Fag eT Ser een eres acer) SS STERLING SECTION 8 ELECTRICALEe de exer Roe nein eee ELECTRICAL WIRING General Practices and Guidelines This section contains the significant wiring schematic drawings for Sterling truck lines, and provides instructions for addition of electrical devices to the vehicle electrical system by body builders. (Vehicles stored on site should have the negative battery cable disconnected to minimize the possibility of a dead battery. This applies to both “incomplete” and “complete” vehicles in storage.) FCC, FICMVSS AND CANADIAN RFI REQUIREMENTS 1. All Sterling vehicles built and fully completed by Sterling, comply with FMVSS and CMVSS No. 108, “Lamps, Reflective Devices and ‘Associated Equipment" and other applicable FMVSS and CMVSS that affect electrical components. 2. Incomplete vehicles (i.e, chassis cab, stripped chassis, chassis cowl, etc.) will conform to these Federal and Canadian Motor Vehicle Safety Standards according to the provisions and conditions stated in tne Incomplete Vehicle Manual attached to each incomplete vehicle. Care must be taken that modifications do not conceal, alter or change ‘components installed provided by Sterling Truck Corporation to achieve this conformance. 3. All vehicles powered by spark ignition internal combustion engines (€.9., gasoline oF liquid petroleum gas engines) and manufactured for sale or Use in Canada are subject to the Canadian “Regulations for the Control of Interference to Radio Reception’, SOR/75-629, Canada Gazette Part Il, Vol. 109, No. 21, November 12, 1975 as amended by SOR/77-860, Canada Gazette Part Il, Vol. 111, No. 21, November 9, 1977, by SOR/78: 727, Canada Gazette Part ll, Vol. 112, No. 18, September 27, 1978, and by SOR/80-915, Canada Gazette Part Il, Vol. 114, No. 23, December 10, 1980. Violation of these regulations is punishable by fine or imprisonment. Sterling-built incomplete vehicles other than stripped chassis are designed and manufactured to be capable of meeting the regulatory requirements or such modifications thereof as may be authorized by the Canadian Department of Communications. However, because Sterling has no control over how an incomplete vehicle is completed by subsequent stage manufacturers, Sterling does not represent that the — STERLING. ‘completed vehicle incorporating the Sterling-build components will ‘comply with applicable requirements. Devices that emit radio frequency (RF) energy, such as AMIFM radios, mobile communications systems, and radio-controlled security systems marketed for sale in the United States are subject to the rules and regulations of the Federal Communications Commission (FCC), 47 C.F. Parts 2 and 15. Similar radio regulations are in piace in Canada: see, ¢.9, Radio Standards Specification RSS-119 and Radio Standards Procedure RSP-100, ame em Page 8-1 Warch 1998Se eek ead ELECTRICAL WIRING General Practices and Guidelines ROUTING & CLIPPING 1 It is strongly recommended that wiring in areas of heavy rework, or in areas where welding operations are to be performed, be removed prior to the rework operations and reinstalled after the rework is completed. If wire removal is not practical, the wires must be shielded from damage due to the rework and welding heat. All components and wiring must be reinstalled as closely as possible to the way it was installed before removal. Wire routings of newly installed components or wire routing revisions of the Sterling hamesses necessitated by reworks must conform to the following: * Wires routed through holes in sheet metal or castings must be protected by nylon conduit and grommets in the holes. + Wires should be routed to avoid metal edges, screws, trim fasteners and abrasive: surfaces. When such routings are not possible, protective devices (shields. caps, etc.) must be used to protect the wires and when wires must cross a metal edge the edge should be covered with a protective shield and the wiring fastened within three inches on each side of the edge. + Wires must be routed to provide at least three inches clearance to moving parts, unless positively fastened and protected with conduit + Wire routings should avoid areas where temperatures exceed 1805F and a minimum clearance of six inches should be maintained trom exhaust system components. Where compliance with this requirement is not possible, high temperature insulation and heat shields are required + When wiring is routed between two members where relative motion can occur, the wiring should be secured to each member, with enough wire stack to allow flexing without damage to the wire * Wiring to all citcuit components (switches, relays, etc.) in exposed locatons must provide a drip loop to prevent moisture from being Conducted into the device via the wire connection. ess Page 8-2 Maren 1999, STERLING Routing wires into areas exposed to wheel wash should be avoided. When such routings cannot be avoided, adequate clipping or protective shields are required to protect the wires from stone and ice damage. Routing wires under the frame side members or at points lower than the bottom frame flange should be