SERVICE MANUAL

TRUCK SERVICE MANUAL

3100 Bus Starting October, 2009 ELECTRICAL CIRCUIT DIAGRAMS

Model: 3100
Start Date: 10/01/2009

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02/24/2010

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Copyright 02/24/2010 Navistar, Inc.
 TRUCK SERVICE MANUAL i

Table of Contents

SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 3100 BUS CIRCUIT DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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SAFETY INFORMATION
IMPORTANT Read the following before starting the service procedure.

The information contained in this International Service Manual Section was current at the time of printing
and is subject to change without notice or liability.

You must follow your company safety procedures when you service or repair equipment. Be sure to understand
all of the procedures and instructions before you begin work on the unit.

International uses the following types of notations to give warning of possible safety problems and to give
information that will prevent damage to the equipment being serviced or repaired.

WARNING A warning indicates procedures that must be followed exactly. Personal injury
or possible death can occur if the procedure is not followed.

CAUTION A caution indicates procedures that must be followed exactly. If the procedure is not
followed, damage to equipment or components can occur.

NOTE A note indicates an operation, procedure or instruction that is important for correct service.

Some procedures require the use of special tools for safe and correct service. Failure to use these special
tools when required can cause injury to service personnel or damage to vehicle components.

This service manual section is intended for use by professional technicians, NOT a do-it-yourselfer. It is
written to inform these technicians of conditions that may occur on some vehicles, or to provide information
that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools,
safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume
that the service section applies to your vehicle. See your International Truck Dealer for information on whether
this service section applies to your vehicle.

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Table of Contents

1. INSTRUCTIONS AND CHARTS (CHAPTER 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1. SCHEMATIC SYMBOL CHART, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. SCHEMATIC SYMBOL CHART, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.7. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.8. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.9. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.10. CIRCUIT DIAGRAM INSTRUCTIONS, P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
1.11. ECM PIN IDENTIFICATION TABLE, P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
1.12. ECM PIN IDENTIFICATION TABLE, P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
1.13. INSTRUMENT CLUSTER PIN IDENTIFICATION TABLE, P. 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2. POWER DISTRIBUTION (CHAPTER 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.1. BATTERY, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.2. FEED AND GROUND JUNCTION POINTS, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.3. FUSE BLOCK, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

3. CAB ACCESSORIES (CHAPTER 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.1. HORN, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

4. ENGINE SYSTEMS (CHAPTER 4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

4.1. CHARGING SYSTEM, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2. CRANKING SYSTEM, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

5. GAUGES (CHAPTER 5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

5.1. FUEL LEVEL, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

6. WARNING LIGHTS (CHAPTER 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

6.1. LOW OIL PRESS./HIGH WATER TEMP., STOP ENGINE, ENGINE, BRAKE WARNINGS, P.
1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

7. CHASSIS ACCESSORIES (CHAPTER 7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

7.1. WATER IN FUEL, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
7.2. BODY BUILDER CONNECTIONS, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
7.3. AIR DRYER, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

8. LIGHT SYSTEMS (CHAPTER 8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

8.1. BACK-UP LIGHT SYSTEM, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
8.2. HEADLIGHT SYSTEM, HIGH BEAM, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.3. TURN SIGNAL SYSTEM, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.4. STOP LIGHTS SYSTEM, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

9. ELECTRONIC CONTROLS (CHAPTER 9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

9.1. FEED, P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

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9.2. J1939 INTERFACE, J1939 TO J1708, P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

9.3. VEHICLE SPEED SENSOR, P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.4. THROTTLE POSITION SENSOR, P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.5. COOLANT LEVEL, P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
9.6. EXHAUST SYSTEM, P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
9.7. GATEWAY, P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
9.8. INSTRUMENT CLUSTER, P. 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
9.9. INSTRUMENT CLUSTER, P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

