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WIRING DIAGRAMS
All diagrams contained in this manual are based on the latest product information available at the time of
publication approval. The right is reserved to make changes at any time without notice.

CONTENTS

SUBJECT PAGE

Wiring Diagrams Description............................................................................................................................................. 2

Basic Electrical..................................................................................................................................................................... 2
Circuits................................................................................................................................................................................2
Wire Size Conversion Table........................................................................................................................................... 4
Circuit Malfunctions........................................................................................................................................................ 4
Circuit Diagnosis.............................................................................................................................................................. 4
Diagnostic Tools.............................................................................................................................................................. 4
Circuit Maintenance And R e p a ir.................................................................................................................................. 6

VEHICLE DIAGRAM

CK T ru c k .................................................................................................................................................................15598474
ST T ru c k .................................................................................................................................................................15598477
G V a n ....................................................................................................................................................................... 15598475
M Van....................................................................................................................................................................... 15598478
P M o d e l...................................................................................................................................................................15598476
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WIRING DIAGRAMS DESCRIPTION

These diagrams use a new format. The diagram is The individual circuits at the connector are shown as
surrounded by a alpha/numeric loaction grid. All the a simple line in the harness.
wires at the connectors have alpha/numeric addresses
showing where the other end of the wire is located ac­ T junctions show the branches in the harness.
cording to the grid. Splices in the harness are shown as dots with triangles
The connectors are shown with end-on views, with around the dots. All the branches of a splice are listed
each circuit shown in the connector by circuit number. at the splice.

BASIC ELECTRICAL

CIRCUITS
An electrical circuit starts from a supply of electricity
and conducts the electricity back to the supply of elec­
tricity. There should be a device to open and close the
circuit, and a protective device to open the circuit in
case too much current flows in the circuit.
Electrical circuits can be set up as series circuits or
parallel circuits. The circuits in trucks are usually
parallel circuits.

SERIES CIRCUITS (Figure 1)

In series circuits, each electrical device is connected
in the circuit so that the current can only go along one
path as it flows from the power supply, around the
circuit and back to the power supply.

PARALLEL CIRCUITS (Figure 1)

In parallel circuits, the electrical devices are
connected by parallel wires that are joined at the start
of the circuit. The current divides: part of it flows into
one device, part into another.
With circuits in parallel, each circuit can be switched
on and off by itself since each circuit receives
electricity directly from the power supply.

CIRCUIT COMPONENTS (Figure 2)

The usual circuit path starts at the power supply frame, thus returning the electricity to the power
which is the battery/generator system. Next in the supply. The body and frame are connected by flexible
circuits is the circuit protection component which can ground straps.
be a fusible link, a fuse, or a circuit breaker. Then the
circuit goes to the circuit controller which can be a FUSIBLE LINK
switch or a relay. From the circuit controller the circuit A fusible link is a section of wire that is usually four
goes into the circuit load. The circuit load can be one gage sizes smaller than the circuit it protects. A special
light or many lights in parallel, an electric motor or a insulation is used that swells when heated by the wire.
solenoid. After the electricity has passed through the Fusible links are usually found in the engine
load it must return to the power supply via the ground compartment harnesses. The function of the fusible
path. The ground path can be a wire in the harness or link is to melt open when an overload occurs, thus
it could be through the load housing into the body or preventing any damage to the circuit.
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CIRCUIT CONTROLLERS
Circuit controllers consist of switches or relays.
Switches are usually operated by a mechanical means
such as a hand or lever. Switches are usually at the
beginning of a circuit but can be used to control a
ground path. For example the switch controlling the
headlights is at the power end of the circuit while the
door switch controlling the domelight completes the
ground path.

Relays are remotely controlled switches. They are

used in high current circuits and in circuits controlled
by sensors.

Relays are designed so that a small current circuit

will be able to control a large current circuit.

