASH, P. 6.............65
8.7. HORN, P. 7.................................................................................................66
8.8. MIRROR LIGHTS AND HEATED MIRRORS, P. 8.....................................................67
8.9. RIGHT MOTORIZED MIRROR, P. 9.....................................................................68
8.10. DUAL AXIS MOTORIZED MIRRORS, P. 10..........................................................69
8.11. POWER SOURCE (CB), P. 11..........................................................................70
8.12. RADIO-CB ACCOMMODATION PACKAGE, P. 12..................................................71
8.13. RADIO-CAB, SPEAKERS, P. 13.......................................................................72
8.14. OWNER/OPERATOR SPARE SWITCH, P. 14........................................................73
8.15. ELECTRIC LOCK — RIGHT AND LEFT, P. 15.......................................................74
8.16. INTERVISION DISPLAY, P. 16..........................................................................75
8.17. EATON VORAD — COLLISION AVOIDANCE, P. 17................................................76
8.18. EATON VORAD — COLLISION AVOIDANCE, P. 18................................................77
8.19. TEMPERATURE/COMPASS DISPLAY, P. 19.........................................................78
8.20. ROAD RELAY IV, P.20..................................................................................79
8.21. HEATED SEAT — DRIVER, P. 21......................................................................80
8.22. HEATED SEAT — PASSENGER, P. 22...............................................................81
9. CHASSIS ACCESSORIES (CHAPTER 9).........................................................................82
S08316
5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
iii
9.1. AIR DRYER, P. 1...........................................................................................82
9.2. ABS/ATC (BENDIX), P. 2.................................................................................83
9.3. ABS/ATC (BENDIX) (CONT.), P. 3.......................................................................84
9.4. ABS/ATC (BENDIX) (CONT.), P. 4.......................................................................85
9.5. ABS/ATC (WABCO), P. 5.................................................................................86
9.6. ABS/ATC (WABCO) (CONT.),P. 6......................................................................87
9.7. ABS/ATC (WABCO) (CONT.),P. 7......................................................................88
9.8. TRAILER CONNECTION — BACK OF SLEEPER MOUNTED W/TRACTOR ABS, P. 8.........89
9.9. TRAILER CONNECTION W/FOUR WHEEL TRAILER — FRAME MOUNTED, P. 9..............90
9.10. TWO SPEED AXLE WIRING, P. 10....................................................................91
9.11. TRUCK BODY CONNECTION, P. 11..................................................................92
9.12. TRAILER CONNECTION N/SLEEPER — BACK OF CAB MOUNTED, P. 12....................93
9.13. TRAILER CONNECTION W/FOUR WHEEL TRAILER — FRAME MOUNTED W/5000, P.
13.............................................................................................................94
9.14. MERITOR G SERIES TRANSMISSION, P. 14........................................................95
9.15. EATON AUTOSHIFT TRANSMISSION — CAB WIRING, P. 15....................................96
9.16. EATON AUTOSHIFT TRANSMISSION — TRANSMISSION WIRING, P. 16.....................97
9.17. EATON LIGHTNING TRANSMISSION — TRANSMISSION WIRING, P. 17......................98
9.18. EATON ULTRASHIFT/DM2 — TRANSMISSION WIRING, P. 18...................................99