10. CONNECTOR COMPOSITES (CHAPTER 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

10.1. CONNECTOR COMPOSITES (1), P. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
10.2. CONNECTOR COMPOSITES (1C), (2F), P. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
10.3. CONNECTOR COMPOSITES (2M), P. 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
10.4. CONNECTOR COMPOSITES (16M), (20M), (26M), P. 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
10.5. CONNECTOR COMPOSITES (27M), (28M), (60M), P. 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
10.6. CONNECTOR COMPOSITES (61M), (63M), (79M), (80M), P. 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
10.7. CONNECTOR COMPOSITES (100M), (101M), (192F), P. 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
10.8. CONNECTOR COMPOSITES (193M), (222M), (378M), (382M), (386F), P. 8. . . . . . . . . . . . . . . . . . . .49
10.9. CONNECTOR COMPOSITES (402), (419M), (422), (423), (426), P. 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
10.10. CONNECTOR COMPOSITES (644F), (661), (662), (663), P. 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
10.11. CONNECTOR COMPOSITES (1657M), (3040), P. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
10.12. CONNECTOR COMPOSITES (6026), P. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
10.13. CONNECTOR COMPOSITES (6108), (6323M), (6324M), (7500M), (7601M), P. 13. . . . . . . . . . . .54
10.14. CONNECTOR COMPOSITES (7801), (8310), (8311), (8312), (9101), P. 14. . . . . . . . . . . . . . . . . . . . .55
10.15. CONNECTOR COMPOSITES (9108A), (9108B), P. 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

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1. INSTRUCTIONS AND CHARTS (CHAPTER 1)

1.1. SCHEMATIC SYMBOL CHART, P. 1

Figure 1 Schematic Symbol Chart

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1.2. SCHEMATIC SYMBOL CHART, P. 2

Figure 2 Schematic Symbol Chart

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1.3. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 3

Figure 3 Circuit Number Identification and Location

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1.4. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 4

Figure 4 Circuit Number Identification and Location

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1.5. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 5

Figure 5 Circuit Number Identification and Location

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1.6. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 6

Figure 6 Circuit Number Identification and Location

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1.7. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 7

Figure 7 Circuit Number Identification and Location

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1.8. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 8

Figure 8 Circuit Number Identification and Location

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1.9. CIRCUIT NUMBER IDENTIFICATION AND LOCATION, P. 9

Figure 9 Circuit Number Identification and Location

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1.10. CIRCUIT DIAGRAM INSTRUCTIONS, P. 10

Figure 10 Circuit Diagram Instructions

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1.11. ECM PIN IDENTIFICATION TABLE, P. 11

Figure 11 ECM Pin Identification Table

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1.12. ECM PIN IDENTIFICATION TABLE, P. 12

Figure 12 ECM Pin Identification Table

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1.13. INSTRUMENT CLUSTER PIN IDENTIFICATION TABLE, P. 13

Figure 13 Instrument cluster Pin Identification Table

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2. POWER DISTRIBUTION (CHAPTER 2)

2.1. BATTERY, P. 1

Figure 14 Battery

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2.2. FEED AND GROUND JUNCTION POINTS, P. 2

Figure 15 Feed and Ground Junction Points

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2.3. FUSE BLOCK, P. 3

Figure 16 Fuse Block

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3. CAB ACCESSORIES (CHAPTER 3)

3.1. HORN, P. 1

Figure 17 Horn

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4. ENGINE SYSTEMS (CHAPTER 4)

4.1. CHARGING SYSTEM, P. 1

Figure 18 Charging System

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4.2. CRANKING SYSTEM, P. 2

Figure 19 Cranking System

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5. GAUGES (CHAPTER 5)
5.1. FUEL LEVEL, P. 1

Figure 20 Fuel Level

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6. WARNING LIGHTS (CHAPTER 6)

6.1. LOW OIL PRESS./HIGH WATER TEMP., STOP ENGINE, ENGINE, BRAKE
WARNINGS, P. 1

Figure 21 Low Oil Press./High Water Temp., Stop Engine, Engine, Brake Warnings

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7. CHASSIS ACCESSORIES (CHAPTER 7)

7.1. WATER IN FUEL, P. 1

Figure 22 Water in Fuel

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7.2. BODY BUILDER CONNECTIONS, P. 2