avoided to prevent damage to the wires from brush contact in off-road operations. ‘The wire retainers and grommets installed by the assembly pant are usually designed to accommodate only the Sterling-installed wires ‘Additional wiring or tubing should be retained by additional clips. When added wires or tubes are routed through steel metal panels, new holes, with proper wire protection and sealing, must be used. ‘All wiring connections to components of the factory-installed system must be accomplished by using the proper mating wire termination (Connections on studs and ground connections must use eyelet terminations, connections to female bullets must terminate in male bullets, ote.)Ragen de sk Roa enue os ELECTRICAL WIRING General Practices and Guidelines SPLICE/REPAIR When necessary to splice wire for repair or circuit length revisions, the following guide should be followed: Wire ends should be stripped making sure that individual conductor strands are not damaged. When soldering, make sure an adequate mechanical joint exists before applying solder. Use only rosin core solder - never acid core. For crimp joints, use butt-type metal barrel fasteners and a proper tool (such as Motorcraft crimp tool S-9796) specifically designed for this type of work. Splice joints must be adequately sealed and insulated. Heat shrink tubing is highly recommended to cover soldered and bare metal barrel, crimp joints. Quality electrical tape can be used inside the vehicle but is not recommended for an outside environment. All sealed joints must be free of sharp edges or burrs that may work through the insulation, Sterling part numbers E4HT-14488-CA or EGEB-14488-AA are recommended for all splices invalving wire sizes 18-22 AWG. Sterling part numbers E4HT-14488-DA or E6EB-14488-BA are recommended for all splices involving wire sizes 14-16 AWG. Sterling part numbers E6FZ-14488-C is recommended for all splices involving wire sizes 10-12 AWG. For electronic circuits (ie., speedometer, tachometer, low coolant level, etc.) splicing is not recommended and replacement of the damaged wire is preferred. However, if the wire cannot be replaced then soldering of the wires and applying heat shrink tubing over the wire is required. Mechanical splice joints (ie, metal barrel fasteners) must not be used. Splicing of speedometer sensor leads to provide a speed signal to auxiliary equipment should be avoided. A dual speed sensor that is capacitively coupled should be used to reduce the potential for electrical interference in the speedometer and the auxiliary = STERLING equipment, or connect to customer access circuit. With customer access circuits, connect to customer access stud “J in the /P fuse relay panel, Circuit #715, wire color GR. CIRCUIT PROTECTION 1 Modification to existing vehicle wiring should be done only with extreme caution and consideration of effects on the completed vehicle electrical system. Circuitry changes should be studied to ensure that adequate circuit protection will exist and that undesirable current paths are not created Any added circuitry must be protected either by a base vehicle fuse or breaker, or by a similar device provided by the body builder. When adding loads to a base vehicle protected circuit, make sure that the total current draw on the base vehicle protected circuit is less than 80% of the base vehicle fuse rating or less than 100% ot the base vehicle circuit breaker rating + Total current draw is the sum of the base vehicle circuit current requirement (measured with an ammeter) and the add-on component's current requirements. + Never increase the rating ofa factory-installed fuse or circuit breaker. + For added lamp loads, the “Bulb Chart” on page 8-6 will aid in determination of common lamp current draws. If the total electrical load on the circuit, after the addition of electrical equipment, is less than 80% of the fuse or 100% of the circuit breaker protection rating in that circuit and less than the capacity of any limiting ‘components (switches, relays, etc.), the items to be added can be connected directly to that circuit It the total electrical load to be imposed on a circuit exceeds the value of the circuit protection, or the value of some limiting component, the items to be added cannot be added directly to the circuit, Page 8-3 March 1999 ELECTRICALSST eek ELECTRICAL WIRING General Practices and Guidelines GENERAL GUIDELINES ‘The Wire Size and Fuse Selection Table (below) indicates the smallest recommended wire that should be used when splicing or connecting into an existing circuit. It also indicates the maximum recommended current for each fuse. WIRE SIZE AND FUSE SELECTION TABLE | SMALLEST WIRE GAUGE FOR VARIOUS noo |e AMBIENTS: (opeRarine an RATING ‘CURRENT 125° MAX 150° MAK 200"F Max | ar (aus) + [Re Dare [ear ure ro T e Te 22 16 20 | 18 |=) tee | ef tet a 20 raves savas [estore erie anisiss ta 25 xyes fee feces aga cena 30 a 7 > «| 8 | @ p10 Ita smaller wire is to be used, or if the circuit being spliced into is not protected by a fuse oF a circuit breaker, then a fuse or circuit breaker consistent with the