9.19. EATON ULTRASHIFT/DM2 — TRANSMISSION WIRING (CONT.), P. 19.......................100
9.20. EATON ULTRASHIFT/DM2 AND COBRA SHIFTER, P. 20.......................................101
9.21. ABS6/ATC BENDIX AIR, P. 21........................................................................102
9.22. ABS6/ATC BENDIX AIR, P. 22........................................................................103
9.23. ABS6/ATC BENDIX AIR, P. 23........................................................................104
9.24. ABS6 ADVANCE ECU, W/BENDIX RSP, P. 24.....................................................105
9.25. EATON AUTOSHIFT 3, P. 25..........................................................................106
9.26. EATON AUTOSHIFT 3, P. 26..........................................................................107
9.27. EATON AUTOSHIFT 3 W/PUSH BUTTON SHIFTER, P. 27.......................................108
9.28. EATON AUTOSHIFT 3 W/COBRA SHIFTER, P. 28................................................109
10. SLEEPER LIGHTING AND ACCESSORIES (CHAPTER 10).................................................110
10.1. AUXILIARY CIRCULATION FAN (LOW ROOF), P.1..............................................110
10.2. AUXILIARY CIRCULATION FAN (HIGH ROOF), P. 2..............................................111
10.3. AUXILIARY CIRCULATION FAN (SKYRISE), P. 3.................................................112
10.4. BUNK FLUORESCENT AND READING LIGHTS, P. 4............................................113
10.5. BUNK SPEAKERS, P. 5...............................................................................114
10.6. LUGGAGE COMPARTMENT LIGHTS, P. 6.........................................................115
10.7. POWER SOURCE, P. 7................................................................................116
10.8. REFRIGERATOR WIRING, P. 8.......................................................................117
10.9. TV/VCR WIRING, P. 9..................................................................................118
10.10. OVERHEAD CABINETS, ACCENT LIGHTS, P. 10...............................................119
10.11. OPTIONAL SLEEPER MOUNTED RADIO CONTROLS, P. 11..................................120
10.12. SHORE POWER WIRING (08WET) NOT WITH INVERTER, P. 12.............................121
10.13. SHORE POWER WIRING (08WET) WITH INVERTER (08WES), P. 13........................122
11. LIGHT SYSTEMS (CHAPTER 11)................................................................................123
11.1. BACK-UP LIGHTS, P. 1................................................................................123
11.2. CAB AND TRAILER LIGHTS SWITCH AND RELAYS WIRING, P. 2............................124
11.3. CAB CLEARANCE AND IDENTIFICATION LIGHTS, P. 3.........................................125
11.4. WORK LIGHT N/SLEEPER, P. 4......................................................................126
11.5. CAB DOME, READING AND COURTESY LIGHTS N/SKYRISE, P. 5...........................127
11.6. CAB DOME, READING AND COURTESY LIGHTS W/SKYRISE, P. 6..........................128
11.7. DAYTIME RUNNING LIGHTS (DRL) — USA, P. 7.................................................129
S08316
iv 5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
11.8. FOGLIGHTS — CAB/FRONT END EFFECTS, P. 8................................................130
11.9. HEADLIGHT SWITCH AND DIMMER SWITCH WIRING, P. 9....................................131
11.10. HEADLIGHTS, P. 10..................................................................................132
11.11. PANEL LIGHTS, P. 11................................................................................133
11.12. PARK/TURN/SIDE MARKER LIGHTS — WITH DRL, P. 12.....................................134