Figure 2—Circuit Components WIRING HARNESS AND WIRES

Every wire is a specific size with colored or striped
FUSES insulation that is indicated on the wiring diagrams.
The most common protector in the vehicle circuit is a Insulation colors help to trace circuits and to make
fuse. A fuse consists of a fine wire or strip of metal proper connections. Abbreviations and symbols used
inside a glass tube or plastic housing. The strip melts for indicating wire insulation colors and patterns are as
and interrupts the flow of current in the circuit when follows:
there is an overload caused by an unwanted short or
ground. The fuse is designed to melt before the wiring BLK......................Black ORG . . . . ........Orange
or electrical components in a circuit can be damaged. BRN........ ..........Brown PPL........ ..........Purple
Naturally, the cause must be located and corrected CH.......... ..........Check T R .......... ..........Tracer
before the fuse is replaced or the new fuse will also C R .......... ..........Cross Y E L ........ .........Yellow
blow. GRN ..........Green / / ............ ........Parallel
NAT........ ........Natural WHT........ ..........White
Since different circuits handle different amounts of LT............ ............ Light B L U ........ ............Blue
current, fuses of various ratings are used. Fuses are SGL........ .......... Single S T R ........ ..........Stripe
rated in amperes. Be sure to replace a blown fuse with ORN ........Orange P N K ........ ............Pink
a fuse of the connecting rating. GRA........ ............ Gray D K .......... ............Dark
Some wires are grouped and taped together or
encased in a split plastic casing. This grouping of
CIRCUIT BREAKERS
wires is called a harness. For some purposes, it is
Circuit breakers are another form of circuit protector.
more practical to use a single wire protected by a
There are two types of circuit breakers; automatic reset braided tubing called a loom.
and remote reset.
The automatic reset breaker opens when excess Wiring harnesses are joined by using a multiple plug
current heats a bimetallic strip, causing the strip to and receptacle connector block, or a terminal post
bend and open a set of contacts. Then the strip cools chassis junction block. In the instrument panel area
and closes the contacts. So the circuit breaker opens plastic insulated blade-type connectors and screw-type
and closes until the excess current condition is terminals are used.
corrected or the circuit is disconnected from the power
supply. Each harness or wire must be held securely in place
by clips or other holding devices to prevent chafing of
The remote reset circuit breaker has a heating wire the insulation.
wound around the bimetallic strip. When an excess
current happens, the strip heats, bends, and opens the
contacts. Then a small current flows through the WIRE SIZE
heating wire, keeping the strip hot and the contacts Wire size in a circuit is determined by the amount of
open. This type of breaker will stay open until either current, the length of the circuit and the voltage drop
the power supply is disconnected from the circuit or allowed. Wire size is specified using the metric gage.
the breaker is removed from the circuit. Then the The metric gage describes the wire size directly in
breaker can cool and reset. cross section area measured in square millimeters.
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s/V W '

f f T
OPEN CI RCUI T S HO R T CIRCUIT GROUNDED UNI T A-8573

Figure 3—Circuit Malfunctions

WIRE SIZE GROUNDED CIRCUIT (Figure 3)

A ground circuit is like a short circuit but the current
CONVERSION TABLE flows directly into a ground circuit that is not part of the
original circuit. This may be caused by a wire rubbing
METRIC AWG against the frame or body. Sometimes a wire will break
SIZE SIZE and fall against metal that is connected electrically to
(mm)2 the ground side of the power supply. A ground circuit
0.22 24 may also be caused by deposits of oil, dirt and
0.35 22 moisture around connections or terminals, which
0.5 20 provide a good path to ground.
0.8 18
1.0 16
2.0 14 CIRCUIT DIAGNOSIS
3.0 12 A clear understanding of the circuit and a wiring
5.0 10 diagram are needed for effective diagnosis. Use a
8.0 8 logical sequence of testing to find the trouble. Use the
13.0 6 diagnostic tools. After the trouble is fixed, make sure
19.0 4 the circuit works correctly.
32.0 2
40.0 1
50.0 0 DIAGNOSTIC TOOLS
62.0 00
UNPOWERED TEST LIGHT
This tool consists of a 12 volt light with leads. The
CIRCUIT MALFUNCTIONS ends of the leads usually have alligator clamps, but
various kinds of probes, terminal spades, and special
There are three electrical conditions that can cause connectors are used also.
a nonworking circuit; an “ Open Circuit” , a “ Short The unpowered test light is used on an open circuit.
Circuit” , and a “ Ground Circuit.” One lead of the test light is grounded and the other
lead is moved around the circuit to find the open.
Depending on the physical layout of the circuit,
OPEN CIRCUIT (Figure 3) sometimes it will be easier to start at the power supply
An open circuit occurs whenever there is a break in and other times it is easier to start at the circuit load or
the circuit. The break can be corrosion at the ground circuit.
connector, a wire broken off in a device, or a wire that
burned open from too much current. POWER TEST LIGHT
This light is a pencil shaped unit with a self
contained battery, a 1.5 volt light bulb, a sharp probe
SHORT CIRCUIT (Figure 3) and a ground lead fitted with an alligator clip.
A short circuit happens when the current bypasses This test light is used mainly for testing components
part of the normal circuit. This bypassing is usually that are disconnected from the vehicle power supply.
caused by wires touching, salt water in or on a device The power test light is also useful for testing suspected
such as a switch or a connector or solder melting and high resistance points in a circuit such as connectors
bridging conductors in a device. and ground circuits that are corroded or loose.
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JUMPER
The jumper is usually a long wire with alligator
clamps. A version of the jumper has a fuse holder in it
with a 10 Amp fuse. This will prevent damaging the
circuit if the jumper is connected in the wrong way.
The jumper is used to locate opens in a circuit. One
end of the jumper is attached to a power source and
then the other end is attached to the load in the circuit,
i.e.; light, motor. If the load works, try “ jumping” to
circuit points that are progressively closer to the power
supply. When the circuit load stops working, the open
has been located.