Wire Size and Fuse Selection Table, MUST be installed within 6 inches of the splice or connection point Added devices should be powered from a relay if the operating current exceeds the maximum recommended current. Otherwise, nuisance fuse failures may occur. The operating current includes the current requirements of all devices added to the circuit, plus the current requirements of devices already serviced by the circuit. Relays should be installed in accordance with the following: + The existing circuit can be spliced or connected to a new wire that powers one side of the relay col. The size and insulation of this new (relay coil) circuit MUST be selected consistent with the Wire Size and Fuse Selection Table. Page 8-4 March 1999 + The other side of the relay coil should be connected to a good {ground. Never splice or connect to an existing ground wie. + Power for the relay can be taken from any recommended power source, The size and insulation material of the wire that powers the relay and the wire that delivers power from the relay to the added device(s) MUST be selected consistent with the Wire Size and Fuse Selection Table. Note that in most cases, the relay will be powered from a circuit that has no fuse or circuit breaker, and will therefore require a new fuse within 6 inches of the splice or connection. + Added devices, exceeding the current capabilities of the factory- installed system, are best controlled through the use of a relay or hhand-on switch. The coil of the relay can be fed from the circuit in the factory hamess (now acting as a signal circuit) with added wiring providing feeds to the added electrical device. (The relay selection is important and depends on current requirements, number of cycles expected in the relay lifetime, whether the relay is to be operated intormittontly or for long poriods of time, and whether the rolay ic exposed to weather conditions or is installed in a protected area. When the current requirements of a circuit exceed the capacity of an available relay, more than one relay can be used if the circuit is wired to spiit the load) + Added wire feeds to the switch or relay power contacts should not be tapped into basic vehicle wiring. Draw power as close to the battery as possible (Le., the starter motor relay, etc) Circuit protection (fuses or circuit breakers) must be provided for all added witing and should be installed as close to the point of tapped power as possible. The protection device rating should be greater than the combined current requirements of the add-on components: The combined current requirements should be less than 80% of the rating for a fuse and less than 100% of the rating for a circuit breaker.Beers ELECTRICAL WIRING General Practices and Guidelines WARNING Devices that emit radio frequency (RF) energy such as AM/FM radios, mobile ‘communication systems (two-way radios, telephones) and radio-controlled security systems, are subject to the rules and regulations of the Federal Communications Commission (FCC), 47 C.F.R. Parts 2 and 15. Any such system installed in your vehicle should comply with those rules and should be installed only by a qualified technician. Mobile communication systems, particularly it not properly designed for automotive use, or not properly installed, may adversely affect the operation of the vehicle. For example, such systems, when operated, may cause the engine to stumble or stall. In addition, such systems may themselves be damaged, or their operations affected, by the operation of the vehicle. Citizens Band (CB) transceivers, garage door openers, and other transmitters whose power output is 5 watts or less, ordinarily will NOT affect vehicle operation. Because Sterling has no control over the design or manufacture of such systems or their installation, Sterling cannot assume responsibility for any such adverse effects or damage en dads) SS STERLING WELDING When welding is performed anywhere on the vehicle, precautionary measures should be taken to prevent damage to electrical/electronic system wiring or ‘components, Prior to welding, parts which could be damaged by excessive temperatures should be removed or shielded from the heat of the welding process. Battery cables, both positive and negative, must be disconnected at the battery. The welding ground clamp should be positioned as close to the affected welding area as possible. Disconnect all electronic control modules and devices in close proximity to the area being welded due to the possibilty of sneak paths for induced voltage and currents that could damage the electronic component. The following list of electronic components is provided to give an example of the type of components that should be disconnected but should not be considered as a complete listing + Powertrain Control Module (PCM) Diesel Engines + Governor Control + Shutdown/Warning Electronics + Startignition Controls + Transmission Control Electronics Module + AnticLock Brake (ABS) Electronics + Electronic Speedometer/Tachometer NOTE: Connectors for the disconnected components are_selerenced in the apolcable ‘Becincal