11.13. SPOTLIGHT, P. 13....................................................................................135
11.14. STOP, TAIL, TURN AND HAZARD SIGNAL LIGHTS WITH FLASHER, P. 14................136
11.15. WORK LIGHT W/SLEEPER, P. 15..................................................................137
12. HEATER AND AIR CONDITIONER (CHAPTER 12)...........................................................138
12.1. AIR CONDITIONER — CAB, P. 1....................................................................138
12.2. HEATER — CAB, P. 2..................................................................................139
12.3. HEATER — BUNK AUXILIARY BLOWER, P. 3....................................................140
12.4. HEATER — BUNK W/STANDARD TEMPERATURE CONTROL, P. 4...........................141
12.5. HEATER — BUNK W/THERMOSTAT TEMPERATURE CONTROL, P. 5.......................142
12.6. LOWERED HEATER BOX, P. 6.......................................................................143
12.7. AUX HEATER, P. 7.....................................................................................144
12.8. APU SYSTEM: DISTRIBUTION BOX, P. 8..........................................................145
12.9. APU SYSTEM: DISTRIBUTION BOX, P. 9..........................................................146
12.10. APU SYSTEM, P. 10..................................................................................147
13. CONNECTOR COMPOSITES (CHAPTER 13).................................................................148
13.1. LEFT GAUGE CLUSTER (CONNECTOR 423), P. 1...............................................148
13.2. LEFT GAUGE CLUSTER (CONNECTOR 424), P. 2...............................................149
13.3. LEFT GAUGE CLUSTER — GAUGE INFORMATION, P. 3.......................................150
13.4. LEFT GAUGE CLUSTER — TERMINAL INFORMATION, P. 4...................................151
13.5. LEFT GAUGE CLUSTER — TERMINAL INFORMATION, P. 5...................................152
13.6. RIGHT GAUGE CLUSTER (CONNECTOR 420), P. 6..............................................153
13.7. RIGHT GAUGE CLUSTER — GAUGE INFORMATION, P. 7.....................................154
13.8. RIGHT GAUGE CLUSTER — TERMINAL INFORMATION, P. 8.................................155
13.9. SPEEDOMETER/TACHOMETER MODULE — TERMINAL INFORMATION, P. 9............. 156
13.10. SPEEDOMETER/TACHOMETER MODULE — TERMINAL INFORMATION, P. 10...........157
13.11. CONNECTOR COMPOSITES (1), (2), (3), P. 11...................................................158
13.12. CONNECTOR COMPOSITES (4), (9), (11), (15), (20), (27), P. 12...............................159
13.13. CONNECTOR COMPOSITES (40), (41), (42), (43), (48), (65), P. 13............................160
13.14. CONNECTOR COMPOSITES (66), (71), (72), (76), (77), (94), P. 14............................161
13.15. CONNECTOR COMPOSITES (100), (100A), (105), (111), (112), (113), (115), P. 15..........162
13.16. CONNECTOR COMPOSITES (116), (117), (118), (127A), (128), P. 16.........................163
13.17. CONNECTOR COMPOSITES (137), (141), (142), (143), (144), (145), (146), (147), (148), P.
17...........................................................................................................164
13.18. CONNECTOR COMPOSITES (149), (150), (151), (152), (161), (162), P. 18...................165
13.19. CONNECTOR COMPOSITES (165), (166), (167), (170), (171), (180), P. 19...................166
13.20. CONNECTOR COMPOSITE (190), P. 20...........................................................167
13.21. CONNECTOR COMPOSITES (196), (199), (200), (201), (209), (211), (214), (216), P. 21....168
13.22. CONNECTOR COMPOSITES (217), (218), (220), (221), P. 22..................................169