The jumper is also used to test components in the

circuit such as connectors, switches, and suspected
high resistance points.

NOTICE: The following instruments: Ammeter,

Voltm eter, and Ohmmeter, each have a
particular application for trouble shooting VOLTMETER (Figure 6)
electrical circuits. The voltmeter (properly observed) will give the
technician more information than the ammeter,
When using a ammeter or voltmeter, and the ohmmeter and test light combined. Its application for
value being tested is unknown always use the troubleshooting here is to measure the electrical
highest scale first and work downward to a pressure (voltage) drop in a resistance circuit.
midscale reading whenever possible. This will
avoid damage to the instrument. To use a voltmeter for troubleshooting an electrical
problem, connect it in parallel with the existing circuit.
Never use an ohmmeterr in a power circuit, If the voltmeter is connected in series with the circuit
or as a substitute for a voltmeter or ammeter being tested, the nature of the circuit would be
as damage to the instrument will result. changed and the reading would have no particular
value or use. Connect the meter terminals according to
polarity as shown.
AMMETER (Figure 4)
Disconnect the circuit from the power source before The dash mounted voltmeter (in the vehicle) should
also be observed for monitoring proper operation of the
connecting the ammeter. The ammeter measures the
generator battery cranking motor, and cranking circuit.
amount of electrical current, amperes, moving through
a conductor. The ammeter must be placed in series In this application, battery voltage drop can be
monitored while the engine is cranking; and after the
with the circuit being tested. Be sure that the
ammeter's positive terminal is connected to the
positive (battery) side of the circuit and is negative
terminal to the negative (ground) side of the circuit.

OHMMETER (Figure 5)
The ohmmeter is an instrument designed to indicate
resistance in ohms. It is used to test the condition of a
unit disconnected from the circuit.

Ohmmeter Calibration
When the ohmmeter probes are connected together,
a circuit is completed causing the meter needle to
deflect. The needle should read ZERO ohms, if it does
not, rotate the CAL or ADJ knob to ZERO the needle.

When the probes are held apart, the needle moves

to the maximum (infinite) resistance side of the scale.

The meter is now ready for use.

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Figure 7—Removing Terminals From The

Connector

-►* Install or Connect (Figure 8)

1. Pry up on the tang (70).

2. Terminal into the connector.
engine is running, generator output voltage can be
monitored. This can be a valuable first step prior to
diagnosing other electrical problems. WIRING CONNECTOR TERMINAL
REPLACEMENT (TWIN LOCK TYPE)

Remove or Disconnect (Figure 9)

CIRCUIT MAINTENANCE
AND REPAIR Tool Required:
J-22727 Terminal Remover

MAINTENANCE AND REPAIR

1. Connector lock tangs.
All electrical connections must be kept clean and 2. Terminal locks using J-22727.
tight. Loose or corroded connections may cause a 3. Terminal.
discharged battery, difficult starting, dim lights, and
possible damage to the generator and regulator. Wires
-n - Install or Connect (Figure 8)
must be replaced if insulation becomes burned,
cracked, or deteriorated.
1. Pry out the tangs.
To splice a wire or repair one that is frayed or broken 2. Terminal into the connector.
always use rosin flux solder to bond the splice and
insulating tape to cover all splices or bare wires.

When replacing wire, it is important that the correct

size wire be used as shown on applicable wiring
diagrams or parts book. Each harness or wire must be
held securely in place to prevent chafing or damage to
the insulation due to vibration.

Never replace a wire with one of a smaller size or

replace a fusible link with a wire of a larger size.

WIRING CONNECTOR TERMINAL

REPLACEMENT (BLADE TYPE)

Remove or Disconnect (Figure 7)

1. Terminal lock tang.

2. Terminal (61). Figure 8—Resetting Lock Tang

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circuit is indicated while troubleshooting. Intermittent

problems may also be caused by oxidized or loose
connections.