and. Vacuum Troubleshooting Manual” (EVTM) for te affected venice ‘module year You can tnd the connecter locations In the Tocaton index” sectans Of these ETH, In addition, welding cables should never be allowed to lay on, near, or across any electrical wiring or electronic component during welding. After welding, when parts are cool, carefully inspect wiring and electrical components for shorts or other damage which could draw excessive currents and possibly cause an electrical system short when components and batteries are reconnected Page 8-5 March 1999 ELECTRICAIpage 8 ELECTRICAL WIRING STERLING General Practices and Guidelines BULB CHART thabe | CANDLE |eatepworrace| mae | SANDLE |afepvaltace| fmaoe | CANDLE |matepvoctace] fmabe | CANDLE [nAtep voLTace| NUMBER taps) | ue ames) | NUMBER ‘amps) “|| NUMBER iamPs) 0 6 058 562 6 ova 445 7 one aa | sewarrs vat oe 5 1.00 a3 x 20 ses 14 020 woos [25,6warTs| 204,546 a 4 088 eat 6 06s |e 3 os (|| s_ | aswarrs 278 7 Na 0.69 1076 32 180 [ 1891 028 ‘aes | a0 warTS 2a4 108 2 1.00 1156 2 210 || tae 75 oe | as | t5000 238 161 + | on HER | wes 2ioose || 1609 2 023 aa7s_ | 30waTTS 224 108 3 035 1178 4 68 1685 2 027 eois | 300000 | 420,407 13 2 "oar 95 0 300 wooo | Ga | ava || com | ZERO | azoaer aire | oer 1196 50 300 4001 | 28000 aia ana |ao,sowarrs| 10,91 aiee «| on woos |as.cowatrs| 294546 | ao0e | 442040 | azoar4 We 16 a7 aie aii ea eose |s5.e5warts| 429,507 | 440s | sooo 258 scot [S7WATIS| 350,508 vei | 0a |) wenar |oo-eowarrs] asesce | ana | aswans | 270STERLING L-LINE - Cab and Chassis Vocational Reference Guide ELECTRICAL WIRING Adding Lights or Electrical Devices Although there are many points in the truck electrical system to connect additional circuits, certain connection points are recommended for reliability and convenience. This section defines the recommended connection points for each Sterling Truck model and the maximum electrical loads allowable. Alternative connections or wiring practices are not recommended as certain modifications may result in other circuits becoming nonfunctional. Disconnect the battery negative (ground) cable and remove it from the battery cartier prior to any vehicle modification. Upon completion of body or equipment installation, all wiring should be checked for proper routing, etc., to preclude electrical shorts upon reinstallation of the battery negative cable. No additional electrical connections are allowed to any electronic engine control system circuits. This includes all electronic engine control circuits to sensors, switches, ground, battery (+) or battery (). Proper grounding of vehicle and engine electrical systems is necessary for correct vehicle performance and reliability. Refer to the Engine Manufacturer's Service Information for each engine as required or contact the nearest Engine Manufacturer's Service Center. SS STERLING 1. ADDED LIGHTS CONTROLLED BY HEADLAMP/PARKLAMP SWITCH NOTE: For mer access oicUt S80 page 8-16 0 8:22 Connections to any point in the circuits controlled by the headlamp switch will be on the customer access connectors, except connections to the #12 circuit (headlamp hi-beam, green wire - black stripe), the #13 circuit (headlamp low-beam, red wire - black stripe) and the #15 circuit (feed wire to dimmer switch, red wire - yellow stripe). Connections to the 12-13 ‘ 15 circuits (headlamp bulb circuits) must be avoided. The maximum load on this circuit is 24 amps. TRACTOR: Engine compartment customer access connectors Connect to circuit #491, wire color R-W, in cavity “A” of connector “A” or Stud #2 in the optional customer access box. TRUCK: Rear chassis customer access connectors = Connect to circuit #491, wire color P-W, in cavity “A” of connector “A” or Stud #2 in the optional customer access box. ‘TRUCK or TRACTOR: Rear of cab customer access circuits ~ Circuit #491, wire color R-W, will also be available in rear of cab in cavity "A" of connector “A.” This is in addition to the above locations, 2. ADDED LIGHTS CONTROLLED BY MARKER LAMP SWITCH ‘The maximum load on this circuit is 24 amps. ‘TRUCK: Rear chassis customer access connectors — Connect to circuit #490, wire color BL-R, in cavity "C" of connector “B’ or Stud #5 in the optional customer access box. ‘TRUCK or TRACTOR: Rear of cab customer access circuits ~ Circuit #490, wire color BL-R, wil also be available in rear of cab in cavity “C” of connector “B.” This is in addition to the above locations. Page 8-7 arch 1998sie de eke Nee ELECTRICAL WIRING Adding Lights or Electrical Devices 3A. LIGHTS CONTROLLED BY TURN INDICATOR SWITCH NOTE: The load on each circuit is limited to the 4.0 amps. TRUCK or TRACTOR: Engine Compartment or Rear chassis customer access connectors = RH Stop /Turn Function Connect to circuit #2, wire color W1-BL, in cavity "C of connector *C” or Stud #8 in the optional customer access box — LH Stop ‘Turn Function Connect to circuit #3, wire color GR-W, in cavity "D” of connector "C or Stud #9 in the optional customer access box TRACTOR or TRUCK: Rear of cab customer access CRTS. ~ RH Turn Function Connect to circuit #2, wire color W-BL, in