13.23. CONNECTOR COMPOSITES (227), (228), (229), P. 23..........................................170
13.24. CONNECTOR COMPOSITES (230), (231), (236), (241), P. 24..................................171
13.25. CONNECTOR COMPOSITES (243), (244), (249), (250), (251), P. 25..........................172
13.26. CONNECTOR COMPOSITES (252), (260), (267), P. 26..........................................173
13.27. CONNECTOR COMPOSITES (268), (273), (275), (278), (282), (289), P. 27...................174
13.28. CONNECTOR COMPOSITES (290), (291), (292), (293), (294), (296), P. 28...................175
13.29. CONNECTOR COMPOSITES (298), (299), (311), (312), (313), (315, 316), P. 29.............176
13.30. CONNECTOR COMPOSITES (316), (318), (320), (321), (322), (323), P. 30...................177
S08316
5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
v
13.31. CONNECTOR COMPOSITES (325), (345), (350), (351), (352), (353), (354), P. 31...........178
13.32. CONNECTOR COMPOSITES (355), (360), (363), (379), (393), (396), P. 32...................179
13.33. CONNECTOR COMPOSITES (400), (402), (403), (404), (406), (409), P. 33...................180
13.34. CONNECTOR COMPOSITES (417), (420), (421), P. 34..........................................181
13.35. CONNECTOR COMPOSITES (422), (423), (424), (425), (426), P. 35..........................182
13.36. CONNECTOR COMPOSITES (427), (428), (429), (430), P. 36..................................183
13.37. CONNECTOR COMPOSITES (433), (434), (435), P. 37..........................................184
13.38. CONNECTOR COMPOSITES (436), (437), (440), (441), (442), P. 38..........................185
13.39. CONNECTOR COMPOSITES (453), (454), P. 39.................................................186
13.40. CONNECTOR COMPOSITES (455), (456), (460), (462), P. 40..................................187
13.41. CONNECTOR COMPOSITES (462), (463), P. 41.................................................188
13.42. CONNECTOR COMPOSITES (463), P. 42.........................................................189
13.43. CONNECTOR COMPOSITES (464), P. 43.........................................................190
13.44. CONNECTOR COMPOSITES (464), (465), (466), (468), (470), (1000), P. 44.................191
13.45. CONNECTOR COMPOSITES (474), (480), (481), (482), (483), (489), P. 45...................192
13.46. CONNECTOR COMPOSITES (491), (492), (494), (495), (497), (498), (499), (501), P. 46. . .193
13.47. CONNECTOR COMPOSITES (502), (503), (504), (506), P. 47..................................194
13.48. CONNECTOR COMPOSITES (509), (511), (512), (513), (514), (515), P. 48...................195
13.49. CONNECTOR COMPOSITES (517), (520), (521), (522), (523), (524), (525), (526), P. 49. . .196
13.50. CONNECTOR COMPOSITES (528), (529), (530), (531), (550), (560), (562), (574), P. 50. . .197
13.51. CONNECTOR COMPOSITES (575), (576), (577), (578), (579), (582), P. 51...................198
13.52. CONNECTOR COMPOSITES (584), (585), (587), P. 52..........................................199
13.53. CONNECTOR COMPOSITES (592), (592F), (593), (594), (600), P. 53.........................200
13.54. CONNECTOR COMPOSITES (603), (604), (605), (606), (607), (610), (611), P. 54...........201
13.55. CONNECTOR COMPOSITES (612), (613), (640), (642), (643), (659), P. 55...................202
13.56. CONNECTOR COMPOSITES (662), (675), (676), (690), P. 56..................................203
13.57. CONNECTOR COMPOSITES (720), (753), (755), (766), (767), (768), P. 57...................204
13.58. CONNECTOR COMPOSITES (769), (770), (771), (774), (775), (776), (777), (778), (789), P.
58...........................................................................................................205