Figure 23 Body Builder Connections

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7.3. AIR DRYER, P. 3

Figure 24 Air Dryer

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8. LIGHT SYSTEMS (CHAPTER 8)

8.1. BACK-UP LIGHT SYSTEM, P. 1

Figure 25 Back-Up Light System

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8.2. HEADLIGHT SYSTEM, HIGH BEAM, P. 2

Figure 26 Headlight System, High Beam

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8.3. TURN SIGNAL SYSTEM, P. 3

Figure 27 Turn Signal System

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8.4. STOP LIGHTS SYSTEM, P. 4

Figure 28 Stop Lights System

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9. ELECTRONIC CONTROLS (CHAPTER 9)

9.1. FEED, P. 1

Figure 29 Feed

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9.2. J1939 INTERFACE, J1939 TO J1708, P. 2

Figure 30 J1939 Interface, J1939 to J1708

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9.3. VEHICLE SPEED SENSOR, P. 3

Figure 31 Vehicle Speed Sensor

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9.4. THROTTLE POSITION SENSOR, P. 4

Figure 32 Throttle Position sensor

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9.5. COOLANT LEVEL, P. 5

Figure 33 Coolant Level

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9.6. EXHAUST SYSTEM, P. 6

Figure 34 Exhaust System

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9.7. GATEWAY, P. 7

Figure 35 Gateway

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9.8. INSTRUMENT CLUSTER, P. 8

Figure 36 Instrument Cluster

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9.9. INSTRUMENT CLUSTER, P. 9

Figure 37 Instrument Cluster

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10. CONNECTOR COMPOSITES (CHAPTER 10)

10.1. CONNECTOR COMPOSITES (1), P. 1

Figure 38 Connector Composites (1)

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10.2. CONNECTOR COMPOSITES (1C), (2F), P. 2

Figure 39 Connector Composites (1C), (2F)

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10.3. CONNECTOR COMPOSITES (2M), P. 3

Figure 40 Connector Composites (2M)

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10.4. CONNECTOR COMPOSITES (16M), (20M), (26M), P. 4

Figure 41 Connector Composites (16M), (20M), (26M)

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10.5. CONNECTOR COMPOSITES (27M), (28M), (60M), P. 5

Figure 42 Connector Composites (27M), (28M), (60M)

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10.6. CONNECTOR COMPOSITES (61M), (63M), (79M), (80M), P. 6

Figure 43 Connector Composites (61M), (63M), (79M), (80M)

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10.7. CONNECTOR COMPOSITES (100M), (101M), (192F), P. 7

Figure 44 Connector Composites (100M), (101M), (192F)

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10.8. CONNECTOR COMPOSITES (193M), (222M), (378M), (382M), (386F), P. 8

Figure 45 Connector Composites (193M), (222M), (378M), (382M), (386F)

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10.9. CONNECTOR COMPOSITES (402), (419M), (422), (423), (426), P. 9

Figure 46 Connector Composites (402), (419M), (422), (423), (426)

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10.10. CONNECTOR COMPOSITES (644F), (661), (662), (663), P. 10

Figure 47 Connector Composites (644F), (661), (662), (663)

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52 1 3100 Bus Circuit Diagrams

10.11. CONNECTOR COMPOSITES (1657M), (3040), P. 11

Figure 48 Connector Composites (1657M), (3040)

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 1 3100 Bus Circuit Diagrams 53

10.12. CONNECTOR COMPOSITES (6026), P. 12

Figure 49 Connector Composites (6026)

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10.13. CONNECTOR COMPOSITES (6108), (6323M), (6324M), (7500M), (7601M), P. 13

Figure 50 Connector Composites (6108), (6323M), (6324M), (7500M), (7601M)

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10.14. CONNECTOR COMPOSITES (7801), (8310), (8311), (8312), (9101), P. 14

Figure 51 Connector Composites (7801), (8310), (8311), (8312), (9101)

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56 1 3100 Bus Circuit Diagrams

10.15. CONNECTOR COMPOSITES (9108A), (9108B), P. 15

Figure 52 Connector Composites (9108A), (9108B)

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Printed in the United States of America