cavity “C" of connector °C. ~ LH Turn Function Connect to circuit #3, wire color GR-W, in cavity “D" of connector “C. Page 8-8 Maren 1999 = 3B. STOP LAMPS (ONLY) SWITCH The stop lamp SW controls customer access stop lamp relay R13, + Connection outside cab with rear of cab customer access TRACTOR or TRUCK: = Connect to circuit #809, wire color R-BK, in cavity “B" of connector c ~ This circuit is controlled by relay R13 and protected with a 15 amp. fuse. Fuse #33, TRUCK: = Connect to circuit #809, wire color R-BK, in cavity “B" of connector "©" in rear chassis customer access or Stud #7 in the optional customer access box. This circuit is protected with a 15 amp, fuse. Fuse #33, * Connection inside cab; auxiliary switch package or auxiliary circuit package. ‘TRUCK OR TRACTOR: = Connect to circuit #809, wire color R-BK, at stud °M’ in UIP fuse relay panel. This circuit is protected with a 15 amp. fuse. Fuse #33.Fee ee ee kon eee ELECTRICAL WIRING Adding Lights or Electrical Devices 4, ADDED LIGHTS OR ACCESSORIES CONTROLLED BY ADDED SWITCHES This section describes the connection points for added electrical accessories when these accessories are to be controlled by added switches not a part of the Sterling-eleased vehicle. The added switches and wiring must have sufficient electrical capacity for the accessory load land must be protected by appropriate fuses or circuit breakers. Also, added current draw must not cause total loads to exceed capabilties of the base vehicle wiring. + Key *Onilgn’ or “Hot” in Fun and Accy Function TRUCK or TRACTOR: = Connect to customer access stud "B” in the IP fuse relay panel Circuit #297, wire color BK-GR. * This circuit is protected with a 25 amp. tuse. Fuse #25. + *Battery’ Power Function TRUCK or TRACTOR = Connect to customer access stud “A” in the I/P fuse panel. Circuit #37. This circuit is protected with a 30 amp. maxi fuse, Maxi fuse “X" in power cistribution box + “Ground” Function TRUCK or TRACTOR: ~ Connect to customer access stud #57, wire color BK. in the VP fuse panel. Circuit = STERLING 4A. ADDITIONAL CIRCUITS NOTE: The following circuits are not connected tothe vehicle electrical system, and so can be sed or any purpose. rts fo be a poner crcut, a iuse corsision wih the We Size ‘and Fuse Selecton Table, MUST be mslated within 6 inches of ie connection to the Source ofthe power ‘The circuits may be connected between studs in the VP to provide specific functions. Refer to figure on page 8-37, “Adding Lights or Electrical Devices”. + Feed from /P fuse panel to chas: TRACTOR: Feed #1: A 14GA wire, circuit #384, wire color W-BL, © between stud "D" in the fuse panel to cavity “ connector “A” in the engine compartment customer access connectors, or stud #2 in the optional customer access box. —Feed #2: A 12GA wire, circuit #985, wire color W-R, exists between stud “E” in the fuse panel to cavity °C” of connector “A” in the engine customer access connector, or stud #3 in the optional customer access box. TRACTOR: Rear of cab customer access connectors — Feed #1: Circuit #384, wire color W-BL, also exists in cavity “B* of connector “A’, or stud #2 in the optional customer access box. — Feed #2: Circuit #985, wire color W-R, also exists in cavity “B” of connector “A’, or stud #3, TRUCK: —Feed #1: A 14GA wire, circuit #384, wire color W-BL, exists between stud *D" in the fuse panel to cavity “B" of connector “A” in the rear chassis customer access connectors, or stud #2 in the optional customer access box. Feed #2: A 12GA wire, circuit #385, wire color W-R, exists between stud “E” in the fuse panel to cavity “C” of connector “A in the rear chassis customer access connectors, or stud #3 in the optional customer access box. Page 8-9 Merch 1699 ELECTRICAISENSE eae! ELECTRICAL WIRING Adding Lights or Electrical Devices ‘TRUCK: Rear of cab customer access connector ~ Feed #1 Circuit #384, wire color W-BL, also exists in cavity "B" of connector “A", or stud #2 in the optional customer access box. ~ Feed #2) Circuit #385, wire color W-R, also exists in cavity °C" of connector “A”, or stud #3 in the optional customer access box. + Vehicle Data Link Connections TRUCK or TRACTOR: With customer access circuits Connect to customer access stud °K" positive signal circuit #716, color Y, and to stud “L” negative signal, circuit #712, wire color P, in the UP fuse relay panel. + Start Circuit TRACTOR: Or tractor engine compartment customer access connector. = Connect to circuit #32, wire color A-BL, at terminal "E” connector in the engine compartment customer access connector, oF stud. #10 in the optional customer access box. + Auxiliary UP Switches TRUCK or TRACTOR: Optional customer access circuits - auxiliary switch package. — Auxiliary Switch #1 Circuit #196, wire color A (16GA), runs between feed side of the switch and stud “F” in the fuse relay panel. Circuit #197, wire color R BL (16GA), exists between the other side of the switch and stud “G" inthe fuse relay panel — Auxiliary Switch #2 Circuit #388, wire color Y-R (16GA), runs between the feed side of the switch and stud ‘N" in the fuse relay panel. Circuit #832, wire color Y-BK (16GA), runs between the switch and stud *P" in the fuse relay panel. Page 8-10 March 1999 STERLING + Additional Battery Power TRUCK or TRACTOR: Optional customer access circuits - auxiliary circuits pkg, ~ Circuit is limited to max of 18 amps. Connect to customer access stud “H' circuit #37, wire color BK-Y, in the I/P fuse relay panel. This, Circuit is protected with 30 amp. fuse #BB in the power distribution box. Refer to page 8-38, "Engine Compartment Power Distribution Box’ag eS Penne eink or ELECTRICAL WIRING Adding Lights or Electrical Devices 5, RADIO FREQUENCY INTERFERENCE (RF!) During modifications to the vehicle, manufacturers should take the necessary precautions to maintain the RFI integrity of components. (Canada has an RFI regulation in effect and the U.S. Federal Communication Commission has rules and regulations in effect on devices that emit RF energy. See Electrical Wiring General Practices and Guidelines under heading tiled “FCC, F/ CMVSS and Canadian AFI Requirements.”) Precautionary procedures and components listed below are examples and do not necessarily represent a complete list. All components required to suppress RFI emissions, which are removed during service, repair, or completion of the vehicle, must be reinstalled in the manner in which they were installed by Sterling, Metallic components installed on the body or chassis must be (rounded to the chassis. Electronic circuits are to be located a minimum at 8 in. from electrical noise sources, i.¢., ignition wires, distributors, alternator wiring, tachometer circuits, starter motor and associated wiring as well as any other noise sources. With very sensitive circuits, it may be necessary to shield the circuits as well Only “static conductive” accessory drive belts should be used. Fan, water pump, power steering and other belts should be of the OEM type or equivalent that will not build up a static electrical charge. If the distributor rotor tip is coated with silicone grease, do not remove the coating, Electrical grounds on all components must be retained, 6. GROUNDING OF ELECTRONIC DEVICES To reduce the effects of intermittent operation and EMMI, all electronic devices added to the vehicle are to be grounded at the battery or ground plane. It the ground plane method is selected, resistance between the battery negative terminal and ground plane(s) must be less than 200 MILLI OHMS. When attaching to ground planes, use a serrated eyelet and ground serew/bolt, zine and iridescent chromate plating (S-36 Finish) minimum 72-hour corrosion requirement, protected from the harsh environments, .¢., road splash, vehicle fluids. Ground connections to sheet metal shall not be made via punched pierced hole but by extruded hole or weld nut: Drill point screws are not recommended to ground low signal devices. ‘Sensors and actuators of an electronic module are to be grounded at the same vehicle location Metalic components installed on the body or chassis must be {grounded to the chassis. Electrical circuits added to the vehicle should not be installed near the high tension ignition components ‘Only “static conductive” accessory drive belts should be used. Fan, water pump, power steering and other belts should be of the CEM type or equivalent that will not build up a static electrical charge. Page 8-11 March 1999 ELECTRIC,BERS INE TT neces — Page 8-12 March 1999 ELECTRICAL CONNECTIONS STERLING Instrument Panel Terminals F, G, N & P can be configured to auxiliary dash switches with wiring on Trucks and Tractors equipped with the Auxiliary Switch Package: 329-002 (Sales Code) ~ two extra switches in dash, The electrical load must meet the requirements described in INSTRUMENT “Electrical Wiring General Practices and Guidelines’. EL ‘CONNECTOR PART # WATING CONNECTOR PART FORT 14446-AB #10 INSULATED EYELET Wine TERM DESCRIPTIONS care | GRE | cauce x BATTERY POWER | 37 | eR) | 14 ‘@ | -RUNACCESSORY POWER [207 | (eKIGN) | 16 € GROUND, 7) eK |i or CHASSIS FEED FT oe wey [a E CHASSIS FEED #2 as |_ way] 2 7 AuxnooKcn owrrorat | 0 | a 7 os sopy Se Ee f saceg rE gemenrrerieep) eer |) eae LeaDS = TRAINS Te} eS : T DATALINK: 72, ® eS ram a aa ™ STOP LAN mex |e) RESO : [AUR ROCKER SWITCH AE wm) | 18 ie ele [CRO ROGREP STE wae [ie] pl Paar ali tnypurptse, Gren srolcion vega tx ny aes ret aed aria eeaion Ase SERS arenes ee on eae oo ooSean de Sek ence eed ELECTRICAL CONNECTIONS Instrument Panel A HOT AT ALL TIMES FG AUX ROCKER SWITCH #1 HH porarau tives J SPEEDOMETER eyes detely Shes | | foul) oe e & a = ng SIRRILESES SEERA ore cs esa a (ovata (satan) ee ssongatens — cco aces (unsGtSH2Si Dina] | (orbit Bes PLN AUX ROCKER SWITCH #2 DE ‘TO RPO BOX ENGINE-COMPARTMENT INSTRUMENT-PANEL ——«eLe>— ee ieee = % anaes SOMETEST SERA & Ayatanie wins ayauneve wr Sea wou (asuBt8GERMce) (nm OREA ce) ts. Sy —EEanecronA Terenas} SONS Rocess oPmonat cusroweR — Bewiau io) —econmectona tenmiats } CUsTOUee cess (TRUCK OF TRACTOR) (TRUCK ONLY) ELECTRIC: Page 8-13 Marc 1969Se korea! SS Page 8-14 Maren 1999, ELECTRICAL CONNECTIONS STERLING Instrument Panel B RUNIACCESSORY HOT AT ALL