13.59. CONNECTOR COMPOSITES (791), (823), (851), (854), (884), (885), (887), P. 59...........206
13.60. CONNECTOR COMPOSITES (904), (905), (906), P. 60..........................................207
13.61. CONNECTOR COMPOSITES (907), (909), (912), (913), (914), (915), (916), (918), P. 61. . .208
13.62. CONNECTOR COMPOSITES (922), (923), (925), P. 62..........................................209
13.63. CONNECTOR COMPOSITES (926), (930), (935), (936), (937), P. 63..........................210
13.64. CONNECTOR COMPOSITES (938), (939), (940), (941), (942), P. 64..........................211
13.65. CONNECTOR COMPOSITES (955), (956), (962), (963), (992), (993), (994), P. 65...........212
13.66. CONNECTOR COMPOSITES (995–999), (1000), (1033), (1034), P. 66........................213
13.67. CONNECTOR COMPOSITES (1039), (1040), (1041), (1042), (1043), (1044), P. 67..........214
13.68. CONNECTOR COMPOSITES (1045), (1046), (1047), (1048), P. 68............................215
13.69. CONNECTOR COMPOSITES (1049), (1050), (1051), P. 69.....................................216
13.70. CONNECTOR COMPOSITES (1053), (1054), (1056), (1057), P. 70............................217
13.71. CONNECTOR COMPOSITES (1058), (1059), (1060), (1084), (1085), (1086), (1088), (1090F),
P. 71........................................................................................................218
13.72. CONNECTOR COMPOSITES (1090M), (1091), (1093), (1094), (1095), P. 72.................219
13.73. CONNECTOR COMPOSITES (1097), (1098), (1099), (1108), P. 73............................220
13.74. CONNECTOR COMPOSITES (1110), (1112), (1113), (1125), (1126), P. 74....................221
13.75. CONNECTOR COMPOSITES (1127), (1128), (1130), (1135), P. 75.............................222
13.76. CONNECTOR COMPOSITES (1137), (1138), (1139), (1140), (1141), P. 76....................223
13.77. CONNECTOR COMPOSITES (1155), (1156), (1157), (1158), (1159), (1170), P. 77...........224
13.78. CONNECTOR COMPOSITES (1171), (1188), (1189), AND JUNCTION POINTS J7 AND J4, P.
78...........................................................................................................225
13.79. CONNECTOR COMPOSITES (1190), (1193), (1194), (1195), (1223), (1224), (1225), P.
79...........................................................................................................226
S08316
vi 5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
13.80. CONNECTOR COMPOSITES (1227), (1229), (1239A, B, C), (1239), (1240), P. 80.......... 227
13.81. CONNECTOR COMPOSITES (1241), (1243), (1244), (1258), (1260), (1261), P. 81..........228
13.82. CONNECTOR COMPOSITES (1262), (1263), (1264), (1265), (1279), P. 82...................229
13.83. LEFT BLANK INTENTIONALLY, P. 83.............................................................230
13.84. CONNECTOR COMPOSITE (1285), P. 84.........................................................231
13.85. CONNECTOR COMPOSITES (1286), (1287), (1288), (1289), (1290), P. 85...................232
13.86. CONNECTOR COMPOSITES (1304), (1305), (1306), (1307), (1308), (1309M), P. 86........233
13.87. CONNECTOR COMPOSITES (1310), (1311), (1312), (1313), (1315), (1316OL), (1316PL), P.
87...........................................................................................................234
13.88. CONNECTOR COMPOSITES (1321), (1322), (1323), (1324), (1327), (1328), P. 88..........235
13.89. CONNECTOR COMPOSITES (1331), (1332), P. 89..............................................236
13.90. CONNECTOR COMPOSITES (1348), (1349), P. 90..............................................237
13.91. CONNECTOR COMPOSITES (1360), (1361), (5710L), P. 91....................................238
14. POWER DISTRIBUTION LAYOUT (CHAPTER 14)............................................................239
14.1. POWER DISTRIBUTION CENTER, FUSE AND CIRCUIT BREAKER LOCATION, P. 1 ...... 239
14.2. FUSE AND CIRCUIT BREAKER LOCATION (CONT.), P. 2.......................................240
14.3. RELAY LOCATION, P. 3...............................................................................241
14.4. PRO SLEEPER FUSE INDEX, P. 4...................................................................242
S08316
5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
1
1. INSTRUCTIONS AND CHARTS (CHAPTER 1)
1.1. CIRCUIT IDENTIFICATION CHART, P. 1
INTERNATIONAL TRUCK AND ENGINE CORPORATION
NAME
DATE
THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND
IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE
INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PART NO.