WEATHER-PACK TERMINAL REPLACEMENT

4-+ Remove or Disconnect (Figure 10)

Tool Required:
J-28742 Terminal Remover
1. Primary lock (121) by lifting.
2. Connector sections.
3. Secondary lock (125) by spreading the sides of
the hasp, thus clearing the staples and rotating
the hasp (127).
4. Terminal (131) by using J-28742 (128).
• Snip off the old terminal assembly.
5. 5 mm (0.2 inch) of the wire insulation (130).
WEATHER-PACK CONNECTORS (Figure 10)
Clean
Special connectors known as Weather-Pack
connectors require a special tool J-28742 for servicing.
Terminal barrel (124).
This special tool is required to remove the pin and
sleeve terminals. If removal is attempted with an
ordinary pick, there is a good chance that the terminal + *■ Install or Connect (Figure 10)
will be bent or deformed. Unlike standard blade-type
terminals, these terminals cannot be straightened once 1. Terminal insulator (134) on the wire. Slide the
they are bent. insulator back on the wire about 8 cm (3 inches).
Make sure that the connectors are properly seated 2. Terminal (131) on the wire.
and all of the sealing rings in place when connecting • Roll crimp (132) and solder the terminal.
the leads. The hinge-type flap provides a back-up, or 3. Terminal insulator (134) and the roll crimp (133).
secondary locking feature for terminals. They are used 4. Terminal into the connector.
to improve the connector reliability by retaining the
5. Secondary lock (125).
terminals if the small terminal lock tangs are not
positioned properly. 6. Connector sections until the primary lock (121)
M olded-on-connectors require com plete engages.
replacement of the connection. This means splicing a
new connector assem bly into the harness. WIRING REPAIR
Environmental connections cannot be replaced with The wire repair is very important for the continued
standard connections. Instructions are provided with reliable operation of the vehicle. This repair must be
the Weather-Pack connector and terminal packages. done as described in the following procedures.
With the low current and voltage levels found in
some circuits, it is important that the best possible Twisted Leads (Figure 11)
bond at all wire splices be made by soldering the
splices. Remove or Disconnect
Use care when probing the connections or replacing
terminals in them, it is possible to short between 1. Jacket (90).
opposite terminals. If this happens to the wrong 2. Twisted wires (91).
terminal part, it is possible that damage may be done 3. Insulation from the wire.
to certain components. Always use jumper wires
between connectors for circuit checking. Never probe -n- Instali or Connect (Figure 11)
through the Weather-Pack seals.
When diagnosing for possible open circuits, it is 1. Splice clip (93).
often difficult to locate them by sight because oxidation
• Crimp.
or terminal misalignment are hidden by the connectors.
Merely wiggling a connector on a sensor or in the • Solder.
wiring harness may correct the open circuit condition. 2. Electrical tape wrap (94) on wires.
This should always be considered when an open 3. Outer electrical tape wrap (95).
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126

134

133
120. Connector Seal 128. J 28742 Terminal Remover
121. Primary Lock 129. Wire
122. Secondary Lock Staple 130. 5 mm (.2 inch)
123. Secondary Lock 131. Terminal
124. Terminal Barrel 132. Roll Crimp
125. Secondary Lock 133. Roll Crimp
126. Lock Opened 134. Terminal Insulator
127. Lock Opened
B-06232

Figure 10—Weather Pack Terminals

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90. Jacket
91. Twisted Wires
92. Splice Clip
93. Crimp and Solder
94. Electrical Tape Wrap
95. Outer Electrical Tape Wrap. B-06230 107
100. Jacket
Figure 11—Twisted Lead Repair 101. Aluminum/Mylar Tape
102. Drain Wire
Twisted Leads/Shielded Cable 103. Splice Clip
104. Crimp and Solder
105. Electrical Tape Wrap
Remove or Disconnect (Figure 12) 106. Drain Wire Splice Clip, Crimped And Sol­
dered.
1. Jacket (100). 107. Outer Electrical Tape Wrap. B-06231
2. Unwrap aluminum/mylar tape (101).
3. Drain wire (102).
4. Leads. Figure 12—Twisted/Shield Lead Repair
5. Insulation on the leads.

+ 4- Install or Connect (Figure 12)

1. Splice clips (103).

2. Crimp and solder the splice clips (104).
3. Electrical tape (105) on the splices.
4. Aluminum/mylar tape by wrapping and taping.
5. Drain wire with a splice clip (106). Crimp and
solder the splice clip.
6. Outer jacket electrical tape wrap (107).