TIMES c TO OCA 0X. BACK-OF-CAB TO OCA BOX INSTRUMENT-PANEL eAee Rs cutSRieess exon SHERIwenr Crowe access a husruse aa caSignen access Ene C088 iow AscesS SoRNESTORS aS, seas CONNEC ORB SERRINALA Somnecton a ERAINALA ‘TERN ERMINALA i ¥ Y 4 x 0 7 % » x x . aky & i & a cy ‘io a i és & ewso rzs0 -—_1—_4 t vat 3 L xen odor woroR x x SRALER AEUAY x) % ex HEATEDSEATS gp a cr) “5 slgwennoior ay ih Rey ica) r euuctean y a va? jruwaccessony etary ¥ Laie a | TYPE-4 GROUND a SPSS TOUGH stu 2 a 4 akiy I © a & i © 4 Fuse 25 Oye Us i t ra sr a v 4 INSTRUMENT PANEL COTOUER RECESS ve ‘OPTIONAL CUSTOMER [ACCESS BOX LOCATED IN ENGINE COMPARTIIENT (TRUCK OR TRACTOR) OR AT REAR OF FRAME (TRUCK ONLY),ELECTRICAL CONNECTIONS Instrument Panel SS STERLING KL DATALINK M HOT AT ALL TIMES ABSOEE 4oAMr) (30 AMP) ris 7 Co ei’y—y>—ak'v: [ABS MODULE. a 8 8 OPTIONAL CUSTOMER ‘ACCESS BOX LOCATED IN ENGINE COMPARTMENT (TRUCK OR TRACTOR) ORAT REAR OF FRAME (TRUCK ONLY) STOR Low pressure OPERATING "owitcn e642 dauege Yenis Fuse 33 (sane) as oan) REAR. CHASSIS Eoxnecroee, TERNAL BACK.OF-caB BUS ieAccess Connecrone TERMINAL NSTRUMENT-PANEL Usromen access Stuon (AVAILABLE winuLRY ‘incurs PACKAGE) [aE oat los Page 8-15 March 1998STERLING L-LINE - Cab and Chassis Vocational Reference Guide SS Page 8-16 STERLING ELECTRICAL CONNECTIONS Latina Back of Cab and Rear of Chassis ‘Available for accessory equipment only on Trucks (not available for Tractors). The electrical load must meet the requirements described in “Electrical Wiring General Practices and Guidelines.” CONNECTOR MATING CONNECTOR {7 /2°-5- CONN NUM = Rey (Boor suitoER sive) ¥ Sgs,| [Tertnta | Fuvcriow cern [coon _[_ Gane RTO [COLOR [ag ATI —[- TERNAL NEAREST ma FARRAR a FANT-1@Ad60-5A | BLACK | FIHT-14A6D4-AA | FIHT-14421-BA [FIHT-4A1SSEAP) 10 Ae ‘CAB INTERCONNECT ‘384 Wi) 10 FIHB-14AG46-AA | GRAY 7 FIHS-14A482-AA | FSHT-14421-184 | EBT TAATSS: EA| 1214 AO ‘CAB INTERCONNECT 385, (WAR) 10 Rese cece ene 2 oreue a a of Y42) LA WARKER LAMP 790 BUA) 0 ex} — ancien —| ian | wer | 78 STOP ae __|_RIGHT TURN LAMP ¥ (wet) 8 LEFTTUANLAMP [3 enw | 18 Rear aw oaee ag aaa 0% : ' (see pages 8-13 through 8-15, 8-18 through 8-21, and 8-23 through 8-26 for schematic of each Customer Access Connector) ee or esa Fac. (Ug Yoo CUSTOMER ACCESS CONNECTORSen ee see eek) ELECTRICAL CONNECTIONS Back of Cab and Rear of Chassis Customer Access Connector Location POSITION A an connector 8 Finesancen oa ace Ree an ‘ony POSITION B REAR FRAME RAIL, ELECTRICAL Page 8-17 March 1999STERLING NS ELECTRICAL CONNECTIONS Back of Cab and Rear of Chassis — Connector Circuit Diagrams ab and Chassis Vocational Reference Guide Ss Page 8-18 Maron 1609 eee AA 110) aRREAD Paci conc oan fo cugtonaceess ‘EE ooo Mouuren 5 StF FRONT PARKCANE aight ace ae ae S]em [ wessts(S 8 ale tee & ww i wages gs JSTOMER ACCESS Sane, mine's” Yan ents 2 fa to Xd es | “EiRroue acuese TERMINAA A A -Bexaine-courarrment nstRuMENT Pane C oUsTéieR Access ‘Gasromen Access SS REE % ‘iar ta ‘ior to J) 385 _comecrora | 354 __-conecron.a L_ #& _comecrona wi wk ~ SEMtnAISe BACK OF ca ROR Rccess HB —< Fenn FERS) on BL —— BL-R— orion cusrower aoeesboe Sourane (TRUCK OR TRACTOR} OR AT REAR OF FRAME (TRUCK ONLY) ECTRICAI Page 8-19 aren 1900ee UR re aka Ld Page 8-20 Maren 1968 ELECTRICAL CONNECTIONS re Back of Cab and Rear of Chassis — Connector Circuit Diagrams CA RUN CB oraraucrmes HOT AT ALL TIMES: lo pL si8—ce 02. ase 2 : wosrusek ti eaten § tases ss § taney UREA ” ii Cg im 10 12 ey BER —<€J0 Por d>— we 110) ‘o 3 te r rumour — ov guycieso BULGEXD ——_BULIAEAD Anse Re a wR? Ue i PA ath RE ae ANTILOCK BRA R Bey eh ts CS NeBE | t i} sromaue t ig Back Lau Sores TSTMS ae Sess io suuciean a rita ace is Y ¥ 5 J ceiohue access 4 ee vy aK ‘i ‘io Seder is wo mAawor-one as >t Shi BIS Recess (8) FERINALA OPTIONAL cusromen ‘aceess Box LOCATED IN ENGINE te COMPARTMENT (TRUCK OR TRACTOR) ‘oly Presste Reaoussis OR AT REAR OF FRAME ‘switch «sioner access TRUCK ONLY) si Semanal a 8) 19 BACK-OF-CAB s Akeni ie) eae ‘sy “cote INLINE C eet aaa INSTRUMENT-PANEL SOMERS yaaa wageELECTRICAL CONNECTIONS Back of Cab and Rear of Chassis — Connector Circuit Diagrams STERLING cc cD LEFT REAR, uN SIGNAL vite Tec TURN SIGNAL sircy Sona star. ‘TURN SIGNAL SoH cRw wal iy) LEFT TURN SIGNAL Front + Fender Hood 3 2 caw wat ae) ee tw ee Gat “FOR REAR OF CHASSIS, ‘connecroRs fae OPTIONAL CUSTOMER ruses ruse as ‘ACCESS BOX ea ei LOCATED IN ENGINE 9 COMPARTHIENT T (RUCK OR TRACTOR) ctw GR ATREAR OF FRAME sea ousas Remousss | 63 ‘ie te NS ce (TRUCK ONLY} custivenaatess on auatno euoieso, | PES Sbineoe FES c a h conne SRS teens” 8) BULK ey ig} > ak. 7 (19) BULKHEAD (2) ay Y g Al if ahs ae 8 we ie Leer Rean pac ap royue i ‘3 “8 eo ae sats 0, mee 16) im. ne we ae a mh wie) te ane as (9) ser nooo wounteo 1s" 9) ase aes week WR Erreur oan 7 Maa aS ‘it nisi nges ueuKres es ee #8 _coommecron.a tt FRONT PAPC SEIT HR PORE | cae » 38 convacros CUSTOMER ACCESS 1 — Wat Feat “ia vee — Bh FREE) ccrccoas yous gat _comecrona | Soar eoess Pa Wk — FEROS to Yio)“ TOOCABaX* Mae 40.8 6 42 a ‘OPTIONAL cusTOwER , to ‘ROCESS Box LOCATED IN ENGINE COMPARTMENT