DATE REFERENCE REV CHK
P52600M
NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR
29JUL98 01
INSTRUCTIONS AND CHARTS FOR ALL MODELS RROEPKE
AE08-52011
CHAPTER 1
ADDED DESC AT 38 & 41. A 55093F JKP 4MAR02
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
CIRCUIT
NUMBER
DESCRIPTION - COLOR
GENERATOR - CHARGE - RED
GROUND - WHITE
BATTERY FEED - RED
STARTER CONTROL - PINK
ENGINE SHUT-OFF - GRAY
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
ETHER START - TAN
ENGINE COOLING - TAN
ENGINE BRAKE GRAY
VOLTMETER - TAN
INSTRUMENT FEED - TAN
ENGINE WATER TEMPERATURE - TAN
ENGINE OIL TEMPERATURE - TAN
TRANSMISSION OIL TEMPERATURE - TAN
AXLE OIL TEMPERATURE - TAN
WATER LEVEL - TAN
ENGINE OIL PRESSURE - TAN
FUEL LEVEL - TAN
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
LOW AIR PRESSURE WARNING - GRAY
POWER DIVIDER LOCK (PDL) - GRAY
SPEEDOMETER - GRAY
TACHOMETER - GRAY
HEADLIGHT - HIGH BEAM - YELLOW
TURN SIGNAL - ORANGE
CLEARANCE AND IDENTIFICATION LIGHTS - BROWN 58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
PANEL LIGHTS - DARK BLUE
COURTESY AND DOME LIGHTS - DARK BLUE
AUXILIARY LIGHTS - YELLOW
5TH WHEEL/WORK LIGHT - ORANGE
DAYTIME RUNNING LIGHTS - YELLOW
TAIL LIGHTS - BROWN
STOP LIGHTS - ORANGE
BACK-UP LIGHTS - ORANGE
CIRCUIT
NUMBER
DESCRIPTION - COLOR
IGNITION FEED - PINK
KEY SWITCH FEED - RED
AIR DRYER - GRAY
LIGHT SWITCH FEED - YELLOW
DIMMER SWITCH - YELLOW
HEADLIGHT - LOW BEAM - YELLOW
TURN SIGNAL LIGHTS - LEFT - ORANGE
TURN SIGNAL LIGHTS - RIGHT - ORANGE
TRAILER AUXILIARY - ORANGE
PYROMETER - TAN
DIFFERENTIAL LOCK - GRAY
PARKING/MARKER LIGHTS - BROWN
HAZZARD LIGHTS - ORANGE
ALTERNATOR - RESISTANCE - RED
ACCESSORY FEED - LIGHT BLUE
FRONT AXLE - GRAY
FUEL PUMP - TAN GENERATOR - FIELD - LIGHT BLUE
GLOW PLUG/PRE-HEATER - PINK
AMMETER - TAN
ENGINE OIL LEVEL - TAN
PARK BRAKE WARNING - GRAY
ANTI-THEFT WARNING - LIGHT GREEN
POWER TAKE-OFF WARNING - GRAY
AIR SUSPENSION - GRAY
LICENSE PLATE LIGHT - BROWN
OUTSIDE AIR TEMP/COMPASS - TAN
HEATED SEAT - LIGHT GREEN
Figure 1 Circuit Identification Chart, page 1
S08316
2 5500i, 5600i, 5900i, 9200i, 9400i and 9900i Chassis Built December 1, 2005 and
After — ELECTRICAL CIRCUIT DIAGRAMS
1.2. CIRCUIT IDENTIFICATION CHART, P. 2
INTERNATIONAL TRUCK AND ENGINE CORPORATION
NAME
DATE
THIS PRINT IS PROVIDED ON A RESTRICTED BASIS AND
IS NOT TO BE USED IN ANY WAY DETRIMENTAL TO THE
INTEREST OF INTERNATIONAL TRUCK AND ENGINE CORPORATION.
RELEASE NO.
ELECTRICAL CIRCUIT DIAGRAM
CHANGE
SHEET
DRAWN
PART NO.