ot “ An (TRUCK OR TRACTOR) ro ay eh GRAT REAR OF FRAME is tor ta (TRUCK ONLY) A A A * FOR ENGINE-COMPARTMENT REAR-CHASSIS, BACK-OF-CAB_ ENGINE-COMPARTMENT EL ” cuRTOUEANESs cuss ERENT Smadar SERS ToOen BR TO eaboe Page 8-23 March 1999 ELECTRIC,STERLING L-LINE — Cab and Chassis Vocational Reference Guide ELECTRICAL CONNECTIONS Engine Compartment SS STERLING. Page 8-24 Mare 1968 BA scancunssis BAcorcas ENGINE-coupsserueNT InsTRUMENT PANEL CONNECTORS CONNECTORS Connectors Pe “TERMINAL, TERVINALA TERMINAT, TOOcABR TOOcA BK 2 a es TYPE GROUND euKHEAD t Pass tnnouce TRUNEC & 2 g eg 2 g img cr ® e © @ és ee) 6k —d+ STARTER MOTOR GROUND 12" EYELE ® BC auras aay ouerscn OPTIONAL CUSTOMER : ACCESS BOX LOCATED IN ENGINE ‘COMPARTMENT (TRUCK OR TRACTOR) OR AT REAR OF FRAME (TRUCK ONLY) wo_ONs) am rut _go___ Sleusequeyee *FOR ENGINE-COMPARTMENT Gioy ato 5) akg Ay SONMEETORS Tear tea04 ‘as TOOK Lack Crate,ELECTRICAL CONNECTIONS Engine Compartment => STERLING CA cB ae oe aaa r ; i aay “ ean Ae ee reannee wees, atu _| ot LL a wesc uy ame, a2 | , esa Tan cis * FOR ENGINE-COMPARTMENT OPTIONAL CUSTOMER ‘ACCESS BOX LOCATED IN ENGINE ‘COMPARTMENT (TRUCK OR TRACTOR) OR AT REAR OF FRAME (TRUCK ONLY) 8642 ELECTRICAI Page 8-25 Maren 1909ETN Puke neice ELECTRICAL CONNECTIONS Engine Compartment oc START RUN muse as ruse 1 Bi eas, f 2 7 a a way nS starrer [H] S0S%8frron Ra tay 2 RL te ‘BULB CHECK RELAY (R-17) RNS i ‘s I omega STERLING * FOR ENGINE-COMPARTMENT ‘OPTIONAL CUSTOMER. ACCESS BOX LOCATED IN ENGINE ‘COMPARTMENT (TRUCK OR TRACTOR) OR AT REAR OF FRAME (TRUCK ONLY) e642 Page 8-26 Maren 1999‘STERLING L-LINE — Cab and Chassis Vocational Reference Guide ELECTRICAL CONNECTIONS Allison Transmission ALLISON TRNSMISSION Page 8-27 March 1998ELECTRICAL CONNECTIONS ate Detroit Diesel Engine Controls SS a Tee ee UC ROR ra eae eel ey SS Page 8-28 st. cs DETROIT DIESEL ENGINE CONTROLSSS ELECTRICAL CONNECTIONS : STERLING Cummins Engine Controls ‘ CUMMINS oBtEsee, ENGINE CONTROLS ET Page 8-29 March 1999S ELECTRICAL CONNECTIONS Caterpillar Engine Controls ; Page 8-30 March 1908 ING CATERPILLAR ENGINE CONTROLSBg eee ieee SS ELECTRICAL CONNECTIONS Able Body Sleeper ABLE BODY SLEEPER [aE Page 8-31 Maren 1999March 1999 Page 8-32 bs dam; HB STERLING 1 ai ancaanstas Sod sor = PEK Beas ELECTRICAL CONNECTIONS Radio/Phone Rabio/See ke knee SS ELECTRICAL CONNECTIONS Engine/Exhaust Brake for Mechanical and Encore Engines ENGINE \ EXHAUST BRAKE FOR MECHANICAL AND "SPR" ENCORE ENGINES ELECTRIC, Page 8-33 March 1999STERLING L-LINE - Cab and Chassis Vocational Reference Guide SS Page 8-34 Maren 1990 ELECTRICAL CONNECTIONS STERLING Full Electrical SchematicSTERLING L-LINE - Cab and Chassis Vocational Reference Guide STERLING a | Peon tile) Page 8-35 ‘Maret 1999Page 26 ELECTRICAL CONNECTIONS ee Circuit Numbers and Wire Colors CIRCUIT | WiRE] GRCUN | WIRE [| CIRCUIT | WIRE] CRCUN | WIRE | CRCUN | WIRE] GROUT | WIRE] CRCUN | WIRE] cIRCUTT | vane: Nuaer | covon || NuMBER | coLon | NUMBER | CoLon | NUMBER | coor |NuMAER | coLon ||NuMBeR | COLOR |NUMaER | COLOR || NUMBER | coLoR z [wa sr [eK | wo | exR | ter | Re | a0 wo | Rao [ ey || ome 3 [srw [se | wo iat | er 188 | eK a5 ero | PK] [AY] 908 ¢ [war | se [one] [cn fof ar we | 0 || ae | wf 307 8 OY 60, BKW 143 R 201 By | 478 er? GR ‘807 oO ‘910 | eey [6s] on [as] aK eo aee oe | caw [ae [Rak] on v2 | rakes | RGR [wae | ex ]|ae [eK a90 wa | ow ao | Rex] 92 7a Reka Ga tar | Rese ea car [| ee [wero | ay] oe aket_ || 20 | ey] ir wo [ PK eer VR sf 16 RGA || 90 GRW 149 GRY a7 GR 514 692 ‘BR B28 BA-GR O16 BK-O 7 Ww 700 BKA 150 a 282 ci 317 KW 697 ‘OBK 830 GAW || 82 GRP va | ace ff or] ay [wee | yea | vax | os [mf vor | wr ee | ven If eee] ow ie [en || we |e] | was nae] oe] weak | en] GA 2 o_[_[ eke fas] 0 | wf | we 24 “BLY 104 GR 158 ‘BK-W 287 BK 580 aL 70a BK 848 AW 936 BK 2 [ako] 0 |v] [nome cy | se oR || 708 [ys | ecw oor] 8k 3 [aK] v0] ekcR | veo [ we [RO er | wy est] ck] ze [-eew | aR er one aon | S80 | aLw 7a | ako || ase] at oso] wep Ree vex] te ka ae | ow [so | exw | 7a | wal] ese | RGR || 02] A 3 Y 77 PRae | ies [ay] ae [ 0 Ga 70] wer || ese [arf aaa uo |e Ae | aw me] eR | 00] | mn] ORBK ess | Pf are | aon 36 Y-BK 119 PRY 173 ‘BLO 348 CRW or BL 712 P 856 oO 77 PW a aky | vao[eK ae aca ae oe) wd woe] [30a | coh aven | a8 vfs] ans] ones [aw || eKo lw ar a | Rf syed aso] P| eo] a aky [fea esas corn ece | wets | er “| @ | | ca | a ]| 0 | va | oe | aw | 7e | aw || es [acy || oo | _¥ eam ese are ay of ay a | cro ees | ek we [ek [ve [Ga] tes kee wat a Ea | 54 GRY 137, YK 180, ¥ 388 VR 634 BL 723 LW 868 BR - =| aca || ae | we || 15 | a || oo | ax | os cn [| ver] cnw || ea] wx ale % [at wo [ anv [vee] as] ann foo [av] vos _[ an ee | ¥Rial) ut ELECTRICAL CONNECTIONS Adding Lights or Electrical Devices er EU Rou ttc dened olde cdbheallcneh cheek OUTSIDE OPTIONAL OUTSIDE OPTIONAL CAB CUSTOMER ACCESS BOX CAB CUSTOMER ACCESS BOX enoine-conmarmwent ENone-cowpazrvenr REAR Ouse, REAR.CHASSIS See nag ROEM RETO) GONE RRR few Hat] A Ara} mw Hs] A Area DrcHoet (RoR eos <| B ] mpauaay Aaunay war}{ 2 cc Since Sencar 5 Eat E GRW. 3 ELECTRICAI Page 8-37 March 1989