DATE REFERENCE REV CHK
P52600M 29JUL98 02
INSTRUCTIONS AND CHARTS FOR ALL MODELS RROEPKE
GSC2 ADDED CIR 73 DESC
AE08-52011
CHAPTER 1
A P53583S JPM 10DEC01
ADDED SEAT BELTS. B 55093F JKP 4MAR02
73
74
75
76
77
78
79
80
81
82
83
84
85
86
CIRCUIT
NUMBER
DESCRIPTION - COLOR
HEATER BLOWER MOTOR - LIGHT GREEN
87
88
89
90
91
92
93
94
95
96
97
98
99
CIRCUIT
NUMBER
DESCRIPTION - COLOR
AIR CONDITIONER - LIGHT GREEN
MIRRORS - HEATED * MOTORIZED - LIGHT GREEN
POWER WINDOW - LIGHT GREEN
CIGAR LIGHTER - LIGHT GREEN
HORN - ELECTRIC - GRAY
RADIO - ENTERTAINMENT - LIGHT GREEN
WINDSHIELD WASHER - GRAY
CLOCK/HOURMETER - LIGHT GREEN
DATA LINK AND DIAGNOSTICS - BLACK
AXLE SHIFT CONTROL - TAN
THROTTLE POSITION SENSOR - VIOLET
CRUISE CONTROL AND ELECTRONIC ENGINE - VIOLET
AUXILIARY FAN - LIGHT GREEN
POWER DOOR LOCKS - LIGHT GREEN
WINDSHIELD WIPERS - GRAY
TRANSMISSION (ELECTRONIC) - TAN
ANTILOCK BRAKES - GRAY
EXHAUST EMISSION - TAN
SNOW PLOW LIGHTS - YELLOW
* NOTE:
NOT ALL CIRCUITS MAY BE USED.
COLORS ABOVE ARE NEW STD COLORS
FOR MAJOR HARNESSES.
INTERCOMMUNICATIONS - VIOLET
HYDRAULIC BRAKE PUMP - GRAY
COLLISION AVOIDANCE SYSTEM - LIGHT BLUE
NAVISTAR CIRCUIT NUMBER IDENTIFICATION & COLOR
SEAT BELTS - LIGHT GREEN
Figure 2 Circuit Identification Chart, page 2
S08316
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2005-2007 International 5500i, 5600i, 5900i, 9200i, 9400i, 9900i Wiring Diagrams Manual
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Description
2005-2007 International 5500i, 5600i, 5900i, 9200i, 9400i, 9900i Wiring Diagrams Manual
Models Covered:
- International 5500i
- International 5600i
- International 5900i
- International 9200i
- International 9400i
- International 9900i
Engines Covered:
- Caterpillar C10, C11, C12, C13, C15, C16
- Cummins ISM, ISX
- International I6 HEUI
The 2005-2007 International 5500i, 5600i, 5900i, 9200i, 9400i, 9900i Electrical Wiring Diagrams manual is an official service resource providing complete schematics and circuit layouts for heavy-duty i-Series trucks produced between late 2005 and early 2007. This manual is indispensable for technicians diagnosing complex electrical issues or performing in-depth electrical repairs on these International Class 8 trucks.
It includes fully labeled diagrams, connector pinouts, wire colors, and signal paths for all major systems, including starting, charging, lighting, engine control, HVAC, and transmission wiring. Whether dealing with a Caterpillar, Cummins, or International powertrain, this manual covers the electrical systems for all configurations during the specified production range.
Content Overview:
- System Identification: Circuit charts, diagram legends, symbol keys, and relay functions
- 12V Power Distribution: Starter circuits, accessory feeds, batteries, ignition systems
- Charging & Cranking: Alternator wiring, overcrank protection, battery system types
- Engine Management: Cruise control, engine brake, and module communication for Cat, Cummins, and I6 HEUI engines
- Fan Controls: Horton and Kysor fan systems with override switch diagnostics
- Gauges & Sensors: Tachometer, oil pressure/temp, fuel level, manifold pressure, voltmeter
- Cab & Chassis Accessories: Power windows, radio wiring, CB accommodations, air dryers
- Transmission Systems: Eaton AutoShift, UltraShift, Lightning, and Meritor G Series wiring
- Lighting Systems: Exterior marker, dome, DRL, fog, stop/tail/turn/hazard lights
- Connector Composites: Terminal pinouts for dozens of factory connectors and modules
This manual is an essential tool for diagnosing wiring faults, verifying connector outputs, or retrofitting auxiliary systems. With hundreds of high-resolution schematics across all major subsystems, it supports factory-accurate repairs and efficient electrical troubleshooting.
Printable: Yes
Language: English
Compatibility: Works on all devices (Windows, Mac, iOS, Android)
Requirements: PDF reader (e.g. Adobe Reader)
